Prizm L4-1800cc 1.8L DOHC (1993)
SPECIAL TOOLS REQUIRED (or equivalents)
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J-1859-03, Crankshaft pulley puller.
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J-8614-01, Crankshaft pulley holder.
REMOVE OR DISCONNECT
1. Battery ground cable.
2. Wiper reservoir, cruise control actuator cover and cable.
3. Cruise control actuator.
4. Raise and support engine.
5. Right tire and wheel assembly then the wheel housing.
6. Accessory drive belts.
7. Lower vehicle.
8. A/C compressor keeping hoses attached and position in a out of the way location.
9. A/C compressor bracket.
10. Power steering pump keeping hoses attached and position in a out of the way location.
11. Alternator and oil pressure switch electrical connections.
12. Wiring harness cover and harness from cylinder head.
13. Spark plug wires and plugs.
14. PCV hoses from cylinder head covers.
15. Cylinder head covers and gaskets.
16. Turn crankshaft to position # 1 cylinder at TDC on its compression stroke. Valve lifters for # 1 cylinder should be loose.
17. Engine ground wire from right fender apron.
18. Engine mounts and water pump pulley.
19. Crankshaft pulley using puller J-1859-03 and holder J-8614-01.
20. Timing belt cover bolts and the timing belt covers.
21. Slide timing belt guide from crankshaft.
22. Ensure timing marks are aligned (figures 1 and 2).
23. If timing belt is to reused, mark timing belt with arrow showing direction of engine rotation. Put matchmarks where timing belt meets with
crankshaft timing gear and camshaft timing gear to ensure installation in the same position (figure 20).
24. Idler pulley bolt, idler pulley and tension spring.
25. Timing belt from camshaft and crankshaft timing gears.
CAUTION: Do NOT turn crankshaft or camshaft independently after removal of timing belt. Binding or damage to engine components could
result.
26. Camshaft timing gear while holding camshaft by the hexagonal wrench head section.
27. Remove crankshaft timing gear using two flat blade screwdrivers to pry off.
Inspect
1. Timing belt for the following:
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Premature parting.
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Cracked or damaged teeth.
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Noticeable wear or cracks in the belt face.
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Wear or damage only on one side of the belt. If found, check alignment of each gear, tensioner and guide.
2. Idler pulley for freedom of rotation. If any roughness is found, replace the idler pulley.
INSTALL OR CONNECT
1. Camshaft and crankshaft timing gear aligning keyways on shafts.
2. Tighten camshaft timing gear while holding camshaft by the hexagonal wrench head section to 59 Nm (43 ft lbs).
3. Idler pulley and idler pulley spring.
4. Push idler pulley to its extreme left travel and tighten idler pulley.
5. Ensure timing marks are aligned (figures 1 and 2) and install timing belt to camshaft and crankshaft timing gears and idler pulley.
6. Loosen idler pulley bolt allowing spring to pull pulley to the right.
7. Temporarily install crankshaft pulley bolt and turn crankshaft two complete revolutions clockwise.
8. Ensure timing marks are still aligned.
9. Measure timing belt deflection (figure 22). Belt deflection should be 0.20 - 0.24 inch with 4.4 lbs. of pressure applied.
10. Replace timing belt if not with specification.
11. If timing belt is within specification, tighten idler pulley.
12. Timing belt guide, facing cupped side outward.
13. Timing belt covers starting with the lowest cover to the highest.
14. Crankshaft pulley and secure with one bolt.
15. Engine mount to body.
16. Raise and support vehicle.
17. Mounting brackets to engine mount.
18. Right side wheel housing and tire and wheel assembly.
