Installation
Installation1. Transfer the three knock sensor 1 pigtail clips to the new rear timing belt cover.
2. Transfer fuel line bracket to new rear timing belt cover.
Tighten
Tighten the fuel line bracket bolt to 8 Nm (71 lb in).
3. Install new rear timing belt cover that came in the kit.
4. Install rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolt to 8 Nm (71 lb in).
5. Coat threaded pin with Threadlocker Loctite(R) 242 compound or equivalent.
6. Install rear timing belt threaded pin.
Tighten
Tighten the timing belt cover threaded pin to 10 Nm (89 lb in).
7. Install knock sensor 1 pigtail into the three clips on rear timing belt cover.
8. Install new timing belt tensioner bracket with tensioner and idler that came in the kit.
9. Install timing belt tensioner bracket bolts.
Tighten
Tighten the rear timing belt cover thread pin to 8 Nm (71 lb in).
Important:
Install alignment pin in correct numbered, alignment slot on each camshaft gear.
10. Install camshaft gears.
11. Install camshaft gear bolts.
Important:
Use new camshaft gear bolts. The required tightening method will stretch to it's yield point therefore, the bolt it not reuseable.
^ Use Timing Belt Alignment Kit J 42069-1 and J 42069-2 to hold camshaft gears and camshaft in place while tightening camshaft gear bolts.
^ Tighten camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 50 Nm (37 lb ft) + 60° + 15°.
12. Mark upper and lower idler pulleys. Use a felt pen to mark the face of the idler pulleys. The mark should line up with the point furthest away from the Torx(R) head mounting bolt.
13. Align timing marks on each cam shaft sprocket with notch in rear timing belt cover.
14. Reinstall crankshaft locking tool J 42069-40 and rotate crankshaft to TDC.
15. Remove crankshaft locking tool J 42069-40 to ease installation of timing belt.
NOTICE:
The upper idler pulley (cam 1 and 2) and lower idler puller (cams 3 and 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 pulley uses an 11 mm (0.40 in.) thick spacer and a silver bolt.
Important:
The idler pulleys provide adjustment by rotating on an eccentric circle around the attachment bolt.
16. Install lower idler pulley. Tighten just enough to allow the pulley to rotate with slight resistance using idler pulley wrench J42069-40.
17. With upper idler pulley removed, install timing belt.
17.1. Align marks on timing belt with corresponding marks on # 3 and # 4 camshaft sprockets.
17.2. Install timing belt around lower idler pulley
17.3. Install timing belt around crankshaft sprocket. Ensure that mark on timing belt is aligned with mark on crankshaft sprocket face.
17.4. Lock timing belt onto crankshaft sprocket using plastic wedge J 42069-30.
17.5. Install timing belt around timing belt tensioner and align marks on timing belt with corresponding marks on # 1 and #2 camshaft sprockets.
17.6. Install upper idler pulley. Tighten just enough to allow the pulley to rotate with slight resistance using idler pulley wrench J 42069-40.
18. Reinstall crankshaft locking tool J 42069-10, and tighten lever arm to the water pump pulley flange.
19. Adjust timing belt tensioner so that the center alignment mark is about 3 mm (1/8 in.) above alignment mark on spring loaded idler.
20. Remove plastic wedge J 42069-30 from crankshaft sprocket.
21. Adjust upper idler pulley to approximately the 10 o'clock position. This will get the # 1 and # 2 timing marks close to their settings. Tighten until snug, but do not torque at this time.
22. Adjust lower idler pulley to approximately the 11 o'clock position. This will get the #3 and # 4 timing marks close to their settings. Tighten until snug, but do not torque at this time.
23. Remove 1-2 and 3-4 camshaft locks, timing belt alignment kit J 42069-1 and J 42069-2.
24. Install J 42069-20 checking gauge to cams 3 and 4.
25. Pull belt between the timing belt tensioner and crankshaft sprocket to take up slack between cams 3-4 and the lower idler pulley.
Important:
Ensure that the 3-4 timing marks are about 1 mm (approximately the width of the timing marks on the sprockets) on the retard side. If they are not, turn lower idler clockwise to allow retard of the 3-4 cams and repeat previous step.
26. Remove crankshaft locking tool J 42069-10.
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.
27. Rotate crankshaft 1-3/4 turns clockwise. Install J 42069-10 and then stop at TDC.
28. Tighten lever arm to the water pump pulley flange.
Important:
Timing marks on timing belt are used for initial installation only.
29. Adjust lower idler pulley by rotating counterclockwise until the 3-4 timing marks on the sprockets are lined up with marks on J 42069-20 checking gauge.
30. Tighten idler pulley, using J 42069-40 alignment tool to hold pulley while tightening fastener.
Tighten
Tighten the idler pulley fastener to 20 Nm (15 lb ft).
31. Remove J 42069-10 crankshaft locking tool.
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.
32. Rotate crankshaft 1-3/4 turns clockwise. Install J 42069-10 and then stop at TDC.
Important:
Timing marks on timing belt are used for initial installation only.
33. Tighten lever arm to the water pump pulley flange.
34. Inspect 3-4 timing marks for alignment and realign if necessary.
35. Remove J 42069-20 checking gauge from 3-4 camshaft sprockets and install on 1-2 camshaft sprockets.
36. Install J 42069-2 green camshaft locking tool onto 3-4 camshafts.
37. Adjust upper idler pulley by rotating counterclockwise until the 1-2 timing marks on the sprockets are lined up with marks on J 42069-20 checking gauge.
38. Tighten idler pulley, using J 42069-40 alignment tool to hold pulley while tightening fastener.
Tighten
Tighten the idler pulley fastener to 20 Nm (15 lb ft).
39. Remove J 42069-2 green camshaft locking tool from 3-4 camshafts and J 42069-10 crankshaft locking tool from crankshaft.
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.
40. Rotate crankshaft 1-3/4 turns clockwise. Install J 42069-10 and then stop at TDC.
Important:
If timing marks are off, repeat procedures to readjust. Removal of timing belt is not necessary.
41. Tighten lever arm to the water pump pulley flange.
42. Recheck both pairs of camshaft timing marks using J 42069-20 checking gauge.
43. Tighten both idler pulleys using J 42069-40 alignment tool to hold pulleys while torquing fasteners.
Tighten
Tighten the idler pulley fastener to 20 Nm (15 lb ft).
44. Adjust timing belt tensioner so that the center alignment mark is about 3 mm above alignment mark on spring loaded idler.
45. Tighten timing belt tensioner.
Tighten
Tighten the timing belt tensioner fastening nut to 20 Nm (15 lb ft).
46. Verify timing marks are still aligned.
47. Remove J 42069-10 crankshaft locking tool and J 42069-20 checking gauge.
48. Install front timing belt cover.
49. Install front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolt to 8 Nm (71 lb in).
50. Install crankshaft balancer.
Tighten
Tighten the crankshaft balancer bolt to 20 Nm (15 lb ft).
51. Install accessory drive belt tensioner.
52. Install accessory drive belt tensioner bolts.
Tighten
Tighten the belt tensioner bolt to 40 Nm (30 lb ft).
53. Install power steering pump pulley.
54. Install power steering pump pulley bolts.
55. Snug power steering pump pulley bolts. The bolts will be tightened to proper specification when serpentine drive belt is installed.
56. Install water pump pulley.
57. Install water pump pulley bolts. Snug the water pump pulley bolts. The bolts will be tightened to proper specification when the accessory drive belt is installed.
58. Install wiring harness channel to front timing belt cover.
Tighten
Tighten the wire harness channel to 6 Nm (53 lb in).
Important:
prior to installing bolts, slide the washer from kit (P/N 11011619) onto bolt (1) as shown in the illustration.
59. Install accessory drive belt.
60. Tighten water pump pulley and power steering pulley bolts.
Tighten
Tighten the water pump pulley bolt to 8 Nm (71 lb in).
Tighten
Tighten the power steering pulley bolt to 20 Nm (15 lb ft).
61. Install throttle body wire harness rosebud into fuel line bracket.
62. Install EGR pipe heat shield bolt.
Tighten
Tighten the EGR pipe heat shield bolt to 8 Nm (71 lb in).
63. Install fuel lines into both clips on top of engine.
64. Install engine mount bracket and tighten bolts.
Tighten
Tighten the engine mount bracket bolts to 55 Nm (41 lb ft).
65. Install engine mount to frame rail and engine mount bracket.
Tighten
Tighten the engine mount-to-bracket bolt to 55 Nm (41 lb ft).
66. Remove engine support fixture.
Important:
Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.
67. Raise vehicle.
68. Install splash shield.
69. Install splash shield bolts. Tighten splash shield bolts until fully seated. Do not strip bolts
70. Lower vehicle.
71. Reconnect A/C pressure sensor electrical connector.
72. Install air cleaner assembly.
72.1 Install air box. Ensure that lower pin engages into rubber mount grommet and that lower duct fits into resonator outlet.
72.2. Install air box mount bolt.
Tighten
Tighten the air box mount bolt to 6 Nm (53 lb in).
72.3. Install air cleaner.
72.4 Install air cleaner lid. Ensure that the lid hinge is fully engaged in air box slots or the lid may not properly seal.
- Install air cleaner lid, MAF sensor, and hose as an assembly.
- Clamp air cleaner lid.
- Slide flexible MAF hose and hose clamp on throttle body.
- Tighten hose clamp.
72.5 Install EVAP purge valve assembly.
72.6. Connect MAF electrical connection.
73. Install EVAP purge line into clip on rear of strut tower.
74. Reconnect negative battery cable.
Tighten
Tighten the battery terminal bolts to 17 Nm (13 lb ft).