Timing Belt: Service and Repair
TIMING BELT AND SPROCKETSREMOVAL - TIMING BELT
1. Remove front timing belt cover (Fig. 156).
2. Remove spark plugs.
CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine CLOCKWISE with the crankshaft (Fig. 166).
3. Loosen timing belt tensioner lock nut (Fig. 157).
4. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate CLOCKWISE until there is enough slack in timing belt to allow for removal (Fig. 157).
5. Remove timing belt.
CAUTION: Do not rotate the camshaft once the timing belt has been removed or damage to valve components may occur.
REMOVAL - CAMSHAFT SPROCKET
1. Remove timing belt.
2. Hold camshaft sprocket with Special Tools C-4687 and modified Adaptor C-4687-1 (Fig. 158), while removing attaching bolt.
NOTE: For Special Tool Identification, (Refer to -ENGINE - SPECIAL TOOLS).
3. Remove camshaft sprocket.
REMOVAL - CRANKSHAFT SPROCKET
1. Remove timing belt
2. Remove the crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 159).
INSTALLATION - CRANKSHAFT SPROCKET
NOTE: Make sure the word "front" on the sprocket is facing outward.
CAUTION: Use of Special Tool 6792 is required to install the crankshaft sprocket to the proper depth. Failure to use this tool will cause improper timing belt tracking.
1. Install the crankshaft sprocket (Fig. 160) using Special Tool 6792.
INSTALLATION - CAMSHAFT SPROCKET
1. Install camshaft sprocket. While holding sprockets with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 115 Nm (85 ft. lbs.).
2. Install timing belt.
INSTALLATION - TIMING BELT
1. 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 (Fig. 161).
2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear timing belt cover (Fig. 162).
3. Move crankshaft to 1/2 mark before TDC (Fig. 163) for belt installation.
4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket, then around the camshaft sprocket, and finally route the back side of the timing belt around the timing belt tensioner pulley.
5. Move crankshaft sprocket to TDC to take up belt slack.
6. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Fig. 164). Using the alien wrench to prevent the top plate from moving, torque the tensioner lock nut to 30 Nm (22 ft. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued.
7. Remove alien wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible.
8. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position (Fig. 166).
9. Check if the spring tang is within the tolerance window (Fig. 165). If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 6 through 8.
10. Install front timing belt cover.
11. Install spark plugs.
12. Perform camshaft and crankshaft timing relearn procedure as follows:
^ Connect the DRB III- scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column.
^ Turn the ignition switch on.
^ Access "Engine" diagnostics.
^ Select "Miscellaneous" option.
^ Select "Relearn Cam Crank" option and follow directions on DRBIII screen.