Holden DOHC V6 Frontera 6VD1 3.2L 1999 2004 Jackaroo 6VE1 3.5L 1998 2004 Rodeo TF 6VD1 3.2L 1998 2003 Rodeo RA 6VE1 3.5L 2003 2005 Important: Read through all the instructions before proceeding with the task. Notes: Due to the gear ratio between the camshafts and the idler shafts, alignment of the timing belt marks does not guarantee alignment of the camshafts. The camshafts will need to be aligned with the idler timing marks before alignment with the marks on the belt. Timing marks are referenced to cylinder number two TDC, (LH bank front cylinder). The left hand camshaft timing is set in a twostage process. If the camshaft belt has broken or the engine has been miss-timed. It is recommended that a new belt be fitted, and then either carry out a compression test or check valve clearances, to determine if the valves have been damaged. Timing Belt Removal 1. Disconnect the negative battery terminal. 2. Remove the air cleaner assembly and cooling fan upper shroud. 3. Remove the ignition coil packs and the spark plugs. tensioner can be removed by loosening the 8mm Allen key bolt. 7. Depending on the vehicle, you will need to remove either the power steering pump or just the pump pulley. 8. Lock the crankshaft pulley, undo the centre bolt, and then remove the pulley. Remove the right side timing cover, before removing the left, and then lower covers. 9. Temporarily refit the crankshaft pulley bolt to allow the engine to be turned over by hand. 10. Rotate the engine until the crankshaft and camshaft timing marks are aligned as shown in Diagram 2. Due to the camshaft idler gear ratio, you may need to rotate the engine a number of times before they are correctly aligned. Note: When the timing marks are aligned, Number Two piston will be at Top Dead Centre. 11. Loosen the lower tensioner retaining bolt. 12. Loosen and remove the upper timing belt tensioner bolt. 4. Using a spanner on the serpentine belt tensioner pulley, release the belt tension and slide the serpentine belt off. 5. Undo the four nuts securing the cooling fan assembly, and remove. 6. Remove the cooling fan, idler pulleys, and serpentine belt tensioner. The serpentine belt The tensioner should always be maintained in the upright position to prevent oil leaks Lock pin Diagram #1 Timing Belt Tensioner 3294
LE RE View C Diagram #2 Timing Marks For Belt Fitting View D D View C RI LI View D RE Right Cylinder Head Left Cylinder Head LE Water Pump Idler Pulley Tensioner Pulley View B View A View B Note: The camshafts need to be aligned before the belt marks can be used. View A V 3295
RH Retainer Mark Diagram #3 Camshaft Alignment Marks Right Exhaust Camshaft Single Marks Right Hand Cylinder Head Right Inlet Camshaft Dowel should point to this hole LH Retainer Mark Left Inlet Camshaft Left Hand Cylinder Head Left Exhaust Camshaft Double Marks Note: These timing belts are prone to breakage if the vehicle has been poorly serviced. This can be caused by oil feed holes to the camshafts becoming blocked with carbon. If this happens, the camshaft bearing cap will look blue or discoloured around the site where the bearing seized. All the dowel pins will then need to be checked to ensure they have not been sheared, allowing the gears to move on the shafts. 13. Remove the lower tensioner retaining bolt, and remove the tensioner. Note: Always keep the tensioner upright. Failure to do so may allow air to enter the oil chamber, rendering it unserviceable. Component Inspection It is recommended that the belt tensioner, as well as the idler and tensioner pulley bearings be replaced whenever the timing belt is replaced. If you are reusing the tensioner, inspect it carefully for leaks or damage. Using a hydraulic press, compress the tensioner plunger until the hole in the tensioner body lines up with the hole in the plunger. Using a 1.4mm piece of wire as a lock pin, insert it into the side of the tensioner as shown in Diagram 1. Inspect water pump, crankshaft, and camshaft idler pulleys for wear or damage. Scissor Gears If you need to remove the camshafts, you should fit holding bolts to the scissor gears, before removal. The bolts required are metric M5 x 0.8. These bolts only need to be nipped up to hold the gears in place. Ensure that you remove the bolts after fitting and timing the camshafts. Diagram #4 Aligned RH Head Marks 3296 If the bolts were not installed before removing the camshafts, carefully hold the camshafts in a vice, without touching the lobes or bearings, and lever the scissor gear with Kent Moore special tool J-42686, or
similar, until the gear teeth are aligned and the holding bolt can be fitted. If refitting the idler shaft retainers, ensure that the reference marks on the retainers match those shown in Diagram 3. These reference marks will align with the camshaft dowel pins when the reference marks on the camshaft gears are aligned with the idler shafts. Camshaft Gears This V6 engine is a quad cam engine, with an inlet and exhaust camshaft on each of the two cylinder heads. Both the inlet and exhaust camshafts are gear driven by a single idler gear, which is in turn driven by the timing belt. Correct timing of these gears is vital. The right and left intake camshafts are marked with the letters RI and LI respectively. The right and left exhaust camshaft gears are interchangeable, however, care must be taken to ensure that the correct alignment marks are used for each application, or damage to the valves may occur. Both intake and exhaust camshafts on the right cylinder head are timed to the idler gear using the single dot reference mark on each gear. The gear timing on the left cylinder head is achieved using the double dot reference marks on the gears. These marks can only be seen with rocker covers removed. See Diagrams 3 & 4. Once all camshafts and idler shafts timing marks are correctly aligned, rotate the LH camshaft sprocket 90 clockwise to align the sprocket timing mark with the 12 o clock timing mark on the cylinder head. See Diagram 5. Caution: Ensure that the LH camshaft idler sprocket is at the 12 o clock timing belt installation position, (turned from the 9 o clock camshaft reference position). Note: Ensure that the scissor gear holding bolts, if fitted, have been removed. 1. Re check that the timing marks are correctly aligned. The groove on the flange of the crankshaft sprocket should be aligned with the mark on the oil pump casing. This will be TDC of cylinder number 2. See Diagrams 6 & 2, View A. Note: As the genuine timing belt has matching marks to assist with its initial installation it is important to ensure that when the belt is fitted, it is facing the correct way. When fitted correctly, the arrows on the belt will point in the direction of engine rotation. 2. Locate the dotted line on the timing belt and begin to fit the belt, aligning this dotted line with the single dot (or line) on the front of the crankshaft sprocket. See Diagrams 7 & 2, View B. Diagram #5 LH head reference marks with cam idler turned (90 ) to belt installation position. Note that the marks are no longer aligned. Important: Do not move the camshafts again until the timing belt has been installed, otherwise you will need to correctly align the camshaft and idler shaft marks again. Timing Belt Installation Note: Before fitting the new belt, ensure that the timing marks have been correctly set up, either by alignment before belt removal or by carrying out the alignment as mentioned in the Camshaft Gears section. 3297
3. Ensure that the marks on each of the camshaft drive pulleys are still correctly aligned with their respective marks. 4. Begin to fit the belt in a clockwise direction, around the tensioner pulley and onto the right hand camshaft drive pulley. There is a white alignment mark on the belt that should line up with both the alignment mark on the pulley and the mark on the cylinder head cover. See Diagram 2, View C. 5. If necessary, use a spanner on the drive pulley bolt to manoeuvre it into the correct position and then, with another paper clip, temporarily clamp the belt to the pulley as shown in Diagram 8. Continue feeding the belt on in a clockwise direction, under the water pump pulley and then onto the left hand camshaft pulley. Diagram #6 Crankshaft to Timing Case Timing Mark 6. A second white alignment mark on the belt will have to be matched to the marks on both the pulley and the cylinder head cover (See Diagram 2, View D), before being clamped with the second paper clip. See Diagram 9. 7. The belt can now be fitted around the final idler pulley. 8. Temporarily install the crankshaft pulley bolt. Using a spanner on the pulley bolt, gently rotate the crankshaft to create some slack in the belt between the crankshaft and right hand camshaft sprockets. Bolt the tensioner into place and then remove the lock pin. 9. Remove the paper clips. 10. Recheck the timing marks are all still in place. 11. With the spanner on the crankshaft pulley bolt, gently rotate the crankshaft through a complete engine revolution to settle the belt in and to check that everything moves freely without hitting. Note: The timing marks will no longer be aligned, as these marks are to assist with initial installation only and will begin to `hunt as soon as the engine is rotated. To recheck the timing marks you will need to keep rotating the crankshaft until the marks come around again. Diagram #7 Timing Belt Aligned With Crankshaft 12. Remove the crankshaft pulley bolt to refit the timing covers, before refitting the remaining components in the reverse order of their removal. 3298
Bolt Torque Camshaft Bearing Caps Camshaft Drive Gear Pulley Crankshaft Pulley Bolt Cylinder Head Bolts Exhaust Manifold Bolts Fan & Clutch Unit Fan Pulley & Fan Bracket Ignition Coil Bolts Intake Common Chamber Bolts/Nuts Power Steering Pump - M10 Bolts Power Steering Pump - M8 Bolts Power Steering Pump Pulley Rocker Cover Bolts Serpentine Belt Idler Bolt Serpentine Belt Tensioner Bolt - Long Serpentine Belt Tensioner Bolt - Short Spark Plugs Timing Belt Tensioner Bolts Timing Cover Bolts Water Pump Spec. 10Nm 98Nm 167Nm 64Nm 57Nm 10Nm 22Nm 4Nm 25Nm 46Nm 22Nm 78Nm 9Nm 52Nm 39Nm 20Nm 18Nm 25Nm 19Nm 25Nm Diagram #9 Belt Installation Marks on LH Head Installation Mark On Belt Paper Clip Installation Mark On Belt Diagram #8 Belt Installation Marks on RH Head Idler Pulley Power Steering Paper Clip Tensioner Pulley Fan Pulley Alternator Diagram #10 Serpentine Belt Crankshaft Airconditioner Note: These engines have been identified as interference fit. 3299