Timing Belt and Drive Assembly Installation
SPECIAL TOOLS- Counterhold tool No. 999 5199, or equivalent
- Counterhold tool No. 999 5433, or equivalent
- Drift tool No. 999 5450, or equivalent
- Drift tool No. 999 5455, or equivalent
PROCEDURES
1. Install oil pump
- Use new gasket.
- Use drift tool No. 999 5455, or equivalent to install pump, using bolts as guides.
- Pull in pump using crankshaft center nut.
NOTE: Do not let crankshaft turn, as this may damage valves.
- Use thread locking compound part No. 1 161 056-5, or equivalent, on bolts.
- Tighten bolts in star pattern to 10 Nm (7 ft. lbs.).
2. Install belt drive pulley on crankshaft
- Install belt drive pulley using center nut and spacer.
- Install oil thermostat housing, use new O-ring.
NOTE: Do not let crankshaft turn, as this may damage valves.
3. Install:
- inner timing belt cover
- coolant pump, using new gasket, tightening bolts alternately to 20 Nm (15 ft. lbs.).
- thermostat and thermostat housing, using new gasket.
4. Install upper timing belt cover
- Install camshaft pulleys, aligning timing marks as shown.
- Insert two bolts in each pulley until they just touch the camshaft pulleys.
- Remove upper timing belt cover.
NOTE: Check that camshaft bolt holes are centered in the oval holes.
5. Install pulleys and tensioner
- Install idler pulley, tighten to 24 Nm (18 ft. lbs.)
- Install tensioner pulley, apply grease to surfaces of the actuator arm bushing, screw and sleeve. Use grease part No. 1161246-2, or equivalent.
- Tighten tensioner pulley as shown.
1992 - 93 Engines: Tighten to 39 Nm (29 ft. lbs.)
1994 - 98 Engines: Tighten to 30 Nm (22 ft. lbs.)
- Install tensioner/damper, tighten to 24 Nm (18 ft. lbs.).
6. Install timing belt
- Place belt over camshaft pulleys, around coolant pump and press the belt over the tensioner pulley.
- Undo the two camshaft pulley bolts. Pull lock pin out of tensioner/dampening unit.
- Locat the belt by tapping lightly (twice) with a rubber mallet between the camshaft pulleys and coolant pump.
- Install the washer to limit the tensioner/dampener unit as shown. The plastic washer is supplied with the camshaft belt kit (white, P/N 1271851-6)
- Install the third camshaft pulley bolt and tighten all bolts to 20 Nm (15 ft. lbs.).
- Install upper timing cover.
- Install belt cover (snowguard).
7. Remove locking tool
- Remove crankshaft locking tool No. 999 5451, or equivalent, and install new plug.
- Remove camshaft locating tool No. 999 5452, or equivalent.
8. Install camshaft rear seals
- Use drift tool No. 999 5450, or equivalent.
- Grease seals.
- Press seals in place.
NOTE: If shaft end shows signs of wear, seal can be pressed another 2 mm in by turning tool sleeve.
9. Install vibration damper
- Install vibration damper using counterhold tool No. 999 5433, or equivalent.
- Tighten center nut to 300 Nm (221 ft. lbs.)
- Remove counterhold and tighten damper bolts to 35 Nm (26 ft. lbs.) then an additional 60°.
10. Check timing marks
- Turn crankshaft through two revolutions.
- Check that timing marks on crankshaft and camshaft pulleys line up.
- Install outer transmission cover.