Mechanics

SATURN L300 TIMING BELT PROBLEM

2001 Saturn L300 • 127 miles

Timing chain replacement
AD
Avatar
Guest
November 25, 2012.



Timing Belt Removal

Notice: Failure to follow the described timing belt inspection and maintenance may result in a broken timing belt and cause severe engine damage.

Check the cold start counter (also called a heavy duty register) with a scan tool. If there are any cold starts below -28°C (-20°F) visually inspect the timing belt for cracks. If cracks are noted, do not reuse the belt. Replace the belt and clear the cold start counter. If the belt is okay, and is reused, do not clear the cold start counter.
Rotate the crankshaft clockwise to 60 degrees Before Top Dead Center (BTDC).

Install the J 42069-10 to the crankshaft drive gear with the knurled bolt.
Use the J 42098to carefully turn the crankshaft in the engine rotational direction (clockwise) until the lever of the J 42069-10 firmly contacts the water pump pulley flange.

Important Ensure that the crankshaft is not 180 degrees off TDC. The reference marks on the camshaft gears should be aligned with the corresponding notches on the rear timing belt cover at this point. If they are not aligned, the engine is 180 degrees off.

Secure the moveable lever of the tool to the water pump pulley flange.

Install the J 42069-1 and the J 42069-2 to the camshaft gears. If the J 42069-1 or the J 42069-2 do not fit into the teeth of the camshaft gears, it may be necessary to loosen the relevant timing belt idler pulley and turn the eccentric until the J 42069-1 or the J 42069-2 can be inserted.
Loosen the timing belt tensioner and idler pulleys.

Important Do not move the crankshaft while the timing belt is removed. Do not remove the J 42069-1 and 342069-2 while the belt is removed.

Remove the timing belt.
Remove the 342069-10,342069-1 and the 342069-2 from the engine.
Rotate the crankshaft clockwise to 60 degrees (BTDC) to prevent valve-to-piston contact.

Timing Belt Installation

Tools Required

J 42069 Timing Belt Alignment Kit
J 42098 Crank Hub TORX Socket

Installation and Initial Adjustment Procedure

Notice: When installing a new or used timing belt, the directional arrows on the timing belt must be matched with the rotation of the crankshaft. If this precaution is not observed, excessive wear and timing belt failure may occur.

Important: Guide marks are printed on the timing belt to aid in installation. If these marks are not identifiable, install a new belt. Arrows are printed on the timing belt indicating the required direction of travel. When installing the timing belt, ensure the arrows are traveling in engine rotational direction (clockwise). Install the timing belt with the engine at room temperature. Do not crimp or bind the timing belt when handling or installing.

Start at the crankshaft drive gear and install the timing belt with the double dash (TDC) mark on the belt aligned with the marks on the oil pump and on the belt drive gear.
Use the J 42069-30 to pinch the belt to prevent the teeth from jumping.

Route the timing belt through the timing belt tensioner (2).
Slip the timing belt through camshaft gears 1 and 2 simultaneously (3), ensuring the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.
Route the timing belt through the idler pulley for camshafts 1 and 2 (4).
Route the timing belt through the idler pulley for camshafts 3 and 4 (5).
Slip the timing belt through camshaft gears 3 and 4 simultaneously (6), ensuring the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.

Measure the timing belt deflection between camshaft gear number 4 and the idler pulley for camshafts 3 and 4, the deflection must be no more than 1 cm (0.4 in).

If timing belt deflection adjustment is necessary: Turn the timing belt idler pulley eccentric for camshafts 3 and 4 COUNTER CLOCKWISE, with J 42069-40, until the high point of the eccentric is in approximately the 12 o'clock position.
Tighten the idler pulley locking bolt, while holding the eccentric with J 42069-40, until snug. The idler pulley bolt will be tightened to specifications after all final adjustments are made.

Apply additional tension to the timing belt, at the idler pulley for camshafts 1 and 2, by turning the high point of the eccentric to approximately the 9 o'clock position. Then, tighten the idler pulley locking bolt, while holding the eccentric with J 42069-40, until snug. The idler pulley bolt will be tightened to specifications after all final adjustments are made.

Set the INITIAL timing belt tension: Turn the tensioner eccentric COUNTER CLOCKWISE to full stop, then, turn the eccentric back until the reference mark is 1 mm (0.003 in) over the flange.
Tighten the timing belt tensioner locking nut until snug, the locking nut will be tightened to specifications after all final adjustments are made.

Inspect the alignment marks on the timing belt to ensure that they are aligned with the appropriate reference points on the camshaft gears, the rear timing belt cover and on the oil pump housing.

Remove the J 42069-30, the J 42069-1 and the J 42069-2 locking tools from the engine.
Rotate the crankshaft, with J 42069, in the clockwise direction two revolutions stopping at 60 degrees BTDC.

Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Turn the crankshaft until the lever of the J 42069-10 Crankshaft Locking Tool firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.

Important: The alignment marks on the timing belt will no longer align with the marks on the camshaft gears after one or more engine revolutions.

Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft drive gear and oil pump housing.
Use the J 42069-20 checking gauge to inspect the alignment of camshaft gears 3 & 4
Use the J 42069-20 checking gauge to inspect the alignment of camshaft gears 1 & 2.

Important: The reference marks on both sets of the camshaft gears must match exactly with the marks on the J 42069-20 checking gauge. If timing belt adjustment is necessary, always set the adjustment for camshafts 3 and 4 first.

If timing belt adjustment IS REQUIRED, continue further on to the Timing Belt Timing Procedure.

If timing belt adjustment IS NOT REQUIRED, set the final timing belt tension: Loosen the timing belt tensioner eccentric locking nut.
Turn the eccentric counterclockwise to full stop, then back until the reference mark is 2-4 mm (0.078-0.157 in) ABOVE the reference mark on the flange.

Tighten

Tighten the timing belt tensioner eccentric locking nut 20 Nm (15 lb ft).

Hold the timing belt idler pulley eccentrics in place for camshafts 1 & 2 and 3 & 4 with the J 42069-40 adjustment wrench.

Tighten
Tighten both idler pulley bolts 40 Nm (30 lb ft).

Inspect the high-points of the timing belt tensioner eccentrics. The idler pulley eccentric high point for camshafts 3 and 4 will be in approximately the 12 o'clock position. The idler pulley eccentric high point for camshafts 1 and 2 will be in approximately the 9 o'clock position.
Remove the J 42069-20 checking gauge and the J 42069-10 crankshaft locking tool.
For final inspection, rotate the engine in the clockwise direction two revolutions until reaching 60 degrees BTDC.

Install the 342069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Turn the crankshaft until the lever of the 3 42069-10 Crankshaft Locking Tool firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft gear and the mark on the oil pump housing.
Use the 342069-20 checking gauge to inspect the alignment of camshaft gears 3 and 4.
Use the 3 42069-20 checking gauge to inspect the alignment of camshaft gears 1 and 2.
If the reference marks on the camshaft gears do not match exactly, timing belt adjustment IS REQUIRED. Continue further on to the Timing Belt Timing Procedure.
If the reference marks match exactly and further timing belt adjustment IS NOT necessary. Continue with reassembly of the engine.
Ensure all of the tools are removed from the engine.

Timing Belt Timing Procedure

Important: The following steps are the continuation of installing the timing belt and must not be performed as a stand-alone operation. It is not uncommon to repeat steps and make several engine revolutions to achieve the proper level of timing belt adjustment.

Important: Whenever timing belt adjustment is necessary, always start with, and adjust, camshafts 3 and 4 first.

Apply the J 42069-20 checking gauge to camshaft gears 3 and 4.

Inspect the relationship of the marks on the camshaft gears to the marks on the J 42069-20 checking gauge. They must match exactly, if not, timing belt adjustment is required.
Apply the J 42069-20 checking gauge to camshaft gears 1 and 2.
Inspect the relationship of the marks on the camshaft gears to the marks on the J 42069-20 checking gauge. They must match exactly, if not, timing belt adjustment is required.
Continue to the next applicable procedure: Marks on Camshaft Gears 3 and 4 Align to the LEFT of J 42069-20

Loosen the timing belt idler pulley for camshaft gears 3 & 4.

Use the J 42069-40 adjustment wrench to turn the eccentric on the idler pulley COUNTERCLOCKWISE until the marks on the camshaft gears and on the J 42069-20 Checking Gauge are in alignment (the high point of the idler pulley eccentric will be in approximately the 12 o'clock position).

Tighten

Tighten the timing belt idler pulley bolt, while holding the eccentric in place with the J 42069-40 adjustment wrench to prevent movement, to 40 Nm (30 lb ft).

Remove the J 42069-10 crankshaft locking tool and the J 42069-20 checking gauge.
Turn the crankshaft in the engine rotational direction two revolutions with the J 42069. Stop at 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the 3 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Install the 342069-20 checking gauge to camshaft gears 3 & 4.
Inspect the alignment of the marks on the camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the procedure again if the marks do not align.
If camshaft gears 3 and 4 are properly aligned, continue checking the timing belt adjustment of camshaft gears 1 & 2. Make necessary corrections as outlined further on in this section.
AFTER all applicable camshaft gear adjustments are made, set the final timing belt tensioner as outlined in Timing Belt Tensioner Adjustment at the end of this procedure.

Marks on Camshaft Gears 3 and 4 Align to the RIGHT of J 42069-20

loosen the timing belt idler pulley for camshaft gears 3 & 4.

Slacken the timing belt by turning the eccentric on the idler pulley CLOCKWISE with the J 42069-40 adjustment wrench until the marks on the camshaft gears and the marks on the J 42069-20 checking gauge are in alignment (the high point of the idler pulley eccentric will be in approximately the 12 o'clock position).

Tighten

Tighten the timing belt idler pulley bolt, while holding the eccentric in place with the J 42069-40 adjustment wrench to prevent movement, to 40 Nm (30 lb ft).

Remove the J 42069-10 crankshaft locking tool and the J 42069-20 checking gauge.
Turn the crankshaft in the engine rotational direction two revolutions with the J 42069. Stop at 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the J 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Install the J 42069-20 checking gauge to camshaft gears 3 & 4.
Inspect the alignment of the marks on the camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the procedure again if the marks do not align.
If camshaft gears 3 and 4 are properly aligned, continue checking the timing belt adjustment of camshaft gears 1 and 2. Make necessary corrections as outlined further on in this section.
AFTER all applicable camshaft gear adjustments are made, set the final timing belt tensioner as outlined in Timing Belt Tensioner Adjustment at the end of this procedure.

Marks on Camshaft Gears 1 and 2 Align to the LEFT of J 42069-20

Loosen the timing belt idler pulley for camshaft gears 1 & 2.

Use the J 42069-40 adjustment wrench to turn eccentric on the idler pulley COUNTERCLOCKWISE until the marks on the camshaft gears and on the 342069-20 checking gauge are in alignment (the high point of the idler pulley eccentric will be in approximately the 9 o'clock position).

Tighten

Tighten the timing belt idler pulley bolt, while holding the eccentric in place with the J 42069-40 adjustment wrench to prevent movement, to 40 Nm (30 lb ft).

Remove the J 42069-10 crankshaft locking tool and the J 42069-20 checking gauge.
Turn the crankshaft in the engine rotational direction two revolutions with the J 42069. Stop at 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the J 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Install the J 42069-20 checking gauge to camshaft gears 1 & 2.
Inspect the alignment of the marks on the camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the procedure again if the marks do not align.
If camshaft gears 1 and 2 are properly aligned, set the final timing belt tensioner as outlined in Timing Belt Tensioner Adjustment at the end of this procedure.

Marks on Camshaft Gears 1 and 2 Align to the RIGHT of J 42069-20

Loosen the timing belt idler pulley for camshaft gears 1 & 2.
Slacken the timing belt by turning the eccentric on the idler pulley CLOCKWISE with the J 42069-40 adjustment wrench until the marks on the camshaft gears and the marks on the J 42069-20 checking gauge are in alignment (the high point of the idler pulley eccentric will be in approximately the 9 o'clock position).

Tighten

Tighten the timing belt idler pulley bolt, while holding the eccentric in place with the J 42069-40 adjustment wrench to prevent movement, to 40 Nm (30 lb ft).

Remove the J 42069-10 crankshaft locking tool and the J 42069-20 checking gauge.
Turn the crankshaft in the engine rotational direction two revolutions with the J 42069. Stop at 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the J 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Install the J 42069-20 checking gauge to camshaft gears 1 & 2.
Inspect the alignment of the marks on the camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the procedure again if the marks do not align.
If camshaft gears 1 and 2 are properly aligned, set the final timing belt tensioner as outlined in Timing Belt Tensioner Adjustment at the end of this procedure.

Marks on Camshaft Gears 1 and 2 Align to the RIGHT of J 42069-20

Loosen the timing belt idler pulley for camshaft gears 1 & 2.
Slacken the timing belt by turning the eccentric on the idler pulley CLOCKWISE with the J 42069-40 adjustment wrench until the marks on the camshaft gears and the marks on the J 42069-20 checking gauge are in alignment (the high point of the idler pulley eccentric will be in approximately the 9 o'clock position).

Tighten

Tighten the timing belt idler pulley bolt, while holding the eccentric in place with the J 42069-40 adjustment wrench to prevent movement, to 40 Nm (30 lb ft).

Remove the J 42069-10 crankshaft locking tool and the J 42069-20 checking gauge.
Turn the crankshaft in the engine rotational direction two revolutions with the J 42069. Stop at 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the J 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Install the J 42069-20 checking gauge to camshaft gears 1 & 2.
Inspect the alignment of the marks on the camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the procedure again if the marks do not align.
If camshaft gears 1 and 2 are properly aligned, set the final timing belt tensioner as outlined in Timing Belt Tensioner Adjustment at the end of this procedure.

Timing Belt Tensioner Adjustment

Important: The following steps are the COMPLETION of adjusting the timing belt and must not be performed as a stand alone operation.

With the J 42069-10 in place locking the crankshaft at TDC: Loosen the timing belt tensioner eccentric locking nut.
Turn the eccentric counterclockwise to full stop, then back until the reference mark is 2-4 mm ABOVE the reference mark on the flange.

Tighten

Tighten the timing belt tensioner locking nut to 20 Nm (15 lb ft).

If the timing belt idler pulley bolts for camshafts 3 & 4 and 1 & 2 have not been previously torqued to specification: Tighten

Tighten the timing belt idler pulley bolts while holding the eccentric in place with the J 42069-40 Adjusting Wrench to prevent movement, to 40 Nm (30 lb ft).

Remove all checking tools.
As a final inspection, once again rotate the engine in the clockwise direction two revolutions until reaching 60 degrees BTDC.
Install the J 42069-10 crankshaft locking tool to the crankshaft drive gear with the knurled bolt.
Use the J 42069 to carefully turn the crankshaft until the lever of the J 42069-10 firmly contacts the water pump pulley flange.
Secure the moveable lever of the tool to the water pump pulley flange.
Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft gear with the mark on the oil pump housing.
Inspect the alignment of the marks on all four camshaft gears in reference to the marks on the J 42069-20 checking gauge.
Repeat the Timing Belt Timing Procedure again if the marks do not align.
Continue with the engine reassembly if further timing belt adjustment is not needed.

ASEMaster6371
Nov 25, 2012.


AD