How to inspect & change the cambelt

Caution: Do not try to turn the crankshaft with the camshaft sprocket bolt and do not rotate the crankshaft counterclockwise. Also, don't turn the crankshaft after the cambelt (timing belt) has been removed.

1. Position the number one piston at Top Dead Centre.
2. Disconnect the negative cable from the battery.
3. Set the parking brake and block the rear wheels. Raise the front of the vehicle and support it securely on jack-stands.
5. Remove the left engine mount. Note: Make sure the engine is supported with a piece of wood and a floor jack placed under the oil pan. The wood will prevent the floor jack from denting or damaging the oil pan.

Removal

1. Loosen the water pump pulley bolts and remove the drive-belts.
2. Unbolt and remove the water pump pulley.
3. Remove the bolts that secure the cambelt upper cover and lift the cover off. Remove the bolts that secure the lower cover and lift it off.
4. If you plan to reuse the cambelt, paint an arrow on it to indicate the direction of rotation (clockwise).
5. Loosen the adjusting bolts and move the cambelt tensioner towards the water pump as far as possible. Temporarily secure the tensioner by tightening the bolt.
6. Remove the splash pan from beneath the drivebelt end of the engine, then remove the large bolt from the crankshaft pulley.
7. If you intend to remove the camshaft, unscrew the camshaft sprocket bolt and slide the sprocket off - a large screwdriver inserted through a hole in the sprocket will keep it from turning while you remove the bolt. Also, remove the oil pump sprocket at this time and inspect the oil pump seal for leaks or apparent damage.
8. If you intend to replace the crankshaft front oil seal , unscrew the four bolts for the crankshaft pulley and slide it off; then slide off the camshaft sprocket and the belt guide flange located behind the crankshaft sprocket. When removing the flange, note the way it's installed (chamfered side faces out).
9. On 1.8L and 2.0L turbo engines, remove the plug at the left side of the cylinder block and insert a screwdriver or a long punch to hold the Silent Shaft stationary. The screwdriver or punch should have an approximate diameter of 5/16-inch and a length of 2 3/8-inches.
10. Loosen the bolt that retains the Silent Shaft sprocket.
11. Loosen the Silent Shaft tensioner and remove the Silent Shaft belt (timing belt B). Caution: Do not attempt to loosen the sprocket bolt by holding the sprocket stationary with pliers.

Inspection

1. Rotate the tensioner pulley by hand and move it side-to-side to detect roughness and excess play. Visually inspect the sprockets for any signs of damage or wear. Replace parts as necessary.
2. Inspecting the cambelt for cracks, separation, wear, missing teeth and oil contamination. Replace the belt if it's in questionable condition.

Installation

1. Reinstall the cambelt sprockets, if they were removed. Slip the belt guide flange onto the crankshaft before installing the lower sprocket - the chamfered side of the flange faces out. The crankshaft sprocket has two different size flats which match those on the crankshaft.
2. Align the timing marks located on the camshaft, crankshaft and oil pump sprockets with the marks on the cylinder head and the front case. Note: Different engines have different types of alignment marks. Some alignment marks are notches or raised arrows and some are punch indentations. Identify the exact type and location of the alignment marks on each sprocket before continuing the procedure. When aligning the oil pump sprocket marks, it is critical that the Silent Shaft has the weighted portion at the bottom of the shaft (it is possible to align the marks with the Silent Shaft weight at the top; if you do this accidentally, severe engine vibration will result). Before installing the cambelt, slightly rock the oil pump sprocket by hand and watch carefully that the sprocket has a tendency to remain stationary (return to approximately the marks aligned position) when the sprocket is rotated. This means the sprocket is CORRECTLY timed. If the sprocket has the tendency to rotate clockwise when spun lightly, the shaft is INCORRECTLY timed. If there is any doubt about whether or not the Silent Shaft is in the correct position, insert a screwdriver through the hole in the side of the cylinder block. Make sure the screwdriver extends approximately two inches into the hole and also make the sprocket cannot be rotated with the screwdriver in place ; now you can be sure the timing is correct.
3. On turbo models, align the timing marks on each sprocket with the timing marks on the front case.
4. After installing the timing belt, make sure the tension sprocket for timing belt B has the centre located just to the left side of the mounting bolt with the pulley directed to the front of the engine. Lift the tensioner up with one finger to tighten the belt and tighten the tensioner bolt (32 to 40) and the Silent Shaft bolt (22 to 28). Note: Use the index finger and press firmly on the timing belt. The belt deflection should be 13/64 to 9/32 inch (5.0 to 7.0mm).
5. On all engine, slip the timing belt onto the crankshaft sprocket. While maintaining tension on the rear (firewall) side of the belt, slip the belt onto the camshaft sprocket.
6. Release the tensioner hold-down bolt to apply spring tension against the belt. Re-tighten the bolt.
7. Install the crankshaft pulley, taking care to align the locating pin with the small hole in the pulley. Install the crankshaft pulley bolts (both the pulley securing bolts and the centre bolt) and tighten them to 108 to 132 in-lbs for securing bolts and centre bolt 80 to 94. When tightening the bolts, hold the crankshaft in place using one of the methods explained earlier.
8. Using the bolt in the centre of the crankshaft pulley, turn the crankshaft clockwise through two complete revolutions (720-degrees). Recheck the alignment of the timing marks. If the marks do not align properly, loosen the tensioner, slip the belt off the camshaft sprocket, align the marks, reinstall the belt, and check the alignment again.
9. Tighten the tensioner bolts to 32 to 40. Starting with the adjustment bolt; then tighten the bolt that goes through the tension spring.
10. Reinstall the remaining parts in the reverse order of removal. Note that the timing belt cover bolts come in different lengths.
11. Start the engine, set the ignition timing and road test the vehicle.

Scott,
BOOSTU