57. Timing Belt Installation

TIMING BELT INSTALLATION

Tools Required
J 42069 Timing Belt Alignment Kit

Installation Procedure






1. Position the 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 thickness. The upper idler pulley uses a narrow 5 mm (0.20 in.) thick spacer and a black bolt. The lower idler puller uses a 1 mm (0.40 in.) thick spacer and a silver bolt.

2. Install the lower idler pulley.

Tighten
Tighten the idler pulley bolt to 40 Nm (30 lb. ft.).

3. Install the upper idler pulley and hand tighten the bolt.






4. Install the timing belt tensioner and hand tighten the nut and washer.

Important: With camshaft locks installed, verify the distance between the camshaft sprockets with the Green Test Belt located in the J 42069.

5. Start at # 1 and # 2 camshaft sprockets. Route the belt around # 1 and # 2 sprockets while aligning the belt marks to the marks on the sprockets and the rear cover.

6. Install the belt around the timing belt tensioner.

7. Route the belt around the upper idler pulley.

8. Route the belt around # 3 and # 4 camshaft sprockets while aligning the belt marks to the marks on the sprockets and the rear cover.

9. Route the belt around the crankshaft hub sprockets while aligning the marks on the belt to the marks on the crankshaft hub sprocket.






10. Install the plastic wedge kit tool J42069-30 within the J 42069 to lock the timing belt onto the crankshaft hub sprocket.






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

12. Route the belt around the lower idler pulley.






13. Remove the kit tool J42069-30.






14. Install the crankshaft locking kit tool J42069-10 within the J 42069 and tighten the lever arm to the water pump pulley flange.






15. Install the camshaft checking gauge to cams 3 and 4 and verify the alignment marks are within 2 mm (0.079 in) of each other.

16. Install the 3 and 4 camshaft locks, if properly aligned.

17. Install the camshaft checking gauge to cams 1 and 2.






18. Rotate the # 1 camshaft sprocket counterclockwise to remove slack between the 1 and 2, and the 3 and 4 cams.

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

19. Rotate the upper idler pulley counterclockwise until the marks are properly aligned within 2 mm (0.079 in) of each other.

20. Install the 1 and 2 camshaft locks when properly aligned.

Tighten
Tighten the upper pulley bolt to 40 Nm (30 lb ft).






21. Adjust the timing belt tensioner so that the center alignment mark is about 3 mm (1/8 in) above the alignment mark on the spring loaded idler.






22. Remove the 1-2 and the 3-4 camshaft lock kit tools J42069-1 and J42069-2.

23. Remove the kit tool J42069-10.

Important: If TDC is passed, do not rotate the crankshaft counterclockwise. This will not allow proper slack to be taken up between the timing belt tensioner and the crankshaft sprocket. To correct this, rotate the crankshaft an additional 2 turns.

24. Rotate the crankshaft 1 3/4 turns clockwise. Install the crankshaft locking kit tool J42069-10 within the J 42069, and then stop at TDC.






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






26. Install the checking gauge kit tool J42069-20 within the J 42069 and verify the marks are within 2 mm (0.079 in) of each other.






27. Adjust the timing belt tensioner so that the center alignment mark is about 3 mm (1/8 in) above the alignment mark on the spring loaded idler.

28. Tighten the timing belt tensioner.

Tighten
Tighten the timing belt tensioner fastening nut to 20 Nm (15 lb. ft.).


29. Remove the J42069-10 and the J42069-20.