I'm trying to get the bottom pulley off to get to bottom timing cover & can not get the bolt out, any suggestions?

#2 reidk Focus Enthusiast Join Date: Jul 2012 Fan#: 101538 Location: Winnetka, CA What I Drive: 2000 Red Focus SE Wagon Posts: 72 FF Reputation: 1 Buy-Sell-Trade Rating: (0) That leak is coming from the water pump, which in the SPI is behind the timing belt. That plate to which the hoses attach is, in fact, the water pump. You\'re going to have to replace it, and you should (must!) replace the timing belt too since you\'ll have it out anyway. The pulley below the camshaft pulley (top) is the tensioner and doesn\'t need to be removed if it\'s working correctly (turns smoothly). The next pulley down is part of the water pump that you\'ll be removing. The pump is held on with four bolts that you\'ll see after you get the belt off. Since you\'ve already uncovered the timing belt, you\'re about halfway there. I assume that the car is up on stands, you\'ve removed the engine mount and are supporting the engine from below on a jack or stand, and you\'ve got both the upper (metal) and lower (plastic) timing covers off as well as the serpentine belt and its cover (splash guard). If not, do all that. You\'ll also want the steering fluid reservoir and coolant reservoir out of the way. Removing the passenger tire and the inner fender lining can make things easier as well. In general, removing things that are in the way and putting them back later will end up being less hassle than trying to work around them, at least in my experience. From there, the steps are: Drain the coolant (valve at the bottom of the radiator). CLOSE THE VALVE. Remove the crankshaft damper (bottom-most serpentine pulley) to uncover the crankshaft timing pulley. (This step sounds so simple... it\'s just one bolt... hah hah hah...) Rotate the engine until the timing marks on the cam timing pulley and crank timing pulley are at 12 o\'clock (they line up with marks on the engine). Loosen the timing tensioner bolt, rotate the tensioner to slack the belt, and tighten the bolt again, just enough to hold the tensioner off the belt. Remove the belt. Disconnect the hoses and unbolt the pump. Clean the mating surfaces, trying not to get any crap in the engine\'s water passages. Apply a new gasket with sealant, install the new pump, torque the four bolts to spec. Re-attach hoses. Install the new belt, making sure that the timing marks are where you left them. Rotate cam or crank as needed if not. (Removing the sparkplugs makes this easier). Loosen the tensioner bolt to re-tension the belt, then torque the tensioner bolt to spec. If the tensioner doesn\'t turn smoothly, replace it. Check the timing marks again. Put everything else back and torque the crank damper to spec. If you figure out the serpentine routing on the first try, consider yourself very cool. Refill coolant and fire it up.

Instructions

1. Check Your Timing Belt
   • Check your owner's manual for the recommended mileage for replacing your timing belt. Replacement for a Toyota Camry is 60,000 miles for 1984 to 1997 models and 90,000 for 1998 to 2004 models.
     
   • 2Locate the timing belt and examine it for breaks, damage, fraying, worn spots or looseness.
     
   • 3
     
   • Inspect the belt for cracked or missing teeth. It's possible that foreign material collected between them.
   • 4Determine if there's damage on both sides of the timing belt. Single-side damage may be caused by the timing belt's guide.
     
   Remove Your Timing Belt
   • 5Unscrew the bolts to release the lower timing belt cover.
     
   • 6Disconnect the engine wire protector from the rear belt cover.
     
   • 7Remove the clamp holding the rear cover's engine wire protector clamp.
     
   • 8Take the bolts off the front cover and lift it from the engine.
     
   • 9Line up the crankshaft timing pulley groove with the oil pump by rotating the engine to the right.
     
   • 10Be sure the camshaft timing pulleys and rear belt covers line up. You may need to rotate the engine one full turn.
     
   • 11Undo the crankshaft pulley bolt and release the tensioner and dust boot.
     
   • 12Unscrew the bolts to release the lower timing belt cover.
     
   Install Your Timing Belt
   • 13Wipe off any oil or water on the pulleys.
     
   • 14Align the timing belt's front mark with that of the crankshaft timing pulley's mark and the timing belt's installation marks with those on the camshaft pulley.
     
   • 15Install the pulleys in this order: crankshaft, water pump, left camshaft, No. 2 idler, right camshaft and No. 1 idler.
     
   • 16Compress the tensioner until the pushrod's holes and housing align. Connect the dust boot to the tensioner then tauten the tensioner's bolts to 20 foot pounds (27 Nm).
     
   • 17Rotate the crankshaft to the right and line up its timing pulley groove with the oil pump. The camshaft timing marks and those on the rear timing belt cover should match up.
     
   • 18Put in the timing belt guide and secure the bolts to 21 foot pounds (28 Nm).
     
   • 19Secure the upper timing belt cover to 74 inch pounds (8 Nm).
     
   • 20Reinstall the engine wire protector and clamp to the timing belt cover. Replace the lower timing belt cover and secure the bolts to 74 inch pounds (8 Nm).
     
   • 21Reconnect any remaining items. Start the engine and check that the timing belt is functioning properly.
     

it may be reverse threaded

Yes, the crank pulley has to be removed to access the timing belt.
The plastic Wheelwell covers are held on with 10mm bolts, the actual metal wheelwell is welded to the subframe, firewall & core support and can't be removed.
To easily change the timing belt you have to put a floor jack under the oil pan (i recommend using a block of wood between the jack & oil pan to prevent damage), remove the Upper Motor Mount on the Right side of the car, and then use the jack to raise & lower the engine as needed to access each bolt.

It's a bit of a pain but here is what you set it to:

Aligning the marks on the flywheel with the marks on the flywheel cover

Driver side timing belt (No. 2) and No. 2 tensioner-1.8L engine

Passenger side timing belt (No. 1) and No. 1 tensioner

1. Disconnect the negative battery cable.
   
2. Loosen the water pump pulley mounting bolts.
   
3. Loosen the alternator mounting bolts and remove the alternator belt.
   
4. Remove the water pump pulley bolts and remove the water pump pulley.
   
5. Disconnect the electrical harness from the oil pressure switch.
   
6. Remove the dipstick tube.
   
7. Remove the crankshaft pulley.
   
8. Remove the timing belt cover plate, if equipped.
   
9. Remove the timing belt cover bolts on the left, right, and center covers.
   
10. Remove the timing belt covers.
    
11. Remove the rubber cover seal. Clean all mating surfaces.
    

To install:

1. Install a new timing belt cover seal.
   
2. Install the timing belt covers on the engine using the mounting bolts. Tighten the bolts to 48 inch lbs. (5 Nm).
   
3. Install the timing belt cover plate, if removed.
   
4. Install the crankshaft pulley, and tighten the bolt to 69-76 ft. lbs. (93-103 Nm)
   
5. Install the dipstick tube.
   
6. Connect the electrical harness to the oil pressure switch.
   
7. Install the water pump pulley and loosely install the mounting bolts.
   
8. Install the drive belt and adjust the tension as necessary. Tighten the alternator mounting bolts.
   
9. Tighten the water pump pulley mounting bolts.
   
10. Connect the negative battery cable.
    

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Thank you for the inquiry.




Disconnect the negative (black) cable from the battery.

Remove all accessories that are in the way of the timing belt cover. The Intrepid's 3.5 liter engine and small engine bay make for very cramped working conditions; it is thus necessary to remove all engine accessories so that you can properly work on the timing belt. Begin by loosening the tension bolt on the alternator with a belt tensioner, then use a socket wrench to remove the bolts on the water pump, air condition compressor and power steering pump.

Remove the four bolts on the top timing belt cover, using a socket wrench, then remove the cover.

Use a jack to lift the front end of the Intrepid and place the front end securely on two jack stands. Get underneath the engine.

Remove the three bolts on the bottom timing belt cover, using a socket wrench, then remove the cover.

Use the belt tensioner to put some slack into the timing belt, then remove the belt from the pulleys with your hands.

Line up the pulleys, so that the engine is at the top dead center and the two marks on the camshaft are lined up with the marks on the cams.

Place the new timing belt over the pulleys, making sure not to move any of the pulleys in either direction.

Use the tensioner to tighten the belt.

Reattach the top and bottom timing belt covers and secure them in place, using the bolts you had removed earlier.

Reattach all of the accessories you have removed (in any order), using a socket wrench. When done, place the belts over the pulleys and return tension to them by using the belt tensioner to tighten the tension bolt on the alternator.

Attach the negative (black) battery cable to the battery.

Hi, there should be marks on the belt itslf that align with hatch marks on the timing gears. Below are the instructions for installation. From these, you should be able to verify that the belt is in time. There are also some diagrams here: http://www.2carpros.com/diagrams/cadillac/catera/1997


To install:

1. Install the timing belt.
   1. Start at the crankshaft pulley.
   2. Install the timing belt with a double dash (TDC) mark on the belt aligned with the marks on the oil pump and belt drive gear.
   3. Pinch the belt with special tool J 42069-30 to prevent the splines from jumping.
   
   
2. Route the timing belt through the idler pulley for camshafts 3 & 4 then route the timing belt through the camshaft gears 3 & 4.
   1. Ensure the dash marks on the timing belt align with marks on the camshaft gears and the notches on the rear timing belt cover.
   2. If necessary, loosen timing belt idler pulley or move the cam gears slightly, with J 42069-1 and 2 still in place, until the timing belt can be installed.
   3. Tighten the idler pulley locking bolt until snug. The idler pulley bolt will be tightened to specifications after the final adjustments are made.
   
   

NOTE Timing belt deflection between the camshaft gears number 4 and the idler pulley for camshafts 3 & 4, must be no more than 0.4 inch (1 CM.).

1. If necessary, adjust the timing belt deflection by turning the timing bolt idler pulley eccentric, for camshafts 3 & 4, counter-clockwise with the special tool J 42069-40, or equivalent.

1. Route the timing belt through the timing belt idler pulley for camshafts 1 & 2 then route the timing belt through camshaft gears 1 & 2.
   1. Ensure the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.
   2. If necessary, loosen the timing belt idler pulley or move the cam gear slightly, with J 42069-1 and 2 still in place, until the timing belt can be installed.
   3. Apply sufficient tension to the timing belt to prevent it from slipping off the gears by turning the timing belt idler pulley eccentric for camshafts 1 & 2 counter-clockwise with special tool J 42069-40 or equivalent.
   4. Tighten the idler pulley locking bolt until snug. Idler pulley bolt will be tightened to specifications after final adjustments are made.
   
   
2. Route the timing belt through the timing belt tensioner.
3. Apply initial tension to the timing belt by turning tensioner eccentric counter-clockwise, with a 5 mm hex wrench, until marks are set.
   1. Tighten the belt tensioner-locking nut to 15 ft. lbs. (20 Nm).
   
   
4. Adjust the timing belt.
   1. The timing belt must be properly adjusted or engine damage may occur. Do not continue with the engine assembly procedure until the timing belt is properly adjusted.
   
   
5. Install the timing belt cover. Tighten the timing belt cover bolts to 71 inch lbs. (8 Nm).
6. Install the power steering pump pulley and bolts. Install the water pump pulley and bolts.
   1. Tighten the power steering pump pulley bolts and the water pump pulley bolts after the serpentine drive belt is installed.

from autozone.com

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Disconnect the Manifold Air Temperature (MAT) sensor connector.
4. Disconnect the air cleaner outlet hose from the throttle body.
5. Disconnect the breather tube from the camshaft cover.
6. Remove the air cleaner housing bolts.
7. Remove the air cleaner housing.
8. Remove the right front wheel.
9. Remove the right front wheel well splash shield.
10. Remove the serpentine drive belt.
11. Remove the crankshaft pulley bolts and the crankshaft pulley.
12. Remove the right engine mount bracket.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.
15. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.
    

Fig. Aligning the timing mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

1. Fig. Aligning the camshaft gears with the notches on the camshaft cover.
3. Align the camshaft gears with the notch on the camshaft cover.
4. Remove the timing belt.
5. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
6. 
   

To install:

1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
3. Install the timing belt.
4. Turn the hex-key tab in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch.
5. Install the automatic tensioner bolt and tighten to 18 ft. lbs. (25 Nm).
6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
7. Recheck the automatic tensioner pointer.
8. Install the front timing belt cover.
9. Install the front timing belt cover bolts and tighten to 53 inch lbs. (6 Nm).
10. Install the right engine mount bracket.
11. Install the crankshaft pulley and tighten the crankshaft pulley bolts to 15 ft. lbs. (20 Nm).
12. Install the serpentine drive belt.
13. Install the right front wheel well splash shield.
14. Install the right front wheel.
15. Install the air cleaner housing.
16. Install the air cleaner housing bolts and tighten to 89 inch lbs. (10 Nm).
17. Connect the air cleaner outlet hose to the throttle body.
18. Connect the breather tube to the camshaft cover.
19. Connect the MAT sensor connector.
20. Connect the negative battery 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