Timing Belt: Service and Repair
Tools Required:
- Puller T67L-3600-A
- Vibration Damper and Seal Installer T82L-6316-A
- Crankshaft Seal Installer/Cover Aligner T88T-6701-A
- Screw and Washer Set T89P-6701-A
- Step Plate Adapter D80L-630-3
- Inch Pound Torque Wrench D81L-600-A
- Rotunda Offset Belt Tension Gauge 021-0028A
Images of some of these tools are found under Tools and Equipment. Tools and Equipment
Removal
Note: This engine is a dual overhead cam motor with a single timing belt sprocket on each bank, the second camshaft is driven by a chain under the valve cover of each cylinder head. For Service and Repair of the chain and tensioner, refer to Camshaft Service and Repair. Service and Repair
1. Disconnect battery cables.
2. Remove battery.
Engine Roll Dampener:
3. Remove RH engine roll damper.
4. Disconnect wiring to ignition control module (ICM).
5. Remove intake manifold crossover tube bolts.
6. Loosen intake manifold crossover tube hose clamps.
7. Remove intake manifold crossover tube.
8. Loosen generator/A/C (6 rib) belt tensioner pulley and relieve tension on belt by backing out adjustment screw.
9. Remove generator/A/C belt.
10. Loosen water pump/power steering (4 rib) belt tensioner pulley and relieve tension on belt by backing out adjustment screw.
11. Remove water pump/power steering belt.
12. Remove generator/A/C belt tensioner pulley and bracket assembly.
13. Remove water pump/power steering belt tensioner pulley only.
14. Remove upper timing belt cover.
15. Disconnect crankshaft sensor connectors.
16. Place transaxle in NEUTRAL.
Timing Marks:
17. Set engine to TDC on No. 1 cylinder.
Ensure that "white" mark on crankshaft damper aligns with 0 degree index mark on lower timing belt cover and that marks on intake camshaft pulleys align with index marks on metal timing belt cover.
18. Raise vehicle on a hoist.
19. Remove RH front wheel and tire assembly.
20. Loosen fender splash shield and place out of the way.
21. Remove crankshaft damper using Steering Wheel Puller T67L-3600-A, Step Plate Adapter D80L-630-3 and Screw and Washer Set T89P-6701-A or equivalent.
22. Remove lower timing belt cover.
23. Remove center timing belt cover and disconnect crankshaft sensor wire and grommet from the slot in the cover and stud on water pump.
Timing Belt Tensioner Unloaded:
24. Loosen timing belt tensioner, rotate pulley 180 degrees clockwise using an Allen wrench, and tighten tensioner nut to hold pulley in the "unload position."
25. Lower vehicle.
26. Remove timing belt.
Installation
CAUTION:
- Before installing timing belt, inspect if for cracks, wear or other damage. Replace if damaged.
- Do not allow timing belt to come in contact with gasoline, oil, water, coolant or steam.
- Do not turn belt inside out or twist belt.
- Always store belt in a cool dark place.
- Always keep belt in protective packaging until ready for use.
- Never hit or squeeze belt with hammer or screwdriver.
1. Ensure engine is at TDC on No. 1 cylinder.
Check that camshaft pulley marks line up with index marks on upper steel belt cover and that crankshaft pulley aligns with index mark on oil pump housing.
2. Install timing belt on crankshaft pulley and route to camshaft pulleys.
Lettering on belt "KOA" should be readable from rear of engine (top of lettering to front of engine). Also ensure that the yellow lines are aligned with the index marks on the pulley.
Note: The timing belt has three yellow lines. Each line aligns with the index marks shown.
3. Release tensioner locknut and leave nut loose.
4. Raise vehicle on hoist.
5. Install center timing belt cover.
Ensure crankshaft sensor wiring and grommet are installed and routed properly.
Tighten retaining bolts to 7-11 Nm (62-97 In lbs).
6. Install lower timing belt cover.
Tighten retaining bolts to 7-11 Nm (62-97 In lbs).
7. Install crankshaft damper using Crankshaft Seal Installer/Cover Aligner TB8T-670 1-A with forcing screw from Vibration Damper and Seal Installer T82L-6316-A or equivalent.
Yellow Index Mark:
8. Rotate crankshaft two revolutions in the clockwise direction until the yellow mark on damper aligns with 0 degree mark on lower timing belt cover.
9. Remove plastic door in the lower timing belt cover.
Tighten belt tensioner lock nut to 33-51 Nm (24-38 ft lbs) and install plastic door.
White Index Mark:
10. Rotate crankshaft 60 degrees more in the clockwise direction until the white mark on damper aligns with 0 degree mark on lower timing belt cover.
11. Lower vehicle.
12. Ensure index marks on camshaft pulleys align with marks on rear metal timing belt cover.
13. Route crankshaft sensor wiring and connect with engine wiring harness.
14. Install upper timing belt cover.
Tighten retaining bolts to 7-11 Nm (62-97 In lbs).
15. Install water pump pulley.
Tighten retaining nut to 16-23 Nm (12-17 ft lbs).
16. Install generator/A/C tensioner pulley and bracket assembly.
Tighten bolts to 15-23 Nm (11-17 ft lbs).
17. Install water pump/power steering (4 rib) belt. Using Rotunda Offset Belt Tension Gauge 021-0028A or equivalent, set tension.
Tighten idler pulley retaining nut to 34-50 Nm (25-36 ft lbs).
Belt Tension:
- New belt: 690-880 N (154-198 lb)
- Used belt: 500-700 N (112-157 lb)
18. Install generator/A/C (6 rib) belt. Using Rotunda Offset Belt Tension Gauge 021-0028A or equivalent, set tension.
Tighten idler pulley retaining nut to 34-50 Nm (25-36 ft lbs).
Belt Tension:
- New belt: 980-1180 N (220-265 lb)
- Used belt: 660-850 N (148-192 lb)
19. Install intake manifold cross over tube.
Tighten bolts to 15-23 Nm (11-17 ft lbs).
20. Install engine roll damper.
21. Install battery.
22. Connect battery cables.
23. Raise vehicle.
24. Install splash shield.
25. Install RH front tire and wheel assembly.
Tighten wheel lug nuts to 115-142 Nm (85-105 ft lbs).
26. Lower vehicle.