Contents: Removal ⇊ To install: ⇊
Removal
Cm. figures 95 and 97.
1. Disconnect the cable from the negative battery terminal.
2. Rotate the engine to align the marks on the camshaft pulley and set cylinder #1 to TDC. Once the engine is set to this position, it must not be rotated or moved.
3. Remove the splash guard from the bottom of the engine.
4. Disconnect the electrical connector from the cruise control actuator, then remove the actuator. Do not disconnect the cable; simply move the drive out of the work area.
5. Remove the power steering pump belt. Remove the pump mounting bolts. Without disconnecting the hoses, move the pump out of the work area.
6. Disconnect the generator wiring and connectors; remove the engine wiring from the valve cover.
7. Loosen the alternator and/or compressor adjusting and mounting bolts. Remove the drive belt(s).
8. Remove the valve cover.
9. Remove the side engine mount bracket, if equipped.
10. Remove the upper camshaft drive belt cover.
11. Support the engine with a jack below the center of the center crossmember. Adjust the jack so that it only supports the crossmember, but does not lift it.
12. Remove the side engine mount through bolt and remove the mount.
13. Remove the oil dipstick and its tube.
14. Remove the adjusting nut.
15. Remove the crankshaft pulley bolt and the pulley itself.
This bolt is one of the tightest on the entire car. The pulley should be held in place while the bolt is loosened. Wrap an old drive belt around the pulley to hold it steady - don't try this with a belt that's still on the car; it will stretch or become damaged.
16. Remove the two rear bolts from the center beam. Slowly lower the jack and engine until the gap increases to allow removal of the lower camshaft belt cover.
17. Remove the lower camshaft drive belt cover.
18. There are two belts in this system; one that goes to the camshaft pulley is the camshaft drive belt. The other, shorter one, controls the balance shaft and is called the balance belt, or timing belt. Pull the belt tensioner away from the belts to reduce the tension. While holding the tensioner, install the adjusting nut and tighten it to hold the tensioner in place.
19. Carefully remove the balance belt and camshaft drive belt. Do not twist or bend the belts; protect them from contact with oil or coolant. Remove belts from pulleys.
20. This is a good time to check or replace the water pump. Even if you are only planning on replacing the timing belt as part of your maintenance program, plan to replace the pump at the same time.
To install:
21. If the water pump is to be replaced, install a new sealing ring and position it correctly. Install the water pump and fixing bolts. Tighten the fixing bolts to 12 Nm.
22. Check the engine position. The pointer on the back of the cylinder block should be exactly aligned with the white mark on the flywheel; the camshaft pulley should be aligned so that the word UP is on the top of the pulley and the marks on the edge of the pulley are aligned with the surfaces of the head. Additionally, the front surface of the balancer pulley has a mark that should be aligned with the mark on the oil pump housing. This pulley should be installed at the "10 o'clock" position relative to the crankshaft pulley, when viewed from the center of the crankshaft pulley.
23. Align the rear balance shaft pulley (2 o'clock position as viewed from the center of the crankshaft pulley) using a 6 x 100mm bolt or rod. Mark the bolt or rod 74mm from the end. Remove the bolt from the service hole on the side of the block; insert the rod into the hole. Align the 74mm mark with the plane of the hole. This rod will hold the shaft in place during installation.
24. Place the camshaft timing belt on the pulleys and tensioners. Install the balance belt. Once the belts are in place, double check that all engine alignment parts are in the correct position. If not, remove the belts, re-align the engine and install the belts. Once the belts are properly installed, slowly loosen and remove the adjusting nut, allowing the tensioner to move against the belts. Remove the rod from the service hole and reinstall the bolt and washer.
25. Install the bottom cover, inserting the rubber gaskets and positioning them correctly. Tighten the fixing bolts to 12 Nm.
26. Lift the lower beam and engine into place. Install the lower (center) beam rear bolts, tightening them to 39 Nm.
27. Install the key on the crankshaft and install the crankshaft pulley. Lubricate the bolt threads with oil and tighten them to 230 Nm.
28. Adjust the camshaft drive belt tension. Turn the crankshaft counterclockwise until the camshaft pulley rotates 3 teeth; this will create tension on the camshaft drive belt. Install the adjusting nut and tighten it to 45 Nm.
29. Install the oil dipstick and tube.
30. Install the side engine mount. Tighten the mounting bolt, nut and through bolt to 55 Nm. Remove the jack from under the center beam.
31. Install the upper camshaft drive belt cover.
32. Install the side engine mount bracket if removed.
33. Install the valve cover.
34. Install the compressor and/or generator drive belt; adjust the tension.
35. Route the wiring around the valve cover and connect the wiring to the generator.
36. Install the power steering pump, tightening the bolt to 45 Nm, and install the belt.
37. Install the cruise control actuator. Connect the vacuum hose and electrical connector.
38. Double check all installed parts, paying particular attention to loose hoses or sagging wires, loose nuts, poorly routed hoses or wires (too tight or rubbing), and tools left in the engine area.
39. Install the splash guard under the engine.
40. Connect the wire to the negative battery terminal.
41. Run the engine at idle speed. Check for any signs of leaks or any sounds of rubbing or sticking belts.