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Timing Belt/Chain And Sprocket(S): Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: There are marks on both camshaft gears. These ARE NOT alignment marks and should be disregarded.
  1. With both camshaft alignment pins still installed and the engine rotated at 90° after TDC (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) , and verify that the camshaft gears are loose.
    Fig 1: INJECTION PUMP GEAR TIMING MARKS
    GC0026257Courtesy of DAIMLERCHRYSLER CORP.
    1 - TIMING MARK ON COVER
    2 - TIMING MARK ON INJECTION PUMP SPROCKET
    3 - INJECTION PUMP SPROCKET
  2. Align the timing mark on the high pressure injection pump gear with the timing mark on the inner cover. See Fig 1.
    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.
  3. Install timing belt on crankshaft hub.
    Fig 2: TIMING BELT ROUTING
    GC0026255Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTAKE CAMSHAFT
    2 - IDLER PULLEY
    3 - HIGH PRESSURE PUMP
    4 - CRANKSHAFT GEAR
    5 - TIMING BELT TENSIONER
    6 - WATER PUMP
    7 - IDLER PULLEY
    8 - EXHAUST CAMSHAFT
  4. Route the belt around high pressure injection pump, idler pulley, intake camshaft gear, exhaust camshaft gear, idler pulley, and water pump gear. See Fig 2.
  5. 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 N.m ( 20 ft. lbs.). (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN TENSIONER & PULLEY - ADJUSTMENTS) .
    Fig 3: VM.1085 CAMSHAFT LOCKING TOOL
    GC0026125Courtesy of DAIMLERCHRYSLER CORP.
  6. Install special tool VM.1085 between camshaft gears and tighten thumb screws to engage and retain the camshaft gears. See Fig 3.
  7. Tighten the camshaft gear bolts to 108 N.m (80 ft. lbs.) while holding the gears with special tool VM 1085.
  8. Remove camshaft gear locking tool.
  9. Remove intake and exhaust alignment pins.
    Fig 4: FRONT CRANKSHAFT HUB
    GC0026240Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT CRANKSHAFT HUB
    2 - WITNESS MARK
    WARNING: IF INTAKE MANIFOLD/CYLINDER HEAD COVER WAS REMOVED WAIT 30 MINUTES BEFORE ROTATING CRANKSHAFT.
  10. Rotate the engine clockwise 2 revolutions (looking at engine from the belt side).
  11. With the crankshaft hub witness mark aligned to 90 degrees ATDC, or the three O'clock position, check that the intake and exhaust camshaft alignment pins (VM 1052 and VM 1053) can be installed into the camshaft alignment access holes. See Fig 4.
  12. Install timing belt outer cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION) .
    WARNING: IF THE CAMSHAFT ALIGNMENT PINS CAN NOT BE INSTALLED AT THIS TIME, REPEAT THE PROCEDURE FROM THE BEGINNING.
  13. Install the camshaft access plugs.
  14. Install vibration damper (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) .
  15. Install the alternator.
  16. Install cooling fan support (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  17. Install accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  18. Install cooling fan and fan drive viscous clutch assembly. Refer to RADIATOR - FAN - VISCOUS .
  19. Install engine cover. Refer to ENGINE COVER .
  20. Connect negative battery cable.
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