Removal of cam belt
1 drain water
2 remove air intake pipe from volume air flow sensor
3 coolant expansion tank
4 disconnect
PAS sensor multi plug
PAS pump hoses
throttle cable
crankshaft pulley cover
5 support engine and remove right hand engine mount
6 Remove
auxilliary drive belt and tensioner
water pump pulley
7 lower engine slightly
8 slacken crank pulley
9 Turn crank to number 1 TDC
10 Remove
crank pulley bolt and pulley
timing belt upper cover
timing belt centre cover
timing belt lower cover
cylinder head cover
Fit setting bar to both camshafts at rear this is the important part. If you have not got the bar you can buy an after market timing kit from Partco or someone like that. Or you can make your own. You will need something to slide between the two camshafts so the don't move. If they do move your timing will be out.
11 slacken tensioner bolt, turn tensioner clockwise away from belt then lightly tighten bolt.
12 Remove timing belt.
Installation
1 Starting at crank fit belt in an anti-clockwise direction
2 ensure belt is taut between sprockets.
3 Release tensioner to tighten belt automatically
4 Remove your all important setting bar.
5 temporarilly fit crank pulley
6 turn crankshaft two full turns to TDC
7 Ensure setting bar can be fitted.
8 If setting bar cannot be fitted then while holding camshaft sprockets slacken bolts.
9 Tap both camshaft sprockets to loosen them from there tapers. Ensure both sprockets can turn freely on camshafts.
10. Carefully turn each camshaft so that setting bar can be inserted.
11. Then tighten both camshaft bolts to 67 - 72 Nm.
12. Tighten tensioner bolt to 35 - 40 Nm.
13. Install other components is reverse of removal.
14. Tighten Crank Pulley bolt to 100 - 115 Nm.
15. Refill cooling system and away you go easy.
chris, December 2005
