Step 12:
With all the belts removed it’s time to loosen the crankshaft bolt itself so that the pulley can be removed. This can be done several ways:
Impact Driver: select the correct impact socket and fit it onto your driver. Place over crankshaft bolt and let’er rip!
Screwdriver: remove the flywheel cover and insert a screwdriver between the teeth. Put a breaker bar onto the bolt and remove it. Don’t ask me where the flywheel cover is: I looked but couldn’t find it.
Chain wrench: wrap the pulley with fabric to protect it from marring. Wrap the chain wrench over the pulley/fabric and tighten it appropriately. Place breaker bar with socket over the bolt and carefully loosen. Make sure chain wrench isn’t slipping or excessively marring the pulley. File off and smooth any excessive marring from the pulley before re-installation.
Bump Start: place a breaker bar and socket over the bolt and position the breaker bar against a frame member. Use wire to secure it if necessary. Ensure battery is disconnected. Get your keys and bump the starter (i.e. try to start the car briefly). This will make the crankshaft bolt turn clockwise. If you have the breaker bar positioned correctly against a frame member it shouldn’t move with the crankshaft bolt and will thus loosen it. Be careful doing this. The starter creates a great amount of force.
Crank Shaft Bolt Removed
Crank Shaft Pulley Removed
Crankshaft spacer removed: Behold the elusive crankshaft sprocket!
Step 13:
Remove the upper and lower timing belt covers. The upper belt cover has a metal bar across it which attaches to the plastic crankshaft cover removed earlier. It is attached with the same screws that hold the upper timing belt cover in place.
The upper cover has 4 screws and the lower has 3. Remove the upper first and then the lower. You may need to wiggle the upper cover out of position.
Lower timing belt cover, as indicated by red arrow and lettering
Upper cover is located to the left of the power steering pump pulley
Below is what the camshaft sprocket looks like and what you will see once the upper timing belt cover is removed.
Below is what the crankshaft sprocket looks like and what you will see once the lower timing belt cover is removed.
View of the timing belt tensioner assembly and pulley; the idler, which I do not have a picture of, is to the tensioner’s 1 o’clock position
Step 14:
Reinstall the crankshaft bolt and align the timing marks on the crankshaft sprocket and the camshaft sprocket. It is easier to rotate the crankshaft when you remove the spark plugs as the pistons won’t be compressing any air. I didn’t find it overly difficult to turn the crankshaft with the plugs in so I never removed them. It’s up to you.
Alignment is the simplest step in the whole procedure but also the most critical. Align the crankshaft sprocket’s yellow mark/indented arrow with the nipple (no giggling please) and indent on the crankcase. See picture below for clarification.
You may wish to make marks with your white paint marker or white out on the timing belt and sprocket and transfer them over to the new belt. I found this to be more of a chore and to no real advantage. Some people may prefer the added assurance, which I totally understand.
View of a properly aligned sprocket; take your time when doing this and try to view it from different angles to make sure you're dead on. Note that the crankshaft revolves twice for every one revolution of the camshaft. That is, you may have to rotate this sprocket twice to get the cam sprocket into alignment.
Aligning the camshaft is more of the same. Align the hole in the sprocket with the indent on the upper crankcase (see photo below).
You can mark the belt here too if you like and match it to the blue paint on the top of the sprocket.
Tip: I used a finishing nail inserted through the hole and a 6 inch metal ruler to check the alignment. I held the straight edge against the sprocket spoke and inserted the nail through the hole while holding it flush against the straight edge.
I found using the straight edge helps prevent the nail angling too much.
You can shine a light near the camshaft sprocket in order to see behind it and determine where the nail is touching. I used a small flashlight. If you have a bright shop you may not need either the flashlight or the nail and might be able to see the mark through the hole.
Step 15:
De-tension the timing belt by loosening the bolt to the right in this picture with the white mark on it. Then pry the pulley away from the belt (to the left) and retighten the same bolt to hold it in place temporarily. You may need to loosen the tension spring bolt as well (2nd bolt in picture; on the left with the wire spring around it).
Once tension is free you can remove the timing belt.
Note: once tension is relieved you may notice that the crankshaft sprocket has moved counter-clockwise a little. This is normal and not anything to worry about. Once the belt is fully removed you may notice that the belt has moved even farther to the left. Again, don’t worry—yet.
My timing was off by nearly two teeth once the belt was off. My advice here is to attempt to correct the crankshaft as much as possible without over advancing the timing (moving the arrow to the right of the nipple and indent on the crankshaft) before putting the new belt on.
It may take some trial and error, but the key is to retard the timing as little as possible in order to get the belt back on. It probably won’t be perfect until tension is re-applied and you have turned the crankshaft over two to three times.
IMPORTANT: The reason for retarding the timing rather than advancing it is because once tension is re-applied the belt will advance clockwise. If you have advanced the timing already then when you re-tension the belt the sprocket/timing will advance even farther. This is bad.
Step 16:
Since you’re all down in it, now is a good time to check all your pulleys and idlers for good operation before you button everything back up. Check for play (up, down, left, right) in all pulleys—especially the timing belt idlers and water pump.
If play is excessive (more than .5mm or 1/32 of an inch) they should be replaced now or very soon. Spin them and check for whining or scraping (metal on metal noises indicate the bearing’s grease is gone and it will seize shortly under load).
Also check for obvious grease leaks from the idlers themselves. Replace as necessary.
The water pump has a weep hole. If you see coolant pooling here then it’s time to replace it.
Check for oil leaks behind the cam and crank sprockets. If you see oil, then your cam or crank seals are probably failing or have already failed and need to be replaced. This is important because if oil gets onto the timing belt it could slip a tooth (or five or six). It isn’t likely because of the teeth in the belt, but personally that’s not a chance I would take.
Step 17:
Put your new timing belt on. It should be put on in this order as per HMA instructions:
“Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt.
Crankshaft sprocket (A) →idler pulley (B ) →camshaft sprocket (C) →timing belt tensioner (D).”
As I stated above you may need to trial and error the timing mark on the sprocket a bit here. Ensure that timing is retarded if it must be off in order to get the belt on. Do your best to keep the marks aligned on the crankshaft sprocket when putting the belt on but don’t have an embolism if they are off by as much as two teeth. You should not, however, notice the camshaft sprocket move at all. If it does, then it might be trouble. If you wish, you can hold the camshaft sprocket with a large c-clamp.
Remember that when you adjust the crankshaft sprocket it must be done with the belt OFF the crankshaft sprocket; otherwise you are adjusting the timing of not only the crankshaft but also the cam. This screws things up. DON’T DO IT.
Optional: you can use a C-clamp to ensure that the camshaft does not move when putting the new belt on. Don’t make it too tight.
Step 18:
Tension in the timing belt is measured by pushing down on it with light force. Push on the non-tension side of the belt and make sure that the belt meets half of the radius of the tensioner bolt head (half of radius = quarter of bolt head; HMA’s choice of words, not mine). See HMA’s poor quality picture below for reference.
Step 19:
At this point you are ready to test things out. Grab your breaker bar and 22mm socket and turn the engine over a few times VERY SLOWLY. Listen for any tell tale scraping/grinding/clinking noises that could indicate valve/piston contact.
If you hear any, STOP, BACK UP and re-set your timing.
If you have the plugs in it is normal to hear air and feel some resistance. Metal to metal noises are the key to watch for here.
After you’ve rotated the engine a few times realign everything and see how it all stacks up. As long as when the crankshaft is aligned the camshaft is also aligned you should be good to go. I rotated the engine about 12 times and checked alignment each time just to be extra **** sure.
Note: if the crankshaft is aligned and the camshaft is off by half a rotation don’t panic; recall that the crankshaft must revolve twice for the camshaft to revolve once. Rotate the crankshaft and align it one more time and then check the cam. If it’s still off then you have a problem.
Step 20:
Button everything back up. No special procedures needed. From here forward everything is just the reverse of removal.
Drive belts should be tensioned approximately 13 to 15/32 of an inch. Check HMA or a Haynes’ manual for exact tension play amounts. Albeit this isn’t critical—if the belts are too loose, you’ll know. Trust me.
See belt routing diagram below if you don’t have one or didn’t draw the routing before belt removal.
Step 21:
Once everything is all put back together you might want to turn the engine over with your breaker bar a few times just to be sure nothing got screwed up during re-installation.
If everything seems okay still, start the car and take it for a test drive (hopefully around the block and not to the junk yard).