REMOVAL & INSTALLATION

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1 REMOVAL & INSTALLATION CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. TIMING BELT Removal (Standard Tensioner - Up To 1997) 1. Remove accessory drive belts. See Fig. 2 or Fig. 3. Remove accessory drive belt tensioner bracket. See Fig Remove crankshaft pulley bolts and pulley (it is NOT necessary to remove center bolt). 3. Remove water pump pulley. Remove upper and lower timing belt covers. CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. Valve damage may result. 4. If reusing timing belt, mark belt with arrow to indicate original direction of rotation. 5. Place crankshaft at TDC by aligning flywheel (M/T) or drive plate (A/T) TDC marks. See Fig. 5. Ensure camshaft timing mark is aligned with mark on belt guard. See Fig. 6. Loosen belt tensioner. Remove timing belt. Friday, March 19, :49:43 7:49:46 PM Page Mitchell Repair Information Company, LLC.

2 Friday, March 19, :49:43 PM Page Mitchell Repair Information Company, LLC.

3 Fig. 2: Removing & Installing Ribbed (Accessory) Drive Belts (Without A/C) Friday, March 19, :49:43 PM Page Mitchell Repair Information Company, LLC.

4 Friday, March 19, :49:43 PM Page Mitchell Repair Information Company, LLC.

5 Fig. 3: Removing & Installing Ribbed (Accessory) Drive Belts (With A/C) Fig. 4: Exploded View Of Timing Belt & Components (With Standard Tensioner) Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

6 Fig. 5: Aligning Crankshaft & Distributor Timing Marks Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

7 Fig. 6: Aligning Camshaft Timing Marks Installation (Standard Tensioner - Up To 1997) NOTE: Disregard marking on intermediate shaft drive belt sprocket. 1. Ensure crankshaft is still at TDC position. See Fig. 5. Remove distributor cap. Rotate intermediate shaft counterclockwise until rotor is pointed at No. 1 cylinder mark. See Fig. 5. Ensure camshaft timing mark is still aligned with mark on belt guard. See Fig Install timing belt around crankshaft, intermediate shaft, tensioner, and camshaft sprockets. 3. Loosen timing belt tensioner center nut. Using spanner wrench, rotate tensioner pulley clockwise to tension belt. Belt tension is correct when it is possible to rotate belt 90 degrees with thumb and forefinger, half-way between camshaft and intermediate shaft sprockets. See Fig While holding tensioner pulley stationary, tighten tensioner pulley center nut to specification. Rotate crankshaft 2 revolutions and recheck check belt tension. Adjust tension as necessary. Recheck all timing marks again. Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

8 5. Install timing belt covers. Install drive belt tensioner bracket. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Fig. 7: Adjusting Timing Belt Tension Removal (Thermo Tensioner Roller & Up) CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. Valve damage may result. Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

9 1. Remove air cleaner with hot air intake and intake air duct. 2. Remove accessory drive belts. Release tension on ribbed (accessory) belt tensioner using Ribbed Belt Installation Tool (3299) and remove ribbed belt at generator. Remove ribbed belt tension roller and upper timing belt guard. Remove lower V-belt cover. Hold hydraulic (P/S) pump pulley using (VAG1590) or mandrel, and remove fasteners for coolant pump pulley. Remove coolant pump pulley and V-belt. Remove vibration damper/pulley. See Fig. 2 and Fig Turn drive plate (A/T) or flywheel (M/T) to align mark (arrows in illustration) and place No. 1 cylinder at TDC. See Fig. 5. Remove lower timing belt guard. 4. Mark the running direction on the timing belt. Remove fastener for timing belt thermo tension roller. Remove belt and roller. Remove timing belt thermo tensioner. See Fig. 8. Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

10 Fig. 8: Exploded View Of Timing Belt & Components (With Thermo Tensioner Roller) Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

11 Installation (Thermo Tensioner Roller & Up) CAUTION: DO NOT turn the camshaft while any piston is at TDC position. There is risk of damage to valves and piston crowns. Assemble NEW thermo tension roller and install on engine block. See Fig. 9. Tighten bolt/washer assembly (2), Collar screw and 6-mm fastening nut to specification. See TORQUE SPECIFICATIONS. 1. Place timing belt on crankshaft gear (note running direction of belt). Ensure crankshaft timing is correct. See Fig. 5. Align mark on camshaft drive sprocket with mark on cylinder head cover and/or timing belt guard. See Fig Turn tension roller to the right using two-pin spanner wrench, with one pin inserted in hole in roller and other pin in slot at bottom of roller pivot bracket (arrows in illustration) until tensioner piston No. 1 is driven all the way out, and piston No. 2 lifts up about 0.040" (1.0 mm). See Fig Tighten mounting bolt by hand. See Fig. 10. Rotate engine 2 revolutions in running direction. Counterhold thermo tension roller with two-pin spanner, and tighten mounting bolt to specification. See TORQUE SPECIFICATIONS. Install lower timing belt guard. Install vibration damper/pulley. 4. Install ribbed belt tension roller. Using Ribbed Belt Installation Tool (3299), adjust tension on ribbed belt tensioner and position belt. Position V-belt, and bolt coolant pump pulley to coolant pump. Install upper timing belt guard. Install air cleaner with pre-heated air hose and intake air duct. Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

12 Fig. 9: Identifying Thermo Tensioner Roller Assembly Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

13 Fig. 10: Installing & Adjusting Thermo Tensioner Roller Friday, March 19, :49:44 PM Page Mitchell Repair Information Company, LLC.

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