STEPS
OPTIONAL items make for easier, more convenient work.
Recommend doing radiator, air-con core clean, idler bearings and water pump work concurrently.

1. Place vehicle on car ramps at front. Ideally, downhill onto ramps brings vehicle level with front on ramps.
2. [OPTIONAL] Remove bullbar, bumper bar, radiator grill.
3. Drain coolant.
4. Disconnect upper, lower and overflow hoses from radiator.
5. Remove fan cowling - 2 parts. 2 bolts (nuts captive) driver's side, 3 bolts/nuts passenger side, a small bolt/nut holding two cowling parts together on passenger side, two bolt/nut/bracket assemblies top. Lifting the lower cowling half will extract it from the two tabs retaining the bottom side of the cowling.
6. [OPTIONAL] Remove radiator - 4 bolts (2 nuts captive). The bolts between the turbo intercooler on driver side may require the removal of the intercooer if a thin 3/8" driveshaft and slender socket are not available.
7. Undo the two V-belt tensioners. Loosening the tensioner screw clamping blocks and the pivot bolts helps.
8. Undo fan blade/pully bolts and remove fan and pulley assembly. If radiator not removed; special care required not to damage radiator core during this step.
9. Remove both V-belts.
10. Remove timing belt covers. Start by removing the 3 hairpin clips (locations circled red on picture). Now remove the 2 small bolts (one each side) holding the lower cover around the bottom half of crankshaft pulley. The bolts are accessible from below. Next, slip out the driver-side cover. Finally, the remaining cover.
11. Rotate crankshaft until cam cog and injector cog timing lock holes line up with receiving threads. Use two of the fan bolts to lock the cam and injector cogs. This picture shows the locking locations at approximately 1 o'clock on injector cog and 4 o'clock on cam cog with arrows. Some jiggling may be required.
    NOTE: There is also a locking hole and thread in the crankshaft flywheel, at the rear of the engine, but because the crank has little chance of turning there is little need to fit this lock unless timing has been compromised.
12. Undo the timing belt tensioner bolt and lever back tensioner to end of its travel. Re-tighten tensioner bolt in this position.
13. Remove timing belt; taking note of its path.
14. Check all idlers for V-belts, timing belt and fan (this is not the water pump) bearing for smooth operation. Check water pump for leaks/wear (small tooth cog and assembly at 10 o'clock from crank pulley). Service as necessary.
15. Compare old with new timing belt to confirm identical.
16. Install new timing belt. Keep tensioned on passenger side. Mesh teeth on all cogs. Confirm teeth meshed on injector to crank cog side with belt tight. This is the important side. The driver's side will be slack.
17. Loosen tensioner bolt. If the tensioner doesn't return, assist. Confirm the timing belt is tight. Re-tighten the tensioner bolt.
18. Remove the 2 timing cog locking bolts.
19. Confirm timing belt assembly is operating correctly by turning crank by hand 2 turns clockwise without incident.
20. [OPTIONAL] Start motor and run for 10 seconds to confirm correct operation. (This can be done safely without coolant providing the duration is not longer than 20 seconds).
21. Re-assemble all items in reverse of disassembly.
22. Run and test.

RETURN