Timing Belt

REMOVAL
TIMING BELT
1. Disconnect negative battery cable.
2. Raise vehicle on hoist. Remove right front wheel.
3. Remove belt splash shield.
4. Remove accessory drive belts.
5. Remove crankshaft damper bolt, and remove damper.
6. Remove AC/Generator belt tensioner.
7. Disconnect generator connections. Remove generator and bracket.





8. Remove upper and lower timing belt covers (Fig. 114).
9. Remove coolant recovery container.
10. Remove right engine mount.
11. Remove engine support bracket (Fig. 114).

CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt.





12. Before the removal of the timing belt, rotate crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth) (Fig. 115).

NOTE: The crankshaft sprocket TDC mark is located on the trailing edge of the sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause the camshaft timing marks to be misaligned.





13. Install 6 mm Allen wrench into belt tensioner. Before rotating the tensioner, insert the long end of a 1/8" or 3 mm Allen wrench into the pin hole on the front of the tensioner (Fig. 116). While rotating the tensioner counterclockwise, push in lightly on the 1/8" or 3 mm Allen wrench, until it slides into the locking hole.
14. Remove timing belt.

CAUTION: If timing belt was damaged due to incorrect tracking (alignment), the belt tensioner assembly must be replaced.

CAMSHAFT SPROCKETS
1. Disconnect negative battery cable.
2. Remove timing belt.





3. Hold camshaft sprockets with Special Tool 6847 while removing center bolts (Fig. 117).

CRANKSHAFT SPROCKET
1. Disconnect negative cable from battery.
2. Remove timing belt.





3. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 118).

CLEANING
Do not attempt to clean a timing belt. If contamination from oil, grease, or coolants have occurred, the timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean all sprocket grooves of any debris.

INSTALLATION
CRANKSHAFT SPROCKET

CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage.





1. Install crankshaft sprocket using Special Tool 6792 (Fig. 119).
2. Install timing belt.

CAMSHAFT SPROCKETS
1. Install camshaft sprockets. Hold camshaft sprockets with Special Tool 6847 while tightening center bolts to 101 Nm (75 ft. lbs.) (Fig. 117).
2. Install timing belt.
3. Connect negative battery cable.

TIMING BELT
1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.





2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Fig. 120).

CAUTION: Ensure that the arrows on both camshaft sprockets are facing up.





3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Fig. 121).
4. Move the exhaust camshaft sprocket counterclockwise (Fig. 121) to align marks and take up belt slack.

NOTE: A new tensioner is held in the wound position by a pull pin.

5. Remove the pull pin or Allen wrench from the belt tensioner.





6. Once the timing belt has been installed and tensioner released, rotate the crankshaft two (2) complete revolutions. Verify that the TDC marks on crankshaft and timing marks on the camshafts are aligned as shown in (Fig. 122).
7. Install engine mount support bracket.
8. Install upper timing belt cover. Torque fasteners to 4.5 Nm (40 in. lbs.).
9. Install the lower timing belt cover. Torque fasteners to 4.5 Nm (40 in. lbs.).
10. Install generator and bracket. Connect generator connections.
11. Install AC/Generator belt tensioner.
12. Install crankshaft damper.
13. Install right engine mount.
14. Install coolant recovery container.
15. Install accessory drive belts.
16. Install belt splash shield.
17. Install right front wheel.
18. Connect negative battery cable.