COMP Cams 6535 Hi-Tech Belt Drive - Manual (Page 2)

COMP Cams®
3406 Democrat Rd.
Memphis, TN 38118
Phone: (901) 795-2400 Fax: (901) 366-1807
www.compcams.com
Part #163
Revised 08/28/06
These instructions begin with the previous cam drive system removed and the cam still in the
block. Rocker arms should be removed to facilitate easily rotating the cam itself. It is also best to
start a first time installation with the oil pan removed, since some interference between the block
and belt drive main plate may exist, necessitating repeated trail fittings of the main plate.
Step 1 – Main Plate Installation
Temporarily install the main plate on the front of the engine, checking for a flush fit to the gasket
surface. Interference between the back of the plate and the block may exist, preventing the plate from
going on all the way. Note the location of the interference, remove the plate, and grind the block
accordingly, to provide adequate clearance. Do not grind the plate. This may weaken it and cause
failure! Some blocks may not need to be clearanced at all.
Once adequate clearance has been obtained, install the lower gear seal into the main plate. Then place
the tensioner over the stud extending from the main plate and install the washer and nut. This needs to
be done with the main plate off the block to access the back of the stud with a 5/16" Allen wrench.
Torque the nut to 45 ft/lbs. Install the two dowel pins in the standard locations on the front of the
block. Place a standard timing cover gasket onto the block surface and install the main plate with the
four (4) supplied 3/8" x 18 Allen bolts in the lower bolt hole locations. Torque to 35 ft/lbs. Install the
two (2) 5/16" x 20 Allen bolts in the upper bolt hole locations. Torque to 20 ft/lbs. Then install the cam
retention plate to the block using the stock location using the two (2) 1/4" x 20 countersink Allen bolts
to secure the retention plate to the block. Torque to 144 in/lbs. The oiling groove should face the cam.
Next, install the oil seal into the upper gear hub seal plate. Then install the large o-ring in the groove
on the backside of the seal plate. Install the seal plate using the five (5) 1/4" button head Allen bolts.
Step 2 – Upper Gear Assembly
With the upper gear hub and upper gear separated, install the six (6) 5/16" button head Allen bolts
from the back of the hub using thread locker to prevent the bolts from backing out later. Clean the
thread locker from the threads that extend from the hub. Install the upper gear onto the hub over the
studs, with the tapered outer edge facing out. Then install the six (6) washers and bolts to the upper
gear assembly. Do not fully tighten at this time.
Step 3 – Lower Gear Assembly
Remove the outer belt guard from the lower gear by loosening and removing the four button head
Allen screws from the front of the gear. Set the guard and screws aside for reinstallation later. Lightly
oil the sealing surface of the lower gear with COMP Cams® Cam & Lifter Installation (#152, #153)
Lube to prevent seal damage during installation. Install the lower gear with the proper installation tool,
like COMP Cams® Professional Harmonic Balancer Puller/Installation Tool (Part #300). Do not use a
hammer to beat the lower gear on! Severe damage to the lower gear may result from doing so. Make
sure the lower gear goes on all the way on the crank up against the shoulder of the snout. Some cranks
have an extremely generous radius that may prevent the gear from going on all the way back against
the step. Provisions must be made to eliminate this potential interference if it exists or belt
misalignment will occur.