Timing Belt (Unit Repair): Installation

WARNING: This page is about a different car, the 2002 Saturn LW300 and 2002 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.

Position crank at 60° before TDC.
NOTE: The upper idler pulley (cams 1 & 2) and lower idler puller (cams 3 & 4) use different bolts and spacers of different thicknesses. The upper idler pulley uses a narrow 5 mm (0.20 in.) thick spacer and a black bolt. The lower idler puller uses a 11 mm (0.40 in.) thick spacer and a silver bolt.
Install lower idler pulley.
Torque:

Idler Pulley Bolt: 40 N.m (30 ft-lbs)
Install upper idler pulley and hand tighten bolt.

Fig 1: Setting Up Timing Belt Alignment
Courtesy of GENERAL MOTORS CORP.
Install timing belt tensioner and hand tighten nut and washer
NOTE: With camshaft locks installed, verify distance between camshaft sprockets with Green Test Belt located in Timing Belt Alignment Kit J42069.
Start at #1 and #2 camshaft sprockets, route belt around #1 and #2 sprockets while aligning belt marks to marks on sprockets and rear cover.
Install belt around timing belt tensioner.
Route belt around upper idler pulley.
Route belt around #3 and #4 camshaft sprockets while aligning belt marks to marks on sprockets and rear cover.
Route belt around crankshaft hub sprockets while aligning marks on belt to marks on crankshaft hub sprocket.

Fig 2: Securing Timing Belt On Cam Gears
Courtesy of GENERAL MOTORS CORP.
Install Wedge Tool J42069-30 to lock timing belt onto crankshaft hub sprocket.

Fig 3: Installing Wedge Tool To Lock Crankshaft
Courtesy of GENERAL MOTORS CORP.
With belt firmly engaged on crankshaft hub, carefully rotate crankshaft counterclockwise to get belt slack on lower idler pulley side.
Route belt around lower idler pulley.
Remove wedge tool J42069-30.

Fig 4: Removing Wedge Tool
Courtesy of GENERAL MOTORS CORP.
Reinstall crankshaft locking tool J42069-10 and tighten lever arm to the water pump pulley flange.

Fig 5: Reinstalling Crankshaft Locking Tool
Courtesy of GENERAL MOTORS CORP.
Perform the following in sequence:
1. Install camshaft checking gauge to cams 3 and 4 and verify alignment marks are within 2 mm of each other.
2. Install 3 and 4 camshaft lock if properly aligned.
3. Install camshaft checking gauge to cams 1 and 2.
  
  Fig 6: Installing Camshaft Checking Gauge
  Courtesy of GENERAL MOTORS CORP.
4. Rotate #1 camshaft sprocket counter-clockwise to remove slack between 1 and 2, and 3 and 4 cams.
  IMPORTANT: Ensure that camshaft timing marks are to the left (retard) side of the checking gauge.
5. Rotate upper idler pulley counter-clockwise until marks are properly aligned within 2 mm of each other.
6. Install 1 and 2 camshaft lock when properly aligned.
  Torque:
  
  Upper Pulley Bolt: 40 N.m (30 ft-lbs)
  
  Fig 7: Installing Camshaft Lock
  Courtesy of GENERAL MOTORS CORP.
Adjust timing belt tensioner so that the center alignment mark is about 3 mm (1/8 in.) above alignment mark on spring loaded idler.

Fig 8: Positioning Center Alignment Mark
Courtesy of GENERAL MOTORS CORP.
Remove 1-2 and 3-4 camshaft locks, timing belt alignment kit J42069-1 and J42069-2.
Remove crankshaft locking tool J42069-10.
IMPORTANT: If TDC is passed, do not rotate crankshaft counterclockwise. This will not allow proper slack to be taken up between timing belt tensioner and crankshaft sprocket. To correct, rotate crankshaft additional two turns.
Rotate crankshaft 1 3/4 turns clockwise, install crankshaft locking tool J42069-10, and then stop at TDC.

Fig 9: Turning Crankshaft Clockwise
Courtesy of GENERAL MOTORS CORP.
Tighten lever arm to the water pump pulley flange.

Fig 10: Tightening Lever Arm To Water Pump Pulley
Courtesy of GENERAL MOTORS CORP.
Install checking gauge J42069-20 and verify marks are within 2 mm of each other.

Fig 11: Using Checking Gauge To Verify Cam Timing Marks
Courtesy of GENERAL MOTORS CORP.
Adjust timing belt tensioner so that the center alignment mark is about 3 mm above alignment mark on spring loaded idler.
Tighten timing belt tensioner.
Torque:

Timing Belt Tensioner Fastening Nut: 20 N.m (15 ft-lbs)
Remove crankshaft locking tool J42069-10 and checking gauge J42069-20.

Fig 12: Positioning Center Alignment Mark
Courtesy of GENERAL MOTORS CORP.