AutoZone 1997 Chevrolet Truck Astro Van 2WD 4.3L SFI 6cyl | Repair Guides | Engine And Engine Overhaul | Engine Mechanical | Timing Belt Sprockets | AutoZone.com

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    1997 Chevrolet Truck Astro Van 2WD 4.3L SFI 6cyl

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    VW Passat & Audi A4 1990-2000

    Timing Belt Sprockets

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    removal & installation
    1. Note the radio security code and disconnect the negative battery cable.
    2.  
    3. On 1.8L engines, place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
    4.  
    5. Rotate the engine to Top Dead Center (TDC) on the firing stroke for cylinder No. 1.
    6.  
    7. Remove the accessory drive belts.
    8.  
    9. Remove the accessory drive belt pulley/damper assembly.
    10.  
    11. On 1.8L engines, remove the torque arm mounting bracket.
    12.  
    13. Hold the crankshaft timing belt gear, using Tool No. 3099, or its equivalent.
    14.  
    15. Loosen the crankshaft and/or camshaft and/or intermediate shaft sprocket mounting bolt(s) 1 turn.
    16.  
    17. Remove the timing belt.
    18.  
    19. Remove the sprocket mounting bolt(s), if necessary remove the retaining tool and remove the sprocket(s). If the sprocket is seized to the shaft, install the mounting bolt flush and then back it out 3 turns and use a suitable gear puller to loosen and remove the sprocket. If a gear puller is used, as the sprocket moves off the shaft, in may be necessary to back out the mounting bolt.
    20.  

    To install:

    1. Clean the shaft mounting surface(s) and sprocket(s) as necessary. The surfaces must be clean and dry.
    2.  


    NOTE
    If removed, the crankshaft sprocket bolt must not be reused.

    1. If the crankshaft sprocket and/or bolt were removed:
    2.  
      1. The crankshaft sprocket bolt must be replaced.
      2.  
      3. If removed, install the sprocket onto the crankshaft.
      4.  
      5. Using a new bolt, lightly oil the threads and thrust surface of the bolt.
      6.  
      7. Install the bolt finger tight.
      8.  

    3. Install the timing belt gear holding Tool No. 3099, or its equivalent.
    4.  
    5. If the crankshaft mounting bolt was previously loosened or removed, using a new, properly oiled bolt, tighten and torque as follows:
    6.  

    1.8L and 2.0L SOHC (ABA) engines:



    Step 1: 66 ft. lbs. (90 Nm)
     
    Step 2: 90° ( 1 / 4 turn)
     

    2.0L DOHC (9A) engine:



    Step 1: 22 ft. lbs. (30 Nm)
     
    Step 2: 90° ( 1 / 4 turn)
     

    1. If the camshaft or intermediate shaft sprockets were removed, install the removed sprocket(s) making sure the TDC timing marks are properly aligned and install the mounting bolt(s) until they are lightly bottomed and the sprocket seated. Do NOT allow the shafts to move.
    2.  
    3. Install and properly tension the timing belt.
    4.  
    5. Tighten the camshaft and/or intermediate shaft sprocket bolt(s) as follows:
    6.  

    1.8L engine:



    Camshaft/intermediate shaft: 48 ft. lbs. (65 Nm)
     

    2.0L SOHC (ABA) engine:



    Camshaft/intermediate shaft: 60 ft. lbs. (80 Nm)
     

    2.0L DOHC (9A) engine:



    Camshaft/intermediate shaft: 48 ft. lbs. (65 Nm)
     

    1. The balance of the assembly is in reverse order of removal, making sure all gears and shafts are properly timed and installed.
    2.  

    2.8L V6 Engines
    1. Note the radio security code and disconnect the negative battery cable.
    2.  
    3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
    4.  
    5. Remove the accessory drive belt.
    6.  
    7. Rotate the engine to Top Dead Center (TDC), then remove from the left side of the engine:
    8.  
      1. On SOHC (AFC) engines, the Crankshaft Position (CKP) sensor.
      2.  
      3. On DOHC 5V engines, the sealing plug.
      4.  

    9. Install and lock the crankshaft in position using tool No. 3242 or its equivalent.
    10.  
    11. If the crankshaft sprocket and/or bolt is to be removed, loosen the crankshaft sprocket mounting bolt 1 turn.
    12.  
    13. If the camshaft sprocket and/or bolt is to be removed,
    14.  
      1. On SOHC (AFC) engines, install camshaft holding fixture Tool No. 3243.
      2.  
      3. On DOHC 5V engines, install camshaft holding fixture Tool No. 3391.
      4.  

    15. Loosen the camshaft sprocket mounting bolt(s) 1 turn.
    16.  
    17. Remove the timing belt.
    18.  


    NOTE
    The sprockets are not keyed and are mounted on a tapered shaft. A suitable gear/sprocket puller most likely will be needed.

    1. Remove the sprocket mounting bolt(s) and sprocket(s). If the sprocket is seized to the shaft, install the mounting bolt flush and then back it out 3 turns and use a suitable gear puller such as Tool No. 3032 or Kukko® 20-10 or their equivalent to loosen and remove the sprocket. If a gear puller is used, as the sprocket moves off the shaft, in may be necessary to back out the mounting bolt.
    2.  

    To install:

    1. Clean the shaft mounting surface(s) and sprocket(s) as necessary. The surfaces must be clean and dry.
    2.  


    NOTE
    If removed, the crankshaft sprocket bolt must not be reused.

    1. If the crankshaft sprocket and/or bolt were removed:
    2.  
      1. The crankshaft sprocket bolt must be replaced.
      2.  
      3. If removed, install the sprocket onto the crankshaft.
      4.  
      5. Using a new bolt, lightly oil the threads and thrust surface of the bolt.
      6.  
      7. Install the bolt finger tight.
      8.  

    3. Install Tool No. 3342, or its equivalent.
    4.  
    5. If the crankshaft mounting bolt was previously loosened or removed, using a new, properly oiled bolt, tighten and torque as follows:
    6.  
    7. Step 1: 148 ft. lbs. (200 Nm)
    8.  
    9. Step 2: 180° ( 1 / 2 a turn)
    10.  
    11. If the camshaft sprockets were removed, install the removed sprocket(s) and install the mounting bolt(s) until they are lightly bottomed and the sprocket lightly seated but still moveable.
    12.  
    13. On SOHC (AFC) engines, install camshaft holding fixture Tool No. 3243.
    14.  
    15. On DOHC 5V engines, install camshaft holding fixture Tool No. 3391
    16.  
    17. Install and properly tension the camshaft timing belt.
    18.  
    19. Tighten the camshaft shaft sprocket bolts as follows:
    20.  

    SOHC (AFC) engine:



    Step 1: 22 ft. lbs. (30 Nm)
     
    Step 2: 180° ( 1 / 2 a turn)
     

    On DOHC 5V engines:



    41 ft. lbs. (55 Nm)
     

    1. The balance of the assembly is in reverse order of removal, making sure all gears and shafts are properly timed and installed.
    2.  

    Inspection

    Inspect the sprockets for the following:



    Cracks
     
    Damaged or worn teeth
     
    Sharp edges
     

     
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