B. Timing Belt Installation
B1. Rotate the tensioner pulley so that the pinholes are to the left of the center bolt. Tighten the center bolt finger-tight (Figure 5).
Note:
leave the alien wrench installed in the auto tensioner.
B2. Make sure the camshaft sprocket dowel pins are located at the 12 o'clock position and the camshaft sprocket timing marks are aligned together (left sprocket at the 3 o'clock and right sprocket at the 9 o'clock positions). Both camshaft sprocket timing marks should be in line with the top surface of the cylinder head (Figure 3).
Note:
The exhaust camshaft sprocket, may rotate in the counterclockwise direction. This should be considered when installing the timing belt on the sprockets.
B3. Make sure notch on the crankshaft sprocket and arrow on the oil pump sprocket is aligned with timing mark pointers (Figure 7).
B4. Remove the balance shaft plug on the rear side of the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] through the hole (Figure 8). The balance shaft is in the correct position if the screwdriver can be inserted at least 60 mm (2.4 in.). If the inserted depth is less than this (only 20-25 mm (.8-1.0 in.), the oil pump sprocket must be rotated one full turn and timing marks realigned. Recheck the balance shaft position using the screwdriver to ensure that it can be inserted 60 mm (2.4 in.) or more. Keep the screwdriver inserted until timing belt installation is complete.
Caution:
MAKE SURE THE BALANCE SHAFT IS PROPERLY POSITIONED. It is possible for the oil pump sprocket timing marks to be properly aligned, and have the balance shaft out of phase. This could result in a SEVERE engine vibration.
B5. Install the provided timing belt over the intake side camshaft sprocket and clamp it in position with a clip (Figure 9).
B6. Install the timing belt over the exhaust side sprocket, aligning the timing marks as shown in Figure 3 (two wrenches may be required) and clamp the belt in position with a clip (Figures 10 & 11).
B7. Position the timing belt around the idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley (in that order) as shown in Figure 12.
B8. Lift the tensioner pulley in the direction of arrow and tighten the center bolt (Figure 13).
NOTE:
MAKE SURE ALL TIMING MARKS ARE PROPERLY ALIGNED.
B9. Remove the screwdriver from the balance shaft hole and install the plug. Remove the two clips holding the belt to the camshaft sprockets.
B10. Rotate the crankshaft a 1/4 turn counterclockwise, then rotate it clockwise until the timing marks are aligned again. Crankshaft position should still be at the No. 1 piston TDC position of the compression stroke.
NOTE:
MAKE SURE ALL TIMING MARKS ARE PROPERLY ALIGNED.
B11. Loosen the tensioner pulley center bolt, attach special tool no. MD998752 (or MD998767) and apply 2.7 N-m (24 in.lbs.) torque to pulley (with beam type torque wrench) as shown in Figure 14. WITH TORQUE APPLIED TO THE TENSIONER PULLEY, tighten the attaching bolt, then torque to 49 +/- 6 N-m (36 +/- 4 ft.lbs.).
Caution:
Failure to follow this procedure will cause the belt tension to exceed the range of the auto tensioner limits and result in premature timing belt failure or jumping.
Note:
If the vehicle body interferes with the special tool and the torque wrench, raise the engine up slightly until there is adequate clearance.
B12. SLOWLY rotate the special tool no. MD998738 until it makes contact with the tensioner arm and remove the alien wrench from the auto tensioner.
B13. Back off special tool and rotate the crankshaft SIX complete turns clockwise. Measure the auto tensioner push rod position with a drill bit (distance between the tensioner arm and auto tensioner body) to ensure that it falls within the specification of 3.8-4.5 mm (.15-.18 in.) as shown in Figure 15.
Note:
Wait 15 minutes after the alien wrench is removed from auto tensioner and crankshaft has been rotated (for plunger rod to stabilize) before measuring. If the plunger rod is out of specification, reset the auto tensioner (steps A10 & A11) and repeat steps B11 through B13 until the specified value is obtained.
B14. Remove special tool no. MD998738 and install the rubber plug to the inner timing belt cover.
B15. Install the upper and lower timing belt covers as shown in Figure 2.
Note that timing cover bolts vary in length. Make sure that the proper size bolts (Figure 2) are installed in the correct hole locations.
B16. Install crankshaft pulley and torque to 25 +/- 5 N-m (18 +/- 4 ft.lbs.).
B17. Install A/C tensioner bracket with A/C belt and torque to 25 +/- 2 N-m (18 +/- 4 ft.lbs.). Adjust belt tension to 5.5-6.0 mm (.220-.240 in.) belt deflection.
B18. Install water pump pulley.
B19. Install alternator/water pump and power steering drive belts and adjust belt tension as follows:
Belt Deflection
Alternator/Water Pump Belt 9.0-11.5 mm (.354-.453 in.)
Power Steering Belt 6.0-9.0 mm (.240-.354 in.)
B20. Install left front engine mount and bracket and torque to the specifications shown in Figure 1.
B21. Remove engine support fixture.
B22. Install lower engine compartment splash shield.