Installation and Timing

1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

Compressing Timing Belt Tensioner:

2. Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger.

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

3. When plunger is compressed into the tensioner body install a 1.9 mm (5/64) Allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed.

Crankshaft Sprocket Timing:

4. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC.

Camshaft Timing Mark:

5. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover.

Adjusting Crankshaft Sprocket For Timing Belt Installation:

6. Move crankshaft to 1/2 mark before TDC for belt installation.
7. Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket.
8. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners.

Adjusting Timing Belt Tension:

9. Using a torque wrench on the tensioner pulley apply 28 Nm (250 inch lbs.) of torque.
10. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (23 lbs.).
11. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed.
12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks.
13. Install front half of timing cover.
14. Install engine mount bracket.

Generator And Brackets:

15. Install generator bracket to engine. Tighten attaching bolts to 61 Nm (45 ft. lbs.).
16. Install generator.
17. Install right engine mount.
18. Remove jack from under engine.

Crankshaft Damper - Installation:

19. Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.)).
20. Install accessory drive belts.
21. Raise vehicle on hoist and install right inner splash shield.
22. Lower vehicle and connect negative cable.