Timing belt

CAUTION: Camshaft or crankshaft should not be rotate after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt.

REMOVAL
Remove crankshaft damper bolt.
Remove engine mount bracket and timing belt cover fasteners, remove cover.
Align camshaft timing marks. Loosen timing belt tensioner fasteners and remove timing belt.

CAUTION: Do not loosen, tighten, or remove the tensioner pivot bolt.

INSTALLATION
When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

Place the tensioner into a vise and slowly compress the plunger.
CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.

When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed.

Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC.

Set camshafts timing marks together by aligning notches on sprockets.

Rotate crankshaft 1/2 tooth counterclockwise from TDC.

Install timing belt in this direction. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley.
Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to Clock but do not tighten fasteners.
Using a torque wrench on the tensioner pulley apply 28 Nm (250 inch lbs.) Of torque to tensioner.
With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 inch lbs.).
Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed freely.
Rotate crankshaft 2 revolutions and check the alignment of the timing marks.
Install front half of timing cover.
Install engine mount bracket.
Install right engine mount.
Remove jack from under engine.

Install crankshaft damper using M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. Lbs.).
Install accessory drive belts.
Raise vehicle on hoist and install right inner splash shield.
After timing belt has been replaced, use a Diagnostic Readout Box (DRB), or equivalent select adjustments and then relearn CMP/CKP, to relearn camshaft and crankshaft timing.