In-vehicle Repair Special Tool(s) | Alignment Peg, Crankshaft 303-732 (21-260) | | Locking Tool, Crankshaft 303-734 (21-262) | | Alignment Peg, Camshaft 303-735 (21-263) | General Equipment Trolley jack Wooden blocks Removal CAUTION:Never install a used timing belt. CAUTION:Only install the timing belt after the engine has cooled to workshop temperature. | -
Disconnect the coolant degas hose from the coolant expansion tank. | | -
Detach the coolant expansion tank from the coolant expansion tank bracket and secure it to one side. | | -
Disconnect the fuel temperature sensor electrical connector. | | -
Detach the wiring harness from the timing belt upper cover. | | -
Remove the timing belt upper cover. | | -
CAUTION:Make sure that the special tool engages correctly. NOTE:Only turn the engine in the normal direction of rotation. Using the special tool, lock the flywheel. - Turn the engine until the special tool fits into one of the slots in the flywheel.
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Remove the crankshaft pulley. | | -
Detach the crankshaft speed sensor wiring harness from the timing belt lower cover. | | -
Remove the timing belt lower cover. | | -
CAUTION:Do not touch the outer sensor ring. Install the crankshaft pulley retaining bolt. | | -
NOTE:Only turn the engine in the normal direction of rotation. Using the special tool, align the camshaft. - Turn the engine until the alignment hole in the camshaft pulley is at the 2 o'clock position.
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Remove the timing belt guide. | | -
Remove the timing belt tensioner. | | -
CAUTION:Do not touch the outer sensor ring. Remove the crankshaft timing belt pulley. | | -
CAUTION:Do not support the engine directly on the oil pan. | | -
Detach the power steering fluid reservoir from the radiator grille opening panel and position it to one side. | | -
Remove the engine front mount. | | -
Remove the engine front mount bracket. | Installation | -
NOTE:Do not tighten the timing belt tensioner retaining bolt at this stage. Install the timing belt tensioner. | | -
CAUTION:Never install a used timing belt. CAUTION:Install the timing belt with the direction arrows in the direction of engine rotation. CAUTION:Only install the timing belt after the engine has cooled to workshop temperature. NOTE:Install a new timing belt. Install the timing belt. | | -
Install the engine front mount bracket. | | -
NOTE:Install new engine front mount retaining nuts. Install the engine front mount. | | -
Attach the power steering fluid reservoir to the radiator grille opening panel. | | -
Using the special tool, align the high pressure fuel pump pulley (engine shown removed for clarity) . - If there is no hole in the high pressure fuel pump bracket to install the special tool go to the next step.
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Make sure the high pressure fuel pump alignment holes are in line (engine shown removed for clarity). | | -
Remove the special tool from the high pressure fuel pump pulley (engine shown removed for clarity). | | -
Make sure the camshaft alignment holes are in line. | | -
Check the correct position of the crankshaft timing belt pulley Woodruff key. | | -
CAUTION:Do not touch the outer sensor ring. NOTE:Install the old crankshaft pulley bolt. NOTE:Do not tighten the crankshaft pulley bolt at this stage. Install the crankshaft timing belt pulley. | | -
CAUTION:Do not touch the outer sensor ring. Using the special tool, align the crankshaft. | | -
NOTE:Using an allen key, maintain tension until the timing belt tensioner bolt is tightened. Tension the timing belt (engine shown removed for clarity). - Turn the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slightly.
- The pointer must be positioned between the sides of the window.
- Tighten the timing belt tensioner retaining bolt.
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CAUTION:Do not touch the outer sensor ring. Remove the special tool from the crankshaft timing belt pulley. | | -
Install the timing belt guide. | | -
NOTE:Only turn the engine in the normal direction of rotation. Turn the engine ten revolutions. | | -
CAUTION:Do not touch the outer sensor ring. Using the special tool, align the crankshaft. | | -
Install the special tool. - If the special tool cannot be installed, repeat the previous steps.
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CAUTION:Do not touch the outer sensor ring. Remove the special tool from the crankshaft timing belt pulley. | | -
Install the special tool (engine shown removed for clarity) . - If there is no hole in the high pressure fuel pump bracket to install the special tool go to the next step.
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Check that the high pressure fuel pump alignment holes are in line (engine shown removed for clarity). - If the alignment holes are not in line, repeat the previous steps.
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Remove the special tool (engine shown removed for clarity). | | -
CAUTION:Do not touch the outer sensor ring. Remove the crankshaft pulley retaining bolt. | | -
Install the timing belt lower cover. | | -
Attach the crankshaft speed sensor wiring harness to the timing belt lower cover. | | -
CAUTION:Make sure the special tool engages correctly. NOTE:Only turn the engine in the normal direction of rotation. Using the special tool, lock the flywheel. - Turn the engine until the special tool aligns with one of the slots in the flywheel.
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NOTE:Install a new crankshaft pulley retaining bolt. Install the crankshaft pulley. - Tighten the crankshaft pulley bolt in two stages.
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Remove the special tool from the flywheel. | | -
Install the timing belt upper cover. | | -
Attach the wiring harness to the timing belt upper cover. | | -
Connect the fuel temperature sensor electrical connector. | | -
Attach the coolant expansion tank to the coolant expansion tank bracket. | | -
Connect the coolant degas hose to the coolant expansion tank. | | |