Engine Serial Number 578511 and Prior

NUMBER PRIOR TO 578511

TOOLS REQUIRED

J42069 Timing Belt Alignment Kit
J42098 Crank Hub Torx Socket

REMOVAL

1. Disconnect negative battery cable.
2. Remove timing belt front cover.






3. Rotate crankshaft using Crank Hub Torx Socket J42098 until #1 cylinder is at 60° Before Top Dead Center (BTDC).
4. Install crankshaft locking tool, Timing Belt Alignment Kit J42069-10.
5. Rotate crankshaft in the engine rotational direction (clockwise) using Crank Hub Torx Socket J42098 until #1 cylinder is at TDC and tighten lever arm to the water pump pulley flange.

IMPORTANT: Ensure that the alignment of crankshaft is not 180 degrees off. The alignment marks must align with the corresponding notches on the rear timing belt cover.










6. Install 1-2 and 3-4 camshaft locks, timing belt alignment kit J42069-1 and J42069-2.
7. Loosen timing belt tensioner.
8. Remove timing belt.

IMPORTANT: Do not rotate crankshaft if camshafts are not locked in place with 1-2 and 3-4 camshaft locks, timing belt alignment kit J42069-1 and 142069-2.

IMPORTANT: Do not rotate camshafts unless crankshaft is at 60° BTDC or valves may contact crankshaft.

INSPECTION






NOTICE: Failure to follow the described timing belt inspection and maintenance may result in a broken timing belt and cause severe engine damage.

1. When checking the condition of the timing belt, inspect for the following conditions and possible causes:
Tooth is broken and/or tooth root is cracked - Camshaft jamming, damaged camshaft/crankshaft oil seal and/or coolant leak, old age, tensioner not functioning properly.

Back surface of the belt is cracked/worn/scratched/scored - Excessive cold starts, tensioner jamming, overheated engine, interference with the belt cover.

Side of belt surface is worn - Improper installation of belt, overload or misalignment of cam drive components, tensioner jamming, heavy thrust loading against idler guide flanges, damaged idler guide.

Teeth are worn - Poor belt cover sealing, excessive belt tension, tension jamming, rough and/or scored cam sprockets.

Clean break across fibers - Kinked belt before or during assembly, foreign material under the belt.

Oil/coolant impregnated and/or swollen belt - Poor oil sealing, coolant leak at pump, poor belt cover seal.
2. Check that the tensioner turns smoothly and that no binding occurs in the bearing.

INSTALLATION






1. Remove crankshaft locking tool. This will ease installation of timing belt.

NOTICE: The upper idler pulley (cams 1 & 2) and lower idler puller (cams 3 & 4) use different bolts and spacers of different thicknesses. The upper idler pulley uses a narrow 5 mm (0.20 In.) thick spacer and a black bolt. The lower idler puller uses a 11 mm (0.40 in.) thick spacer and a silver bolt.






2. With tensioner pulley loose, install timing belt.
2.1 Align marks on timing belt with corresponding marks on #1 and #2 camshaft sprockets.
2.2 Install timing belt around upper idler pulley.
2.3 Install timing belt around timing belt tensioner and align marks on timing belt with corresponding marks on #3 and #4 camshaft sprockets.
2.4 Install timing belt around lower idler pulley.
2.5 Install timing belt around crankshaft sprocket. Ensure that mark on timing belt is aligned with mark on crankshaft sprocket face
2.6 Lock timing belt onto crankshaft sprocket using plastic wedge J42069-30.






3. Reinstall crankshaft locking tool J42069-lO, and tighten lever arm to the water pump pulley flange.
4. Adjust timing belt tensioner so that the center alignment mark is about 3 mm (1/8 in.) above alignment mark on spring loaded idler. Tighten until snug. It will be torqued at a later time.






5. Remove plastic wedge J42069-30 from crankshaft sprocket.






6. Remove 1-2 and 3-4 camshaft locks, timing belt alignment kit 142069-1 and J42069-2.
7. Install 142069-20 checking gauge to cams 3 and 4.






8. Pull belt between the timing belt tensioner and crankshaft sprocket to take up slack between cams 3-4 and the lower idler pulley.
9. Check marks to ensure that timing belt is not a tooth off on the camshaft gear.
10. Remove crankshaft locking tool J42069-10.

IMPORTANT: If TDC is passed, do not rotate crankshaft counterclockwise. This will not allow proper slack to be taken up between turning belt tensioner and crankshaft sprocket. To correct, rotate crankshaft additional two turns.






11. Rotate crankshaft 1 3/4 turns clockwise. Install J42069-10 and then stop at TDC.






12. Tighten lever arm to the water pump pulley flange.

IMPORTANT: Timing marks on timing belt are used for initial installation only.

IMPORTANT: If timing marks are off, repeat procedures to readjust. Removal of timing belt is not necessary.






13. Tighten lever arm to the water pump pulley flange.






14. Recheck both pairs of camshaft timing marks using J42069-20 checking gauge.






15. Adjust timing belt tensioner so that the center alignment mark is about 3 mm above alignment mark on spring loaded idler.
16. Tighten timing belt tensioner.

Torque: Timing Belt Tensioner Fastening Nut: 20 Nm (15 ft-lbs)

17. Verify timing marks are still aligned.
18. Remove J42069-1O crankshaft locking tool and J42069-20 checking gauge.
19. Install timing belt front cover.
20. Connect negative battery cable.