Date Added: 10/14/2015
Viewed: 502 times
1. Disconnect battery cables 13mm and remove battery
2. Disconnect wiring to ignition control module (ICM/DIS) which is located on the intake balance tube with2 plugs, one grey and one black. Also disconnect the other 2 connectors for the CPS (crank position sensor) one has a single wire and the other is a multi-wire connector
3. Remove intake manifold balance tube that the DIS module is mounted on, you will need to unscrew the hose clamps and remove 2x 14mm bolts on top.
4. Loosen alternator and A/C (6 rib) belt tensioner pulley and relieve tension on belt by backing out adjustment screw. Note, you must loosen the nut on the pulley before being able to loosen the 5mm hex holt and remove the belt.
5. Remove Engine Dampener, 4x 14mm bolts
6. Loosen water pump/power steering (4 rib) belt tensioner pulley and relieve tension on belt by backing out adjustment screw and remove the belt.
7. Remove alternator and A/C belt tensioner pulley and bracket assembly.
8. Remove water pump/power steering belt tensioner pulley only.
9. Remove upper timing belt cover 8mm or 5/16" bolts.
10. Loosen RH front lug nuts (19mm or 3/4") and raise vehicleand support safely on jack stands (BE CAREFUL).
11. Loosen fender splash shield and place out of the way.
12. Remove the crank pulley bolt using a impact wrench 19mm or 3/4", if you cannot get it broken free AND THE CAR IS A MANUAL TRANSMISSION (WILL NOT WORK ON AUTOMATICS) then take a breaker bar with the socket put it on the bolt, prop the bar against the front of the frame of the car, roll the car forward in 4th gear with the clutch disengaged and pop the clutch while the car is rolling, it will break the bolt free. DO NOT DO NOT NOT NOT USE THE STARTER TO BREAK THE BOLT FREE, that is stupid and can damage the starter or flywheel and make this job more expensive and complicated.
13. Place gear selector in NEUTRAL.
14. Set engine to TDC on No. 1 cylinder. Ensure that "white" mark on crankshaft damper aligns with 0 degree index mark on lower timing belt cover and that marks on intake camshaft pulleys align with index marks on metal timing belt cover. You can also line up the dimple on the crank timing sprocket with the timing mark at the 5 o'clock position.
15. Remove crankshaft damper using Puller, make sure to lubricate the puller threads with some clean oil, ESPECIALLY if you use a impact wrench on the tool or it will damage your tool.
16. Remove lower timing belt cover.
17. Remove center timing belt cover and disconnect crankshaft sensor wire and grommet from the slot in the cover and stud on water pump.
18. Loosen timing belt tensioner, rotate pulley 180 degrees clockwise using an 6mm Allen wrench, and tighten tensioner nut to hold pulley in the "unload position." and remove the belt.
19. Remove the two small philips head screws holding the Camshaft Position Sensor in place. If you strip these removing them, they are Metric 4 by 10 mm. (M4x10mm).
20. Remove timing belt sprocket. Located behind it is the front main seal. This can be removed by GENTLY stabbing the seal with a small screwdriver and prying the edge of it loose, working your way around the outside edge.
21. Install new front main seal by lightly oiling the outside edge of the seal. Insert it the best you can.
22. Install new CPS sensor and set the gap against the timing belt sprocket to .030" or .8mm.
23. Ensure engine is still at TDC on No. 1 cylinder. Check that camshaft pulley marks line up with index marks on upper steel belt cover and that crankshaft pulley aligns with index mark on oil pump housing.
The timing belt has three white or yellow lines. Each line aligns with the index marks shown.
24. Install timing belt on crankshaft pulley and route to camshaft pulleys. Lettering on belt "KOA" should be readable from rear of engine (top of lettering to front of engine). Also ensure that the yellow lines are aligned with the index marks on the pulleys.
25. Release tensioner locknut and leave nut loose.
26. Install center timing belt cover. Ensure crankshaft sensor (CPS) wiring and grommet are installed and routed properly. Tighten retaining bolts to 7-11 N-m (62-97 lb-in).
27. Install lower timing belt cover. Tighten retaining bolts to 7-11 N-m (62-97 lb-in).
28. Install crankshaft damper.
29. Rotate crankshaft two revolutions in the clockwise direction until the yellow mark on damper aligns with 0 degree mark on lower timing belt cover.
30. Remove plastic door in the lower timing belt cover. Tighten belt tensioner lock nut to 33-51 N-m (24-38 lb-ft) and install plastic door.
31. Rotate crankshaft 60 degrees more in the clockwise direction until the white mark on the damper aligns with 0 degree index mark on lower timing belt cover.
32. Ensure index marks on camshaft pulleys align with marks on rear metal timing belt cover.
33. Route crankshaft sensor (CPS) wiring and connect with engine wiring harness.
34. Install upper timing belt cover. Tighten retaining bolts to 7-11 N-m (62-97 lb-in).
35. Install water pump pulley. Tighten retaining nut to 16-23 N-m (12-17 lb-ft).
36. Install alternator and A/C tensioner pulley and bracket assembly. Tighten bolts to 15-23 N-m (11-17 lb-ft).
37. Install water pump/power steering (4 rib) belt. Tighten idler pulley retaining nut to 34-50 N-m (25-36 lb-ft).
New belt: 690-880 N (154-198 lb)
Used belt: 500-700 N (112-157 lb)
38. Install alternator and A/C (6 rib) belt. Tighten idler pulley nut to 34-50 N-m (25-36 lb-ft).
New belt: 980-1180 N (220-265 lb)
Used belt: 660-850 N (148-192 lb)
39. Install intake manifold cross over tube. Tighten bolts to 15-23 N-m (11-17 lb-ft).
40. Install engine roll damper.
41. Install splash shield.
42. Install tire.
43. Lower vehicle.
44. Install battery.
Always remember safety first, properly support the car with a jack stand and NOT a jack and use safety glasses.
When doing this, I recommend you go ahead and change your water pump and CPS.
Always keep belt in protective packaging and clean until ready for use.
Never hit or squeeze belt with hammer, screw driver, or any other tool and do not use a screw driver to push belt onto pulleys.
Do NOT use the cars starter to break the engine crank bolt free, I don't care what other people say this can cause more damage and cost more money.
lubricate the puller threads with some clean oil, ESPECIALLY if you use a impact wrench on the tool or it will damage your tool.