Timing Belt and Balance Shaft Belt Replace

REMOVAL

CAUTION: As a rule make sure the toothed belts and drive belts are not kinked during assembly, packing and storage. Improper handling may cause incipient damage to the camshaft toothed belts and may eventually lead to engine damage.

TDC Marks:

Camshaft Position TDC:

TDC Mark (Flywheel):

- Turn engine in direction of rotation and set cylinder 1 to firing TDC.
- Remove engine undertray. Slacken and take off Poly-Rib belt for air conditioning compressor/alternator and belt for power pump.
- Loosen crankshaft bolts, remove toothed belt cover, guide rail (balance shaft belt) as well as toothed belt.
- Take guide rail off coolant pump housing and toothed belt tensioner off support. The toothed belt tensioner may be taken off in forward direction without having to lock the parts.
- Remove tensioner lever and take off toothed belt.

CAUTION: Never continue to rotate engine if the toothed camshaft belt is not fitted of has not been tightened since this may to valve damage.

INSTALLATION
Pre-tensioning the hydraulic toothed belt tensioner
- After removal, the hydraulic toothed belt tensioner must be pre-tensioned in a vise. Fit aluminum jaws into vise. Insert the crank- shaft bolt washer (pan no. 944.102.210.02) at the lower section of the tensioner housing to protect the tensioner bottom.

CAUTION: Do not apply pressure to inner surface of the tensioner housing. Press only on outer edge of the tensioner housing.

- Tighten vise slowly until resistance is felt. Wait for a couple of seconds and then tighten somewhat more.
- Continue to tighten in this order until the push rod housing bores are flush with each other and the push rod may be locked with Special Tool 9530 (Lock Pin).

Timing Belt Arrangement:

- Reinstall timing belt in the following sequence:
- Install and lock tensioning lever (Preload the lock ring, replace if required)
- Camshaft drive pinion
- Coolant pump recirculation gear
- Tensioning pulley
- Install hydraulic toothed belt tensioner and rotate lock pin to pull out. Rotate crankshaft by two turns and check TDC marks on flywheel and camshaft drive, respectively.
- Ensure alignment of balance shaft marks. Install balance shaft belt.
- Using special tool 9201, tighten balance shaft belt to 2.7 +/- 0.3, Checking and Adjusting Tension
- Rotate engine one full revolution and recheck belt tension.
- Finish installation by reversing removal procedures.