Timing Belt Removal and Installation

Figure 59:

CAUTION: The 2.5L engine is a Non-freewheeling design. When the timing belt is removed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage

REMOVAL
1. Remove timing belt covers.

Figure 60:

2. Mark timing belt running direction for installation (Fig. 60).

Figure 61:

3. Loosen timing belt auto tensioner bolts (Fig. 61) and remove timing belt.

CAUTION: Coolant or oil leakage on timing belt will shorten its life drastically. If timing belt is seriously contaminated, it must be replaced. Clean all components and correct source of leak.

CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE
TIMING BELT TENSIONER
1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

Figure 62:

2. Place the tensioner into a vise and slowly compress the plunger (Fig. 62).

CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper locking pin orientation when tensioner is installed on the engine.

3. When plunger is compressed into the tensioner body, install a locking pin through the body and plunger.

INSTALLATION

Figure 63:

1. Set crankshaft sprocket to TDC by aligning the sprocket mark with the mark on the oil pump housing. Then rotate crankshaft 3 notches before Top Dead Center (TDC) (Fig. 63).

Figure 64:

2. Set camshaft sprockets to the aligning marks on the sprockets with the marks on the rear timing belt cover (Fig. 64).
3. Install timing belt on right camshaft sprocket. Install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the belt taught, install belt under the water pump pulley and then around the left camshaft sprocket. Install an additional binder clip on the left sprocket and belt.

Figure 65:

4. Rotate the crankshaft to TDC (Fig. 65). Continue routing the belt around the idler pulley, crankshaft sprocket, and tensioner pulley.
5. To tension belt perform the following:
a. Apply rotating force to the crankshaft sprocket in the clockwise direction, check that all timing marks are aligned.

Figure 66:

b. Using Special Tool MD 998767 and a torque wrench on the tensioner pulley. Apply 4.4 Nm (38.9 inch lbs.) of torque to tensioner (Fig. 66). Tighten tensioner pulley bolt to 48 Nm (35 ft. lbs.).
c. With torque being applied to the tensioner pulley install the tensioner to the tensioner pulley bracket and tighten fasteners to 23 Nm (205 inch lbs.).
d. Pull tensioner plunger pin.

Figure 61:

6. Rotate crankshaft 2 revolutions in a clockwise direction ONLY and check the alignment of the timing marks. Install tensioner pin into assembly. The pin should slide in and out without any resistance. If the pin does not slide freely, perform the procedure again.
7. Install timing belt covers.
8. Install right engine mount.
9. Install crankshaft damper and crankshaft damper bolt. Tighten to 182 Nm (134 ft. lbs.).
10. Install accessory drive belts. Refer to Drive Belts, Mounts, Brackets and Accessories for the procedure.
11. Raise vehicle on hoist and install drive belt splash shield.