Installation

Fig. 31 Timing Belt Replacement (part 1 Of 2):

Fig. 31 Timing Belt Replacement (part 2 Of 2):

TIMING BELT INSTALLATION
Install timing belt in numbered sequence shown in Fig. 30 parts 1 and 2, noting following:

Fig. 32 Support Bracket Bolt:

1. Apply sealant to engine support bracket bolt shown in Fig. 32.

Fig. 33 Crankshaft Sprocket B Installation:

2. Install crankshaft sprocket B as shown in Fig. 33.
3. Install right silent shaft sprocket spacer with chamfered edge pointed toward oil seal.
4. Ensure crankshaft sprocket B and silent shaft sprocket timing marks are aligned then install timing belt B.
5. Adjust timing belt B tension as follows:

a. Temporarily install timing belt B tensioner to that center of tensioner is to left and above installation bolt.
b. Place tension on timing belt B so tension side of belt is tight then tighten tensioner bolt.

Fig. 34 Timing Belt B Tension Inspection:

c. At point marked "A and ensure belt is within .20-.28 inch when depressed for correct tension, Fig. 34.

Fig. 35 Crankshaft Flange & Sprocket Installation:

6. Install crankshaft flange and pulley as shown in Fig. 35.
7. Install auto tensioner as follows:

a. Keeping auto tensioner level clamp it in a soft jawed vise. If plug at bottom of tensioner protrudes, surround it with a washer to prevent plug from being in direct contact with vise.

Fig. 36 Tensioner Set Hole Alignment:

b. Push in rod slowly with vise until set holes are aligned, Fig. 36.
c. Insert a wire 0.055 inch in diameter into set holes and release tensioner from vise.
d. Install tensioner, keeping wire installed in set holes.

8. Install tensioner pulley onto tensioner arm. Position pinhole in tensioner pulley shaft to left of center bolt, then tighten center bolt finger tight.

Fig. 31 Silent Shaft Lock:

9. Ensure timing marks are aligned and remove plug on side of engine block, Fig. 31. Insert a Phillips screwdriver into hole to block left silent shaft.
10. If screwdriver cannot be inserted 2.4 inch or more turn oil pump sprocket one turn and realign timing marks. Ensure screwdriver can be inserted 2.4 inches or more. Screwdriver should not be removed until installation of timing belt is complete.
11. Install timing belt as follows:

a. Install timing belt around tensioner pulley and crankshaft sprocket and secure timing belt onto tensioner pulley with your left hand.
b. Pulling timing belt with your right hand, install it around oil pump sprocket.
c. Install belt around idler pulley.
d. Install belt around camshaft sprocket.

Fig. 37 Timing Belt Tension Pulley Position:

e. Gently raise tensioner pulley so that belt does not sag then temporarily tighten center bolt, Fig. 37.

12. Adjust timing belt tension as follows:

a. >Remove screwdriver and install plug in side of cylinder block.
b. Turn crankshaft 90.0degrees counterclockwise.
c. Turn crankshaft back to position No. 1 cylinder at TDC.

Fig. 38 Timing Belt Tension Adjustment:

d. Loosen tensioner pulley center bolt, then attach socket wrench tool No. MD998752, or equivalent, and a torque wrench and apply a torque of 1.88-2.03 ft. lbs., Fig. 38.
e. Holding tensioner pulley with special tool, tighten center bolt to specification.

Fig. 39 Setscrew Tool Installation:

f. Install setscrew tool No. MD998738, or equivalent, into engine left support bracket until its end makes contact with tensioner arm, Fig. 39.
g. Turn setscrew tool to increase pressure on tensioner arm then remove wire from tensioner set holes.
h. Rotate crankshaft two complete turns clockwise and allow to sit for 15 minutes.
i. After 15 minutes, measure auto tensioner rod protrusion, and verify that it is within 0.15-0.18 inch specification. If not as specified, repeat steps a through h.
j. Install rubber plug to timing belt rear cover.

Fig. 40 Timing Belt Cove Installation:

13. Install timing belt cover screws into proper location as shown in Fig. 40.