TIMING BELT TORE BOUGHT NEW ONE HAVE ENGINE AT TDC HOW DO I KNOW THE INTAKE CAM FROM THE EXHAUST AND HOW TO MAKE SURE THEY ARE IN THE CORRECT POSITIN FOR TIMING

With Cam Caps loosened, FIRST loosen timing chain tensioner, press it in to loosen tension, Crank using ratchet to TDC (Top Dead Center on crank pully, (to keep from damage to pistons), align Exhaust Cam Timing Mark to mark on #1 Exhaust cam cover, then take up slack between Exhaust & Intake Cams (on top between the cams), Then align the Intake Cam to mark on #1 Cam Cap, "Now" loosen the 17mm bolt to tighten timing chain, rotate engine using rachet two times, reset TDC at the crank, and look at "Cam Timing Marks on both the Exhaust, and Intake Cams. If you did all this correctly the "Timing Marks" should be lined up so TDC,Exhaust, and Intake marks are all the same.

double posted anon,.
backup one.
my guess is you for got to say
who to time a G16a or G16b CAM
read it. all G16's time at TDC 0degr. #4 firing, period.

http://www.fixkick.com/t-belt/tbelt-index.html#Tbelt-main

I would suggest to get a propane torch and turn on with out lighting it (flame less) Place in intake port to manifold crank and see if starts. this will let you know if injectors are cycling or not. This engine has Three sensors that keep the engine running crank,TDC,cam. The TDC and CAM are in the distributor and crank is behind timing belt cover.

Take the rocker cover and the upper timing belt cover off.
Set No 1 Cylinder to TDC - use the markings on the cam spocket to get this - and confirm it's on the compression stroke by check both inlet and exhaust valves are closed and on the heel of the cam.
In this position, check rockers 1,2,4 and 5.
Take care with the feeler guage to make sure you're right under the pad under the adjuster screw properly and completely passing under it, not sticking part way.
Rotate the engine (crank shaft) 360 degrees. This should bring No 4 to TDC - confirm that both inlet and exhaust valves are closed and on the heel of the cam.
In this position, check rockers 3,6,7 and 8.

Clearance for Intake and Exhaust is 0.25mm at normal engine operating temp.

Don't forget to fit a new rocker cover gasket and half moon seal (use something like Hylomar to help make sure the half moon is sealed properly - usual suspect when rocker cover leaks at the back of the engine).

The cams make 2 complete rotations for every 1 rotation of the crank so you could be out of time by 180 degrees.With the valve cover off turn the engine over by hand. As #1 piston comes up on TDC the intake valves should be open and starting to close. As you go past TDC the exhaust valves should start to open. If this is not what is happening in this order then your timing is off. Your engine should be at TDC when the timing marks are lined up with the marker on the engine. Hope this helps.

With engine Crankshaft on TDC and cam timing set correctly this is the position where No. 1 cylinder is firing at the start of the power stroke. At this point No. 4 cylinder is also at TDC but is just at the end of the exhaust stroke and starting the intake stroke so the exhaust valve will be almost finished closing and the inlet valve will just be starting to open. This is referred to as the inlet and exhaust valves rocking.

You will need these tools:

13mm open end wrench 10mm shallow and deep socket 8mm socket long flathead screwdriver 17mm deep socket T50 torx socket 1/4", 3/8ths and 1/2" ratchets and extensions E10 inverted torx sockets 6mm Allen wrench 15mm open end wrench 7mm socket 12mm open end wrench 14mm socket 12mm socket 8mm, 9mm and 10mm Allen head sockets 19mm socket pry bar needle nose pliers.

If you are doing this because your timing belt broke, you will also need to buy a complete cylinder head, head gasket set, and both idler pulleys. ALL DAEWOO MODELS WILL BREAK THE INTAKE AND EXHAUST VALVES WHEN THE TIMING BELT BREAKS.
Start by removing the air cleaner assembly from the throttle body, remove the air filter and housing jack up the vehicle and remove the wheel, remove the plastic shielding in front of the accessory drive belt assembly, remove the accessory drive belt, place a jack with a block of wood on top underneath the engine oil pan remove the front engine mount, remove the crank shaft pulley (the four Allen head bolts only not the 17mm bolt in the center.) Remove the metal plate behind the engine mount bracket on the engine, remove the plastic timing belt cover, three clips on top and two 10mm bolts on bottom. Rotate the engine until the #1 cyl. is at Top Dead Center (TDC) on the compression stroke or line up the crankshaft timing mark with the mark on the inner timing belt cover (notch in cover with notch in pulley) on the camshaft pulleys (intake cam line up the line on the pulley with the line on the inner cover) (exhaust cam line up the arrow on the pulley with the arrow on the inner cover) Now loosen the 13mm bolt in the belt tensioner and using the Allen wrench, rotate the tab until there is slack in the belt. Remove the timing belt. At this time I would recommend you replace the water pump, both plastic idler pulleys as they tend to overheat and lockup, and the belt tensioner. Make sure all your marks are lined up, you may need a helper to hold the exhaust cam in place as it tends to move during belt installation. Put the timing belt underneath the crankshaft pulley, install the belt leaving the intake cam for last and NO BELT SLACK on the right side between the crank and the exhaust cam. Once the belt is installed, rotate the crankshaft over two revolutions and make sure is rotates freely, and your timing marks are aligned perfectly. If not, the engine will not run properly, tension the belt as needed. Installation is the same as removal. To clarify, on the DOHC engine, the intake cam gear has a line on it, and the exhaust cam gear has an arrow on it. These should be lined up with the corresponding line and arrow on the VALVE COVER, pointing straight up. I just went through this process over the weekend, and spent quite a bit of time looking for these marking as I had removed the valve cover. Once I found them, it was plain and simple. In addition, be sure to not over tighten the belt when reinstalling. The tensioner has markings on it for "old" and "new". DO NOT adjust past "new", as the car will sound like a jet engine, and the belt will not last for very long. One more item that you might as well replace while you are in there is the cam position sensor if you have not already replaced it as there have been issues with them, and the timing housing has to be opened to get to it. The timing is set at: 8 degrees (both manual and automatic transmission)

PATH: Engine Mechanical > Engine Mechanical Components > Timing Belt & Sprockets > Removal & Installation Removal & Installation

1. Disconnect the negative battery cable.
   
2. Position crankshaft so that No. 1 piston is at Top Dead Center (TDC).
   
3. Remove the splash guard.
   
4. If equipped, remove the cruise control actuator.
   
5. Loosen and remove the power steering pump drive belt.
   
6. Remove the two bolts that attach the top power steering hose to the power steering pump. Cover and seal the hose and the open port of the pump.
   
7. Clamp shut the power steering reservoir return hose, remove it from the return line, and remove the power steering pump and reservoir as an assembly.
   
8. Remove the remaining accessory drive belts. Refer to Section 1 for specific details.
   
9. Place a piece of wood between the oil pan and the jack, support the engine with a jack.
   
10. Remove upper engine bracket.
    
11. Remove the valve cover.
    
12. Make sure the engine is at Top Dead Center (TDC) for No. 1 cylinder. The engine is at TDC for No. 1 cylinder when:
    
    • The white Top Dead Center (TDC) mark on the crankshaft pulley is aligned with the raised pointer.
      
    • The UP marks on both camshaft sprockets are at the topmost (12 O'clock) position.
      
    • The holes in the No. 1 exhaust and intake cam journals align with the holes in the camshaft. A 4.5 mm or 5/32inch drill bit or Allen key can be placed through the holes to prevent the cams from rotating while removing or installing the cam belt.
      
13. Remove the crankshaft pulley. For details, see crankshaft pulley removal in this section.
    
14. Remove the timing belt covers.
    
15. Loosen the adjusting bolt 1/2-1 turn. Release the tension from the belt by pushing on the tensioner, then retighten the adjusting bolt.
    
16. Remove the timing belt.
    

To install:

1. Be sure the timing marks are properly aligned.
   
2. Install the timing belt around the crankshaft sprocket and then stuff a clean rag or paper towel between the belt and the sensor guard to hold the belt engaged with the sprocket teeth.
   
3. Place the flat side of the belt clockwise around the top of the tensioner and then engage the toothed portion of the timing belt counterclockwise around the bottom of the water pump sprocket.
   
4. Carefully pull the timing belt upward but do notmove the crankshaft. If the crankshaft moved, carefully realign the crankshaft timing belt sprocket with the TDC marks. Carefully engage the teeth of the timing belt onto the exhaust camshaft sprocket, but only install the belt about 1/3 of the way onto the sprocket.
   
5. Grasp the timing belt on the toothed side and gently lift the belt enough to begin sliding it onto the intake camshaft sprocket.
   
6. Once the belt has started to slide onto the intake camshaft sprocket, slide the belt equally onto both the intake and exhaust camshaft sprockets.
   
7. Quickly loosen and then retighten the timing belt tensioner bolt.
   
8. Remove the tools from the camshaft caps used for securing the camshafts, and remove the cloth used to keep the timing belt engaged in the crankshaft sprocket.
   
9. Apply a clockwise load on the intake camshaft sprocket bolt to remove any slack between the intake camshaft sprocket, exhaust camshaft sprocket and the crankshaft timing belt sprocket, then loosen and retighten the timing belt tensioner adjusting bolt to allow tension to be applied to the belt.
   
10. Install the crankshaft pulley sprocket/timing belt guide washer.
    
11. Install the lower and upper timing covers.
    
12. Install the crankshaft pulley and tighten the bolt to 130 ft. lbs. (177 Nm).
    
    WARNING

    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.
    
    

13. Rotate the crankshaft about 5-6 times counterclockwise to seat the timing belt.
    
14. Position the No. 1 piston to TDC.
    
15. Locate and remove the rubber plug for the timing belt tensioner on the lower timing belt cover.
    
16. Loosen the adjusting bolt 1/2 turn by
    
17. Rotate the crankshaft counterclockwise 3 teeth on the camshaft pulley.
    
18. Tighten the adjusting bolt to 40 ft. lbs. (54Nm).
    
19. Retighten the crankshaft pulley bolt to 130 ft. lbs. (177 Nm).
    
20. Install the valve cover.
    
21. Install the engine mounting bracket, then remove the jack.
    
22. If removed, install the cruise control actuator.
    
23. Install the accessory drive belts.
    
24. Install the splash guard.
    
25. Connect the negative battery cable.
    
26. Check the engine operation and road test.
    

WARNING

Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.

It is typical to have to stretch the belt a tad as you install--needs to be tight across the cam sprockets and from the right cam to the crank gear. Then the tensioner should take up the slack on the other side.

1. 
2. Fig. Camshaft and crankshaft alignment marks-2.4L engine

2. 
   

To install:

Fig. Install the belt tensioner


Fig. Proper timing belt routing

1. Set the crankshaft sprocket at TDC by aligning the sprocket with the arrow on the oil pump housing.
2. Set the camshafts timing marks so that the exhaust camshaft sprocket is a 1 / 2 notch below the intake camshaft sprocket.
3. Install the timing belt by starting at the crankshaft. Go around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner.
4. Move the exhaust camshaft sprocket counterclockwise to align the marks and to remove any slack.
5. Insert a 6mm Allen wrench into the tensioner opening on the top plate of the tensioner pulley. Rotate the top plate counterclockwise. The pulley will move against the belt and the tensioner setting notch will start to move clockwise. Continue to move the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench, to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). Make sure the setting notch and spring tang are still aligned after the lock nut is tighten. If not repeat the procedure.
6. Remove the wrench from the belt tensioner.
   NOTE When repositioning the crankshaft to the TDC position, this must be done during the clockwise rotation movement. If the TDC is missed, rotate a further two full turns until TDC is reached. Do not rotate the crankshaft counterclockwise as this will result in improper tensioner settings.
   
7. Rotate the crankshaft two full revolutions and verify that the TDC marks are properly aligned.
8. Check the spring tang is within the tolerance window, if not repeat the previous two steps.

To align both sets of timing marks, turn engine crankshaft to the right with belt on cam and crank. Once you have done this the crankshaft alignment mark (on front of crankshaft gear) will line up with mark to the rear of gear on engine block.The two cam gear timing marks should be alines across from one another. The right cam gear is the intake side and the left side is the exhaust side. After removing the belt turn the exhaust cam down 1/2 notch. Timing mark on exhaust 1/2 notch down from the intake side. Install new belt and recheck everything to make sure it's all correct. Hope this will help you.