Timing Belt: Service and Repair
TIMING BELT REMOVAL
1. Disconnect the negative cable from the battery.
2. Remove accessory drive belts.
3. Remove air conditioning compressor with lines attached and set aside.
4. Remove the generator.
5. Remove air conditioning compressor belt idler.
Solid Mount Accessory Bracket:
6. Remove 5 side mounting bolts; Nos.1, 4, 5, 6 and 7.
7. Remove front mounting nut No.2.
8. Remove front bolt No.3. Coolant will leak from bolt hole. If in vehicle, fully loosen bolt No.3 and remove with assembly.
9. Rotate solid mount bracket away from engine and slide on stud (No.2 nut mounting stud) until free. Front mounting bolt and spacer will be removed with bracket.
10. If in vehicle, replace front mounting bolt No.3 in WET hole to prevent further coolant loss.
11. Remove the water pump pulley.
12. Remove the crankshaft pulley.
13. Remove nuts holding cover to cylinder head.
14. Remove bolts holding cover to cylinder block.
Timing System And Seals:
15. Remove both halves of timing belt cover and lay aside.
16. Place a jack under the engine.
17. Remove the right engine mount thru-bolt. Raise the engine slightly.
Timing System And Seals:
18. Loosen the timing belt tensioner and remove the timing belt.
TIMING BELT INSTALLATION
Fig. 1 Crankshaft And Intermediate Sprocket Timing Marks:
1. Turn crankshaft and intermediate shaft until markings on sprockets are inline.
Fig. 2 Camshaft Sprocket:
2. Turn camshaft until arrows on hub are inline with No.1 camshaft cap to cylinder headline. Small hole must be in vertical center line.
CAUTION: DO NOT allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.
Cam Belt Routing:
3. Install timing belt.
4. Remove spark plugs and rotate crank to Top Dead Center (TDC) position.
Fig. 21 Adjusting drive belt tension:
5. Put Belt Tension Tool C-4703 horizontally on large hex of timing belt tensioner pulley and loosen tensioner locknut.
Fig. 21 Adjusting drive belt tension:
6. Reset Belt Tension Tool C-4703 index, if necessary to have axis within 15° of horizontal.
7. Turn engine clockwise from TDC two crankshaft revolutions back to TDC. DO NOT reverse rotate crankshaft or attempt to rotate engine using camshaft or accessory shaft attaching bolt.
8. Holding weighted wrench in position, tighten locknut on tensioner to 61 Nm (45 ft. lbs.) torque.
9. Lower the engine onto the right engine mount. Tighten the thru-bolt nut to 68 Nm (50 ft. lbs.) torque.
10. Remove the jack from under the engine.
11. Position both halves of timing belt cover together.
12. Install the nuts and bolts holding cover to cylinder head and cylinder block. Tighten the nuts and bolts to 4 Nm (40 in. lbs.) torque.
Fig. 2 Camshaft Sprocket:
13. Rotate crankshaft two full revolutions and check valve timing. With No.1 cylinder at TDC, the small hole in sprocket must be centered in timing belt cover hole.
14. Install the spark plugs and tighten to 27 Nm (20 ft. lbs.) torque.
15. Install the water pump pulley. Tighten the bolts to 28 Nm (21 ft. lbs.) torque.
16. Install the crankshaft pulley. Tighten the bolt to 28 Nm (21 ft. lbs.) torque.
17. Front mounting bolt and spacer need to be installed simultaneously with bracket. Install bracket on front mounting stud and slide bracket over timing belt cover into position.
18. Loosen assembly bracket to engine fasteners (No.1 through 7).
Solid Mount Accessory Bracket:
19. Fasteners MUST BE TIGHTENED IN SEQUENCE and to specified torque as follows:
(a) Tighten bolt No.1 to 3 Nm (30 in. lbs.) torque.
(b) Tighten nut No.2 and bolt No.3 to 54 Nm (40 ft. lbs.) torque.
(c) Tighten bolts No.1 (second tightening), No.4 and 5 to 54 Nm (40 ft. lbs.) torque.
(d) Tighten bolts No.6 and 7 to 54 Nm (40 ft. lbs.) torque.
20. Install the generator and A/C compressor. Tighten compressor mounting bracket bolts to 27 Nm (20 ft. lbs.) torque.
21. Install the accessory drive belts.
22. Connect the negative cable to the battery.