Cam Gear Installation version 1
WARNING: THIS IS NOT FOR THE FAINT AT HEART. This job has been known to make tow truck drivers rich, and cause backyard mechanics to feel the wrath of their professional counterparts.

1. Disconnect battery

2. Remove the wart of a vibration weight mounted above the front motor mount, in front of the timing cover. 17mm socket.

3. Remove 3 8mm bolts holding upper timing cover.

4. Disconnect throttle linkage at TB, remove bracket at front of head (10mm wrench), and at drivers side of head (unclip cable and bend bracket out of the way works too).

5. Pull all 4 sparkplug boots, and grommet loom off of valve cover.

6. Remove all the cam cover bolts (10mm)

7. Unplug VCT solenoid wire on top of head, near timing gears, and disconnect PCV breather.

8. Remove cam cover bolts and cover.

9. Now here's where it gets easy or hard... turn the engine over by hand (crank pulley bolt) until you can fit the cal alignment tool in the back of the cams. Once you have everything lined up, mark the location of the timing belt to exhaust pulley and crank pulley to some bolt near the pulley prior to loosening/removing cam bolt. Don't put the tool in yet, you need to loosen the cam bolt first.

10. Loosen intake cam bolt a little (T55 torx). Put a screwdriver through a pulley hole, resting on a nice chunk of metal. It is the easiest way to keep the pulley from turning while loosening... be careful not to break anything. If you have a small pair of vise grips, see if you can clamp (not too hard on the belt) the tim belt to the exh cam pulley to keep it there (1-3 o clock position is good).

11. Loosen the front bolt of the tensioner pulley. This will allow you to slide the tension lever clockwise with a screwdriver. There's a slot in a stamped steel lever behind the pulley, pry it down (clockwise).

BTW, tensioner pulley is located below intake gear.

12. With the tensioner pulley loosened, and the timing belt clamped to the exhaust gear, put the torx socket in the exhaust gear and apply pressure as if you're going to loosen it.

This should make the timing belt real loose around the intake gear. Take socket off the exhaust gear, and complete loosening the intake gear bolt.

13. Remove intake gear, and install new gear (make sure degreed settings are at zero, and the 6mm Allen bolts on the gear are tight). Put bolt on loosely. Slip belt over new gear.

14. Fit the cam timing tool into the back of the cams. Remove vise grip from timing belt/exhaust gear.

15. With the belt on, and the crank and exhaust timing marks all lined up, and the cam timing tool in back of the cams, re-tighten the the tensioner by moving the lever back to it's original position and tightening the bolt. It should take up the belt slack. Make sure the timing belt has no slack between the intake and exhaust gears. If all looks good, tighten the intake bolt snug (slight torque, any more might break the cam slot or timing tool).

16. Remove the cam timing tool, tighten the intake bolt a little more, and then

17. Rotate the motor clockwise two full crankshaft revolutions (via crank timing mark), and try to re-install cam timing tool in the back of the cams with the crank timing mark lined up once more.

18. If everything fits, you're ready to tighten cam bolt (take that tool out again), and button it up. If not, well...

19. Line up crank timing mark, and see which cam is not fitting into the cam tool. If it's the exhaust and intake cam, there's too much belt between crank and exh gear, you'll need to pull the belt off and refit between crank and cams. If it's just the intake cam, then loosen bolt to intake gear and rotate cam (channel locks on the cam works good - not the machined surfaces though) until it also fits into slot, then retighten intake gear bolt.