As expected, I'm very sore today. Huge respect to mechanics that do this on a daily basis. Anyhow, here are some notes from the yesterday's adventure.
1. As many suggested, I've started off by breaking the crank bolt loose. Very uneventful, two hits with the Milwaukee high torque impact paired with Leslie socket - and it was free.
2. Disassembly was pretty straightforward, up until I got to the last bolt holding the lower timing cover (the one that sits behind the drive belt tensioner). No matter what I tried, I couldn't get it off so ended up removing the tensioner. I didn't have the swiveling 10 mm socket, which would definitely help. Wasted an hour or so just on one bolt.
3. Setting the timing wasn't too hard, but I spent excessive amount of time verifying the marks. Marking the old belt, counting the teeth and transferring the marks on the new belt was super helpful. I've initially installed the belt (what I thought looked good), but then sure enough rear cam was one tooth off. Traced the belt back and sure enough it wasn't seated properly. Once re-seated, all marks on the belt lined up perfectly. For someone who's doing the timing job for the first time this method is a must.
4. As expected, timing belt tensioner was leaking. Timing belt itself looked perfect with no cracks or signs of major degradation (it could probably go another 100k).
5. Once all timing components were re-installed, pulled the pin and spun the crank twice with cam marks lining up.
6. Putting the rest back together wasn't too bad, up until I got to the drive belt tensioner and belt itself. Getting that belt on was a nightmare. Spent at least an hour trying to get it on. Anyhow, got it on, put the rest back on. Torqued the crank bolt to 46 ft-lb, and then added a couple of light hits with the impact and called it good.
7. Refilled the radiator with 1.6 gal of Zerex Blue, started up, heat to the max and let it idle and burp the air. Squeeze the hose, ran for 15-20 minutes till no more air was seeing in the coolant bowl I've used. Took the car for a spin, cleaned up the mess. Wanted to do the spark plugs as well, but was too tired...will change them later this week.
Total time was 12 hrs (8 am - 8 pm), with one hour for a work related call and 30 min lunch. My buddy's ridgline is next (he stopped by to help but ended up changing the spark plugs in his truck and leaving) and I hope it will take less time now that I have some experience (or idea I should say) doing it.
The lowlight, looks my front driver shock is done and leaking, so that will need to be addressed sooner rather than later. If anyone has a suggestion on solid aftermarket option, please let me know.
Below are some pics of original timing components and water pump.
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