Timing Belt: Service and Repair

Removal

1. Remove accessory drive belts and accessories.
2. Remove vibration damper using suitable puller.
3. Remove intake and exhaust manifolds and brackets.

Fig. 8 Loosening timing belt tensioner.:

4. Remove timing belt cover, loosen tensioner bolt (1) and tensioner (2), Fig. 8, then remove timing belt.




Installation

1. Align camshaft sprocket (A) timing mark with cylinder head static timing mark, Fig. 24.

Fig. 24 Aligning camshaft & crankshaft sprockets.:

Fig. 25 Installing TDC locking tool Mot. 861.:

2. Rotate crankshaft to position cylinder No. 1 at TDC compression stroke, Fig. 24. Remove crankcase plug, then install TDC tool Mot. 861 through crankcase hole and into crankshaft TDC hole, Fig. 25. Do not use TDC tool Mot. 861 to restrain crankshaft from turning while removing or installing bolts.
3. Install timing belt on sprockets, ensuring belt is tight between crankshaft and idler shaft sprockets, and between idler shaft and camshaft sprockets.
4. Position timing belt cover over sprockets and ensure camshaft timing mark is aligned with index mark on cover.
5. To adjust belt tension, proceed as follows:
a. Remove TDC tool Mot. 861 from crankshaft and install crankcase plug.
b. Rotate crankshaft clockwise 2 complete revolutions. Do not rotate crankshaft counterclockwise.
c. Remove timing belt cover, then loosen belt tensioner bolts 1/4 turn.
d. The belt tensioner will automatically adjust to the proper tension.
e. Torque bottom tensioner attaching bolt to 18 ft.lbs., then the top bolt to 18 ft.lbs.
f. Check timing belt deflection between camshaft sprocket and intermediate shaft. Deflection should be 5.5-7.0 mm (0.222-0.276 inch).
6. Install timing belt cover.