Driving down the road, started sputturing and died ,timing gear moving 1/2 inch

Table of Contents Removal Installation Print Options Print Text Only Print Text and images Print Camshaft, Replace Removal 1. Bring lock carrier into service position as follows: a. Remove radiator grille. b. Remove upper bolts (2), Fig. 1. c. Remove quick release screw (6) from below, Fig. 1. d. Remove bolts (5 and 4) pointing upward in area of wheel housing liner, Fig. 1. e. With aid from an assistant, pull cover parallel out of guides. f. Disconnect harness connectors of installed electrical components and hoses. g. Remove noise insulation. h. Remove intake air duct between lock carrier (1) and air cleaner housing at lock carrier, Fig. 2. i. Remove bolt (5) on bumper carrier (4) and install guide rods tool No. 3411, or equivalent, (6) on righthand and lefthand longitudinal member, Fig. 2. j. Remove bolts (2 and 3), Fig. 2. k. Lock carrier (1) can be pulled approximately .39 inch toward front onto guide rods tool No. 3411, (2), Fig. 3. 2. Remove upper toothed belt guard. 3. Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must be flush with marking on cylinder head cover, Fig. 4. 4. Loosen tensioner and remove toothed belt from camshaft sprocket. 5. Turn crankshaft back slightly. 6. Remove camshaft sprocket. To loosen bolt, counter hold camshaft gear using tool No. 3036, or equivalent. 7. Remove hall sensor housing. 8. Remove washer and cover for hall sensor. 9. Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking. Do not mark chain using a center punch or similar means. Distance between both arrows or colored markings consists of 16 rollers of drive chain, Fig. 5. 10. Secure camshaft adjuster or chain tensioner using bracket for chain adjustment tool No. 3366, or equivalent. If chain tensioner retainer is fastened too tightly, chain tensioner or camshaft adjuster can be damaged, Fig. 6. 11. First remove bearing caps 3 and 5 from intake and exhaust camshafts, Fig. 7. 12. Remove double bearing cap. 13. Remove both bearing caps from chain gears on intake and exhaust camshafts. 14. Remove securing bolts of camshaft adjuster/chain tensioner. 15. Alternating in diagonal sequence, loosen bearing caps 2 and 4 of intake and exhaust camshafts and remove. 16. Remove intake and exhaust camshaft, chain tensioner or camshaft adjuster and chain tensioner retainer tool No. 3366, or equivalent. Installation When installing the camshafts, cam lobes for cylinder 1 must point upward. When installing bearing caps, verify marking on cap is readable from intake side of cylinder head. 1. When reusing old drive chain, mount drive chain according to color markings onto both camshafts. When using a new drive chain, distance between notches (A) and (B) must be 16 rollers on chain, Fig. 8. Illustration shows where first and sixteenth drive chain rollers must be installed on chain gears. 2. Notch (A) is slightly offset inward toward chain roller (1), Fig. 8. 3. Replace rubber/metal seal for camshaft adjuster or chain tensioner and coat hatched surface with thin coat of sealant D 454 300 A2, or equivalent, Fig. 9. 4. Insert camshaft adjuster/chain tensioner between drive chain. 5. Oil running surfaces of both camshafts. 6. Insert camshafts with drive chain and camshaft adjuster/chain tensioner into cylinder head. 7. Tighten camshaft adjuster/chain tensioner to specification, pay attention to bushing. 8. Alternating in diagonal sequence, tighten bearing caps 2 and 4 of intake and exhaust camshafts and tighten to specification, pay attention to bushing, Fig. 7. 9. Install both bearing caps on gears on intake and exhaust camshafts. Inspect camshaft for proper adjustment (arrows) and tighten bearing cap to specification, pay attention to alignment bushing, Fig. 10. 10. Remove chain tensioner/camshaft adjuster tool No. 3366, or equivalent. 11. Coat hatched surfaces of double bearing cap lightly using sealant D 454 300 A2, or equivalent, install and tighten to specification, pay attention to bushing, Fig. 11. 12. Install remaining bearing caps and tighten to specification, pay attention to alignment bushing. 13. Install camshaft gear, thin rib toward outside (arrows) and TDC marking visible and tighten screw to specification, use retainer tool No. 3036, or equivalent, Fig. 12. 14. Inspect setting of camshafts to each other. 15. After installing camshafts, engine may not be started for approximately 30 minutes. Hydraulic adjusting elements must seat themselves, otherwise valves will seat themselves on pistons. 16. Pistons must not be positioned at TDC. Ensure that crankshaft is still positioned before cylinder 1 TDC. 17. Align marking on camshaft sprocket with marking on cylinder head cover. 18. Place toothed belt onto crankshaft sprocket, observe direction of rotation. 19. Install lower toothed belt guard. 20. Install vibration damper/belt pulley with new bolts. Tighten to specification. 21. Turn crankshaft to set cylinder 1 at TDC. 22. Place toothed belt on in this order coolant pump, tensioning roller and camshaft gear. 23. Tension toothed belt as follows: a. If toothed belt tensioner is completely driven out, it must be pressed back by tensioner roller when installed. This procedure can last approximately five minutes. Pressing together with too much force can damage tensioner roller. b. Turn eccentric pulley counterclockwise using tensioning device tool No. 3387, or equivalent, tab (A) of eccentric pulley must not be bent, until tensioning device locking tool No. T10008, or equivalent, can be pulled free of stress, Fig. 13. c. Rotate eccentric pulley clockwise direction of (arrow) until a drill bit (2) with dimension (a) .31 inch, can be pulled through between tensioning lever and housing of tensioning device, Fig. 14. 24. Turn over crankshaft twice and inspect if markings on camshaft and crankshaft still align with their reference points. 25. Inspect dimension (a) .24-.39 inch between tensioning lever and housing of tensioning device using a drill bit (2), Fig. 14. 26. If dimension (a) is not obtained, release tension of toothed belt and tension it again. 27. Install upper and center toothed belt guards. 28. Install tensioner for serpentine belt. Tighten to specification. 29. Install serpentine belt. When installing serpentine belt, ensure that belt is seated correctly in belt pulleys. 30. Place torque wrench tool No. V.A.G 1331, or equivalent, in seven o'clock position and tighten A/C compressor belt tensioner to specification. Hold torque wrench securely and tighten bolts (A) to specification, Fig. 15. 31. Install lock carrier. 32. Install front bumper. 33. Tighten fasteners to specification. 34. Fill cooling system with coolant.

• Fig. 1 Front bumper removal
• Fig. 2 Lock carrier disconnection
• Fig. 3 Lock carrier service position
• Fig. 4 Camshaft sprocket alignment
• Fig. 5 Camshaft drive chain marking location
• Fig. 6 Camshaft drive chain tensioner securing location
• Fig. 7 Camshaft bearing cap removal
• Fig. 8 Camshaft installation
• Fig. 9 Camshaft chain tensioner seal installation
• Fig. 10 Camshaft installation mark alignment
• Fig. 11 Double bearing cap installation
• Fig. 12 Camshaft gear installation
• Fig. 13 Toothed belt tensioning device release
• Fig. 14 Toothed belt tensioning device
• Fig. 15 Air conditioning compressor belt installation

If you want a picture of one of the fig, let me know which one, there are several pictures. All I'm doing is copying out of my database.

Won't turn over or won't start?

Has to turn over fairly fast

Check for fuel pressure & either spark or
injector pulse while cranking

Hi, there should be marks on the belt itslf that align with hatch marks on the timing gears. Below are the instructions for installation. From these, you should be able to verify that the belt is in time. There are also some diagrams here: http://www.2carpros.com/diagrams/cadillac/catera/1997


To install:

1. Install the timing belt.
   1. Start at the crankshaft pulley.
   2. Install the timing belt with a double dash (TDC) mark on the belt aligned with the marks on the oil pump and belt drive gear.
   3. Pinch the belt with special tool J 42069-30 to prevent the splines from jumping.
   
   
2. Route the timing belt through the idler pulley for camshafts 3 & 4 then route the timing belt through the camshaft gears 3 & 4.
   1. Ensure the dash marks on the timing belt align with marks on the camshaft gears and the notches on the rear timing belt cover.
   2. If necessary, loosen timing belt idler pulley or move the cam gears slightly, with J 42069-1 and 2 still in place, until the timing belt can be installed.
   3. Tighten the idler pulley locking bolt until snug. The idler pulley bolt will be tightened to specifications after the final adjustments are made.
   
   

NOTE Timing belt deflection between the camshaft gears number 4 and the idler pulley for camshafts 3 & 4, must be no more than 0.4 inch (1 CM.).

1. If necessary, adjust the timing belt deflection by turning the timing bolt idler pulley eccentric, for camshafts 3 & 4, counter-clockwise with the special tool J 42069-40, or equivalent.

1. Route the timing belt through the timing belt idler pulley for camshafts 1 & 2 then route the timing belt through camshaft gears 1 & 2.
   1. Ensure the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.
   2. If necessary, loosen the timing belt idler pulley or move the cam gear slightly, with J 42069-1 and 2 still in place, until the timing belt can be installed.
   3. Apply sufficient tension to the timing belt to prevent it from slipping off the gears by turning the timing belt idler pulley eccentric for camshafts 1 & 2 counter-clockwise with special tool J 42069-40 or equivalent.
   4. Tighten the idler pulley locking bolt until snug. Idler pulley bolt will be tightened to specifications after final adjustments are made.
   
   
2. Route the timing belt through the timing belt tensioner.
3. Apply initial tension to the timing belt by turning tensioner eccentric counter-clockwise, with a 5 mm hex wrench, until marks are set.
   1. Tighten the belt tensioner-locking nut to 15 ft. lbs. (20 Nm).
   
   
4. Adjust the timing belt.
   1. The timing belt must be properly adjusted or engine damage may occur. Do not continue with the engine assembly procedure until the timing belt is properly adjusted.
   
   
5. Install the timing belt cover. Tighten the timing belt cover bolts to 71 inch lbs. (8 Nm).
6. Install the power steering pump pulley and bolts. Install the water pump pulley and bolts.
   1. Tighten the power steering pump pulley bolts and the water pump pulley bolts after the serpentine drive belt is installed.

Things You'll Need:

• 2 camshaft timing clamps (#J38613-A)
• Set of metric ½-inch drive sockets
• Set of metric 3/8-inch drive sockets
• Set of metric ¼-inch drive sockets
• ½-inch drive ratchet
• ½-inch drive air gun
• ½-inch extensions (4 to 8 inches long)
• 3/8-inch drive ratchet
• 3/8-inch drive air gun
• 3/8-inch extensions (4 to 8 inches long)
• ¼-inch drive ratchet
• ¼-inch drive air gun
• ¼-inch extensions (4 to 8 inches long)
• Pry bar
• Common screwdriver
• Small common screwdriver
• Small piece of wire at least 1.85 inches long
• Phillips screwdriver
• Pliers
• Adjustable wrench
• Torque wrench

Removing the Timing Belt
1. Remove the air cleaner, air duct and the coolant reservoir. The coolant reservoir can remain attached to the hoses---just unbolt it and move it to the side out of your way. Remove the serpentine belt. Before removing the serpentine belt, make sure there is a diagram on the hood or radiator support to show you the belt routing. If the belt routing sticker is missing, sketch out a picture of the belt routing.
   
2. Siphon the fluid out of the reservoir of the power steering pump, or be prepared to cap the line ports off. You can cap the line ports off with a piece of rubber hose. Close the open end of the hose with a large bolt. Unbolt the power steering pump from its bracket and set it aside. Cap any open hose ends or pipe fittings. This will prevent additional fluid loss.
   
3. Remove the right timing belt cover, spark plug wire cover, left timing belt cover and the ECM harness cover using the ¼-inch tools. Remove the serpentine belt tensioner with the 3/8-inch tools. Unclip the power steering hose from the alternator. Using the ¼-inch tools or the 3/8-inch tools, remove the center timing belt cover and the right and left camshaft covers.
   
4. Remove the tensioner side plate. The side plate is located just under the left cams and has three bolts holding it on. The tensioner is hydraulic and includes a plunger unit. Turn the plunger unit to remove it from the pulley arm and socket. Make sure you do not lose the tapered brush that sits between the plunger and the mount. Loosen and remove the tensioner pulley bolt (located at about 10 o'clock on the tensioner pulley). Tape the pulley pivot bushing to the pulley so it doesn't fall out. Remove the pulley and the arm. Remove the timing belt.
Installing the Timing Belt
5. Bend a thick paper clip so you have a straight piece of wire at least 1.85 inches long. Clamp the tensioner plunger at its center in a vise, with the plunger pointing toward the ground. Allow it to sit for 5 minutes to get the oil into the rubber boot. Remove the plug from the flat base of the plunger and insert a small screwdriver into the vent hole. Turn the screwdriver counterclockwise until the pushrod is retracted. Make sure the pushrod is fully retracted before moving on to the next step.
   
6. Push the wire peg you created in Step 1 into the vent hole and turn the screwdriver counterclockwise until you feel the wire peg lock into the pushrod. Fill the plunger with 5W-30 synthetic engine oil to the bottom of the hole. Do not overfill the plunger. Put the plug back on the plunger. Make sure the plug is in securely and the plunger is completely sealed. Wipe the plunger clean of spilled oil.
   
7. Clean the tensioner pulley, but do not lubricate it. Turn the crankshaft clockwise until the number 1 cylinder (front cylinder on the driver's side) is at top dead center and the timing marks on the crank pulley and the block are lined up. Top dead center is achieved when the piston in the number 1 hole reaches its complete height in the rotation. You can feel for this by sticking a screwdriver in number 1 spark plug hole while turning the crank pulley.
   
8. Turn all four of the camshaft pulleys so that the machined flats are facing up. Install the timing clamps on each camshaft carrier. Torque the bolt on the timing clamp to 22 foot pounds of torque. If there are any timing marks drawn on the camshaft pulleys, erase them.
   
   
9. Loosen the camshaft sprocket bolts. Using a rubber hammer, tap each camshaft sprocket to remove any taper. Tighten the sprocket bolts finger-tight. Spin each sprocket to be sure the sprocket turns freely. Make sure there is no back and forth freeplay when the sprockets are being turned.
   
10. Install the timing belt starting with the crankshaft pulley. Route the belt to the right guide pulley (as you are facing the engine), then the right exhaust camshaft sprocket, over the top of the right intake camshaft sprocket, then under the center guide pulley, over the left intake camshaft sprocket and over the left exhaust camshaft sprocket. Make sure the timing belt is tight on the right side and loose on the left side (again, as you are facing the engine).
    
11. Install the tensioner pulley, making sure the pivot brush does not fall out. Leave it taped or use a magnet to hold it in. Torque the tensioner pulley bolt to 37 foot pounds of torque. Install the tensioner and the side plate. Be sure the pushrod end is seated properly against the tensioner pulley. Torque the side plate retaining bolts to 18 foot pounds of torque. Remove the locking pin and let the plunger extend to its normal position.
    
12. Set the torque wrench to 89 foot pounds of torque, then put the torque wrench on the square lug of the tensioner and torque it. This applies initial tension to the timing belt. Turn the crankshaft sprocket three times by hand. This ensures seating of the timing belt and makes sure the engine turns freely without the valves hitting the pistons. Check to be sure the crankshaft pulley timing marks are still lined up.
    
13. Torque the bolts on the left camshaft exhaust and intake pulleys to 96 foot pounds of torque. You will need to hold the sprockets to keep them from turning while torquing the bolts. Remove the timing clamp from the left side camshaft carrier. The cams should not move when removing the timing clamp. Turn the crankshaft one complete clockwise rotation and align the crankshaft pulley marks.
    
14. Repeat Step 9 for the right camshaft exhaust and intake pulleys, expect when turning the engine, turn it two complete clockwise rotations and align the crankshaft pulley marks. The flat, machined surfaces on the camshafts will be facing up on one side and facing down on the other side.
    
15. Mark the left camshaft exhaust pulley at 2 o'clock and the left camshaft intake pulley at 8 o'clock (the marks should be in line with each other) with fingernail polish or heat paint. Mark the right camshaft exhaust pulley at 10 o'clock and the right camshaft intake pulley at 4 o'clock, lining up the marks. Install all components in the reverse order of removal.

This should give you a clue as to how to replace the timing belt on the camshaft pulleys. Camshaft and Valve Lifters REMOVAL & INSTALLATION 1.6L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Timing belt
   • Crankcase ventilation tube from the valve cover
   • Spark plug cover bolts and the cover
   • Camshaft Position (CMP) sensor connector
   • Spark plug wires from the plugs
   • Valve cover nuts, washers, cover and gasket
   NOTE: Be very careful not to nick or scratch the camshafts.
   
4. Hold the flats of the intake camshaft in position using an open ended wrench and remove the camshaft gear bolt. Remove the gear.
5. Hold the flats of the exhaust camshaft in position using an open ended wrench and remove the camshaft gear bolt. Remove the gear.
6. Mark the camshaft cap locations so that they may be returned to their original positions.
7. Remove the camshaft cap bolts in the sequence illustrated.
8. Remove the caps and the camshafts. Fig. 1: Loosen the camshaft cap bolts in this sequence using several passes - 1.6L engine
   To install:
   
9. Lubricate the camshafts and caps with engine oil.
10. Install the caps and the camshafts in their original positions.
11. Tighten the camshaft cap bolts in the sequence illustrated to 12 ft. lbs. (16 Nm). Fig. 2: Tighten the camshaft cap bolts in the sequence illustrated using several passes - 1.6L engine
    
    
12. Measure the camshaft endplay on both camshafts. The endplay should be 0.003-0.009 in. (0.10-0.25mm).
13. Install the intake camshaft gear. Hold the flats of the intake camshaft in position using an open ended wrench and tighten the camshaft gear bolt to 49 ft. lbs. (67 Nm).
14. Install the exhaust camshaft gear. Hold the flats of the exhaust camshaft in position using an open ended wrench and tighten the camshaft gear bolt to 49 ft. lbs. (67 Nm).
15. Apply a small amount of gasket sealer to the corners of the front camshaft caps and to the top of the rear valve cover-to-cylinder head seal.
16. Install or connect the following:
    • Valve cover, washers and nuts. Tighten the nuts to 89 inch lbs. (10 Nm).
    • Spark plug wires to the plugs
    • Spark plug cover and bolts. Tighten the bolts to 27 inch lbs. (3 Nm).
    • CMP sensor connector
    • Crankcase ventilation tube to the valve cover
    • Timing belt

2.0L and 2.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Timing belt
   • Crankcase ventilation tube from the valve cover
   • Spark plug cover bolts and the cover
   • Spark plug wires from the plugs
   • Camshaft Position (CMP) sensor connector
   • Valve cover nuts, washers, cover and gasket
   NOTE: Be very careful not to nick or scratch the camshafts.
   
4. Hold the flats of the intake camshaft in position using an open ended wrench and remove the camshaft gear bolt. Remove the gear.
5. Hold the flats of the exhaust camshaft in position using an open ended wrench and remove the camshaft gear bolt. Remove the gear.
6. Mark the camshaft cap locations so that they may be returned to their original positions.
7. Remove the camshaft cap bolts in several passes of one half turn each in the sequence illustrated.
8. Remove the seal ring from the camshafts. NOTE: Make sure the camshafts detaches evenly from the bearing seats in the front guide bearing.
   
9. Remove the caps and the camshafts. Fig. 3: Remove the camshaft cap bolts in several passes of one half turn each in the sequence illustrated - 2.0L and 2.2L engines
   To install:
   
10. Lubricate the camshafts and caps with engine oil.
11. Install the caps and the camshafts in their original positions.
12. Tighten the camshaft cap bolts in the sequence illustrated to 71 inch lbs. (8 Nm). Fig. 4: Tighten the camshaft cap bolts in the sequence illustrated using several passes - 2.0L and 2.2L engines
    
    
13. Measure the camshaft endplay on both camshafts. The endplay should be 0.0015-0.0056 in. (0.040-0.144mm).
14. Install the intake camshaft gear. Hold the flats of the intake camshaft in position using an open ended wrench and tighten the camshaft gear bolt to 37 ft. lbs. (50 Nm), retighten the bolt an additional 60 degree turn and finally an additional 15 degree turn.
15. Install the exhaust camshaft gear. Hold the flats of the exhaust camshaft in position using an open ended wrench and tighten the camshaft gear bolt to 37 ft. lbs. (50 Nm), retighten the bolt an additional 60 degree turn and finally an additional 15 degree turn.
16. Install or connect the following:
    • Valve cover, washers and nuts. Tighten the nuts to 71 inch lbs. (8 Nm).
    • CMP sensor connector
    • Spark plug wires to the plugs
    • Spark plug cover and bolts. Tighten the bolts to 27 inch lbs. (3 Nm).
    • Crankcase ventilation tube to the valve cover
    • Timing belt
    • Negative battery cable

from autozone.com

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Disconnect the Manifold Air Temperature (MAT) sensor connector.
4. Disconnect the air cleaner outlet hose from the throttle body.
5. Disconnect the breather tube from the camshaft cover.
6. Remove the air cleaner housing bolts.
7. Remove the air cleaner housing.
8. Remove the right front wheel.
9. Remove the right front wheel well splash shield.
10. Remove the serpentine drive belt.
11. Remove the crankshaft pulley bolts and the crankshaft pulley.
12. Remove the right engine mount bracket.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.
15. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.
    

Fig. Aligning the timing mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

1. Fig. Aligning the camshaft gears with the notches on the camshaft cover.
3. Align the camshaft gears with the notch on the camshaft cover.
4. Remove the timing belt.
5. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
6. 
   

To install:

1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
3. Install the timing belt.
4. Turn the hex-key tab in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch.
5. Install the automatic tensioner bolt and tighten to 18 ft. lbs. (25 Nm).
6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
7. Recheck the automatic tensioner pointer.
8. Install the front timing belt cover.
9. Install the front timing belt cover bolts and tighten to 53 inch lbs. (6 Nm).
10. Install the right engine mount bracket.
11. Install the crankshaft pulley and tighten the crankshaft pulley bolts to 15 ft. lbs. (20 Nm).
12. Install the serpentine drive belt.
13. Install the right front wheel well splash shield.
14. Install the right front wheel.
15. Install the air cleaner housing.
16. Install the air cleaner housing bolts and tighten to 89 inch lbs. (10 Nm).
17. Connect the air cleaner outlet hose to the throttle body.
18. Connect the breather tube to the camshaft cover.
19. Connect the MAT sensor connector.
20. Connect the negative battery cable.

If I recall correctly there was a recall on the camshaft position sensor. In some cases it would melt.
MAKE: DAEWOO MODEL: NUBIRA YEAR: 2001 DEFECT SUMMARY:
ON CERTAIN PASSENGER VEHICLES, THE CAMSHAFT POSITION SENSOR MAY MELT RESULTING IN A BURNING SMELL AND VISIBLE SMOKE, WHICH MAY SUBSEQUENTLY LEAD TO THE MELTING OF THE CAMSHAFT COVER AND THE CAMSHAFT POSITION SENSOR WIRE HARNESS.
CONSEQUENCE SUMMARY:
THIS COULD POSSIBLY CAUSE AN UNDERHOOD FIRE.
CORRECTIVE SUMMARY:
DEALERS WILL REPLACE THE CAMSHAFT POSITION SENSORS AND INSTALL AN ADDITIONAL FUSE. THE RECALL BEGAN ON SEPTEMBER 7, 2004. OWNERS SHOULD CONTACT DAEWOO AT 1-877-362-1234, OPTION 6, OR FIND A LOCAL DEALER THROUGH THEIR WEBSITE AT WWW.DAEWOOUS.COM.

2.0L Engine SOHC ENGINE

1. Remove the drive belt and timing cover.
2. Raise the car and support it with safety stands.
3. Remove the right-hand splash shield and the crankshaft pulley. Fig. 11: The timing marks on both the camshaft and crankshaft pulleys must be aligned like this before removing or installing the timing belt — 2.0L SOHC engines
   
   
4. Align the timing marks as illustrated in the accompanying illustration.
5. Refer to the accompanying illustration and remove the timing belt as follows:
   1. Loosen the timing belt tensioner bolt (1).
   2. Use an 8mm Allen wrench, and turn the tensioner (2) counterclockwise 1⁄4 turn.
   3. Insert a 1⁄8 inch drill bit in the hole (3) to lock the belt tensioner in place.
   4. Remove the timing belt (4). Fig. 12: Remove the timing belt by following these 4 numbered steps (refer to the text for an explanation) — 2.0L SOHC engine
      
      
   5. Inspect the belt for damage and signs of oil leakage. To install: NOTE: Install the timing belt over the sprocket in a counterclockwise direction starting at the crankshaft. Keep the belt span between the crankshaft and camshaft tight when installing the belt over the camshaft.
      
6. Install the timing belt and remove the drill bit.
7. Tighten the tensioner bolt to 15–22 ft. lbs. (20–30 Nm).
8. Rotate the engine two complete revolutions and make sure the timing marks are aligned.
9. Install the timing belt cover and crankshaft pulley.
10. Install the right-hand splash shield and the drive belt.
11. Start the car and check for proper operation.

DOHC ENGINE NOTE: A camshaft alignment timing tool (No. T94P-6256-CH or equivalent) and a crankshaft Top Dead Center (TDC) timing peg tool (No. T97P-6000-A or equivalent) are required for this procedure. NOTE: Make sure the correct notch in the pulley is indexed to the lower cylinder block. Refer to the accompanying illustration. Fig. 13: A camshaft alignment timing tool . . .
Fig. 14: . . . and a crankshaft TDC timing peg tool are required when removing and installing the timing belt

1. Remove the spark plugs.
2. Rotate the crankshaft to TDC.
3. Locate and remove the plug bolt by the Crankshaft Position (CKP) sensor (refer to the illustration) and install the TDC timing peg. Fig. 15: Remove the plug bolt by the Crankshaft Position (CKP) sensor and install the TDC timing peg
   
   
4. Raise the car and support it with safety stands.
5. Unfasten the splash shields bolts and remove the shield.
6. Lower the car and remove the water pump pulley.
7. Remove the valve cover and the timing belt covers.
8. Align the camshafts and install the camshaft alignment tool on the back of the camshafts as illustrated. Fig. 16: Align the camshafts and install the alignment tool
   WARNING
   If the camshaft belt is being reused, mark the direction of the camshaft belt to the rotation of the camshaft prior to removal, or premature wear and belt failure could occur.
   
9. Loosen the tensioner pulley bolt and relieve the tension on the belt by disconnecting the tensioner tab from the timing cover back plate.
10. Slide the belt off the sprockets.
11. Inspect the belt for wear and replace as necessary. Fig. 17: Timing belt routing — 2.0L DOHC engine
    To install:
    
12. If, for any reason, the engine was disturbed, the camshafts moved or the sprockets replaced, perform the following procedure: NOTE: Make sure the correct notch in the pulley is indexed to the lower cylinder block.
    1. Position the crankshaft just prior to Top Dead Center (TDC).
    2. If not already done, locate and remove the plug bolt by the Crankshaft Position (CKP) sensor (refer to the illustration) and install the TDC timing peg.
    3. Rotate the crankshaft clockwise against the TDC peg. NOTE: Installation of the alignment tool into the exhaust camshaft may require the camshafts to be rotated clockwise.
       
    4. Install the camshaft alignment tool on the back of the camshafts.
    5. Install the timing belt and engage the timing belt tensioner tab into the upper timing cover backplate. NOTE: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt.
       
    6. Using a 6mm Allen wrench, adjust the tensioner until the index marks are aligned and tighten the bolt to 17–20 ft. lbs. (22–28 Nm).
    7. Rotate the crankshaft clockwise against the TDC alignment peg, then remove the camshaft alignment tool.
    8. Remove the TDC peg tool and install the plug bolt.
    9. Install the timing and valve covers.
    10. Install the water pump pulley and the splash shield.
    11. Install the spark plugs. If the engine or the camshaft were not disturbed in any way, or the sprockets were not removed, perform the following procedure:
        
13. Install the timing belt and engage the timing belt tensioner tab into the upper timing cover backplate. Fig. 18: Engage the timing belt tensioner tab into the upper timing cover backplate . . .
    Fig. 19: . . . then use a 6mm Allen wrench to adjust the tensioner until the index marks are aligned
    Fig. 20: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt (arrow) — 2.0L DOHC engine
    NOTE: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt.
    
14. Using a 6mm Allen wrench, adjust the tensioner until the index marks are aligned and tighten the bolt to 17–20 ft. lbs. (22–28 Nm).
15. Rotate the crankshaft clockwise against the TDC alignment peg, then remove the camshaft alignment tool. Fig. 21: Rotate the crankshaft clockwise against the TDC alignment peg
    
    
16. Remove the TDC peg tool and install the plug bolt.
17. Install the timing and valve covers.
18. Install the water pump pulley and the splash shield.
19. Install the spark plugs.

Instructions
Things You'll Need: · Set of quarter-inch drive sockets Quarter-inch drive ratchet Set of half-inch drive sockets Half-inch drive air gun Set of metric wrenches Special tools for holding camshaft timing #2065-A and injection pump #2064

Step 1

Remove the accessory drive belts and the accessory drive belt tensioner. Remove the upper timing belt cover and the valve cover. Turn the crankshaft clockwise until the No.1 cylinder is atop, dead center, with the flywheel timing marks aligned.

Step 2

Install the special tool setting bar (#2065-A) on the rear of the camshaft. If it does not fit, turn the crankshaft once more and line up the timing marks again in the hole of the transmission housing.

Step 3

Insert locking pin #2064 into the injection pump to hold it in position. Remove the crankshaft pulley bolts, the crankshaft pulley and the lower timing belt cover. Loosen the tensioner pulley nut and allow the tensioner to move away from the belt. Loosely tighten the nut to hold the tensioner out of the way. Remove the top guide pulley and the timing belt.

Step 4

Make sure that the timing mark on the flywheel is lined up and that the camshaft setting bar and injection locking pin are in place. Loosen the camshaft bolt a half turn and tap the sprocket with a soft mallet to loosen it off its taper. The sprocket should move freely. Install the top guide pulley and torque to 18 foot pounds of torque.

Step 5

Install the new timing belt, starting on the right side and working counterclockwise. Keep the tension on the right nontensioned side. Loosen the tensioner pulley nut. Using the two-pin wrench, turn the tensioner pulley clockwise until the notch and raised mark are aligned. Torque the tensioner pulley nut to 15 foot pounds of torque. Make sure the flywheel timing mark is still aligned.

Step 6

Torque the camshaft bolt to 33 foot pounds of torque. Remove the locking pin from the injection pump and remove the camshaft setting bar. Turn the crankshaft two turns and check the alignment on the flywheel. Make sure that the setting bar can be inserted easily and that the injection pump locking pin can be inserted. Install all components in reverse order of removal and torque the crankshaft bolt to 18 foot pounds of torque.

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Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
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Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10.Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
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Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
6A–30 ENGINE MECHANICAL
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
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Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
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Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
ENGINE MECHANICAL 6A–31
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
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Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N·m (2.5 Kg·m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
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