Timing Belt: Service and Repair

IMPORTANT OPERATIONS
REMOVAL

1. Starter assembly




Rotate the crankshaft to position the No.4 cylinder at Top-Dead-Center on the compression stroke. Align the crankshaft pulley with marks on timing cover. Remove the starter assembly, then install the special tool.

Flywheel holder : J-35271

2. Alternator assembly




Remove the bolt for alternator adjusting plate. Remove the alternator assembly.

3. Pulley




Remove the crankshaft bolt and remove the boss and the crank pulley.

4. Knock sensor




Knock sensor wrench : J-22898-A

5. Oil filter




Remover J-36390




6. Exhaust manifold and turbocharger assembly

7. Timing cover




Remove the timing cover.

Be sure the mark on the cam pulley is aligned with the upper surface of the cylinder head, and the dowel pin on the camshaft is positioned at the top.

8. Head cover




Disconnect the PCV hoses. Remove the high tension cables from the clip. Then remove the head cover.

Note: If the cover adheres to the cylinder head, strike the end of the head cover with rubber mallet. This should shear it off. If the cover still will not come loose, carefully pry it away from the cylinder head. Take care not to distort the sealing flange.

9. Bolt




Insert a hex wrench into the tension puiley hexagonal hole.
Loosen the timing belt tension by rotating the tension pulley clockwise.

10. Timing belt




Remove the timing belt.

NOTE:
^ Do not bend or twist the belt
Severely twisting or bending the belt could damage the core.
The belt should not be bent at a radius of less than 30 mm (1.2 in.).

^ Do not allow oil or other chemical substances to come in contact with the belt.
These substances will shorten belt life.

^ Do not attempt to pry or stretch the belt with a screw driver or any other tool during the installation procedure.

^ Store timing belts in a cool and dark place. Never expose them to direct sunlight or heat.




INSTALLATION
Important Operations

1. Water Pump




Install water pump if removed.
Torque kgm (ft.lbs.) 24 (17.4)




2. Tension spring
Position the spring ends as shown on the illustration.

3. Timing belt




Set the timing belt letter mark in the direction of engine rotation and perform the installation procedure in the following order:

1) Crankshaft timing pulley
2) Camshaft timing pulley
3) Water pump pulley
4) Tension pulley




NOTE: There must be no slack in the belt after it has been installed. The teeth of the belt and the teeth of the pulley must be in perfect alignment.