I finally replaced the timing belt and water pump. I read online of people getting over 200,000 miles on a timing belt in these engines, but for me, when I pass the recommended interval, I feel like I'm pulling the pin on a grenade every time I turn the key. The last thing I need is to be towing a trailer or worse yet, have my wife driving when the timing belt gives out.
Not a hard job, but lots of bolts to turn and parts to pull off. There's plenty of good internet documentation and I easily found a .pdf from the factory manual detailing the job. I still managed to get to the part where the crank pulley comes off without noticing that I would need a special tool. This is not the time to order tools online or drive around for a few hours to find one. It is a 'What am I going to do to get this off Right Now' time. Two minutes of internet told me that this happens to almost everyone and the sure-fire method is to brace a breaker bar against the frame and crank the starter with the spark plugs disconnected. It worked so well I wondered why anyone would consider buying a $40 - $90 tool.
With everything on the front of the engine removed, the water pump and timing belt went on easily. I really liked how the belt came with labeled lines to match up with a mark on the cam gears and crank. No tooth counting or cam locking. Just make sure it is lined up and bolt it all back down.
All was smooth and easy until it was time to put the crank pulley back on and torque it to 245 Nm/181 ft. A quick review of the forums impressed me that the correct torque is important. Guessing the Ugga Duggas with an impact wrench may cause failure in the future. The starter trick does not work for tightening the bolt. The pulley would have to be braced against 245 Nm of force. I saw a variety of solutions. Chains or ratchet straps holding it to one side were sworn by, but sounded pretty sketchy. One guy made a functioning 'holder' with a 2x4 and two bolts. Others had fabbed a brace with metal bars. I looked around my junk pile and found some metal scraps - a chassis brace from a Boxster and a short piece of angle iron. It went together well and was just long enough to brace against the frame while I torqued the bolt.
I wish I could tell you that I got out my torque wrench and turned it to 245/181, but my sad old collection of torque wrenches only does up to 150 lbs Tq. I needed oil and a filter anyway, so while I was out, I stopped at Harbor Freight, thinking I could grab a ~$20 wrench. Nope, it's well over $100 to get up to 245 Nm. I did grab a Quinn digital torque adapter for $30 and about $100 of other probably useful stuff, but ended up balancing my 190 lb body on one foot, standing about 12" out on a breaker bar. My wrenches all agreed that it was over 150 lbs of torque. Good enough for a 222,000+ mile truck (I hope).
All in all, it seems a success. No extra parts, nuts, or bolts left when I was done and I even added in a bolt for one that was missing from the AC compressor. I'm planning to just drive it for a while now, but the next maintenance will probably be the brakes. A good flush of the fluid and replacing pads and rotors. I may go ahead an upgrade to larger calipers then as well.