Withdrawal
See drawings 100, 101 and 102.
1. Disconnect the wire from the negative battery terminal.
2. Rotate the engine to align the marks on the camshaft pulley and set the number 1 cylinder to TDC. Once the motor is in this position, it must not be rotated or moved.
3. Remove the engine support bolts and nuts, and then remove the side support rubber and bracket. Remove the cruise control drive, if installed; move the actuator out of the work area without removing or twisting the actuator cable.
4. Remove the mudguard from the bottom of the engine.
5. Loosen the power steering belt adjusting nut and remove the belt. Remove the control pulley and power steering pump. Move pump out of work area with hoses attached.
6. Disconnect the electrical wiring from the generator. Remove the alternator through bolt; remove the mounting and adjusting bolts and remove the alternator and belt.
7. On vehicles with air conditioning, remove the compressor mounting bolts. Remove the compressor and belt; do not disconnect the lines from the compressor. Move the compressor out of the work area and secure it with a rigid wire.
8. On vehicles with fuel injection, remove the ignition wires from the valve cover and the wiring protection from the cylinder head.
9. Remove valve cover.
10. Remove the crankshaft bolt and remove the crankshaft pulley.
This bolt is one of the tightest in the entire car. The pulley should be held in place while the bolt is loosened. Wrap the old drive belt around the pulley to hold it in place - don't try this with a belt that's on a car; it will stretch or break.
11. Remove the camshaft drive belt covers.
12. Loosen, but do not remove, the adjusting bolt on the camshaft drive belt tensioner. Move the tensioner away from the belt and retighten the bolt.
13. Use a piece of chalk or a marker to draw an arrow on the camshaft drive belt. The arrow can identify the direction of rotation or the outer edge of the belt. The belt must be reinstalled so that it runs in the same direction. Carefully remove the belt from the pulleys without bending. Protect the belt from oil, coolant, etc.
14. This is an excellent time to check or replace the water pump. Even if you only plan to replace the camshaft drive belt as part of a maintenance program, schedule a pump replacement at the same time.
For installation:
15. If the water pump must be replaced, install a new o-ring and install the water pump. Make sure that the O-ring is not deformed or moved from its place. Tighten the mounting bolts to 12 Nm.
16. Double check the position of the motor; it must be at TDC for cylinder Number 1. All of the following conditions must be met: the pointer on the back of the cylinder block is aligned with the white mark on the flywheel, the UP mark on each camshaft pulley is up, and the alignment marks on each camshaft pulley are aligned with the edges of the head cylinder block.
On fuel injected engines, each of the camshafts can be held at TDC by 5mm diameter punches inserted into the alignment holes just behind each camshaft pulley. This makes mounting the belt much easier.
17. Install the camshaft drive belt so that it rotates in the same direction as before. Remove the punches holding the camshafts, if fitted.
18. Loosen the adjuster and let it tension the belt. Tighten the adjusting bolt.
19. Install the belt covers, except for the top cover on engines with one camshaft.
20. Install the crankshaft pulley and key. Coat the bolt threads with a light oil, but do not lubricate the end of the bolt that contacts the washer. On engines with fuel injection, tighten the bolt to 150 Nm; on carbureted engines, tighten the bolt to 115 Nm.
This tightening is best done with the wheels locked (using the parking brake) and a manual transmission in gear or with the "PARK" selector lever for automatic transmission.
21. Rotate the engine counterclockwise until the camshaft pulley rotates 3 teeth. Loosen the adjusting bolt, then retighten it to 43 Nm.
22. Install the valve cover and camshaft drive belt top cover on carbureted vehicles. On vehicles with fuel injection, connect the ignition wires and wiring protection.
23. Install the A/C compressor and belt. Tighten the bolts to 25 Nm. Adjust belt tension.
24. Install the alternator and belt. Tighten the through bolt to 45 Nm.
25. Install the power steering pump and belt, tightening the bolts to 27 Nm.
26. Install the side engine mount and. cruise control actuator, if removed. Tighten the engine mounting bolts to 40 Nm and nuts to 65 Nm.
27. Connect a wire to the negative plug of the accumulator.
28. Start the engine at idle. Carefully inspect the work area for any sign of fluid leakage or the presence of belt thumping sounds or connections vibrating.
29. Turn off the engine. Install the splash guard.