Timing Belt: Service and Repair

REMOVAL

1. Remove engine as described under ``Engine, Replace.''
2. Remove accessory drive belts, then the engine mounting bracket from front cover.
3. Rotate crankshaft to position No. 4 piston at TDC of compression stroke.
4. Remove starter motor, then install flywheel holder tool No. J-35271 or equivalent.
5. Remove crankshaft bolt, then the boss and crank pulley.
6. Remove front cover, then loosen tension pulley fixing bolt.
7. Loosen timing belt tension using a hex wrench in the tension pulley hole.
8. Remove timing belt.

Fig. 10 Crankshaft pulley alignment:

INSTALLATION

1. Install crankshaft timing pulley, ensuring Woodruff key is properly positioned, Fig. 10.
2. Position pulley on crankshaft, aligning pulley timing groove with mark on oil pump, Fig. 10.

Fig. 11 Camshaft pulley alignment:

3. Ensure camshaft pulley timing mark is aligned with upper surface of cylinder head and dowel pin is in up position, Fig. 11.

Fig. 12 Timing belt installation:

4. Position timing belt arrow mark in direction of engine rotation and install belt over pulleys, Fig. 12, in the following order: crankshaft, camshaft, water pump, tension.
5. Loosen tension pulley bolt. Insert a hex wrench into tension pulley hole, then temporarily tighten bolt while holding pulley stationary.
6. Turn crankshaft two complete revolutions and align crankshaft timing pulley groove with mark on oil pump.
7. Loosen tension pulley bolt, then apply tension to belt and torque bolt to 37 ft. lbs., while holding pulley stationary.
8. Turn crankshaft back approximately 50° and set crankshaft at that position.
9. Check belt tension using suitable tension gauge. Tension should measure 33.1-41.9 lbs.
10. Check valve clearances as previously described.
11. Apply suitable sealant to cylinder head mating surface and four points of each arched area of Nos. 1 and 5 rocker brackets.
12. Install valve cover and torque bolts to 7 ft. lbs.
13. Install timing cover and torque bolts to 7.2 ft. lbs.
14. Install crankshaft pulley and torque bolt to 108.5 ft. lbs.
15. Install starter and torque bolts to 36.9 ft. lbs.
16. Install engine mount bracket and torque bolts to 17.3 ft. lbs.
17. Install engine.