Timing Belt: Service and Repair

Removal

1. Remove undercover.
2. Disconnect battery ground cable.
3. Remove clamp securing power steering pressure hose and air conditioner high pressure hose to body.
4. Using a wood block and a jack, place wood block on engine oil pan and raise engine only enough to relieve tension on top engine mount, then remove mount and bracket.
5. Remove engine drive belts. Prior to removing water pump drive belt, loosen water pump pulley bolts.
6. Remove tensioner pulley and bracket.
7. Remove crankshaft pulley and water pump pulley.
8. Remove upper and lower timing covers.
9. Disconnect PCV and breather hoses, then remove center cover, spark plug wires, rocker cover, gasket and semicircular packing.

Fig. 13 Timing Mark Locations:

Fig. 14 Timing Belt Assembly (Part 1 Of 2):

Fig. 14 Timing Belt Assembly (Part 2 Of 2):

10. Rotate crankshaft clockwise to bring No. 1 cylinder to top dead center compression stroke. Rotate crankshaft only in clockwise direction. The No. 1 cylinder is at top dead center of compression stroke when the timing marks on camshaft sprockets are aligned with upper surface of cylinder head and dowel pins on camshaft sprockets are facing up as shown, Fig. 13.
11. Remove auto tensioner, Fig. 14.
12. Remove timing belt. If timing belt is to be reused, mark timing belt indicating direction of rotation.
13. Remove tensioner pulley and arm, then remove idler pulley.
14. Using a wrench, hold the camshaft at the hexagonal portion (between No. 2 and No. 3 journals) and remove camshaft sprocket bolt, then remove camshaft sprockets. Locking the camshaft sprocket with a tool may damage the sprocket.
15. Remove plug on left side of cylinder block. Retain left silent shaft, using a suitable screwdriver, then remove oil pump sprocket retaining nut and sprocket.
16. Remove crankshaft sprocket bolt, special washer, sprocket and flange.
17. Remove tensioner ``B,'' then mark normal direction of rotation on timing belt ``B'' and remove belt.
18. Remove silent shaft sprocket and spacer, then crankshaft sprocket ``B'' and timing belt undercovers.

Installation

Fig. 15 Crankshaft Sprocket "B" Installation:

Fig. 16 Silent Shaft Sprocket Spacer Installation:

Fig. 17 Timing Belt "B" Installation:

1. Install rear timing belt covers.
2. Install crankshaft sprocket ``B'' as shown in Fig. 15.
3. Install silent shaft sprocket spacer and sprocket. Install spacer as follows:
a. Apply a thin coat of engine oil to outer circumference of spacer.
b. Install spacer with chamfered end facing oil seal as shown, Fig. 16. Tighten silent shaft bolt to specifications.
4. Align timing marks of silent shaft sprocket and crankshaft sprocket ``B,'' Fig. 17, then install timing belt ``B'' over both sprockets and ensure belt has no slack.
5. Adjust timing belt ``B'' tension as follows:

Fig. 18 Timing Belt "B" Tensioner Pulley Installation:

Fig. 19 Adjusting Timing Belt "B" Tension:

Fig. 20 Checking Timing Belt "B" Tension:

a. Temporarily install timing belt ``B'' tensioner so that the center of the tensioner pulley is to the left and above the center of the installation bolt, then temporarily attach tensioner pulley so that the flange is toward front of engine, Fig. 18.
b. Hold timing belt ``B'' tensioner up in direction shown by arrow, Fig. 19, then place pressure on timing belt so that the tension side of the belt is taut.
c. Tighten tensioner ``B'' bolt to specifications. When tightening the bolt, do not allow tensioner pulley shaft to rotate.
d. To check belt tension, depress belt at point (A), Fig. 20. Belt deflection should be .20-.28 inch (5-7mm). If not, readjust belt tension.

Fig. 21 Crankshaft "B" Sprocket & Flange Installation:

Fig. 22 Securing Silent Shaft:

6. Install crankshaft sprocket flange, sprocket and special washer. Tighten crankshaft sprocket bolt to specifications. Ensure flange and sprocket are correctly installed as shown in Fig. 21.
7. Insert a Phillips screwdriver with a shaft diameter of .31 inch (8mm) through plug hole on left side of cylinder head to retain left silent shaft, Fig. 22. then install oil pump sprocket and tighten attaching nut to specifications.
8. Install camshaft sprockets. Using a wrench, hold the camshaft at the hexagonal portion (between No. 2 and No. 3 journals) and tighten attaching bolt to specifications. Locking the camshaft sprocket with a tool may damage the sprocket.
9. Install auto tensioner. If tensioner rod is fully extended, proceed as follows:
a. Position auto tensioner level in a soft jawed vise. If plug at bottom of tensioner protrudes, apply a plain washer to prevent the plug from direct contact with vise.

Fig. 23 Aligning Tensioner Rod:

Fig. 24 Aligning Caamshaft Sprocket Timing Marks:

Fig. 25 Positioning Camshaft Sprockets:

Fig. 26 Aligning Crankshaft & Oil Pump Sprockets:

b. Slowly push tensioner rod in, using the vise, until set hole (A) is aligned with hole (B) in the tensioner cylinder, Fig. 23.
c. Insert a wire .055 inch (1.4mm) in diameter into the set holes, then remove auto tensioner from the vise.
d. Install auto tensioner, tighten attaching bolt to specifications. Leave the wire installed in the auto tensioner.
10. Install tensioner pulley onto tensioner arm, position the hole in pulley shaft to the left of the center bolt, then tighten center bolt finger tight.
11. Rotate camshaft sprockets so that their dowel pins are located on top, then align the timing marks facing each other with the top surface of cylinder head, Fig. 24. When exhaust camshaft is released, it will rotate one tooth in the counterclockwise direction. This should be taken into account when installing timing belt on sprockets. The camshaft sprockets are interchangeable and have two sets of timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with dowel pin hole on top. For the intake sprocket, use the mark on the left with dowel pin hole on top, Fig. 25.
12. Align crankshaft sprocket and oil pump sprocket timing marks as shown, Fig. 26.
13. With oil pump sprocket timing marks aligned, remove plug from lefthand side of cylinder block and insert a screwdriver with a shaft diameter of .3 inch. If screwdriver can be inserted 2.4 inches or more, alignment is correct. If screwdriver can be inserted only 1 inch, rotate oil pump sprocket one revolution and realign timing marks. Then check to ensure screwdriver can be inserted 2.4 inches or more. This check is performed to ensure silent shaft and oil pump sprocket are properly positioned. Leave screwdriver inserted in hole until after timing belt has been installed.

Fig. 27 Timing Belt Installation:

14. Install timing belt as follows:
a. Install timing belt around tensioner pulley and crankshaft sprocket, Fig. 27, and hold the timing belt onto the tensioner pulley with your left hand.
b. Pulling timing belt with your right hand, install belt around oil pump sprocket.
c. Install timing belt around idler pulley, then around the intake camshaft sprocket.
d. Rotate exhaust camshaft sprocket one tooth clockwise to align timing mark with cylinder head top surface, then pulling the belt with both hands, install around exhaust camshaft sprocket.
e. Gently raise tensioner pulley in direction shown by arrow in Fig. 27, so belt does not sag, then temporarily tighten center bolt.

Fig. 28 Tightening Tensioner Pulley Center Bolt:

Fig. 29 Setscrew Tool Installation:

15. Adjust timing belt tension as follows:
a. Rotate crankshaft 1/4 turn counterclockwise, then rotate clockwise to move No. 1 cylinder to top dead center.
b. Loosen tensioner pulley center bolt, then using wrench tool No. MD998752 or equivalent and a torque wrench, apply a torque of 1.88-2.03 ft. lbs., Fig. 28. Use a torque wrench capable of measurement within a range of 0-2.2 ft. lbs. If vehicle body interferes with torque wrench, use a jack to slightly raise engine.
c. Holding tensioner pulley with the tool, tighten tensioner pulley center bolt to specifications.
d. Screw setscrew tool No. MD998738 or equivalent, into left engine support bracket until end of tool makes contact with tensioner arm, Fig. 29. Turn the tool enough to relieve tension on auto tensioner rod, then remove set wire previously installed in auto tensioner.
e. Remove setscrew tool.
f. Rotate crankshaft clockwise two complete turns, then let sit for 15 minutes.

Fig. 30 Checking Tensioner Arm Clearance:

g. Measure clearance (A) between tensioner arm and auto tensioner body, Fig. 30. If clearance is not .15-.18 inch (3.8-4.5mm), repeat steps a-g until clearance is correct.
h. If clearance (A) cannot be measured with engine in vehicle, screw in setscrew tool No. MD998738 or equivalent, until end of tool makes contact with tensioner arm.
i. Starting in this position, count the number of turns of the tool required to bring tensioner arm in contact with auto tensioner body. Ensure contact is made within 2.5-3 turns.
j. Install rubber plug into timing belt rear cover.
16. Reverse procedure to install remaining components, noting the following:
a. When installing rocker cover, apply 3M sealant No. 8660 or equivalent to semi-circular packing.