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Engine Replacement - 1.6L LDE - 6T40 > < Timing Belt Tensioner Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH

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Timing Belt Tensioner Replacement (1.6L LLU)

Special Tools

•  EN-6333   Timing Belt Tensioner Locking Pin
•  EN-6340   Camshaft Locking Tool
•  EN-6625   Crankshaft Locking Device

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
3. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement .
4. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle .
5. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .

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7. Set engine to "TDC".
  Set crankshaft balancer in direction of engine rotation to "cylinder 1 TDC of combustion stroke" (1).
8. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

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9. Remove the 4 lower timing belt cover bolts (2).
10. Remove the lower timing belt cover (1).
11. Lower the vehicle.

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12. Prepare the right half of the EN-6340   locking tool .
  12.1 Remove the 2 bolts (2)
  12.2 Remove the front panel (1)

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Note:  Markings (3) on EN-6340   locking tool (1, 2) must align.
13. Insert the EN-6340   locking tool (1, 2) into the camshaft sprocket wheels.
14. Raise the vehicle.

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15. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
16. Install the EN-6333   locking pin (3).
17. Lower the vehicle.
18. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .

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Note:  Note the direction of the belt, if the timing belt will be reused.
19. Remove the timing belt (1).
20. Remove and DISCARD the timing belt tensioner bolt (3).
21. Remove the timing belt tensioner (2).

Installation Procedure

1. Re-cut the timing belt tensioner thread.

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2. Install the timing belt tensioner (2).

Note:  Service may offer bolts that are not microencapsulated. If this is the case apply thread lock agent to the bolt.
3. If fastener is microencapsulated, install a NEW timing belt tensioner bolt (3). DO NOT reuse the old bolt.

Caution: Refer to Fastener Caution .
4. Tighten the timing belt tensioner bolt to 20 N·m (15 lb ft) .
5. Install the timing belt (1).
6. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
7. Place the timing belt on the exhaust and intake camshaft sprockets.
8. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
9. Raise the vehicle.

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10. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
11. Remove the EN-6333   locking pin (3).

Note:  The timing belt tensioner moves automatically to the correct position.
12. Release tension on timing belt tensioner.

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13. Remove the fastener (1).
14. Remove EN-6625   locking device (2).
15. Lower the vehicle.
16. Remove the EN-6340   locking tool .
17. Check position of the camshaft sprocket.
  17.1 Turn crankshaft 720° in the direction of engine rotation by the crankshaft balancer bolt.
Note:  Note marking, camshaft sprocket.
  17.2 Insert EN-6340   locking tool into camshaft sprockets.

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Note:  The crankshaft sprocket and oil pump housing must align.
18. Check the crankshaft position.
19. Lower the vehicle.
20. Remove the EN-6340   locking tool .
21. Raise the vehicle.

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22. Install the lower timing belt cover (1).

Caution: Refer to Fastener Caution .
23. Install the 4 lower timing belt cover bolts (2) and tighten to 6 N·m (53 lb in) .
24. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
25. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
26. Install the compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
27. Lower the vehicle.
28. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement .
29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
30. Close the hood.

Engine Replacement - 1.6L LDE - 6T40 > < Timing Belt Tensioner Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH