2005 Chevrolet Optra (CANADA) L4-2.0L
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1 1 of 13 9/28/2013 7:54 PM 2005 Chevrolet Optra (CANADA) L4-2.0L Vehicle» Engine, Cooling and Exhaust» Engine» Timing Belt» Service and Repair Timing Belt Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution See: Starting and Charging\Battery\Service Precautions\Technician Safety Information\Battery Disconnect Caution in Cautions and Notices Disconnect the negative battery cable. Disconnect the intake air temperature (IAT) sensor. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover.
2 of 13 9/28/2013 7:54 PM Remove the air cleaner housing bolts. Remove the air cleaner. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation See: Maintenance\Wheels and Tires\Service and Repair in Tires and Wheels. Remove the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement See: Body and Frame\Splash Guard\Service and Repair in Body Front End.
3 3 of 13 9/28/2013 7:54 PM Notice: Refer to Belt Dressing Notice See: Drive Belt\Service Precautions in Cautions and Notices Remove the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement See: Drive Belt\Service and Repair in Power Steering System. Remove the crankshaft pulley bolts. Remove the crankshaft pulley. Remove the right engine mount bracket. Refer to Engine Mount Replacement See: Engine Mount\Service and Repair.
4 4 of 13 9/28/2013 7:54 PM Remove the front timing cover bolts. Remove the front timing belt cover.
5 5 of 13 9/28/2013 7:54 PM 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.
6 6 of 13 9/28/2013 7:54 PM Important: The camshaft gears must align with the notch on the valve cover or damage to the engine could result. Important: Use the intake gear mark for the intake camshaft gear and the exhaust gear (1) mark for the exhaust camshaft gear (2) since both gears are interchangeable. 16. Align the camshaft gears with the notch on the valve cover.
7 of 13 9/28/2013 7:54 PM Loosen the automatic tensioner bolt. Turn the hex key tab to relieve the belt tension. Remove the timing belt. Installation Procedure
8 8 of 13 9/28/2013 7:54 PM 1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
9 9 of 13 9/28/2013 7:54 PM 2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear (1) and the exhaust gear mark for the exhaust gear (2). 3. Install the timing belt.
10 10 of 13 9/28/2013 7:54 PM 4. Turn the hex-key tab in a counterclockwise direction to tension the belt. Turn until the pointer aligns with the notch. Notice: Refer to Fastener Notice See: Service Precautions\Vehicle Damage Warnings\Fastener Notice in Cautions and Notices. 5. Install the automatic tensioner bolt. Tighten the automatic tensioner bolt to 25 Nm (18 lb ft) Rotate the crankshaft 2 full turns clockwise using the crankshaft gear bolt. Inspect the automatic tensioner pointer.
11 11 of 13 9/28/2013 7:54 PM Install the front timing belt cover. Install the front timing belt cover bolts. Tighten the front timing belt cover bolts to 6 Nm (53 lb in). 10. Install the right engine mount bracket. Refer to Engine Mount Replacement See: Engine Mount\Service and Repair.
12 2 of 13 9/28/2013 7:54 PM Install the crankshaft pulley. Install the crankshaft pulley bolts Tighten the crankshaft pulley bolts to 20 Nm (15 lb ft). Notice: Refer to Belt Dressing Notice See: Drive Belt\Service Precautions in Cautions and Notices Install the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement See: Drive Belt\Service and Repair in Power Steering System. Install the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement See: Body and Frame\Splash Guard\Service and Repair in Body Front End. Install the right front wheel. Refer to Tire and Wheel Removal and Installation See: Maintenance\Wheels and Tires\Service and Repair in Tires and Wheels.
13 13 of 13 9/28/2013 7:54 PM Install the air filter housing. Install the air filter housing bolts. Tighten the air filter housing bolts to 10 Nm (89 lb in) Connect the air intake tube to the throttle body. Connect the breather tube to the valve cover. Connect the IAT sensor connector. Connect the negative battery cable.
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