Disconnect negative battery cable. Drain coolant. Remove timing belt. See TIMING BELT. Remove water inlet pipe and gasket. Remove water pump bolts, and remove water pump. Remove gasket and clean gasket mating surface of engine block.
Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley. Remove crankshaft pulley and timing belt guide plate. Remove upper and lower timing belt covers.
Turn crankshaft so timing mark on timing belt pulley aligns with timing mark on engine. See Fig. 4. Ensure "I" mark on intake camshaft pulley aligns with mark on cylinder head cover. Ensure "E" mark on exhaust camshaft pulley aligns with mark on cylinder head cover. See Fig. 5.
NOTE:DO NOT move camshaft or crankshaft once timing marks have been correctly positioned.
If timing belt is to be reused, mark direction of timing belt rotation before removal. Loosen timing belt tensioner lock bolt. Move tensioner away from belt with spring fully extended. Tighten tensioner bolt while belt tension is released. Remove timing belt.
Loosen tensioner pulley lock bolt. Remove tensioner pulley. Remove timing belt. Mark direction of timing belt rotation for proper reinstallation.
Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.
Install tensioner pulley. Pull tensioner pulley to its farthest point, and tighten lock bolt. Ensure timing belt and engine marks align. Ensure intake and exhaust camshaft sprocket marks align.
Install timing belt onto crankshaft sprocket first, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and tensioner pulley in order Ensure there is no looseness between belt and pulleys and sprockets.
Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Tighten tensioner pulley lock bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks do not align, remove belt, realign all timing marks, and repeat installation procedure.
Check timing belt deflection. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. Timing belt deflection should be.36-.45" (9.1-11.4 mm). If timing belt deflection is not within specification, repeat procedure and/or replace timing belt tensioner spring. If timing belt deflection is within specification, reverse removal procedure to complete installation. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.
Wednesday, April 8th, 2009 AT 12:11 PM