B. Replace Timing Belt

1. Lower the vehicle.

2. For JA/JX vehicles: Remove the generator belt sound shield (if equipped).





3. Loosen the generator adjusting bolt locknut (A) and pivot bolt (B) (Figure 2).

4. Back off the belt tension adjuster and remove the generator/air conditioning compressor drive belt.





5. Loosen the power steering pump pivot bolt (C) and the two (2) pump locking bolts (D and E) (Figure 3).

6. Remove the power steering pump drive belt.

7. For JA/JX vehicles: Loosen the three (3) upper right engine mount bolts three (3) turns each to allow the engine to tip slightly to improve access to the crankshaft damper.

8. Raise the vehicle.

9. Remove the crankshaft damper bolt.





10. Remove the crankshaft damper using Special Tool 1026 and Insert 6827-A or equivalent (Figure 4).

NOTE:
On JA/JX vehicles, the special tool must be removed from the damper before the damper can be removed from the crankshaft.

11. Remove the generator/compressor drive belt idler pulley.








12. Remove the lower timing belt cover fasteners and then remove the lower timing belt cover (Figure 5 -- JA/JX, Figure 6 -- NS).

13. Lower the vehicle.

14. For JA/JX vehicles: Remove the coolant recovery bottle. Remove the Air conditioning drier bracket bolt (if not equipped with generator belt sound shield).

15. Remove the upper timing belt cover fasteners and then remove the upper timing belt cover (Figure 5 -- JA/JX, Figure 6 -- NS).

16. Carefully support the engine assembly with a floor jack.

17. For NS vehicles: Disconnect the purge solenoid and electrical harness from the right engine mount.








18. Remove the bolts that attach the right engine support assembly to the engine bracket (Figure 7 -- JA/JX, Figure 8 -- NS).

19. Remove the right engine support assembly fasteners from the frame rail and then remove the right engine support assembly (Figure 7 -- JA/JX, Figure 8 -- NS).

20. Remove the right engine support bracket from the engine.





21. Install the crankshaft damper bolt, then align the crankshaft and camshaft timing marks to TDC (Figure 9)

NOTE:
When aligning the crankshaft and camshaft timing marks, always rotate the engine from the crankshaft. The camshafts should not be rotated after the timing belt is removed. Always align the timing marks before removing the timing belt.





22. Install a 6 mm Allen wrench into the belt tensioner. Before rotating the tensioner insert the long end of a 1/8" (3 mm) Allen wrench into the pin hole on the front of the tensioner (Figure 10).

23. While rotating the tensioner counter-clockwise, push lightly on the 1/8" (3 mm) Allen wrench, until it slides into the locking hole.

24. Remove and discard the timing belt.

25. Remove and discard the timing belt idler pulley (Figure 10).





26. Remove both cam sprockets by holding the camshaft sprocket with Special Tool 6847 and removing the bolt (Figure 11).





27. Remove the rear timing belt cover fasteners and remove the rear timing belt cover (Figure 12).





28. Remove the lower timing belt tensioner bracket attaching bolt and remove the tensioner and bracket as an assembly (Figure 13). Discard the tensioner and bracket assembly.

NOTE:
Tensioner and bracket must be replaced as an assembly. Reusing the old bracket will cause timing belt failure.

29. Align the provided tensioner and bracket assembly to the engine and install the lower bracket mounting bolt but DO NOT TIGHTEN (Figure 13).

30. Loosely install an engine support bracket bolt (M10) five to seven (5-7) turns into the upper tensioner bracket hole (Figure 13).

31. Tighten the lower tensioner bracket mounting bolt to 45 ft-lbs (61 N.m).

32. Remove the bolt from the upper tensioner bracket bolt location.

33. Install the rear timing belt cover (Figure 12). Tighten the attaching bolts to 105 in-lbs (12 N.m).

34. Install both camshaft sprockets. Tighten each attaching bolt to 75 ft-lbs (101 N.m) while holding the gear with special tool 6847 (Figure 11).

35. Install the provided timing belt idler pulley. Tighten the mounting bolt to 45 ft-lbs (61 N.m).





36. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing (Figure 14).





37. Set the camshaft timing marks so that the exhaust camshaft sprocket is 1/2 notch below the intake sprocket (Figure 15).

NOTE:
Ensure that the arrows on both camshaft sprockets are pointing up.

38. Install the provided timing belt. Start at the crankshaft, go around the water pump sprocket, the idler pulley, both camshaft sprockets and then around the tensioner (Figure 14).

39. Move the exhaust camshaft sprocket counter-clockwise to align the timing marks and take up the belt slack (Figure 14).

40. Remove the pull pin from the new tensioner (Figure 14).

41. Rotate the crankshaft two (2) revolutions and then check the alignment of the timing marks (Figure 9).

42. Install the engine support bracket on the engine (Figures 5 and 6). Tighten the three attaching bolts to 45 ft-lbs (61 N.m).

43. Install the engine support assembly on the engine bracket (Figures 7 and 8).
For JA/JX vehicles: Tighten the attaching bolts to 45 ft-lbs (61 N.m).
For NS vehicles: First tighten the vertical attaching bolt to 75 ft-lbs (102 N.m), then tighten the horizontal attaching bolt to 110 ft-lbs (150 N.m).

44. Install the engine support vertical fasteners through the frame rail. Tighten to 45 ft-lbs (61 N.m). Remove the floor jack.

45. For NS vehicles: Connect the purge solenoid and wiring harness to the engine support.

46. Install the upper timing belt cover (Figures 5 and 6). Tighten the bolts to 40 in-lbs (4.5 N.m).

47. For JA/JX vehicles: Install the coolant recovery bottle.

48. Raise the vehicle on the hoist.

49. Install the lower timing belt cover (Figures 5 and 6). Tighten the bolts to 40 in-lbs (4.5 N.m).

50. Install the generator/compressor drive belt idler pulley.





51. Remove crankshaft bolt. Install the crankshaft damper using the M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792 (Figure 16).

52. Install the crankshaft damper bolt and tighten to 105 ft-lbs (142 N.m).

53. Install the power steering pump drive belt. Adjust belt tension to 80 lbs using a belt tensioning tool and a 1/2" breaker bar installed in the adjusting bracket (Figure 3).

54. Tighten the two (2) power steering pump locking bolts and pivot bolt to 40 ft-lbs (54 N.m) (Figure 3).

55. Install the generator/air conditioning compressor drive belt.

56. Install the right wheel well lower splash shield.

57. Install the right front wheel and tire assembly.

58. Lower the vehicle.

59. Adjust the generator/compressor belt tension to 80 lbs using a belt tensioning tool. Tighten the generator lock nut and pivot bolt to 40 ft-lbs (54 N.m) (Figure 2).

60. For JA/JX vehicles: Install the generator sound shield (if equipped).