Installation - Front Seal
- Grease the new seal. Install the new seal for the intake camshaft using Drift (999 5719). Install the new seal for the exhaust camshaft using Drift (999 5718). See Fig 1.
- Detach the brake vacuum hose from the intake.
- Remove the air duct for the control module box and the air cleaner air intake hose.
- Unplug the connectors, relays and canister purge valve from the fan shroud. Place the wiring to one side.
- Remove the screws for the fan shroud and the relay holder mounting.
- Lift up the relay holder and remove the upper hose between the charge air cooler and the intake.Seal the openings.
- Slacken off the screw clip on the throttle body (electronic throttle module) so that the charge air pipe can be pressed backwards.
- Press the charge air pipe backward and lift up the engine cooling fan with its cover. See Fig 2.
- Pull the charge air pipe forward. Remove the 3 starter motor mounting bolts. Pull out the starter motor and place it to one side.
- Remove the blind cover plug and sealing washer. Turn the crankshaft slightly clockwise slightly to avoid the camshaft adjustment tool being in the wrong position.
- Install Crankshaft Stop (999 5451). See Figure. Ensure that it bottoms out against the cylinder block. Turn the crankshaft counterclockwise until it stops against the crankshaft stop. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump. See Figure.
- Loosen, but do not remove the bolts which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear on to the camshaft. Install the center bolt which secures the variable valve timing unit to the camshaft.Do not tighten yet.
- Install the upper timing belt cover. Turn the timing gear pulley clockwise until the bolts at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover. See Figure. Check that the timing gear pulley is still in its limit position at the oval holes.
- Tighten the center bolt for the variable valve timing unit to 88 ft. lbs. (120 N.m). Check that the variable valve timing unit does not rotate when tightening. Install the center plug.
- Install the timing gear pulley on the intake camshaft with two screws, but do not tighten yet. Check that the markings on the timing gear pulley and the upper timing cover correspond. See Figure.
- Tighten the center bolt on the camshaft belt tensioner to 44 INCH lbs. (5 N.m). Turn the variable valve timing unit clockwise to the stop. See Fig 3. Hold it secure in the clockwise limit position while timing belt is installed.
- Install the timing belt in the following order:
- Adjust the timing gear pulleys so that the bolts are not at a limit position in the oval holes. Ensure that the markings correspond. See Figure.
- Timing belt tension adjustment is always carried out on a cold engine 68°F (20°C). At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. See Figure.
- Hold the center bolt secure and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position. Tighten the 3 bolts on the exhaust camshaft timing gear pulley to 89 INCH lbs. (10 N.m). Install the bolt missing on the intake timing belt pulley. Tighten intake camshaft timing gear pulley bolts to 15 ft. lbs. (20 N.m).
- Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center bolt secure at the same time. Hold the eccentric secure and tighten the center bolt to 15 ft. lbs. (20 N.m). Check that the indicator is in the correct position.
- Remove Camshaft Adjustment Tool (999 5451). Remove Crankshaft Stop (999 5452). Install the plug with a new sealing washer.
- Check the timing belt markings and tension. Press the timing belt to check that the indicator on the tensioner moves easily. See Figure.
- Install the upper timing belt cover. Turn the crankshaft 2 turns. Check that the markings on the crankshaft pulley and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively. Check that the indicator on the belt tensioner is within the marked position.
- Install the following components;
- Front timing cover.
- Cable duct to the mountings on the right suspension turret.
- Auxiliaries (accessory drive) belt. See DRIVE BELT ROUTING .
- Expansion tank.
- Power steering Servo oil reservoir.
- Bleed hose to the expansion tank. Tighten the clamp. Check that the hoses are correctly positioned.
- Install starter motor. Tighten support bracket screw to 18 ft. lbs. (25 N.m).
- Install the engine cooling fan. Install the hose between the charge air cooler and the intake. Tighten the clamp on the charge air pipe at the throttle body.
- Screw the relay bracket and the fan shroud into place. Install the canister purge valve, relays and connectors.
- Install the air ducts. Connect the brake vacuum hose.
- Install camshaft position sensor trigger wheel. Tighten to 12 ft. lbs. (17 N.m). Install camshaft position sensor housing and a new cover.
- Install the torque rod bracket. Tighten bolts to specification. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER .
- Install cover over ignition coils. Install the charge air pipe over the engine.
- Install the air cleaner cover and the intake air hose. Install the solenoid valves on the air cleaner cover.
- Connect negative battery terminal. Install fender liner cover and front wheel. Start engine and check for oil leaks. See BATTERY DISCONNECT PRECAUTIONS & RELEARN PROCEDURES .
NOTE:
Hold variable valve timing unit secure in the clockwise limit position while timing belt is installed.
NOTE:
The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
WARNING:
The key must be in position 2. No one must be in the car when the battery is connected. This is a safety precaution in case an airbag module activates when the power is connected.