Timing Belt: Service and Repair
SPROCKET(S)-TIMING BELT AND CHAINREMOVAL
CAUTION: BEFORE REMOVING THE TIMING BELT, THE ENGINE MUST BE PLACED AT 90° AFTER TDC. FAILURE TO DO SO MAY RESULT IN VALVE AND/OR PISTON DAMAGE DURING ASSEMBLY.
1. Disconnect negative battery cable.
2. Remove engine cover.
3. Remove cooling fan and fan drive viscous clutch assembly.
4. Remove accessory drive belt.
5. Remove cooling fan support.
6. Bring piston #1 to TDC, turn crankshaft until notch on the crankshaft hub is at the 12 o'clock position.
7. Looking at the engine from the belt side, rotate the crankshaft 90° clockwise.
8. Install the 90° alignment pin into the crankcase threaded hole on the right side of the engine to lock the crankcase (make sure the crankshaft does not rotate).
9. Remove vibration damper.
10. Paint mark the crankshaft hub and the oil pump cover (this will be useful during the timing check).
11. Remove the alternator.
12. Remove the intake and exhaust camshaft plugs from the camshaft cover, to introduce the camshaft timing pins VM.1052 Intake, and VM.1053 Exhaust (if the engine is timed correctly, the pins can be installed).
13. Remove timing belt outer cover.
14. Loosen timing belt tensioner and remove timing belt.
15. Remove the intake and exhaust camshaft alignment pins, VM.1052 Intake, and VM.1053 Exhaust.
16. Loosen camshaft gears using special tool VM 1085 to retain the gears when removing bolts.
17. Use camshaft bolt to rotate the intake camshafts until the intake alignment hole lines up with the hole on the camshaft cover. Install alignment pin VM 1052 and tighten with a wrench (repeat the operation for the exhaust camshaft alignment using alignment pin VM 1053).
INSTALLATION
NOTE: There are marks on the high pressure pump gear and both camshaft gears. These ARE NOT alignment marks and should be disregarded.
1. With both camshaft alignment pins still installed and the engine locked at 90° after TDC, verify that the camshaft gears are loose.
NOTE: DO NOT remove the timing belt from the package until it's ready to be installed. DO NOT expose timing belt to oil, grease or water contamination. DO NOT crimp belt at a sharp angle. DO NOT clean belt, pulleys or tensioner with solvent. Check that pulleys and bearings are not seized or damage before installing belt.
2. Install timing belt on crankshaft hub and fix it with special tool VM 1074.
3. Route the belt around high pressure injection pump, idler pulley, intake camshaft gear, exhaust camshaft gear, idler pulley, and water pump gear.
4. Adjust the timing belt tensioner (turn it clockwise) using special tool VM.9660, lining up the center notch with the aluminum cover dowel pin. Tighten the retaining bolt to 28 Nm.
5. Install special tool VM.1085 between camshaft gears and tighten thumb screws to engage and retain the camshaft gears.
6. Tighten the camshaft gear bolts to 108 Nm (80 ft. lbs.) while holding the gears with special tool VM 1085.
7. Remove camshaft gear locking tool.
8. Remove intake and exhaust alignment pins.
9. Remove engine locking pin from engine block.
10. Install timing belt outer cover.
WARNING: IF CAMSHAFT COVER WAS REMOVED WAIT 30 MINUTES BEFORE ROTATING CRANKSHAFT.
11. Rotate the engine clockwise 2 revolutions (looking at engine from the belt side).
12. Carefully line up the crankshaft hub painted mark with the oil pump cover mark.
13. Check that the intake and exhaust camshaft alignment pins can be installed.
WARNING: IF THE CAMSHAFT ALIGNMENT PINS CAN NOT BE INSTALLED AT THIS TIME, REPEAT THE PROCEDURE FROM THE BEGINNING.
14. Install the camshaft access plugs.
15. Install vibration damper.
16. Install the alternator.
17. Install cooling fan support.
18. Install accessory drive belt.
19. Install cooling fan and fan drive viscous clutch assembly.
20. Install engine cover.
21. Connect negative battery cable.