Timing Belt: Service and Repair

Timing Belt Replacement

^ Tools Required
- J 42069 Timing Belt Alignment Kit
- J 42098 Crank Hub TORX Socket

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the timing belt front cover.
3. Rotate the crankshaft using the J 42098 until the #1 cylinder is at 60 degrees Before Top Dead Center (BTDC).
4. Install the crankshaft locking tool, J 42069.
5. Rotate the crankshaft in the engine rotational direction (clockwise) using the J 42098 until the #1 cylinder is at TDC and tighten the lever arm to the water pump pulley flange.






Important: Ensure that the alignment of the crankshaft is not 180 degrees off. The alignment marks must align with the corresponding notches on the rear timing belt cover.

6. Install the 1-2 and 3 camshaft locks, J 42069 and J 42069-2.





7. Loosen the timing belt tensioner.

Important: Do not rotate the crankshaft if the camshaft is not locked in place with 1-2 and 3 camshaft locks, J 42069 and J 42069-2.

Important: Do not rotate the camshafts unless the crankshaft is at 60 degrees BTDC or valves may contact crankshaft.

8. Remove the timing belt.

Inspection Procedure

Important: Failure to follow the described timing belt inspection and maintenance may result in a broken timing belt and cause severe engine damage.





1. When checking the condition of the timing belt, inspect for the following conditions and possible causes:
^ Tooth is broken and/or tooth root is cracked Camshaft jamming, damaged camshaft crankshaft oil seal and/or coolant leak, old age, tensioner not functioning properly.
^ Back surface of the belt is cracked/worn/scratched/scored-Excessive cold starts, tensioner jamming, overheated engine, interference with the belt cover.
^ Side of belt surface is worn-Improper installation of belt, overload or misalignment of cam drive components, tensioner jamming, heavy thrust loading against idler guide flanges, damaged idler guide.
^ Teeth are worn-Poor belt cover sealing, excessive belt tension, tension jamming, rough and/or scored cam sprockets.
^ Clean break across fibers-Kinked belt before or during assembly, foreign material under the belt.
^ Oil/coolant impregnated and/or swollen belt- Poor oil sealing, coolant leak at pump, poor belt cover seal.





2. Check that the tensioner turns smoothly and that no binding occurs in the bearing.

Installation Procedure





1. Remove the crankshaft tool. This will ease installation of the timing belt.

Important: With the camshaft locks installed, verify the distance between the camshaft sprockets with the green test belt located in the J 42069.

2. 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.
3. Install the belt around the timing belt tensioner.
4. Route the belt around the upper idler pulley.
5. Route the belt around the #3 and the #4 camshaft sprockets while aligning the belt marks to the marks on the sprockets and the rear cover.
6. Route the belt around the crankshaft hub sprockets while aligning the marks on the belt to the marks on the sprockets and the rear cover.





7. Install the J 42069-30 to lock the timing belt onto the crankshaft hub sprocket.





8. With the belt firmly engaged on the crankshaft hubs carefully rotate the crankshaft counterclockwise to get the belt slack on the lower idler pulley side.
9. Route the belt around the lower idler pulley.





10. Remove the J 42069-30.





11. Install the J 42069-2 and tighten the lever arm to the water pump pulley flange.





12. Perform the following in sequence:
12.1. Install the camshaft gage to cams 3 and 4 and verify alignment marks are within 2 mm (0.08 inch) of each other.
12.2. Install 3 and 4 camshaft lock, if properly aligned.
12.3. Install the camshaft checking gage to cams 1 and 2.





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

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

14. Rotate the upper idler pulley counterclockwise until the marks are properly aligned within 2 mm (0.08 inch) of each other.

Notice: Refer to Fastener Notice in Service Precautions.

15. Install 1 and 2 camshaft lock, when properly aligned.
^ Tighten the upper pulley bolt to 40 Nm (30 ft. lbs.).





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





17. Remove 1-2 and 3-4 camshaft locks, J 42069 and J 42069-2.
18. Remove the J 42069-10.






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, rotate the crankshaft an additional two turns.

19. Rotate the crankshaft 1 3/4 turns clockwise, install J 42069-10, and then stop at TDC.

Important: Timing marks on the timing belt are used for initial installation only.

Important: If the timing marks are off, repeat the procedures to readjust. Removal of the timing belt is not necessary.

20. Tighten the lever arm to the water pump pulley flange.
21. Recheck both pairs of the camshaft timing marks using the J 42069-20.





22. Adjust the timing belt tensioner to the center alignment mark is about 3 mm (1/8 inch) above the alignment mark on the spring loaded idler.
23. Tighten the timing belt tensioner.
^ Tighten the timing belt tensioner fastening nut to 20 Nm (15 ft. lbs.).
24. Verify the timing marks are still aligned.
25. Remove the J 42069-10 and J 42069-20.
26. Install the timing belt front cover.
27. Connect the negative battery cable.
^ Tighten the battery terminal bolts to 17 Nm (13 ft. lbs.).