Belt Tension & Valve Timing Check

1. Turn crankshaft in normal direction of rotation and set No. 1 piston to TDC of compression stroke.

Fig. 107 Aligning marks on No. 2 timing belt cover with marks on camshaft sprockets. 5M-GE engine:

2. Ensure marks on camshaft sprockets are aligned with marks on No. 2 timing belt cover, Fig. 107.

Fig. 108 Checking camshaft tooth alignment. 5M-GE engine:

3. If there is more than one tooth of the camshaft sprocket between marks on No. 2 timing belt cover, Fig. 108, note the following:
a. Gradually loosen idler pulley bolt and move idler puller toward the alternator.
b. Finger tighten idler pulley bolt and remove timing belt from camshaft sprockets.
c. Using tool number 09278-54011 or equivalent, turn camshaft sprocket and align marks, Fig. 107.

Fig. 109 Checking timing belt tension at points A and B. 5M-GE, 7M-GE & 7M-GTE engines:

d. Install timing belt. Loosen idler pulley bolt and allow idler pulley to tension timing belt, then torque idler pulley bolt to 36 ft. lbs. Ensure timing belt tension at points A and B, Fig. 109 are approximately equal. If not, loosen, then retighten idler pulley bolt.
e. Turn crankshaft in normal direction of rotation two times and set No. 1 cylinder to TDC of compression stroke. Check camshaft sprocket marks and timing belt tension. Repeat steps 1 through 3e, if necessary.
4. If marks are aligned properly or the differences is less than one tooth, Fig. 108, note the following:

Fig. 110 Aligning hole on No. 2 camshaft journal housing w/No. 2 camshaft journal. 5M-GE engines:

a. Using compressed air, clean out No. 2 camshaft journal housing and No. 2 camshaft journal alignment holes, Fig. 110.
b. Turn crankshaft in normal direction of rotation and align No. 2 camshaft journal housing and No. 2 camshaft journal holes. Hole alignment should be done separately for the intake and exhaust side camshafts.
c. After alignment of holes, place a mark on the crankshaft pulley and note degree angle on the No. 1 timing belt cover.
5. If crankshaft pulley degree angle is within 5° of TDC, crankshaft pulley degree angle is correct. If crankshaft pulley degree angle exceeds 5° of TDC, note the following:
a. Using tool number 09278-54011 or equivalent to prevent camshaft sprockets from turning, remove camshaft sprocket bolt.
b. Ensure No. 2 camshaft journal housing and No. 2 camshaft journal holes align, Fig. 110.
c. Using a suitable magnet, remove alignment pin from camshaft sprocket pin hole.

Fig. 111 Installing pin through camshaft sprocket and into camshaft. 5M-GE engine:

d. Set No. 1 piston to TDC of compression stroke, then insert alignment pin through camshaft sprocket and into camshaft. There are five alignment pin holes on the sprockets and camshafts. Select one overlapped alignment hole and insert pin into it, Fig. 111. If there are no overlapping alignment holes, select a hole which is nearly overlapped. Turn crankshaft slightly to overlap the alignment holes, and insert pin. Turning the crankshaft to overlap the next available alignment holes will change crankshaft sprocket angle approximately 3°.
e. Using tool number 09278-54011 or equivalent to prevent camshaft sprockets from turning, install and torque camshaft sprocket bolts to 51 ft. lbs. (7 kg-m).
f. Turn crankshaft in normal direction of rotation two times and set No. 1 piston to TDC of compression stroke. Recheck crankshaft pulley degree angle.

Fig. 99 Checking timing belt deflection. Engines w/dual overhead camshafts (typical):

6. Using two torque wrenches positioned upright on camshaft sprocket attaching bolts, turn both intake and exhaust cams inward with 14 ft. lbs. of torque at the same time to slacken timing belt at mid-position between cams. While applying a load of 4.4-6.6 pounds, measure belt deflection, Fig. 99. Deflection should be .20-.28 inch on used belt or .16-.24 inch on new belt. If measurement is not within specifications, adjust with idler pulley.