Install the timing belt. HOw do i get the new belt over the crankshaft.. I removed the belt guide. I need help removing the pully on the crankshaft 1989 ford ranger 4l

Removal & Installation

3.5L Engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Record the radio anti theft code data.
3. Remove or disconnect the following:
   
   Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
   
4. Support the engine with a floor jack and remove the engine mount.
5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.
   
   

   Fig. Timing belt routing and timing marks-3.5L Engine
   

6. Remove or disconnect the following:
   
   Auto tensioner Timing belt
   
   

   Fig. Timing belt and related components-3.5L Engine
   
   

To install:

1. Ensure that the engine is set to Top Dead Center (TDC).
2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
3. Install the timing belt in the following order:
   1. Crankshaft sprocket
   2. Idler pulley
   3. Left bank exhaust camshaft sprocket
   4. Left bank intake camshaft sprocket
   5. Water pump pulley
   6. Right bank intake camshaft sprocket
   7. Right bank exhaust camshaft sprocket
   8. Tensioner pulley
   
   
4. Install the auto tensioner. Do not remove the retaining pin at this time.
5. Check that the crankshaft and camshaft timing marks are aligned correctly.
6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
8. Loosen the tensioner pulley center bolt.
9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).
   
   

   Fig. Adjusting the tensioner pulley-3.5L Engine
   

10. Remove the auto tensioner retaining pin.
11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.
    
    

    Fig. Measuring the auto tensioner rod-3.5L Engine
    

13. When the auto tensioner measurement is correct, install or connect the following:
    
    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
    
14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    • REMOVAL & INSTALLATION

    Print
    

    
    Removal & Installation
    
    3.8L Engine
    

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
        
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
        
        

        Fig. Timing chain and related components-3.8L Engine
        

    
    To install:
    
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
       
       

       Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
       

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
        
        

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
        

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Sealant application (1 inch bead width)-3.8L Engine
        

    23. Apply sealant on the chain cover.
        NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Timing cover sealant application-3.8L Engine
        

    24. Install a new gasket to the timing case cover.
        NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
        
        
        

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine
        

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.
        
        

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine
        

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

Timing Belt Removal & Installation SOHC To Remove:

1. Disconnect battery negative cable.
2. Remove fresh air duct.
3. Drain engine coolant into an appropriate container and retighten radiator drain plug.
4. Remove upper radiator hose.
5. Remove fan clutch assembly bolts.
6. Remove 5 cooling fan shroud bolts.
7. Remove fan shroud and fan as an assembly.
8. Loosen alternator mounting bolts and remove drive belt from pulley.
9. Remove fan pulley.
10. Remove 4 cooling fan assembly bolts.
11. Remove cooling fan assembly.
12. Remove 4 bolts and upper timing belt cover.
13. Remove 2 lower bolts and lower timing belt cover.
14. Loosen adjusting bolt and remove A/C belt.
15. Remove alternator belt.
16. Loosen power steering pump lock bolt and mounting bolt.
17. Remove drive belt from crankshaft damper. Camshaft timing marks
    
    
18. Turn crankshaft until timing mark on front housing and the arrow "2" on the camshaft pulley align.
19. Remove 5 bolts and remove damper.
20. Remove timing belt guide from timing belt pulley.
21. Loosen tensioner lock bolt.
22. Pry tensioner away from timing belt and tighten lock bolt to relieve tension on the timing belt. NOTE: Mark the direction of timing belt rotation on the belt if it is being reused.
    
23. Remove timing belt.

To Install:
Timing belt pulley timing marks

NOTE: Timing belt pulley timing mark and timing mark must be aligned.
Camshaft timing marks

NOTE: The arrow at "2" on camshaft pulley must be aligned with timing mark on front housing.
Timing belt installation

1. Install timing belt with minimal slack from timing belt pulley to water pump and from water pump to camshaft pulley.
2. Loosen tensioner lock bolt until tension is applied to timing belt. CAUTION
   Do not turn crankshaft counterclockwise.
   
3. Turn crankshaft pulley 2 full turns clockwise and ensure timing marks are properly aligned.
4. Tighten tensioner lock bolt to 33 ft lb (45 Nm).
5. Apply a force of 21 lb to timing belt midway between idler pulley and camshaft pulley.
   • Deflection should measure 0.43-0.51 inch (11-13 mm)
   NOTE: if timing belt deflection is incorrect remove timing belt and install NEW tensioner spring.
   
6. Install timing belt guide.
7. Install crankshaft damper pulley.
8. Install 5 crankshaft damper pulley bolts. Tighten bolts to 132 in lb (15 Nm).
9. Install power steering pump drive belt.
10. Adjust power steering pump drive belt tension and tighten lock bolt and mounting bolt.
11. Install alternator drive belt.
12. Install A/C drive belt.
13. Install lower timing belt cover and bolts. Tighten bolts to 84 in lb (10 Nm).
14. Install upper timing belt cover and bolts. Tighten bolts to 84 in lb (10 Nm).
15. Install cooling fan assembly and 4 bolts. Tighten bolts to 27 ft lb (37 Nm).
16. Install fan pulley.
17. Install fan clutch and shroud as an assembly. Tighten bolts to 74 in lb (8 Nm).
18. Tighten 4 cooling fan nuts to 16 ft lb (22 Nm).
19. Adjust alternator belt tension and tighten alternator mounting bolts.
20. Install upper radiator hose.
21. Install fresh air duct.
22. Connect battery negative cable.
23. Refill/bleed cooling system.

DOHC To Remove:

1. Disconnect battery negative cable.
2. Remove fresh air duct.
3. Remove 5 cooling fan shroud bolts and 4 thermo-modulated fan nuts.
4. Remove 4 thermo-modulated fan shroud fasteners.
5. Remove generator drive belt.
6. Remove fan pulley (located above crankshaft pulley).
7. Remove 4 bolts and splash shield (located under front of vehicle).
8. Remove A/C drive belt and power steering drive belt. Timing Belt Removal
   
   
9. Remove 5 bolts and upper timing belt cover.
10. Remove 2 bolts and lower timing belt cover.
11. Loosen tensioner lock bolt and pivot tensioner pulley outboard.
12. Retighten tensioner lock bolt. NOTE: Mark timing belt for rotation if it is being reused.
    
13. Remove timing belt.

To Install:
Crankshaft match marks

1. Align marks on timing belt pulley and pump body. Camshaft pulley alignment marks
   
   
2. Align marks on camshaft pulleys with alignment marks on seal plate.
3. Install timing belt. NOTE: No looseness should exist on the tension side and at the camshaft pulleys.
   
4. Loosen tensioner lock bolt.
5. Turn crankshaft 2 revolutions in direction of rotation and check that timing marks are still in alignment.
6. Tighten timing belt tension lock bolt to 27-38 ft lb (32-52 Nm).
7. Apply a force of 22 lbs to timing belt between camshaft sprockets.
   • Belt deflection should measure 0.30-0.33 in (7.5-8.5 mm)
   NOTE: Replace tensioner spring if timing belt deflection is excessive.
   Timing Belt Installation
   
   
8. Install lower timing belt cover.
9. Install upper timing belt cover.
10. Install power steering drive belt and adjust belt tension.
11. Install fan pulley.
12. Install generator drive belt and adjust belt tension.
13. Install A/C drive belt and adjust belt tension.
14. Install splash guard.
15. Install fan and fan shroud.
16. Install 4 fan bolts. Tighten to 24 ft lb (33 Nm).
17. Install fan shroud mounting bolts.
18. Install fresh air duct.
19. Connect hose to resonance chamber.
20. Connect battery negative cable.

Hi,


You find the timing marks on the picture below.





Removal
Remove auxiliary 1. drive belts.
2. Support engine.
Remove:
Engine mounting and bracket.
Timing belt upper cover [1].
3.
4. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Remove:
Crankshaft pulley bolt [4].
Crankshaft pulley [5]. Use tool No.09213-60017.
5.
6. Ensure timing marks aligned [2] & [3].
7. Slacken tensioner bolt [6]. Move tensioner away from belt and lightly tighten bolt.
Remove:
Timing belt lower cover [7].
Crankshaft sprocket guide washer [9].
Timing belt.
Tensioner pulley.

Installation
Installation
1. Check tensioner pulley for smooth operation.
2. Check free length of tensioner spring is 46,0 mm [8]. Replace spring if necessary.
3. Fit tensioner and spring. Ensure spring is connected correctly.
4. tighten bolt [6].
5. Ensure timing marks aligned [2] & [3].
6. Fit timing belt. Ensure belt is taut between sprockets.
Install:
Crankshaft sprocket guide washer [9].
Timing belt lower cover [7].
Crankshaft pulley [5].
7.
8. Slacken tensioner bolt 1/2 turn [6].
9. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Turn crankshaft slowly 1 7/8 turns clockwise until crankshaft pulley timing mark [3] aligned with 45° BTDC mark [10] on
timing belt lower cover [7].
10.
11. Tighten tensioner bolt [6]. Tightening torque: 42 Nm.
12. Install components in reverse order of removal.
13. Tighten crankshaft pulley bolt [4]. Tightening torque: 108 Nm.
Manufacturer: Toyota

Disconnect battery earth lead. Do not turn crankshaft or camshaft whn timing beld removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated) Do not turn engine via camshaft or other sprockets. Observe all tightening torques. Remove engine, remve RH engine mounting. Remove auxiliary drive belts, water pump pulley, crankshaft pulley, timing belt upper cover, timing belt lower cover. Turn crankshaft clockwise to TDC on No. 1 cylinder, slacken tensioner bolts 5 & 6. Move tensioner away from belt and lightly tighten bolts. Remove timing belt. Remove water pump and replace with new one. Suggest to replace cambelt as well.
Installation
Ensure timing marks aligned3 & 4. Fit timing belt in anti-clockwise direction, standing at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner bolt 5. slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner bolt 6. Tighten tensioner bolt 5. Turn crankshaft on turn clockwise. Ensure crankshaft sprocket timing marks aligned 4.
Slacken tensioner bolt 5. Slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner 6. Tighten torque: 20 - 26 Nm. Tighten tensioner bolt 5. tighten torque: 20 - 26 Nm. Apply thumb pressure to belt at middle. Approximately 5kg. Belt should deflect to 1/4 of tensioner bolt head width 7. Belt tention can also be set using burroghs (BT-33-73F) tension gauge 10 at middle. Turn crankshaft 90 ° anti clockwise. Check belt tension is 9.5 16,5kg (engine must be cold). Install components in reverse order of removal. Fit cranckshaft pully. Tighten crankshaft pully bolts 8. G4-J: Tightening torque: 12-15Nm.
G4-N/G4-k: Tightening torque: 10-12Nm
G4EA: Tighten crankshaft pully bolt 9. Tighten torque: 140-150Nm.

Disconnect battery earth lead. Do not turn crankshaft or camshaft when timing belt removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of ratation unless otherwise stated, Support engine. Remove, engine mounting, auxilliaty drive belts. Water pump pulley 1. Crankshaft pulley bolts 21. crankshaft pully 2. timing belt covers 3. Turn crankshaft to TDC on No 1 cyclinder. Ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket and balancer shaft sprocket timing marks aligned. Timing marks on camshaft sprockets should align with cylinder head upper face. Dowel pins on camshaft sprockets should face upwards. Slacken tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove, automatic tensioner unit bolts. Automatic tensioner unit. Timing belt, crankshaft centre bolt, crankshaft sprocket. Crankshaft sprocket guide washer. Slacken blancer shaft belt tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove balancer shaft belt.

Installation
Ensuring timing marks arligned. Note timing marks on camshaft sprockets should align with cylinder head upper face. Exhaust sprocket mark is on recess, but inlet sprocket mark is on tooth. Note: to check oil pump sprocket positioned correctly, removing blanking plug from cylinder block. Insert 8mm diameter Phillips srcrewdriver in hole. Ensure screwdriver is inserted 60mm from face of cylinder block. if screwdriver can only be inserted 20mm: turn oil pump sprocket 360°. Insert screwdriver again. Fit balancer shaft belt in anti-clockwise direction, starting at crankshaft sprocket. Slacken balancer shaft belt tensioner bolt. Turn tensioner clockwise to tension belt. Tighten bolt to 15-22Nm. Apply thumb pressure to belt. Belt should deflect 5-7 mm. If not repeat tensioning procedure. Install crankshaft sprocket guide washer, crnakshaft sprocket. Tighten crankshaft cente bolt. Tighten torque:110-130 Nm. Note ensure crankshaft sprocket guide washer is fitted correclty. Oil treads and contact face of crankshaft body before fitting. Check tensioner body for leakage or damage replace if necessary. Check pushrod protrusion is 12mm. If not replace automatic tensioner unit. Slowly compress pushrod into tensioner body until holes aligned. Resistance should be felt. Place flat washer under tnesioner body to avoid damage to body end plugs. Retain pushrod with suitable pin through hole in tensioner body. install automatic tensioner unit to cylinder block. Tighten bolts to 22-27Nm. Fit timing belt in anti-clockwise direction, starting at the tensioner pulley. Slacken tensioner pulley bolt. Turn tensioner pully clockwise to temporarily tension belt. Tighten bolts to 43-45Nm. Turn crankshaft slowly 1/4 turn anti-cockwise. Turn crankshaft clockwise until timing marks alligned. Slacken tensioner pully bolt. Fit tool to tensioner pulley. Tool No 09244 28100. Apply clockwise torque of 2,6-2,8 Nm to tensioner pulley. Tighten bolt to 43-45Nm. Insert special tool in timing belt rear casing. Tool no 09244-28000. Screw in tool until pin can be removed from automatic tensioner unit. Remove special tool. Tool nr 09244-28000. turn crankshaft two turns clockwise. Wait 15 minutes. Ensure timing marks aligned. Check extended length of pushrod is 3,8-4,5mm. Install components in reverse order of removal. Tighten crankshaft pulley bolts, Tighten torque 20-30Nm

Dear Friend
Removal: Support engine: remove -engine mounting, auxiliary drive belt, water pump pulley, crankshaft pully bots & crankshaft pully, timing belt covers....turn crankshaft to TDC on No 1 cylinder, ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket & balancer shaft sprocket timing marks lighned. Pls note: Timing marks on camshaft sprockets should align with cylinder head uppter face, dowl pins on camshaft sprockets should face downwards....Slacken tensioner botl. Move tensioner away from belt & tighten bolt.
Remove: automatic tensioner unit bolts, automatic tensioner unit, timing belt, crankshaft bolt, crankshaft sprocket, crankshaft sprocket guide washer...slacken balancer shaft belt rensioner bolt, move tensioner away from belt & lightly tighten bolt...Remove balancer shaft belt.

Installation:
ensure timeing marks aligned.Note: Timing marks on camshaft sprockets ahould align with cylinder head upper face, exhaust sprocket mark is on recess but inlet sprocket mark is on tooth. To check oil pump sprocket positionded sorrectly: remove blanking plug from cylinder block, insert 8mm diameter Phillips screwdriver in hole. ensure screwdriver is inserded 60mm from face of cylinder block. If screwdriveer can only be inserted 20mm-turn oil pump sprocket 360". Inset screwdiver again.
Fit balancer shaft delt in anti-clockwise direction starting at crandkshaft sprocket....Slacken balancer shaft belt tensioner notl, turn tensioner clockwise to tension belt. Tighten bolt to 15-22 Nm... Applu thump pressure to belt at tentioner, belt should deflect 5-7mm. If not: Repeat tensioning procedure.... Install - chankshaft sprocket guide washer & crankshaft sprocket.
Thighten crankshaft centre bolt, tightening torque:110-130Nm. Please note, ensure crankshaft sprocket guide washer is fittet correctly. oil threads & contact face crankshaft botl before fitting.

start by removing top front camshaft cover ,revealing camshaft sprockets. now jack veihcul up and place on stands. remove left hand front wheel (cam belt side) . remove power sterring belt and alternater belt.looking at crankshaft pully and using an 18mm socket and bar rotate pully until all three marks line up. crank on 1st timing mark and and cam marks facing each other when all three line up you can then remove crankshaft pully , you will need an impact wrench that can torque up to 300lbs .when pully has been removed you can then remove the lower belt cover you will then see the belt tensioner and unbolt and remove , now place a jack with protection under sump and remove bolts on engine mount, when you have separted the 2 halves of the engine mount you can remove the belt and install new belt , k,series cam holder tool is use full for re-alineing cam marks camshaft marks facing each other and crank line up with raised mark on engine block,it is then a case of putting every thing back inthe same order it came off.there are 2 type of cam belt tensioner you can email me and i will tell you how to do each type. [email protected].

Which engine? 4 cylinder (2.4 lit) or V6 (2.7 lit)? Two different procedures as well as different belts. The 4 cylinder also has a balance belt. See next image:

Here's the 2.7 V6 belt:


The replacement procedure is nearly the same at the start (removing, accy drive belts, pullys, support engine & remove front engine mount, remove T.B covers, disconnect Cam Position Sensor & Crank Position Sensor connectors, etc.). When you get to this point on the V6, you also have to remove the front engine mounting bracket from the front of the engine (4 14mm bolts, also a 12mm bolt which bolts the dipstick tube to the side of it) Put crank shaft at TDC (top dead center w/ALL timing marks aligned) remove hydraulic tensioner (2 12 mm bolts), then remove the belt. You'll need to recompress the hydraulic (auto) tensioner in a vise and insert a retaining pin through the pin-holes at the top (through the tensioner piston) to keep it compressed when you reinstall it. Otherwise, you won't be able to install it. Assembly is reverse order of dissassembly. Inspect your pullys while you're in there (check for pully bearing noise, leaking grease, smooth rotation, also the water pump pully, etc.) Replace components as needed. Careful not to damage Crankshaft Position Sensor wire harness.

The 4 Cylinder is quite different. You not only change the timing belt, but also the countershaft (balance) belt, which is behind the crank position sensor blade. IMPORTANT: ALL TIMING MARKS ALIGNED BEFORE REMOVING ANYTHING) There are two (2) counter-shafts (balance shafts). one driven by the timing belt, the other by the crankshaft sprocket behind the timing belt sprocket at the front of the crankshaft.

1. Remove the alternator & power steering pump drive belts.
2. Remove four (4) 10mm bolts holding the water pump pullys & remove the pullys.
3. Drain the Radiator (save coolant if intend to reuse).
4. Loosen & remove AC compressor belt.
5. Remove crankshaft pully (22mm bolt).
6. Remove lower timing belt cover (10 mm bolts) to access water pump bolts.
7. Remove the water pump (12mm bolts)
(1) Remove the 2 bolts, then remove the alternator brace (A). (2) Remove the water pump (B) and gasket.
8. Clean mating surface on engine & install new gasket & pump - reassemble. Refill w/50-50 coolant.

Required tools: 13mm open end wrench 10mm shallow and deep socket 8mm socket long flathead screwdriver 17mm deep socket T50 torx socket 1/4", 3/8ths and 1/2" ratchets and extensions E10 inverted torx sockets 6mm allen wrench 15mm open end wrench 7mm socket 12mm open end wrench 14mm socket 12mm socket 8mm, 9mm and 10mm allen head sockets 19mm socket prybar needle nose pliers If you are doing this because your timing belt broke you will also need to buy a complete cylinder head, head gasket set, and both idler pullys. ALL DAEWOO MODELS WILL BREAK THE INTAKE AND EXHAUST VALVES WHEN THE TIMING BELT BREAKS. Start by removing the air cleaner assembly from the throttle body, remove the air filter and housing jack up the vehicle and remove the wheel, remove the plastic shielding in front of the accessory drive belt assembly, remove the accessory drive belt, place a jack with a block of wood on top underneath the engine oil pan remove the front engine mount, remove the crank shaft pully ( the 4 allen head bolts only not the 17mm bolt in the center.) remove the metal plate behind the engine mount bracket on the engine, remove the plastic timing belt cover 3 clips on top 2 10mm bolts on bottom. Rotate the engine until the #1 cyl. is at Top Dead Center on the compression stroke or line up the crankshaft timing mark with the mark on the inner timing belt cover ( notch in cover with notch in pully) on the camshaft pullys -- ( intake cam line up the line on the pully with the line on the inner cover)( exhaust cam line up the arrow on the pully with the arrow on the inner cover) loosen the 13mm bolt in the belt tensioner and using the allen wrench rotate the tab until there is slack in the belt. Remove the belt. At this time I would reccomend you replace the water pump, both plastic idler pullys as they tend to overheat and lockup, and the belt tensioner. Make sure all your marks are lined up, you may need a helper to hold the Exhause Cam in place as it tends to move during belt installation. Put the timing belt underneath the crankshaft pully, install the belt leaving the intake cam for last and NO BELT SLACK on the right side between the crank and the exhaust cam. Once the belt is installed rotate the crankshaft over 2 revolutions and make sure is rotates freely, and your timing marks are aligned perfectly if not the engine will not run properly, tension the belt as needed. Installation is the same as removal. To clarify, on the DOHC engine, the intake cam gear has a line on it, and the exhaust cam gear has an arrow on it. These should be lined up with the corresponsing line and arrow on the VALVE COVER, pointing straight up. I just went through this process over the weekend, and spent quite a bit of time looking for these marking as I had removed the valve cover. Once I found them, it was plain and simple. In addition, be sure to not over tighten the belt when reinstalling. The tensioner has markings on it for "old" and "new". DO NOT adjust past "new", as the car will sound like a jet engine, and the belt will not last for very long. One more item that you may as well replace while you are in there is the cam position sensor if you have not already, as there have been issues with them, and the timing housing has to be opened to get to it