See Figures 9 through 23
Fig. 9: Remove the upper idler pulley
Fig. 10: Location of the timing marks on the timing belt cover
Fig. 11: Before removing the timing belt, line up the timing marks on the crankshaft sprocket and the engine block ...
Fig. 12: ... the right side camshaft sprocket and the mark on the cylinder head ...
Fig. 13: ... and the left side camshaft sprocket and the cylinder head
Fig. 14: Mark the direction of rotation on the timing belt if installing the same belt
Fig. 15: Rmove the timing belt
Fig. 16: Remove the timing belt tensioner from the front of the engine
Fig. 17: Remove the cranshaft sprocket by pulling straight off of the crankshaft
Fig. 18: After removing the crankshaft sprocket, remove the woodruff ke. Be careful not to lose this
Disconnect the negative battery cable, and drain the cooling system.
Remove the timing belt covers.
Remove the upper idler pulley.
Turn the crankshaft to align the matching marks on the sprockets. If the timing belt is to be reused, make an arrow on the belt to indicate rotation direction.
Remove the timing belt and automatic tensioner.
Using SST 49 H012 010 tool or its equivalent, loosen and remove the camshaft sprocket lock bolts. Remove the camshaft sprockets.
Using a suitable puller, remove the crankshaft sprocket.
Install the crankshaft sprocket to the crankshaft.
Install the camshaft sprockets with the lock bolts and torque the bolts to 52-59 ft. lbs. (71-80 Nm).
Fig. 19: Place the washer on the tensioner allowing the plug on the tensioner to fit through the hole in the washer
Fig. 20: Mount the tensioner assembly and washer in the bench vise as shown
Fig. 21: When compressing the tensioner and plunger, be sure to line up the holes of the plunger to the hole in the tensioner body
Fig. 22: Once the plunger and tensioner holes are aligned ...
Fig. 23: ... place a small hex key into the holes to keep the plunger compressed
Set a plane washer at the bottom of the tensioner body to prevent damage to the body plug. Press in the tensioner rod slowly, using a press or a vise.
Do not press the tensioner rod more than 2200 lbs. (9800N).
Insert a pin to hold the tensioner rod in the body. Install the automatic tensioner and tighten the mounting bolts to 14-19 ft. lbs. (19-25 Nm).
Install the crankshaft pulley lock bolt and loosely tighten. Check the alignment of the matching marks on the sprockets.
With the upper idler pulley removed, install the timing belt, making sure there is no slack between the crankshaft and camshaft sprockets. If the timing belt is being reused, it must be installed in the same direction of rotation.
Install the upper idler pulley and tighten the attaching bolt to 27-38 ft. lbs. (37-52 Nm).
Turn the crankshaft twice in the direction of rotation and align the matching marks. If the marks do not align, repeat the previous three steps.
Remove the pin from the automatic tensioner. Turn the crankshaft twice and align the matching marks. Make sure the marks are aligned.
Check the timing belt deflection. The deflection should be 0.20-0.28 in. (5-7mm). Do not apply tension other than that of the automatic tensioner.
If the deflection is not correct, repeat the previous three steps.
Remove the crankshaft pulley lock bolt.
Install the timing belt cover, along with the related components.
Reinstall the crankshaft pulley and torque the lock bolt to 116-123 ft. lbs. (37-52 Nm).
Fill and bleed the cooling system.
Run the engine and check for leaks and proper operation. Check the idle speed and the ignition timing.