Engine Serial Number 578512 and After

TIMING BELT REPLACEMENT (IN-VEHICLE)

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 degrees 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 J42069-2.

IMPORTANT: Do not rotate camshafts unless crankshaft is at 60 degrees 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:





Timing Belt Alignment Kit
- 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: With camshaft locks installed, verify distance between camshaft sprockets with Green Test Belt locate in Timing Belt Alignment Kit J42069.

2. Start at #1 and #2 camshaft sprockets, route belt around #1 and #2 sprockets while aligning belt marks to marks on sprockets and rear cover.
3. Install belt around timing belt tensioner.
4. Route belt around upper idler pulley.
5. Route belt around #3 and #4 camshaft sprockets while aligning belt marks to marks on sprockets and rear cover.
6. Route belt around crankshaft hub sprockets while aligning marks on belt to marks on crankshaft hub sprocket.





7. Install Wedge Tool J42069-30 to lock timing belt onto crankshaft hub sprocket.





8. With belt firmly engaged on crankshaft hub, carefully rotate crankshaft counterclockwise to get belt slack on lower idler pulley side.
9. Route belt around lower idler pulley.





10. Remove wedge tool J42069-30.





11. Re-install crankshaft locking tool J42069- 10 and tighten lever arm to the water pump pulley flange.





12. Perform the following in sequence:
12.1. Install camshaft checking gauge to cams 3 and 4 and verify alignment marks are within 2 mm of each other.
12.2. Install 3 and 4 camshaft lock if properly aligned.
12.3. Install camshaft checking gauge to cams 1 and 2.





12.4. Rotate #1 camshaft sprocket counter-clockwise to remove slack between 1 and 2, and 3 and 4 cams.

IMPORTANT: Ensure that camshaft timing marks are to the left (retard) side of the checking gauge.

12.5. Rotate upper idler pulley counter-clockwise until marks are properly aligned within 2 mm of each other.
12.6. Install 1 and 2 camshaft lock when properly aligned.
Torque: Upper Pulley Bolt: 40 Nm (30 ft. lbs.)





13. Adjust timing belt tensioner so that the center alignment mark is about 3 mm (1/8 inch) above alignment mark on spring loaded idler.





14. Remove 1-2 and 3-4 camshaft locks, timing belt alignment kit J42069-1 and J42069-2.
15. 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 timing belt tensioner and crankshaft sprocket. To correct, rotate crankshaft additional two turns.

16. Rotate crankshaft 1 3/4 turns clockwise, install crankshaft locking tool J42069-10, and then stop at TDC.





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.

17. Tighten lever arm to the water pump pulley flange.
18. Recheck both pairs of camshaft timing marks using J42069-20 checking gauge.





19. Adjust timing belt tensioner so that the center alignment mark is about 3 mm above alignment mark on spring loaded idler.
20. Tighten timing belt tensioner.
Torque:
Timing Belt Tensioner Fastening Nut: 20 Nm (15 ft. lbs.)
21. Verify timing marks are still aligned.
22. Remove J42069-10 crankshaft locking tool and J42069-20 checking gauge.
23. Install timing belt front cover.
24. Connect negative battery cable.
Torque: Battery Terminal Bolts: 17 Nm (13 ft. lbs.)