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Thanks again for everyone's advice. I finished up last night, not too bad a task. Here are some thoughts, observations, etc. that I don't recall seeing during my research on this task. I thought I'd post them to hopefully help someone else.
First surprise, the serpentine bett tensioner need a 3/4" drive ratchet or breaker bar, 1/2" won't cut it. An hour spent traveling to Sears, the whopper breaker bar makes easy work of that task.
Torx fasteners are here and there. Be prepared, I was fortunately.
I did remove the fan, I recall seeing some don't and make out fine. It gave me a few inches and help keep the blood letting and profanity to a level that didn't offend the neighbors. I didn't need to disconnect it, I just laid it back over the space above the battery, if that makes sense.
The harmonic dampener really does get in the way of the t-belt tensioner bolts. Removing it is the only I can see to put a torque wrench on those bolts. An offset wrench would also be quite helpful in getting them moving. Not required, just helpful.
The crankshaft timing mark was very difficult to see. I started with only the cam marks lined up with the notches in the plastic t-belt housing. After I got the belt off I saw the marks. The crankshaft mark is small, on the side of the pulley facing the engine, on the very top of a tooth. This is to line up with a tick that is cast onto a cover plate that surrounds the crankshaft. With the belt on, you'd have to look hard to see past all the stuff.
After 5 1/2 years, the belt looked great. The tensioner I think was shot, it didn't extend at all after I removed it. Maybe it wasn't supposed to? Of the 2 pulleys, one was sounding a little bit dry, the other fine. Replaced anyway.
No leaks from cam or crank seals or from the water pump. Did not replace the water pump, I hope I don't regret that.
Putting it back together, getting the t-belt around the underside (I did this all from above) of the crankshaft caused a little consternation. There are various protrusions under there, you have to feel around. I had to orient the belt vertically to slide it in then kind of lay it back, like moving a long couch around a corner. Once set correctly, threading the t-belt on to the other pulleys was pretty easy.
Reassembly was easy. I did discover that the serpentine belt idler pulley is cooked. Bone dry bearings. Tried to clean and grease them to be assured of the next few days while I wait for parts, but it's done. The belt tensioner pulley is also on its way out. So all of them are in the mail, should be here Friday.
Finally, discovered a leak from the upper radiator hose. Will replace that Friday too.
Yes, the car did start and ran fine. I'm always a little amazed by that after I get that far into it.
Thanks again.
Scott
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