Removal and Installation Tips and Hints (Broken Belt)

TIMING BELT REMOVAL
- Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear.

- After the timing belt covers are removed, align the camshaft and crankshaft.
1. Position the crankshaft to a safe position (approaching #1 Top Dead Center (TDC) with no cylinder at or near top dead center)
2. Align the camshaft with its timing marks.
3. Rotate the crankshaft to #1 TDC

WARNING: Valve damage will occur if any cylinder reaches Top Dead Center, while an associated valve is at or near its fully open position.

NOTES
- When positioning the camshaft or crankshaft always rotate the shafts slowly and in small increments, while frequently stopping to observe the relationship of the valves and pistons.
- With the spark plugs removed the crankshaft should rotate easily. If any resistance is felt, immediately stop and verify that a piston is not striking a valve.

- Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt.

INSPECTION
- Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt mating surface will require the pulley to be replaced.

- Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp, causing the pulleys or belts to rub against the inside of the cover.

- Inspect the tensioner/idler/water-pump pulleys for wobble or looseness. The pulleys should spin freely with no rough spots or lateral (side-to-side) movement.

- Inspect the tensioner pulley surface. It should be clean and free of nicks and burrs. If any damage is noted the pulley should be replaced.

- Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage should be replaced.

CAUTION: Oil leakage will damage the new timing belt.

TIMING BELT INSTALLATION
- When positioning or moving the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object.

CAUTION: Any nick or burr left on the pulleys may result in premature belt failure.

- When installing the timing belt:
- Do not use any device to pry the belt over a pulley
- Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on.




- Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect.

- After installing and tensioning the belt, recheck the alignment of the camshafts and crankshafts.