60. Timing Belt Installation

TIMING BELT (UNIT REPAIR)

TOOLS REQUIRED
- J42069 Timing Belt Alignment Kit

INSTALLATION





1. Position crank at 60 degrees before TDC.

NOTICE: The upper idler pulley (cams 1 & 2) and lower idler puller (cams 3 & 4) use different bolts and spacers of different thicknesses. The upper idler pulley uses a narrow 5 mm (0.20 inch) thick spacer and a black bolt. The lower idler puller uses an 11 mm (0.40 inch) thick spacer and a silver bolt.





2. Install lower idler pulley.
Torque:
Lower Idler Pulley Bolt: 40 N.m (30 ft. lbs.)
3. Install upper idler pulley and hand tighten bolt.





4. Install timing belt tensioner and hang tighten nut and washer

NOTICE: With camshaft locks installed, verify distance between camshaft sprockets with Green Test Belt locate in Timing Belt Alignment Kit J42069.

5. Start at #1 and #2 camshaft sprockets, route belt around #1 and #2 sprockets while aligning belt marks to marks on sprockets and rear cover.
6. Install belt around timing belt tensioner.
7. Route belt around upper idler pulley.
8. Route belt around #3 and #4 camshaft sprockets while aligning belt marks to marks on sprockets and rear cover.
9. Route belt around crankshaft hub sprockets while aligning marks on belt to marks on crankshaft hub sprocket.





10. Install Wedge Tool J42069-30 to lock timing belt onto crankshaft hub sprocket.





11. With belt firmly engaged on crankshaft hub, carefully rotate crankshaft counterclockwise to get belt slack on lower idler pulley side.
12. Route belt around lower idler pulley.





13. Remove wedge tool J42069-30.





14. Re-install crankshaft locking tool J42069- 10 and tighten lever arm to the water pump pulley flange.





15. Perform the following in sequence:
15.1. Install camshaft checking gauge to cams 3 and 4 and verify aligN.ment marks are within 2 mm of each other.
15.2. Install 3 and 4 camshaft lock it properly aligned.
15.3. Install camshaft checking gauge to cams 1 and 2.





15.4. Rotate #1 camshaft sprocket counter-clockwise to remove slack between 1 and 2, and 3 and 4 cams.

IMPORTANT: Ensure that camshaft timing marks are to the left (retard) side of the checking gauge.

15.5. Rotate upper idler pulley counter-clockwise until marks are properly aligned within 2 mm of each other.
15.6. Install 1 and 2 camshaft lock when properly aligned.
Torque:
Upper Pulley Bolt: 40 N.m (30 ft. lbs.)





16. Adjust timing belt tensioner so that the center aligN.ment mark is about 3 mm (1/8 inch) above aligN.ment mark on spring loaded idler.





17. Remove 1-2 and 3-4 camshaft locks, timing belt aligN.ment kit J42069- 1 and J42069-2.
18. Remove crankshaft locking tool J42069-10.

IMPORTANT: If TDC is passed, do not rotate crankshaft counterclockwise. This will not allow proper slack to be taken up between timing belt tensioner and crankshaft sprocket. To correct, rotate crankshaft additional two turns.

19. Rotate crankshaft 1 3/4 turns clockwise, install crankshaft locking tool J42069-l0, and then stop at TDC.





20. Tighten lever arm to the water pump pulley flange.





21. Install checking gauge J42069-20 and verify marks are within 2 mm of each other.





22. Adjust timing belt tensioner so that the center aligN.ment mark is about 3 mm above aligN.ment mark on spring loaded idler.
23. Tighten timing belt tensioner.
Torque:
Timing Belt Tensioner Fastening Nut: 20 N.m (15 ft. lbs.)
24. Remove crankshaft locking tool J42069-10 and checking gauge J42069-20.