| Timing Belt Replacement, Pt. 4 -- Installation and Re-Assembly |
From "Weekend Mechanic"
episode WKM-203 |
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Timing-Belt Service -- Installation and Re-Assembly With the water pump, thermostat and tensioner assembly removed, work can begin on installing replacment parts, including the new timing belt. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. - The new water pump needs to be prepped prior to installation. In this case, that means transferring the mounting studs from the old pump to the new one. "Double-nutting" the studs (figure A) allows the removal of the studs without using pliers -- which could damage the threads.
- The next step is installing a new gasket on the pump. Prepare the mating surface on the new pump by applying some sealant (figure B) to ensure a watertight seal.
- Put the new gasket in place (figure C), making certain that it is oriented properly. Set the water pump aside to allow the sealant to dry.
- Prepare the new thermostat and the thermostat-housing for installation. Add some lubricant to the thermostat seal, and install the thermostat in the housing (figure D), making sure that the thermostat is oriented properly.
- Apply some sealant to the mating surface of the thermostat housing, and install a gasket (figure E).
- While the seals are curing on the water pump and thermostat housing, work can begin installing the new timing belt. A new timing belt costs around $20. It's a good idea to visually compare the replacement timing-belt to the old one (figure F) to ensure that the size matches exactly, and the teeth are of the same design.
- Before installing the belt, clean out the sprocket area with an air-compressor and blower-hose, or a dry paint brush. Make certain that the area is clear of debris.
- Reversing the removal process performed earlier, begin installing the replacement parts. Begin with the tensioner assembly. Position the assembly (figure G) and secure it with it's two mounting bolts. Don't tighten the bolts all the way just yet.
- With the tensioner in position, install the new belt (figure H).
- Tighten down the tensioner (figure I).
- Next, align the marks you made earlier by turning the intermediate shaft using a breaker bar (figure J). The camshaft needs to be turned, in the normal rotation of the engine, one full revolution. Therefore, turn crankshaft two full turns. Remember, two revolutions of the crankshaft correspond with one full revolution of the camshaft.
- The water-pump gasket has now had time to set up. Add some sealant to the gasket to form a good seal between the gasket and the engine mounting-surface. Also, add some sealant to the threads of the water-pump bolts.
- Position the water-pump on the mating surface of the engine (figure K), and bolt the pump in postion.
- Position and install the thermostat-housing containing the new thermostat (figure L).
- Carefully re-install the timing cover, using caution not to crack the plastic cover.
- Re-install the harmonic balancer, and secure it with the single balancer bolt (figure M). Be certain that you torque the bolt to the proper specs.
- Re-install the crank-pulley (figure N).
- Install the belt-tensioner for the drive belt.
- Re-install the radiator hose (figure O), with new hose clips.
- Re-install the fan assembly (figure P).
- Install the drive belt and adjust the tension.
- Re-install the fan-shroud, and reconnect any remaining hoses.
- Finally, add new coolant to the radiator and reservoir tank.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
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