Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount.
Remove oil dipstick and pipe. Remove valve cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. Loosen timing belt tension adjuster bolt about 1/2 turn. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tension adjuster bolt. Remove balance shaft drive pulley. Remove balance shaft belt and timing belt from pulleys.
Ensure No. 1 piston is at TDC of compression stroke. See Fig. 1 . Align camshaft pulley with mating marks on back cover upper surface. Ensure "UP" mark is at 12 o'clock position. See Fig. 2 .
Install timing belt in sequence shown. See Fig. 3 . Loosen and retighten the timing belt adjusting nut about one turn. Install balance shaft drive pulley and lower cover. Install crankshaft pulley and center bolt.
Rotate crankshaft about 5-6 times counterclockwise. Set No. 1 piston at TDC. Loosen timing belt adjusting nut about one turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten timing belt adjusting nut. Make sure crankshaft and camshaft pulleys are at TDC.
Remove crankshaft pulley and lower cover. Ensure crankshaft is still at TDC. Lock timing belt adjuster arm in place by installing a 6x1.0 mm bolt. See Fig. 4 . Loosen timing belt adjusting nut about one turn, and make sure balance shaft belt adjuster moves freely.
Push tensioner to remove tension from balance shaft belt adjuster, then retighten nut.
Scribe a line 2.9" (74 mm) from the end of a 6x100 mm bolt. See Fig. 5 . Remove bolt from side of engine block. To align balance shaft, insert bolt through hole and into balance shaft.
Align groove on balance shaft pulley with pointer on oil pump housing. See Fig. 6 . Install balance shaft belt. Loosen adjuster nut about one turn to tension balance shaft belt.
Remove 6x100 mm bolt from balance shaft. Install sealing bolt in side of engine block. Install crankshaft pulley and bolt. Rotate crankshaft about one turn counterclockwise, then tighten adjuster nut. Remove 6x1.0 mm bolt from timing belt adjuster arm.
Remove crankshaft pulley. Install lower cover. Install rubber seal around adjuster nut. DO NOT loosen adjuster nut. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
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Thursday, January 1st, 2009 AT 6:05 PM