Bandas de Tiempo

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Table of Contents
Timing Component Kits . . . . . . . . . . . . . . . I-IV
Alphabetical/Application Listings
with recommended replacement
intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
Changeover Listing . . . . . . . . . . . . . . . . . . A-43
Manuf acturers Part Numbers . . . . . . . . . A-54
Troubleshooting Guide . . . . . . . . . . . . . . . A-56
Overhead Valve Engine Identif ication . . A-58
Interf erence Engine Inf ormation . . . . . . . A-59
Belt Tensioning . . . . . . . . . . . . . . . . . . . . . .A-60
Replacement Instructions . . . . . . . . . . . . . . . . 1
Limited Warranty for the Life of the Merchandise
M erchandise is w arranted to be free from defects in m aterials or w orkm anship for the life of the m erchandise. Dam ages from m isuse, abuse or gradual w ear
from norm al use are excluded from this w arranty. NAPA Belts/Hose (The G ates Rubber Com pany) w ill, at its option, replace or repair any m erchandise proved
defective in m aterial or w orkm anship,or both, during the w arranty period. This is the exclusive rem edy. For w arranty service, please contact the Service
Departm ent, The NAPA Belts/Hose (G ates Rubber Com pany), 990 South Broadw ay, Denver, Colorado 80209. THERE IS NO O THER EXPRESSED W ARRANTY.
IM PLIED W ARRANTIES, INCLUDING THO SE O F M ERCHANTABILITY AND FITNESS FO R A PARTICULAR PURPO SE, ARE LIM ITED TO THE EXPRESSED W ARRA N-
TY PERIO D. LIABILITY FO R CO NSEQ UENTIAL O R INCIDENTAL DAM AG ES UNDER ANY AND ALL W ARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSIO N
IS PERM ITTED BY LAW .
Som e states do not allow the exclusion of lim itation or incidental or consequential dam ages, and som e states do not allow lim itations on how long an
im plied w arranty lasts, so the above lim itation and exclusion m ay not apply to you. This w arranty gives you specific legal rights and you m ay also have other
rights w hich vary from state to state.
DISCLAIMER OF WARRANTIES
A lthough the inform ation contained w ithin this volum e has been obtained from sources generally believed to be reliable, no w arranty (expressed or
im plied) can be m ade as to its accuracy or com pleteness, nor is any responsibility assum ed by M itchell Repair Inform ation C om pany or anyone con-
nected w ith it, for loss or dam ages suffered through reliance on any inform ation contained in this volum e.
SPEC IFIC A LLY, N O W A RRA N TY O F M ERC H A N TA BILITY, FITN ESS FO R A PA RTIC U LA R PU RPO SE O R A N Y O TH ER W A RRA N TY IS M A D E O R TO BE
IM PLIED W ITH RESPEC T TO TH IS VO LU M E A N D ITS C O N TEN TS.
In no event w ill M itchell Repair Inform ation C om pany be liable for any dam ages, direct or indirect, consequential or com pensatory, including, w ith-
out lim itation, lost profits, for any representations, breaches or defaults arising out of the use of this volum e. C ustom er agrees to indem nify
M itchell Repair Inform ation C om pany and hold it harm less against all claim s and dam ages, including w ithout lim itation, reasonable attorneys fees
arising out of the use of this volum e, unless such claim s or dam ages result from the infringem ent of any copyright or other proprietary right of any
third party.
Q uestions regarding installation instructions or interference engine applications should be addressed to M itchell
Repair Inform ation C om panys Tech Line at 888-724-6742 extension 6112.
Prepared Expressly for N A PA Belts/H ose by M itchell Repair Inform ation C om pany
C opyright 2002 M ITC H ELL REPA IR IN FO RM ATIO N C O M PA N Y, LLC
A ll Right Reserved
Printed in the U .S. of A m erica
WARNING
Be safe! D o not use N A PA
Belts/H ose (G ates) belts, pulleys
or sprockets on any aircraft pro-
peller or rotor drive system s or
in-flight accessory drives. Those
N A PA Belts/H ose (G ates) prod-
ucts are not designed or intend-
ed for aircraft use.
CAUTION
U se N A PA Belts/H ose (G ates)
products only on applications
specified in N A PA Belts/H ose
(G ates) literature. Install and
m aintain products according to
the vehicle m anufacturer's rec-
om m ended procedures and w ith
recom m ended tools. Failure to
follow these instructions could
result in injury or property dam -
age. N A PA Belts/H ose (G ates)
disclaim s all liability due to fail-
ure to follow these instructions.
I
NEW! Timing Component Kits
Do the complete job
and reduce your
warranty returns!
Why Replace Timing Belt Drive Components?
W orn idlers and tensioners dam age new tim -
ing belts resulting in costly w arranty returns.
Idler and tensioner w ear, how ever, is difficult
to detect. Bearing w ear, grease degradation
due to increased underhood tem peratures,
seal erosion and tensioner plate seizure all
reduce com ponent life. In som e cases, the
lifespan of the belt tensioner or idler m ay
already be exceeded by the tim e the belt is
due for replacem ent.
The cost of a labor claim associated w ith a
tim ing belt system failure on an interference
engine can be over $1,000 w hen valves are
bent and pistons are dam aged.
W hy take a chance? Avoid the w arranties
and com ebacks by replacing critical system
com ponents.
NAPA Timing
Component Kits Are
The Perfect Solution
W ith N A PAs new Tim ing C om ponent Kits,
you dont have to shop for m ore com ponents,
buy from m ultiple sources or hassle w ith
returning com ponents that dont fit. N A PA
Tim ing C om ponent Kits provide a com plete
system replacem ent solution, so you can do a
com plete tim ing belt system replacem ent right
the first tim e, every tim e. The benefits dont
stop there. You also get
Reduced Labor Claims
and Comebacks
By replacing all the tim ing belt system
com ponents, service technicians w ill
reduce costly labor claim s and com ebacks.
Greater Convenience Elim inate the
frustration of lim ited afterm arket availability
of com ponents. Kits contain the exact com po-
nents needed for the m ost popular and critical
belt replacem ent jobs.
Ease of Parts Sourcing
You save tim e w ith kits that contain all the
N A PA parts needed to do the joball under
a single part num ber.
Save Your Customers Money
By replacing the idler, tensioner and belt at
the sam e tim e, you save your custom ers
extra labor charges.
Detailed Installation
Instructions
N A PA Tim ing C om ponent Kits are unique
in the m arket. Each kit contains a com plete
replacem ent solution, plus detailed installation
instructions specific to each application,
so theres no guessw ork required to
get the right fit.
II
III
OE Quality
Components
In Each Kit
N A PA Tim ing C om ponent
Kits are built w ith quality
you can depend on.
Tam per-evident packaging
assures you that all the
parts you need are in
each box.
N A PA tim ing belts are
m anufactured to the
toughest specifications,
assuring custom ers a
replacem ent belt to m atch the capa-
bilities of the original belt. N A PA tim ing belts
have positioning m arks to m ake installation
fast and easy. You w ont find that w ith m any
com petitive belts, w hich require you to count
individual teeth to correctly position belts.
More Support From
NAPA Belts/Hose
N A PAs Tim ing Belt Replacem ent M anual
contains all the inform ation needed for any
car or light truck tim ing belt installation.
O ver 400 illustrated pages of detailed instruc-
tions. C overs dom estic and im ported vehicles
1970 and new er. N A PA replacem ent belts
are listed w ith each application. Includes
average technician labor tim eas w ell.
IV
Tooth profiles arent
interchangeable
The earliest tim ing belts had a trapezoidal pro-
file. Com petition and m ore dem anding applica-
tions led to the developm ent of a curvilinear
profile. This, in turn, evolved to a m odified
curvilinear profile. Belts w ith different tooth pro-
files are not interchangeable.
NAPAs com plete line of m ore than 250 tim ing
belt num bers continues to grow and set the
industry standard. O ur tim ing belts include the
popular tooth profiles pictured at right.
Dont be mislead by
initial cost
The cost of the belt is only 5 10 percent of
the cost of replacem ent. C hanging any tim ing
belt can be labor intensive and costly. In the
case of interference engines*, the repair bill
for a failed tim ing belt can be up to 10 tim es
the cost of replacing the belt.
NAPA first to use HSN
N eoprene, an excellent m aterial in its ow n
right, w as standard until 1985, w hen G ates
introduced the first belts m ade of highly-satu-
rated nitrile (H SN ). In short supply, and diffi-
cult to engineer, H SN is the m aterial of choice
for m ost new engine tim ing belts. A n
H SN -constructed belt appears no different
than a neoprene belt, but significantly outper-
form s in the high-tem perature engine com -
partm ents of m odern vehicles.
HSN belts are worth
the price
They cost m ore than neoprene belts, but theyre
a sm all percentage of the total cost of replacing
a belt and theyre absolutely necessary for
acceptable service life. The fact is, theyre
w orth every penny. Todays engines require
high-perform ance belts. Thats w hy car m anu-
facturers use HSN in so m any new engines.
NOTE: Trapezoidal, curvilinear and modified
curvilinear tooth profiles will not interchange,
and a neoprene belt will not replace HSN
(Highly Saturated Nitrile). Replacing a high
performance timing belt with a non-OE
equivalent belt may severely shorten the
belt life. NAPA offers OE equivalency in
timing belt replacements.
Many engines from other countries use
different timing belts and sprockets than
like engines designed for the North American
market. While these engines may look identical
and fit exactly the same in similar vehicles, the
belts may be vastly different. Please take spe-
cial care to look for these differences if you
suspect your engine may have been replaced
with an imported engine.
Trapezoidal
Curvilinear
Modif ied Curvilinear
Easy installation
every time
N A PA tim ing belts
have positioning
m arks to m ake
installation fast
and easy. You
w ont find that
w ith m any com -
petitive belts,
w hich require you
to count individual
teeth to correctly
position the belt.
*In interference engines, the valves and the piston m ay contact
each other if the tim ing is not set correctly.
ACURA
Passenger Cars
EL (Canadian)
1997-00 1.6L 4-Cyl. 250224 Yes Yes

105,000
3
1
Integra
1986-89 1.6L 4-Cyl. 250130 Yes Yes 60,000
1
4
1992-93 1.7L 4-Cyl. 250227 Yes Yes 90,000 5
1990-94 1.8L 4-Cyl. (Exc. VTEC) 250184 Yes Yes 90,000 7
1995-96 1.8L 4-Cyl. (Exc. VTEC) 250184 Yes Yes 90,000 Normal
60,000 Severe 7
1997-01 1.8L 4-Cyl. (Exc. VTEC) 250184 Yes Yes

105,000
3
7
1991-94 1.8L 4-Cyl. (VTEC) 250247 Yes Yes 90,000 7
1995-96 1.8L 4-Cyl. (VTEC) 250247 Yes Yes 90,000 Normal
60,000 Severe 7
1997-01 1.8L 4-Cyl. (VTEC) 250247 Yes Yes

105,000
3
7
Legend
1986-87 2.5L V6 250129 Yes Yes 60,000
1
13
1988-89 2.7L V6 250129 Yes Yes 60,000
1
13
1990 2.7L V6 250129 Yes Yes 90,000 13
1991-94 3.2L V6 (C32A1) 250193 Yes Yes 90,000 19
1995 3.2L V6 (C32A1) 250193 Yes Yes 90,000 Normal 19
60,000 Severe 19
MDX
2001 3.5L V6 (J35A3) 250286 Yes Yes

105,000
3
15
Vigor
1992-94 2.5L 5-Cyl. 250211 Yes Yes 90,000 11
2.2CL
1997 2.2L 4-Cyl.
Balance Shaft 250186 Yes Yes

90,000 Normal
2
9
60,000 Severe 9
Camshaft 250244 Yes Yes

90,000 Normal
2
60,000 Severe 9
2.3CL
1999-98 2.3L 4-Cyl.

105,000
3
9

105,000
3
9
2.5TL
1995-96 2.5L 5-Cyl. 250211 Yes Yes 90,000 Normal 11
60,000 Severe 11
1997-98 2.5L 5-Cyl. 250211 Yes Yes

105,000
3
11
3.0CL
1997-99 3.0L V6 (J30A1) 250286 Yes Yes

105,000
3
15
3.2CL
2001 3.2L V6 (J32A1/A2) 250286 Yes Yes

105,000
3
15
3.2TL
1996 3.2L V6 (C32A6) 250193 Yes Yes 90,000 Normal 19
60,000 Severe 19
1997-98 3.2L V6 (C32A6) 250193 Yes Yes

105,000
3
19
1999-01 3.2L V6 (J32A1) 250286 Yes Yes

105,000
3
15
3.5RL
1996 3.5L V6 (C35A1)

90,000 Normal
2
22
60,000 Severe 22

90,000 Normal
2
22
60,000 Severe 22
ALPHABETICAL MODEL LISTING
A-1
Make Timing Belt Recommended
Model/ Belt Component Interference Driven Water Replacement
Year Engine Part No. Kit Part No. Engine* Pump Interval (Miles) Page
* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-59 for
interference engine cautions.
1
- Although the vehicle manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals.
2
- The vehicle manufacturer recommends replacing all belts at the same time.
3
- See timing belt repair procedure for more information on belt replacement interval.
ALPHABETICAL MODEL LISTING (Cont.)
A-2
* - Other interference engine applications may exist which are not indicated here. See page A-59 for
1
2
3
3.5RL (Cont.)
1997-01 3.5L V6

105,000
3
22

105,000
3
22
Light Trucks
SLX
1996-97 3.2L V6 (SOHC) 250221 Yes 60,000 28
1999-98 3.5L V6 (DOHC) 250303 Yes 75,000 26
ALFA ROMEO
164L, LS & S
1991-93 3.0L V6 250120 50,000 30
AMERICAN MOTORS
Concord
1978-79 2.0L 4-Cyl. 250017

2520170

60,000
1
32
Gremlin
1977-78 2.0L 4-Cyl. 250017

2520170

60,000
1
32
Spirit
1979 2.0L 4-Cyl. 250017

2520170

60,000
1
32
ASUNA
Passenger Cars
Sunfire (Canadian)
1993 1.8L 4-Cyl. 250205 Yes 60,000 209
Light Trucks
Sunrunner (Canadian)
1989-95 1.6L 4-Cyl. (8-Valve)
California 250212 60,000 215
Except California 250164 60,000 215
1994-98 1.6L 4-Cyl. (16-Valve)
California 250212 60,000 217
1999-01 1.6L 4-Cyl. (16-Valve) 250212 60,000 217
AUDI
Allroad
2000 2.7L V6 DOHC 250297 Yes Yes 105,000 57
A4
1997-99 1.8L 4-Cyl. Turbo 250291 Yes 90,000 38
1996 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
1997 2.8L V6, 12-Valve 250218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve 250297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve 250297 Yes Yes 75,000 64
A4 Quattro
1997-99 1.8L 4-Cyl. Turbo 250291 Yes 90,000 38
1996 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
1997 2.8L V6, 12-Valve 250218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve 250297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve 250297 Yes Yes 75,000 64
2000 2.7L V6 DOHC 250297 Yes Yes 105,000 57
A6
1995-96 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
1997 2.8L V6, 12-Valve 250218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve 250297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve 250297 Yes Yes 75,000 64
2000 2.8L V6, 30-Valve 250297 Yes Yes 105,000 64
ACURA (Cont.)
A-3
1
2
3
A6 Quattro & Quattro Turbo
1995-96 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
1997 2.8L V6, 12-Valve 250218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve 250297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve 250297 Yes Yes 75,000 64
2000 2.8L V6, 30-Valve 250297 Yes Yes 105,000 64
A8
1997-98 3.7L V8 (AEW) 250207 Yes Yes 90,000 72
1999 3.7L V8 (AEW) 250207 Yes Yes 75,000 72
A8 Quattro
1997-98 3.7L V8 (AEW) 250207 Yes Yes 90,000 72
1999 3.7L V8 (AEW) 250207 Yes Yes 75,000 72
2000 4.2L V8 (AKB, AUX & AYS) 250297 Yes Yes 105,000 76
Cabriolet
1994-96 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
1997-98 2.8L V6, 12-Valve 250218 Yes Yes 90,000 62
Coupe
1981-83 2.2L 5-Cyl. 250065 Yes 60,000
1
79
1984-85 2.2L 5-Cyl.
113 Tooth Belt 250065 Yes 60,000
1
79
120 Tooth Belt 250127 Yes 60,000
1
79
Coupe GT
1986-87 2.2L 5-Cyl. 250127 Yes 60,000
1
79
Coupe Quattro
1990-91 2.3L 5-Cyl. 250197 Yes 60,000
1
47
Fox
1973-79 1.6L 4-Cyl 250017 2520170 Yes 60,000
1
34
Quattro
1983 2.2L 5-Cyl. 250065 Yes 60,000
1
79
1984-85 2.2L 5-Cyl.
113 Tooth Belt 250065 Yes 60,000
1
79
120 Tooth Belt 250127 Yes 60,000
1
79
S4 Quattro
2001 2.7L V6 DOHC 250297 Yes Yes 105,000 53
S4 Sedan
1992-94 2.2L 5-Cyl. Turbo 250225 Yes 60,000
1
49
S6
1995 2.2L 5-Cyl. Turbo 250225 Yes 60,000
1
49
S6 Quattro
1995 2.2L 5-Cyl. Turbo 250225 Yes 60,000
1
49
TT Coupe
& Roadster 1.8L 4-Cyl. Turbo 250306 Yes Yes 120,000 40
V8 Quattro
1990-91 3.6L V8 (PT Engine) 250207 Yes 60,000 67
1992-94 4.2L V8 (ABH Engine) 250207 Yes 90,000 67
80
1988-90 2.0L 4-Cyl. 250017 2520170

60,000
1
43
1991-92 2.3L 5-Cyl. 250170 Yes 60,000
1
51
80 Quattro
1988 2.3L 5-Cyl. 250127 Yes 60,000
1
51
90
1988-90 2.0L 4-Cyl. 250017 2520170

60,000
1
43
1988 2.3L 5-Cyl. 250127 Yes 60,000
1
51
AUDI (Cont.)
A-4
1
2
3
AUDI (Cont.)
90 (Cont.)
1989 2.3L 5-Cyl.
Up To Chas. 89J396702 250127 Yes 60,000
1
51
From Chas. 89J396703 250170 Yes 60,000
1
51
1990-91 2.3L 5-Cyl. 250170 Yes 60,000
1
51
1993-95 2.8L V6, 12-Valve 250218 Yes Yes 60,000
1
62
90 Quattro
1988 2.3L 5-Cyl. 250127 Yes 60,000
1
51
1989 2.3L 5-Cyl.
Up To Chas. 89J394742 250127 Yes 60,000
1
51
From Chas. 89J394743 250170 Yes 60,000
1
51
1990-92 2.3L 5-Cyl. 250170 Yes 60,000
1
51
1993-95 2.8L V6 (12-Valve) 250218 Yes Yes 60,000
1
62
100
1988-91 2.3L 5-Cyl.
Thru Chas. 063969 250127 Yes 60,000
1
51
From Chas. 063970 250170 Yes 60,000
1
51
1990-91 2.3L 5-Cyl. 250170 Yes 60,000
1
51
1992-94 2.8L V6 (12-Valve) 250218 Yes Yes 60,000
1
62
100 Quattro
1988-91 2.3L 5-Cyl.
Thru Chas. 063969 250127 Yes 60,000
1
51
From Chas. 063970 250170 Yes 60,000
1
51
1990-91 2.3L 5-Cyl. 250170 Yes 60,000
1
51
1992-94 2.8L V6 (12-Valve) 250218 Yes Yes 60,000
1
62
200
1989 2.2L 5-Cyl.
Up To Chas. 44K400000 250127 Yes 60,000
1
79
1989 2.2L 5-Cyl.
From Chas. 44K400001 250170 Yes 60,000
1
79
1990-91 2.2L 5-Cyl. 250170 Yes 60,000
1
79
200 Quattro
1989 2.2L 5-Cyl.
Thru Chas. 44K004457 250127 Yes 60,000
1
79
From Chas. 44K004458 250170 Yes 60,000
1
79
1990-91 2.2L 5-Cyl. 250170 Yes 60,000
1
79
4000
1980-83 1.7L 4-Cyl. 250017

2520170 Yes 60,000
1
34
1982-83 1.6L 4-Cyl. Diesel 250043 60,000
1
33
1980-81 2.2L 5-Cyl. 250065 Yes 60,000
1
79
4000CS
1986-87 2.2L 5-Cyl. 250127 Yes 60,000
1
79
4000CS Quattro
1987 2.2L 5-Cyl. 250127 Yes 60,000
1
79
4000S
1984-87 1.8L 4-Cyl. 250017

2520170 Yes 60,000
1
36
4000S Quattro
1984-85 2.2L 5-Cyl.
113 Tooth Belt 250065 Yes 60,000
1
79
120 Tooth Belt 250127 Yes 60,000
1
79
1986 2.2L 5-Cyl. 250127 Yes 60,000
1
79
A-5
1
2
3
5000
1979-83 2.0L 5-Cyl. Diesel
Camshaft 250083 Yes Yes 60,000
1, 2
45
Injection Pump 250082 Yes Yes 60,000
1, 2
45
1979-83 2.0L 5-Cyl.Turbo Diesel
1, 2
45
1, 2
45
1978-83 2.2L 5-Cyl. Turbo 250065 Yes 60,000
1
79
5000 Quattro
1988 2.3L 5-Cyl. 250127 Yes 60,000
1
51
5000CS Quattro
1987-88 2.2L 5-Cyl. 250127 Yes 60,000
1
79
5000S
1987-88 2.3L 5-Cyl. 250127 Yes 60,000
1
51
1984-85 2.2L 5-Cyl.
113 Tooth Belt 250065 Yes 60,000
1
79
120 Tooth Belt 250127 Yes 60,000
1
79
1986-87 2.2L 5-Cyl. 250127 Yes 60,000
1
79
BMW
325 Series
1987-88 2.5L 6-Cyl.
127 Tooth Belt 250131 Yes 60,000 81
128 Tooth Belt 250106 Yes 60,000 81
1989-91 2.5L 6-Cyl. 250131 Yes 60,000 81
1984-88 2.7L 6-Cyl.
127 Tooth Belt 250131 Yes 60,000 81
128 Tooth Belt 250106 Yes 60,000 81
525i
1989-95 2.5L 6-Cyl. 250131 Yes 60,000 81
528e
1982-88 2.7L 6-Cyl.
127 Tooth Belt 250131 Yes 60,000 81
128 Tooth Belt 250106 Yes 60,000 81
BUICK
Skyhawk
1982-86 1.8L 4-Cyl. 250081 Yes 60,000
1
228
1987-88 2.0L 4-Cyl. 250081 Yes 60,000
1
229
CADILLAC
Catera
1997-01 3.0L V6 (DOHC) 250285 Yes Yes 100,000 231
CHEVROLET
Passenger Cars
Chevette
1976 1.4L 4-Cyl. 250037 60,000
1
221
1977 1.4L 4-Cyl. 250039 60,000
1
221
1976 1.6L 4-Cyl. 250037 60,000
1
221
1977-78 1.6L 4-Cyl. 250039 60,000
1
221
1979-87 1.6L 4-Cyl. 250061 60,000
1
221
1981-86 1.8L 4-Cyl. Diesel 250076 Yes 60,000
1
226
Lumina (Exc. Van)
1991-95 3.4L V6 250192 Yes Yes 60,000 238
1996-97 3.4L V6 250273 Yes Yes 60,000 238
AUDI (Cont.)
A-6
1
2
3
Metro
1989-00 1.0L 3-Cyl. 250194 2521941

100,000 211
1998-01 1.3L 4-Cyl. 250194 2521941

100,000 213
Monte Carlo
1995 3.4L V6 250192 Yes Yes 60,000 238
1996-97 3.4L V6 250273 Yes Yes 60,000 238
Nova
1988 1.6L 4-Cyl. (DOHC) 250112 60,000
1
224
1985-88 1.6L 4-Cyl. (SOHC) 250070

2520700

60,000
1
224
Spectrum
1985-87 1.5L 4-Cyl
Up To 4/30/87 250118 Yes Yes 60,000 219
From 5/1/87 250162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. 250162 Yes Yes 60,000 219
Sprint
1985-88 1.0L 3-Cyl. 250095 60,000 211
1989-91 1.0L 3-Cyl. 250166 60,000 211
CHEVROLET/G.M.C.
Light Trucks
LUV
1981-82 2.2L 4-Cyl. Diesel 250075 Yes 60,000 323
S10 & S15 Pickups
1983-85 2.2L 4-Cyl. Diesel 250075 Yes 60,000 323
Tracker
1998 1.6L 4-Cyl. (16-Valve)
California 250212 60,000 217
1999-01 1.6L 4-Cyl. (16-Valve) 250212 60,000 217
CHRYSLER
Cirrus
2000 2.0L 4-Cyl. (SOHC, VIN C) 250245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
1995-99 2.4L 4-Cyl. (DOHC, VIN X) 250265 Yes 105,000 106
2000 2.4L 4-Cyl. (DOHC, VIN X) 250265 Yes 100,000 Federal 106
105,000 California 106
1995-00 2.5L V6 250259 Yes Yes

60,000
3
108
Concorde
1998-99 3.2L V6 250295 Yes Yes 105,000 123
2000 3.2L V6 250295 Yes Yes 100,000 Federal 123
1993-94 3.5L V6 250219 Yes 105,000 123
1995-97 3.5L V6 250255 Yes 105,000 123
2000 3.5LV6 250295 Yes 100,000 Federal 123
E Class
1983-84 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Executive Limo (Canadian)
1986 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Intrepid (Canadian)
1998-99 3.2L V6 250295 Yes Yes 105,000 123
1993-94 3.5L V6 250219 Yes 105,000 123
1995-97 3.5L V6 250255 Yes 105,000 123
CHEVROLET (Cont.)
A-7
1
2
3
Laser
1984-86 2.2L 4-Cyl. 250071

2520710

60,000
1
101
1986 2.5L 4-Cyl. 250114 60,000
1
101
LeBaron & LeBaron GTS
1982-88 2.2L 4-Cyl. 250071

2520710

60,000
1
101
1989-90 2.2L 4-Cyl. 250153

2521530

60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989-94 2.5L 4-Cyl. 250153

2521530

60,000
1
101
1990-93 3.0L V6 (SOHC) 250139

2521390

60,000 110
1994-95 3.0L V6 (SOHC) 250139

2521390

60,000
1
110
LHS
1994 3.5L V6 250219 Yes 105,000 123
1995-97 3.5L V6 250255 Yes 105,000 123
1998-99 3.5LV6 250295 Yes 105,000 123
2000 3.5LV6 250295 Yes 100,000 Federal 123
New Yorker
1983-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1988-89 3.0L V6 (SOHC) 250139

2521390 60,000 110
1994 3.5L V6 250219 Yes 105,000 123
1995-96 3.5L V6 250255 Yes 105,000 123
Sebring Coupe
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 250246 Yes Yes 60,000
3
133
1995-00 2.5L V6 250259 Yes Yes 60,000
3
108
Sebring Convertible
1997-00 2.5L V6 250259 Yes Yes 60,000
3
108
TC
1990 2.2L 4-Cyl. (DOHC, VIN R) 250153

2521530 60,000
1
98
1990-91 3.0L V6 (SOHC) 250139

2521390

60,000 110
Town & Country
1982-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
300M
1998-99 3.5LV6 250295 Yes 105,000 123
2000 3.5LV6 250295 Yes 100,000 Federal 123
DAEWOO
Laganza
1999-01 2.2L 4-Cyl. (DOHC) 250305 Yes Yes 72,000 Federal 150

102,000 Federal
3
150
Lanos

102,000 Federal
3
145
Nubira

102,000 Federal
3
148
CHRYSLER (Cont.)
A-8
1
2
3
Optima (Canadian)
1988-91 1.6L 4-Cyl. 250081 Yes 60,000
1
147
1988-89 2.0L 4-Cyl. 250081 Yes 60,000
1
147
1990-91 2.0L 4-Cyl. 250163 2521630 Yes 60,000
1
147
DAIHATSU
Passenger Cars
Charade
1988-92 1.0L 3-Cyl. 250178 Yes 60,000 152
1988-92 1.3L 4-Cyl. 250181 Yes 60,000 154
Light Trucks
Rocky
1990-92 1.6L 4-Cyl. 250182 Yes 60,000 154
DATSUN (SEE NISSAN)
DODGE
Passenger Cars
Aries
1981-88 2.2L 4-Cyl. 250071 2520710 60,000
1
101
1989 2.2L 4-Cyl. 250153 2521530 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989 2.5L 4-Cyl. 250153

2521530 60,000
1
101
Avenger
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 250246 Yes Yes 60,000
3
133
1995-00 2.5L V6 250259 Yes Yes 60,000
3
108
Challenger
1978-79 (RWD) 1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1978-79 1.6L 4-Cyl.
Balance Shaft 250062

60,000
2
85
Camshaft 250013 60,000
2
85
Charger
1983 1.7L 4-Cyl 250017

2520170 60,000
1
89
1983-87 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Colt
1979-84 1.4L 4-Cyl. 250073 Yes 60,000 83
1985-86 1.5L 4-Cyl. 250073 Yes 60,000 114
1987-90 1.5L 4-Cyl. 250128

2521280 Yes 60,000 114
1991-94 1.5L 4-Cyl. 250191

2521910 60,000 114
1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1983-89 1.6L 4-Cyl. w/o Bal. Shaft 250093 60,000 87
1977-80 1.6L 4-Cyl.
Balance Shaft 250062 60,000
2
85
Camshaft 250013 60,000
2
85
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
1989-90 1.8L 4-Cyl. (VIN T) 250093 60,000 91
1992-94 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
Colt (Canadian)
1985-86 1.5L 4-Cyl. 250073 Yes 60,000 114
1989-91 1.5L 4-Cyl. 250128

2521280 Yes 60,000 114
1992 & 1995 1.5L 4-Cyl. 250191

2521910 60,000 114
DAEWOO (Cont.)
A-9
1
2
3
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
1984-86 2.0L 4-Cyl. (SOHC)
2
121
Camshaft 250089 60,000
2
121
1987-91 2.0L 4-Cyl. (SOHC)

2521581 60,000
2
121
Camshaft 250158

2521581 60,000
2
121
1992 2.4L 4-Cyl.
2
136
Camshaft 250204 60,000
2
136
1993 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
1994 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
Colt Wagon (Includes Canadian)
1989-90 1.8L 4-Cyl. (VIN T) 250093 60,000 91
1992 2.4L 4-Cyl.
2
136
Camshaft 250204 60,000
2
136
1993 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
1994 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
Colt 100 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
Colt 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
Daytona & Daytona Shelby
1984-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989-93 2.2L 4-Cyl. 250153

2521530 60,000
1
101
1992-93 2.2L 4-Cyl. (DOHC, VIN A) 250206 60,000
1
96
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989-93 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1990-93 3.0L V6 (SOHC) 250139

2521390 60,000 110
Dynasty
1989-93 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1988-93 3.0L V6 (SOHC) 250139 2521390 60,000 110
Expo (Canadian)
1987-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989 2.2L 4-Cyl. 250153

2521530 60,000
1
101
Intrepid
1998-99 3.2L V6 250295 Yes Yes 105,000 123
1993-94 3.5L V6 250219 105,000 123
1995-97 3.5L V6 250255 105,000 123
2000 3.5L V6 250295 100,000 Federal 123
DODGE (Cont.)
A-10
1
2
3
Lancer
1985-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989 2.2L 4-Cyl. 250153

2521530 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989 2.5L 4-Cyl. 250153

2521530 60,000
1
101
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 250246 Yes Yes 105,000 133
1995-00 2.0L 4-Cyl. (SOHC, VIN C) 250245 Yes Yes 105,000 93
Omni
1978-83 1.7L 4-Cyl. 250017

2520170 60,000
1
89
1981-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989-90 2.2L 4-Cyl. 250153

2521530

60,000
1
101
Rampage
1982-84 2.2L 4-Cyl. 250071

2520710

60,000
1
101
Shadow
1987-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989-94 2.2L 4-Cyl. 250153

2521530 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989-94 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1992-93 3.0L V6 (SOHC) 250139

2521390 60,000 110
1994 3.0L V6 (SOHC) 250139

2521390 60,000
3
110
Spirit
1991-92 2.2L 4-Cyl. (DOHC, VIN A) 250206 60,000
1
96
1989-95 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1989-93 3.0L V6 (SOHC) 250139

2521390 Yes 60,000 110
1994-95 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
Stealth
1991-96 3.0L V6 (DOHC) 250195 Yes Yes 60,000
3
142
1991-93 3.0L V6 (SOHC) 250139

2521390 60,000 110
1994-96 3.0L V6 (SOHC) 250139

2521390 60,000
3
110
Stratus
2000 2.0L 4-Cyl. (SOHC, VIN C) 250245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
1995-00 2.5L V6 250259 Yes Yes 60,000
3
108
024
1981-82 1.7L 4-Cyl. 250017

2520170 60,000
1
89
1981-82 2.2L 4-Cyl. 250071

2520710 60,000
1
101
400
1982-83 2.2L 4-Cyl. 250071

2520710 60,000
1
101
600
1983-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
2000 GTX (Canadian)
1989-92 2.0L 4-Cyl. (SOHC)
2
121
Camshaft 250155 60,000
2
121
DODGE (Cont.)
A-11
1
2
3
DODGE/PLYMOUTH
Light Trucks
Caravan
1982-88 2.2L 4-Cyl. 250071

2520710 60,000 101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989-95 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1996-00 2.4L 4-Cyl. (DOHC, VIN B) 250265 Yes 120,000 104
1987-93 3.0L V6 (SOHC) 250139

2521390 Yes 60,000 110
1994-96 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
1997-00 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
Dakota
1987-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989-95 2.5L 4-Cyl. 250153

2521530 60,000
1
101
Mini Ram Van
1984-87 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1987 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1987-93 3.0L V6 (SOHC) 250139

2521390 Yes 60,000 110
Raider
1989 3.0L V6 (SOHC) 250139

2521390 60,000 110
Ram 50
1983-86 2.0L 4-Cyl. (SOHC)
2
121
Camshaft 250089 60,000
2
121
1987-89 2.0L 4-Cyl. (SOHC)

2521581 60,000
2
121
Camshaft 250158

2521581 60,000
2
121
1983-85 2.3L 4-Cyl. Diesel
Balance Shaft 250092 Yes 50,000
2
138
Camshaft 250091 Yes 50,000
2
138
1990-92 2.4L 4-Cyl.

2521240 60,000
2
140
Camshaft 250124

2521240 60,000
2
140
1993 2.4L 4-Cyl.
2
140
Camshaft 250229 60,000
2
140
1990-91 3.0L V6 (SOHC) 250139

2521390 60,000 110
Scamp Pickup
1983 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Light Trucks
Voyager
1982-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114 60,000
1
101
1988 2.5L 4-Cyl. 250132 60,000
1
101
1989-95 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1987-93 3.0L V6 (SOHC) 250139

2521390 Yes 60,000 110
1994-96 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
1997-00 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
EAGLE
Medallion
1989 2.2L 4-Cyl. 250140 60,000
1
156
A-12
1
2
3
Summit
1989-90 1.5L 4-Cyl. 250128

2521280 Yes 60,000 114
1991-96 1.5L 4-Cyl. 250191

2521910 60,000 114
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
1992-96 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
1992 2.4L 4-Cyl.
2
136
Camshaft 250204 60,000
2
136
1993-96 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
Summit Wagon
1992-96 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
Talon
1993-94 1.8L 4-Cyl.

2521580 60,000
2
128
Camshaft 250158

2521580 60,000
2
128
1995-98 2.0L 4-Cyl. (DOHC, VIN Y) 250246 Yes Yes

60,000
3
133
1990-99 2.0L 4-Cyl. (DOHC)

2521670 Yes 60,000
2
116
Camshaft 250167

2521670 Yes 60,000
2
116
Vision
1993-94 3.5L V6 250219 Yes 105,000 123
1995-97 3.5L V6 250255 Yes 105,000 123
Vista (Canadian)
1989-91 1.5L 4-Cyl. 250128

2521280 Yes 60,000 114
1992 1.5L 4-Cyl. 250191

2521910 60,000 114
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
1989 1.6L 4-Cyl. w/o Bal. Shaft 250093 60,000 87
1989-91 2.0L 4-Cyl. (SOHC)

2521581 60,000
2
121
Camshaft 250158

2521581 60,000
2
121
2000GTX (Canadian)
1989-93 2.0L 4-Cyl. (DOHC)

2521670 Yes 60,000
2
116
Camshaft 250167

2521670 Yes 60,000
2
116
1989-92 2.0L 4-Cyl. (SOHC)
2
121
Camshaft 250155 60,000
2
121
FIAT
Brava
1974-78 1.8L 4-Cyl. 250020 Yes 25,000 158
1979-83 2.0L 4-Cyl. 250068 Yes 30,000 160
Spider 2000
1979-82 2.0L 4-Cyl. 250068 Yes 30,000 160
Strada
1979-82 1.5L 4-Cyl. 250069 Yes 30,000 157
X1/9
1974-78 1.3L 4-Cyl. 250018 Yes 36,000 157
1979-83 1.5L 4-Cyl. 250069 Yes 30,000 157
EAGLE (Cont.)
A-13
1
2
3
124 Series
1971-74 1.6L 4-Cyl. 250020 Yes 25,000 158
1974-78 1.8L 4-Cyl. 250020 Yes 25,000 158
128 Series
1973-79 1.3L 4-Cyl. 250018 Yes 36,000 157
131 Series
1975-78 1.8L 4-Cyl. 250020 Yes 25,000 158
FORD
Passenger Cars
Aspire
1994-97 1.3L 4-Cyl. 250185 60,000 Federal 161
Contour
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) 250258

60,000
1
178
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 250294 Inspect at 120,000;
Replace if needed 180
Escort
1981-85 1.6L 4-Cyl. (SOHC) 250067

2520670 Yes Yes 60,000 165
1991-96 1.8L 4-Cyl. (DOHC) 250179

TCK179 60,000 169
1985-90 1.9L 4-Cyl. 250067

2520670 Yes Yes 60,000 165
1991 1.9L 4-Cyl.
Before 3/25/1991 250067

2520670 Yes Yes 60,000 165
After 3/26/1991 250194

2521940 Yes Yes 60,000 165
1992-96 1.9L 4-Cyl. 250194

2521940 Yes Yes 60,000 165
1984-87 2.0L 4-Cyl. Diesel

100,000
2
172
2
172
1997-00 2.0L 4-Cyl. (SOHC, VIN P) 250283 Inspect at 120,000;
2001 2.0L 4-Cyl. (SOHC, VIN P) 250283 120,000 184
Escort Coupe & ZX2
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 250294 Inspect at 120,000;
2001 2.0L 4-Cyl. (DOHC, VIN 3) 250294 120,000 180
EXP
1981-85 1.6L 4-Cyl. (SOHC) 250067

2520670 Yes Yes 60,000 165
1985-90 1.9L 4-Cyl. 250067

2520670 Yes Yes 60,000 165
Fairmont
1978-83 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Festiva
1988-89 1.3L 4-Cyl. 250141

TCK141 60,000 161
1990-93 1.3L 4-Cyl. 250185 60,000 161
Focus
2000 2.0L 4-Cyl. (DOHC, VIN 3) 250294 Inspect at 120,000;
2001 2.0L 4-Cyl. (DOHC, VIN 3) 250294 120,000 180
2000 2.0L 4-Cyl. (SOHC, VIN P) 250283 Inspect at 120,000;
2001 2.0L 4-Cyl. (SOHC, VIN P) 250283 120,000 184
Granada
1981-82 2.3L 4-Cyl. 250014

2520140 60,000
1
189
LTD
1983-86 2.3L 4-Cyl. 250014

2520140 60,000
1
189
FIAT (Cont.)
A-14
1
2
3
Mustang
1974-91 2.3L 4-Cyl. 250014

2520140 60,000
1
189
1992 2.3L 4-Cyl.
Square Tooth Sprocket 250014 2520140 60,000
1
189
Round Tooth Sprocket 250210

60,000
1
189
1993 2.3L 4-Cyl. 250210

60,000
1
189
Pinto
1971-74 2.0L 4-Cyl. 250013

60,000
1
168
1974-80 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Probe
1989-92 2.2L 4-Cyl. 250134

TCK134 Yes 60,000 186
1993-97 2.0L 4-Cyl. 250228

TCK228 Yes 60,000 Federal 186
1993-97 2.5L V6 250214 Yes 60,000 Federal 196
Taurus SHO
1989-95 3.0L V6 250248 100,000 200
1993-95 3.2L V6 250248 100,000 200
Tempo
1984-86 2.0L 4-Cyl. Diesel

100,000
2
172
Injection Pump 250102 Yes Yes

100,000
2
172
Thunderbird
1983-88 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Light Trucks
Aerostar
1987 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Courier
1977-82 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Escape
2001 2.0L 4-Cyl. (DOHC) 250294 120,000 175
Ranger
1983-88 2.0L 4-Cyl. 250014

60,000
1
189
1983-91 2.3L 4-Cyl. 250014

2520140 60,000
1
189
1992 2.3L 4-Cyl.
Square Tooth Sprocket 250014

2520140 60,000
1
189
Round Tooth Sprocket 250210

60,000
1
189
1993-94 2.3L 4-Cyl. 250210

60,000
1
189
1995-97 2.3L 4-Cyl. 250276 60,000 194
1985-87 2.3L 4-Cyl. Diesel
Camshaft 250091 Yes

60,000
1
192
Balance Shaft 250092 Yes

60,000
1
192
1998-00 2.5L 4-Cyl. 250276 Inspect At 120,000;
Replace, if needed 195
2001 2.5L 4-Cyl. 250276 120,000 195
G.M.C. (SEE CHEVROLET/G.M.C.)
GEO
Passenger Cars
Metro
1989-92 1.0L 3-Cyl. 250166 60,000 211
1993 1.0L 3-Cyl.
4-Bolt Sprocket 250166 60,000 211
5-Bolt Sprocket 250241 60,000 211
FORD (Cont.)
A-15
1
2
3
Metro (Cont.)
1994-95 1.0L 3-Cyl. 250241 60,000 211
1996 1.0L 3-Cyl. 250194

2521940 60,000 211
1997-00 1.0L 3-Cyl. 250194

2521940 100,000 211
1992-93 1.3L 4-Cyl. 250095 60,000 213
1994 1.3L 4-Cyl. 250243 60,000 213
1995-97 1.3L 4-Cyl. 250272 60,000 213
Metro (Canadian)
1992-93 1.3L 4-Cyl. 250095 60,000 213
1994 1.3L 4-Cyl. 250243 60,000 213
Prizm
1937-97 1.6L 4-Cyl. (DOHC, VIN 6) 250236

TCK236 Yes 60,000 207
Prizm GSI
1990-92 1.6L 4-Cyl. (DOHC) 250176 60,000 203
Spectrum
1985 1.5L 4-Cyl. 250118 Yes Yes 60,000 219
1986-87 1.5L 4-Cyl
Up To 6/30/1986 250118 Yes Yes 60,000 219
From 7/1/1986 250162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. 250162 Yes Yes 60,000 219
Storm
1990-91 1.6L 4-Cyl. (DOHC) 250169 Yes 60,000 209
1990-93 1.6L 4-Cyl. (SOHC) 250177 Yes Yes 30,000 205
1992-93 1.8L 4-Cyl. (DOHC) 250205 Yes 60,000 209
Light Trucks
Tracker
1989-95 1.6L 4-Cyl. (8-Valve)
California 250212

60,000
1
215
Except California 250164

60,000
1
215
1994-98 1.6L 4-Cyl. (16-Valve)
California 250212 60,000 217
1999-01 1.6L 4-Cyl. (16-Valve) 250212 60,000 217
HONDA
Passenger Cars
Accord
1976-83 1.6L 4-Cyl. (SOHC) 250041 Yes

60,000
1
253
1979-83 1.8L 4-Cyl. 250041 Yes

60,000
1
263
1984-85 1.8L 4-Cyl. 250094 TCK160 Yes

60,000
1
263
1986-89 2.0L 4-Cyl. 250160 TCK160 Yes 60,000
1
269
1990-93 2.2L 4-Cyl. (SOHC)
Balance Shaft 250186 TCK186 Yes Yes 90,000
2
278
Camshaft 250187 TCK186 Yes Yes 90,000
2
278
1994 (EX) 2.2L 4-Cyl. (SOHC)
Balance Shaft 250186 TCK186 Yes Yes

90,000
2
278
2
278
1994 (Exc. EX) 2.2L 4-Cyl. (SOHC)
2
278
2
278
GEO (Cont.)
A-16
1
2
3
HONDA (Cont.)
Accord (Cont.)
1995 (EX) 2.2L 4-Cyl. (SOHC)

90,000
2
, Normal 278
60,000
2
, Severe 278
Camshaft 250244 TCK186 Yes Yes

90,000
2
, Normal 278
60,000
2
, Severe 278
1995 (Exc. EX) 2.2L 4-Cyl. (SOHC)

90,000
2
, Normal 278
60,000
2
, Severe 278
2
, Normal 278
60,000
2
, Severe 278
1996 2.2L 4-Cyl. (SOHC)
Balance Shaft 250186 Yes Yes 90,000
2
, Normal 278
60,000
2
, Severe 278
Camshaft (w/o VTEC) 250187 TCK186 Yes Yes 90,000
2
, Normal 278
60,000
2
, Severe 278
Camshaft (w/ VTEC) 250244 TCK186 Yes Yes 90,000
2
, Normal 278
60,000
2
, Severe 278
1997 2.2L 4-Cyl. (SOHC)
2, 3
278
Camshaft (w/o VTEC) 250187 TCK186 Yes Yes 105,000
2, 3
278
Camshaft (w/ VTEC) 250244 Yes Yes 105,000
2, 3
278
1998-01 2.3L 4-Cyl. (SOHC)
2, 3
282
2, 3
282
1996 2.7L V6 250263 Yes Yes 90,000 Normal 287
60,000 Normal 287
1997 2.7L V6 250263 Yes Yes 105,000
3
287
1998-01 3.0L V6 250286 Yes Yes 105,000
3
288
Civic
1973-79 1.2L 4-Cyl. 250028 Yes 60,000
1
241
1980-83 1.3L 4-Cyl.
Canada 250028 Yes 60,000
1
243
USA 250073 Yes 60,000
1
243
1984-85 1.3L 4-Cyl. 250099 Yes Yes 60,000
1
243
1986-87 1.3L 4-Cyl. 250161

TCK161 Yes Yes 60,000
1
243
1980-83 1.5L 4-Cyl. 250041 Yes 60,000
1
246
1984-85 1.5L 4-Cyl. 250099 Yes Yes 60,000
1
246
1986-87 1.5L 4-Cyl. 250161

1
246
1988-89 1.5L 4-Cyl. 250143

1
246
1990-94 1.5L 4-Cyl. 250143

TCK143 Yes Yes 90,000 246
1995 1.5L 4-Cyl. 250143

TCK143 Yes Yes 90,000, Normal 246
60,000, Severe 246
1988-89 1.6L 4-Cyl. (SOHC) 250145 Yes Yes 60,000
1
253
1991 1.6L 4-Cyl. (SOHC) 250145 Yes Yes 90,000 253
1992
Except Si 1.6L 4-Cyl. (SOHC) 250145 Yes Yes 90,000 253
Si 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 90,000 253
1993-94 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 90,000 253
1995 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 90,000 Normal 253
60,000 Severe 253
60,000 Severe 257
A-17
1
2
3
Civic (Cont.)
1997-00 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 105,000
3
257
2001 1.7L 4-Cyl. (SOHC) 250312 Yes

110,000
3
260
Civic CVCC
1975 1.5L 4-Cyl. 250036 TCK036 Yes 60,000
1
246
1976-79 1.5L 4-Cyl. 250041 Yes 60,000
1
246
Civic CRX
1984 1.3L 4-Cyl. 250099 Yes Yes 60,000
1
243
1984-85 1.5L 4-Cyl. 250099 Yes Yes 60,000
1
246
1986-87 1.5L 4-Cyl. 250161

1
246
1988-89 1.6L 4-Cyl. (SOHC) 250145 Yes Yes 60,000
1
253
1990-91 1.6L 4-Cyl. (SOHC) 250145 Yes Yes 90,000 253
Civic del Sol (Except VX)
1993-94 1.5L 4-Cyl. 250143

TCK143 Yes Yes 90,000 246
1995 1.5L 4-Cyl. 250143 TCK143 Yes Yes 90,000, Normal 246
60,000, Severe 246
1993-94 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 90,000 253
60,000 Severe 253
60,000 Severe 257
1997 1.6L 4-Cyl. (SOHC) 250224 Yes Yes 105,000
3
257
1994 1.6L 4-Cyl. (DOHC) 250227 Yes Yes 90,000 251
1995-95 1.6L 4-Cyl. (DOHC) 250227 Yes Yes 90,000 Normal 251
60,000 Severe 251
1997 1.6L 4-Cyl. (DOHC) 250227 Yes Yes 105,000
3
251
Civic del Sol VX
1993-94 1.5L 4-Cyl. 250223 Yes Yes 90,000 246
1995 1.5L 4-Cyl. 250223 Yes Yes 90,000, Normal 246
60,000, Severe 246
Civic VX
1992-94 1.5L 4-Cyl. 250223 Yes Yes 90,000 246
60,000, Severe 246
Prelude
1980-82 1.6L 4-Cyl. (SOHC) 250041 Yes 60,000
1
253
1979-82 1.8L 4-Cyl. 250041 Yes 60,000
1
263
1983-85 1.8L 4-Cyl. 250094 TCK160 Yes Yes 60,000
1
263
1986-87 1.8L 4-Cyl. 250160 TCK160 Yes Yes 60,000
1
263
1985 2.0L 4-Cyl. 250094 TCK160 Yes 60,000
1
269
1986-87 2.0L 4-Cyl. (SOHC) 250160 TCK160 Yes 60,000
1
269
1988-89 2.0L 4-Cyl. (SOHC) 250144 Yes Yes 60,000
1
269
1990 2.0L 4-Cyl. (SOHC) 250144 Yes Yes 90,000 269
1988-89 2.0L 4-Cyl. (DOHC) 250142 Yes Yes 60,000
1
271
1990-91 2.0L 4-Cyl. (DOHC) 250141 Yes Yes 90,000 271
1990-91 2.1L 4-Cyl. (DOHC) 250142 Yes Yes 90,000 271
1993-94 2.2L 4-Cyl. (DOHC)

90,000
2
273

90,000
2
273
1995-96 2.2L 4-Cyl. (DOHC)

90,000
2
, Normal 273
60,000
2
, Severe 273

90,000
2
, Normal 273
60,000
2
, Severe 273
HONDA (Cont.)
A-18
1
2
3
Prelude (Cont.)
1997-01 2.2L 4-Cyl. (DOHC)

105,000
2, 3
273
2, 3
273
1992-94 2.2L 4-Cyl. (SOHC)

90,000
2
278

90,000
2
278
1995-96 2.2L 4-Cyl. (SOHC)
2
, Normal 278
60,000
2
, Severe 278
2
, Normal 278
60,000
2
, Severe 278
1992-94 2.3L 4-Cyl. (DOHC)

90,000
2
278

90,000
2
278
1995-96 2.3L 4-Cyl. (DOHC)
2
, Normal 278
60,000
2
, Severe 278
2
, Normal 278
60,000
2
, Severe 278
Light Trucks
CR-V
1997-01 2.0L 4-Cyl. 250184 Yes Yes 105,000
3
266
Odyssey
1995-96 2.2L 4-Cyl. (SOHC)

90,000
2
276

90,000
2
276
1997 2.2L 4-Cyl. (SOHC)

105,000
2, 3
276
2, 3
276
1998 2.3L 4-Cyl. (SOHC)
2, 3
282
2, 3
282
1999-01 3.5L V6 250286 Yes Yes 105,000
3
288
Passport
1994-96 2.6L 4-Cyl. 250147 Yes 60,000 285
1994-97 3.2L V6 (SOHC) 250221 Yes 60,000 28
1998-99 3.2L V6 (DOHC) 250303 Yes

75,000 291
2000-01 3.2L V6 (DOHC) 250303 Yes 105,000
3
291
HYUNDAI
Accent
1995-96 1.5L 4-Cyl. (DOHC) 250282 Yes 60,000 293
1997 1.5L 4-Cyl. (DOHC) 250282 Yes 60,000
3
293
1995-96 1.5L 4-Cyl. (SOHC) 250191 2521910 Yes 60,000 294
1997-01 1.5L 4-Cyl. (SOHC) 250191 2521910 60,000
3
294
2001 1.6L 4-Cyl. (DOHC) 250282 Yes 60,000
3
296
Elantra
1992-95 1.6L 4-Cyl. (DOHC)
2
297
2
297
1993-95 1.8L 4-Cyl. (DOHC)
Balance Shaft 250168 2521670 Yes 60,000
2
297
Camshaft 250167 2521670 Yes 60,000
2
297
HONDA (Cont.)
A-19
1
2
3
Elantra (Cont.)
1996-98 1.8L 4-Cyl. 250278 Yes 60,000
3
301
1999-01 2.0L 4-Cyl. 250284 Yes 60,000
3
301
Excel
1986-89 1.5L 4-Cyl. (SOHC) 250073 Yes 60,000 294
1990-94 1.5L 4-Cyl. (SOHC) 250128 2521280 Yes 60,000 294
Scoupe
1991-93 1.5L 4-Cyl. (SOHC) 250128 2521280 Yes 60,000 294
1994-95 1.5L 4-Cyl. (SOHC) 250128 2521910 Yes 60,000 294
Sonata
1992-98 2.0L 4-Cyl. (DOHC)
2, 3
302
Camshaft 250167 2521670 Yes 60,000
2, 3
302
1989-91 2.4L 4-Cyl. (SOHC)
2
305
Camshaft 250124 2521240 Yes 60,000
2
305
1990-98 3.0L V6 250139 2521390 Yes 60,000
3
308
Tiburon
1997 1.8L 4-Cyl. 250278 Yes 60,000
3
301
1999-01 2.0L 4-Cyl. 250284 Yes 60,000
3
301
INFINITI
Passenger Cars
J30
1993 3.0L V6 250180 Yes 60,000 310
1994-97 3.0L V6 250251 Yes 60,000 310
M30
1990-92 3.0L V6 250104 Yes 60,000 313
Light Trucks
QX4
1997-01 3.3L V6 (SOHC) 250249 105,000 456
ISUZU
Passenger Cars
I-Mark
1981-84 1.8L 4-Cyl. Diesel 250076 Yes 60,000 318
1985-87 1.5L 4-Cyl.
Up To 6/30/86 250118 Yes Yes 60,000 219
From 7/1/86 250162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. 250162 Yes Yes 60,000 219
1989 1.6L 4-Cyl. (DOHC) 250169 Yes Yes 60,000 315
Impulse
1985-89 2.0L 4-Cyl. Turbo 250121 Yes 60,000 320
1988-89 2.3L 4-Cyl. 250122 Yes 60,000 315
1990-92 1.6L 4-Cyl. (DOHC) 250169 Yes 60,000 315
1991-93 1.6L 4-Cyl. Turbo 250169 Yes Yes 60,000 315
1992 1.8L 4-Cyl. 250205 Yes 60,000 315
Stylus
1991 1.6L 4-Cyl. (DOHC) 250169 60,000 315
1991-93 1.6L 4-Cyl. (SOHC) 250177 Yes 60,000 315
1992-93 1.8L 4-Cyl. 250205 Yes 60,000 315
Light Trucks
Amigo
1998 2.2L 4-Cyl. 250305 Yes Yes 75,000 325
HYUNDAI (Cont.)
A-20
1
2
3
Amigo (Cont.)
1999-00 2.2L 4-Cyl. 250305 Yes Yes 100,000, Normal 325
75,000, Severe 325
1989-93 2.3L 4-Cyl. 250122 Yes 60,000 320
1989-94 2.6L 4-Cyl. 250147 Yes 60,000 320
1998 3.2L V6 250303 Yes 75,000 334
1999 3.2L V6 250303 Yes 100,000 Normal 334
75,000 Severe 334
Oasis
1996 2.2L 4-Cyl. (SOHC)

90,000
2
327

90,000
2
327
1997 2.2L 4-Cyl. (SOHC)

105,000
2, 3
327
2, 3
327
1998 2.3L 4-Cyl. (SOHC)
2, 3
329
2, 3
329
Pickup & PUP
1981-87 2.2L 4-Cyl. Diesel 250075 Yes 60,000 323
1986-95 2.3L 4-Cyl. 250122 Yes 60,000 320
1988-95 2.6L 4-Cyl. 250147 Yes 60,000 320
Rodeo
1998 2.2L 4-Cyl. 250305 Yes Yes 75,000 325
1999-00 2.2L 4-Cyl. 250305 Yes Yes 100,000, Normal 325
75,000, Severe 325
60,000, Severe 325
1991-97 2.6L 4-Cyl. 250147 Yes 60,000 320
1993-97 3.2L V6 (SOHC) 250221 Yes 60,000 332
1998 3.2L V6 250303 Yes 75,000 334
1999-01 3.2L V6 250303 Yes 100,000 Normal 334
75,000 Severe 334
Trooper
1990-91 2.6L 4-Cyl. 250147 Yes 60,000 320
1992-95 3.2L V6 (DOHC) T220 Yes 60,000 332
1992-97 3.2L V6 (SOHC) 250221 Yes 60,000 332
1998 3.5L V6 250303 Yes 75,000 334
1999-01 3.5L V6 250303 Yes 100,000 Normal 334
75,000 Severe 334
Trooper II
1984-87 2.2L 4-Cyl. Diesel 250075 Yes 60,000 323
1986-87 2.3L 4-Cyl. 250122 Yes 60,000 320
1988-89 2.6L 4-Cyl. 250147 Yes 60,000 320
VehiCROSS
1999-01 3.5L V6 250303 Yes 100,000 Normal 334
75,000 Severe 334
KIA
Passenger Cars
Sephia
1994-95 1.6L 4-Cyl. (SOHC) 250185 Yes

105,000 (Calif.)
3
337
1994-95 1.6L 4-Cyl. (SOHC) 250185 Yes 60,000 (Exc. Calif.) 337
1996-97 1.6L 4-Cyl. (DOHC) 250179 TCK179 Yes

105,000 (Calif.)
3
336
1996-97 1.6L 4-Cyl. (DOHC) 250179 TCK179 Yes 60,000 (Exc. Calif.) 336
ISUZU (Cont.)
A-21
1
2
3
Sephia (Cont.)
1995-97 1.8L 4-Cyl. (DOHC) 250179 TCK179 Yes

105,000 (Calif.)
3
336
1995-97 1.8L 4-Cyl. (DOHC) 250179 TCK179 Yes 60,000 (Exc. Calif.) 336
1998-01 1.8L 4-Cyl. (DOHC) 250302 Yes

105,000 (Calif.)
3
339
1998-01 1.8L 4-Cyl. (DOHC) 250302 Yes 60,000 (Exc. Calif.) 339
1996-97 1.8L 4-Cyl. (SOHC) 250185 Yes

105,000 (Calif.)
3
337
1996-97 1.8L 4-Cyl. (SOHC) 250185 Yes 60,000 (Exc. Calif.) 337
Spectra
2000-01 1.8L 4-Cyl. (DOHC) 250302 Yes

105,000 (Calif.)
3
339
Light Trucks
Sportage
1995-01 2.0L 4-Cyl. (DOHC) 250281 Yes

105,000 (Calif.)
3
341
1995 2.0L 4-Cyl. (SOHC) 250264 Yes

105,000 (Calif.)
3
343
1995 2.0L 4-Cyl. (SOHC) 250264 Yes 60,000 (Exc. Calif.) 343
LANCIA
Beta
1976-78 1.8L 4-Cyl. 250020 Yes 25,000 344
LEXUS
ES250
1990-91 2.5L V6 250157 Yes 60,000
1, 3
345
ES300
1992-93 3.0L V6 250200 Yes 60,000
1, 3
345
1994-98 3.0L V6 250257 Yes 60,000
1, 3
345
1999-01 3.0L V6 250257 Yes 90,000 349
GS300
1993-97 3.0L 6-Cyl. 250215 60,000
1, 3
353
1998-01 3.0L 6-Cyl. 250215 90,000 355
GS400
1998-00 4.0L V8 250298 Yes 90,000 362
LS400
1990-94 4.0L V8 250190 Yes 60,000
1, 3
358
1995-97 4.0L V8 250190 Yes 90,000, Normal 358
60,000, Severe 358
1998-00 4.0L V8 250298 Yes 90,000 362
SC300
1993-97 3.0L 6-Cyl. 250215 60,000
1, 3
353
1998-00 3.0L 6-Cyl. 250215 90,000 355
SC400
1992-94 4.0L V8 250190 Yes 60,000
1, 3
358
1995-97 4.0L V8 250190 Yes 90,000, Normal 358
60,000, Severe 358
1998-00 4.0L V8 250298 Yes 90,000 362
Light Trucks
LX470
1998-01 4.7L V8 250298 Yes Yes 90,000 366
RX-300
1999-01 3.0L V6 250257 Yes 90,000 349
KIA (Cont.)
A-22
1
2
3
MAZDA
Passenger Cars
Miata & MX-5 Miata
1990-92 1.6L 4-Cyl. (DOHC) 250179 TCK179 60,000 373
1993 1.6L 4-Cyl. (DOHC) 250179 TCK179 60,000 Federal 373
105,000 Calif. 373
1994-96 1.8L 4-Cyl. (DOHC) 250179 TCK179 60,000 Federal 376
105,000 Calif. 376
1997-00 1.8L 4-Cyl. (DOHC) 250179 TCK179 105,000
3
376
1997-00 1.8L 4-Cyl. (DOHC) 250179 TCK179 60,000
3
376
2001 1.8L 4-Cyl. (DOHC) 250179 TCK179 60,000 376
Millenia
1995-96 2.3L V6 (Miller Cycle) 250267

60,000 Federal 396
105,000 Calif. 396
1997-00 2.3L V6 (Miller Cycle) 250267 105,000
3
396
1997-00 2.3L V6 (Miller Cycle) 250267

60,000
3
396
1995-96 2.5L V6 250214

60,000 Federal 399
105,000 Calif. 399
1997-00 2.5L V6 250214 105,000
3
399
1997-00 2.5L V6 250214

60,000
3
399
2001 2.5L V6 250214

105,000
3
399
MX-3 (Includes Canadian)
1988-89 1.6L 4-Cyl. (DOHC) 250149 60,000 373
105,000 Calif. 373
1992 1.6L 4-Cyl. (SOHC) 250185 60,000 373
1993 1.6L 4-Cyl. (SOHC) 250185 60,000 Federal 373
105,000 Calif. 373
1992 1.8L V6 250214 Yes 60,000 393
1993-95 1.8L V6 250214 Yes 60,000 Federal 393
105,000 Calif. 393
MX-6
1993 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000 382
1994-96 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000 Federal 382
105,000 Calif. 382
1997 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 105,000
3
382
1997 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000
3
382
1988-92 2.2L 4-Cyl. 250134 TCK134 Yes 60,000 387
1993 2.5L V6 250214 60,000 399
1994-96 2.5L V6 250214

60,000 Federal 399
105,000 Calif. 399
1997 2.5L V6 250214 105,000
3
399
1997 2.5L V6 250214

60,000
3
399
Protege
1995-97 1.5L 4-Cyl. 250266 60,000 (Ex. CA & MA) 370
1995-97 1.5L 4-Cyl. 250266 105,000 (CA & MA)
3
370
1998 1.5L 4-Cyl.
Up To Eng. No. 19472 250266 60,000 (Ex. CA & MA) 370
105,000 (CA & MA)
3
370
From Eng. No. 19473 250308 60,000 (Ex. CA & MA) 370
105,000 (CA & MA)
3
370
1999-00 1.6L 4-Cyl. (DOHC) 250308 60,000
3
371
2001 1.6L 4-Cyl. (DOHC) 250308 105,000
3
371
1990-92 1.8L 4-Cyl. (DOHC) 250179 60,000 373
105,000 Calif. 373
A-23
1
2
3
Protege (Cont.)
105,000 Calif. 376
1997-98 1.8L 4-Cyl. (DOHC) 250179 TCK179 60,000
3
376
1997-98 1.8L 4-Cyl. (DOHC) 250179 TCK179 105,000
3
376
1999-00 1.8L 4-Cyl. (DOHC) 250316 60,000
3
380
1999-00 1.8L 4-Cyl. (DOHC) 250316 105,000
3
380
1990-92 1.8L 4-Cyl. (SOHC) 250185 60,000 373
1993-94 1.8L 4-Cyl. (SOHC) 250185 60,000 Federal 373
105,000 Calif. 373
2001 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 105,000
3
382
323
1988-89 1.6L 4-Cyl. (DOHC) 250149 60,000 373
1986 1.6L 4-Cyl. (SOHC) 250123 60,000 373
1987-89 1.6L 4-Cyl. (SOHC) 250141 TCK141 60,000 373
1990-92 1.8L 4-Cyl. (SOHC) 250185 60,000 373
1993-94 1.6L 4-Cyl. (SOHC) 250185 60,000 Federal 373
105,000 Calif. 373
626
1983 2.0L 4-Cyl. (SOHC) 250088 Yes 60,000 387
1984-85 2.0L 4-Cyl.
Square Tooth Sprocket 250088 Yes 60,000 387
Round Tooth Sprocket 250113 Yes 60,000 387
1986-87 2.0L 4-Cyl. 250117 Yes 60,000 387
1984-85 2.0L 4-Cyl. Diesel
Camshaft 250103 Yes

100,000 389
Injection Pump 250102 Yes 100,000 389
1993 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000 382
1994-96 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000 Federal 382
105,000 Calif. 382
1997-00 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 105,000
3
382
1997-00 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 60,000
3
382
2001 2.0L 4-Cyl. (DOHC) 250228 TCK228 Yes 105,000
3
382
1988-92 2.2L 4-Cyl. 250134 TCK134 Yes 60,000 387
1993 2.5L V6 250214 60,000 399
1994-96 2.5L V6 250214

60,000 Federal 399
105,000 Calif. 399
1997-00 2.5L V6 250214 105,000
3
399
1997-00 2.5L V6 250214

60,000
3
399
2001 2.5L V6 250214

105,000
3
399
929
1990-93 3.0L V6 (DOHC) 250183 Yes 60,000 402
1994-95 3.0L V6 (DOHC) 250183 Yes 60,000 Federal 402
105,000 Calif. 402
1988-91 3.0L V6 (SOHC) 250146 TCK146 Yes 60,000 404
Light Trucks
B2000
1986 2.0L 4-Cyl. (SOHC)
Up To Chas. 568707 250113 Yes 60,000 387
From Chas. 568708 250117 Yes 60,000 387
1987 2.0L 4-Cyl. (SOHC) 250117 Yes 60,000 387
B2200
1987-93 2.2L 4-Cyl. 250134 TCK134 Yes 60,000 387
MAZDA (Cont.)
A-24
1
2
3
B2300
1994 2.3L 4-Cyl. 250210 60,000 391
1997-95 2.3L 4-Cyl. 250276 60,000 391
B2500
1998-00 2.5L 4-Cyl. 250276 120,000 392
MPV
1988-93 3.0L V6 (SOHC) 250146 TCK146 Yes 60,000 404
1994-96 3.0L V6 (SOHC) 250146 TCK146 Yes 60,000 Federal 404
105,000 Calif. 404
1997-98 3.0L V6 (SOHC) 250146 TCK146 Yes 105,000
3
404
1997-98 3.0L V6 (SOHC) 250146 TCK146 Yes 60,000
3
404
Tribute
2001 2.0L 4-Cyl. (DOHC) 250294 120,000 384
MERCURY
Passenger Cars
Bobcat
1974-80 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Capri
1972 1.6L 4-Cyl. 250013 60,000
1
168
1971-74 2.0L 4-Cyl. 250013 60,000
1
168
1991-94 1.6L 4-Cyl. (DOHC) 250179

TCK179 60,000 163
1976-86 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Cougar
1981-86 2.3L 4-Cyl. 250014

2520140 60,000
1
189
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 250294 Inspect at 120,000,
2001 2.0L 4-Cyl. (DOHC, VIN 3) 250294 120,000 180
LN7
1981-85 1.6L 4-Cyl. (SOHC) 250067

2520670 Yes Yes 60,000 165
1981-85 1.6L 4-Cyl. (SOHC) 250067

2520670 Yes Yes 60,000 165
1985-87 1.9L 4-Cyl. 250067

2520670 Yes Yes 60,000 165
1984-87 2.0L 4-Cyl. Diesel

100,000
2
172
2
172
Marquis
1983-86 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Mystique
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) 250258 60,000
1
000 178
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 250294 Inspect at 120,000,
Topaz
1984-86 2.0L 4-Cyl. Diesel
2
172
2
172
Tracer
1987-90 1.6L 4-Cyl. (SOHC) 250141

TCK141 Yes Yes 60,000 165
1991-96 1.8L 4-Cyl. (DOHC) 250179

TCK179 60,000 169
1991 1.9L 4-Cyl.
Before 3/25/1991 250067

2520670 Yes Yes 60,000 165
After 3/26/1991 250194

2521940 Yes Yes 60,000 165
1992-96 1.9L 4-Cyl. 250194

2521940 Yes Yes 60,000 165
MAZDA (Cont.)
A-25
1
2
3
Tracer (Cont.)
1997-00 2.0L 4-Cyl. (SOHC, VIN P) 250283 Inspect at 120,000,
2001 2.0L 4-Cyl. (SOHC, VIN P) 250283 120,000 184
Zephyr
1978-83 2.3L 4-Cyl. 250014

2520140 60,000
1
189
Light Trucks
Villager
1993 3.0L V6 (SOHC) 250104

TCK104 Yes 105,000 198
1994-98 3.0L V6 (SOHC) 250249 Yes 105,000 198
MERKUR
XR4Ti
1985-89 2.3L 4-Cyl. 250014

2520140 60,000
1
189
MITSUBISHI
Passenger Cars
Cordia & Tredia
1983-84 1.8L 4-Cyl.
2
411
Camshaft 250089 60,000
2
411
1985-86 1.8L 4-Cyl.
2
411
Camshaft 250089 60,000
2
411
1987-88 1.8L 4-Cyl.
Balance Shaft 250159 2521580 60,000
2
411
Camshaft 250158 2521580 60,000
2
411
1984 2.0L 4-Cyl.
2
411
Camshaft 250089 60,000
2
411
1985-86 2.0L 4-Cyl.
2
411
Camshaft 250089 60,000
2
411
1987-88 2.0L 4-Cyl.
2
411
Camshaft 250158 60,000
2
411
Diamante
1992-93 3.0L V6 (DOHC) 250195 Yes Yes 60,000 142
1994-96 3.0L V6 (DOHC) 250195 Yes Yes 60,000
3
142
1992-93 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 430
1994-96 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 Federal 430
100,000 Calif. 430
1997-01 3.5L V6 (SOHC) 250287 Yes Yes

60,000
3
442
Eclipse
1990-94 1.8L 4-Cyl.

2521580 60,000
2
128
Camshaft 250158

2521580 60,000
2
128
1995-97 2.0L 4-Cyl. (Non-Turbo)
DOHC, VIN Y

250246 Yes Yes

60,000 Federal
3
133

100,000 Calif.
3
133
1998-99 2.0L 4-Cyl. (Non-Turbo)
DOHC, VIN Y 250246 Yes Yes 60,000
3
133
MERCURY (Cont.)
A-26
1
2
3
Eclipse (Cont.)
1990-94 2.0L 4-Cyl. (DOHC)
Balance Shaft 250168 2521670 Yes

60,000
2
414
Camshaft 250167 2521670 Yes

60,000
2
414
1995-97 2.0L 4-Cyl. (DOHC) Turbo
Balance Shaft 250168 2521670 Yes 60,000 Federal
2, 3
414
100,000 Calif.
2, 3
414
Camshaft 250167 2521670 Yes 60,000 Federal
2, 3
414
100,000 Calif.
2, 3
414
1998-99 2.0L 4-Cyl. (DOHC) Turbo
2, 3
414
100,000
2, 3
414
Camshaft 250167 2521670 Yes 60,000
2, 3
414
100,000
2, 3
414
1996 2.4L 4-Cyl. (SOHC, VIN G)

60,000 Federal
2
425
100,000 Calif.
2
425
Camshaft 250230 Yes

60,000 Federal
2
425
100,000 Calif.
2
425
1997-98 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
2000-01 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
2000-01 3.0L V6 (SOHC, 24-Valve) 250259 Yes Yes 60,000
3
435
Expo & Expo LRV
1992-93 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
1994 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 Federal 131

100,000 California
3
131
1992 2.4L 4-Cyl.
2
136
Camshaft 250204 60,000
2
136
1993-95 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
Galant
1989-92 2.0L 4-Cyl.
Balance Shaft 250159 TCK155 60,000
2
411
Camshaft 250155 TCK155 60,000
2
411
1993 2.0L 4-Cyl.
Balance Shaft 250168 TCK232 60,000
2
411
Camshaft 250232 TCK232 60,000
2
411
1989-92 2.0L 4-Cyl. (DOHC)
Balance Shaft 250168 2521670 Yes

60,000
2
414
Camshaft 250167 2521670 Yes

60,000
2
414
1993 2.0L 4-Cyl. (DOHC)
Balance Shaft 250168 TCK232 Yes

60,000
2
414
Camshaft 250232 TCK232 Yes

60,000
2
414
MITSUBISHI (Cont.)
A-27
1
2
3
Galant (Cont.)
1994 2.4L 4-Cyl. (DOHC)
Balance Shaft 250168 Yes 60,000 Federal 419
100,000 Calif. 419
Camshaft
Up To May, 1994 250256 TCK256 Yes 60,000 Federal 419
100,000 Calif. 419
From June, 1994 250230 Yes 60,000 Federal 419
100,000 Calif. 419
1995-96 2.4L 4-Cyl. (DOHC)
Balance Shaft 250168 Yes 60,000 Federal 419
100,000 Calif. 419
Camshaft 250230 Yes 60,000 Federal 419
100,000 Calif. 419
1985-87 2.4L 4-Cyl. (SOHC)
Balance Shaft 250159 2521240 60,000
2
422
Camshaft 250124 2521240 60,000
2
422
1994-96 2.4L 4-Cyl. (SOHC, VIN G)

60,000 Federal
2
425
100,000 Calif.
2
425
Camshaft 250230 Yes

60,000 Federal
2
425
100,000 Calif.
2
425
1997-98 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
1999-01 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
1988 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 430
3
435
Mirage
1985-86 1.5L 4-Cyl. 250073 Yes 60,000 406
1987-90 1.5L 4-Cyl. 250128 2521280 Yes 60,000 406
1991-93 1.5L 4-Cyl. 250191 2521910 60,000 406
1994-96 1.5L 4-Cyl. 250191 2521910 Yes

60,000 Federal 406
60,000 Calif.
3
406
1997-01 1.5L 4-Cyl. 250289 Yes

100,000
3
406
1997-01 1.5L 4-Cyl. 250289 Yes 60,000
3
406
1985-88 1.6L 4-Cyl. (SOHC) 250093 Yes 60,000 409
1989-92 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
1993 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
1994-96 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 Federal 131

100,000 Calif.
3
131
1997-00 1.8L 4-Cyl. 250288 Yes

100,000
3
131
1997-00 1.8L 4-Cyl. 250288

Yes

60,000
3
131
Precis
1987-89 1.5L 4-Cyl. 250073 Yes 60,000 406
1990-93 1.5L 4-Cyl. 250128 2521280 Yes 60,000 406
Sigma
1989-90 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 430
Tredia (See Cordia)
MITSUBISHI (Cont.)
A-28
1
2
3
3000GT
1991-93 3.0L V6 (DOHC) 250195 Yes Yes 60,000 142
1992-98 3.0L V6 (DOHC) 250195 Yes Yes 60,000
3
142
1997-98 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes

60,000
3
430
Light Trucks
Montero
1989-93 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 430
1994 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 Federal 430
100,000 Calif. 430

Federal 435
100,000 Calif. 435
1994-96 3.5L V6 (DOHC) 250253 Yes

60,000 Federal 439

100,000 Calif. 439
1997-00 3.5L V6 (SOHC) 250287 Yes Yes

60,000
3
442
Montero Sport
1997-98 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
1999 2.4L 4-Cyl. (SOHC, VIN G)

60,000
2 , 3
425
2 , 3
425
3
435
1997-01 3.5L V6 (SOHC) 250287 Yes Yes

60,000
3
442
Pickup
1983-86 2.0L 4-Cyl.
2
411
Camshaft 250089 60,000
2
411
1987-89 2.0L 4-Cyl.
Balance Shaft 250159 2521581 60,000
2
411
Camshaft 250158 2521581 60,000
2
411
1983-86 2.3L 4-Cyl. Diesel
2
138
2
138
1990-92 2.4L 4-Cyl.
Balance Shaft 250159 2521240 60,000
2
140
Camshaft 250124 2521240 60,000
2
140
1993-96 2.4L 4-Cyl.
2
140
Camshaft 250229 60,000
2
140
1990-93 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 430
1994 3.0L V6 (SOHC, 12-Valve) 250139 2521390 Yes 60,000 Federal 430
100,000 Calif. 430
Van
1987-90 2.4L 4-Cyl. (SOHC)
Balance Shaft 250159 2521240 60,000
2
422
Camshaft 250124 2521240 60,000
2
422
NISSAN
Passenger Cars
Maxima
1985 3.0L V6 (SOHC) 250104 TCK104 Yes 454
1996-91 3.0L V6 (SOHC) 250104 TCK104 Yes 60,000 454
MITSUBISHI (Cont.)
A-29
1
2
3
Maxima (Cont.)
1992-94 3.0L V6 (SOHC)
Square Tooth Sprocket 250104 TCK104 Yes 60,000 454
Pulsar & Pulsar NX
1983-84 1.5L 4-Cyl. 250077 TCK077 Yes

60,000
1
446
1987 1.6L 4-Cyl. (DOHC) 250137 Yes 60,000 448
1983-88 1.6L 4-Cyl. (SOHC) 250077 TCK077 Yes

60,000
1
446
1988-89 1.8L 4-Cyl. (DOHC) 250137 Yes 60,000 448
Sentra
1982-83 1.5L 4-Cyl. 250077 TCK077 Yes

60,000
1
446
1983-88 1.6L 4-Cyl. (SOHC) 250077 TCK077 Yes

60,000
1
446
1983-87 1.7L 4-Cyl. Diesel
Camshaft 250096 Yes

60,000
1
450
Injection Pump 250097 Yes

60,000
1
450
Stanza
1982-85 2.0L 4-Cyl. 250078 Yes

60,000
1
451
1986-89 2.0L 4-Cyl. 250078 Yes 60,000 451
Stanza Wagon
1982-89 *2.0L 4-Cyl. 250078 60,000 451
200SX
1984-85 1.8L 4-Cyl. (Turbo) T100

60,000
1
451
1986-87 1.8L 4-Cyl. (Turbo) T100 60,000 451
1984-85 2.0L 4-Cyl. 250078 Yes

60,000
1
451
1986-88 2.0L 4-Cyl. 250078 Yes 60,000 451
1987-88 3.0L V6 (SOHC) 250104 TCK104 Yes 60,000 454
300ZX
1984-85 3.0L V6 (SOHC) 250104 TCK104 Yes

60,000
1
454
1986-89 3.0L V6 (SOHC) 250104 TCK104 Yes 60,000 454
1990-93 3.0L V6 (DOHC) 250180 Yes 60,000 452
1994-96 3.0L V6 (DOHC) 250251 Yes 60,000 452
310
1982 1.5L 4-Cyl. 250077 TCK077 Yes

60,000
1
446
Light Trucks
Frontier
1999-01 3.3L V6 (SOHC) 250249 105,000 456
Pathfinder
1986-92 3.0L V6 (SOHC) 250104 TCK104 Yes 60,000 454
1993-94 3.0L V6 (SOHC)
1995-96 3.0L V6 (SOHC) 250249 Yes 60,000 454
1999-00 3.3L V6 (SOHC) 250249 Yes 105,000 456
Pickup
1986-92 3.0L V6 (SOHC) 250104 TCK104 Yes 60,000 454
1993-94 3.0L V6 (SOHC)
1995-96 3.0L V6 (SOHC) 250249 Yes 60,000 454
Quest
1993-94 3.0L V6 (SOHC)
1995-98 3.0L V6 (SOHC) 250249 Yes 60,000 454
1999-01 3.3L V6 (SOHC) 250249 105,000 456
NISSAN (Cont.)
A-30
1
2
3
Xterra
2000-01 3.3L V6 (SOHC) 250249 105,000 456
OLDSMOBILE
Cutlass Supreme
1991-95 3.4L V6 250192 Yes Yes 60,000 238
1996 3.4L V6 250273 Yes Yes 60,000 238
Firenza
1982-86 1.8L 4-Cyl. 250081

60,000
1
228
1987-88 2.0L 4-Cyl. 250081

60,000
1
229
PEUGEOT
405
1989-91 1.9L 4-Cyl. (DOHC) T188

60,000
1
460
1991-89 1.9L 4-Cyl. (SOHC) 250189

60,000
1
460
505
1986-91 2.2L 4-Cyl. (Exc. Turbo) 250140

60,000
1
462
PLYMOUTH
Passenger Cars
Acclaim
1985-89 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1989-93 3.0L V6 (SOHC) 250139

2521390 Yes 60,000 110
1994-95 3.0L V6 (SOHC) 250139

2521390 Yes 60,000
3
110
Arrow
1978-80 1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1977-80 1.6L 4-Cyl.

60,000
2
85
Camshaft 250013

60,000
2
85
Breeze
1996-00 2.0L 4-Cyl. (SOHC, VIN C) 250245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
105,000 Calif. 106
Caravelle
1983-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114

60,000
1
101
1988 2.5L 4-Cyl. 250132

60,000
1
101
Champ
1979-82 1.4L 4-Cyl. 250073 Yes 60,000 83
1979-82 1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1979-80 1.6L 4-Cyl.

60,000
2
85
Camshaft 250013

60,000
2
85
Colt
1979-84 1.4L 4-Cyl. 250073 Yes 60,000 83
1985-86 1.5L 4-Cyl. 250073 Yes 60,000 114
1987-90 1.5L 4-Cyl. 250128

2521280 Yes 60,000 114
1991-94 1.5L 4-Cyl. 250191

2521910 60,000 114
1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1983-89 1.6L 4-Cyl. w/o Bal. Shaft 250093 60,000 87
1977-80 1.6L 4-Cyl.

60,000
2
85
Camshaft 250013

60,000
2
85
NISSAN (Cont.)
A-31
1
2
3
Colt (Cont.)
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
1989-90 1.8L 4-Cyl. (VIN T) 250093 60,000 91
1992-94 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) 250201 Yes 60,000 131
1984-86 2.0L 4-Cyl. (SOHC)
2
121
Camshaft 250089 60,000
2
121
1987-91 2.0L 4-Cyl. (SOHC)

2521581 60,000
2
121
Camshaft 250158

2521581 60,000
2
121
1992 2.4L 4-Cyl.
2
136
Camshaft 250204 60,000
2
136
1993 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
1994 2.4L 4-Cyl.
2
136
Camshaft 250230 60,000
2
136
Colt 100 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
Colt 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) 250165 Yes 60,000 125
Horizon
1978-83 1.7L 4-Cyl. 250017

2520170 60,000
1
89
1981-88 2.2L 4-Cyl. 250071

2520710 60,000
1
101
1989-90 2.2L 4-Cyl. 250153

2521530 60,000
1
101
Laser
1990-94 1.8L 4-Cyl.

2521580 60,000
2
128
Camshaft 250158

2521580 60,000
2
128
1990-94 2.0L 4-Cyl. (DOHC)

2521670 Yes

60,000
2
116
Camshaft 250167

2521670 Yes

60,000
2
116
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 250246 Yes Yes 105,000 133
1995-00 2.0L 4-Cyl. (SOHC, VIN C) 250245 Yes Yes 105,000 93
Reliant
1981-88 2.2L 4-Cyl. 250071 2520710 60,000
1
101
1989 2.2L 4-Cyl. 250153 2520710 60,000
1
101
1986-87 2.5L 4-Cyl. 250114

60,000
1
101
1988 2.5L 4-Cyl. 250132

60,000
1
101
1989 2.5L 4-Cyl. 250153

2521530 60,000
1
101
Sapporo
1978-80 1.6L 4-Cyl. w/o Bal. Shaft 250064 60,000 87
1977-80 1.6L 4-Cyl.

60,000
2
85
Camshaft 250013

60,000
2
85
Sundance
1987-88 2.2L 4-Cyl. 250071 2520710 60,000
1
101
1989-94 2.2L 4-Cyl. 250153

2521530 60,000
1
101
1988 2.5L 4-Cyl. 250132

60,000
1
101
PLYMOUTH (Cont.)
A-32
1
2
3
Sundance (Cont.)
1989-94 2.5L 4-Cyl. 250153

2521530 60,000
1
101
1992-93 3.0L V6 (SOHC) 250139

2521390 60,000 110
1994 3.0L V6 (SOHC) 250139

2521390 60,000
3
110
TC3
1981-82 1.7L 4-Cyl. 250017

2520170 60,000
1
89
1981-82 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Turismo
1983 1.7L 4-Cyl. 250017

2520170 60,000
1
89
1983-87 2.2L 4-Cyl. 250071

2520710 60,000
1
101
Light Trucks
(See DODGE/PLYMOUTH Light Trucks)
PONTIAC
Passenger Cars
Acadian (Canadian)
1976 1.4L 4-Cyl. 250037

60,000
1
221
1977 1.4L 4-Cyl. 250039

60,000
1
221
1976 1.6L 4-Cyl. 250037

60,000
1
221
1977-78 1.6L 4-Cyl. 250039

60,000
1
221
1979-87 1.6L 4-Cyl. 250061

60,000
1
221
1981-85 1.8L 4-Cyl. Diesel 250076 Yes

60,000
1
226
Firefly (Canadian)
1985-88 1.0L 3-Cyl. 250095 60,000 211
1989-91 1.0L 3-Cyl. 250166 60,000 211
1994-95 1.0L 3-Cyl. 250243 60,000 211
1996-97 1.0L 3-Cyl. 250194

2521940 60,000 211
1998-00 1.0L 3-Cyl. 250194

2521940 100,000 211
1995-97 1.3L 4-Cyl. 250272 60,000 213
1998-00 1.3L 4-Cyl. 250194

2521940 100,000 213
Grand Am
1987-88 2.0L 4-Cyl. 250081 Yes

60,000
1
229
1989 2.0L 4-Cyl. (Turbo) 250163

2521630 Yes

60,000
1
229
Grand Prix
1991-95 3.4L V6 250192 Yes Yes 60,000 238
1996 3.4L V6 250273 Yes Yes 60,000 238
J2000
1982 1.8L 4-Cyl. 250081 Yes

60,000
1
228
LeMans
1988-89 1.6L 4-Cyl. Yes

60,000
1
223
1990 1.6L 4-Cyl.
With Tensioner 250203 Yes Yes

60,000
1
223
Without Tensioner 250148 Yes Yes

60,000
1
223
1991-93 1.6L 4-Cyl. 250203 Yes Yes

60,000
1
223
1989 2.0L 4-Cyl.
First Design 250081 Yes

60,000
1
229
Second Design 250163 2521630 Yes

60,000
1
229
1990 2.0L 4-Cyl. 250163 2521630 Yes

60,000
1
229
Sunbird
1985-86 1.8L 4-Cyl. 250081 Yes

60,000
1
228
1987-88 2.0L 4-Cyl. 250081 Yes

60,000
1
229
1989-94 2.0L 4-Cyl. 250163 2521630 Yes

60,000
1
229
Sunburst (Canadian)
1985-88 1.5L 4-Cyl. 250162 Yes Yes 60,000 219
PLYMOUTH (Cont.)
A-33
1
2
3
T1000
1981-82 1.6L 4-Cyl. 250061 60,000
1
221
1000
1983-87 1.6L 4-Cyl. 250061 60,000
1
221
2000
1983 1.8L 4-Cyl. 250081 Yes 60,000
1
228
2000 Sunbird
1984 1.8L 4-Cyl. 250081 Yes 60,000
1
228
Light Trucks
Sunrunner (Canadian)
1989-95 1.6L 4-Cyl. (8-Valve)
California 250212 60,000
1
215
Except California 250164 60,000
1
215
1994-98 1.6L 4-Cyl. (16-Valve)
California 250212

60,000 215
Except California 250164

60,000 215
PORSCHE
924
1977-82 2.0L 4-Cyl. 250017 Yes 45,000 463
1987-88 2.5L 4-Cyl.

45,000 464
Camshaft 250107 Yes

45,000 464
928
1978-82 4.5L V8 250196 Yes 60,000 467
1983-84 4.5L V8 250196 Yes 60,000 467
1985-91 5.0L V8 250196 Yes 60,000 467
1992-95 5.4L V8 250196 Yes 60,000 467
944
1983-89 2.5L 4-Cyl.

45,000 464
Camshaft 250107 Yes

45,000 464
1989 2.7L 4-Cyl.

45,000 464
Camshaft 250107 Yes

45,000 464
1989-91 3.0L 4-Cyl.

45,000 464
Camshaft 250152 Yes

45,000 464
944S & 944 Turbo
1987-88 2.5L 4-Cyl.

45,000 464
Camshaft 250152 Yes

45,000 464
968
1992-95 3.0L 4-Cyl.

45,000 464
Camshaft 250152 Yes

45,000 464
RENAULT
Alliance & Encore
1985-87 1.7L 4-Cyl. 250119 Yes

60,000
1
470
Fuego & Sportwagon
1984-86 2.2L 4-Cyl. 250140

60,000
1
472
PONTIAC (Cont.)
A-34
1
2
3
SAAB
900
1994-97 2.5L V6 250285 Yes 60,000 474
9000
1995-97 3.0L V6 250285 Yes 60,000 474
SATURN
L Series
2000-01 3.0L V6 (DOHC) 250285 Yes Yes 100,000 235
STERLING
825
1987-88 2.5L V6 250129 Yes

60,000
1
475
827
1989-91 2.7L V6 250129 Yes

60,000
1
475
SUBARU
Coupe
1985-89 1.8L 4-Cyl.
Right Hand Belt 250300 TCK300 52,000
2
478
Left Hand Belt 250299 TCK299 52,000
2
478
Impreza & Outback Sport
1993 1.8L 4-Cyl. 250172 TCK172 60,000 480
1994 1.8L 4-Cyl. 250254 60,000 480
1995-97 1.8L 4-Cyl. 250254 60,000 Federal 480
105,000 Calif. 480
1995-98 2.2L 4-Cyl. 250254 60,000 Federal 480
105,000 Calif. 480
1999-01 2.2L 4-Cyl. (SOHC) 250304 105,000 482
1996-97 2.5L 4-Cyl. (DOHC) 250277 Yes 60,000 484
1998-99 2.5L 4-Cyl. (DOHC) 250277 Yes 105,000 484
Justy
1987-95 1.2L 3-Cyl. T135 60,000 477
Legacy & Outback
1993 2.2L 4-Cyl. 250172 TCK172 60,000 480
1994 2.2L 4-Cyl. 250254 60,000 480
1995-98 2.2L 4-Cyl. 250254 60,000 Federal 480
105,000 Calif. 480
1999-01 2.2L 4-Cyl. (SOHC) 250304 105,000 482
1996-97 2.5L 4-Cyl. (DOHC) 250277 Yes 60,000 484
1998-99 2.5L 4-Cyl. (DOHC) 250277 Yes 105,000 484
2000-01 2.5L 4-Cyl. (SOHC) 250307 105,000 482
Loyale
1990-94 1.8L 4-Cyl.
2
478
2
478
RX
1985-89 1.8L 4-Cyl.
2
478
2
478
Sedan & Station Wagon
1985-89 1.8L 4-Cyl.
2
478
2
478
A-35
1
2
3
SVX
1992-94 3.3L 6-Cyl. T209 60,000 491
1995-97 3.3L 6-Cyl. T209 60,000 Federal 491
105,000 Calif. 491
XT
1985-91 1.8L 4-Cyl.
2
478
2
478
XT6
1988-91 2.7L 6-Cyl.
Right Hand Belt 250150

60,000
2
487
Left Hand Belt 250151

60,000
2
487
Light Trucks
Forester
1998 2.5L 4-Cyl. (DOHC) 250277 Yes 105,000 484
1999-01 2.5L 4-Cyl. (SOHC) 250304 105,000 482
SUZUKI
Passenger Cars
Esteem
1995-00 1.6L 4-Cyl. 250212

60,000 497
Esteem (Canadian)
2001 1.6L 4-Cyl. 250212

60,000 497
Swift
1989-92 1.3L 4-Cyl. (DOHC) T171 Yes 60,000
1
492
1993-94 1.3L 4-Cyl. (DOHC) T171 Yes 60,000 492
1989-92 1.3L 4-Cyl. (SOHC) 250095

60,000
1
494
1993 1.3L 4-Cyl. (SOHC) 250095 60,000 494
1994 1.3L 4-Cyl. (SOHC) 250243 60,000 494
1995-97 1.3L 4-Cyl. (SOHC) 250272 60,000 494
1998-01 1.3L 4-Cyl. (SOHC) 250194 2521941 60,000 494
Light Trucks
Samurai
1985-92 1.3L 4-Cyl. (SOHC) 250095

60,000
1
494
1993 1.3L 4-Cyl. (SOHC) 250095 60,000 494
1994 1.3L 4-Cyl. (SOHC)
VIN R4100375 & Earlier 250095 60,000 494
From VIN R4100376 250243 60,000 494
1995 1.3L 4-Cyl. 250243 60,000 494
Sidekick
1989 1.3L 4-Cyl. (SOHC) 250095

60,000
1
494
1989-91 1.6L 4-Cyl. 250164

60,000
1
497
1992 1.6L 4-Cyl.
Convertible 250164 60,000
1
497
Hardtop 250212

60,000
1
497
1993-95 1.6L 4-Cyl.
Convertible 250164 60,000 497
Hardtop 250212 60,000 497
1996-98 1.6L 4-Cyl. 250212 60,000 497
Vitara
1999-01 1.6L 4-Cyl. 250212 60,000 497
X-90
1996-98 1.6L 4-Cyl. 250212 60,000 497
SUBARU (Cont.)
A-36
1
2
3
TOYOTA
Passenger Cars
Avalon
1995-97 3.0L V6 250257 Yes 60,000, Severe 543
1998-01 3.0L V6 250257 90,000 547
Camry
1984-85 1.8L 4-Cyl. Diesel 250098 60,000 516
1983-85 2.0L 4-Cyl. 250087 TCK087 Yes 60,000
1
518
1986 2.0L 4-Cyl. 250087 TCK087 Yes 60,000, Severe 518
1987-91 2.0L 4-Cyl. 250199 TCK199 Yes 60,000, Severe 518
1998-01 2.2L 4-Cyl. 250199 TCK199 90,000 525
1988-91 2.5L V6 250157 Yes 60,000, Severe 543
1992-93 3.0L V6 250200 Yes 60,000, Severe 543
1995-97 3.0L V6 250257 Yes 60,000, Severe 543
1998-01 3.0L V6 250257 90,000 547
Camry Solara
1999-01 2.2L 4-Cyl. 250199 TCK199 90,000 525
1998-01 3.0L V6 250257 90,000 547
Celica, Celica GT & ST
1990-92 1.6L 4-Cyl. (DOHC, 4A-F) 250036 TCK036 60,000, Severe 512
1993 1.6L 4-Cyl. (DOHC, 4A-F) 250239 60,000, Severe 512
1994-97 1.8L 4-Cyl. (7A-FE) 250235 60,000, Severe 512
1986 2.0L 4-Cyl. 250087 TCK087 Yes 60,000, Severe 518
1990-93 2.0L 4-Cyl. 250125 Yes 60,000, Severe 518
1998-01 2.2L 4-Cyl. 250199 TCK199 Yes 90,000 525
Celica GTS
1986-88 2.0L 4-Cyl. 250125 Yes 60,000, Severe 518
Celica Supra
1982-83 2.8L 6-Cyl. 250074 60,000, Severe 533
1984-86 2.8L 6-Cyl. 250101 60,000, Severe 533
Corolla
1983-85 1.6L 4-Cyl. (SOHC) 250070 2520700 60,000
1
509
1986-88 1.6L 4-Cyl. (SOHC) 250070 2520700 60,000, Severe 509
1984-85 1.8L 4-Cyl. Diesel 250098 60,000 516
1993-97 1.8L 4-Cyl. (7A-FE) 250235 60,000, Severe 512
Corolla FX & FX-16
1986-88 1.6L 4-Cyl. 250070 2520700 60,000, Severe 509
1985 1.6L 4-Cyl. (4A-GE) 250112 60,000
1
506
1986-88 1.6L 4-Cyl. (4A-GE) 250112 60,000, Severe 506
Corolla GTS
1989-91 1.6L 4-Cyl. (4A-GE/GELC) 250176 60,000, Severe 506
Corolla SR5
1985 1.6L 4-Cyl. 250070 2520700 60,000
1
509
1986-88 1.6L 4-Cyl. 250070 2520700 60,000, Severe 509
Corolla Tercel
1980-82 1.5L 4-Cyl. 250070 2520700 60,000
1
499
Cressida
1983 2.8L 6-Cyl. 250074 60,000, Severe 533
1984-88 2.8L 6-Cyl. 250101 60,000, Severe 533
A-37
1
2
3
Cressida (Cont.)
1989-91 3.0L 6-Cyl. 250126 60,000, Severe 535
1992 3.0L 6-Cyl. 250238 60,000, Severe 535
MR2
1985 1.6L 4-Cyl. (4A-GE) 250112 60,000
1
506
1986-88 1.6L 4-Cyl. (4A-GE) 250112 60,000, Severe 506
1989 1.6L 4-Cyl. (4A-GE) 250176 60,000, Severe 506
1991-95 2.0L 4-Cyl. 250125 Yes 60,000, Severe 518
Paseo
1992-97 1.5L 4-Cyl. (5E-FE) 250208 60,000, Severe 504
1998 1.5L 4-Cyl. (5E-FE) 250208 90,000, Severe 504
1999 1.5L 4-Cyl. (5E-FE) 250208 90,000 504
Supra
1986-90 3.0L 6-Cyl. (7M-GE) 250126 60,000, Severe 535
1991-92 3.0L 6-Cyl. (7M-GE) 250238 60,000, Severe 535
1993-97 3.0L 6-Cyl. (2JZ) 250215 60,000, Severe 537
1998 3.0L 6-Cyl. (2JZ) 250215 90,000, Severe 539
Tercel
1983-86 1.5L 4-Cyl. (3A-C)) 250070 2520700 60,000
1
499
1987 1.5L 4-Cyl. (Sedan, 3E) 250136 Yes 60,000, Severe 501
1988-94 1.5L 4-Cyl. (3E) 250233 TCK233 Yes 60,000, Severe 501
1995-97 1.5L 4-Cyl. (5E-FE) 250208 60,000, Severe 504
1998 1.5L 4-Cyl. (5E-FE) 250208 90,000, Severe 504
1999 1.5L 4-Cyl. (5E-FE) 250208 90,000 504
Tercel Wagon
1987-88 1.5L 4-Cyl. (3A-C) 250070 2520700 60,000, Severe 499
Light Trucks
Highlander
2001 3.0L V6 250257 90,000 547
Land Cruiser
1998-01 4.7L V8 250298 Yes Yes 90,000 366
Pickup
1981 2.2L 4-Cyl. Diesel 250079 Yes 100,000 529
1982 2.2L 4-Cyl. Diesel
Up To May 31 250079 Yes 100,000 529
From June 1 250084 Yes 100,000 529
1983 2.2L 4-Cyl. Diesel 250084 Yes 100,000 529
1984-87 2.4L 4-Cyl. Diesel 250084 Yes 100,000 531
1988-92 3.0L V6 (3V-ZE) 250154 Yes 60,000, Severe 552
1993-95 3.0L V6 (3V-ZE) 250240 Yes 60,000, Severe 552
RAV4
1996-97 2.0L 4-Cyl. 250199 Yes 60,000, Severe 523
1998 2.0L 4-Cyl. 250199 Yes 90,000, Severe 523
1999-00 2.0L 4-Cyl. 250199 Yes 90,000 523
Sienna
1998-01 3.0L V6 250257 90,000 547
Tacoma
1995-97 3.4L V6 250271 Yes 60,000, Severe 555
1999-01 3.4L V6 250271 Yes 90,000 555
Tundra
2000-01 3.4L V6 250271 Yes 90,000 555
2000-01 4.7L V8 250298 Yes Yes 90,000 366
TOYOTA (Cont.)
A-38
1
2
3
T100
1995-97 3.4L V6 250271 Yes 60,000, Severe 555
1998 3.4L V6 250271 Yes 90,000 555
4Runner
1988-92 3.0L V6 (3V-ZE) 250154 Yes 60,000, Severe 552
1993-95 3.0L V6 (3V-ZE) 250240 Yes 60,000, Severe 552
1996-97 3.4L V6 250271 Yes 60,000, Severe 555
1999-01 3.4L V6 250271 Yes 90,000 555
VOLKSWAGEN
Passenger Cars
Beetle (New Beetle)
1999-01 1.8L 4-Cyl. (APH & AWV) 250306 Yes Yes 105,000 561
1998-00 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
2001 2.0L 4-Cyl. (AEG) 250296 Yes Yes 105,000 583
1998-01 1.9L 4-Cyl. Diesel (ALH) 250301 Yes 60,000 (Man. Trans.) 578
40,000 (Auto. Trans.) 578
Cabrio
1995-01 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
1999 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
Cabriolet
1985-89 1.8L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1985-93 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Corrado
1990-92 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Dasher
1974-75 1.5L 4-Cyl. 250017 2520170

60,000
1
558
1979-80 1.5L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1976-80 1.6L 4-Cyl. 250017 2520170

60,000
1
558
1981 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
Fox
1987-93 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Golf
1985-87 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1985-89 1.8L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1985-92 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
1993-96 1.9L 4-Cyl. Diesel
AAZ, AHU & 1Z Engines 250242 Yes 60,000 573
40,000 (Auto. Trans.) 578
1993-99 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
1999 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
2000 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
Golf (Canadian)
1988-92 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1993-95 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
1995 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
GTI
1985-89 1.8L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1985-92 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
1990-92 2.0L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1996-99 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
1999 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
TOYOTA (Cont.)
A-39
1
2
3
GTI (Canadian)
1993-95 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
Jetta
1980 1.6L 4-Cyl. 250017 2520170

60,000
1
558
1981-86 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1989-92 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1981-84 1.7L 4-Cyl. 250017 2520170

60,000
1
558
1985-89 1.8L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1984-92 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
1993-98 1.9L 4-Cyl. Diesel
AAZ, AHU & 1Z Engines 250242 Yes 60,000 573
40,000 (Auto. Trans.) 578
1990-92 2.0L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1993-99 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
1999-00 2.0L 4-Cyl. (AEG) 250296 Yes Yes 60,000
1
583
Jetta (Canadian)
1993-95 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Passat
1998-99 1.8L 4-Cyl. (AEB & ATW)
152 Tooth Belt 250291 Yes Yes 90,000 564
2000-01 1.8L 4-Cyl. (AUG & AWM)
1990-92 2.0L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1993-96 2.0L 4-Cyl. (ABA) 250262 Yes 60,000
1
581
1998 2.8L V6 250297 Yes Yes 90,000 585
1999 2.8L V6 250297 Yes Yes 75,000 585
2000-01 2.8L V6 250297 Yes Yes 105,000 585
Passat (Canadian)
1992-94 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Quantum
1982-86 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1982-83 1.7L 4-Cyl. 250017 2520170

60,000
1
558
1985 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
1984-85 2.1L 5-Cyl.
.70 Belt Width 250127 Yes
1
60,000 79
1
60,000 79
1983-86 2.2L 5-Cyl.
1
60,000 79
1
60,000 79
1987-88 2.2L 5-Cyl. 250127 Yes
1
60,000 79
Rabbit
1975-79 1.5L 4-Cyl. 250017 2520170

60,000
1
558
1977-80 1.5L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1980 1.6L 4-Cyl. 250017 2520170

60,000
1
558
1981-84 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1981-84 1.7L 4-Cyl. 250017 2520170

60,000
1
558
1983-84 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Scirocco
1978 1.5L 4-Cyl. 250017 2520170

60,000
1
558
1976-80 1.6L 4-Cyl. 250017 2520170

60,000
1
558
1981-83 1.7L 4-Cyl. 250017 2520170

60,000
1
558
VOLKSWAGEN (Cont.)
A-40
1
2
3
Scirocco (Cont.)
1985-89 1.8L 4-Cyl. (DOHC) 250292 Yes 60,000
1
571
1983-89 1.8L 4-Cyl. (SOHC) 250017 2520170

60,000
1
569
Light Trucks
Pickup & Rabbit Pickup
1980 1.5L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1980 1.6L 4-Cyl. 250017 2520170

60,000
1
558
1981-83 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
1981-83 1.7L 4-Cyl. 250017 2520170

60,000
1
558
Vanagon
1982 1.6L 4-Cyl. Diesel 250043 Yes 60,000
1
559
VOLVO
C70, S70 & V70
1998 2.3L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 70,000 598
From Eng. VIN 1266128 250311 Yes Yes 70,000 598
1999-01 2.3L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 105,000
3
598
From Eng. VIN 1266128 250311 Yes Yes 105,000
3
598
1998 2.4L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 70,000 598
1999-01 2.4L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 105,000
3
598
3
598
Coupe
1991 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 593
DL & GL
1980-83 2.1L 4-Cyl. 250032 TCK032

Yes 40,000 592
1982-85 2.3L 4-Cyl. 250032 TCK032

Yes 40,000 592
1980-84 2.4L 6-Cyl. Diesel
2
602
Injection Pump 250082 Yes 75,000
2
602
GLE (Canadian)
1984 2.1L 4-Cyl. 250032 TCK032

Yes 40,000 592
GLT
1981-83 2.1L 4-Cyl. 250032 TCK032

Yes 40,000 592
GLT (Canadian)
1983 2.3L 4-Cyl. 250032 TCK032

Yes 40,000 592
GT Turbo
1984-85 2.1L 4-Cyl. 250032 TCK032

Yes 40,000 592
S40 & V40
2000-01 1.9L 4-Cyl. Turbo
Up Eng. VIN 1219110 250252 Yes Yes 105,000 587
S60
2001 2.3L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 105,000
3
598
3
598
2001 2.4L 5-Cyl.
To Eng. VIN 1266127 250252 Yes Yes 105,000
3
598
3
598
VOLKSWAGEN (Cont.)
A-41
1
2
3
S90 & V90
1997-98 2.9L 6-Cyl. 250270 Yes Yes 70,000 600
240
1986-92 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 593
1993 2.3L 4-Cyl. 250234 Yes 50,000 593
242, 244 & 245
1976-79 2.1L 4-Cyl. 250032 TCK032

Yes 40,000 592
740
1986-92 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 593
1985-86 2.4L 6-Cyl. Diesel
2
602
2
602
740 (Canadian)
1986-88 2.3L 4-Cyl. (B234, DOHC)

50,000
2
594

50,000
2
594
1989 2.3L 4-Cyl. (B234, DOHC)
Automatic Tensioner

50,000
2
594
Camshaft T198 Yes Yes

50,000
2
594
Manual Tensioner

50,000
2
594

50,000
2
594
1990 2.3L 4-Cyl. (B234, DOHC)

50,000
2
594

50,000
2
594
760
1985-90 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 593
1985 2.4L 6-Cyl. Diesel
2
602
2
602
760 GLE
1984 2.3L 4-Cyl. 250032 TCK032

Yes 40,000 592
1983-84 2.4L 6-Cyl. Diesel
2
602
2
602
780
198-90 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 593
850
1994 2.3L 5-Cyl. Turbo
Up To Eng. No. 131034 250217 Yes Yes 50,000
3
600
From Eng. No. 131035 250252 Yes Yes 70,000
3
600
Up To Eng. No. 131034 250217 Yes Yes 50,000
3
600
From Eng. No. 131035 250252 Yes Yes 70,000
3
600
850 (Canadian)
1996 2.3L 5-Cyl. Turbo 250252 Yes Yes 70,000 600
Up To Eng. No. 131034 250217 Yes Yes 70,000 600
From Eng. No. 131035 250269 Yes Yes 70,000 600
VOLVO (Cont.)
A-42
1
2
3
940
1991-92 2.3L 4-Cyl. 250032 TCK032

Yes 50,000 592
1993 2.3L 4-Cyl. 250234 Yes 50,000 592
1994-95 2.3L 4-Cyl. (B230FT) 250234 Yes 50,000 w/o EGR 593
100,000 w/ EGR 593
940 (Canadian)
1991-92 2.3L 4-Cyl. (B234, DOHC)

50,000
2
594
Camshaft T198 Yes Yes

50,000
2
594
960
1992 2.9L 6-Cyl. 250217 Yes Yes 30,000
3
600
1993 2.9L 6-Cyl. 250252 Yes Yes 50,000 600
1994 2.9L 6-Cyl. 250252 Yes Yes 50,000 600
1995-97 2.9L 6-Cyl. 250270 Yes Yes 70,000 600
YUGO
GV Series
1986-89 1.1L 4-Cyl. 250018 Yes

60,000
1
604
1987 1.3L 4-Cyl. 250018 Yes

60,000
1
604
VOLVO (Cont.)
ACDELCO
TB013 ............. 250013
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB020 ............. 250020
TB028 ............. 250028
TB032 ............. 250032
TB036 ............. 250036
TB037 ............. 250037
TB039 ............. 250039
TB041 ............. 250041
TB043 ............. 250043
TB061 ............. 250061
TB062 ............. 250062
TB064 ............. 250064
TB065 ............. 250065
TB067 ............. 250067
TB070 ............. 250070
TB071 ............. 250071
TB073 ............. 250073
TB074 ............. 250074
TB075 ............. 250075
TB076 ............. 250076
TB077 ............. 250077
TB078 ............. 250078
TB079 ............. 250079
TB081 ............. 250081
TB082 ............. 250082
TB083 ............. 250083
TB084 ............. 250084
TB087 ............. 250087
TB088 ............. 250088
TB089 ............. 250089
TB090 ............. 250090
TB091 ............. 250091
TB092 ............. 250092
TB093 ............. 250093
TB094 ............. 250094
TB095 ............. 250095
TB096 ............. 250096
TB097 ............. 250097
TB098 ............. 250098
TB099 ............. 250099
TB100 ............. 250100
TB101 ............. 250101
TB102 ............. 250102
TB103 ............. 250103
TB104 ............. 250104
TB106 ............. 250106
TB107 ............. 250107
TB112 ............. 250112
TB113 ............. 250113
TB114 ............. 250114
TB117 ............. 250117
TB118 ............. 250118
TB119 ............. 250119
TB121 ............. 250121
TB122 ............. 250122
TB123 ............. 250123
TB124 ............. 250124
TB125 ............. 250125
TB126 ............. 250126
TB127 ............. 250127
TB128 ............. 250128
TB129 ............. 250129
TB130 ............. 250130
TB131 ............. 250131
TB132 ............. 250132
TB134 ............. 250134
TB135 ............. 250135
TB136 ............. 250136
TB137 ............. 250137
TB138 ............. 250138
TB139 ............. 250139
TB140 ............. 250140
TB141 ............. 250141
ACDELCO - Cont.
TB142 ............. 250142
TB143 ............. 250143
TB144 ............. 250144
TB145 ............. 250145
TB146 ............. 250146
TB147 ............. 250147
TB148 ............. 250148
TB149 ............. 250149
TB150 ............. 250150
TB151 ............. 250151
TB153 ............. 250153
TB154 ............. 250154
TB155 ............. 250155
TB157 ............. 250157
TB158 ............. 250158
TB159 ............. 250159
TB160 ............. 250160
TB161 ............. 250161
TB162 ............. 250162
TB163 ............. 250163
TB164 ............. 250164
TB165 ............. 250165
TB166 ............. 250166
TB167 ............. 250167
TB168 ............. 250168
TB169 ............. 250169
TB170 ............. 250170
TB171 ............. 250171
TB172 ............. 250172
TB173 ............. 250173
TB174 ............. 250174
TB176 ............. 250176
TB177 ............. 250177
TB178 ............. 250178
TB179 ............. 250179
TB180 ............. 250180
TB181 ............. 250181
TB182 ............. 250182
TB183 ............. 250183
TB184 ............. 250184
TB185 ............. 250185
TB186 ............. 250186
TB187 ............. 250187
TB190 ............. 250190
TB191 ............. 250191
TB192 ............. 250192
TB193 ............. 250193
TB194 ............. 250194
TB195 ............. 250195
TB199 ............. 250199
TB200 ............. 250200
TB201 ............. 250201
TB203 ............. 250203
TB204 ............. 250204
TB205 ............. 250205
TB206 ............. 250206
TB207 ............. 250207
TB208 ............. 250208
TB209 ............. 250209
TB210 ............. 250210
TB211 ............. 250211
TB212 ............. 250212
TB214 ............. 250214
TB215 ............. 250215
TB216 ............. 250216
TB217 ............. 250217
TB218 ............. 250218
TB219 ............. 250219
TB220 ............. 250220
TB221 ............. 250221
TB223 ............. 250223
TB224 ............. 250224
TB225 ............. 250225
TB226 ............. 250226
TB227 ............. 250227
TB228 ............. 250228
ACDELCO - Cont.
TB229 ............. 250229
TB230 ............. 250230
TB232 ............. 250232
TB233 ............. 250233
TB234 ............. 250234
TB235 ............. 250235
TB236 ............. 250236
TB237 ............. 250237
TB239 ............. 250239
TB240 ............. 250240
TB241 ............. 250241
TB242 ............. 250242
TB244 ............. 250244
TB245 ............. 250245
TB246 ............. 250246
TB247 ............. 250247
TB248 ............. 250248
TB249 ............. 250249
TB251 ............. 250251
TB252 ............. 250252
TB253 ............. 250253
TB254 ............. 250254
TB255 ............. 250255
TB256 ............. 250256
TB257 ............. 250257
TB258 ............. 250258
TB259 ............. 250259
TB260 ............. 250260
TB262 ............. 250262
TB263 ............. 250263
TB264 ............. 250264
TB265 ............. 250265
TB266 ............. 250266
TB267 ............. 250267
TB270 ............. 250270
TB271 ............. 250271
TB272 ............. 250272
TB273 ............. 250273
TB276 ............. 250276
TB277 ............. 250277
TB278 ............. 250278
TB279 ............. 250279
TB280 ............. 250280
TB281 ............. 250281
TB282 ............. 250282
TB283 ............. 250283
TB284 ............. 250284
TB285 ............. 250285
TB286 ............. 250286
TB287 ............. 250287
TB288 ............. 250288
TB289 ............. 250289
TB290 ............. 250290
TB291 ............. 250291
TB292 ............. 250292
TB293 ............. 250293
TB294 ............. 250294
TB295 ............. 250295
TB296 ............. 250296
TB297 ............. 250297
TB298 ............. 250298
TB299 ............. 250299
TB300 ............. 250300
TB301 ............. 250301
TB302 ............. 250302
TB303 ............. 250303
TB304 ............. 250304
TB305 ............. 250305
TB306 ............. 250306
TB308 ............. 250308
TB309 ............. 250309
TB310 ............. 250310
TB311 ............. 250311
88925830........ 250270
ATLAS
689900............ 250067
689901............ 250071
689902............ 250014
689903............ 250061
689904............ 250017
689905............ 250081
689906............ 250070
689907............ 250089
689908............ 250077
689909............ 250094
ATLAS (CANADA)
TB1001 ........... 250121
TB1002 ........... 250127
TB1003 ........... 250128
TB1004 ........... 250101
TB1005 ........... 250125
TB1006 ........... 250126
TB1007 ........... 250130
TB1008 ........... 250129
TB1010 ........... 250114
TB1011 ........... 250300
TB1012 ........... 250299
TB1013 ........... 250091
TB1014 ........... 250092
TB1015 ........... 250117
TB1016 ........... 250119
TB1017 ........... 250292
TB1018 ........... 250134
TB1020 ........... 250136
TB1021 ........... 250137
TB1022 ........... 250138
TB1023 ........... 250139
TB1024 ........... 250140
TB1026 ........... 250141
TB1027 ........... 250123
TB1028 ........... 250090
TB1031 ........... 250113
TB1032 ........... 250132
TB1033 ........... 250142
TB1034 ........... 250143
TB1035 ........... 250144
TB1036 ........... 250145
TB1037 ........... 250146
TB1038 ........... 250147
TB1039 ........... 250148
TB1040 ........... 250149
TB1041 ........... 250150
TB1042 ........... 250151
TB1044 ........... 250102
TB1045 ........... 250103
TB1047 ........... 250124
TB1048 ........... 250154
TB1049 ........... 250155
TB1051 ........... 250157
TB1052 ........... 250158
TB1053 ........... 250159
TB1054 ........... 250160
TB1055 ........... 250161
TB1056 ........... 250162
TB1057 ........... 250153
TB1058 ........... 250163
TB1059 ........... 250164
TB1060 ........... 250165
TB1061 ........... 250166
TB1062 ........... 250169
TB1063 ........... 250167
TB1064 ........... 250168
TB6401 ........... 250014
TB6402 ........... 250013
TB6403 ........... 250037
TB6404 ........... 250017
TB6406 ........... 250018
TB6408 ........... 250020
TB6409 ........... 250039
TB6410 ........... 250032
TB6411 ........... 250041
ATLAS (CANADA) - Cont.
TB6412 ........... 250062
TB6415 ........... 250028
TB6416 ........... 250064
TB6417 ........... 250065
TB6418 ........... 250061
TB6419 ........... 250073
TB6425 ........... 250070
TB6427 ........... 250071
TB6428 ........... 250067
TB6429 ........... 250076
TB6430 ........... 250075
TB6431 ........... 250078
TB6432 ........... 250077
TB6433 ........... 250043
TB6434 ........... 250074
TB6435 ........... 250081
TB6436 ........... 250088
TB6437 ........... 250087
TB6438 ........... 250093
TB6439 ........... 250094
TB6440 ........... 250104
TB6442 ........... 250100
TB6443 ........... 250084
TB6444 ........... 250099
TB6446 ........... 250082
TB6447 ........... 250083
TB6448 ........... 250095
TB6450 ........... 250176
TB6451 ........... 250089
TB6452 ........... 250118
TB6453 ........... 250079
TB6454 ........... 250122
AUTOZONE (See GOOD-
YEAR)

AVON AUTO
B0100.............. 250100
B0101.............. 250101
B0102.............. 250102
B0103.............. 250103
B0104.............. 250104
B0114.............. 250114
B0118.............. 250162
B013................ 250013
B014................ 250014
B017................ 250017
B018................ 250018
B020................ 250020
B028................ 250028
B032................ 250032
B036................ 250036
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B062................ 250062
B063................ 250073
B064................ 250064
B065................ 250065
B067................ 250067
B070................ 250070
B071................ 250071
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B079................ 250079
B081................ 250081
B082................ 250082
B083................ 250083
B084................ 250084
B087................ 250087
B088................ 250088
Changeover Listing
Automotive Timing Belt Numbers
Showing Competitive Numbers with Corresponding NAPA Stock Numbers
The NAPA numbers shown in the following listings were determined by comparing the applications and physical characteristics of the product. This is
a guide for changing over stocks to NAPA numbers, and does not mean that the competitive number shown will fit all applications recommended for
the NAPA number. If a customer asks for a product to replace a product of another brand, do not use this list. Ask for the make, model, year and engine
size on which it is to be used, and refer to the alphabetical listing to determine the proper replacement.
Competitive NAPA Competitive NAPA Competitive NAPA Competitive NAPA Competitive NAPA
No. No. No. No. No. No. No. No. No. No.
A-43
AVON AUTO - Cont.
B089................ 250089
B090................ 250090
B091................ 250091
B092................ 250092
B093................ 250093
B094................ 250094
B095................ 250095
B096................ 250096
B099................ 250099
BALKAMP
9-013............... 250013
9-014............... 250014
9-017............... 250017
9-018............... 250018
9-020............... 250020
9-028............... 250028
9-032............... 250032
9-036............... 250036
9-037............... 250037
9-039............... 250039
9-041............... 250041
9-043............... 250043
9-061............... 250061
9-062............... 250062
9-063............... 250073
9-064............... 250064
9-065............... 250065
9-067............... 250067
9-070............... 250070
9-071............... 250071
9-073............... 250073
9-074............... 250074
9-075............... 250075
9-076............... 250076
9-077............... 250077
9-078............... 250078
9-079............... 250079
9-081............... 250081
9-082............... 250082
9-083............... 250083
9-084............... 250084
9-087............... 250087
9-088............... 250088
9-089............... 250089
9-090............... 250090
9-091............... 250091
9-092............... 250092
9-093............... 250093
9-094............... 250094
9-095............... 250095
9-096............... 250096
9-098............... 250098
9-099............... 250099
9-100............... 250100
9-101............... 250101
BANDO
100ZA19.......... 250061
109ZA19.......... 250088
111ZA19.......... 250121
113ZA19.......... 250065
121ZA19.......... 250017
124ZA25.......... 250071
135ZA25.......... 250043
142ZA25.......... 250074
206AL050........ 250062
315AL075........ 250028
326AHL125..... 250075
330AL075........ 250070
345AL075........ 250073
398AL075........ 250077
458AL075........ 250013
89ZA19 ........... 250095
94ZA19 ........... 250036
97ZA25 ........... 250067
99ZA15 ........... 250037
99ZA19 ........... 250039
BAP-GEON
54-70301......... 250062
54-70302......... 250073
54-70303......... 250064
54-70901......... 250041
54-70902......... 250028
54-70904......... 250073
54-71501......... 250070
54-72001......... 250017
54-72100......... 250065
54-76000......... 250020
54-76301......... 250018
54-77801......... 250014
54-77802......... 250067
54-79800......... 250013
BECK ARNLEY
026-0018......... 250028
026-0026......... 250020
026-0034......... 250020
026-0042......... 250018
026-0067......... 250036
026-0075......... 250041
026-0083......... 250013
026-0091......... 250014
026-0109......... 250032
026-0117......... 250065
026-0133......... 250062
026-0158......... 250064
026-0175......... 250070
026-0176......... 250017
026-0177......... 250043
026-0178......... 250083
026-0179......... 250073
026-0180......... 250082
026-0182......... 250088
026-0183......... 250078
026-0184......... 250077
026-0185......... 250089
026-0186......... 250090
026-0187......... 250092
026-0188......... 250091
026-0189......... 250084
026-0190......... 250074
026-0191......... 250087
026-0192......... 250079
026-0193......... 250076
026-0194......... 250075
026-0195......... 250107
026-0196......... 250093
026-0197......... 250096
026-0198......... 250106
026-0199......... 250140
026-0202......... 250100
026-0205......... 250097
026-0206......... 250101
026-0207......... 250095
026-0208......... 250161
026-0209......... 250160
026-0212......... 250300
026-0213......... 250299
026-0215......... 250158
026-0216......... 250104
026-0217......... 250112
026-0218......... 250293
026-0219......... 250119
026-0220......... 250138
026-0221......... 250071
026-0222......... 250162
026-0223......... 250113
026-0224......... 250117
026-0225......... 250149
026-0226......... 250141
026-0228......... 250122
026-0229......... 250124
026-0230......... 250128
026-0231......... 250134
026-0232......... 250129
026-0233......... 250139
026-0234......... 250146
026-0235......... 250148
026-0236......... 250292
026-0237......... 250170
026-0238......... 250143
026-0239......... 250131
026-0240......... 250144
026-0242......... 250142
026-0243......... 250135
026-0244......... 250179
026-0245......... 250147
026-0246......... 250126
026-0247......... 250136
026-0248......... 250125
026-0249......... 250164
026-0250......... 250166
026-0251......... 250165
026-0252......... 250130
026-0253......... 250121
026-0255......... 250167
026-0256......... 250043
026-0259......... 250137
026-0260......... 250171
026-0261......... 250177
026-0262......... 250179
026-0263......... 250103
026-0264......... 250102
026-0265......... 250157
026-0266......... 250159
026-0267......... 250151
026-0268......... 250182
BECK ARNLEY - Cont.
026-0269......... 250184
026-0270......... 250181
026-0271......... 250155
026-0272......... 250144
026-0273......... 250178
026-0274......... 250104
026-0275......... 250150
026-0276......... 250187
026-0277......... 250180
026-0278......... 250186
026-0279......... 250176
026-0280......... 250191
026-0281......... 250174
026-0282......... 250183
026-0283......... 250154
026-0284......... 250168
026-0285......... 250173
026-0286......... 250172
026-0294......... 250208
026-0295......... 250211
026-0296......... 250201
026-0297......... 250204
026-0298......... 250218
026-0299......... 250216
026-0300......... 250203
026-0301......... 250212
026-0302......... 250193
026-0303......... 250185
026-0304......... 250221
026-0305......... 250220
026-0306......... 250194
026-0307......... 250224
026-0308......... 250226
026-0309......... 250223
026-0310......... 250227
026-0311......... 250214
026-0312......... 250209
026-0314......... 250229
026-0316......... 250230
026-0317......... 250232
026-0318......... 250217
026-0319......... 250195
026-0320......... 250234
026-0322......... 250235
026-0323......... 250252
026-0324......... 250241
026-0325......... 250236
026-0326......... 250262
026-0327......... 250228
026-0329......... 250252
026-0334......... 250249
BORG WARNER
TB013 ............. 250013
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB020 ............. 250020
TB028 ............. 250028
TB029 ............. 250104
TB032 ............. 250032
TB036 ............. 250036
TB037 ............. 250037
TB039 ............. 250039
TB041 ............. 250041
TB043 ............. 250043
TB061 ............. 250061
TB062 ............. 250062
TB063 ............. 250073
TB064 ............. 250064
TB065 ............. 250065
TB067 ............. 250067
TB070 ............. 250070
TB071 ............. 250071
TB073 ............. 250073
TB074 ............. 250074
TB075 ............. 250075
TB076 ............. 250076
TB077 ............. 250077
TB078 ............. 250078
TB079 ............. 250079
TB081 ............. 250081
TB082 ............. 250082
TB083 ............. 250083
TB084 ............. 250084
TB087 ............. 250087
TB088 ............. 250088
TB089 ............. 250089
TB090 ............. 250090
TB091 ............. 250091
TB092 ............. 250092
TB093 ............. 250093
TB094 ............. 250094
TB095 ............. 250095
BORG WARNER - Cont.
TB096 ............. 250096
TB098 ............. 250098
TB099 ............. 250099
TB100 ............. 250100
TB101 ............. 250101
TB102 ............. 250102
TB103 ............. 250103
TB104 ............. 250104
TB106 ............. 250106
TB107 ............. 250107
TB112 ............. 250112
TB113 ............. 250113
TB114 ............. 250114
TB115 ............. 250299
TB116 ............. 250300
TB117 ............. 250117
TB118 ............. 250118
TB119 ............. 250119
TB121 ............. 250121
TB122 ............. 250122
TB123 ............. 250123
TB124 ............. 250124
TB125 ............. 250125
TB126 ............. 250126
TB127 ............. 250127
TB128 ............. 250128
TB129 ............. 250129
TB130 ............. 250130
TB131 ............. 250131
TB132 ............. 250132
TB133 ............. 250292
TB134 ............. 250134
TB135 ............. 250135
TB136 ............. 250136
TB137 ............. 250137
TB138 ............. 250138
TB139 ............. 250139
TB140 ............. 250140
TB141 ............. 250141
TB142 ............. 250142
TB143 ............. 250143
TB144 ............. 250144
TB145 ............. 250145
TB146 ............. 250146
TB147 ............. 250147
TB148 ............. 250148
TB153 ............. 250153
TB154 ............. 250154
TB155 ............. 250155
TB157 ............. 250157
TB158 ............. 250158
TB159 ............. 250159
TB160 ............. 250160
TB161 ............. 250161
TB162 ............. 250162
TB163 ............. 250163
TB164 ............. 250164
TB165 ............. 250165
TB166 ............. 250166
TB167 ............. 250167
TB168 ............. 250168
TB169 ............. 250169
TB170 ............. 250170
TB171 ............. 250171
TB172 ............. 250172
TB177 ............. 250177
TB178 ............. 250178
TB179 ............. 250179
TB183 ............. 250183
TB184 ............. 250184
TB185 ............. 250185
TB186 ............. 250186
TB187 ............. 250187
TB191 ............. 250191
TB192 ............. 250192
TB194 ............. 250194
TB195 ............. 250195
TB199 ............. 250199
TB200 ............. 250200
TB201 ............. 250201
TB202 ............. 250248
TB204 ............. 250204
TB206 ............. 250206
TB208 ............. 250208
TB210 ............. 250210
TB214 ............. 250214
TB228 ............. 250228
TB233 ............. 250233
TB235 ............. 250235
TB236 ............. 250236
TB237 ............. 250237
T219................ 250219
BRYCO
B013................ 250013
B014................ 250014
B017................ 250017
B028................ 250028
B036................ 250036
B041................ 250041
B043................ 250043
B062................ 250062
B064................ 250064
B067................ 250067
B070................ 250070
B071................ 250071
B073................ 250073
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B079................ 250079
B087................ 250087
B088................ 250088
B089................ 250089
B090................ 250090
B091................ 250091
B092................ 250092
B093................ 250093
B094................ 250094
B095................ 250095
B096................ 250096
B099................ 250099
B100................ 250100
B101................ 250101
B102................ 250102
B103................ 250103
B104................ 250104
B112................ 250112
B113................ 250113
B114................ 250114
B115................ 250299
B116................ 250300
B117................ 250117
B118................ 250118
B121................ 250121
B122................ 250122
B123................ 250123
B124................ 250124
B126................ 250126
B127................ 250127
B128................ 250128
B130................ 250130
B132................ 250132
B133................ 250292
B134................ 250134
B136................ 250136
B137................ 250137
B138................ 250138
B139................ 250139
B141................ 250141
B142................ 250142
B143................ 250143
B144................ 250144
B145................ 250145
B146................ 250146
B147................ 250147
B149................ 250149
B153................ 250153
B154................ 250154
B155................ 250155
B157................ 250157
B158................ 250158
B159................ 250159
B160................ 250160
B161................ 250161
B162................ 250162
B164................ 250164
B165................ 250165
B167................ 250167
B168................ 250168
B169................ 250169
B176................ 250176
B177................ 250177
B179................ 250179
B182................ 250182
B184................ 250184
B185................ 250185
B186................ 250186
B187................ 250187
B191................ 250191
B194................ 250194
B195................ 250195
B199................ 250199
B201................ 250201
B204................ 250204
Changeover Listing - Timing Belts
A-44
BRYCO - Cont.
B208................ 250208
B210................ 250210
B223................ 250223
B224................ 250224
B227................ 250227
B228................ 250228
B229................ 250229
B230................ 250230
B235................ 250235
B236................ 250236
B237................ 250237
B258................ 250258
T115................ 250299
54700.............. 250095
54742.............. 250075
54754.............. 250112
54755.............. 250176
54788.............. 250076
CARQUEST
T013................ 250013
T014................ 250014
T096................ 250096
T097................ 250097
T098................ 250098
T099................ 250099
T100................ 250100
T101................ 250101
T102................ 250102
T103................ 250103
T104................ 250104
T106................ 250106
T107................ 250107
T112................ 250112
T113................ 250113
T114................ 250114
T117................ 250117
T118................ 250118
T119................ 250119
T121................ 250121
T122................ 250122
T123................ 250123
T124................ 250124
T125................ 250125
T126................ 250126
T127................ 250127
T128................ 250128
T129................ 250129
T130................ 250130
T131................ 250131
T132................ 250132
T134................ 250134
T135................ 250135
T136................ 250136
T137................ 250137
T138................ 250138
T139................ 250139
T140................ 250140
T141................ 250141
T142................ 250142
T143................ 250143
T144................ 250144
T145................ 250145
T146................ 250146
T147................ 250147
T148................ 250148
T149................ 250149
T150................ 250150
T151................ 250151
T153................ 250153
T154................ 250154
T155................ 250155
T157................ 250157
T158................ 250158
T159................ 250159
T160................ 250160
T161................ 250161
T162................ 250162
T163................ 250163
T164................ 250164
T165................ 250165
T166................ 250166
T167................ 250167
T168................ 250168
T169................ 250169
T170................ 250170
T171................ 250171
T172................ 250172
T173................ 250173
T174................ 250174
T176................ 250176
T177................ 250177
T178................ 250178
T179................ 250179
CARQUEST - Cont.
T180................ 250180
T181................ 250181
T182................ 250182
T183................ 250183
T184................ 250184
T185................ 250185
T186................ 250186
T187................ 250187
T190................ 250190
T191................ 250191
T192................ 250192
T193................ 250193
T194................ 250194
T195................ 250195
T199................ 250199
T200................ 250200
T201................ 250201
T203................ 250203
T204................ 250204
T205................ 250205
T206................ 250206
T207................ 250207
T208................ 250208
T209................ 250209
T210................ 250210
T211................ 250211
T212................ 250212
T214................ 250214
T215................ 250215
T216................ 250216
T217................ 250217
T218................ 250218
T219................ 250219
T220................ 250220
T221................ 250221
T223................ 250223
T224................ 250224
T225................ 250225
T226................ 250226
T227................ 250227
T228................ 250228
T229................ 250229
T230................ 250230
T232................ 250232
T233................ 250233
T234................ 250234
T235................ 250235
T236................ 250236
T237................ 250237
T239................ 250239
T240................ 250240
T241................ 250241
T242................ 250242
T244................ 250244
T245................ 250245
T246................ 250246
T247................ 250247
T248................ 250248
T249................ 250249
T251................ 250251
T252................ 250252
T253................ 250253
T254................ 250254
T255................ 250255
T256................ 250256
T257................ 250257
T258................ 250258
T259................ 250259
T260................ 250260
T262................ 250262
T263................ 250263
T264................ 250264
T265................ 250265
T266................ 250266
T267................ 250267
T271................ 250271
T272................ 250272
T273................ 250273
T276................ 250276
T277................ 250277
T278................ 250278
T279................ 250279
T280................ 250280
T281................ 250281
T282................ 250282
T283................ 250283
T284................ 250284
T285................ 250285
T286................ 250286
T287................ 250287
T288................ 250288
T289................ 250289
T290................ 250290
CARQUEST - Cont.
T291................ 250291
T292................ 250292
T293................ 250293
T294................ 250294
T295................ 250295
T296................ 250296
T297................ 250297
T298................ 250298
T299................ 250299
T300................ 250300
T301................ 250301
T302................ 250302
T303................ 250303
T304................ 250304
T305................ 250305
T306................ 250306
CHIEF
TB401 ............. 250014
TB402 ............. 250013
TB403 ............. 250037
TB404 ............. 250017
TB409 ............. 250039
TB411 ............. 250041
TB415 ............. 250028
CLEVELAND MOTIVE
B013................ 250013
B014................ 250014
B037................ 250037
B043................ 250043
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B081................ 250081
CLOYES GEAR
B013................ 250013
B014................ 250014
B017................ 250017
B018................ 250018
B020................ 250020
B028................ 250028
B032................ 250032
B036................ 250036
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B062................ 250062
B063................ 250073
B064................ 250064
B065................ 250065
B067................ 250067
B070................ 250070
B071................ 250071
B073................ 250073
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B079................ 250079
B081................ 250081
B082................ 250082
B083................ 250083
B084................ 250084
B087................ 250087
B088................ 250088
B089................ 250089
B090................ 250090
B091................ 250091
B092................ 250092
B093................ 250093
B094................ 250094
B095................ 250095
B096................ 250096
B097................ 250097
B098................ 250098
B099................ 250099
B100................ 250100
B101................ 250101
B102................ 250102
B103................ 250103
B104................ 250104
B106................ 250106
B107................ 250107
B108................ 250293
B112................ 250112
B113................ 250113
B114................ 250114
CLOYES GEAR - Cont.
B115................ 250299
B116................ 250300
B117................ 250117
B118................ 250118
B119................ 250119
B121................ 250121
B122................ 250122
B123................ 250123
B124................ 250124
B125................ 250125
B126................ 250126
B127................ 250127
B128................ 250128
B129................ 250129
B130................ 250130
B131................ 250131
B132................ 250132
B133................ 250292
B134................ 250134
B135................ 250135
B136................ 250136
B137................ 250137
B138................ 250138
B139................ 250139
B140................ 250140
B141................ 250141
B142................ 250142
B143................ 250143
B144................ 250144
B145................ 250145
B146................ 250146
B147................ 250147
B148................ 250148
B149................ 250149
B150................ 250150
B151................ 250151
B153................ 250153
B154................ 250154
B155................ 250155
B157................ 250157
B158................ 250158
B159................ 250159
B160................ 250160
B161................ 250161
B162................ 250162
B163................ 250163
B164................ 250164
B165................ 250165
B166................ 250166
B167................ 250167
B168................ 250168
B169................ 250169
B170................ 250170
B171................ 250171
B172................ 250172
B174................ 250174
B176................ 250176
B177................ 250177
B178................ 250178
B179................ 250179
B180................ 250180
B181................ 250181
B182................ 250182
B183................ 250183
B184................ 250184
B185................ 250185
B186................ 250186
B187................ 250187
B190................ 250190
B191................ 250191
B192................ 250192
B193................ 250193
B194................ 250194
B195................ 250195
B199................ 250199
B201................ 250201
B203................ 250203
B204................ 250204
B205................ 250205
B206................ 250206
B208................ 250208
B209................ 250209
B210................ 250210
B211................ 250211
B212................ 250212
B214................ 250214
B216................ 250216
B219................ 250219
C013 ............... 250013
C014 ............... 250014
C017 ............... 250017
C018 ............... 250018
C020 ............... 250020
CLOYES GEAR - Cont.
C028 ............... 250028
C032 ............... 250032
C037 ............... 250037
C039 ............... 250039
C041 ............... 250041
C043 ............... 250043
C061 ............... 250061
C062 ............... 250062
C063 ............... 250073
C064 ............... 250064
C065 ............... 250065
C067 ............... 250067
C070 ............... 250070
C071 ............... 250071
C074 ............... 250074
C075 ............... 250075
C076 ............... 250076
C077 ............... 250077
C078 ............... 250078
C081 ............... 250081
C087 ............... 250087
C088 ............... 250088
C093 ............... 250093
C094 ............... 250094
C095 ............... 250095
C099 ............... 250099
C104 ............... 250104
C112 ............... 250112
CONTINENTAL
6585901.......... 250065
6585902.......... 250017
6585910.......... 250013
6585911.......... 250082
6585912.......... 250083
6585913.......... 250032
6585914.......... 250043
6585916.......... 250018
6585918.......... 250020
6585924.......... 250078
6585929.......... 250064
6585933.......... 250062
6585934.......... 250073
6585935.......... 250077
6585939.......... 250028
6585943.......... 250041
6585949.......... 250070
6589089.......... 250131
6589092.......... 250084
6589095.......... 250107
6589100.......... 250081
6589103.......... 250106
6598500.......... 250062
6598506.......... 250028
6598512.......... 250073
6598513.......... 250041
6598519.......... 250077
6598521.......... 250088
6598530.......... 250087
6598534.......... 250075
6598550.......... 250094
6598551.......... 250293
CONTITECH
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB032 ............. 250032
TB036 ............. 250036
TB041 ............. 250041
TB043 ............. 250043
TB061 ............. 250061
TB063 ............. 250073
TB064 ............. 250064
TB065 ............. 250065
TB070 ............. 250070
TB074 ............. 250074
TB075 ............. 250075
TB076 ............. 250076
TB077 ............. 250077
TB078 ............. 250078
TB079 ............. 250079
TB081 ............. 250081
TB082 ............. 250082
TB083 ............. 250083
TB084 ............. 250084
TB087 ............. 250087
TB088 ............. 250088
TB089 ............. 250089
TB090 ............. 250090
TB091 ............. 250091
TB092 ............. 250092
TB093 ............. 250093
TB094 ............. 250094
A-45
CONTITECH - Cont.
TB095 ............. 250095
TB096 ............. 250096
TB097 ............. 250097
TB098 ............. 250098
TB099 ............. 250099
TB100 ............. 250100
TB101 ............. 250101
TB102 ............. 250102
TB103 ............. 250103
TB104 ............. 250104
TB106 ............. 250106
TB107 ............. 250107
TB108 ............. 250293
TB112 ............. 250112
TB113 ............. 250113
TB115 ............. 250299
TB116 ............. 250300
TB117 ............. 250117
TB118 ............. 250118
TB119 ............. 250119
TB121 ............. 250121
TB122 ............. 250122
TB123 ............. 250123
TB124 ............. 250124
TB125 ............. 250125
TB126 ............. 250126
TB127 ............. 250127
TB128 ............. 250128
TB129 ............. 250129
TB130 ............. 250130
TB131 ............. 250131
TB133 ............. 250292
TB134 ............. 250134
TB135 ............. 250135
TB136 ............. 250136
TB137 ............. 250137
TB138 ............. 250138
TB139 ............. 250139
TB140 ............. 250140
TB141 ............. 250141
TB142 ............. 250142
TB143 ............. 250143
TB144 ............. 250144
TB145 ............. 250145
TB146 ............. 250146
TB147 ............. 250147
TB148 ............. 250148
TB150 ............. 250150
TB151 ............. 250151
TB154 ............. 250154
TB155 ............. 250155
TB157 ............. 250157
TB158 ............. 250158
TB159 ............. 250159
TB160 ............. 250160
TB162 ............. 250162
TB163 ............. 250163
TB164 ............. 250164
TB165 ............. 250165
TB166 ............. 250166
TB167 ............. 250167
TB168 ............. 250168
TB169 ............. 250169
TB170 ............. 250170
TB171 ............. 250171
TB172 ............. 250172
TB173 ............. 250173
TB174 ............. 250174
TB176 ............. 250176
TB177 ............. 250177
TB178 ............. 250178
TB179 ............. 250179
TB180 ............. 250180
TB181 ............. 250181
TB182 ............. 250182
TB183 ............. 250183
TB184 ............. 250184
TB185 ............. 250185
TB186 ............. 250186
TB187 ............. 250187
TB190 ............. 250190
TB191 ............. 250191
TB193 ............. 250193
TB195 ............. 250195
TB199 ............. 250199
TB200 ............. 250200
TB201 ............. 250201
TB203 ............. 250203
TB204 ............. 250204
TB205 ............. 250205
TB208 ............. 250208
TB209 ............. 250209
TB210 ............. 250210
CONTITECH - Cont.
TB211 ............. 250211
TB212 ............. 250212
TB214 ............. 250214
TB215 ............. 250215
TB216 ............. 250216
TB217 ............. 250217
TB218 ............. 250218
TB220 ............. 250220
TB221 ............. 250221
TB224 ............. 250224
TB225 ............. 250225
TB227 ............. 250227
TB228 ............. 250228
TB229 ............. 250229
TB230 ............. 250230
TB232 ............. 250232
TB233 ............. 250233
TB235 ............. 250235
TB236 ............. 250236
TB239 ............. 250239
TB240 ............. 250240
TB241 ............. 250241
TB252 ............. 250252
CY-LENT
C013 ............... 250013
C014 ............... 250014
C017 ............... 250017
C018 ............... 250018
C020 ............... 250020
C028 ............... 250028
C032 ............... 250032
C037 ............... 250037
C039 ............... 250039
C041 ............... 250041
C043 ............... 250043
C061 ............... 250061
C062 ............... 250062
C063 ............... 250073
C064 ............... 250064
C065 ............... 250065
C067 ............... 250067
C070 ............... 250070
C071 ............... 250071
C073 ............... 250073
C075 ............... 250075
C076 ............... 250076
C077 ............... 250077
C078 ............... 250078
C081 ............... 250081
DAYCO
A206L050........ 250062
A234L075........ 250073
A315L075........ 250028
A356L075........ 250041
A371L059........ 250037
A375L075........ 250061
A450L075........ 250064
A453L075........ 250017
A457L075........ 250013
A484L088........ 250014
A547L075........ 250020
94011.............. 250092
94075.............. 250070
94078.............. 250203
94080.............. 250203
94098.............. 250089
94100.............. 250090
94123.............. 250117
94133.............. 250128
94165.............. 250146
94169.............. 250148
94185.............. 250163
94266.............. 250091
94283.............. 250124
94284.............. 250185
94293.............. 250165
94294.............. 250179
94340.............. 250155
94341.............. 250139
94350.............. 250167
94351.............. 250168
94430.............. 250155
95013.............. 250013
95014.............. 250014
95017.............. 250017
95018.............. 250018
95020.............. 250020
95028.............. 250028
95032.............. 250032
95036.............. 250036
95037.............. 250037
95039.............. 250039
DAYCO - Cont.
95041.............. 250041
95043.............. 250043
95061.............. 250061
95062.............. 250062
95063.............. 250073
95064.............. 250064
95065.............. 250065
95067.............. 250067
95070.............. 250070
95071.............. 250071
95073.............. 250073
95074.............. 250074
95075.............. 250075
95076.............. 250076
95077.............. 250077
95078.............. 250078
95079.............. 250079
95081.............. 250081
95082.............. 250082
95083.............. 250083
95084.............. 250084
95087.............. 250087
95088.............. 250088
95089.............. 250089
95090.............. 250090
95091.............. 250091
95092.............. 250092
95093.............. 250093
95094.............. 250094
95095.............. 250095
95096.............. 250096
95097.............. 250097
95098.............. 250098
95099.............. 250099
95100.............. 250100
95101.............. 250101
95102.............. 250102
95103.............. 250103
95104.............. 250104
95106.............. 250106
95107.............. 250107
95108.............. 250293
95112.............. 250112
95113.............. 250113
95114.............. 250114
95115.............. 250299
95116.............. 250300
95117.............. 250117
95118.............. 250118
95119.............. 250119
95121.............. 250121
95122.............. 250122
95123.............. 250123
95124.............. 250124
95125.............. 250125
95126.............. 250126
95127.............. 250127
95128.............. 250128
95129.............. 250129
95130.............. 250130
95131.............. 250131
95132.............. 250132
95133.............. 250292
95134.............. 250134
95135.............. 250135
95136.............. 250136
95137.............. 250137
95138.............. 250138
95139.............. 250139
95140.............. 250140
95141.............. 250141
95142.............. 250142
95143.............. 250143
95144.............. 250144
95145.............. 250145
95146.............. 250146
95147.............. 250147
95148.............. 250148
95150.............. 250150
95151.............. 250151
95153.............. 250153
95154.............. 250154
95155.............. 250155
95157.............. 250157
95158.............. 250158
95159.............. 250159
95160.............. 250160
95161.............. 250161
95162.............. 250162
95163.............. 250163
95164.............. 250164
95165.............. 250165
95166.............. 250166
DAYCO - Cont.
95167.............. 250167
95168.............. 250168
95169.............. 250169
95170.............. 250170
95171.............. 250171
95172.............. 250172
95173.............. 250173
95174.............. 250174
95176.............. 250176
95177.............. 250177
95178.............. 250178
95179.............. 250179
95180.............. 250180
95181.............. 250181
95182.............. 250182
95183.............. 250183
95184.............. 250184
95185.............. 250185
95186.............. 250186
95187.............. 250187
95190.............. 250190
95191.............. 250191
95192.............. 250192
95193.............. 250193
95194.............. 250194
95195.............. 250195
95199.............. 250199
95200.............. 250200
95201.............. 250201
95202.............. 250248
95203.............. 250203
95204.............. 250204
95205.............. 250205
95206.............. 250206
95207.............. 250207
95208.............. 250208
95210.............. 250210
95211.............. 250211
95212.............. 250212
95214.............. 250214
95215.............. 250215
95216.............. 250216
95217.............. 250217
95218.............. 250218
95219.............. 250219
95220.............. 250220
95221.............. 250221
95223.............. 250223
95224.............. 250224
95225.............. 250225
95226.............. 250226
95227.............. 250227
95228.............. 250228
95229.............. 250229
95230.............. 250230
95232.............. 250232
95233.............. 250233
95234.............. 250234
95235.............. 250235
95236.............. 250236
95237.............. 250237
95240.............. 250240
95241.............. 250241
95244.............. 250244
95245.............. 250245
95246.............. 250246
95247.............. 250247
95248.............. 250248
95249.............. 250249
95251.............. 250251
95252.............. 250252
95253.............. 250253
95254.............. 250254
95255.............. 250255
95257.............. 250257
95258.............. 250258
95259.............. 250259
95262.............. 250262
95263.............. 250263
95264.............. 250264
95265.............. 250265
95266.............. 250266
95271.............. 250271
95272.............. 250272
95273.............. 250273
95276.............. 250276
95277.............. 250277
95278.............. 250278
95281.............. 250281
95283.............. 250283
95284.............. 250284
95286.............. 250286
95287.............. 250287
DAYCO - Cont.
95288.............. 250288
95289.............. 250289
95291.............. 250291
95292.............. 250292
95293.............. 250293
95294.............. 250294
95295.............. 250295
95296.............. 250296
95298.............. 250298
95299.............. 250299
95300.............. 250300
95302.............. 250302
95303.............. 250303
95304.............. 250304
DURKEE-ATWOOD
24-436PD........ 250018
24-457PD........ 250017
24-542PD........ 250020
28-457PD........ 250013
28-487PD........ 250014
88013.............. 250013
88014.............. 250014
88017.............. 250017
88018.............. 250018
88020.............. 250020
88028.............. 250028
88032.............. 250032
88037.............. 250037
88039.............. 250039
88041.............. 250041
88043.............. 250043
88046.............. 250013
88047.............. 250014
88050.............. 250018
88052.............. 250020
88057.............. 250037
88058.............. 250039
88060.............. 250017
88061.............. 250061
88062.............. 250062
88063.............. 250073
88064.............. 250064
88065.............. 250065
88067.............. 250067
88070.............. 250070
88071.............. 250071
88074.............. 250074
88075.............. 250075
88076.............. 250076
88077.............. 250077
88078.............. 250078
88079.............. 250079
88081.............. 250081
88082.............. 250082
88083.............. 250083
88084.............. 250084
88087.............. 250087
88088.............. 250088
88089.............. 250089
88090.............. 250090
88091.............. 250091
88092.............. 250092
88093.............. 250093
88094.............. 250094
88095.............. 250095
88099.............. 250099
88100.............. 250100
88101.............. 250101
88102.............. 250102
88104.............. 250104
88106.............. 250106
88107.............. 250107
88112.............. 250112
88113.............. 250113
88114.............. 250114
88115.............. 250299
88116.............. 250300
88117.............. 250117
88118.............. 250118
88121.............. 250121
88122.............. 250122
88124.............. 250124
88125.............. 250125
88126.............. 250126
88127.............. 250127
88130.............. 250130
88131.............. 250131
88132.............. 250132
88133.............. 250292
88134.............. 250134
88136.............. 250136
88138.............. 250138
88141.............. 250141
A-46
DURKEE-ATWOOD - Cont.
88143.............. 250143
88144.............. 250144
88146.............. 250146
88153.............. 250153
88157.............. 250157
88158.............. 250158
88159.............. 250159
88160.............. 250160
88161.............. 250161
88162.............. 250162
88163.............. 250163
88165.............. 250165
88170.............. 250170
DYNAFLEX (See DAYCO)

DYNAGEAR
B013................ 250013
B014................ 250014
B017................ 250017
B018................ 250018
B020................ 250020
B028................ 250028
B032................ 250032
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B062................ 250062
B063................ 250073
B064................ 250064
B065................ 250065
B067................ 250067
B070................ 250070
B071................ 250071
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B081................ 250081
B087................ 250087
B088................ 250088
B093................ 250093
B094................ 250094
B095................ 250095
B099................ 250099
B104................ 250104
B112................ 250112
TB013 ............. 250013
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB020 ............. 250020
TB028 ............. 250028
TB029 ............. 250104
TB032 ............. 250032
TB036 ............. 250036
TB037 ............. 250037
TB039 ............. 250039
TB041 ............. 250041
TB043 ............. 250043
TB061 ............. 250061
TB062 ............. 250062
TB063 ............. 250073
TB064 ............. 250064
TB065 ............. 250065
TB067 ............. 250067
TB070 ............. 250070
TB071 ............. 250071
TB073 ............. 250073
TB074 ............. 250074
TB075 ............. 250075
TB076 ............. 250076
TB077 ............. 250077
TB078 ............. 250078
TB079 ............. 250079
TB081 ............. 250081
TB082 ............. 250082
TB083 ............. 250083
TB084 ............. 250084
TB087 ............. 250087
TB088 ............. 250088
TB089 ............. 250089
TB090 ............. 250090
TB091 ............. 250091
TB092 ............. 250092
TB093 ............. 250093
TB094 ............. 250094
TB095 ............. 250095
TB096 ............. 250096
TB098 ............. 250098
DYNAGEAR - Cont.
TB099 ............. 250099
TB100 ............. 250100
TB101 ............. 250101
TB102 ............. 250102
TB103 ............. 250103
TB104 ............. 250104
TB106 ............. 250106
TB107 ............. 250107
TB108 ............. 250293
TB112 ............. 250112
TB113 ............. 250113
TB114 ............. 250114
TB115 ............. 250299
TB116 ............. 250300
TB117 ............. 250117
TB118 ............. 250118
TB119 ............. 250119
TB121 ............. 250121
TB122 ............. 250122
TB123 ............. 250123
TB124 ............. 250124
TB125 ............. 250125
TB126 ............. 250126
TB127 ............. 250127
TB128 ............. 250128
TB129 ............. 250129
TB130 ............. 250130
TB131 ............. 250131
TB132 ............. 250132
TB133 ............. 250292
TB134 ............. 250134
TB135 ............. 250135
TB136 ............. 250136
TB137 ............. 250137
TB138 ............. 250138
TB139 ............. 250139
TB140 ............. 250140
TB141 ............. 250141
TB142 ............. 250142
TB143 ............. 250143
TB144 ............. 250144
TB145 ............. 250145
TB146 ............. 250146
TB147 ............. 250147
TB148 ............. 250148
TB149 ............. 250149
TB150 ............. 250150
TB151 ............. 250151
TB153 ............. 250153
TB154 ............. 250154
TB155 ............. 250155
TB157 ............. 250157
TB158 ............. 250158
TB159 ............. 250159
TB160 ............. 250160
TB161 ............. 250161
TB162 ............. 250162
TB163 ............. 250163
TB164 ............. 250164
TB165 ............. 250165
TB166 ............. 250166
TB167 ............. 250167
TB168 ............. 250168
TB169 ............. 250169
ELGIN MACH.
LB-013 ............ 250013
LB-014 ............ 250014
LB-017 ............ 250017
LB-018 ............ 250018
LB-020 ............ 250020
LB-028 ............ 250028
LB-032 ............ 250032
LB-036 ............ 250036
LB-037 ............ 250037
LB-039 ............ 250039
LB-041 ............ 250041
LB-043 ............ 250043
LB-061 ............ 250061
LB-062 ............ 250062
LB-063 ............ 250073
LB-064 ............ 250064
LB-065 ............ 250065
LB-067 ............ 250067
LB-070 ............ 250070
LB-071 ............ 250071
LB-073 ............ 250073
LB-074 ............ 250074
LB-075 ............ 250075
LB-076 ............ 250076
LB-077 ............ 250077
LB-078 ............ 250078
LB-081 ............ 250081
LB-088 ............ 250088
ELGIN MACH. - Cont.
LB-093 ............ 250093
FEDERAL MOGUL
LB013.............. 250013
LB014.............. 250014
LB020.............. 250020
LB028.............. 250028
LB032.............. 250032
LB036.............. 250036
LB037.............. 250037
LB039.............. 250039
LB041.............. 250041
LB043.............. 250043
LB061.............. 250061
LB062.............. 250062
LB064.............. 250064
LB065.............. 250065
LB067.............. 250067
LB070.............. 250070
LB071.............. 250071
LB073.............. 250073
LB074.............. 250074
LB075.............. 250075
LB076.............. 250076
LB077.............. 250077
LB078.............. 250078
LB081.............. 250081
LB082.............. 250082
LB083.............. 250083
LB087.............. 250087
LB088.............. 250088
LB089.............. 250089
LB090.............. 250090
LB093.............. 250093
LB094.............. 250094
LB095.............. 250095
LB099.............. 250099
LB101.............. 250101
LB102.............. 250102
LB103.............. 250103
LB104.............. 250104
LB107.............. 250107
LB108.............. 250293
LB112.............. 250112
LB113.............. 250113
LB114.............. 250114
LB115.............. 250299
LB116.............. 250300
LB117.............. 250117
LB118.............. 250162
LB119.............. 250119
LB122.............. 250122
LB124.............. 250124
LB125.............. 250125
LB126.............. 250237
LB128.............. 250128
LB129.............. 250129
LB130.............. 250130
LB131.............. 250131
LB132.............. 250132
LB133.............. 250292
LB134.............. 250134
LB135.............. 250135
LB136.............. 250233
LB138.............. 250199
LB139.............. 250139
LB141.............. 250141
LB142.............. 250142
LB143.............. 250143
LB144.............. 250144
LB145.............. 250145
LB146.............. 250146
LB147.............. 250147
LB148.............. 250148
LB149.............. 250149
LB153.............. 250153
LB154.............. 250154
LB155.............. 250155
LB157.............. 250157
LB158.............. 250158
LB159.............. 250159
LB160.............. 250160
LB161.............. 250161
LB162.............. 250162
LB163.............. 250163
LB164.............. 250164
LB165.............. 250165
LB166.............. 250166
LB167.............. 250167
LB168.............. 250168
LB169.............. 250169
LB170.............. 250170
LB172.............. 250254
LB176.............. 250176
FEDERAL MOGUL - Cont.
LB177.............. 250177
LB179.............. 250179
LB180.............. 250180
LB183.............. 250183
LB184.............. 250184
LB185.............. 250185
LB186.............. 250186
LB187.............. 250187
LB193.............. 250193
LB194.............. 250194
LB202.............. 250248
LB210.............. 250210
FIRESTONE
51309510........ 250017
51309618........ 250061
51309677........ 250067
51309693........ 250071
51309766........ 250081
FRESHSTART (See GOOD-
YEAR)

GATES (CANADA)
T013................ 250013
T014................ 250014
T017................ 250017
T018................ 250018
T020................ 250020
T028................ 250028
T032................ 250032
T036................ 250036
T037................ 250037
T039................ 250039
T041................ 250041
T043................ 250043
T061................ 250061
T062................ 250062
T063................ 250073
T064................ 250064
T065................ 250065
T067................ 250067
T070................ 250070
T071................ 250071
T073................ 250073
T074................ 250074
T075................ 250075
T076................ 250076
T077................ 250077
T078................ 250078
T079................ 250079
T081................ 250081
T082................ 250082
T083................ 250083
T084................ 250084
T087................ 250087
T088................ 250088
T089................ 250089
T090................ 250090
T091................ 250091
T092................ 250092
T093................ 250093
T094................ 250094
T095................ 250095
T096................ 250096
T097................ 250097
T098................ 250098
T099................ 250099
T100................ 250100
T101................ 250101
T102................ 250102
T103................ 250103
T104................ 250104
T106................ 250106
T107................ 250107
T108................ 250293
T112................ 250112
T113................ 250113
T114................ 250114
T115................ 250299
T116................ 250300
T117................ 250117
T118................ 250118
T119................ 250119
T121................ 250121
T122................ 250122
T123................ 250123
T124................ 250124
T125................ 250125
T126................ 250126
T127................ 250127
T128................ 250128
T129................ 250129
GATES (CANADA) - Cont.
T130................ 250130
T131................ 250131
T132................ 250132
T133................ 250292
T134................ 250134
T135................ 250135
T136................ 250136
T137................ 250137
T138................ 250138
T139................ 250139
T140................ 250140
T141................ 250141
T142................ 250142
T143................ 250143
T144................ 250144
T145................ 250145
T146................ 250146
T147................ 250147
T148................ 250148
T149................ 250149
T150................ 250150
T151................ 250151
T153................ 250153
T154................ 250154
T155................ 250155
T157................ 250157
T158................ 250158
T159................ 250159
T160................ 250160
T161................ 250161
T162................ 250162
T163................ 250163
T164................ 250164
T165................ 250165
T166................ 250166
T167................ 250167
T168................ 250168
T169................ 250169
T170................ 250170
T171................ 250171
T172................ 250172
T173................ 250173
T174................ 250174
T176................ 250176
T177................ 250177
T178................ 250178
T179................ 250179
T180................ 250180
T181................ 250181
T182................ 250182
T183................ 250183
T184................ 250184
T185................ 250185
T186................ 250186
T187................ 250187
T190................ 250190
T191................ 250191
T192................ 250192
T193................ 250193
T194................ 250194
T195................ 250195
T199................ 250199
T200................ 250200
T201................ 250201
T203................ 250203
T204................ 250204
T205................ 250205
T206................ 250206
T207................ 250207
T208................ 250208
T209................ 250209
T210................ 250210
T211................ 250211
T212................ 250212
T214................ 250214
T215................ 250215
T216................ 250216
T217................ 250217
T218................ 250218
T219................ 250219
T220................ 250220
T221................ 250221
T223................ 250223
T224................ 250224
T225................ 250225
T226................ 250226
T227................ 250227
T228................ 250228
T229................ 250229
T230................ 250230
T232................ 250232
T233................ 250233
T234................ 250234
A-47
T235................ 250235
T236................ 250236
T237................ 250237
T239................ 250239
T240................ 250240
T241................ 250241
T242................ 250242
T244................ 250244
T245................ 250245
T246................ 250246
T247................ 250247
T248................ 250248
T249................ 250249
T251................ 250251
T252................ 250252
T253................ 250253
T254................ 250254
T255................ 250255
T256................ 250256
T257................ 250257
T258................ 250258
T259................ 250259
T260................ 250260
T262................ 250262
T263................ 250263
T264................ 250264
T265................ 250265
T266................ 250266
T267................ 250267
T270................ 250270
T271................ 250271
T272................ 250272
T273................ 250273
T274................ 250274
T275................ 250275
T276................ 250276
T277................ 250277
T278................ 250278
T279................ 250279
T280................ 250280
T281................ 250281
T282................ 250282
T283................ 250283
T284................ 250284
T285................ 250285
T286................ 250286
T287................ 250287
T288................ 250288
T289................ 250289
T290................ 250290
T291................ 250291
T292................ 250292
T293................ 250293
T294................ 250294
T295................ 250295
T296................ 250296
T297................ 250297
T298................ 250298
T299................ 250299
T300................ 250300
T301................ 250301
T302................ 250302
T303................ 250303
T304................ 250304
T305................ 250305
T306................ 250306
T308................ 250308
T309................ 250309
T310................ 250310
T311................ 250311
6401................ 250014
6402................ 250013
6403................ 250037
6404................ 250017
6406................ 250018
6408................ 250020
6409................ 250039
6410................ 250032
6411................ 250041
6412................ 250062
6415................ 250028
6416................ 250064
6417................ 250065
6418................ 250061
6419................ 250073
6425................ 250070
6427................ 250071
6428................ 250067
6429................ 250076
6430................ 250075
6431................ 250078
6432................ 250077
6433................ 250043
6434................ 250074
GATES (U.S.)
T013................ 250013
T014................ 250014
T017................ 250017
T018................ 250018
T020................ 250020
T028................ 250028
T032................ 250032
T036................ 250036
T037................ 250037
T039................ 250039
T041................ 250041
T043................ 250043
T061................ 250061
T062................ 250062
T063................ 250073
T064................ 250064
T065................ 250065
T067................ 250067
T070................ 250070
T071................ 250071
T073................ 250073
T074................ 250074
T075................ 250075
T076................ 250076
T077................ 250077
T078................ 250078
T079................ 250079
T081................ 250081
T082................ 250082
T083................ 250083
T084................ 250084
T087................ 250087
T088................ 250088
T089................ 250089
T090................ 250090
T091................ 250091
T092................ 250092
T093................ 250093
T094................ 250094
T095................ 250095
T096................ 250096
T097................ 250097
T098................ 250098
T099................ 250099
T100................ 250100
T101................ 250101
T102................ 250102
T103................ 250103
T104................ 250104
T106................ 250106
T107................ 250107
T108................ 250293
T112................ 250112
T113................ 250113
T114................ 250114
T115................ 250299
T116................ 250300
T117................ 250117
T118................ 250118
T119................ 250119
T121................ 250121
T122................ 250122
T123................ 250123
T124................ 250124
T125................ 250125
T126................ 250126
T127................ 250127
T128................ 250128
T129................ 250129
T130................ 250130
T131................ 250131
T132................ 250132
T133................ 250292
T134................ 250134
T135................ 250135
T136................ 250136
T137................ 250137
T138................ 250138
T139................ 250139
T140................ 250140
T141................ 250141
T142................ 250142
T143................ 250143
T144................ 250144
T145................ 250145
T146................ 250146
T147................ 250147
T148................ 250148
T149................ 250149
T150................ 250150
T151................ 250151
GATES (U.S.) - Cont.
T153................ 250153
T154................ 250154
T155................ 250155
T157................ 250157
T158................ 250158
T159................ 250159
T160................ 250160
T161................ 250161
T162................ 250162
T163................ 250163
T164................ 250164
T165................ 250165
T166................ 250166
T167................ 250167
T168................ 250168
T169................ 250169
T170................ 250170
T171................ 250171
T172................ 250172
T173................ 250173
T174................ 250174
T176................ 250176
T177................ 250177
T178................ 250178
T179................ 250179
T180................ 250180
T181................ 250181
T182................ 250182
T183................ 250183
T184................ 250184
T185................ 250185
T186................ 250186
T187................ 250187
T190................ 250190
T191................ 250191
T192................ 250192
T193................ 250193
T194................ 250194
T195................ 250195
T199................ 250199
T200................ 250200
T201................ 250201
T202................ 250248
T203................ 250203
T204................ 250204
T205................ 250205
T206................ 250206
T207................ 250207
T208................ 250208
T209................ 250209
T210................ 250210
T211................ 250211
T212................ 250212
T214................ 250214
T215................ 250215
T216................ 250216
T217................ 250217
T218................ 250218
T219................ 250219
T220................ 250220
T221................ 250221
T223................ 250223
T224................ 250224
T225................ 250225
T226................ 250226
T227................ 250227
T228................ 250228
T229................ 250229
T230................ 250230
T232................ 250232
T233................ 250233
T234................ 250234
T235................ 250235
T236................ 250236
T237................ 250237
T239................ 250239
T240................ 250240
T241................ 250241
T242................ 250242
T244................ 250244
T245................ 250245
T246................ 250246
T247................ 250247
T248................ 250248
T249................ 250249
T251................ 250251
T252................ 250252
T253................ 250253
T254................ 250254
T255................ 250255
T256................ 250256
T257................ 250257
T258................ 250258
GATES (U.S.) - Cont.
T259................ 250259
T260................ 250260
T262................ 250262
T263................ 250263
T264................ 250264
T265................ 250265
T266................ 250266
T267................ 250267
T270................ 250270
T271................ 250271
T272................ 250272
T273................ 250273
T274................ 250274
T275................ 250275
T276................ 250276
T277................ 250277
T278................ 250278
T279................ 250279
T280................ 250280
T281................ 250281
T282................ 250282
T283................ 250283
T284................ 250284
T285................ 250285
T286................ 250286
T287................ 250287
T288................ 250288
T289................ 250289
T290................ 250290
T291................ 250291
T292................ 250292
T293................ 250293
T294................ 250294
T295................ 250295
T296................ 250296
T297................ 250297
T298................ 250298
T299................ 250299
T300................ 250300
T301................ 250301
T302................ 250302
T303................ 250303
T304................ 250304
T305................ 250305
T306................ 250306
T308................ 250308
T309................ 250309
T310................ 250310
T311................ 250311
6401................ 250014
6402................ 250013
6403................ 250037
6404................ 250017
6406................ 250018
6408................ 250020
6409................ 250039
6410................ 250032
6411................ 250041
6412................ 250062
6415................ 250028
6416................ 250064
6417................ 250065
6418................ 250061
6419................ 250073
6425................ 250070
6427................ 250071
6428................ 250067
6429................ 250076
6430................ 250075
6431................ 250078
6432................ 250077
6433................ 250043
6434................ 250074
GOODYEAR
CD-100............ 250100
CD-101............ 250101
CD-104............ 250104
CD-106............ 250106
CD-112............ 250112
CD-113............ 250113
CD-114............ 250114
CD-115............ 250299
CD-116............ 250300
CD-117............ 250117
CD-118............ 250118
CD-122............ 250122
CD-124............ 250124
CD-125............ 250125
CD-126............ 250126
CD-127............ 250127
CD-128............ 250128
CD-129............ 250129
CD-13.............. 250013
GOODYEAR - Cont.
CD-130............ 250130
CD-131............ 250131
CD-132............ 250132
CD-133............ 250292
CD-134............ 250134
CD-136............ 250136
CD-137............ 250137
CD-138............ 250138
CD-139............ 250139
CD-14.............. 250014
CD-140............ 250140
CD-141............ 250141
CD-142............ 250142
CD-143............ 250143
CD-144............ 250144
CD-145............ 250145
CD-146............ 250146
CD-147............ 250147
CD-148............ 250148
CD-149............ 250149
CD-150............ 250150
CD-151............ 250151
CD-153............ 250153
CD-154............ 250154
CD-155............ 250155
CD-157............ 250157
CD-158............ 250158
CD-159............ 250159
CD-160............ 250160
CD-161............ 250161
CD-162............ 250162
CD-163............ 250163
CD-164............ 250164
CD-165............ 250165
CD-166............ 250166
CD-167............ 250167
CD-168............ 250168
CD-169............ 250169
CD-17.............. 250017
CD-170............ 250170
CD-171............ 250171
CD-172............ 250172
CD-173............ 250173
CD-174............ 250174
CD-176............ 250176
CD-177............ 250177
CD-178............ 250178
CD-179............ 250179
CD-18.............. 250018
CD-180............ 250180
CD-181............ 250181
CD-182............ 250182
CD-183............ 250183
CD-184............ 250184
CD-185............ 250185
CD-186............ 250186
CD-187............ 250187
CD-190............ 250190
CD-191............ 250191
CD-192............ 250192
CD-193............ 250193
CD-194............ 250194
CD-195............ 250195
CD-199............ 250199
CD-20.............. 250020
CD-200............ 250200
CD-201............ 250201
CD-202............ 250248
CD-203............ 250203
CD-204............ 250204
CD-205............ 250205
CD-206............ 250206
CD-207............ 250207
CD-208............ 250208
CD-209............ 250209
CD-210............ 250210
CD-211............ 250211
CD-212............ 250212
CD-214............ 250214
CD-215............ 250215
CD-216............ 250216
CD-217............ 250217
CD-218............ 250218
CD-219............ 250219
CD-220............ 250220
CD-221............ 250221
CD-223............ 250223
CD-224............ 250224
CD-225............ 250225
CD-226............ 250226
CD-227............ 250227
CD-228............ 250228
CD-229............ 250229
A-48
GOODYEAR - Cont.
CD-230............ 250230
CD-232............ 250232
CD-233............ 250233
CD-234............ 250234
CD-235............ 250235
CD-236............ 250236
CD-237............ 250237
CD-239............ 250239
CD-240............ 250240
CD-241............ 250241
CD-242............ 250242
CD-244............ 250244
CD-245............ 250245
CD-246............ 250246
CD-247............ 250247
CD-248............ 250248
CD-249............ 250249
CD-251............ 250251
CD-252............ 250252
CD-253............ 250253
CD-254............ 250254
CD-255............ 250255
CD-256............ 250256
CD-257............ 250257
CD-258............ 250258
CD-259............ 250259
CD-260............ 250260
CD-262............ 250262
CD-263............ 250263
CD-264............ 250264
CD-265............ 250265
CD-266............ 250266
CD-267............ 250267
CD-271............ 250271
CD-272............ 250272
CD-273............ 250273
CD-276............ 250276
CD-277............ 250277
CD-278............ 250278
CD-279............ 250279
CD-28.............. 250028
CD-280............ 250280
CD-281............ 250281
CD-282............ 250282
CD-283............ 250283
CD-284............ 250284
CD-285............ 250285
CD-286............ 250286
CD-287............ 250287
CD-288............ 250288
CD-289............ 250289
CD-290............ 250290
CD-291............ 250291
CD-292............ 250292
CD-293............ 250293
CD-294............ 250294
CD-295............ 250295
CD-296............ 250296
CD-297............ 250297
CD-298............ 250298
CD-299............ 250299
CD-300............ 250300
CD-301............ 250301
CD-302............ 250302
CD-303............ 250303
CD-304............ 250304
CD-305............ 250305
CD-306............ 250306
CD-32.............. 250032
CD-36.............. 250036
CD-37.............. 250037
CD-39.............. 250039
CD-41.............. 250041
CD-43.............. 250043
CD-61.............. 250061
CD-62.............. 250062
CD-63.............. 250073
CD-64.............. 250064
CD-65.............. 250065
CD-67.............. 250067
CD-70.............. 250070
CD-71.............. 250071
CD-74.............. 250074
CD-77.............. 250077
CD-78.............. 250078
CD-81.............. 250081
CD-87.............. 250087
CD-88.............. 250088
CD-89.............. 250089
CD-90.............. 250090
CD-91.............. 250091
CD-92.............. 250092
CD-93.............. 250093
GOODYEAR - Cont.
CD-94.............. 250094
CD-95.............. 250095
CD-99.............. 250099
40013.............. 250013
40014.............. 250014
40017.............. 250017
40018.............. 250018
40020.............. 250020
40028.............. 250028
40032.............. 250032
40036.............. 250036
40037.............. 250037
40039.............. 250039
40041.............. 250041
40043.............. 250043
40046.............. 250013
40047.............. 250014
40050.............. 250018
40052.............. 250020
40057.............. 250037
40058.............. 250039
40060.............. 250017
40061.............. 250061
40062.............. 250062
40063.............. 250073
40064.............. 250064
40065.............. 250065
40067.............. 250067
40070.............. 250070
40071.............. 250071
40074.............. 250074
40075.............. 250075
40076.............. 250076
40077.............. 250077
40078.............. 250078
40079.............. 250079
40081.............. 250081
40082.............. 250082
40083.............. 250083
40084.............. 250084
40087.............. 250087
40088.............. 250088
40089.............. 250089
40090.............. 250090
40091.............. 250091
40092.............. 250092
40093.............. 250093
40094.............. 250094
40095.............. 250095
40099.............. 250099
40100.............. 250100
40101.............. 250101
40102.............. 250102
40103.............. 250103
40104.............. 250104
40106.............. 250106
40107.............. 250107
40112.............. 250176
40113.............. 250113
40114.............. 250114
40115.............. 250299
40116.............. 250300
40117.............. 250117
40118.............. 250118
40119.............. 250119
40121.............. 250121
40122.............. 250122
40123.............. 250123
40124.............. 250124
40125.............. 250125
40126.............. 250126
40127.............. 250127
40128.............. 250128
40129.............. 250129
40130.............. 250130
40131.............. 250131
40132.............. 250132
40133.............. 250292
40134.............. 250134
40136.............. 250136
40137.............. 250137
40138.............. 250138
40139.............. 250139
40140.............. 250140
40141.............. 250141
40142.............. 250142
40143.............. 250143
40144.............. 250144
40145.............. 250145
40146.............. 250146
40147.............. 250147
40148.............. 250148
40153.............. 250153
GOODYEAR - Cont.
40154.............. 250154
40155.............. 250155
40157.............. 250157
40158.............. 250158
40159.............. 250159
40160.............. 250160
40161.............. 250161
40162.............. 250162
40163.............. 250163
40164.............. 250164
40165.............. 250165
40166.............. 250166
40167.............. 250167
40168.............. 250168
40169.............. 250169
40170.............. 250170
40172.............. 250172
40176.............. 250176
40177.............. 250177
40178.............. 250178
40179.............. 250179
40180.............. 250180
40183.............. 250183
40184.............. 250184
40185.............. 250185
40186.............. 250186
40187.............. 250187
40190.............. 250190
40191.............. 250191
40192.............. 250192
40193.............. 250193
40194.............. 250194
40195.............. 250195
40199.............. 250199
40200.............. 250200
40201.............. 250201
40202.............. 250248
40203.............. 250203
40204.............. 250204
40205.............. 250205
40208.............. 250208
40210.............. 250210
40211.............. 250211
40212.............. 250212
40214.............. 250214
40215.............. 250215
40216.............. 250216
40217.............. 250217
40219.............. 250219
40220.............. 250220
40221.............. 250221
40223.............. 250223
40224.............. 250224
40226.............. 250226
40227.............. 250227
40228.............. 250228
40230.............. 250230
40233.............. 250233
40234.............. 250234
40235.............. 250235
40236.............. 250236
40237.............. 250237
40239.............. 250239
40240.............. 250240
40241.............. 250241
40244.............. 250244
40245.............. 250245
40246.............. 250246
40247.............. 250247
40248.............. 250248
40249.............. 250249
40252.............. 250252
40255.............. 250255
40257.............. 250257
40258.............. 250258
40259.............. 250259
40262.............. 250262
40263.............. 250263
40265.............. 250265
40266.............. 250266
40271.............. 250271
40272.............. 250272
40273.............. 250273
40276.............. 250276
40283.............. 250283
40292.............. 250292
40299.............. 250299
40300.............. 250300
HOOF PRODUCTS
HB013............. 250013
HB014............. 250014
HB017............. 250017
HB018............. 250018
HOOF PRODUCTS - Cont.
HB020............. 250020
HB028............. 250028
HB032............. 250032
HB036............. 250036
HB037............. 250037
HB039............. 250039
HB041............. 250041
HB043............. 250043
HB061............. 250061
HB062............. 250062
HB063............. 250073
HB064............. 250064
HB065............. 250065
HB067............. 250067
HB070............. 250070
HB071............. 250071
HB073............. 250073
HB074............. 250074
HB075............. 250075
HB076............. 250076
HB077............. 250077
HB078............. 250078
HB079............. 250079
HB081............. 250081
HB082............. 250082
HB083............. 250083
HB084............. 250084
HB087............. 250087
HB088............. 250088
HB089............. 250089
HB090............. 250090
HB091............. 250091
HB092............. 250092
HB093............. 250093
HB094............. 250094
HB095............. 250095
HB096............. 250096
HB099............. 250099
HB100............. 250100
HB102............. 250102
HB103............. 250103
HB104............. 250104
HB114............. 250114
HB115............. 250299
HB116............. 250300
HB118............. 250118
HB121............. 250121
HB122............. 250122
HB127............. 250127
HB128............. 250128
LAZORLITE
L55-4014......... 250013
L55-4022......... 250062
L55-4030......... 250064
L55-4049......... 250028
L55-4057......... 250041
L55-4065......... 250041
L55-4081......... 250073
L55-4103......... 250078
L55-4111......... 250077
L55-4120......... 250074
L55-4138......... 250079
L55-4154......... 250088
L55-4162......... 250089
L55-4170......... 250090
L55-4189......... 250092
L55-4200......... 250070
L55-4219......... 250075
L55-4227......... 250076
L55-4235......... 250117
L55-4243......... 250093
L55-4251......... 250091
L55-4260......... 250095
L55-4286......... 250104
L55-4294......... 250101
L55-4308......... 250084
L55-4316......... 250087
L55-4324......... 250094
L55-4332......... 250099
L55-4405......... 250017
L55-4472......... 250300
L55-4480......... 250299
L55-4499......... 250112
L55-4502......... 250161
L55-4510......... 250118
L55-4529......... 250104
L55-4537......... 250137
L55-4596......... 250149
L55-4600......... 250141
L55-4618......... 250141
L55-4626......... 250117
L55-4634......... 250134
L55-4642......... 250128
LAZORLITE - Cont.
L55-4650......... 250124
L55-4669......... 250139
L55-4677......... 250103
L55-4685......... 250135
L55-4693......... 250136
L55-4707......... 250126
L55-4715......... 250098
L55-4723......... 250138
L55-4731......... 250130
L55-4740......... 250129
L55-4758......... 250145
L55-4766......... 250122
L55-4774......... 250121
L55-4782......... 250148
L55-4790......... 250138
L55-4812......... 250146
L55-4820......... 250159
L55-4839......... 250168
L55-4847......... 250144
L55-4855......... 250142
L55-4863......... 250143
L55-4880......... 250167
L55-4898......... 250165
L55-4901......... 250164
L55-4910......... 250150
L55-4928......... 250151
L55-4936......... 250166
L55-4944......... 250113
L55-4952......... 250157
L55-4960......... 250154
L55-4979......... 250125
U55-4367 ........ 250018
U55-4383 ........ 250020
U55-4405 ........ 250017
U55-4413 ........ 250065
U55-4421 ........ 250127
U55-4430 ........ 250083
U55-4448 ........ 250032
U55-4456 ........ 250082
U55-4464 ........ 250043
U55-4545 ........ 250082
U55-4553 ........ 250083
U55-4561 ........ 250293
U55-4570 ........ 250107
U55-4588 ........ 250119
U55-4871 ........ 250292
LEMPCO
TB013 ............. 250013
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB028 ............. 250028
TB037 ............. 250037
TB039 ............. 250039
TB041 ............. 250041
TB063 ............. 250073
TB064 ............. 250064
TB071 ............. 250071
TB112 ............. 250112
LINK-BELT
B013................ 250013
B014................ 250014
B037................ 250037
MBL THREE STARS
100ZA19.......... 250061
106ZA19.......... 250077
109ZA19.......... 250088
113ZA19.......... 250065
116ZA19.......... 250018
120ZA19.......... 250064
121ZA19.......... 250017
122ZA19.......... 250013
123ZA19.......... 250032
124ZA25.......... 250071
129ZA22.......... 250014
134ZA30.......... 250076
134ZB301........ 250076
135ZB25.......... 250043
139ZA25.......... 250087
142ZA25.......... 250074
146ZA19.......... 250020
55ZA13 ........... 250062
84ZA19 ........... 250028
87ZA34 ........... 250075
87ZB34 ........... 250075
88ZA19 ........... 250070
92ZA19 ........... 250073
95ZA19 ........... 250041
97ZA25 ........... 250067
98ZA19 ........... 250078
99ZA15 ........... 250037
A-49
MBL THREE STARS
- Cont.
99ZA19 ........... 250039
MCQUAY-NORRIS
TC013 ............. 250013
TC014 ............. 250014
TC017 ............. 250017
TC018 ............. 250018
TC020 ............. 250020
TC028 ............. 250028
TC032 ............. 250032
TC036 ............. 250036
TC037 ............. 250037
TC039 ............. 250039
TC041 ............. 250041
TC043 ............. 250043
TC061 ............. 250061
TC062 ............. 250062
TC063 ............. 250073
TC064 ............. 250064
TC065 ............. 250065
TC067 ............. 250067
TC070 ............. 250070
TC071 ............. 250071
TC074 ............. 250074
TC075 ............. 250075
TC076 ............. 250076
TC077 ............. 250077
TC078 ............. 250078
TC081 ............. 250081
TC087 ............. 250087
TC088 ............. 250088
TC089 ............. 250089
MELLING AUTOMOTIVE
B0100.............. 250100
B0101.............. 250101
B0102.............. 250102
B0103.............. 250103
B0104.............. 250104
B0106.............. 250106
B0107.............. 250107
B0108.............. 250293
B0112.............. 250176
B0113.............. 250113
B0114.............. 250114
B0115.............. 250299
B0116.............. 250300
B0117.............. 250117
B0118.............. 250162
B0119.............. 250119
B0121.............. 250121
B0122.............. 250122
B0123.............. 250123
B0124.............. 250124
B0125.............. 250125
B0126.............. 250126
B0127.............. 250127
B0128.............. 250128
B0129.............. 250129
B013................ 250013
B0130.............. 250130
B0131.............. 250131
B0132.............. 250132
B0133.............. 250292
B0134.............. 250134
B0135.............. 250135
B0136.............. 250136
B0137.............. 250137
B0138.............. 250138
B0139.............. 250139
B014................ 250014
B0140.............. 250140
B0141.............. 250141
B0142.............. 250142
B0143.............. 250143
B0144.............. 250144
B0145.............. 250145
B0146.............. 250146
B0147.............. 250147
B0148.............. 250148
B0149.............. 250149
B0150.............. 250150
B0151.............. 250151
B0153.............. 250153
B0154.............. 250154
B0155.............. 250155
B0157.............. 250157
B0158.............. 250158
B0159.............. 250159
B0160.............. 250160
B0161.............. 250161
B0162.............. 250162
B0163.............. 250163
MELLING AUTOMOTIVE
- Cont.
B0164.............. 250164
B0165.............. 250165
B0166.............. 250166
B0167.............. 250167
B0168.............. 250168
B0169.............. 250169
B017................ 250017
B0170.............. 250170
B0171.............. 250171
B0172.............. 250172
B0174.............. 250174
B0176.............. 250176
B0177.............. 250177
B0178.............. 250178
B0179.............. 250179
B018................ 250018
B0180.............. 250180
B0181.............. 250181
B0182.............. 250182
B0183.............. 250183
B0184.............. 250184
B0185.............. 250185
B0186.............. 250186
B0187.............. 250187
B0191.............. 250191
B0192.............. 250192
B0193.............. 250193
B0194.............. 250194
B0195.............. 250195
B0199.............. 250199
B020................ 250020
B0202.............. 250248
B0203.............. 250203
B0204.............. 250204
B0205.............. 250205
B0208.............. 250208
B0210.............. 250210
B0216.............. 250216
B0219.............. 250219
B0223.............. 250223
B0224.............. 250224
B0226.............. 250226
B0228.............. 250228
B0229.............. 250229
B0230.............. 250230
B0232.............. 250232
B0233.............. 250233
B0237.............. 250237
B0239.............. 250239
B028................ 250028
B029................ 250104
B032................ 250032
B036................ 250036
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B062................ 250062
B063................ 250073
B064................ 250064
B065................ 250065
B067................ 250067
B070................ 250070
B071................ 250071
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B079................ 250079
B081................ 250081
B082................ 250082
B083................ 250083
B084................ 250084
B087................ 250087
B088................ 250088
B089................ 250089
B090................ 250090
B091................ 250091
B092................ 250092
B093................ 250093
B094................ 250094
B095................ 250095
B096................ 250096
B097................ 250097
B098................ 250098
B099................ 250099
MICROTEST
9-013............... 250013
9-014............... 250014
9-017............... 250017
MICROTEST - Cont.
9-018............... 250018
9-020............... 250020
9-028............... 250028
9-039............... 250039
9-041............... 250041
9-061............... 250061
9-063............... 250073
9-064............... 250064
9-065............... 250065
9-067............... 250067
9-071............... 250071
MIGHTY
CD100............. 250100
CD101............. 250101
CD102............. 250102
CD103............. 250103
CD104............. 250104
CD111............. 250140
CD112............. 250176
CD113............. 250113
CD114............. 250114
CD115............. 250299
CD116............. 250300
CD117............. 250117
CD118............. 250118
CD119............. 250119
CD121............. 250121
CD122............. 250122
CD123............. 250123
CD124............. 250124
CD125............. 250125
CD126............. 250126
CD127............. 250127
CD128............. 250128
CD129............. 250129
CD13............... 250013
CD130............. 250130
CD131............. 250131
CD132............. 250132
CD133............. 250292
CD134............. 250134
CD135............. 250135
CD136............. 250136
CD137............. 250137
CD138............. 250138
CD139............. 250139
CD14............... 250014
CD141............. 250141
CD142............. 250142
CD143............. 250143
CD144............. 250144
CD145............. 250145
CD146............. 250146
CD147............. 250147
CD148............. 250148
CD153............. 250153
CD154............. 250154
CD155............. 250155
CD157............. 250157
CD158............. 250158
CD159............. 250159
CD160............. 250160
CD161............. 250161
CD162............. 250162
CD163............. 250163
CD164............. 250164
CD165............. 250165
CD166............. 250166
CD167............. 250167
CD17............... 250017
CD176............. 250176
CD18............... 250018
CD185............. 250185
CD186............. 250186
CD187............. 250187
CD191............. 250191
CD20............... 250020
CD208............. 250208
CD210............. 250210
CD28............... 250028
CD32............... 250032
CD36............... 250036
CD37............... 250037
CD39............... 250039
CD41............... 250041
CD43............... 250043
CD61............... 250061
CD62............... 250062
CD63............... 250073
CD64............... 250064
CD65............... 250065
CD67............... 250067
CD70............... 250070
MIGHTY - Cont.
CD71............... 250071
CD74............... 250074
CD75............... 250075
CD76............... 250076
CD77............... 250077
CD78............... 250078
CD79............... 250079
CD81............... 250081
CD82............... 250082
CD83............... 250083
CD84............... 250084
CD87............... 250087
CD88............... 250088
CD89............... 250089
CD90............... 250090
CD91............... 250091
CD92............... 250092
CD93............... 250093
CD94............... 250094
CD95............... 250095
CD99............... 250099
MITSUBOSHI
106ZA19.......... 250077
111ZA19.......... 250121
116ZA19.......... 250018
120ZA19.......... 250064
122ZA19.......... 250013
123ZA19.......... 250032
127ZA25.......... 250079
129ZA22.......... 250014
134ZB30.......... 250076
139ZA25.......... 250087
146ZA19.......... 250020
55ZA13 ........... 250062
55ZB13 ........... 250090
83ZB19 ........... 250092
84ZA19 ........... 250028
87ZB34 ........... 250075
88ZA19 ........... 250070
89ZA19 ........... 250095
92ZA19 ........... 250073
94ZA19 ........... 250036
95ZA19 ........... 250041
98ZA19 ........... 250078
MOPAR
BTC-13............ 250013
BTC-14............ 250014
BTC-37............ 250037
BTC-39............ 250020
B0040013........ 250013
B0040017........ 250017
B0040062........ 250062
B0040063........ 250073
B0040064........ 250064
B0040071........ 250071
MOTORCRAFT
CET13............. 250013
CET135........... 250135
CET14............. 250014
CET17............. 250017
CET207........... 250207
CET230........... 250230
CET257........... 250257
CET262........... 250262
CET263........... 250263
CET264........... 250264
CET265........... 250265
CET271........... 250271
CET272........... 250272
CET273........... 250273
CET277........... 250277
CET278........... 250278
CET279........... 250279
CET28............. 250028
CET280........... 250280
CET281........... 250281
CET282........... 250282
CET284........... 250284
CET285........... 250285
CET286........... 250286
CET287........... 250287
CET288........... 250288
CET289........... 250289
CET290........... 250290
CET291........... 250291
CET37............. 250037
CET39............. 250039
CET41............. 250041
CET61............. 250061
CET67............. 250067
CET70............. 250070
MOTORCRAFT - Cont.
CET71............. 250071
CET94............. 250094
PAREX TRANS. PARTS
013.................. 250013
018.................. 250018
020.................. 250020
028.................. 250028
032.................. 250032
037.................. 250037
041.................. 250041
043.................. 250043
062.................. 250062
065.................. 250065
067.................. 250067
070.................. 250070
071.................. 250071
074.................. 250074
075.................. 250075
076.................. 250076
077.................. 250077
078.................. 250078
081.................. 250081
087.................. 250087
088.................. 250088
093.................. 250093
094.................. 250094
095.................. 250095
099.................. 250099
104.................. 250104
PEP BOYS (See DAYCO)

PERFECT CIRCLE
9-100............... 250100
9-101............... 250101
9-102............... 250102
9-103............... 250103
9-104............... 250104
9-13................. 250013
9-14................. 250014
9-17................. 250017
9-18................. 250018
9-20................. 250020
9-28................. 250028
9-32................. 250032
9-36................. 250036
9-37................. 250037
9-39................. 250039
9-41................. 250041
9-43................. 250043
9-61................. 250061
9-62................. 250062
9-63................. 250073
9-64................. 250064
9-65................. 250065
9-67................. 250067
9-70................. 250070
9-71................. 250071
9-74................. 250074
9-75................. 250075
9-76................. 250076
9-77................. 250077
9-78................. 250078
9-79................. 250079
9-81................. 250081
9-84................. 250084
9-87................. 250087
9-88................. 250088
9-89................. 250089
9-90................. 250090
9-91................. 250091
9-92................. 250092
9-93................. 250093
9-94................. 250094
9-96................. 250096
9-98................. 250098
9-99................. 250099
PERFECTION AM
B0101.............. 250101
B0102.............. 250102
B0103.............. 250103
B0104.............. 250104
B0114.............. 250114
B0118.............. 250162
B013................ 250013
B014................ 250014
B017................ 250017
B018................ 250018
B020................ 250020
B028................ 250028
B032................ 250032
A-50
PERFECTION AM - Cont.
B036................ 250036
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B062................ 250062
B063................ 250073
B064................ 250064
B065................ 250065
B067................ 250067
B070................ 250070
B071................ 250071
B074................ 250074
B075................ 250075
B076................ 250076
B077................ 250077
B078................ 250078
B081................ 250081
B082................ 250082
B083................ 250083
B087................ 250087
B088................ 250088
B089................ 250089
B090................ 250090
B093................ 250093
B094................ 250094
B095................ 250095
B099................ 250099
013.................. 250013
014.................. 250014
017.................. 250017
018.................. 250020
037.................. 250037
039.................. 250039
PROVEN VALU
TB-013 ............ 250013
TB-014 ............ 250014
TB-017 ............ 250017
TB-018 ............ 250018
TB-020 ............ 250020
TB-028 ............ 250028
TB-032 ............ 250032
TB-036 ............ 250036
TB-037 ............ 250037
TB-039 ............ 250039
TB-041 ............ 250041
TB-043 ............ 250043
TB-061 ............ 250061
TB-062 ............ 250062
TB-063 ............ 250073
TB-064 ............ 250064
TB-065 ............ 250065
TB-067 ............ 250067
TB-070 ............ 250070
TB-071 ............ 250071
TB-073 ............ 250073
TB-074 ............ 250074
TB-075 ............ 250075
TB-076 ............ 250076
TB-077 ............ 250077
TB-078 ............ 250078
TB-079 ............ 250079
TB-081 ............ 250081
TB-082 ............ 250082
TB-083 ............ 250083
TB-084 ............ 250084
TB-087 ............ 250087
TB-088 ............ 250088
TB-089 ............ 250089
TB-090 ............ 250090
TB-091 ............ 250091
TB-092 ............ 250092
TB-093 ............ 250093
TB-094 ............ 250094
TB-095 ............ 250095
TB-096 ............ 250096
TB-098 ............ 250098
TB-099 ............ 250099
TB-100 ............ 250100
TB-101 ............ 250101
TB-102 ............ 250102
TB-103 ............ 250103
TB-104 ............ 250104
TB-112 ............ 250112
TB-113 ............ 250113
TB-114 ............ 250114
TB-115 ............ 250299
TB-116 ............ 250300
TB-117 ............ 250117
TB-118 ............ 250118
TB-119 ............ 250119
TB-121 ............ 250121
PROVEN VALU - Cont.
TB-122 ............ 250122
TB-123 ............ 250123
TB-125 ............ 250125
TB-126 ............ 250126
TB-127 ............ 250127
TB-128 ............ 250128
TB-129 ............ 250129
TB-130 ............ 250130
TB-134 ............ 250134
TB-139 ............ 250139
REPCOPARTS
4013................ 250013
4014................ 250014
4017................ 250017
4018................ 250018
4020................ 250020
4028................ 250028
4029................ 250104
4032................ 250032
4036................ 250036
4037................ 250037
4039................ 250039
4041................ 250041
4043................ 250043
4061................ 250061
4065................ 250065
4070................ 250070
4071................ 250071
4073................ 250073
4074................ 250074
4077................ 250077
4078................ 250078
4079................ 250079
4081................ 250081
4082................ 250082
4083................ 250083
4084................ 250084
4089................ 250089
4091................ 250091
4092................ 250092
4093................ 250093
4094................ 250094
4095................ 250095
4096................ 250096
4097................ 250097
4098................ 250098
4099................ 250099
4100................ 250100
4101................ 250101
4102................ 250102
4103................ 250103
4104................ 250104
4106................ 250106
REPUBLIC
R0112 ............. 250176
R0113 ............. 250113
R0114 ............. 250114
R0115 ............. 250299
R0116 ............. 250300
R0117 ............. 250117
R0118 ............. 250162
R0119 ............. 250119
R0122 ............. 250122
R0124 ............. 250124
R0125 ............. 250125
R0126 ............. 250126
R0127 ............. 250127
R0128 ............. 250128
R0129 ............. 250129
R0130 ............. 250130
R0132 ............. 250132
R0133 ............. 250292
R0134 ............. 250134
R0135 ............. 250135
R0136 ............. 250233
R0138 ............. 250138
R0139 ............. 250139
R0141 ............. 250141
R0142 ............. 250142
R0143 ............. 250143
R0144 ............. 250144
R0145 ............. 250145
R0146 ............. 250146
R0147 ............. 250147
R0148 ............. 250148
R0153 ............. 250153
R0154 ............. 250154
R0157 ............. 250157
R0158 ............. 250158
R0159 ............. 250159
R0160 ............. 250160
R0161 ............. 250161
REPUBLIC - Cont.
R0162 ............. 250162
R0163 ............. 250163
R0164 ............. 250164
R0166 ............. 250166
R0167 ............. 250167
R0168 ............. 250168
R0169 ............. 250169
R0170 ............. 250170
R0176 ............. 250176
R0177 ............. 250177
R0179 ............. 250179
R0184 ............. 250184
R0185 ............. 250185
R0186 ............. 250186
R0187 ............. 250187
R082 ............... 250082
R083 ............... 250083
REPUBLIC PARTS
R-0100 ............ 250100
R-0101 ............ 250101
R-0102 ............ 250102
R-0103 ............ 250103
R-0104 ............ 250104
R-0112 ............ 250112
R-013 .............. 250013
R-014 .............. 250014
R-017 .............. 250017
R-018 .............. 250018
R-020 .............. 250020
R-028 .............. 250028
R-032 .............. 250032
R-036 .............. 250036
R-037 .............. 250037
R-039 .............. 250039
R-041 .............. 250041
R-043 .............. 250043
R-061 .............. 250061
R-062 .............. 250062
R-063 .............. 250073
R-064 .............. 250064
R-065 .............. 250065
R-067 .............. 250067
R-070 .............. 250070
R-071 .............. 250071
R-073 .............. 250073
R-074 .............. 250074
R-075 .............. 250075
R-076 .............. 250075
R-077 .............. 250077
R-078 .............. 250078
R-079 .............. 250079
R-081 .............. 250081
R-084 .............. 250084
R-087 .............. 250087
R-088 .............. 250088
R-089 .............. 250089
R-090 .............. 250090
R-091 .............. 250091
R-092 .............. 250092
R-093 .............. 250093
R-094 .............. 250094
R-095 .............. 250095
R-096 .............. 250096
R-098 .............. 250098
R-099 .............. 250099
ROCKHILL
TB-100 ............ 250100
TB-101 ............ 250101
TB-102 ............ 250102
TB-103 ............ 250103
TB-104 ............ 250104
TB-112 ............ 250176
TB-118 ............ 250118
TB-13 .............. 250013
TB-14 .............. 250014
TB-17 .............. 250017
TB-18 .............. 250018
TB-20 .............. 250020
TB-28 .............. 250028
TB-32 .............. 250032
TB-36 .............. 250036
TB-37 .............. 250037
TB-39 .............. 250039
TB-41 .............. 250041
TB-43 .............. 250043
TB-61 .............. 250061
TB-62 .............. 250062
TB-63 .............. 250073
TB-64 .............. 250064
TB-65 .............. 250065
TB-67 .............. 250067
TB-70 .............. 250070
ROCKHILL - Cont.
TB-71 .............. 250071
TB-73 .............. 250073
TB-74 .............. 250074
TB-75 .............. 250075
TB-76 .............. 250076
TB-77 .............. 250077
TB-78 .............. 250078
TB-79 .............. 250079
TB-81 .............. 250081
TB-82 .............. 250082
TB-83 .............. 250083
TB-84 .............. 250084
TB-87 .............. 250087
TB-88 .............. 250088
TB-89 .............. 250158
TB-90 .............. 250159
TB-91 .............. 250091
TB-92 .............. 250092
TB-93 .............. 250093
TB-94 .............. 250094
TB-95 .............. 250095
TB-98 .............. 250098
TB-99 .............. 250161
SEALED POWER
222-100........... 250100
222-13............. 250013
222-14............. 250014
222-17............. 250017
222-18............. 250018
222-20............. 250020
222-28............. 250028
222-32............. 250032
222-36............. 250036
222-37............. 250037
222-39............. 250039
222-41............. 250041
222-43............. 250043
222-61............. 250061
222-62............. 250062
222-63............. 250073
222-64............. 250064
222-65............. 250065
222-67............. 250067
222-70............. 250070
222-71............. 250071
222-73............. 250073
222-74............. 250074
222-75............. 250075
222-76............. 250076
222-77............. 250077
222-78............. 250078
222-81............. 250081
222-87............. 250087
222-88............. 250088
222-89............. 250089
222-90............. 250090
222-91............. 250091
222-92............. 250092
222-93............. 250093
222-94............. 250094
222-95............. 250095
222-99............. 250161
222B160.......... 250160
222B161.......... 250161
222B162.......... 250162
222B163.......... 250163
222B164.......... 250164
222B165.......... 250165
222B166.......... 250166
222B167.......... 250167
222B168.......... 250168
222B169.......... 250169
222B170.......... 250170
222B172.......... 250254
222B177.......... 250177
222B179.......... 250179
222B180.......... 250180
222B183.......... 250183
222B184.......... 250184
222B185.......... 250185
222B186.......... 250186
222B187.......... 250187
222B193.......... 250193
222B194.......... 250194
222B202.......... 250248
222B210.......... 250210
222013............ 250013
222014............ 250014
222017............ 250017
222018............ 250018
222020............ 250020
222028............ 250028
222032............ 250032
SEALED POWER - Cont.
222036............ 250036
222037............ 250037
222039............ 250039
222041............ 250041
222043............ 250043
222061............ 250061
222062............ 250062
222063............ 250073
222064............ 250064
222065............ 250065
222067............ 250067
222070............ 250070
222071............ 250071
222074............ 250074
222075............ 250075
222076............ 250076
222077............ 250077
222078............ 250078
222082............ 250082
222083............ 250083
222087............ 250087
222088............ 250088
222089............ 250158
222090............ 250159
222093............ 250093
222094............ 250160
222095............ 250095
222099............ 250161
222101............ 250101
222102............ 250102
222103............ 250103
222104............ 250104
222107............ 250107
222108............ 250293
222112............ 250176
222113............ 250113
222114............ 250114
222115............ 250299
222116............ 250300
222117............ 250117
222118............ 250162
222119............ 250119
222122............ 250122
222124............ 250124
222125............ 250125
222126............ 250237
222128............ 250128
222129............ 250129
222130............ 250130
222131............ 250131
222132............ 250132
222133............ 250292
222134............ 250134
222135............ 250135
222136............ 250233
222138............ 250199
222139............ 250139
222141............ 250141
222142............ 250142
222143............ 250143
222144............ 250144
222145............ 250145
222146............ 250146
222147............ 250147
222148............ 250148
222153............ 250153
222154............ 250154
222155............ 250155
222157............ 250157
222158............ 250158
222159............ 250159
SUNOCO
TB063 ............. 250073
TB070 ............. 250070
TB077 ............. 250077
TB401 ............. 250014
TB402 ............. 250013
TB403 ............. 250037
TB404 ............. 250017
TB409 ............. 250039
TB411 ............. 250041
TB415 ............. 250028
TB418 ............. 250061
TB428 ............. 250067
T1043.............. 250043
T1064.............. 250064
T1071.............. 250071
T1081.............. 250081
T.R.W.
LB074.............. 250074
LB075.............. 250075
LB077.............. 250077
A-51
T.R.W. - Cont.
LB078.............. 250078
LB079.............. 250079
LB081.............. 250081
LB082.............. 250082
LB083.............. 250083
LB084.............. 250084
LB087.............. 250087
LB088.............. 250088
LB090.............. 250090
LB091.............. 250091
LB092.............. 250092
LB093.............. 250093
LB094.............. 250094
LB095.............. 250095
LB100.............. 250100
LB101.............. 250101
LB102.............. 250102
LB103.............. 250103
LB104.............. 250104
LB112.............. 250112
LB113.............. 250113
LB114.............. 250114
LB115.............. 250299
LB116.............. 250300
LB117.............. 250117
LB118.............. 250162
LB119.............. 250119
LB121.............. 250121
LB122.............. 250122
LB123.............. 250123
LB124.............. 250124
LB125.............. 250125
LB126.............. 250237
LB128.............. 250128
LB129.............. 250129
LB13................ 250013
LB130.............. 250130
LB132.............. 250132
LB134.............. 250134
LB136.............. 250233
LB137.............. 250137
LB138.............. 250199
LB139.............. 250139
LB14................ 250014
LB141.............. 250141
LB142.............. 250142
LB143.............. 250143
LB144.............. 250144
LB146.............. 250146
LB148.............. 250148
LB149.............. 250149
LB150.............. 250150
LB151.............. 250151
LB153.............. 250153
LB155.............. 250155
LB157.............. 250157
LB158.............. 250158
LB159.............. 250159
LB160.............. 250160
LB161.............. 250161
LB163.............. 250163
LB164.............. 250164
LB165.............. 250165
LB166.............. 250166
LB167.............. 250167
LB168.............. 250168
LB169.............. 250169
LB17................ 250017
LB18................ 250018
LB20................ 250020
LB28................ 250028
LB32................ 250032
LB36................ 250036
LB37................ 250037
LB39................ 250039
LB41................ 250041
LB43................ 250043
LB61................ 250061
LB62................ 250062
LB63................ 250073
LB64................ 250064
LB65................ 250065
LB67................ 250067
LB70................ 250070
LB71................ 250071
LB73................ 250073
LB74................ 250074
LB75................ 250075
LB76................ 250076
LB77................ 250077
LB78................ 250078
LB79................ 250079
LB81................ 250081
T.R.W. - Cont.
LB82................ 250082
LB83................ 250083
LB84................ 250084
LB87................ 250087
LB88................ 250088
LB89................ 250158
LB90................ 250159
LB91................ 250091
LB92................ 250092
LB93................ 250093
LB94................ 250160
LB95................ 250095
LB96................ 250096
LB98................ 250098
LB99................ 250161
TEXACO
TB401 ............. 250014
TB402 ............. 250013
TB403 ............. 250037
TB404 ............. 250017
TB409 ............. 250039
TB411 ............. 250041
TB415 ............. 250028
ULTRALAST
B013................ 250013
B014................ 250014
B017................ 250017
B028................ 250028
B032................ 250032
B036................ 250036
B037................ 250037
B039................ 250039
B041................ 250041
B043................ 250043
B061................ 250061
B064................ 250064
B067................ 250067
B070................ 250070
B071................ 250071
B073................ 250073
B074................ 250074
B077................ 250077
B078................ 250078
B081................ 250081
B087................ 250087
B088................ 250088
B089................ 250089
B090................ 250090
B094................ 250094
B095................ 250095
B099................ 250099
B101................ 250101
B104................ 250104
B112................ 250112
B113................ 250113
B114................ 250114
B116................ 250300
B117................ 250117
B118................ 250118
B122................ 250122
B124................ 250124
B125................ 250125
B126................ 250126
B128................ 250128
B129................ 250129
B130................ 250130
B132................ 250132
B134................ 250134
B136................ 250136
B138................ 250138
B139................ 250139
B141................ 250141
B142................ 250142
B143................ 250143
B145................ 250145
B146................ 250146
B147................ 250147
B148................ 250148
B153................ 250153
B154................ 250154
B155................ 250155
B157................ 250157
B158................ 250158
B159................ 250159
B160................ 250160
B161................ 250161
B162................ 250162
B163................ 250163
B164................ 250164
B166................ 250166
B167................ 250167
B168................ 250168
ULTRALAST - Cont.
B172................ 250172
B177................ 250177
B179................ 250179
B184................ 250184
B185................ 250185
B186................ 250186
B187................ 250187
B191................ 250191
B194................ 250194
B199................ 250199
B233................ 250233
B236................ 250236
B32.................. 250032
TB063 ............. 250073
TB070 ............. 250070
TB077 ............. 250077
TB401 ............. 250014
TB402 ............. 250013
TB403 ............. 250037
TB404 ............. 250017
TB409 ............. 250039
TB411 ............. 250041
TB415 ............. 250028
TB418 ............. 250061
TB428 ............. 250067
T013................ 250013
T014................ 250014
T017................ 250017
T028................ 250028
T032................ 250032
T037................ 250037
T039................ 250039
T041................ 250041
T043................ 250043
T061................ 250061
T063................ 250073
T064................ 250064
T067................ 250067
T070................ 250070
T071................ 250071
T073................ 250073
T077................ 250077
T081................ 250081
T087................ 250087
T089................ 250089
T092................ 250092
T094................ 250094
T099................ 250099
T1043.............. 250043
T1064.............. 250064
T1071.............. 250071
T1081.............. 250081
T115................ 250299
T203................ 250203
T210................ 250210
T228................ 250228
UNIROYAL
A206L050........ 250062
A206L050S ..... 250090
A315L075........ 250028
A326L134B ..... 250075
A330L075........ 250070
A345L075........ 250073
A356L075........ 250041
A363L100........ 250067
A367L075........ 250078
A371L060........ 250037
A371L075........ 250039
A375L075........ 250061
A397L075........ 250077
A408L075........ 250088
A416L075R..... 250081
A423L075........ 250065
A435L075........ 250018
A450L075........ 250064
A450L075S ..... 250093
A453L075........ 250017
A457L075........ 250013
A457L075S ..... 250158
A461L075........ 250032
A465L100........ 250071
A483L087........ 250014
A484L088........ 250014
A502L118B ..... 250076
A506L100B ..... 250043
A521L100........ 250087
A532L100........ 250074
A547L075........ 250020
UNOCAL
TB063 ............. 250073
TB070 ............. 250070
TB077 ............. 250077
UNOCAL - Cont.
TB401 ............. 250014
TB402 ............. 250013
TB403 ............. 250037
TB404 ............. 250017
TB409 ............. 250039
TB411 ............. 250041
TB415 ............. 250028
TB418 ............. 250061
TB428 ............. 250067
T013................ 250013
T014................ 250014
T017................ 250017
T028................ 250028
T032................ 250032
T037................ 250037
T039................ 250039
T041................ 250041
T043................ 250043
T061................ 250061
T063................ 250073
T064................ 250064
T067................ 250067
T070................ 250070
T071................ 250071
T073................ 250073
T077................ 250077
T081................ 250081
T094................ 250094
T1043.............. 250043
T1064.............. 250064
T1071.............. 250071
T1081.............. 250081
VERA
A326L134B ..... 250075
45-00070......... 250062
45-00096......... 250062
45-00724......... 250028
45-00732......... 250036
45-00740......... 250020
45-00773......... 250032
45-00781......... 250018
45-00799......... 250014
45-00807......... 250013
45-00815......... 250043
45-00823......... 250017
45-00849......... 250065
45-00864......... 250070
45-00930......... 250073
45-00948......... 250064
45-00955......... 250041
45-01051......... 250082
45-01069......... 250083
45-01127......... 250076
45-01135......... 250075
45-01150......... 250078
45-01168......... 250077
45-01176......... 250074
45-01200......... 250107
45-01226......... 250158
45-01234......... 250091
45-01267......... 250106
45-01283......... 250088
45-01291......... 250087
45-01325......... 250104
45-01341......... 250099
45-01366......... 250094
45-01382......... 250093
45-01408......... 250062
45-01424......... 250100
45-01440......... 250103
45-01481......... 250090
45-01499......... 250092
45-01580......... 250127
45-01614......... 250293
45-01622......... 250292
45-01630......... 250118
45-01648......... 250095
45-01655......... 250137
45-01663......... 250300
45-01671......... 250299
45-01689......... 250131
45-01697......... 250135
45-01705......... 250136
45-01713......... 250176
45-01721......... 250126
45-01739......... 250101
45-01754......... 250138
45-01762......... 250129
45-01770......... 250071
45-01788......... 250122
45-01796......... 250141
45-01804......... 250134
45-01812......... 250113
VERA - Cont.
45-01820......... 250117
45-01838......... 250124
45-01853......... 250121
45-01861......... 250140
45-01879......... 250147
45-01887......... 250102
45-01895......... 250119
45-01945......... 250187
45-01952......... 250186
45-01960......... 250143
45-01978......... 250145
45-01986......... 250144
45-01994......... 250142
45-02009......... 250124
45-02017......... 250169
45-02025......... 250149
45-02033......... 250146
45-02041......... 250155
45-02066......... 250167
45-02074......... 250168
45-02082......... 250139
45-02090......... 250300
45-02108......... 250299
45-02116......... 250164
45-02124......... 250157
45-02140......... 250199
45-02157......... 250154
45-02199......... 250127
45-02215......... 250128
45-05074......... 250168
WESTERN AUTO
74-2736-2........ 250067
74-2737-0........ 250061
74-2738-8........ 250039
74-2739-6........ 250037
74-2741-2........ 250013
74-2742-0........ 250014
74-2743-8........ 250017
74-2744-6........ 250071
WOLVERINE
TB013 ............. 250013
TB014 ............. 250014
TB017 ............. 250017
TB018 ............. 250018
TB020 ............. 250020
TB028 ............. 250028
TB032 ............. 250032
TB036 ............. 250036
TB037 ............. 250037
TB039 ............. 250039
TB041 ............. 250041
TB043 ............. 250043
TB061 ............. 250061
TB062 ............. 250062
TB063 ............. 250073
TB064 ............. 250064
TB067 ............. 250067
TB070 ............. 250070
TB071 ............. 250071
TB073 ............. 250073
TB077 ............. 250077
TB078 ............. 250078
TB081 ............. 250081
TB095 ............. 250095
WORLD PARTS
W11-600.......... 250018
W11-601.......... 250020
W11-631.......... 250075
W11-636.......... 250013
W11-639.......... 250013
W11-640.......... 250076
W11-643.......... 250017
W11-645.......... 250020
W11-651.......... 250028
W11-654.......... 250041
W11-655.......... 250014
W11-657.......... 250036
W11-658.......... 250032
W11-659.......... 250043
W11-660.......... 250064
W11-661.......... 250062
W11-665.......... 250070
W11-669.......... 250073
W11-670.......... 250065
W16-801.......... 250079
W16-802.......... 250084
W16-803.......... 250078
W16-804.......... 250087
W16-805.......... 250101
W16-807.......... 250090
W16-808.......... 250158
A-52
WORLD PARTS - Cont.
W16-811.......... 250083
W16-812.......... 250082
W16-814.......... 250299
W16-815.......... 250094
W16-816.......... 250300
A-53
ADO41407............. 250090
AD041407.............. 250090
A326L134B............ 250075
BNP2955 ............... 250028
BPY112205 ........... 250185
BP0112205............ 250185
BP0112205A ......... 250185
BP0112205B ......... 250185
BP0212205............ 250185
BP0212205A ......... 250185
B10112205A.......... 250141
B59712205 ............ 250179
B6S712205A ......... 250179
B6S712205B ......... 250179
B6S712205C......... 250179
B6S712205C (KIA) 250179
B6S712205D......... 250179
B6Y212205............ 250141
B63012205 ............ 250141
B63012205A.......... 250123
B63012205B.......... 250123
B63012205C.......... 250123
B63012205D.......... 250141
B63012205E.......... 250141
B63212205 ............ 250141
B632122050 .......... 250141
B66012205 ............ 250149
B66012205B.......... 250149
B66012205C.......... 250149
C3905942.............. 250165
DBP4131 ............... 250099
DBP9289 ............... 250099
D1FZ 6268 A ........ 250013
D4FZ 6268 A ........ 250014
D4ZE 6268 AE...... 250014
D42E 6268 AB...... 250014
D8EE 6268 AA...... 250014
D9EE 6268 AA...... 250014
ECP244 ................. 250129
E1EE 6268 DA...... 250067
E1FZ 6268 D ........ 250067
E2CE 6268 AA...... 250194
E2EE 6268 AA...... 250067
E3EE 6268 AA...... 250067
E3FZ 6268 A......... 250067
E43Z 6268 B......... 250103
E43Z 6268 C......... 250102
E5FZ 6268 A......... 250067
E5RE 6268 AA...... 250014
E5RE 8286 AA...... 250142
E5TZ 6268 A......... 250092
E5TZ 6268 B......... 250091
E5ZZ 6268 A......... 250014
E7GZ 6268 A........ 250141
E7GZ 6268 B........ 250141
E7GZ 6268 C........ 250141
E80112205 ............ 250077
E9DZ 6268 A........ 250248
E9JY 6268 A......... 250179
FC01201202.......... 250020
FC01201203.......... 250020
FDU1464 ............... 250142
FEO1122050 ......... 250088
FEY812205............ 250113
FEY8122050.......... 250113
FEY912205............ 250113
FE0112205............ 250088
FE01122050.......... 250088
FE0212205............ 250088
FE0312205............ 250113
FE03122050.......... 250113
FE0412205............ 250113
FE04122050.......... 250113
FE0612205............ 250117
FE0812205............ 250117
FE08122050.......... 250113
FE0912205............ 250117
FE09122050.......... 250113
FE7912205............ 250113
FE7915205............ 250113
FSY112205............ 250228
FS0112205A.......... 250228
FS0212205............ 250228
F0BZ 6268 A......... 250185
F1ZZ 6268 A......... 250210
F17E 6268 AA ...... 250210
F2CE 6268 AA...... 250194
F2Y112205............ 250134
F20212205 ............ 250134
F20312205 ............ 250134
F21012205 ............ 250134
F3BZ 6268 A......... 250185
F3CZ 6268 A ........ 250179
F3DZ 6268 A ........ 250248
F3XY 6268 A ........ 250104
F32Z 6268 A......... 250228
F32Z 6268 B......... 250214
F37E 6268 AA ...... 250210
F4BZ 6268 A......... 250185
F4XY 6268 A ........ 250249
F42Z 6268 A......... 250228
F47E 6268 AA ...... 250210
F47Z 6268 B......... 250210
F5RZ 6268 A ........ 250258
F57E 6268 AA ...... 250276
F57E 6268 BB ...... 250276
F57Z 6268 A......... 250276
F7CZ 6268 AA...... 250283
F8CZ 6268 AA...... 250294
F80112205 ............ 250077
F80212205 ............ 250077
F9JY 6268 A......... 250179
GTB1208 ............... 250129
GTB1237 ............... 250142
HM8268BA............ 250013
JE2612205 ............ 250183
JE2612205A.......... 250183
JE2612205B.......... 250183
JE26122050 .......... 250183
JF0112205............. 250146
JF0112205A.......... 250146
JF0112205D.......... 250146
J0856351............... 250140
KJ0112205 ............ 250267
KL0112205 ............ 250214
K0AA352700 ......... 250248
K0BA352700 ......... 250248
MBP0112205B ...... 250185
MB6S712205C...... 250179
MD008960............. 250013
MD008961............. 250062
MD008968............. 250013
MD008969............. 250062
MD009277............. 250064
MD009352............. 250013
MD009651............. 250062
MD009666............. 250064
MD009667............. 250064
MD013805............. 250093
MD015310............. 250093
MD015311............. 250159
MD015701............. 250089
MD030599............. 250073
MD030600............. 250073
MD030610............. 250073
MD040756............. 250062
MD040797............. 250062
MD041390............. 250158
MD041407............. 250159
MD050119............. 250092
MD050130............. 250091
MD050175............. 250092
MD060461............. 250091
MD068173............. 250124
MD095866............. 250093
MD098491............. 250089
MD098492............. 250124
MD098706............. 250073
MD099706............. 250073
MD099707............. 250091
MD099708............. 250090
MD100103............. 250090
MD100619............. 250064
MD100620............. 250013
MD100632............. 250062
MD100679............. 250139
MD100814............. 250128
MD102248............. 250093
MD102249............. 250158
MD106103............. 250159
MD110029............. 250167
MD110041............. 250165
MD110709............. 250124
MD111427............. 250139
MD113561............. 250064
MD113562............. 250013
MD113563............. 250073
MD113564............. 250128
MD113790............. 250158
MD115977............. 250168
MD120487............. 250155
MD133115............. 250167
MD133116............. 250165
MD134377............. 250091
MD13805............... 250093
MD140070............. 250195
MD140227............. 250155
MD140228............. 250158
MD140229............. 250124
MD145713............. 250167
MD145714............. 250165
MD145716............. 250168
MD145813............. 250191
MD152243............. 250159
MD152622............. 250092
MD154243............. 250204
MD160103............. 250090
MD161427............. 250195
MD171748............. 250167
MD171749............. 250168
MD176387............. 250201
MD182195............. 250168
MD182201............. 250165
MD182291............. 250167
MD182292............. 250256
MD182293............. 250232
MD182294............. 250230
MD182295............. 250168
MD183005............. 250195
MD183006............. 250253
MD189522............. 250229
MD191982............. 250288
MD193874............. 250195
MD193875............. 250253
MD199418............. 250165
MD307487............. 250259
MD322641............. 250287
MD326059............. 250167
MD336149............. 250232
MD340625............. 250289
MO4667611........... 250246
OK97212205 ......... 250264
RF0312205............ 250103
RF03122050.......... 250103
RF0312206A ......... 250102
RF4312205............ 250103
RF7112205............ 250103
RF7912205............ 250103
R1463635109........ 250140
T0718752 .............. 250119
T0718836 .............. 250140
T0729581 .............. 250140
XHM460................. 250129
ZZM112205 ........... 250210
ZZM312205 ........... 250276
Z50112205 ............ 250266
Z50212205 ............ 250308
0B59712205 .......... 250179
0K24712205 .......... 250302
0K95412205 .......... 250281
0K97212205 .......... 250264
027109119A.......... 250292
027109119C.......... 250292
028109119M.......... 250242
028109119P.......... 250242
034109119............. 250127
03510911............... 250065
035109119............. 250065
038109119............. 250301
038109119B.......... 250301
038109119D.......... 250301
048109119D.......... 250262
054109119E.......... 250225
054109119H.......... 250225
056109119A.......... 250017
058109119A.......... 250291
06A109119C.......... 250296
06B109119A.......... 250306
06B109119B.......... 250306
068109119............. 250043
068109119A.......... 250043
068109119E.......... 250043
069109119A.......... 250083
069130113A.......... 250082
074109119............. 250170
075RH200 ............. 250082
075109119B.......... 250083
077109119B.......... 250207
077109119C.......... 250297
077109119D.......... 250207
077109119E.......... 250207
078109119A.......... 250218
078109119C.......... 250297
078109119D.......... 250218
081616................... 250018
081632................... 250140
088AG19 ............... 250070
10068553............... 250163
101R24.................. 250099
10162006............... 250192
102500................... 250078
108R24.................. 250094
1125360160........... 250075
113R190................ 250065
11311272384......... 250106
11311286168......... 250106
11311711082......... 250131
11311713361......... 250131
119RH250 ............. 250083
1257223................. 250083
1257237................. 250082
12612650044......... 250129
1272382................. 250106
1272384................. 250106
12723842............... 250106
1276150G00.......... 250194
1276153B00 .......... 250171
1276153B01 .......... 250171
1276160A00 .......... 250164
1276160B10 .......... 250166
1276160E00 .......... 250241
1276163B00 .......... 250095
1276170C00.......... 250194
1276171C00.......... 250212
1276172F00 .......... 250272
1276173000........... 250028
1276173001........... 250028
1276178400........... 250070
1276182000........... 250095
1286168................. 250106
12861684............... 250106
130RG25 ............... 250084
13028AA010.......... 250300
13028AA040.......... 250150
13028AA072.......... 250277
13028AA101.......... 250172
13028AA102.......... 250172
13028AA120.......... 250209
13028AA150.......... 250254
13028AA170.......... 250300
13028AA181.......... 250304
13028D0100.......... 250100
13028D1700.......... 250078
13028D4200.......... 250137
13028D4210.......... 250137
13028D4211.......... 250137
13028KA021.......... 250135
13028V4000 .......... 250017
13028V4310 .......... 250093
13028V5100 .......... 250104
13028V5200 .......... 250104
13028V5201 .......... 250104
13028V5210 .......... 250104
13028V5220 .......... 250104
13028V5221 .......... 250104
130280B700 .......... 250249
130280B785 .......... 250249
1302810M00.......... 250077
1302811M00.......... 250077
1302811M10.......... 250077
1302812C00.......... 250100
1302812G00.......... 250104
1302816A01 .......... 250096
1302816A10 .......... 250096
1302816E00 .......... 250104
1302816E10 .......... 250104
1302816V00 .......... 250180
1302820R00.......... 250078
1302845P00 .......... 250251
1302851E00 .......... 250137
1302851E10 .......... 250137
1302861A00 .......... 250077
1302885E00 .......... 250104
13029AA010.......... 250299
13029AA011.......... 250299
13029AA040.......... 250151
13029AA070.......... 250299
13029AA080.......... 250299
13029AA11............ 250299
1320811M00.......... 250077
1326288................. 250174
13405PAAA01....... 250186
13405PAAA02....... 250186
13405PTO004 ....... 250186
13405PT0004........ 250186
13440P5A004........ 250280
1351415010........... 250070
1351487711........... 250178
135148771100....... 250178
1351487711000..... 250178
1356422021........... 250126
135680A010 .......... 250257
1356803010........... 250138
1356803020........... 250199
1356803021........... 250199
1356809040........... 250199
1356809041........... 250199
1356809050........... 250257
1356811030........... 250136
1356811031........... 250233
1356811032........... 250233
1356811033........... 250233
1356811100........... 250208
1356811101........... 250208
1356811111........... 250208
1356815010........... 250070
1356815011........... 250070
1356815020........... 250070
1356815030........... 250070
1356815040........... 250036
1356815041........... 250036
1356815042........... 250239
1356815050........... 250036
1356816010........... 250112
1356816020........... 250176
1356816040........... 250236
1356816041........... 250236
1356816050........... 250236
1356816051........... 250236
1356816060........... 250235
1356816061........... 250235
1356816070........... 250235
1356816071........... 250235
1356819045........... 250236
1356819046........... 250236
1356819055........... 250235
1356819056........... 250235
1356819085........... 250233
1356819086........... 250233
1356819115........... 250208
1356819116........... 250208
1356819125........... 250070
1356819135........... 250239
1356819145........... 250112
1356820010........... 250257
Manufacturers Part Numbers
NAPA Automotive Timing Belts
Showing Factory Part Numbers for Automotive Timing Belts
With the Corresponding NAPA Replacement Numbers
Mfr. NAPA Mfr. NAPA Mfr. NAPA Mfr. NAPA Mfr. NAPA
Part No. No. Part No. No. Part No. No. Part No. No. Part No. No.
A-54
1356820020........... 250257
1356829015........... 250257
1356829025........... 250257
1356842010........... 250126
1356842011........... 250237
1356842012........... 250126
1356842020........... 250126
1356842021........... 250237
1356843010........... 250074
1356843020........... 250074
1356843030........... 250101
1356843040........... 250101
1356846020........... 250215
1356849015........... 250237
1356849035........... 250215
1356849036........... 250215
1356849046........... 250074
1356849055........... 250101
1356850010........... 250190
1356850020........... 250298
1356854010........... 250079
1356854020........... 250079
1356854030........... 250079
1356854031........... 250079
1356854038........... 250079
1356854050........... 250084
1356854051........... 250084
1356859015........... 250079
1356859016........... 250079
1356859017........... 250079
1356859025........... 250084
1356859026........... 250084
1356859027........... 250084
1356859045........... 250190
1356859095........... 250298
1356862020........... 250157
1356862030........... 250200
1356862030A........ 250200
1356862040........... 250157
1356862050........... 250271
1356863010........... 250087
1356863020........... 250087
1356863022........... 250087
1356864010........... 250098
1356864011........... 250098
1356865010........... 250154
1356865010A........ 250154
1356865020........... 250240
1356869025........... 250200
1356869035........... 250157
1356869045........... 250087
1356869065........... 250098
1356869066........... 250098
1356869075........... 250240
1356869095........... 250271
1356874010........... 250138
1356874011........... 250138
1356874012........... 250199
1356874012B........ 250199
1356874013........... 250199
1356874020........... 250138
1356874021........... 250199
1356879025........... 250199
1356879045........... 250125
1356879095........... 250199
1356887101........... 250181
1356887101000..... 250181
1356887102........... 250181
1356887102000..... 250181
1356887103........... 250182
1356887103000..... 250182
1356887104........... 250182
1356887104000..... 250182
1356887708........... 250178
1356888360........... 250125
1356888361........... 250125
1356888380........... 250125
1356888381........... 250125
1356888382........... 250125
139AG25 ............... 250087
14001168............... 250061
14400PAAA01....... 250244
14400PAAA02....... 250244
14400PC6004........ 250160
14400PC60040...... 250094
14400PC60042...... 250160
14400PD2004........ 250160
14400PD6004........ 250160
14400PE0004........ 250099
14400PE00040...... 250099
14400PE3004........ 250099
14400PE30040...... 250161
14400PG6004 ....... 250130
14400PG60040 ..... 250130
14400PG6014 ....... 250130
14400PG6040 ....... 250130
14400PH7004........ 250129
14400PH70040...... 250129
14400PH7014........ 250129
14400PH70140...... 250129
14400PK1004........ 250144
14400PK10040...... 250144
14400PK2004........ 250142
14400PK20040...... 250142
14400PK3004........ 250142
14400PM3004 ....... 250143
14400PM30040 ..... 250143
14400PM6004 ....... 250145
14400PM70040 ..... 250142
14400PR3004........ 250227
14400PR4A01 ....... 250184
14400PR4A01M1 .. 250184
14400PT0004........ 250187
14400PV1004........ 250211
14400PY3A010 ..... 250193
14400PY3004........ 250193
14400P0A004........ 250244
14400P0GA01....... 250263
14400P0GA010M1 250263
14400P08004 ........ 250223
14400P13004 ........ 250226
14400P14004 ........ 250216
14400P2E004........ 250224
14400P2FA01........ 250224
14400P28004 ........ 250224
14400P5A004........ 250279
14400P7J004 ........ 250184
14400P72004 ........ 250247
14400P72014 ........ 250247
14400P8AA01 ....... 250286
14400P8AA02 ....... 250286
14400TG6004........ 250130
14400634003......... 250028
14400634004......... 250028
14400634005......... 250028
144006340050....... 250028
144006340051....... 250028
14400634014......... 250028
144006340141....... 250028
14400657004......... 250036
144006570040....... 250036
144006570042....... 250041
14400657014......... 250036
144006570140....... 250036
14400657024......... 250041
144006570240....... 250041
144006570241....... 250041
144006570242....... 250041
1440065704........... 250036
14400673004......... 250073
144006730040....... 250073
144006730041....... 250073
144006730042....... 250073
146R190................ 250020
1649170................. 250067
1649171................. 250067
1680616A00 .......... 250097
1680616A10 .......... 250097
1711082................. 250131
1713361................. 250131
2335632010........... 250159
2335632020........... 250159
2335632030........... 250159
2335633110........... 250168
2335633120........... 250168
2335633130........... 250168
2335633140........... 250168
2335633150........... 250168
2335633160........... 250168
2413232010........... 250089
2431221040........... 250073
2431222010........... 250191
2431223001........... 250278
2431223201........... 250284
2431224000........... 250128
2431224010........... 250128
2431224050........... 250128
2431226000........... 250282
2431232610........... 250124
2431232620........... 250124
2431232820........... 250089
2431233010........... 250165
2431233020........... 250165
2431233030........... 250165
2431233040........... 250165
2431233050........... 250165
2431233060........... 250165
2431233110........... 250167
2431233120........... 250167
2431233130........... 250167
2431233140........... 250167
2431233150........... 250167
2431233160........... 250167
2431235000........... 250139
2431235010........... 250139
2431235040........... 250139
24502982............... 250192
24503363............... 250273
271327................... 250252
271705................... 250217
2717056................. 250217
271720................... 250173
271747................... 250234
2717478................. 250234
271834................... 250252
2718344................. 250252
271856................... 250252
2718567................. 250252
2718765................. 250270
271952................... 250217
2719524................. 250217
272327................... 250252
272329................... 250311
2723294................. 250311
272386................... 250270
3250141................. 250017
3342103................. 250119
3507227................. 250083
3507651................. 250217
3507704................. 250234
3514323................. 250173
3547459................. 250174
35474592............... 250174
360525................... 250037
376388................... 250037
376401................... 250037
40028..................... 250028
414701001............. 250028
414705601............. 250079
4164869................. 250020
4176840................. 250018
4182426................. 250020
4300516................. 250122
4302971................. 250122
4304099................. 250075
4343824................. 250114
4343946................. 250071
43439469............... 250071
4387534................. 250132
4387549................. 250153
4406634................. 250032
4420507................. 250018
4484494................. 250206
4504163................. 250285
4573944................. 250219
460165................... 250039
4621348................. 250285
4621844................. 250265
46337..................... 250032
463377................... 250032
4633772................. 250032
4663598................. 250255
4667530................. 250206
4667606................. 250245
4667611................. 250246
4667625................. 250265
4770491................. 250285
4792353................. 250295
484981001............. 250028
512430160............. 250075
512536016............. 250075
5125360160........... 250075
5203401................. 250071
52267904............... 250163
52289664............... 250163
524034................... 250017
5240346................. 250017
5862021480........... 250186
5862021620........... 250187
5862059260........... 250186
5862059340........... 250244
5985163................. 250087
636350................... 250081
636359................... 250081
636363................... 250081
636365................... 250148
636368................... 250148
636370................... 250081
636560................... 250081
636562................... 250148
636565................... 250081
70HM 6268 AB ..... 250013
70HM 6268 BA ..... 250013
7533266................. 250013
7533267................. 250013
7700618657........... 250018
7700663550........... 250018
7700717284........... 250140
7700718725........... 250140
7700718726........... 250140
7700718752........... 250119
7700718836........... 250140
7700729581........... 250140
7700853660........... 250140
7701348801........... 250018
8091287220........... 250305
82317934............... 250065
85867058............... 250096
8920639440........... 250305
894109626............. 250162
8941096260........... 250118
8941583270........... 250121
8941606560........... 250122
8941743060........... 250147
894200372A.......... 250122
8942152540........... 250121
8942187820........... 250088
894220372A.......... 250122
8942209220........... 250076
8942220922........... 250076
8942353620........... 250088
8942372420........... 250121
894337708............. 250177
8943377080........... 250177
8943864970........... 250220
8944161450........... 250088
8944294860........... 250169
8944520940........... 250162
8944795230........... 250162
8970163260........... 250221
8970270620........... 250205
8970417840........... 250122
8970422680........... 250147
8971363210........... 250303
90122429............... 250081
90231883............... 250148
90234902............... 250081
90324698............... 250148
90324699............... 250148
90325576............... 250081
90325578............... 250081
90353179............... 250203
90353211............... 250081
90354783............... 250148
90409900............... 250081
90410014............... 250081
90410768............... 250285
90410771............... 250285
90500360............... 250285
90530599............... 250285
91112009............... 250070
91171175............... 250272
91172367............... 250194
91173157............... 250194
9128500................. 250285
9135031................. 250252
9135450................. 250173
9135733................. 250252
9180954................. 250252
92029834............... 250075
94029834............... 250075
94109626............... 250118
94158327............... 250121
94160656............... 250122
94215254............... 250121
94220922............... 250076
94337708............... 250177
94386497............... 250220
9440383................. 250311
94410221902......... 250293
94410221904......... 250293
94410513703......... 250107
94410515703......... 250107
94410515704......... 250107
94429486............... 250169
94452094............... 250118
94479523............... 250162
94840054............... 250070
94844702............... 250112
94846144............... 250036
94848472............... 250176
94849175............... 250036
94849597............... 250036
94854403............... 250236
94854404............... 250235
94856081............... 250236
94856082............... 250235
95ZA19.................. 250100
95951646............... 250095
96051646............... 250095
96057945............... 250164
96060050............... 250166
96067809............... 250095
96068423............... 250241
96068591............... 250212
96144976............... 250148
97016326............... 250221
97027062............... 250205
97041784............... 250122
97042268............... 250147
978M 6268 AA...... 250294
99314718701......... 250290
Manufacturers Part Numbers
Mfr. NAPA Mfr. NAPA Mfr. NAPA Mfr. NAPA Mfr. NAPA
Part No. No. Part No. No. Part No. No. Part No. No. Part No. No.
A-55
Synchronous belts have been used on automotive
camshaft drives for more than 20 years. Our belts will
give OEM equivalent service if the following points are
observed.
Storage
Belts should be kept in their original packaging until
needed. Store in an environment which avoids:
Temperature extremes
Direct sunlight
High humidity
Contamination by oil, water, chemicals, etc.
Handling
It is important that belts are not crimped during han-
dling since this could seriously damage the tensile
members and lead to premature failure.
Installation Tips
Pulleys should be clean, free from wear or damage
and their alignment must be correct.
Tensioners and idlers (when applicable) should be
free to rotate and move (when appropriate).
Bearings should be in good condition. Belts should be
fitted in accordance with the engine manufacturers in-
structions to ensure that belt tension and engine tim-
ing is correct.
IMPORTANT: Avoid crimping the belt when installing
it on pulleys no tools should be used on the belt.
Refit cover to prevent drive contamination by foreign
matter.
Replacement
Follow vehicle manufacturers instructions regarding
belt replacement intervals. If the belt is removed, then
a new belt should be installed (except where an auto-
matic tensioner is used). If engine is being repaired
and belt is near OEM recommended replacement in-
terval, its a good time to replace the belt.
Symptom Probable Cause Corrective Action
Tensile Failure
1. Excessive shock load.
2. Subminimal diameter.
3.Improper belt handling and storage prior to installation.
4. Debris or foreign object in drive.
5. Extreme sprocket run-out.
1. Redesign drive for increased capacity.
2. Redesign drive using larger diameters.
3. Follow proper storage and handling procedures.
4. Remove objects and check guard.
5. Replace sprocket.
Tooth Shear
1. Excessive shock load.
2. Extreme sprocket run-out.
3. Worn spacer.
4. Backside idler.
5. Misaligned drive.
6. Belt undertensioned.
4. Use inside idler.
5. Realign.
6. Adjust tension to recommended value.
Tooth Wear
1. Too low or high belt tension.
2. Belt running partly off unflanged sprocket.
3.Misaligned drive.
4. Worn sprocket.
5. Rough sprocket teeth.
2. Correct alignment.
Belt Cracking
1. Subminimal diameter.
2. Backside idler.
3. Extreme low temperature at start-up.
4. Extended exposure to harsh chemicals.
5. Cocked bushing/sprocket assembly.
2. Use inside idler or increase diameter of backside idler
3. Pre-heat drive environment.
4. Protect drive.
5. Install bushing per instructions.
Land Wear
1. Excessive tension.
2. Rough pulley(s).
2. Replace pulley(s).
Oil Contamination 1. Oil leak. 1. Replace faulty oil seal(s).
Edge Wear
1. Damage due to handling.
2. Flange damage.
3. Belt too wide.
4. Belt tension too low.
5. Rough flange surface finish.
6. Improper tracking.
7. Belt hitting drive guard or bracketry.
1. Follow proper handling instructions.
2. Repair flange or replace sprocket.
3. Use proper width sprocket.
5. Replace or repair flange to eliminate abrasive surface.
7. Remove obstruction or use inside idler.
Unusual Noise
1. High tension.
2. Low tension.
3. Misalignment.
4. Damaged Flange.
3. Realign pulleys.
4. Replace pulleys.
Timing Belt Troubleshooting Guide
A-57 A-56
Overhead Valve
Engine Identification
The engine illustrations below are all overhead valve type engines. These diagrams are provided
for your reference and convenience. This page is also for customers that may not know the
engine type they havebut may be able to identify it through these illustrations.
Overhead Valve (OHV)
Push Rod Assembly
(No Timing Belt Required)
Double Overhead Cam (DOHC)
Single Overhead Cam (SOHC)
A-58
Free Running or Interference Engine?
You and Your Customers Need to Know.
Automobile engines can be classified as either Free-Running or Interference, depending on what occurs if
piston/valve synchronization is lost.
As illustrated below, in the free-running engine with the crankshaft still moving, there is enough clearance
between the valve and piston, even if the cam stops with a valve fully open.
However, interference engines usually sustain damage if synchronization is lost. As illustrated, disrupted
synchronization allows the piston and valve to collide causing damage and very expensive repairs for the
vehicle owner. Damage can occur to valves, pistons, or headsand in some cases, completely ruin the
engine. Most import (with higher compression engines) and most car and light truck diesel engines are
interference. To avoid costly engine repairs, follow the auto manufacturers mileage replacement
recommendations or we recommend timing belt replacement at around 60,000 miles.
Free-Running
No Valve/Piston
Interference
Interference
Valve/Piston
Collision
NOTE: For your convenience, interference engines have been footnoted with a star in the
application listings of this publication. This lets you easily identify them}and pass that information
on to your customers.
Since timing belts are inside the engine they tend to be an out-of-sight, out-of-mind item and are seldom
thought of as a part of routine maintenance. Here are some questions to ask customers that will help sell
belts and protect the customer from expensive repairs:
1. Did you buy the car new? If yes, theyll know if the belt has ever been replaced.

2. Did you buy the car used? If so, they wont know if the belt has been replaced. This is a flag for
the customer to get the belt checked, replaced or at least be aware that he has a timing belt.

3. How many miles are on the vehicle? Generally belts should be replaced at around 60,000 miles or
less. Our Timing Belt Replacement Recommendations Booklet is an excellent tool for determining
replacement intervals.

4. Have you ever replaced the timing belt? If the answer is yes or no (and the customer knows the
mileage) you can determine where the vehicle is in the replacement cycle.
Heres a helpful hint for your customers with vehicles within a few thousand miles of the recommended
replacement interval. If they are having any engine repair done, have the timing belt checked. If it needs
replacement, do it along with the other repairs and save time and money.
C-5
A-59
Belt Tensioning
V- Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the KR1 Krikit
Tension Gauge, to
determine proper tension from the Installation Chart. Tension ranges below are for drives requiring single
belts. If multiple belts are needed for a drive, divide tension by number of belts to give per belt tension to
be measured.
Position belt and set tension to the prescribed Installation Tension.
Run belt for five minutes.
If belt tension drops below Suggested Tension range, retighten belt to Installation Tension. This will
allow the belt to seat-in and run at Suggested Tension after it has operated under normal driving
conditions.
Belt Top
Width
Suggested
Tension (lbs.)
Ranges
Installation
Tension (lbs.)
Used Belts
Installation
Tension (lbs.)
New Belts
Belt Top
Width
Suggested
Tension (lbs.)
Ranges
Installation
Tension (lbs.)
Used Belts
Installation
Tension (lbs.)
New Belts
45-65 60.0 80.0 13/16 175-240 190.0 255.0

5/16 60-85 75.0 100.0 7/8 190-255 205.0 270.0
3/8 85-115 100.0 130.0 1 215-295 230.0 310.0

105-145 120.0 160.0 1-1/16 225-310 240.0 325.0
5/8 135-185 150.0 200.0 1-1/8 245-330 260.0 345.0
11/16 155-200 170.0 215.0 1-5/16 285-385 300.0 400.0

160-220 175.0 235.0
NOTE: A belt is considered used once it has been run-in.
V-Ribbed Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the KR2 Krikit Tension Gauge, to
determine proper tension from the Installation Chart. Many V-ribbed belts are automatically tensioned by
a spring-loaded automatic tensioner, which does not require tension to be set.
The tension ranges below are used for applications requiring manual tensioning.
For drives with manual take-up on locked-center drives, position the belt and set tension to the
prescribed Installation Tension.
Run belt for five minutes.
If belt tension drops below Suggested Tension range, retighten belt to the Installation Tension. This
will allow the belt to seat-in and run at Suggested Tension after it has operated under normal driving
conditions.
Number
of Ribs
Suggested
Tension (lbs.)
Ranges
Installation
Tension (lbs.)
Used Belts
Installation
Tension (lbs.)
New Belts
Number
Of Ribs
Suggested
Tension (lbs.)
Ranges
Installation
Tension (lbs.)
Used Belts
Installation
Tension (lbs.)
New Belts
3 45-60 67.5 90.0 9 135-180 202.5 270.0
4 60-80 90.0 120.0 10 150-200 225.0 300.0
5 75-100 112.5 150.0 11 165-220 247.5 333.0
6 90-125 135.0 187.5 12 180-240 270.0 360.0
7 105-145 157.5 217.5 14 210-280 292.5 420.0
8 120-160 180.0 240.0
NOTE: A belt is considered used once it has been run-in.
A-60
1
ACURA
*1.6L 4-Cylinder EL
TIMING BELT APPLICATION
Application Labor Time Belt Part No.
1.6L 4-Cyl. SOHC
EL (Canadian)
1997-00................
1
2.0 Hours ................. 250224
1
- With Air Cond. add .4 hours.
With Cruise Control add .3 hours.
MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1997-00 vehicles, normal replacement interval is at
105,000 miles or 84 months. Replace at 60,000 miles if car is
regularly driven in extreme temperatures (over 110 degrees F,
or under -20 degrees F).
*NOTE: This application is an interference engine.
See page A-59 for interference engine cautions.
REMOVAL & INSTALLATION
NOTE: If the radio has a coded theft protection circuit, be sure
to get the customers code before disconnecting battery.
TIMING BELT
Removal:
Disconnect battery negative cable. Remove engine lower
splash shield. Remove power steering, alternator, and A/C
compressor drive belts. Rotate crankshaft counterclock-
wise to TDC of compression stroke. See Fig. 3.
Remove engine oil dipstick. Remove power steering pump
and set aside with hoses attached. Remove timing belt
upper cover and A/C drive belt idler pulley bracket.
Use jack to support engine. Working from front of engine,
remove engine mount bracket nuts. Remove crankshaft
pulley. Remove lower cover and dipstick tube.
Remove Crankshaft Speed Fluctuation (CKF) sensor from
oil pump. Loosen the timing belt tension adjusting bolt 180
degrees. Push tensioner to release belt tension. Retighten
tension adjusting bolt. Mark rotation direction of timing belt
if it is to be reused. Remove timing belt from pulleys. See
Fig. 1.
Installation:
Ensure No. 1 cylinder is at TDC of compression stroke.
Timing belt drive pulley TDC mark must align with pointer
on oil pump housing. See Fig. 2.
Set camshaft pulley to TDC. TDC marks should align with
top surface of cylinder head. See Fig. 3.
Fig. 1: Exploded View Of Timing Belt Components
Courtesy of American Honda Motor Co. , Inc.
2
ACURA
*1.6L 4-Cylinder EL (Cont.)
Fig. 3: Aligning Timing Belt Marks
Install timing belt in this sequence: timing belt drive pulley,
tension adjusting pulley, water pump pulley, and camshaft
pulley. See Fig. 4. DO NOT bend or twist belt excessively.
Ensure arrow on used belt points in original rotation direc-
tion. Ensure crankshaft and camshaft pulley timing mark
are aligned with TDC marks.
Loosen and retighten adjusting bolt to tension timing belt.
Install lower cover. Install crankshaft pulley. Tighten pulley
bolt to specification. See TORQUE SPECIFICATIONS table.
Rotate crankshaft pulley 5-6 turns counterclockwise so tim-
ing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.
To adjust timing belt tension, set No. 1 piston at TDC (White
TDC mark on crankshaft pulley aligned with pointer on
cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Ro-
tate crankshaft counterclockwise 3 teeth on camshaft pul-
ley. Tighten adjusting bolt. If necessary, retoque crankshaft
pulley bolt.
Ensure crankshaft and camshaft pulleys are still aligned at
TDC. If not, timing belt will need to be removed and reposi-
tioned. To complete installation,reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICA-
TIONS. Adjust drive belts to proper tension. See page A-60
for belt tension ranges.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Drive Belt Idler Pulley Bracket Bolt ........................ 17 (24)
Alternator Adjusting Bolt .................................................. 17 (24)
Alternator Mount Bolt ................................................... 33 (45)
Camshaft Pulley Center Bolt .......................................... 27 (37)
Crankshaft Pulley Bolt
1
Step 1 ....................................................................... 14 (20)
Step 2 ...................................... Plus 90 Degrees Clockwise
Engine Mount Bracket Nuts ............................................ 54 (74)
Power Steering Pump Bracket Bolt ............................ 17 (24)
Power Steering Pump Lock Bolt ................................ 17 (24)
Timing Belt Tensioner Adjusting Bolt ........................... 33 (45)
INCH Lbs. (N.m)
CKF Sensor Bolt ....................................................... 106 (12)
Engine Lower Splash Shield .......................................... 89 (10)
Timing Belt Cover Bolt ................................................ 89 (10)
Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and bolt head shoulder.
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark
3
Fig. 5: Locating Timing Belt Adjuster Bolt
ACURA
*1.6L 4-Cylinder EL (Cont.)
Fig. 4: Timing Belt Installation Sequence
4
ACURA
*1.6L 4-Cylinder Integra
Application Labor Time
1
Belt Part No.
1.6L 4-Cyl.
Integra
1986-89................. 2.8 Hours .................. 250130
1
Although the manufacturer does not recommend a specific
scheduled maintenance interval, belt manufacturers suggest
the belt be replaced every 60,000 miles.
* NOTE: This application is an interference engine.
TIMING BELT
Removal:
Disconnect negative battery cable. Turn crankshaft coun-
terclockwise to bring piston in cylinder No. 1 to TDC of its
compression stroke. Remove all drive belts. Remove A/C
compressor and power steering pump and position out of
way without disconnecting hoses. Remove crankshaft pul-
ley.
Remove engine valve cover and upper timing belt cover.
Remove lower timing belt cover from engine block. Loosen
timing belt tensioner to relieve tension on timing belt.
Slide belt off sprockets. Remove bolts, washers, camshaft
sprockets, and Woodruff key (if necessary).
Installation:
Ensure No. 1 piston is still on TDC. Install Woodruff keys,
camshaft sprockets, washer, and retaining bolts (if re-
moved). Position UP mark on sprockets at top. Align
grooves on sprockets. See Fig. 2.
Install timing belt on sprockets. Use care not to excessively
bend or twist belt.
Rotate crankshaft counterclockwise 3 teeth on camshaft
sprockets to create tension on belt. Tighten tensioner ad-
justment bolt. Reverse removal procedure to complete in-
stallation. Adjust the drive belts to proper tension. See
page A-60 for belt tension ranges.
A/C Compressor/Bracket Bolts .................................. 33 (45)
Alternator Belt Adjustment Bolt .................................... 17 (23)
Camshaft Pulley Bolt .................................................. 27 (37)
Crankshaft Pulley Bolt .............................................. 83 (112)
Power Steering Pump Mounting Bolts .............. 29-33 (38-45)
Timing Belt Adjustment Bolt ....................................... 33 (45)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .............................................. 86 (10)
Valve Cover Nuts ........................................................ 86 (10)
Fig. 1: Exploded View of Timing Belt & Components
Fig. 2: Camshaft Timing Marks
96E14682 Courtesy of American Honda Motor Co., Inc.
96D14681 Courtesy of American Honda Motor Co., Inc.
5
ACURA
*1.7L 4-Cylinder
1
Belt Part No.
1.7L 4-Cyl.
Integra
1992-93.................

2.8 Hours.................. 250227
1
- With Air Cond. add .2 Hours.
The manufacturer recommends the belt be replaced every
90,000 miles or 72 months.
TIMING BELT
Removal:
Disconnect negative battery cable. Raise and support ve-
hicle. Remove left front wheel. Remove left front wheelwell
splash shield. Remove drive belts. Remove power steer-
ing pump with hoses attached, and set it aside.
Remove valve cover and middle timing belt cover. See Fig.
1. Rotate crankshaft counterclockwise to bring No. 1 piston
to TDC of its compression stroke. Position UP mark on
sprockets at top. See Fig. 2. Align grooves on sprockets.
Remove crankshaft pulley.
Remove left engine mount. Remove cylinder head cover.
Remove crankshaft pulley. Loosen timing belt tension ad-
juster bolt 180 degrees. Push tensioner to relieve tension
on timing belt. Retighten adjuster bolt. Remove timing belt.
Installation:
Ensure No. 1 piston is at TDC of compression stroke. In-
stall timing belt onto sprockets. DO NOT bend or twist belt
excessively. Adjust timing belt tension.
To complete installation, reverse removal procedure. Lu-
bricate threads only of crankshaft pulley bolt, leaving un-
derside of bolt head dry. On 1993 models, tighten crank-
shaft pulley bolt to 147 ft. Ibs. (200 N.m), loosen, then re-
tighten to 133 ft. Ibs. (180 N.m). Adjust drive belts to proper
tension. See page A-60 for belt tension ranges.
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts ............................................ 27 (37)
1992 ....................................................................... 87 (118)
1993 ..................................................................
1
133 (180)
Power Steering Mount Bolt .......................................... 17 (23)
Timing Belt Tension Adjuster Bolt ............................... 40 (54)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ............................................ 108 (12)
Valve Cover Nuts ......................................................... 84 (10)
1
- Tighten to 147 ft. Lbs. (200 N.m), loosen & retorque to 133 ft.
lbs. (180 N.m).
6
ACURA
*1.7L 4-Cylinder (Cont.)
Fig. 2: Aligning Timing Marks
7
ACURA
*1.8L 4-Cylinder
1
Belt Part No.
1.8L 4-Cyl. (EXC. VTEC)
Integra
1990-01.................. 2.8 Hours ................. 250184
1.8L 4-Cyl. (VTEC)
Integra
1994-01.................. 2.8 Hours ................. 250247
1
For 1990-94 models, manufacturer recommends the belt be
replaced every 90,000 miles. For 1995-96 models, the manu-
facturer recommends the belt be replace every 90,000 miles
for normal service and 60,000 miles for severe service.
For 1997-01 models, normal replacement interval is at 105,000
miles or 84 months. For 1997-01 models, replace belt at
60,000 miles if vehicle is regularly driven in extreme tempera-
tures (over 110 degrees F, or under -20 degrees C).
NOTE: Some vehicles may be equipped with radio/cassette or
radio/CD players that contain anti-theft protection circuit. When
battery is disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE and will be inoperative
until proper code is entered by vehicle owner.
TIMING BELT
Removal:
hicle. Remove left front wheel. Remove left front wheelwell
splash shield. Remove all drive belts. Remove power steer-
ing pump with hoses attached. Set power steering pump
aside.
Remove valve cover and upper timing belt cover. See Fig. 1.
Turn crankshaft counterclockwise to bring No. 1 piston to
TDC of its compression stroke. Position UP mark on sprock-
ets at top. See Fig. 2. Align grooves on sprockets. Remove
crankshaft pulley.
Remove left engine mount bolts and nut. Remove engine
mount. See Fig. 3. Remove lower timing belt cover. Loosen
timing belt tension adjuster bolt. Push tensioner to relieve
tension on timing belt. Retighten adjuster bolt. Remove
timing belt.
Installation:
Ensure No. 1 piston is at TDC. Install timing belt onto sprock-
ets. DO NOT bend or twist belt excessively. Adjust timing
belt tension. To complete installation, reverse removal pro-
cedure. On 1993-96 models, tighten crankshaft pulley bolt
to 147 ft. Ibs. (200 N.m), loosen, then retorque to 133 ft. Ibs.
(180 N.m).
Adjust drive belts to proper tension. See page A-60 for belt
tension ranges.
A/C Compressor/Bracket Bolts .................................. 17 (23)
Alternator Belt Adjustment Bolt .................................... 17 (23)
1990-92 ................................................................. 87 (118)
1993-01 .............................................................
1
133 (180)
Engine Mount Bolts ..............................................................
2
Engine Block-To Transaxle Bolt .................................. 47 (64)
Power Steering Bolt .................................................... 17 (23)
INCH Lbs. (N.m)
Valve Cover Nuts ........................................................ 88 (10)
Water Pump Bolt ...................................................... 106 (12)
1
- Tighten crankshaft pulley bolt to 147 ft. Lbs. (200 N.m),
loosen then retorque to 133 ft. lbs. (180 N.m).
2
- See Fig. 3.
8
ACURA
Fig. 3: Engine/Transaxle Mount Location & Tightening
Sequence
Fig. 4: Positioning Camshaft
9
ACURA
*2.2L & 2.3L 4-Cylinder
1
Belt Part No.
2.2L 4-Cyl.
2.2CL
1997
Balance Shaft .......................................... 250186
Camshaft ............. 2.9 Hours .................. 250244
2.3L 4-Cyl.
2.3CL
1998-99
Balance Shaft .......................................... 250186
Camshaft ............. 2.9 Hours .................. 250244
1
- Balance shaft belt included in labor time.
For the 2.2CL, normal replacement interval is 90,000 miles
for normal service or 60,000 miles for severe service. For the
2.3CL, normal replacement interval is at 105,000 miles or 84
months. Replace at 60,000 miles if car is regularly driven in
extreme temperatures (over 110 degrees F, or under -20 de-
grees F).
TIMING BELT
Removal:
Disconnect negative battery cable. Rotate crankshaft coun-
terclockwise until cylinder No. 1 is at TDC of compression
stroke. While rotating crankshaft, check water pump for
signs of seal leakage. Remove accessory drive belts. Re-
move alternator terminal and connector. Raise and sup-
port vehicle. Remove wheelwell splash shield. Use a jack,
with cushion between oil pan and jack, to support engine.
Remove side engine mount.
Remove oil dipstick and pipe. Remove valve cover. Re-
move crankshaft pulley. Remove upper and lower timing
belt covers. Loosen timing belt tension adjuster bolt about
1/2 turn. Push tensioner to release belt tension from timing
belt and balancer belt. Retighten tension adjuster bolt.
Remove balance shaft drive pulley. Remove balance shaft
belt and timing belt from pulleys.
Installation:
Ensure No. 1 piston is at TDC of compression stroke. See
Fig. 1. Align camshaft pulley with mating marks on back
cover upper surface. Ensure UP mark is at 12 oclock
position. See Fig. 2.
Install timing belt in sequence shown. See Fig. 3. Loosen
and retighten the timing belt adjusting nut about 1 turn.
Install balance shaft drive pulley and lower cover. Install
crankshaft pulley and center bolt.
Rotate crankshaft about 5-6 times counterclockwise. Set
No. 1 piston at TDC. Loosen timing belt adjusting nut about
1 turn. Rotate crankshaft counterclockwise 3 teeth on cam-
shaft pulley. Tighten timing belt adjusting nut. Make sure
crankshaft and camshaft pulleys are at TDC.
Fig. 1: Identifying TDC Mark on Crankshaft Drive Pulley
Align groove on balance shaft pulley with pointer on oil
pump housing. See Fig. 6. Install balance shaft belt. Loosen
adjuster nut about 1 turn to tension balance shaft belt.
Remove 6x100 mm bolt from balance shaft. Install sealing
bolt in side of engine block. Install crankshaft pulley and
bolt. Rotate crankshaft about 1 turn counterclockwise, then
tighten adjuster nut. Remove 6x1.0 mm bolt from timing
belt adjuster arm.
Remove crankshaft pulley. Install lower cover. Install rub-
ber seal around adjuster nut. DO NOT loosen adjuster nut.
Install crankshaft pulley. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.
See page A-60 for belt tension ranges.
Fig. 2: Aligning Camshaft Sprocket Timing Marks
Courtesy of American Honda Motor Co., Inc.
Remove crankshaft pulley and lower cover. Ensure crank-
shaft is still at TDC. Lock timing belt adjuster arm in place
by installing a 6x1.0 mm bolt. See Fig. 4. Loosen timing
belt adjusting nut about 1 turn and make sure balance
shaft belt adjuster moves freely.
Push tensioner to remove tension from balance shaft belt
adjuster, then retighten nut.
Scribe a line 2.9 (74 mm) from the end of a 6x100 mm bolt.
See Fig. 5. Remove bolt from side of engine block. To align
balance shaft, insert bolt through hole and into balance
shaft.
10
ACURA
*2.2L & 2.3L 4-Cylinder (Cont.)
Fig. 5: Aligning & Locking Balance Shaft
Fig. 4: Timing Belt Adjuster Nut
Fig. 6: Aligning Balance Shaft Pulley
Alternator Bracket-to-Engine Bolt ................................. 33 (45)
Camshaft Sprocket Bolt ................................................. 27 (37)
Crankshaft Pulley Bolt ................................................ 181 (245)
Power Steering Pump Mount Bolt ............................... 16 (22)
Timing Belt Tension Adjuster Nut ............................... 33 (44)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ...................................... 86-104 (7.2-8.7)
Valve Cover Bolt ............................................................. 86 (9.8)
11
ACURA
*2.5L 5-Cylinder
2.5L 5-Cyl.
Vigor
1992-94................. 3.1 Hours ................. 250211
2.5TL
1995-98................. 3.1 Hours ..................250211
For Vigor models, normal replacement interval is 90,000 miles.
For 1995-96 2.5TL models, replacement interval is 90,000
miles for normal service and 60,000 for severe service. For
1997-98 2.5TL models, normal replacement interval is at
NOTE: Before disconnecting negative battery cable, obtain radid
anti-theft code from vehicle owner.
TIMING BELT
Removal:
Disconnect battery negative cable. Remove accessory drive
belts. Remove cylinder head cover and upper timing belt
covers. See Fig. 1. Rotate crankshaft counterclockwise to
bring No. 1 piston to TDC of compression stroke. Remove
crankshaft pulley. Remove lower timing belt cover.
Loosen timing belt tension adjuster bolt 180 degrees. See
Fig. 5. Push tensioner to relieve tension on timing belt.
Retighten adjuster bolt. If reusing timing belt, mark direc-
tion of belt rotation before removing. Remove timing belt.
Installation:
Ensure No. 1 piston is at TDC. See Fig. 2. Position timing
marks on camshaft pulley. See Figs. 3 and 6. Install timing
belt, in sequence, onto crankshaft pulley, tension adjuster
pulley, water pump pulley and camshaft pulley. See Fig. 4.
DO NOT bend or twist belt excessively. Ensure arrow on
used belt points in original rotation direction.
Install upper and lower covers. Install crankshaft pulley and
tighten to specification. Rotate crankshaft counterclockwise
about 5-6 turns.
Set No. 1 piston at TDC. Loosen the adjusting bolt 180
degrees. Rotate crankshaft counterclockwise 3 teeth on
camshaft pulley. Tighten adjusting bolt. Ensure camshaft
and crankshaft pulleys are at TDC. If pulleys are not posi-
tioned at TDC, remove and reposition timing belt.
To complete installation, reverse removal procedure.
for drive belt tension ranges.
Fig. 1: Exploded View of Timing Belt Components
Fig. 2: Aligning Crankshaft Timing Marks
12
ACURA
Fig. 3: Aligning Camshaft Timing Marks
A/C Belt Idler Pulley Bolt ............................................. 32 (44)
A/C Compressor Mount Bolts ..................................... 16 (22)
A/C Compressor Bracket Bolts .................................. 36 (49)
Alternator Mounting Bolts ............................................ 33 (45)
Camshaft Pulley Bolts ................................................ 52 (70)
Crankshaft Pulley Bolt ............................................ 181 (245)
Power Steering Pump Mount ...................................... 33 (45)
INCH Lbs. (N.m)
Cylinder Head Cover Nuts ........................................ 106 (12)
Water Pump Bolts .................................................... 106 (12)
13
NOTE: After timing belt installation, rotate engine clockwise
several times to ensure valves DO NOT contact pistons.
A/C Compressor Bolts ............................................... 16 (22)
Alternator Bracket Bolts .............................................. 33 (45)
Alternator Mount Bolts ................................................ 16 (22)
Crankshaft Pulley Bolt ............................................. 123(170)
Engine Mount Bolts .................................................... 40 (54)
Timing Belt Tensioner Bolt ......................................... 33 (45)
INCH lbs (N.m)
Valve Cover Bolts ...................................................... 106 (12)
Water Pump Bolts .................................................... 106 (12)
ACURA
*2.5L & 2.7L V6
Fig 1: Adjusting Timing Belt
2.5L V6
Legend
1986-87 ................ 4.0 Hours ................ 250129
2.7L V6
Legend
1987-90 ................ 4.0 Hours ................ 250129
For 1986-89 models, although the manufacturer does not rec-
ommend a specific scheduled maintenance interval, belt
manufacturers suggest the belt be replaced every 60,000
miles. For 1990 models, the manufacturer recommends the
belt be replaced every 90,000 miles or 72 months.
TIMING BELT
Removal:
Remove negative battery cable. Turn crankshaft clockwise to
bring No. 1 piston to TDC of compression stroke. Remove
pulley cover from upper timing belt cover. Remove engine
wiring harness clamp from right side of engine compartment.
Support front of engine. On right side of engine compart-
ment, remove engine-to-body mount (on front of engine).
Remove lower engine splash shield. Remove A/C, power
steering, and all other drive belts.
Remove alternator. Leaving hoses connected, remove
power steering pump and secure out of way. Remove up-
per timing belt pulley covers. Remove crankshaft pulley.
Remove timing belt lower cover.
Loosen timing belt tensioner to relieve tension on timing
belt. Check belt for damage, missing teeth or cracks.
Installation:
Remove spark plugs. Turn crankshaft clockwise to bring
No. 1 piston to TDC of compression stroke. Advance crank-
shaft an additional 15 degrees from TDC position.
Rotate camshaft pulleys to compression stroke (TDC po-
sition) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley
15 degrees to TDC position.
Push timing belt tensioner to full release position and snug
adjuster bolt. Install timing belt over crankshaft pulley, front
camshaft pulley, water pump pulley, tensioner and rear
camshaft pulley. See Fig. 1.
Note position of timing belt pulley guides on both sides of
crankshaft. Install pulley guides so guides form a V groove
for belt to ride in. Loosen timing belt tensioner bolt.
NOTE: Always adjust timing belt tension with engine cold.
Timing Belt Tension Adjustment:
Set No. 1 piston to TDC on compression stroke. Rotate
crankshaft clockwise 9 teeth on rear camshaft pulley. Blue
mark on crankshaft pulley should match pointer on lower
cover. Loosen timing belt tensioner bolt. See Fig. 1.
Ensure timing belt is seated properly on pulleys. Tighten
adjuster bolt. Reverse removal procedure to complete in-
stallation. Adjust drive belts to proper tension. See page A-
60 for belt tension ranges.
14
ACURA
*2.5L & 2.7L V6 (Cont.)
93H00122 Courtesy Of American Honda Motor Co., Inc.
15
3.0L V6 (J30A1)
3.0CL
1997-99................. 4.0 Hours .................. 250286
3.2L V6 (J32A1/A2)
3.2CL
2001...................... 4.0 Hours .................. 250286
3.2TL
1999-01................. 4.0 Hours ................. 250286
3.5L V6 (J35A3)
MDX
2001...................... 4.0 Hours ................. 250286
Normal replacement interval is at 105,000 miles or 84 months.
Replace at 60,000 miles if car is regularly driven in extreme
temperatures (over 110 degrees F, or under -20 degrees F).
Fig. 1: Exploded View Of Timing Belt Components (1997-99)
ACURA
*3.0L, 3.2L & 3.5L V6
*NOTE: These applications are interference en-
gines. See page A-59 for interference engine cautions.
TIMING BELT
Removal:
Disconnect negative battery cable. Turn crankshaft pulley
so that No. 1 piston is at TDC on compression stroke.
White mark on crankshaft pulley should align with pointer
on front cover. Remove rubber plugs from front and rear
upper timing belt covers. Ensure camshaft sprocket timing
marks are aligned with tabs on bottom of access holes.
Remove lower engine splash shield. Remove the genera-
tor and power steering pump drive belts.
Remove dipstick tube from front of engine. Support engine
with a jack, and remove engine side mount from front of
engine. Remove crankshaft pulley center bolt and pulley.
Remove upper and lower timing belt covers. See Figs. 1
and 2. If reusing timing belt, mark direction of belt rotation
for installation reference.
16
ACURA
*3.0L, 3.2L & 3.5L V6 (Cont.)
Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner
17
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks
ACURA
*3.0L, 3.2L & 3.5L V6 (Cont.)
Remove one of the battery clamp bolts from battery tray.
Grind threaded end of bolt to a partial point (about 45 de-
gree chamfer). Thread battery bolt into rear cover to hold
timing belt adjuster in installed position. Hand tighten ONLY.
See Fig. 3.
Remove side engine mount bracket from front of engine
(above water pump pulley). Loosen timing belt idler pulley
bolt 5-6 turns. Remove timing belt.
Installation
Ensure that engine is at TDC. Align dimple on timing belt
drive pulley with pointer on oil pump. See Fig. 4. Align cam-
shaft pulleys with pointers on back covers.
CAUTION: Handle auto-tension carefully so oil does not spill
or leak out. Replace any oil that may leak out.
Remove battery clamp bolt from back cover. Remove the
timing belt auto-tensioner.
For 1997-98 auto-tensioner with removable bolt, hold auto-
tensioner with maintenance bolt pointing up. Remove main-
tenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed
vise. DO NOT grip auto-tensioner housing. Insert flat blade
screwdriver into maintenance hole. Place stopper on auto-
tensioner while turning screwdriver clockwise to compress
tensioner to bottom.
Replace any oil that may have spilled out of auto-tensioner.
Reinstall maintenance bolt with NEW gasket. Ensure no
oil is leaking around maintenance bolt, then reinstall auto-
tensioner onto engine with stopper in place.
CAUTION: Do NOT exceed 2200 lbs. of pressure when compressing
auto-tensioner.
On 2000-01 models with sealed auto-tensioner, place
tensioner in press. SLOWLY compress tensioner until pin
can be inserted through tensioner body and tensioner ap-
ply pin. See Fig. 5. Install auto-tensioner onto engine.
On all models, install timing belt in following sequence:
Crankshaft pulley, idler pulley, front camshaft pulley, water
pump pulley, rear camshaft pulley and tension adjust pul-
ley. See Fig. 6. Ensure crankshaft and camshaft pulleys
remained aligned with marks on back cover. Tighten idler
pulley bolt.
Remove stopper or pin from auto-tensioner. Install engine
side mount bracket to the front of engine (above water pump
pulley). Install upper and lower covers. Install crankshaft
pulley. Lubricate crankshaft pulley bolt threads and install
bolt. Tighten crankshaft pulley bolt to specification. See
TORQUE SPECIFICATIONS table.
Rotate crankshaft about 5-6 turns clockwise to position
timing belt on pulleys. Ensure crankshaft and camshaft
pulleys are aligned at TDC. Crankshaft pulley White mark
should be aligned with pointer on front cover. Remove rub-
ber plugs from upper covers to check camshaft pulley posi-
tions.
If either camshaft is not at TDC, remove timing belt and
readjust position. To complete installation, reverse removal
procedure. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS. Adjust drive belt to correct ten-
sion. See page A-60 for belt tension ranges.
Camshaft Sprocket Center Bolt ...................................... 67 (90)
Engine Side Mount-to-Engine Bolts ............................... 33 (44)
Engine Side Mount Bracket-to-Mount Through Bolt
3.0CL............................................................................. 47 (64)
Except 3.0CL ................................................................. 40 (54)
Idler Pulley Bolt .............................................................. 33 (44)
Power Steering Pump Mount Bolt ................................... 17 (24)
Power Steering Pump Locknut ....................................... 17 (24)
INCH Lbs. (N.m)
Auto-Tensioner Mount Bolts ......................................... 106 (12)
Auto-Tensioner Maintenance Bolt ..................................... 71 (8)
Lower Engine Splash Shield Bolts ............................... 106 (12)
Water Pump Bolts .................................................... 106 (12)
18
Fig. 7: Installing Timing Belt
Fig. 5: Compressing Auto-Tensioner (1997-99 Models)
ACURA
*3.0L, 3.2L & 3.5L V6 (Cont.)
Fig. 6: Compressing Auto-Tensioner (2000-01 Models)
19
ACURA
*3.2L V6 Legend & 1996-98 3.2 TL
3.2L V6
Legend (C32A1)
1991-95................. 5.6 Hours .................. 250193
3.2TL (C32A6)
1996-98................. 4.0 Hours ................. 250193
For 1991-94 model years, manufacturer recommends belt be
replaced every 90,000 miles or 72 months.
For 1995-96 model years, replacement interval is 90,000 miles
for normal service and 60,000 miles for severe service. For
1997-98 model years, normal replacement interval is at
radio/CD players that contain anti-theft protection circuit. Obtain
radio anti-theft code from vehicle owner before disconnecting
negative battery cable.
TIMING BELT
Removal (1991-93)
Disconnect negative battery cable. Remove injector har-
ness covers. See Fig. 2. Remove engine wiring harness
from front of engine. Disconnect breather pipe. Remove
vacuum pipe bracket. Remove accessory drive belts.
Remove timing belt upper covers. See Fig. 1. Rotate crank-
shaft clockwise until No. 1 piston is at TDC of compression
stroke. Ensure timing marks are aligned. Remove A/C belt
tensioner pulley. Remove crankshaft pulley. Remove en-
gine oil dipstick tube.
Fig. 1: Exploded View Of Timing Belt & Components
20
ACURA
*3.2L V6 Legend & 1996-98 3.2 TL (Cont.)
Remove timing belt lower cover. If timing belt is to be re-
used, mark belt with arrow indicating direction of rotation.
Loosen timing belt adjusting bolt turn. Push tensioner to
release belt tension, then retighten adjusting bolt. Remove
timing belt.
Removal (1994-98)
Disconnect negative battery cable. Use jack to support en-
gine. Remove center bracket and mount from front, lower
part of engine. Remove the generator, A/C compressor, and
power steering belts.
If equipped, remove Traction Control System (TCS) valve
assembly brackets. Disconnect TCS throttle sensor and
actuator connectors. See Fig. 3. Remove TCS control valve
assembly, leaving breather pipe by-pass hose connected.
Remove engine front wiring harness cover with oil pres-
sure switch and engine ground cable connectors. Remove
idler pulley bracket, dipstick, and dipstick pipe. Remove
crankshaft pulley.
Remove timing belt upper and lower covers. See Fig. 1.
Rotate crankshaft clockwise until No. 1 piston is at TDC of
compression stroke. Align timing marks. See Fig. 4. Loosen
timing belt adjusting bolt 180 degrees to remove tension
from belt. Retighten adjusting bolt.
If timing belt is to be reused, mark direction of belt rotation
before removing. Remove timing belt.
CAUTION: DO NOT turn crankshaft or camshaft with timing belt
removed, because pistons may hit valves, causing damage. Do
NOT rotate crankshaft when tension adjusting bolt is loose.
Installation (1991-93)
Remove spark plugs. When installing timing belt, turn crank-
shaft clockwise 15 degrees past No. 1 cylinder TDC. After
adjusting left and right camshaft pulleys to TDC, turn crank-
shaft pulley counterclockwise back to TDC.
Install timing belt in this sequence: Crankshaft pulley,
tensioner pulley, left camshaft, water pump pulley, right cam-
shaft. To ease installation, advance right camshaft pulley
about a half tooth from TDC position.
Loosen timing belt tension adjusting bolt, and retight it af-
ter tensioning the timing belt. Temporarily install lower tim-
ing belt cover and crankshaft pulley. Rotate crankshaft about
5-6 turns clockwise to seat timing belt. Place No. 1 piston
at TDC of compression stroke.
Rotate crankshaft clockwise 9 teeth on camshaft pulley.
Blue mark on crankshaft pulley will should line up with
pointer on lower cover. See Fig. 5.
Loosen timing belt adjusting bolt 180 degrees. Tighten
timing belt adjusting bolt to 31 ft. lbs. (42 N.m). Verify crank-
shaft and camshaft timing marks are still aligned. If timing
marks are not aligned, repeat timing belt installation pro-
cedure. To complete installation, reverse removal proce-
dure. Coat crankshaft pulley center bolt threads with oil
before installation. Adjust accessory drive belt to proper
tension.
NOTE: After installing timing belt, slowly rotate engine clockwise
several times to be sure valves do not contact pistons.
Installation (1994-98)
Remove all spark plugs. Ensure No. 1 piston is at TDC of
compression stroke. Position crankshaft and camshaft pul-
leys as shown. See Fig. 4.
Adjust camshaft pulley(s) until TDC mark on pulley and
pointer on cover plate are aligned. If reusing timing belt,
ensure arrow made in removal procedure points in direc-
tion of original rotation.
Fig. 2: Exploded View Of Intake Manifold (1991-93 Models)
Install timing belt in this sequence: Crankshaft pulley, ten-
sion adjuster pulley, left camshaft pulley, water pump pul-
ley, and right camshaft pulley. Loosen and tighten tensioner
adjuster bolt to remove slack in belt.
Install upper and lower covers and crankshaft pulley. Tighten
pulley bolt to specification. Rotate crankshaft clockwise 5-
6 revolutions to seat timing belt.
Adjust timing belt tension. Remove upper left camshaft
cover. Remove damper from center bracket. Rotate crank-
stroke. Rotate crankshaft 9 teeth clockwise on camshaft
pulley. Align Blue mark on crankshaft pulley with pointer on
lower cover. See Fig. 5. Loosen tensioner adjusting bolt 1/
2 turn , and then tighten bolt to 31 ft. lbs. (42 N.m).
Rotate crankshaft clockwise until No. 1 piston is at TDC Of
compression stroke. Verify camshaft timing marks are
aligned. If timing marks are not aligned, repeat timing belt
installation procedure. To complete installation, reverse
removal procedure. Coat crankshaft pulley center bolt
threads with oil before installation.
21
Fig. 3: Locating TCS Control Valve & Connectors
Fig. 4: Aligning Timing Marks (TDC)
Fig. 5: Adjusting Timing Belt Tension
NOTE: After Installing timing belt, rotate engine clockwise several
times to be sure valves do not contact pistons.
Center Bracket Bolts ................................................... 40 (54)
Power Steering Mount Locknut ....................................... 16 (22)
TCS Lower Bracket Bolts ............................................ 16 (22)
Timing Belt Adjusting Bolt .......................................... 31 (42)
INCH Lbs. (N.m)
Front Engine Wiring Harness Bolts .............................. 106 (12)
TCS Upper Bracket Bolts .......................................... 106 (12)
Timing Belt Cover Bolts................................................ 106 (12)
ACURA
*3.2L V6 Legend & 1996-98 3.2 TL (Cont.)
22
ACURA
*3.5L V6 3.5RL
3.5L V6 (C35A1)
3.5RL
1996-01
Balancer.....................
1
......................... 250280
Camshaft ............ 3.6 Hours .................. 250279
1 -
Balancer belt labor included in camshaft belt
labor time.
For 1996 model year, manufacturer recommends belt be re-
placed at 90,000 miles for normal service and 60,000 miles
on severe service. For 1997-01 model years, normal replace-
ment interval is at 105,000 miles or 84 months. Replace at
60,000 miles if car is regularly driven in extreme temperatures
(over 110 degrees F, or under -20 degrees F).
radio/CD players that contain anti-theft protection circuit. When
battery is disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE and will be inoperative
until proper code is entered by vehicle owner
TIMING BELT
Removal
Remove negative battery cable. Turn crankshaft until No. 1
piston is at TDC of compression stroke. Remove engine
cover, intake air duct, and air cleaner assembly.
Loosen alternator mounting bolt, lock bolt and adjusting
rod, then remove alternator belt. Loosen idler pulley center
nut and adjuster bolt. Remove A/C belt. Remove Traction
Control System (TCS) control valve upper and lower brack-
ets. See Fig. 2. Loosen adjusting bolt, locknut and mount-
ing bolt, then remove power steering pump belt.
Disconnect TCS throttle sensor connector, TCS throttle ac-
tuator connector and throttle position sensor connector. Re-
move TCS control valve assembly. Disconnect vehicle
speed sensor sub-harness connector, then remove wire
harness holder.
Remove crankcase breather hose and vacuum hoses from
front of right upper cover. Remove ignition control module
bracket from right upper cover. Remove idler pulley bracket,
dipstick, and dipstick tube. Remove crankshaft pulley. See
Fig. 1.
Remove upper and lower covers, loosen balancer belt ad-
justing bolt 1/2 turn and push tensioner to remove tension
from balancer belt, then retighten bolt. Remove balancer
belt.
If timing belt is to be reused, mark direction of rotation be-
fore removing. Loosen timing belt adjusting bolt 1/2 turn,
push tensioner to remove tension from timing belt, then
retighten bolt. Remove timing belt.
CAUTION: DO NOT rotate crankshaft pulley or camshaft pulley
with timing belt removed. Pistons may hit valves and cause damage.
NOTE: Ensure water pump turns freely in clockwise direction
and there are no leaks.
Installation
Remove spark plugs. Remove balancer belt drive pulley.
Noting installed position, remove timing belt guide plate
from end of crankshaft. Ensure timing belt drive pulley is
set so that No. 1 piston is at TDC. Align TDC mark on timing
belt drive pulley with pointer on oil pump. See Fig. 4.
Set camshaft pulleys so that No. 1 piston is at TDC. Align
TDC marks on camshaft pulleys to pointers on back cov-
ers. See Fig. 5. Install timing belt, in sequence, on timing
belt drive pulley, adjusting pulley, left camshaft pulley, water
pump pulley, and right camshaft pulley. See Fig. 6. Ensure
camshaft and crankshaft pulleys remain at TDC. Loosen
and retighten timing belt adjusting bolt. Install lower cover
and crankshaft pulley.
To set timing belt tension, rotate crankshaft pulley about 5
or 6 turns clockwise. Set No. 1 piston at TDC of compres-
sion stroke. White mark on crankshaft pulley must be
aligned with pointer on lower cover. See Fig. 3. Rotate
crankshaft clockwise 10 teeth on camshaft pulley. Blue
mark on crankshaft pulley should align with pointer on lower
cover. Loosen timing belt adjusting bolt 180 degrees.
Tighten adjusting bolt to specification.
Remove crankshaft pulley and lower cover. Install timing
belt guide plate and balancer belt drive pulley on crank-
shaft. Ensure guide plate is installed in correction direc-
tion. See Fig. 1.
Remove 12mm sealing bolt from side of engine block. See
Fig. 7. Align maintenance hole and balancer shaft hole.
Insert a 6mm bolt into sealing bolt hole. Ensure balancer
belt pulley pointer aligns with pointer on balancer gear case.
See Fig. 8.
Set timing belt drive pulley to TDC. Install balancer belt
pulley. Install balancer belt. Loosen and retighten balancer
belt adjusting bolt to tension balancer belt. Remove 6 mm
bolt. Install sealing bolt in maintenance hole, using new
washer.
Install crankshaft pulley. Rotate crankshaft pulley about 5
or 6 turns clockwise to position balancer belt on pulleys.
Loosen balancer belt adjusting bolt 180 degrees. Tighten
balancer belt adjusting bolt to specification.
Remove crankshaft pulley. Install upper and lower covers,
then install crankshaft pulley. Ensure crankshaft pulley and
camshaft pulley are at TDC. Remove inspection plugs in
upper camshaft covers to check pulley alignment.
To complete installation, reverse removal procedure. Coat
threads of crankshaft pulley bolt with oil before installation.
Tighten all fasteners to specification. See TORQUE SPECI-
FICATIONS. Adjust drive belts to proper tension. See page
A-60 for belt tension ranges.
23
ACURA
*3.5L V6 3.5RL (Cont.)
Fig. 2: Locating TCS Control Valve & Connectors
Balancer Belt Tension Adjusting Bolt .......................... 33 (44)
Dipstick Tube/Idler Pulley Bolt ........................................ 16 (22)
Engine Sealing Bolt (12mm) .......................................... 14 (20)
TCS Lower Bracket Bolts ............................................ 16 (22)
Water Pump Bolt (8 x 1.25 mm) ..................................... 16 (22)
INCH Lbs. (N.m)
Engine Cover Bolts/Nuts ............................................ 89 (10)
TCS Upper Bracket Bolts .......................................... 106 (12)
Timing Belt Cover Bolts................................................ 106 (12)
Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
24
ACURA
*3.5L V6 3.5RL (Cont.)
Fig. 3: Aligning Timing Marks (TDC)
Fig. 4: Aligning Timing Belt Drive Pulley
Fig. 5: Aligning Camshaft Pulleys
25
ACURA
*3.5L V6 3.5RL (Cont.)
Fig. 7: Installing Balancer Shaft Lock Bolt
Fig. 8: Aligning Balancer Shaft Marks
26
Fig. 2: Aligning Crankshaft Timing Marks (All Models)
ACURA
3.5L V6 DOHC, SLX
3.5L V6 DOHC
SLX
1998-99.................

2.4 Hours.................. 250303
Normal replacement interval is at 75,000 miles for 1998-99
model years.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner as-
sembly. Remove upper fan shroud. Remove serpentine
drive belt.
Remove cooling fan and drive pulley. Remove serpentine
drive belt idler pulley assembly. Remove serpentine drive
belt tensioner assembly.
Remove power steering pump with hoses attached, and
set aside. Remove crankshaft pulley bolt. Using Puller (J-
8614-01) or equivalent, remove crankshaft pulley.
Remove timing belt covers. Rotate crankshaft to align tim-
ing marks. See Figs. 1 and 2. When timing marks are
aligned, No. 2 piston will be at TDC.
If reusing timing belt, mark belt with arrow to indicate origi-
nal rotation direction. Also place mating marks on timing
belt and camshaft sprockets for reassembly reference. Re-
move timing belt tensioner, and set aside with push rod
facing up. Remove timing belt.
CAUTION: To prevent air from entering timing belt tensioner,
tensioner rod must always face up.
NOTE: For correct timing belt installation, lettering on belt must
be able to be read as viewed from the front of the vehicle. Also,
note arrow on belt which indicates direction of rotation.
Installation:
Align grove on crankshaft sprocket with mark on oil pump.
See Fig. 2. Install timing belt on crankshaft pulley, aligning
White dotted line on belt with timing mark on crankshaft
pulley. Secure belt to sprocket with spring clip.
Align timing mark on right hand (passenger side) cam-
shaft sprocket with alignment mark on valve cover. See Fig.
3. Install timing belt on right hand camshaft sprocket, align-
ing the White alignment mark on timing belt with camshaft
sprocket mark. If reusing old timing belt, align mating marks
on belt and camshaft sprocket that were made during re-
moval. Secure belt with spring clip.
Align timing mark on left hand (driver side) camshaft
sprocket with alignment mark on valve cover. See Fig. 4.
Route timing belt around water pump pulley and install on
other left hand camshaft sprocket, aligning the White align-
ment mark on timing belt with camshaft sprocket mark.
Install pinch clip to hold belt on sprocket. Ensure there is
no slack in belt between camshaft pulleys.
Install timing belt around idler pulley and tensioner pulley.
Temporarily install crankshaft pulley. Turn pulley clockwise
slightly to give some belt slack between the crankshaft
sprocket and right hand camshaft sprocket.
NOTE: It will take about 220 lbs. (100 kg) to compress timing belt
tensioner rod.
Holding tensioner upright, SLOWLY compress timing belt
tensioner rod until hole in top of rod and holes in housing
are aligned. Install a locking pin through the holes. See
Fig. 5.
Install tensioner on engine with locking pin in place. Tighten
bolts to specification. See TORQUE SPECIFICATIONS.
Remove locking pin from timing belt tensioner. Remove
clips from camshaft and crankshaft sprockets.
Rotate crankshaft 2 turns clockwise. Ensure timing marks
are still aligned.
Remove crankshaft pulley and install timing belt covers.
Ensure rubber sealing bushings are installed on timing
belt cover bolts. See Fig. 6.
Courtesy of Isuzu Motor Co.
27
Fig. 3: Installing Timing Belt on Right Hand Camshaft
Sprocket
ACURA
3.5L V6 DOHC, SLX (Cont.)
Courtesy of American Honda Motor Co.
Sprocket
Fig. 5: Installing Locking Pin in Timing Belt Tensioner
Fig. 6: Installing Timing Belt Cover Bushings
Install crankshaft pulley. Tighten center bolt to specifica-
tion. Install cooling fan pulley. Install power steering pump.
Install cooling fan. Install serpentine drive belt idler pulley
and tensioner assemblies. Install radiator fan shroud. Con-
nect battery.
Camshaft Sprocket Bolt .............................................. 72 (98)
Cooling Fan Pulley Bolt .............................................. 16 (22)
Power Steering Pump Bolt
M8 Bolt ......................................................................... 16 (22)
M10 ............................................................................. 34 (46)
Timing Belt Idler Arm Pulley Bolt ................................. 38 (52)
Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42)
Water Pump Bolt ......................................................... 18 (25)
28
Fig. 3: Installing Pinch Clip On Timing Belt
ACURA & HONDA
3.2L V6 SOHC
3.2L V6 SOHC
Passport
1994-97................
1
2.8 Hours ................. 250221
SLX
1996-97................
1
2.8 Hours ................. 250221
1
With Pwr. Strng. add .3 hours.
60,000 miles.
TIMING BELT
Removal:
sembly. Remove upper fan shroud. Remove cooling fan
assembly. Remove all accessory drive belts.
Remove fan pulley assembly. Remove crankshaft pulley
bolt. Using Puller (J-8614-01) or equivalent, remove crank-
shaft pulley. Remove oil cooler hose from timing cover. Re-
move timing belt cover. Align all timing marks prior to belt
removal. See Figs. 1 and 2. Remove belt tensioner pusher
and timing belt.
Installation:
Ensuring all timing marks are aligned. Install belt over one
pulley at a time starting at crankshaft sprocket working coun-
terclockwise. Belt should go over tensioner last. Secure
belt at each pulley during installation with pinch clips. See
Fig. 3.
CAUTION: To ensure correct timing belt installation, ensure
direction of rotation arrows are pointing in proper direction.
If timing belt is being reused, install belt in original direction
of rotation.
Compress timing belt tensioner pusher and insert pin to
retain pusher. Apply pressure to tensioner against belt and
install tensioner pusher. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
Loosen tensioner pulley bolt. Apply pressure on belt by
rotating tensioner. Tighten tensioner pulley bolt to specifi-
cation. Remove pin from timing belt tensioner pusher.
Remove pinch clips from timing belt, (if used). Install crank-
shaft pulley, tightening center bolt finger tight. Rotate crank-
shaft 2 turns clockwise. Ensure timing belt tensioner pusher
rod protrudes proper amount. See Fig. 4.
If timing belt tensioner pusher rod protrusion is not within
specification, remove pusher, loosen tensioner pulley bolt
and readjust. Reset timing belt tensioner pusher rod and
repeat timing belt tensioning procedure. Remove crank-
shaft pulley and install timing belt cover. To complete in-
stallation, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS. Ad-
29
Fig. 4: Adjusting Timing Belt Tensioner Pusher
ACURA & HONDA
3.2L V6 SOHC (Cont.)
Fig. 5: Exploded View Of Cylinder Head Components
just drive belts to proper tension. See page A-60 for belt
tension ranges.
Fan Pulley Bolt ............................................................ 16 (22)
Front Plate Bolt ........................................................... 14 (19)
Idler Arm Retaining Bolt .............................................. 33 (44)
Power Steering Pump Bolt .......................................... 34 (46)
Timing Belt Tensioner Pulley Bolt ............................... 32 (43)
Timing Belt Tensioner Pusher Bolt ............................. 14 (19)
Upper Intake Manifold Bolt .......................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ........................................ 87 (10)
Cooling Fan Assembly Nut ........................................... 69 (8)
30
ALFA ROMEO
3.0L V6
3.0L V6
164
1991-93 .............. 4.8 Hours ................. 250120
50,000 miles.
TIMING BELT
Removal:
hicle. Remove right front wheel. Remove right front inner
fenders. Disconnect throttle opening switch electrical con-
nector. Remove throttle body cover.
Remove water pump, air conditioning, and power steering
drive belts. Remove hydraulic belt tensioner. Disconnect
crankshaft position sensor connector, and remove sensor.
Disconnect constant idle speed actuator electrical connec-
tor. Disconnect oil vapor separator hoses.
Disconnect accelerator cable. On model equipped with au-
tomatic transmission, disconnect kickdown cable. On S
models, disconnect engine throttle sensor electrical con-
nector. On all models, disconnect fuel vapor and cruise
control hoses.
Disconnect fuel pressure regulator and power brake unit
vacuum hoses. Disconnect ground strap from air intake
box. Remove air intake box attaching screws and clamps,
and remove air intake box.
Disconnect spark plug wires for cylinders No. 1, No. 2, and
No. 3. Remove intake ducts and gaskets. Remove right
valve cover and gasket. Disconnect spark plug wires for
No. 4, No. 5, and No. 6. Remove left side valve cover and
gasket.
Partially drain cooling system. Disconnect coolant hose
from thermostat unit. Disconnect return hose from water
pump. Disconnect coolant temperature switch and sensor
electrical connectors. If equipped, disconnect oil cooling
tubes from heat exchanger.
Remove timing belt covers. Remove spark plugs Rotate
crankshaft so No. 1 cylinder is at TDC of compression
stroke. Flywheel and transmission housing timing marks
should align. See Fig. 1. Camshaft sprocket timing marks
should align with bearing cap marks. See Fig. 2.
Lift belt tensioner arm from timing belt. Insert Holding Tool
(1.820.053.00) or equivalent into hole on arm to lock in
position. Loosen hydraulic belt tensioner retaining nuts.
Push tensioner downward to limit of travel, and tighten up-
per retaining nut. Remove timing belt.
Installation:
Position Adapter (1.825.007.000) or equivalent, and a dial
indicator into No. 1 cylinder spark plug hole. See Fig. 2.
Ensure camshaft and crankshaft timing marks align.
Install timing belt over crankshaft sprocket, left camshaft
sprocket, right camshaft sprocket, and oil pump sprocket
hydraulic belt tensioner pulley. See Fig. 3. Maintain tension
on timing belt during installation. Loosen timing belt hy-
draulic tensioner upper retaining nut.
Turn crankshaft in normal direction of rotation 2-3 revolu-
tions to seat timing belt. Keep timing belt under tension
and push hydraulic tension pulley against timing belt.
Tighten 2 tensioner retaining nuts. Slightly lift belt tensioner
arm, then release tensioner arm, by removing tool holding
arm in position.
Position No. 1 cylinder at TDC compression stroke. En-
sure crankshaft and camshaft timing marks are aligned. If
timing marks are not aligned, timing belt must be removed
and repositioned. Install spark plugs. Install timing belt
covers.
On models with heat exchanger, connect oil cooler tubes.
On all models, connect coolant hose to thermostat unit,
and return hose to water pump. Plug in coolant switch and
sensor electrical connectors. Install left side valve cover
and gasket.
Connect spark plug wires for cylinders No. 4, No. 5, and
No. 6. Install right side valve cover and gasket. Install in-
take ducts and gaskets. Connect spark plug wires for cylin-
ders No. 1, No. 2, and No. 3. Install air intake box. Connect
ground strap to air intake box. Connect fuel pressure regu-
lator and power brake unit vacuum hoses. Connect fuel
vapor and cruise control hoses.
On S models, connect engine throttle sensor electrical con-
nector. Connect accelerator cable. On models with auto-
matic transmission, connect kickdown cable. Install throttle
body cover. Connect throttle body switch electrical connec-
tor.
Connect oil vapor separator hoses. Connect constant idle
speed actuator electrical connector. Install crankshaft po-
sition sensor and electrical connector. Install hydraulic drive
belt tensioner. Install power steering pump, A/C compres-
sor, and water pump drive belts.
Install front right inner fenders. Install right front wheel and
tire assembly, then lower vehicle. Connect negative cable.
Adjujst accessory drive belt tension. See page A-60 for belt
tension ranges.
Fig. 1: Identifying Flywheel Timing Marks
31 ALFA ROMEO
3.0L V6 (Cont.)
Fig. 2: Identifying Camshaft Timing Marks
32
Belt
Labor Component Part
Application Time
1
Kit No. No.
2.0L 4-Cyl.
Concord & Gremlin
1977-78.......... 1.5 Hrs. ...... 2520170........ 250017
Concord & Spirit
1979............... 1.5 Hrs ....... 2520170....... 250017
1
- With Air Cond. add .2 hours
NOTE: A timing belt component kit is available for
this application. See page I for information on component
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Rotate engine until tim-
ing mark (notch) on crankshaft is pointing to zero. Cam-
shaft sprocket timing mark should now be adjacent to
pointer on cylinder head cover. See Fig. 1.
NOTE: Rotate engine by turning crankshaft. Do not turn engine
by camshaft.
Loosen front pulley retaining screws. Remove alternator
and power steering drive belts. Remove cam drive belt
shield.
Mark rotation of belt rotation before removal. Loosen
tensioner retaining screw and remove camshaft drive belt.
See Fig. 2.
Installation:
Mount belt onto crankshaft sprocket. Position belt in
tensioning pulley groove and install belt to camshaft
sprocket. See Fig. 2.
NOTE: Use hands to install belt. DO NOT pry with tool.
Turn offset adjusting nut on tensioning pulley clockwise to
tighten belt tension. When belt can be twisted 90 with thumb
and forefinger, belt is properly tensioned.
CAUTION: Excessive tension may cause pulley to fail.
Reverse removal procedure to complete installation. Ad-
tension ranges.
AMERICAN MOTORS
2.0L 4-Cylinder
Fig. 2: Timing Belt & Components
Camshaft Belt Tensioning Idler Screw ....................... 29 (39)
Camshaft Sprocket Screw .......................................... 58 (78)
Crankshaft Sprocket Screw .................................... 181 (123)
Water Pump Screw (Large) ....................................... 16 (21)
INCH Lbs. (N.m)
Camshaft Rear Bearing Cap Screw ........................... 84 (10)
Water Pump Screw (Small) ....................................... 84 (10)
33
AUDI
1.6L 4-Cylinder Diesel
1.6L 4-Cyl.
4000
Diesel
1982-83 .............. 2.3 Hours ................ 250043
the belt be replaced at 60,000 mile intervals.
TIMING BELT & SPROCKET
Removal:
Disconnect negative battery cable. Remove accessory drive
belts. Remove timing belt cover and camshaft cover. Turn
crankshaft to place No. 1 piston on TDC at end of compres-
sion stroke. Lobes of camshaft on No. 1 cylinder must point
upward.
Secure camshaft in place by installing Setting Bar (2065)
at rear of camshaft. Tool must be properly installed to pre-
vent camshaft from moving. See Fig. 1.
Insert pin tool (2064) through small cutout in injection pump
sprocket to lock sprocket in place. Injection pump sprocket
must not be allowed to move.
Check that timing marks on injection pump sprocket, pump
body and mounting plate are aligned. Check that TDC mark
on flywheel is aligned with reference mark on bell housing.
Loosen timing belt tensioner to relieve tension on timing
belt. Remove crankshaft pulley. Do not allow crankshaft to
turn. Remove timing belt.
Installation:
Check that TDC mark on flywheel is still aligned with refer-
ence mark. Loosen camshaft sprocket bolt 1/2 turn. Loosen
sprocket from camshaft by tapping with a rubber mallet.
Install timing belt. Tighten camshaft sprocket bolt. Remove
pin tool from injection pump sprocket. Apply tension to belt
by turning timing belt tensioner to right.
Using Tension Gauge (210), check timing belt tension mid-
way between camshaft and injection pump sprockets. Ten-
sion is correct if gauge reads 12-13. See Fig. 2.
Turn crankshaft clockwise 2 turns. Strike timing belt with a
rubber mallet midway between camshaft sprocket and in-
jection pump sprocket. Using Tension Gauge (210), re-
check timing belt tension.
If necessary, readjust timing belt tension. Check injection
pump timing. Install remaining components in reverse or
Crankshaft Pulley/Damper
Standard ............................................................... 108 (150)
Turbo .................................................................... 145 (200)
Injection Pump Sprocket ............................................. 33 (45)
Intermediate Shaft Pulley ............................................ 33 (45)
Timing Belt Tensioner ................................................ 33 (45)
Fig. 1: Camshaft Locking Tool Installation
Fig. 2: Timing Belt Tension Tool Installation
der of removal. Adjust drive belts to proper tension. See
34
AUDI
1.6L & 1.7L 4-Cylinder
Belt
Application Time Kit No. No.
1.6L 4-Cyl.
Fox
1973-79.......... 1.1 Hrs. ...... 2520170....... 250017
1.7L 4-Cyl.
4000
1980-83.......... 1.1 Hrs. ...... 2520170........ 250017
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Ensure No. 1 piston is
at TDC on compression stroke and that crankshaft pulley
notch is aligned with sprocket mark at TDC pointer. See
Fig. 2. Remove radiator grille. Remove accessory drive belts.
Remove water pump pulley. Remove camshaft belt guard.
Loosen mounting nut of camshaft belt tensioner arm and
remove tension from belt. Slide belt forward off camshaft
sprocket.
Installation:
Install new belt and adjust tensioner arm until belt can be
turned 90 with thumb and index finger at a point midway
between camshaft sprocket and intermediate sprocket.
Check valve timing. To complete installation, reverse re-
moval procedure. Adjust drive belts to proper tension. See
page A-60 for belt tension rannges
Fig. 1: Adjusting Timing Belt Tension (1.7L)
Fig. 2: Aligning Timing Marks (1.6L)
Fig. 3: Exploded View Of Timing Belt & Components (1.7L)
Fig. 4: Aligning Camshaft Sprocket With Upper Edge Of
Gasket (1.7L)
35
AUDI
1.6L & 1.7L 4-Cylinder (Cont.)
Camshaft Sprocket ..................................................... 58 (80)
Crankshaft Drive Belt Sprocket ................................... 58 (80)
Crankshaft V Belt Pulley ........................................... 14 (20)
Drive Belt Tension Nut ................................................ 33 (45)
Intermediate Shaft Sprocket ....................................... 58 (80)
36
Belt
Application Time Kit No.
1.8L 4-Cyl.
4000S
1984-87 ........ 1.1 Hrs. ...... 2520170....... 250017
kits.
MANFACTURERS SUGGESTED
Although the manufacturer does not recommend a specified
scheduled maintenance, belt manufacturers suggest the belt
be replaced at 60,000 mile intervals.
See page ,,,, for interference engine cautions.
TIMING BELT
CAUTION: Never use camshaft sprocket attaching bolt to turn
engine as timing belt could be stretched.
Removal:
Disconnect negative battery cable. Loosen alternator ad-
justing bolts. Remove all drive belts. Remove water pump
pulley, crankshaft pulley, and vibration damper. Remove
upper and lower timing belt outer covers. On 16-valve en-
gine, remove upper half of intake manifold.
On all models, remove camshaft cover from cylinder head.
Turn crankshaft to position No. 1 piston at TDC of com-
pression stroke. Make sure distributor housing and flywheel
timing marks are correctly aligned.
Loosen timing belt tensioner to relieve tension on timing belt.
See Fig. 1. Slide timing belt off intermediate shaft sprockets.
Installation:
Set crankshaft at point just before TDC compression for
No. 1 cylinder. Place timing belt on crankshaft and interme-
diate shaft sprockets. Install crankshaft pulley and tighten
all 4 bolts. Align mark on crankshaft pulley with mark on
intermediate shaft sprocket at TDC. See Fig. 2.
Position camshaft so mark on back of sprocket is in line
with upper edge of timing belt rear cover. See Fig. 3. Both
lobes for No. 1 cylinder should point upward at 45 degrees
from camshaft follower so both valves are closed. Install
timing belt on camshaft sprocket.
Adjust timing belt tension by turning tensioner adjusting
hex clockwise against belt. Make sure shaft timing marks
have not moved. Tighten tensioner lock nut and check ten-
sion of timing belt at point midway between camshaft
sprocket and intermediate sprocket. See Fig. 4.
Belt has correct tension when it can be twisted 90 degrees
with thumb and finger pressure. Rotate engine by hand
through 2 revolutions in clockwise direction. Check all tim-
ing marks. To complete installation, reverse removal proce
dure. Adjust drive belts to proper tension. See page A-60 for
belt tension ranges.
AUDI
*1.8L 4-Cylinder 1984-87
Camshaft Sprocket Bolt
8-Valve ...................................................................... 58 (80)
16-Valve .................................................................... 48 (65)
Crankshaft Pulley Nut ................................................. 14 (20)
Crankshaft Sprocket Bolt ........................................ 148 (200)
Intermediate Shaft Sprocket Bolt
8-Valve ...................................................................... 58 (80)
16-Valve .................................................................... 48 (65)
Timing Belt Tensioner Nut .......................................... 33 (45)
Fig. 1: 16-Valve Timing Belt Cover & Timing Belt Assembly
Fig. 2: Aligning Intermediate Shaft & Crankshaft
37
AUDI
*1.8L 4-Cylinder 1984-87 (Cont.)
Fig. 3: Setting Camshaft Timing Marks
38
1.8L 4-Cylinder Turbo
A4 & A4 Quattro
1997-99 ............... 3.5 Hours ................. 250291
The manufacturer suggests the belt be replaced at 90,000
mile intervals.
TIMING BELT
Removal
Remove complete front bumper assembly. Remove en-
gine undercover. Remove air intake duct from air filter hous-
ing. Disconnect all necessary electrical connectors from
front of vehicle.
Install Lock Carrier Support Tool (3369) through lock car-
rier to chassis. See Figs. 4 and 5. Remove lock carrier
support bolts securing lock carrier to vehicle. Slide lock
carrier forward onto support tool. This will allow servicing
of front engine components.
Remove serpentine drive belts. Remove serpentine drive
belt tensioner. Remove viscous fan clutch and pulley as-
sembly. Viscous fan pulley is secured by one Allen-head
bolt. Allen-head bolt is removed from rear of pulley, through
access hole in accessory mount bracket.
CAUTION: Crankshaft center bolt is torque-to-yield type. Manufacturer
recommends replacing bolt if it is loosened or removed.
Remove upper timing belt cover. Rotate crankshaft by hand
to Top Dead Center (TDC). See Fig. 1. Remove crankshaft
vibration damper pulley. It is NOT necessary to remove
crankshaft center bolt. Remove lower timing belt cover.
Mark timing belt running direction. Using Torx T45 bit, loosen
timing belt tensioner. Push timing belt tensioner down and
remove timing belt.
CAUTION: To prevent pistons from hitting valves, make sure crankshaft
is NOT at TDC for any piston before turning camshaft.
Installation
Align mark on camshaft sprocket with mark on cylinder
head cover and/or timing belt guard. See Fig. 1. Install tim-
ing belt on crankshaft sprocket. Install lower timing belt
cover. Install vibration damper pulley and tighten bolts to
specification. See TORQUE SPECIFICATIONS.
Ensure crankshaft vibration damper is correctly aligned to
lower timing belt cover. See Fig. 1.
Install timing belt on the tensioner and camshaft sprocket.
To tension timing belt, use spanner wrench to rotate
tensioner pulley clockwise until tensioner piston No. 1 is
fully extended, and piston No. 2 lifts about .040 (1 mm).
See Fig. 2.
Tighten tensioner pulley bolt to specification. See TORQUE
SPECIFICATIONS. Rotate crankshaft 2 revolutions in nor-
mal direction of rotation. Make sure camshaft and crank-
shaft timing marks are aligned.
AUDI
*1.8L 4-Cylinder Turbo A4 & A4 Quattro
Fig. 2: Identifying Tensioner Pistons
Courtesy of Audi of America, Inc.
Fig. 3: Identifying Tensioner Dimensions
39
AUDI
*1.8L 4-Cylinder Turbo A4 & A4 Quattro (Cont.)
Fig. 4: Exploded View Of A4 Lock Carrier Assembly
Fig. 6: Positioning Lock Carrier Assembly Torx Bolts
Fig. 5: Positioning Lock Carrier Support Tool (3369)
Belt tension is correct if edge of tensioner lever aligns with
piston upper edge (Area A), or piston No. 1 is extended
0.98-1.14 (25-29 mm) (dimension D). See Fig. 3. Check
for wear in Areas B and C.
Install upper timing belt cover. Install serpentine drive belt
tensioner and belt. To complete installation, reverse re-
moval procedure. Ensure lock carrier Torx bolts are in-
stalled in correct position. See Fig. 6.
Crankshaft Sprocket Center Bolt
1
Step 1 ....................................................................... 66 (90)
Step 2 ..................................................... Additional 1/4 Turn
Lock Carrier-To-Body Bolts ............................................ 33 (45)
Lower Timing Belt Cover-To-Engine
M6 .............................................................................. 7 (10)
M8 ............................................................................ 15 (20)
Serpentine Belt Tensioner Bolt ....................................... 18 (25)
Timing Belt Idler Pulley Bolt ............................................ 18 (25)
Vibration Damper Pulley Bolts
2
.................................................................. 30 (40)
Viscous Cooling Fan Pulley Bolt .................................... 33 (45)
INCH Lbs. (N.m)
Lock Carrier-To-Body Torx bolts...................................... 89 (10)
Timing Belt Tensioner Bottom Bolt ................................. 89 (10)
Water Pump Bolt ............................................................ 89 (10)
1
REPLACE torque-to-yield bolt if loosened or removed.
2
Bolt strength grade is 10.9.
40
1.8L 4-Cylinder Turbo (AMU, ATC & AWP)
TT Coupe & Roadster
2000...................... 3.5 Hours ................. 250306
NOTE: Engine code is located on machined pad on bellhousing
flange, where engine connects to transaxle.
mile intervals.
TIMING BELT
Removal
Disconnect charge air cooler duct at bottom of right-hand
crossmember (if equipped). See Fig. 2. Remove center
and right-hand noise insulation panels from under vehicle.
See Fig. 3.
Remove serpentine drive belt and tensioner. See Fig. 4.
Rotate tensioner clockwise (as viewed from front of en-
gine) to relieve belt tension.
Remove cooling system expansion tank and power steer-
ing reservoir bolts. Keeping hoses attached, secure ex-
pansion tank and reservoir out of way.
Rotate crankshaft by hand to Top Dead Center (TDC). See
Fig. 1. Remove crankshaft vibration damper pulley. Remove
lower timing belt cover. Remove vacuum hose connecting
fuel evaporative canister to throttle body.
Unplug electrical connectors on coolant expansion tank
and fuel evaporative canister. Remove upper timing belt
cover.
Remove weight of engine from engine mounts by installing
Support Bracket (10-222) or equivalent. Engine may be sup-
ported from below using floor jack.
Turn crankshaft sprocket center bolt in normal direction of
rotation to align the crankshaft vibration damper at TDC of
No. 1 cylinder. Ensure camshaft sprocket timing mark is
aligned with mark on rear timing belt cover. See Fig. 5.
NOTE: Crankshaft sprocket center bolt is a torque-to-yield type.
If removed, manufacturer recommends replacing the bolt.
Remove 4 bolts around center bolt on vibration damper.
Remove vibration damper. It is NOT necessary to remove
crankshaft center bolt. Do NOT move crankshaft.
NOTE: Engine console and right-hand engine support bolts are
torque-to-yield type. Manufacturer recommends replacing the
bolts if they are removed.
Remove center and bottom timing belt covers. Remove
bolts from engine console and right-hand engine support
arm. See Fig. 6. Remove engine console and right-hand
engine support arm.
AUDI
*1.8L 4-Cylinder Turbo TT
Fig. 2: Identifying Air Duct (ATC & AWP Engines)
Remove bolts for engine support, but do not remove en-
gine support. See Fig. 7. If reusing old timing belt, mark
belt with arrow to indicate original direction of rotation.
Screw a M5 x 55 stud into the timing belt tensioner bracket.
See Fig. 8. Install hex nut and washer onto stud.
SLOWLY turn hex nut on stud to compress timing belt
tensioner. Compress tensioner just enough so that a lock-
ing pin or drill bit can be inserted through the tensioner
body, locking the tensioner in place. Remove timing belt.
CAUTION: To prevent engine damage, do NOT turn camshaft
while the crankshaft is a TDC.
41
AUDI
*1.8L 4-Cylinder Turbo TT (Cont.)
Fig. 3: Identifying Noise Insulation Panels
Fig. 4: Identifying Serpentine Belt & Tensioner
Fig. 6: Identifying Right-Hand Engine Support Arm
Fig. 7: Identifying Right-Hand Engine Support
42
Installation
Install timing belt onto crankshaft sprocket. Install lower
timing belt cover. Install vibration damper pulley, making
sure notch in center hole of vibration damper is aligned
with projection on crankshaft sprocket. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
Ensure camshaft and crankshaft timing marks are still
aligned. See Fig. 5. Install timing belt on water pump,
tensioner pulley and camshaft sprocket.
Remove locking pin or drill bit from timing belt tensioner.
Remove M5 x 55 stud from tensioner bracket. Turn crank-
shaft 2 complete revolutions in normal direction of rotation.
Align camshaft and crankshaft timing marks.
Install engine right-hand engine support arm and console
using NEW bolts. Adjust engine console and right-hand
engine support arm so clearance is about .50 (13 mm).
See Fig. 6.
AUDI
*1.8L 4-Cylinder Turbo TT (Cont.)
Remove engine Support Bracket (10-222) or floor jack from
under vehicle. Install center and upper timing belt covers.
Install serpentine belt tensioner and serpentine belt.
Install coolant expansion tank and power steering reser-
voir. Install vacuum line between fuel evaporative canister
and throttle body. To install remaining components, reverse
removal procedure.
Camshaft Sprocket Bolt ................................................ 48 (65)
1
Step 1 ....................................................................... 66 (90)
Engine Console-To-Body
1
Step 1 ....................................................................... 30 (40)
Engine Support Arm-To-Engine Bracket
1
Step 1 ....................................................................... 44 (60)
Timing Belt Tensioner
Bottom Bolt ................................................................... 11 (15)
Top Bolt ........................................................................ 15 (20)
Timing Belt Tensioner Pulley Bolt ................................. 20 (27)
Vibration Damper-To-Crankshaft Sprocket ..................... 18 (25)
Water Pump Bolt ............................................................ 11 (15)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................... 89 (10)
1
Torque-to-yield type bolt. Manufacturer recommends
replacing bolt if it is removed.
Fig. 8: Compressing Timing Belt Tensioner
43
Belt
2.0L 4-Cyl.
80
1988-90 ......... 1.8 Hrs. ...... 2520170....... 250017
90
1988............... 1.8 Hrs. ...... 2520170....... 250017
kits.
Although the manufacturer does not recommend a specific sched-
uled maintenance interval, belt manufacturers suggest the belt
AUDI
2.0L 4-Cylinder
TIMING BELT
Removal:
Disconnect negative battery cable. Use exploded view to
locate components. See Fig. 1. Match mark all components
for reassembly reference. Place crankshaft at TDC with
No. 1 cylinder on compression stroke. Remove alternator
belt. Remove A/C and power steering belts (if equipped).
Remove upper timing belt cover. Remove water pump and
crankshaft pulleys. Remove lower timing belt cover. Re-
move timing belt.
Installation:
Align flywheel/flex plate 0 mark with pointer. Remove dis-
tributor cap and check position of ignition rotor. Rotate in-
termediate shaft and position rotor at No. 1 cylinder mark
on housing. See Fig. 2. Install timing belt on crankshaft
and intermediate shaft gears.
With intermediate shaft/ignition rotor positioned, rotate crank-
shaft and align mark on crankshaft pulley with mark on
intermediate shaft sprocket. Position camshaft sprocket
mark even with base of valve cover. See Fig. 3. Install timing
belt on camshaft sprocket.
Rotate tensioner clockwise to tighten belt and install lock
nut. Proper tension is achieved when belt can be twisted
90 degrees. See Fig. 4. Rotate crankshaft 2 revolutions
and check timing mark alignment. To complete installa-
tion, reverse removal procedure. Adjust drive belts to proper
Crankshaft Pulley Nut ................................................... 5 (20)
Crankshaft Sprocket Bolt ........................................ 133 (180)
Timing Belt Tensioner Pulley Nut ............................... 33 (45)
Water Pump Pulley ..................................................... 15 (20)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................ 53 (6)
Fig. 2: Aligning Distributor Rotor
44
AUDI
2.0L 4-Cylinder (Cont.)
Fig. 4: Checking Proper Belt Tension
45
2.0L 5-Cyl. Diesel
5000
1979-83
Camshaft ............ 2.6 Hours .................. 250083
Inject. Pump ....... 1.1 Hours .................. 250082
2.0L 5-Cyl. Turbo Diesel
5000
1979-83
Camshaft ............ 2.6 Hours .................. 250083
Inject. Pump........ 1.1 Hours .................. 250082
TIMING BELT & INJECTION PUMP BELT
Removal:
belts. Remove outer half of vacuum pump pulley. Remove
power steering pump with hoses connected, and position
aside. Remove attaching bolts and remove upper and lower
timing belt covers. Remove injection pump covers. Note
position and number of spacer washers on pulley.
Remove cam cover. Rotate crankshaft to position No. 1
cylinder at TDC. Timing marks on flywheel and clutch hous-
ing must be aligned. Also, timing marks on fuel injection
pump sprocket and pump mounting plate must be aligned.
Lock injection pump sprocket with pin tool (2064). Hold
inner half of vacuum pump pulley and injection pump drive
sprocket with tool (3036). Remove sprocket center retain-
ing bolt. Remove inner pulley half, pump sprocket and in-
jection pump drive belt.
Secure crankshaft from moving with support tool (2084).
Loosen crankshaft damper/pulley center bolt. Install cam-
shaft holding tool (2065A) at rear of camshaft.
With camshaft locked in place, loosen water pump bolts to
relieve tension on timing belt. Remove crankshaft pulley
with timing belt sprocket and timing belt.
Installation:
Ensure crankshaft and injection pump timing marks are
aligned. Install crankshaft damper/pulley with sprocket and
timing belt. Using tool (2084) to hold crankshaft, install and
tighten center bolt.
With camshaft still locked in place, loosen camshaft sprocket
bolt 1 full turn. Using a brass drift inserted through hole in rear
timing belt cover, tap camshaft sprocket loose from camshaft
taper.
Attach timing belt to camshaft sprocket. To adjust timing
belt tension, turn water pump until pump sprocket provides
tension against timing belt.
Using tension tester (VW210), check timing belt tension
midway between camshaft and water pump sprockets. Ten-
sion is correct when tester reads 12-13.
Check that crankshaft and injection pump timing marks
are still aligned. Tighten camshaft sprocket bolt and re-
move camshaft holding tool.
Install injection pump sprocket, drive belt and inner pulley
half. Tighten injection pump drive sprocket retaining bolt
until it is just possible to turn sprocket on camshaft by hand.
Adjust fuel injection pump drive belt tension by loosening
mounting bolts and reposition mounting plate and support
on engine. Using tension tester (VW 210), check belt ten-
sion midway between fuel injection pump and drive sprock-
ets.
Tighten fuel injection pump drive sprocket bolt and remove
pin tool (2064) from injection pump sprocket. Install re-
maining components in reverse order of removal. Ensure
valve timing and injection pump timing are correct. Adjust
drive belts to proper tension. See page A-60 for belt tension
ranges.
Camshaft Sprocket
Front ......................................................................... 33 (45)
Rear ....................................................................... 72 (100)
Crankshaft Damper/Pulley (Locktite) ...................... 258 (350)
Water Pump Bolts ...................................................... 14 (20)
AUDI
*2.0L 5-Cylinder Diesel & Turbo Diesel
Fig. 1: Camshaft Timing Belt Replacement
46
Fig. 2: Injection Pump Drive Belt Replacement
AUDI
*2.0L 5-Cylinder Diesel & Turbo Diesel (Cont.)
47
AUDI
2.3L 5-Cylinder Coupe Quattro
2.3L 5-Cyl.
Coupe Quattro
1990-91................. 1.8 Hours ................. 250197
TIMING BELT & COVER
Removal:
Disconnect negative battery cable. Remove upper radiator
cover. Remove drive belts. Remove power steering pump
with pressure hoses connected. Set pump aside. Remove
valve cover and outer timing belt covers.
Using crankshaft bolt, turn crankshaft clockwise to TDC of
No. 1 cylinder compression stroke. Align timing mark on
back of camshaft sprocket with upper edge of gasket. See
Fig. 2.
Loosen water pump adjusting bolts to relieve tension on
timing belt. Remove timing belt. Remove water pump to
check O ring. DO NOT allow crankshaft or camshaft to
move.
92A00398 Courtesy of Audi of America, Inc.
48
AUDI
2.3L 5-Cylinder Coupe Quattro (Cont.)
Fig. 4: Checking Proper Belt Tension
Installation:
Ensure both camshaft lobes on No. 1 cylinder point up-
ward. Mark (notch or dot) on back of camshaft sprocket
must be aligned with top of valve cover gasket or rear tim-
ing belt cover. Crankshaft must be at TDC for No. 1 cylinder.
Flywheel TDC mark must be aligned with index point on
transmission housing.
Install water pump with new sealing O ring. Install timing
belt. Turn water pump body counterclockwise to increase
belt tension. Tension is correct when belt can be twisted 90
degrees using finger pressure at point midway between
camshaft sprocket and water pump sprocket.
Recheck valve timing. Complete installation in reverse or-
der of removal. Adjust drive belts to proper tension. See
Timing Belt Idler Pulley Bolt ........................................ 15 (20)
Vibration Damper Bolt ............................................ 258 (350)
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 84 (10)
Fig. 3: Aligning Ignition Rotor
49
AUDI
2.2L 5-Cylinder Turbo, 1992-95
2.2L 5-Cyl. Turbo
S4
1992-94................. 1.8 Hours .................. 250225
S6 & S6 Quattro
1995....................... 1.8 Hours .................. 250225
TIMING BELT
Removal:
hicle. Remove underpanel. Remove front bumper. Remove
upper radiator support with attached parts. Remove bracket
for trim panel from right side of vehicle. Remove radiator
bolts, radiator air guide and upper air duct from radiator.
Attach special radiator support tool (3251) to right bumper
mount bracket and swing radiator forward. Remove vis-
cous fan and unclip wiring from fan frame. Relieve tension
from accessory drive belt by swinging tensioner in direc-
tion shown. See Fig. 2. Insert Pin (3204) into holes. Re-
move belt. Remove tensioner. Remove upper timing belt
guard.
NOTE: Turn engine by hand using hex flange on hydraulic pump.
Loosen tensioner bolts.
96H14644 Courtesy of Audi of America, Inc.
Turn crankshaft to TDC of No. 1 cylinder. See Fig. 3. Cam-
shaft sprocket mark must align with mark on cylinder cover.
See Fig. 4. Remove vibration damper. Remove lower tim-
ing belt cover. Remove timing belt with vibration damper.
Installation:
Ensure crankshaft and camshaft are at TDC of cylinder No.
1. TDC marking must be positioned below edge in inspec-
tion hole. See Fig. 3. Markings on camshaft sprocket and
cylinder head cover must align. See Fig. 4. Place new belt
on crankshaft pulley. Install vibration damper and at same
time, fit lower timing belt cover. Fit belt onto idler pulley,
water pump and camshaft sprocket. Tension belt by turn-
ing tensioner toward right with bolts loosened. See Fig. 1.
Ensure that belt can just be twisted 90 degrees with thumb
and forefinger between camshaft sprocket and water pump.
Tighten tensioner. To complete installation, reverse removal
procedure. Adjust drive belts to proper tension. See page
Timing Belt Idler Pulley Bolt .......................................... 15 (20)
Timing Belt Tensioner (1992-95) ................................ 15 (20)
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Radiator Mounting Bolts ............................................. 89 (10)
Timing Belt Cover ....................................................... 89 (10)
Valve Cover Nuts/Bolts ............................................... 89 (10)
96F14642 Courtesy of Audi of America, Inc.
Fig. 2: Relieving Tension On Accessory Drive Belt
50
AUDI
2.2L 5-Cylinder Turbo, 1992-95 (Cont.)
Fig. 3: Locating No. 1 Cylinder TDC Inspection Hole
Fig. 4: Aligning Camshaft Sprocket Timing Marking
96G14643 Courtesy of Audi of America, Inc.
51
AUDI
2.3L 5-Cylinder Exc. Coupe Quattro
2.3L 5-Cyl.
80
1991-92.................. 1.8 Hours .................. 250170
80/90 Quattro
1988....................... 1.8 Hours .................. 250127
1989
Thru Chassis No.
89 J 394 742......... 1.8 Hours .................. 250127
From Chassis No.
89 J 394 743........ 1.8 Hours .................. 250170
1990-92................. 1.8 Hours .................. 250170
90
1988....................... 1.8 Hours .................. 250127
1989
Thru Chassis No.
89 J 396 702........ 1.8 Hours .................. 250127
From Chassis No.
89 J 396 703........ 1.8 Hours .................. 250170
1990-91.................. 1.8 Hours .................. 250170
100/100 Quattro
1989-91
Thru Chassis No.
063 969 ............... 1.8 Hours .................. 250127
From Chassis No.
063 970 ............... 1.8 Hours .................. 250170
1990-91.................. 1.8 Hours .................. 250170
5000S
1987-88.................. 2.2 Hours .................. 250127
5000S Quattro
1988....................... 2.2 Hours .................. 250127
TIMING BELT
Removal (1986-90):
cover. Remove drive belts. Remove power steering pump with
pressure hoses connected. Set pump aside. Remove valve
cover and outer timing belt covers. See Fig. 1.
Fig. 2.
move.
Installation (1986-90):
camshaft sprocket and water pump sprocket. Recheck valve
timing. Complete installation in reverse order of removal.
Adjust drive belts to proper tension.
Removal (1991-92):
belts. Remove upper front and lower front timing belt cov-
ers. Rotate crankshaft until timing marks are aligned. See
Fig. 2. Mark an arrow on timing belt (if reusing) to indicate
direction of rotation.
Slightly loosen 3 water pump bolts. Pivot water pump to-
ward center of engine to relieve timing belt tension. Insert
Holder (2084) into vibration damper to prevent crankshaft
from turning. Using Extension (2079) and breaker bar, re-
move vibration damper bolt. Remove vibration damper/
crankshaft sprocket. Remove timing belt.
Ensure timing marks are aligned. See Fig. 3. With crank-
shaft sprocket attached to vibration damper, loop timing
belt around crankshaft sprocket. Install vibration damper/
crankshaft sprocket with belt onto crankshaft end, ensur-
ing belt is not jammed between crankshaft sprocket and
front cover.
Slightly loosen 3 water pump bolts. Pivot water pump to-
ward center of engine to allow belt to be looped around
camshaft sprocket and idler pulley. Take up all slack in belt
between camshaft and water pump, and between water
pump and crankshaft.
Pivot water pump away from engine until belt is tight. To
check belt tension, grasp belt with thumb and forefinger
between camshaft and water pump sprocket. Belt ten-
sion is correct if belt can be twisted 90 degrees. Tighten
water pump bolts to specification. Complete installation
in reverse order of removal. Adjust drive belts to proper
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
52
AUDI
2.3L 5-Cylinder Exc. Coupe Quattro (Cont.)
Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
Fig. 2: Aligning Camshaft Sprocket
96E14641 Courtesy of Audi of America, Inc.
53
AUDI
*2.7L V6 DOHC, S4 Quattro
2.7L V6
S4 Quattro
2000...................... 4.2 Hours .................. 250297
For 2000 model vehicles, manufacturer recommends belt be
replaced at 105,000 miles.
TIMING BELT
CAUTION: Before removal, mark an arrow indicating direc-
tion of rotation on accessory drive belt or timing belt. Damage
may result if belts are installed in opposite direction of rotation.
Removal:
Disconnect negative battery cable. Remove noise insula-
tor. See Fig. 1.
Fig. 2: Removing Front Bumper (Up To VIN 8DXA200000;
Later Models Similar)
Fig. 3: Removing Inner End Of Air Inlet Grill
Fig. 1: Removing Noise Insulation
On VIN up to 8DXA200000, remove bumper by removing
Torx screws at wheel housing liner, and air inlet grill at
bumper by disengaging tabs at top and bottom using a
screwdriver. see Fig. 2. Remove inner end of air inlet grill
first. See Fig 3. Remove combination bolts. Unclip bumper
from bracket and remove toward front.
On VIN 8DXA200001 and forward, remove bumper by re-
moving bolt with washer, impact absorber and hex bolts.
Remove Torx screws at wheel housing liner, and air inlet
grill at bumper by disengaging tabs at top and bottom us-
ing a screwdriver. Remove inner end of air inlet grill first.
See Fig. 3. Remove bolt and washer assembly. Unclip
bumper from bracket and remove toward front.
Move lock carrier to service position by removing 3 quick
release screws on front of noise insulation panel. See Fig.
4. Unbolt air guide between lock carrier and air cleaner at
lock carrier. If installed, remove retaining clamps for wiring
harness on left side of radiator frame. Remove bolt and
install Support Tool (3369) into left bore. Remove bolts.
Remove bolts and pull lock carrier out to stop. To secure
lock carrier, install appropriate M6 bolts into rear bored holes
of lock carrier and fender bore.
Remove viscous fan using Pin Wrench (3212) to hold fan.
See Fig. 5.
NOTE: Viscous fan has left-hand threads.
CAUTION: Mark the direction of rotation of the accessory drive
belt with chalk or felt pen before removing. A used belt can break
if it rotates in the opposite direction when reinstalled.
Loosen accessory drive belt by using a 17 mm wrench to
turn to the right until two holes are aligned. Hold in position
with Mandrel (3204). Remove accessory drive belt. See
Fig. 6.
Unscrew bolts and remove center engine cover panel. Re-
move pressure hoses between charge air coolers and pres-
sure pipes on left and right sides. See Fig. 7. Remove
pressure pipes, noting installed position of retaining strips.
Remove timing belt tensioner 1. Remove left and right
timing belt guards 2 and center guard 3. See Fig. 8.
Rotate crankshaft by hand to TDC. Ensure notch A is
aligned with notch B. See Fig. 9. Check position of cam-
shafts. Ensure that the larger holes in the securing plates
on the camshaft sprockets must face one another on the
inside. See Fig. 15. If this is not the case rotate crankshaft
one revolution more.
Courtesy Of Audi Of America, Inc.
54
AUDI
*2.7L V6 DOHC, S4 Quattro (Cont.)
Fig. 4: Moving Lock Carrier To Service Position
Fig. 5: Removing Viscous Fan
Fig. 6: Loosening Accessory Drive Belt
Fig. 7: Removing Pressure Hoses
Remove sealing plug from left side of cylinder block. The
TDC mark in crankshaft must be visible (or be able to be
felt) in line with sealing plug hole.
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
could result.
Screw Crankshaft Holding Tool (Audi 3242) into sealing
plug and tighten. See Fig 10. Remove crankshaft vibration
damper. See Fig. 11.
NOTE: The center bolt does not have to be loosened to remove
the vibration damper.
Remove idler wheel for accessory drive belt and timing belt
guard behind vibration damper. See Fig. 12.
Using a hex key, turn timing belt tensioner clockwise 8 mm
in direction of arrow. See Fig. 13. Turn until tensioning lever
compresses the oil-damped tensioner element enough to
enable Pin (T40011) to be fitted through holes in tensioner
housing and plunger. This will secure tensioner plunger in
place. Remove timing belt.
Installation:
Insert Camshaft Locator Bar (3391) into securing plates of
the two camshafts. See Fig. 15. Loosen both camshaft
bolts and unscrew approximately 5 turns. Remove Cam-
shaft Locator Bar (3391). Loosen, but do not remove, both
camshaft sprockets with Gear Puller (T40001). See Fig.
14. Reinstall both camshaft sprockets with securing plates
and tighten hand tight.
NOTE: Camshaft sprockets should be just tight enough on the
camshaft tapers so that they can still be turned but do not move
axially (up and down).
55
Fig. 10: Using Crankshaft Holding Tool
AUDI
Fig. 8: Removing Accessory Drive Belt Tensioner
Fig. 11: Removing Vibration Damper
Position timing belt over camshaft sprockets. See Fig. 16.
With large holes in camshaft securing plates facing in-
board, install Camshaft Locator Bar (3391) on camshafts.
Using hex key, turn timing belt tensioner clockwise 8 mm
until pin can be removed. See Fig. 13. Use a torque wrench
to pre-tension timing belt by turning clockwise with a torque
of 11 ft. lbs. (15 N.m). Tighten bolts on camshaft sprockets
to specification. See TORQUE SPECIFICATIONS.
Remove crankshaft holding tool from side of engine block.
Install sealing plug. Remove camshaft locator bar. Install
the accessory drive belt idler wheel and timing belt guard
behind vibration damper. Install vibration damper. Note the
position of locating lugs on belt sprocket.
Install accessory drive drive belt. Install lock carrier to body.
Ensure lock carrier aligns correctly with fender and install
Torx bolts. See Fig. 18. Install bumper. To complete instal-
lation, reverse removal procedure. Tighten all nuts and bolts
Bumper Combination Bolts............................................ 17 (23)
Crankshaft Damper Center Bolt ...........................
1
147 (200)
Idler Wheel Bolt ............................................................ 33 (45)
Impact Absorber Hex Bolts ............................................. 33 (45)
Lock Carrier-
To-Body Support (Hex) Bolts ........................................ 33 (45)
INCH Lbs. (N.m)
Bracket Combination Bolts ........................................... 14 (1.5)
Lock Carrier-
To-Fender Torx Bolts ................................................... 89 (10)
1 -
Plus 190 degrees. Always use new bolt.
56
Fig. 13: Using Hex Key To Compress Timing Belt Tensioner
AUDI
Fig. 12: Removing Timing Belt Guard
Fig. 14: Removing Camshaft Sprockets With Gear Puller
Fig. 16: Installing Timing Belt On Sprockets
Fig. 17: Routing Accessory Drive Belt Properly
Fig. 15: Installing Camshaft Locator Bar
Fig. 18: Locating Lock Carrier To Body
57
AUDI
*2.7L V6 DOHC, A6 Quattro & Allroad
2.7L V6, Twin Turbo (APB)
A6 Quattro
2000...................... 5.3 Hours .................. 250297
Allroad
2000...................... 5.2 Hours .................. 250297
For 2000 model vehicles, manufacturer recommends belt be
replaced at 105,000 miles.
TIMING BELT
Fig. 2: Removing Front Bumper
Fig. 1: Removing Noise Insulator
Removal:
tor. See Fig. 1.
Remove front wheels. Loosen front half of wheelhousing
and unscrew flanged nuts on both sides. Remove screw/
washer assembly from wheelhouse liner. Remove socket-
head bolts and remove bumper cover (together with impact
absorber) toward front. See Fig. 2.
Move lock carrier to service position by removing intake air
duct between lock carrier and air cleaner housing at lock
carrier. On right side, remove bolt and install Support Tool
(3369) into right bore. See Fig. 3. On left side, install Sup-
port Tool (3369) into threaded hole. Remove bolts on left
and right. See Figs. 3 and 4.
Remove bolts and pull lock carrier forward until rear hole in
lock carrier aligns with front threaded hole in fender flange.
Secure lock carrier using bolts. See Fig. 5.
NOTE: Viscous fan has left-hand threads.
Remove viscous fan using spanner wrench or Pin Wrench
(3212) to hold fan. See Fig. 6.
58
Fig. 4: Inserting 3369 Support Tool
AUDI
*2.7L V6 DOHC, A6 Quattro & Allroad (Cont.)
CAUTION: Mark the direction of rotation of the accessory drive
belt with chalk or felt pen before removing. A used belt can break
if it rotates in the opposite direction when reinstalled.
Loosen accessory drive belt by using a 17 mm wrench to
turn to the right until two holes are aligned. Hold in position
with Mandrel (3204). Remove accessory drive belt. See
Fig. 7.
Unscrew bolts and remove center engine cover panel. Re-
move pressure hoses between charge air coolers and pres-
sure pipes on left and right sides. See Fig. 8. Remove
turbocharger pressure pipes.
NOTE: Take note of the position of retaining strips.
Remove accessory drive belt tensioner 1. Remove left
and right timing belt guards 2 and center guard 3. See
Fig. 9.
Rotate crankshaft by hand to TDC. Ensure notch A is
aligned with notch B. See Fig. 10. Check position of cam-
shafts. Ensure that the larger holes in the securing plates
on the camshaft sprockets must face one another on the
inside. If this is not the case rotate crankshaft one revolu-
tion more.
Fig. 5: Securing Lock Carrier
Fig. 6: Removing Viscous Fan
Fig. 7: Loosening Accessory Drive Belt
Fig. 8: Removing Pressure Hoses
59
AUDI
Fig. 9: Removing Accessory Drive Belt Tensioner
Fig. 12: Removing Vibration Damper
Fig. 13: Removing Accessory Drive Belt Idler Wheel
Remove sealing plug from left side of cylinder block. See
Fig 11. The TDC mark in crankshaft must be visible (or be
able to be felt) in line with sealing plug hole.
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
could result.
Screw Crankshaft Holding Tool (Audi 3242) into sealing
plug and tighten. See Fig 11. Remove vibration damper.
See Fig. 12.
NOTE: The center bolt does NOT have to be loosened to remove
the vibration damper.
Remove idler wheel for accessory drive belt. Remove tim-
ing belt guard behind vibration damper. See Fig. 13.
Using a hex key, turn timing belt tensioner clockwise 8 mm
in direction of arrow. See Fig. 14. Turn until tensioning lever
compresses the oil-damped tensioner element enough to
enable Pin (T40011) to be fitted through the holes in the
tensioner body and the plunger. This will secure plunger in
position. Remove timing belt.
Installation:
Insert Camshaft Locator Bar (3391) into securing plates of
the two camshafts. See Fig. 16. Loosen both camshaft
bolts and unscrew approximately 5 turns.
60
Fig. 14: Using Hex Key To Compress Timing Belt Tensioner
AUDI
*2.7L V6 DOHC, A6 Quatto & Allroad (Cont.)
Fig. 15: Removing Camshaft Sprockets With Gear Puller
Fig. 18: Routing Accessory Drive Belt
Remove Camshaft Locator Bar (3391). Loosen, but do not
remove, both camshaft sprockets with Gear Puller (T40001).
See Fig. 15.
NOTE: Camshaft sprockets should be just tight enough on the
camshaft tapers so that they can still be rotated, but do not move
axially (up and down).
Reinstall both camshaft sprockets with securing plates and
tighten hand tight.
Install Camshaft Locator Bar (3391) on camshafts. Using
hex key, turn timing belt tensioner clockwise 8 mm until pin
can be removed from tensioner. See Fig. 14.
Pre-tension timing belt by turning tensioner pulley center
bolt clockwise with a torque of 11 ft. lbs. (15 N.m). Tighten
bolts on camshaft sprockets to specification. See TORQUE
SPECIFICATIONS.
Remove camshaft locator bar. Remove crankshaft holding
tool. Install plug in engine block. Install timing belt guards.
Install accessory drive belt idler wheel behind crankshaft
pulley. Install crankshaft pulley. Note position of locating
lugs on crankshaft pulley.
Install accessory drive belt. See Fig. 18. Install viscous fan.
Install lock carrier to body. Ensure lock carrier-to-fender
Torx bolts are installed correctly. See Fig. 5.
Install bumper. Install turbocharge pressure pipes and
hoses. Install engine cover. Install noise insulator.
61
AUDI
Bumper Combination Bolts ............................................ 17 (23)
Camshaft Pulley-To-Sprocket Bolt .............................. 40 (55)
Crankshaft Damper Center Bolt
1
Step 1 ....................................................................... 147 (200)
Step 2 ......................................................... Plus 180 Degrees
Crankshaft Pulley-To-Sprocket Bolt ............................ 15 (20)
Idler Wheel Bolt ............................................................ 33 (45)
Impact Absorber Hex Bolts ............................................. 33 (45)
Lock Carrier-To-Body Hex Bolt ....................................... 37 (50)
Viscous Fan ................................................................... 52 (70)
INCH Lbs. (N.m)
Lock Carrier-To-Fender Torx Bolt ................................... 89 (10)
Timing Belt Tensioner Bolt .......................................... 89 (10)
Water Pump Bolt ............................................................ 89 (10)
1
ALWAYS replace bolt if loosened or removed.
62
AUDI
*2.8L V6 12-Valve
2.8L V6
A4
1996-97................. 2.5 Hours .................. 250218
A4 Quattro
1996-97................. 2.5 Hours .................. 250218
A6
1995-97................. 2.5 Hours .................. 250218
A6 Quattro
1995-97................. 2.5 Hours .................. 250218
Cabriolet
1994-98................. 2.5 Hours .................. 250218
90 & 90 Quattro
1993-95................. 2.5 Hours .................. 250218
100 & 100 Quattro
1992-94................. 2.5 Hours ................. 250218
For 1997-98 model vehicles, manufacturer recommends belt
be replaced at 90,00 miles. For 1996 and earlier model years,
the manufacturer does not recommend a specific scheduled
maintenance interval. However, belt manufacturers suggest
*NOTE: This is application is an interference engine.
TIMING BELT
Removal:
belt guard. Hold accessory drive belt in place with Mandrel
(3204). Using a 15-mm wrench at accessory drive belt
tensioner, slacken and remove accessory drive belt.
Rotate crankshaft by hand until cylinder No. 3 is at TDC.
Ensure notch A is aligned with notch B. See Fig. 1. Note
locating plate on front end of each camshaft sprocket. If
large hole in each plate does not face inward, toward cen-
ter of engine, rotate crankshaft one revolution.
Remove Crankshaft Position (CKP) sensor from left side
of cylinder block, behind oil filter and above oil pan. Insert
finger in CKP sensor hole. TDC hole in crankshaft should
be felt. Install Crankshaft Holding Tool (Audi 3242) in CKP
sensor hole. See Fig. 3. Lightly tighten crankshaft holder.
Remove crankshaft vibration damper. Remove lower tim-
ing belt guard. Install Camshaft Holding Tool (Audi 3243).
See Fig. 4. Loosen camshaft sprocket bolts about 3 turns.
DO NOT remove bolts. Remove camshaft holder. Using
puller, loosen camshaft sprockets. Loosen and remove
timing belt.
NOTE: Camshaft sprockets must be loose enough to rotate on
camshaft, but not loose enough to tilt.
Installation:
Install camshaft holder. Position timing belt over all sprock-
ets, then position over tensioner. Lightly tighten tensioner
bolt (ensure tensioner can be rotated by hand).
Tighten belt by rotating tensioner on bolt. Tighten belt until
it can be twisted 90 degrees by hand at midway point be-
tween right camshaft sprocket and water pump pulley.
Tighten tensioner bolt to specification. See TORQUE SPECI-
FICATIONS.
Tighten camshaft sprocket bolts to specification. Remove
Camshaft Holding Tool. Remove Crankshaft Holding Tool.
Install Crankshaft Position (CKP) sensor. To install acces-
sory drive belt, install mandrel. Position accessory drive
belt over drive sprockets and idler roller, then over tensioner
roller. Remove mandrel. To complete installation, reverse
63
AUDI
*2.8L V6 12-Valve (Cont.)
Fig. 4: Using Camshaft Holding Tool
Camshaft Bearing Cap Nut ........................................ 11 (15)
Crankshaft Damper Bolt ......................................... 295 (400)
INCH Lbs. (N.m)
Crankshaft Position Sensor (CKP) ............................. 96 (10)
Valve Cover Bolt .................................................. 53-89 (6-10)
64
AUDI
*2.8L V6 30-Valve
2.8L V6, 30-Valve (AHA & ATQ Engines)
A4 & A4 Quattro
1998-99................. 4.2 Hours .................. 250297
A6 & A6 Quattro, Non-Turbo
1998-00................. 4.6 Hours .................. 250297
A6 & A6 Quattro, Turbo
1998-00................. 5.2 Hours ................. 250297
mile intervals for 1997-98 models, 75,000 mile intervals for
1999 models, and 105,000 miles on 2000 models.
TIMING BELT
NOTE: Obtain radio anti-theft code before disconnecting battery.
Removal
Disconnect negative battery cable. Remove engine top cover.
Remove noise insulation panel from under front of vehicle.
Remove front bumper. See Figs. 1 and 2. Remove air in-
take duct from air cleaner housing. On right side of lock
carrier, remove bolt and install Lock Carrier Support Tool
(3369). See Figs. 3, 4 and 5. Remove lock carrier-to-body
bolts. Carefully slide lock carrier forward on support tool.
Hold cooling fan pulley with spanner wrench. Unscrew and
remove viscous cooling fan clutch from pulley. Viscous cool-
ing fan is LEFT-HAND threaded.
Fig. 1: Exploded View Of A4 Bumper Assembly
Fig. 2: Exploded View Of A6 Bumper Assembly
Use a 17 mm box wrench to turn serpentine belt tensioner
counterclockwise to relieve belt tension and remove ser-
pentine belt. If reusing belt, mark belt rotation direction with
arrow for reassembly reference.
Unclip timing belt guard on front of both camshafts and
remove. Turn crankshaft in normal direction of rotation until
TDC marks on crankshaft pulley and timing belt cover are
aligned. See Fig. 6.
Note securing plate on front end of each camshaft sprocket.
If large hole in each plate does not face inward, toward
center of engine, rotate crankshaft one revolution. See Fig.
7. Ensure crankshaft timing marks are still aligned.
Remove sealing plug from left side of engine block. TDC
mark on crankshaft must be visible or be felt through seal-
65
AUDI
Fig. 5: Positioning Lock Carrier Support Tool (3369)
ing plug hole. Install Crankshaft Holding Tool (Audi 3242)
into sealing plug hole. See Fig. 8.
Remove serpentine belt tensioner. Remove center and left
timing belt covers.
Using an 8 mm hex wrench, SLOWLY turn timing belt
tensi oner pul l ey cl ockwi se to compress ti mi ng bel t
tensioner. See Fig. 9. Compress timing belt tensioner just
enough so that a 2 mm pin can be inserted through the
holes in top of tensioner body and push rod. This will hold
the tensioner in the compressed position.
CAUTION: If reusing old timing belt, mark an arrow indicating
direction of rotation on accessory drive belt or timing belt. Damage
Remove crankshaft vibration damper from crankshaft. It is
NOT necessary to remove center bolt. If center bolt is re-
moved, manufacturer recommends using NEW bolt on re-
assembly. Remove serpentine belt idler pulley.
Remove lower timing belt guard (if equipped). Remove tim-
ing belt.
Installation:
Install Camshaft Locator Bar (3391) into locking plates of
camshafts. See Fig. 10. Loosen camshaft sprocket bolts
about 5 turns. Remove locator bar. Leaving camshaft
sprocket bolts in place, use gear puller to loosen camshaft
sprockets on camshaft taper.
NOTE: Camshaft sprockets must be loose enough to rotate on
camshaft, but not loose enough to tilt.
Ensure all timing marks are still aligned. Install timing belt
on engine. Ensure belt routing is correct and there is no
slack in belt. See Fig. 11. Install Camshaft Locator Bar
(3391) into locking plates of camshafts.
Using an 8 mm hex wrench, SLOWLY compress timing
belt tensioner so that 2 mm pin can be removed from
tensioner.
Using 8 mm hex socket, place torque wrench on timing belt
tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in
direction of tension (clockwise). This will preload belt ten-
sion.
Tighten camshaft sprocket bolts to specification. See
TORQUE SPECIFICATIONS. Remove camshaft locator bar.
Remove crankshaft holder. Install sealing plug. To com-
plete installation, reverse removal procedure. When install-
ing crankshaft pulley, ensure notches in pulley are aligned
with locating lugs in crankshaft. On A4, A6 and Quattro mod-
els, ensure lock carrier-to-body Torx bolts are correctly po-
sitioned. See Fig. 12.
66
AUDI
Fig. 8: Installing Crankshaft Holding Tool
Fig. 7: Locating Camshaft Sprocket Holes
Fig. 11: Timing Belt Routing
Fig. 12: Positioning Lock Carrier Torx Bolts
Crankshaft Pulley-To-Crankshaft Hex Bolt ..................... 15 (20)
Crankshaft Pulley
Center Bolt ...................................
1
148 (200) + 180 Degrees
Lock Carrier-To-Body Bolts ........................................... 37 (50)
Timing Belt Idler Pulley Bolt ........................................... 33 (45)
Timing Belt Tensioner Center Bolt .............................. 15 (20)
INCH Lbs. (N.m)
Timing Belt Tensioner Bolt/Nut ................................... 89 (10)
Water Pump Bolt ........................................................ 89 (10)
1
If removed, manufacturer recommends using NEW bolt.
67
AUDI
3.6L & 4.2L V8 1990-94
3.6L V8 (PT Engine)
V8 Quattro
1990-91................. 4.3 Hours .................. 250207
4.2L V8 (ABH Engine)
V8 Quattro
1992-94................. 4.3 Hours ................. 250207
The manufacturer recommends belt be replaced at 60,000
miles on 3.6L engines, and 90,000 miles on 4.2L engines.
Replacement interval revision is from Audi technical service
bulletin 93-02, September 1, 1993.
TIMING BELT
CAUTION: If serpentine or timing belt is being reused, mark belt
with an arrow indicating direction of rotation. Damage may
result if belts are installed in opposite direction of rotation.
Fig. 1: Exploded View Of Serpentine Belt Assembly
Removal:
Disconnect negative battery cable. Battery is under rear
seat. Remove noise insulation panel from under front of
vehicle. Remove coolant expansion tank cap. Drain cool-
ant from radiator. Remove alternator cooling air duct. See
Fig. 2. Loosen clip and disconnect coolant temperature
sensor harness connector.
Disconnect outer half of air duct at alternator. Remove
screws securing wiring harness at alternator. Using 13
mm box wrench, turn serpentine belt tensioner clockwise
to relieve tension. See Figs. 1 and 3. Remove alternator
and set aside.
Working from under vehicle, remove lower timing belt cover.
In engine compartment, remove bolt securing intake air
ducts. Remove left and right side intake air ducts. Remove
upper part of air cleaner housing and air filter.
Remove bolts securing lower part of air cleaner housing.
Lift out lower part of air cleaner housing. Remove upper
radiator hose. Remove electric cooling fan bolts. See Fig.
4. Remove electric cooling fan. Remove serpentine belt.
Remove lower radiator hose from thermostat housing. Move
lower radiator hose to right at rear. Remove viscous fan
shroud. Remove bolts securing viscous fan to pulley and
remove fan.
Disconnect fan shrouds for viscous fan and electric fan.
Hold viscous cooling fan mount with a spanner wrench.
Loosen viscous cooling fan by turning clockwise. Viscous
cooling fan is LEFT-HAND threaded. See Fig. 5. Lift out fan
and shroud.
68
AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Fig. 4: Removing Electric Cooling Fan
Fig. 2: Locating Coolant Temperature Sensor
Remove front engine support mount. Note number and
position of shims for reassembly. Remove lower radiator
hose. Loosen center bolt of cranshaft pulley one turn while
using Crankshaft Pulley Holder (3197). See Fig. 6.
Remove flanged nuts and left side timing belt cover. See
Fig. 7. Remove lower radiator hose support from front of
engine.
Turn serpentine belt tensioner clockwise and insert Set-
ting Tool (3204) below mounting bolt. See Fig. 9. Remove 2
lower mounting bolts from right side timing belt cover. Do
not loosen upper mounting bolt yet. Remove Setting Tool
(3204). Remove top mounting bolt from right side timing
belt cover. Remove right side timing belt cover.
Noting positions for reassembly, disconnect ignition sec-
ondary wires at ignition coils. Remove both ignition dis-
tributor caps.
Rotate crankshaft to TDC of compression stroke. Ensure
TDC mark on crankshaft pulley aligns with mark on timing
belt cover. See Fig. 10.
Fig. 3: Removing Serpentine Belt
Fig. 5: Removing Viscous Cooling Fan (Left-Hand Threads)
Fig. 6: Loosening Crankshaft Pulley Center Bolt
69
AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Fig. 7: Removing Left Side Timing Belt Cover
Fig. 8: Exploded View Of Timing Belt Assembly
Fig. 9: Positioning Serpentine Belt Tension
Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.
70
AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Ensure distributor rotor points to mark on distributor hous-
ing. If not, turn crankshaft one more revolution. See Fig. 11.
Remove both distributors.
For 3.6L engine, loosen stop plate at timing belt tensioner.
See Fig. 12. On 3.6L and 4.2L engines, loosen center bolt
on tensioner pulley with eccentric center (right side of en-
gine block). See Fig. 13. Remove timing belt damper top
bolt. Remove timing belt tensioner pulley with eccentric
center.
Fit Locating Flange (3199) at end of each camshaft. Locat-
ing pin on distributor flange should fit in slot in locating
Fig. 10: Aligning Crankshaft Pulley Timing Marks
Fig. 11: Aligning Distributor Rotor To Housing
Fig. 14: Positioning Camshafts With Locating Flange (3199)
Fig. 13: Timing Belt Tensioner With Eccentric Center
Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate
(3.6L Engine)
flange. See Fig. 14. Secure locating flange with distributor
mounting bolts.
Using spanner wrench, hold camshaft sprocket. Loosen
camshaft sprocket bolts about 2 turns. DO NOT use Locat-
ing Flange (3199) to hold camshaft while loosening sprocket
bolt.
Using a plastic hammer, LIGHTLY tap edge of camshaft
sprockets until camshaft sprockets are loose. Remove
camshaft sprocket Woodruff keys.
71
AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Fig. 16: Rotate Tensioner Lever In Direction Of Arrow
Fig. 17: Setting Timing Belt Damper Length
Remove 4 bolts fastening crankshaft pulley to crankshaft
sprocket. Remove crankshaft center bolt and remove crank-
shaft pulley. It is not necessary to remove sprocket from
crankshaft. Remove timing belt.
Inspection:
Inspect tensioner and idler pulley for ease of rotation and
rough bearings. Replace as necessary.
Installation:
Ensure crankshaft is still at TDC position. Place timing
belt over crankshaft sprocket. Install crankshaft pulley on
crankshaft. Install 4 bolts that hold crankshaft pulley to
sprocket. Hand tighten temporarily.
Apply locking sealant (AMV 188 0012), or equivalent, to crank-
shaft center bolt threads. Install crankshaft pulley center
bolt and hand tighten temporarily.
Loosen camshaft sprocket center bolts by about 1 turn.
Camshaft sprocket should still be loose on camshaft. In-
stall Vibration Damper Locking Tool (3211). If there is no
hole to accept Vibration Damper Locking Tool, ensure TDC
mark on vibration damper is aligned with pointer before
and after tightening camshaft sprockets.
Position timing belt in position over idler pulleys, water
pump pulley and camshaft sprockets. Install tensioner pul-
ley with eccentric center. Leave center nut loose so that
eccentric can be turned. Fully tighten 4 crankshaft pulley
On 3.6L engine, insert Adjusting Tool (3204) into tensioner
lever so that tool engages recess on back of stop plate.
See Fig. 15. Firmly press tensioner lever once by hand
clockwise. See Fig. 16.
On 3.6L and 4.2L engines, set basic timing belt tension by
turning tensioner pulley with eccentric center in clockwise
direction. Use spanner wrench to turn eccentric. Turn ec-
centric until damper length is at specified dimension. See
Fig. 17. Tighten tensioner pulley center nut to specification.
See TORQUE SPECIFICATIONS table.
Holding camshaft sprockets in place, tighten camshaft
sprocket center bolts to specification. Remove camshaft
Locating Flanges (3199). Turn crankshaft at least 2 turns.
Tighten crankshaft pulley center bolt to specification.
Ensure timing belt damper length is still correct. Readjust,
if necessary. On 3.6L engine, tighten stop plate mounting
bolt to specifcation. See TORQUE SPECIFICATIONS table.
Remove Adjusting Tool (3204).
On 3.6L and 4.2L engines, complete installation reverse
removal procedure. When refilling cooling system, manu-
facturer recommends using Audi anti-freeze (Part No. G
001 1V8A). Use 50/50 mix of coolant and water.
To bleed air from cooling system, turn on ignition with en-
gine off. Set A/C controls to high. Open radiator expansion
tank. Fill with coolant while squeezing upper hoses to al-
low trapped air to escape. Install expansion tank cap.
Start and run engine between 2000-3000 RPM until warm.
With A/C still on high, raise engine RPM to 4000-5000 RPM
several times. Coolant temperature gauge must read just
under 212F (100C). Turn off ignition. After about 5-10
minutes, carefully open expansion tank cap. Top off cool-
ant level to MAX mark. Restart engine and repeat topping
off procedure. Adjust drive belts to proper tension. See page
A-60 for belt tension information.
Alternator Bottom Mount Bolt .......................................... 18 (25)
Alternator Top Mounting Bolt ........................................... 33 (45)
Crankshaft Pulley Center Bolt .................................
1
332 (450)
Crankshaft Pulley-To-Sprocket Bolts .............................. 18 (25)
Engine Front Support Mount Bolt .................................... 30 (40)
Serpentine Belt Idler Pulley Bolt ..................................... 18 (25)
Timing Belt Adjustment Damper Bolts ........................... 18 (25)
Timing Belt Damper Mount Bolt ..................................... 18 (25)
INCH Lbs. (N.m)
Fan Shroud Bolts ........................................................... 89 (10)
Stop Plate Mounting Bolt (3.6L) ..................................... 89 (10)
Timing Belt Cover Flanged Nut ...................................... 89 (10)
Water Pump Bolts ...................................................... 89 (10)
1
- Installwith thread locking sealant AMV 18800102.
72
AUDI
*3.7L & 4.2L V8 1997-99
3.7L V8 (AEW Engine)
A8
1997-99................. 4.3 Hours .................. 250207
4.2L V8 (ABZ Engine)
A8 Quattro
1997-99................. 4.3 Hours ................. 250207
For 1997 and 1998 model vehicles, manufacturer recom-
mends belt be replaced at 90,000 miles. For 1999 model
year, the manufacturer recommends the belt be replaced at
75,000 miles.
*NOTE: This is an interference engine. See page
A-59 for interference engine cautions.
TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark
belt with an arrow indicating direction of rotation. Damage
Fig. 1: Exploded View Of Serpentine Belt Assembly
Removal:
tion panel from under front of vehicle. Remove air intake
grille from front of bumper. Drain coolant from radiator.
Using box wrench, turn serpentine belt tensioner clock-
wise to relieve tension. Remove serpentine belt. See Fig.
1. Remove engine top trim cover. Remove coolant hose
retaining clamp on right side upper timing belt cover.
Remove air intake duct between air cleaner and throttle
body. Disconnect fan shrouds for viscous fan and electric
fan.
Hold viscous cooling fan pulley with a spanner wrench.
Remove viscous fan by turning clockwise. Viscous fan is
LEFT-HAND threaded. See Fig. 2.
Remove right front engine mount. See Fig. 3. Remove cool-
ant hoses at front of engine. Rotate crankshaft to TDC of
compression stroke. Ensure TDC mark on crankshaft pul-
ley aligns with mark on timing belt cover. See Fig. 4.
CAUTION: Manufacturer recommends that crankshaft pulley
center bolt be REPLACED whenever the bolt is loosened or removed.
Holding crankshaft pulley with Crankshaft Pulley Holder
(3197), loosen center bolt about 1 turn. See Fig. 5. Remove
camshaft position sensor at housing at rear of left cylinder
head. See Fig. 6. If camshaft sensor is NOT positioned
behind sensor plate window, rotate crankshaft 1 full revolu-
tion. Remove camshaft flange at rear of right side cylinder
head.
73
AUDI
*3.7L & 4.2L V8 1997-99 (Cont.)
Fig. 4: Aligning Crankshaft Pulley TDC Marks
Disconnect harness connector from switch for intake mani-
fold change-over valve. Remove timing belt guard. Unclip
cap at guide pulley for serpentine belt at right side timing
belt guard. Remove top of air cleaner housing. Remove
right side timing belt guard mounting bolts. Carefully lift
right side timing belt guard up and out.
Holding camshaft sprocket with Sprocket Holder (3036),
loosen camshaft sprocket bolts. See Fig. 7. Remove cam-
shaft position sensor plate and housing. See Fig. 6. Install
Camshaft Locking Device (3341) at rear of each cylinder
head. If necessary, rotate camshaft to allow locking device
to engage. See Fig. 8. Camshafts can be rotated by remov-
ing the valve cover and using the hex machined into the
front end of the camshaft.
CAUTION: The Camshaft Locking Devices (3341) are NOT to be
used to hold camshafts in place when loosening or tightening
the camshaft sprocket bolts.
Using spanner wrench, hold timing belt tensioner pulley.
Loosen tensioner pulley center nut. See Figs. 9 and 10.
Turn tensioner pulley to relieve timing belt tension.
Remove timing belt from camshaft sprockets. LIGHTLY
strike edge of camshaft sprockets with plastic hammer to
loosen sprocket from tapered ends of camshafts.
Fig. 3: Removing Right Front Engine Mount
Fig. 5: Loosening Crankshaft Pulley Center Bolt
Fig. 6: Camshaft Position Sensor & Housing
Fig. 7: Loosening Camshaft Sprocket Bolts
74
AUDI
*3.7L & 4.2L V8 1997-99 (Cont.)
Fig. 8: Installing Camshaft Locking Device (3341)
Fig. 9: Exploded View Of Timing Belt Assembly
Fig. 10: Locating Timing Belt Tensioner Pulley
75
Remove 4 bolts fastening crankshaft pulley to crankshaft
sprocket. Remove crankshaft center bolt and remove crank-
shaft pulley. It is not necessary to remove sprocket from
crankshaft. Remove timing belt.
Installation:
belt over crankshaft sprocket. Install crankshaft pulley on
crankshaft. Install 4 bolts that hold crankshaft pulley to
sprocket. Hand tighten temporarily.
CAUTION: Manufacturer recommends that crankshaft pul-
ley center bolt be REPLACED whenever the bolt is loos-
ened or removed.
Lightly oil threads and contact surfaces of NEW center bolt.
Using locking compound AMV 00102, or equivalent, install
crankshaft pulley center bolt and hand tighten temporarily.
Loosen camshaft sprocket center bolts by about 1 turn.
Camshaft sprocket should still be loose on camshaft tapers.
Position timing belt in position over idler pulleys, water
pump pulley and camshaft sprockets. See Fig. 9.
Push timing belt over tensioner pulley. Tighten tensioner
pulley center nut hand tight. Eccentric insert should still be
able to turn.
Tighten 4 crankshaft pulley-to-crankshaft sprocket mount-
ing nuts. See TORQUE SPECIFICATIONS.
To set basic timing belt tension, turn tensioner pulley ec-
centric insert clockwise. Use a spanner wrench inserted
into the 2 holes in the eccentric insert. Adjust position of
timing belt tensioner until damper length is within speci-
fied range. See Fig. 11.
Tighten timing belt tensioner center nut to specification.
See TORQUE SPECIFICATIONS. Holding camshaft sprock-
ets in place, tighten camshaft sprocket center bolts to speci-
fication.
Remove Camshaft Locking Device (3341) from rear of each
camshaft. Install housing behind camshaft position sen-
sor and tighten bolts to specification. Camshaft position
sensor plate MUST engage in camshaft with catch.
Turn crankshaft at least 2 revolutions in normal direction of
rotation. Tighten crankshaft center bolt to specification.
Check timing belt damper length. Readjust timing belt ten-
sion, if necessary.
To complete installation, reverse removal procedure. When
refilling cooling system, use Audi coolant additive G12-A8D
TL 774D (Red color). Use 50/50 mix of coolant and water.
Before filling cooling system, open vent screws at heater
core feed and return lines (rear of engine). Remove cap
from radiator expansion tank. Add coolant until it flows from
vent valves. Close vent valves. Install cap on radiator ex-
pansion tank.
Disconnect 2-pin electrical connector from coolant pump
unit. Coolant pump unit is located in left rear corner of en-
gine compartment, near power brake booster.
Fig. 11: Adjusting Timing Belt Damper Length
AUDI
*3.7L & 4.2L V8 1997-99 (Cont.)
Set A/C controls to LO position. Start engine and run at
about 2000 RPM for about 3 minutes. Check coolant level
in radiator expansion tank. Refill to MAX level, if necessary.
Turn off ignition. Reconnect coolant pump 2-pin connector.
Set A/C controls to HI position, and blower motor to lowest
setting. Start and run engine at 2000-3000 RPM for about
10 minutes. Turn off ignition. Turn ignition on, with engine
off.
With ignition on, and A/C controls set to HI, coolant pump
must NOT make any noise. Noise indicates that air is
trapped in system and bleed procedure needs to be re-
peated. If there are no unusual noises from coolant pump,
turn off ignition. Refill radiator expansion tank.
Camshaft Position Sensor Housing Bolt ................... 15 (20)
Crankshaft Pulley Center Bolt .................................
1
332 (450)
Timing Belt Adjustment Damper Bolts ........................... 18 (25)
INCH Lbs. (N.m)
Timing Belt Cover Flanged Nut ...................................... 89 (10)
Water Pump Bolts ...................................................... 89 (10)
1
- Use NEW bolt if loosened or removed. Oil threads. Install
with thread locking compound AMV 00102, or equivalent.
76
Fig. 3: Aligning Camshaft Sprocket Securing Plate Holes
AUDI
*4.2L V8 2000
4.2L V8 (AKB, AUX & AYS Engines)
A8 Quattro
2000...................... 4.3 Hours ................. 250297
The manufacturer recommends belt be replaced at 105,000
miles.
TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark
belt with an arrow indicating direction of rotation. Damage
Removal:
Remove trim cover at front of engine compartment. Re-
move air intake duct for air cleaner. Remove engine top
trim cover and cylinder head trim covers. Disengage spring
clips at timing belt covers. Remove timing belt covers. Re-
move noise insulation panel from under front of vehicle.
Using box wrench, turn serpentine belt tensioner clock-
wise to relieve tension. Remove serpentine belt.
Remove electric cooling fan. Remove viscous cooling fan
shroud. Hold viscous cooling fan pulley with a spanner
wrench. Remove viscous fan by turning clockwise. Vis-
cous fan is LEFT-HAND threaded. See Fig. 1.
Rotate crankshaft to TDC of compression stroke. Ensure
TDC mark on crankshaft pulley aligns with mark on engine.
See Fig. 2.
Check position of camshafts. Larger hole in camshaft
sprocket securing plates must face inboard and align with
each other. See Fig. 3.
Remove sealing plug from lower left side of engine block.
TDC drilling in crankshaft MUST be behind sealing plug
hole. Screw Crankshaft Clamping Bolt (3242) into hole.
See Fig. 4.
Remove serpentine belt tensioner from front of engine block.
Remove crankshaft pulley retaining bolts. It is NOT neces-
sary to remove center bolt. Remove crankshaft pulley.
Fig. 4: Locating Crankshaft Clamping Bolt (3242)
77
AUDI
*4.2L V8 2000 (Cont.)
CAUTION: Manufacturer recommends REPLACING crankshaft
pulley center bolt if it has been loosened or removed.
Remove bracket for viscous cooling fan. See Fig. 5.
Using 8 mm hex wrench, SLOWLY compress hydraulic tim-
ing belt tensioner by turning tensioning lever counterclock-
wise. See Fig. 6. Insert Spring Pin (T40011) through top of
timing belt tensioner and through hole in top of tensioner
piston.
Install Camshaft Bar (T40005) onto securing plates of both
camshafts. See Fig. 7.
Loosen both camshaft sprocket securing bolts about 5
turns. Remove Camshaft Bar (T40005). Using 2-jaw gear
puller, loosen camshaft sprockets so that they are free to
rotate, but not tilt, on the end of the camshaft.
Loosen center bolt of timing belt tensioner pulley with ec-
centric center. Tensioner pulley is located above and to the
right of crankshaft sprocket. Remove timing belt along with
camshaft sprocket for cylinders No. 1 through No. 4 (pas-
senger side cylinder head).
Fig. 7: Installing Camshaft Bar (T40005)
Fig. 8: Measuring Tensioning Lever-To-Piston Clearance
Fig. 6: Relieving Timing Belt Tension
Fig. 5: Viscous Cooling Fan Mounting Bracket
Installation:
belt over crankshaft sprocket, tensioner pulleys, camshaft
sprocket for cylinders No. 5 through No. 8, water pump
pulley and dampener pulley.
Hand tighten camshaft sprocket bolts. Camshaft sprock-
ets must be tight enough on camshaft tapers to be turned,
but should not tilt back and forth.
Attach Camshaft Bar (T40005) to camshafts. Insert a 5 mm
drill bit between the tensioning lever and the tip of the hy-
draulic tensioner piston.
Set initial timing belt tension using Tensioning Key
(T40009), Socket Attachment (5122) and Torque Wrench
(1410). See Fig. 9. Set tension to 35 INCH lbs. (4 N.m).
While holding tensioner at this point, tighten center nut to
16 ft. lbs. (22 N.m). Remove 5 mm drill bit.
Using 8 mm hex wrench, rotate timing belt tensioning lever
counterclockwise until Spring Pin (T40011) can be removed
from hydraulic tensioner.
Rotate timing belt tensioner lever CLOCKWISE until a 7
mm drill bit can be inserted between the tip of the tensioning
lever and the top of the hydraulic tensioner body. Tighten
camshaft sprocket bolts to specification. See TORQUE
SPECIFICATIONS. Keep Camshaft Bar (T40005) in place
to prevent camshafts from moving.
78
AUDI
*4.2L V8 2000 (Cont.)
Fig. 9: Setting Initial Timing Belt Tension
Fig. 10: Measuring Timing Belt-To-Guard Clearance
(Right-Side Cylinder Head)
Remove Camshaft Bar (T40005) after camshaft sprocket
bolts are tightened. Remove 7 mm drill bit. Remove Crank-
shaft Clamping Bolt (3242) from side of engine block. In-
stall sealing plug in hole. Turn crankshaft 2 revolutions in
normal direction of rotation.
Measure distance between tensioning lever and top of hy-
draulic tensioner body. Dimension should be .197 (5 mm).
See Fig. 8. If dimension is not correct, readjust timing belt
tension until dimension is .197 (5 mm).
Measure clearance between bottom of right hand timing
belt guard and top of timing belt. See Fig. 10. If clearance is
not correct, turn crankshaft until all rear timing belt cover
bolts are exposed. Loosen bolts and adjust clearance to
.0393 (1 mm). Tighten rear timing belt cover bolts.
Measure clearance between bottom of left hand timing belt
guard and top of timing belt. See Fig. 11. If clearance is not
correct, turn crankshaft until all rear timing belt cover bolts
are exposed. Loosen bolts and adjust clearance to .0393
(1 mm). Tighten rear timing belt cover bolts.
Install crankshaft pulley. Tighten all bolts to specification.
To complete installation reverse removal procedure.
Crankshaft Pulley Center Bolt
Step 1 .....................................................................
1
148 (200)
Step 2 ................................................. Plus 180 Degrees Turn
Timing Belt Tensioner Center Nut ................................ 16 (22)
Viscous Cooling Fan-To-Pulley ...................................... 52 (70)
Water Pump Bolts ...................................................... 10 (14)
INCH Lbs. (N.m)
Timing Belt Hydraulic Tensioner Bolts ........................... 89 (10)
Timing Belt Rear Cover Bolts ......................................... 89 (10)
Viscous Cooling Fan Bracket Mount Bolts ..................... 89 (10)
1
- Use NEW bolt if loosened or removed.
Fig. 11: Measuring Timing Belt-To-Guard Clearance
(Left-Side Cylinder Head)
79
AUDI & VOLKSWAGEN
2.1L & 2.2L 5-Cylinder, 1978-91
2.1L 5-Cyl.
Quantum
1984-85
.70 Belt T.W. ....... 1.8 Hours .................. 250127
.75 Belt T.W. ....... 1.8 Hours .................. 250065
2.2L 5-Cyl.
Coupe
1981-83 ................ 2.2 Hours .................. 250065
1984-85
120 Tooth Belt .... 2.2 Hours .................. 250127
113 Tooth Belt ..... 2.2 Hours .................. 250065
1986-87.................. 2.2 Hours .................. 250127
Quantum
1983-86
.70 Belt T.W. ....... 1.8 Hours .................. 250127
.75 Belt T.W. ....... 1.8 Hours .................. 250065
1987-88.................. 1.8 Hours .................. 250127
Quattro
1983....................... 1.1 Hours .................. 250065
1984-85
120 Tooth Belt .... 2.2 Hours .................. 250127
113 Tooth Belt ..... 2.2 Hours .................. 250065
200
1989
(Thru Chassis No.
44 K 400 000) ....... 2.5 Hours .................. 250127
(From Chassis No.
44 K 400 001) ....... 2.5 Hours .................. 250170
1990-91 ................ 2.5 Hours .................. 250170
200 Quattro
1989
(Thru Chassis No.
44 K 004 457) ....... 2.5 Hours .................. 250127
(From Chassis No.
44 K 004 458) ....... 2.5 Hours .................. 250170
1990-91.................. 2.5 Hours .................. 250170
4000
1980-81.................. 1.8 Hours .................. 250065
4000CS
1986-87.................. 1.8 Hours .................. 250127
4000CS Quattro
1987....................... 1.8 Hours .................. 250127
4000S Quattro
1984-85
120 Tooth Belt .... 1.8 Hours .................. 250127
113 Tooth Belt ..... 1.8 Hours .................. 250065
1986....................... 1.8 Hours .................. 250127
5000
1978-83.................. 1.1 Hours .................. 250065
5000CS Quattro
1987-88.................. 2.2 Hours .................. 250127
5000S
1984-85
120 Tooth Belt .... 1.8 Hours .................. 250127
113 Tooth Belt ..... 1.8 Hours .................. 250065
1986-87................. 1.8 Hours ................. 250127
TIMING BELT
Removal:
cover. Remove drive belts. Remove power steering pump
with pressure hoses connected. Set pump aside. Remove
valve cover and outer timing belt covers. See Fig. 1.
Fig. 2.
move.
Installation:
camshaft sprocket and water pump sprocket. Recheck valve
timing. Reverse installation order of removal. Adjust drive
belts.See page A-60 for belt tension ranges.
NOTE: Turn engine by hand using hex flange on hydraulic pump.
Loosen tensioner bolts.
Timing Belt Idler Pulley Bolt .......................................... 15 (20)
Timing Belt Tensioner (1992-95) ................................ 15 (20)
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Radiator Mounting Bolts ............................................. 89 (10)
Valve Cover Nuts/Bolts ............................................... 89 (10)
80
AUDI & VOLKSWAGEN
2.1L & 2.2L 5-Cylinder, 1978-91 (Cont.)
92A00398 Courtesy of Audi of America, Inc.
96I14520 Courtesy of Audi of America, Inc.
Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
Fig. 2: Aligning Camshaft Sprocket
96E14641 Courtesy of Audi of America, Inc.
81
BMW
*2.5L & *2.7L 6-Cylinder
2.5L 6-Cyl.
325 Series
1987-88
127 Tooth Belt ... 3.2 Hours .................. 250131
128 Tooth Belt ... 3.2 Hours .................. 250106
1989-91................. 3.2 Hours .................. 250131
525i
1989-95................. 3.2 Hours .................. 250131
2.7L 6-Cyl.
325 Series
1984-88
127 Tooth Belt ... 3.2 Hours .................. 250131
128 Tooth Belt ... 3.2 Hours .................. 250106
528e
1982-88
127 Tooth Belt ... 3.2 Hours .................. 250131
128 Tooth Belt ... 3.2 Hours ................. 250106
NOTE: Use 127 tooth belt with retrofit tensioner pulley. Use 128
tooth belt with with OEM tensioner pulley. DO NOT use 128 tooth
belt on new style adjusting pulley.
60,000 miles or whenever tensioner roller has been released.
TIMING BELT COVER
Removal:
Disconnect negative battery cable. Remove lower splash
shield. Remove all drive belts. Remove cooling fan and
water pump pulley. Drain cooling system. Disconnect both
hoses and transmission cooling line. Disconnect electri-
cal connector from radiator switches. Remove radiator. Hold
crankshaft in place and remove center bolt from vibration
damper hub.
Using a puller, remove vibration damper hub from crank-
shaft. Remove distributor cap and rotor. Remove cover from
distributor housing. Ensure cylinder No. 1 is set to TDC on
compression stroke. See Fig. 1. Remove alternator ten-
sion bracket and move aside.
Remove front cover. Loosen timing belt tensioner mount-
ing bolts and press in on tension roller. Tighten upper
mounting bolt to hold tensioner in place. Remove timing
belt.
Installation:
Ensure arrow on camshaft sprocket is still aligned with
timing mark on cylinder head. Ensure timing mark on crank-
shaft sprocket is aligned with notch in cover (about one
oclock position). See Fig. 1.
Install timing belt on sprockets. Loosen tensioner adjust-
ing bolt to allow spring tension on timing belt. Turn crank-
shaft in direction of normal rotation until timing belt tight-
ens. Tighten tensioner bolt.
Clean gasket mating surfaces. Coat oil pan-to-cover gas-
ket with gasket sealer. Install Centering Tool (11 2 211) on
crankshaft and on intermediate shaft to align front cover.
Using new gasket, install and tighten timing belt cover.
When installing crankshaft sprocket, lettering must face
forward. Install remaining components in reverse order of
TIGHTENING SPECIFICATIONS
Application Ft. Lb.s. (N.m)
Camshaft Sprocket ........................................... 47-50 (65-70)
Intermediate Shaft Sprocket ............................. 40-47 (55-64)
Vibration Damper Hub .............................. 283-311 (390-430)
Fig. 1: Aligning Timing Sprockets
82
BMW
*2.5L & *2.7L 6-Cylinder (Cont.)
Fig. 2: Exploded View Of Camshaft Drive Assembly
83
CHRYSLER
*1.4L 4-Cylinder
Application
1
Labor Time Belt Part No.
1.4L 4-Cyl.
Colt
1979-84................. 1.1 Hours .................. 250073
Champ
1979-82................. 1.1 Hours .................. 250073
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. On front wheel drive mod-
els, remove air cleaner assembly, then disconnect accel-
erator cable and oxygen sensor lead. On all models, mark
position of spark plug wires for installation, then remove
wires from spark plugs. On front wheel drive models, sup-
port engine using a suitable engine support bar.
Remove left engine mount bracket. Remove fan, spacer,
water pump pulley and drive belt. Remove rocker arm cover
and timing belt cover. Move timing belt tensioner upward
toward water pump and secure. Remove timing belt from
camshaft sprocket. Mark belt with an arrow indicating di-
rection of rotation for installation reference, and remove
timing belt.
Installation:
Align camshaft and crankshaft sprockets. Mount belt
tensioner, spring, spacer and temporarily tighten bolt. Po-
sition spring against tensioner first, then against case and
tighten bolt. See Fig. 2. Position and secure tensioner to-
ward water pump.
Install timing belt on crankshaft and camshaft sprockets.
Ensure tension side is tight and timing marks are aligned
when pressure is applied to turn camshaft in reverse di-
rection. Align dowel and install crankshaft pulley. Loosen
tensioner bolt. Ensure proper mesh of belt and sprocket.
With only spring tension applied to belt, tighten tensioner
spring bolt first and slotted adjustment hole bolt last.
Slowly turn crankshaft one revolution clockwise and realign
crankshaft sprocket timing mark at TDC. Do not push or
shake belt while turning or turn crankshaft in counterclock-
wise direction. Loosen tensioner spring bolt first then slot-
ted adjustment hole bolt. Tighten tensioner bolts by tight-
ening slotted adjustment hole bolt first and tensioner spring
bolt last.
Check belt tension by pushing tension side of timing belt in
horizontally using about 11 lbs. (5 kg) force. Timing belt
tooth end should be approximately 1/4 of tensioner mount-
ing bolt head width (across flats) away from bolt head cen-
ter. See Fig. 3. Adjust drive belts to proper tension. See
Crankshaft Sprocket Bolt .................................. 37-43 (50-58)
Timing Chain Tensioner ................................... 15-18 (20-24)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt .................................... 90-102 (10-11)
Oil Pump Cover ................................................ 72-108 (8-10)
Fig. 1: Removing/Installing Timing Belt
84
Fig. 3: Checking Timing Belt Tension
Fig. 2: Installing Timing Belt Tensioner
CHRYSLER
85
Fig. 1: Counterbalance & Timing Belt Routing
Fig. 3: Aligning Counterbalance Shaft Timing Marks
CHRYSLER
1.6L 4-Cylinder With Balance Shaft
1.6L 4-Cyl. SOHC
Arrow & Sapporo
1977-80................
1
1.7 Hours ..............
2
250013
1977-80................
1
1.7 Hours ..............
3
250062
Challenger
1978-79................
1
1.7 Hours ..............
2
250013
1978-79................
1
1.7 Hours ..............
3
250062
Champ
1979-80................
1
1.7 Hours ...............
2
250013
1979-80................
1
1.7 Hours ...............
3
250062
Colt
1977-80................
1
1.7 Hours ...............
2
250013
1977-80................
1
1.7 Hours ...............
3
250062
1
- Counterbalance shaft belt included in labor
time.
With Air Cond. add .2 hours.
2
Camshaft timing belt.
3
Counterbalance shaft belt.
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Rotate crankshaft so
that No. 1 cylinder is at TDC of compression stroke. Re-
move crankshaft pulley, upper and lower timing belt front
covers. Loosen timing belt tensioner mounting nut and bolt.
Move tensioner away from timing belt and temporarily tighten
nut. Remove timing belt. See Fig. 1.
Remove plug at bottom of left side of cylinder block. See
Fig. 2. Insert a screwdriver to keep left counterbalance
(silent) shaft in position. Screwdriver MUST insert at least
2.36 (59.9 mm). If not, turn oil pump sprocket (which drives
left counterbalance shaft) one full turn until timing mark is
aligned again. Keep screwdriver in place until timing belt is
installed.
Remove outer crankshaft sprocket and flange. Loosen cen-
ter bolt on counterbalance belt tensioner pulley. Remove
counterbalance shaft belt.
Installation:
Align counterbalance shaft and crankshaft sprocket timing
marks. See Fig. 3. Install counterbalance shaft belt so that
there is no slack on tension side of belt.
Position counterbalance shaft tensioner so that the eccen-
tric in the center of the pulley is located to the left and above
the bolt. See Fig. 4. Ensure pulley flange faces toward front
of engine. While keeping tension on counterbalance shaft
belt, tighten tensioner pulley bolt. DO NOT allow tensioner
pulley to rotate while tightening center bolt.
If camshaft timing belt tensioner was removed, install
tensioner. Ensure tension spring is seated in correct posi-
tion on water pump body. See Fig. 5. Secure tensioner away
from timing belt.
Fig. 2: Installing Screwdriver To Hold Counterbalance
(Silent) Shaft In Place
86
CHRYSLER
1.6L 4-Cylinder With Balance Shaft (Cont.)
Fig. 4: Positioning Counterbalance Pulley
Install outer crankshaft sprocket. Install camshaft timing
belt first on crankshaft sprocket, then around the oil pump
sprocket and camshaft sprocket. Keep slack out of belt
during installation. Ensure crankshaft, camshaft and oil
sprocket timing marks are still aligned.
Remove screwdriver inserted in left side of engine block.
Install plug. Temporarily install crankshaft pulley to prevent
timing belt movement when crankshaft is turned. Loosen
camshaft timing belt tensioner nut and bolt.
Lightly push camshaft belt tensioner toward timing belt.
Ensure timing belt fully meshes with all teeth on sprockets.
Tighten camshaft timing belt tensioner mounting nut first,
Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring
then bolt. If bolt is tightened first, the tensioner may also
turn more than necessary.
Ensure all camshaft timing marks are still aligned. Turn
crankshaft one revolution in normal direction of rotation
(clockwise). Do NOT turn crankshaft counterclockwise.
CAUTION: Do NOT push or twist camshaft timing belt during
final tension adjustment.
Loosen tensioner mounting bolt and nut. This will take any
slack out of timing belt. Final tighten tensioner mounting
nut to specified torque. See TORQUE SPECIFICATIONS.
Tighten tensioner mounting bolt.
To check timing belt tension, grasp camshaft timing belt
between thumb and forefinger. Clearance between back of
timing belt and edge of rear timing case seal line should
be .47 (12 mm). See Fig. 6. Readjust camshaft timing belt
tension, if necessary.
Remove crankshaft pulley. Install timing belt covers. Install
crankshaft pulley. Tighten crankshaft sprocket center bolt
and pulley bolts to specification. Install accessory drive
belts. Adjust drive belts to proper tension. See page A-60
Camshaft Sprocket Bolt ...................................... 44-57 (60-78)
Crankshaft Sprocket Center Bolt ........................ 44-50 (60-68)
Oil Pump Sprocket Bolt ....................................... 25-28 (34-39)
Timing Belt Tensioner Mounting Bolt ................ 16-21 (22-29)
Timing Belt Tensioner Mounting Nut ................ 16-21 (22-29)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt ...................................... 90-102 (10-11)
Fig. 6: Checking Camshaft Timing Belt Tension
87
CHRYSLER
1.6L 4-Cylinder Without Balance Shaft
1.6L 4-Cyl. SOHC, Without Balance Shaft
Arrow & Sapporo
1978-80................
1
1.6 Hours ...............

250064
Challenger & Colt (RWD)
1978-79................
1
1.6 Hours ................. 250064
Champ
1979-82................. 2.8 Hours .................. 250064
Colt (FWD)
1979-82................
1
2.8 Hours ................. 250064
1983-89................
1
2.8 Hours ................. 250093
Vista (Canadian)
1989.....................
1
2.8 Hours ................. 250093
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. On front wheel drive only,
support engine under oil pan with a floor jack. Remove
engine mount on timing belt end of engine.
On all models, remove accessory drive belts. Remove crank-
shaft pulley, upper and lower timing belt front covers. Turn
crankshaft clockwise to align camshaft and crankshaft tim-
ing marks. See Fig. 1.
Loosen belt tensioner mounting nut and bolt. Move
tensioner away from belt and temporarily tighten nut. Re-
move timing belt. See Fig. 1.
Installation:
Fig. 1: Timing Belt Routing & Alignment
Ensure that all timing marks are still in alignment. See Fig.
1. If tensioner was removed, ensure spring is positioned
correctly under water pump body. See Fig. 2. Secure
tensioner out of way so that timing belt can be installed.
Install timing belt on crankshaft sprocket, on oil pump
sprocket and camshaft sprocket, in that order. Keep slack
out of belt during installation.
Ensure all timing marks are still aligned. Temporarily in-
stall crankshaft pulley.
Loosen tensioner mounting bolt so that spring-loaded
tensioner applies pressure to the timing belt. Lightly push
tensioner up by hand to ensure timing belt completely
meshes with drive sprockets. Tighten tensioner mounting
nut, then tighten mounting bolt. See Fig. 3.
Turn crankshaft one turn in normal direction of rotation. Do
NOT turn in opposite direction. Loosen the timing belt
tensioner mounting bolt and nut. This will take out any slack
in belt. Tighten mounting nut to specifed torque. See
TORQUE SPECIFICATIONS. Tighten timing belt tensioner
bolt.
To check timing belt tension, grasp belt between thumb
and forefinger near timing belt tensioner. See Fig. 4. Ten-
sion is correct when distance between back of belt and
edge of rear timing case cover is .47" (12 mm) with finger
pressure. Readjust tension, if necessary.
88
CHRYSLER
1.6L 4-Cylinder Without Balance Shaft (Cont.)
Remove crankshaft pulley. Install timing belt covers. Install
crankshaft pulley and tighten bolts to specification. On front
wheel drive vehicles, install engine mount. Adjust drive
belts to proper tension. See page A-60 for belt tension
ranges.
Timing Belt Tensioner Nut/Bolt ......................... 16-21 (22-29)
INCH Lbs. (N.m)
89
CHRYSLER
1.7L 4-Cylinder
Belt
Application Time
1
Kit No. No.
1.7L 4-Cyl.
Charger
1983............... 3.1 Hours... 2520710........ 250017
Horizon
1978-83.......... 3.1 Hours... 2520710........ 250017
Omni
1978-83.......... 3.1 Hours... 2520710........ 250017
TC3
1981-82.......... 3.1 Hours... 2520710........ 250017
Turismo
1983............... 3.1 Hours... 2520710........ 250017
024
1981-82.......... 3.1 Hours... 2520710........ 250017
1
With Air Pump add .2 hours.
With Pwr. Strng. add .2 hours
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. If equipped, remove A/C
compressor and power steering pump from mounting
brackets and position aside, leaving refrigerant lines and/
or hoses connected. Remove alternator from mounting
bracket and position aside.
Raise vehicle and remove inner fender splash shield. On
1981-83 Models, remove water pump. If equipped, remove
AIR pump belts. Remove idler pulley assembly. Remove
crankshaft pulley and power steering belt. Remove lower
plastic timing belt cover. See Fig. 1.
Lower vehicle and place jack under engine. Remove right
motor mount through bolt and raise engine slightly. Loosen
timing belt tensioner and remove timing belt.
Installation:
Align timing marks on crankshaft and intermediate sprock-
ets. See Fig. 2. Turn camshaft sprocket until timing mark
on sprocket is lined up with camshaft cover sealing sur-
face. See Fig. 3.
Install timing belt and Belt Tensioner Tool (L-4502 or equiva-
lent) horizontally on large hex of belt tensioner pulley and
loosen tensioner lock nut. See Fig. 4. If necessary, reset
belt tensioner tool to have axis within 15 of horizontal.
NOTE: Do not turn engine by turning camshaft pulley. This will
cause belt to skip teeth.
Turn engine clockwise from TDC 2 complete crankshaft
revolutions to TDC. Tighten tensioner lock nut while hold-
ing belt tensioner wrench in position. Reverse removal pro-
cedure to complete installation. Adjust drive belts to proper
Fig. 2: Crankshaft & Intermediate Sprocket Timing Marks
Courtesy of DaimlerChrysler Corp.
90
CHRYSLER
Fig. 3: Camshaft Timing Mark
Fig. 4: Tensioning Timing Belt
Application Ft. Lbs (N.m)
Crankshaft Sprocket Bolt ............................................ 58 (80)
Intermediate Shaft Retainer Bolt ................................. 18 (29)
Intermediate Shaft Sprocket Bolt ................................. 58 (80)
Timing Belt Cover Screw ............................................... 8 (11)
Water Pump Bolts ...................................................... 30 (41)
91
CHRYSLER
1.8L 4-Cylinder VIN T
1
Belt Part No.
1.8L 4-Cyl.
Colt & Colt Wagon
1989-90................. 2.4 Hours ................. 250093
1
60,000 miles.
TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft
counterclockwise (as viewed from timing belt end of engine).
Removal:
Disconnect negative battery cable. Remove protective cover
below engine. Support engine and remove engine mount
from timing belt end of engine. Remove spark plug wires
and rocker cover. Remove drive belts and water pump pul-
ley. Remove A/C belt tensioner (if equipped).
Remove crankshaft pulley assembly. Remove upper front
and lower timing belt covers. Note bolt lengths and loca-
tions. Rotate engine clockwise (as viewed from timing belt
end of engine) to align timing mark on camshaft sprocket
with mark on upper rear cover. See Fig. 1.
If reusing belt, mark timing belt position on camshaft
sprocket and indicate direction of belt rotation. Loosen tim-
ing belt tensioner bolt and nut. Move timing belt tensioner
toward water pump to release tension and tighten nut tem-
porarily to maintain tensioner position. See Fig. 2. Remove
timing belt.
Inspection:
Check belt teeth for cracks, damage or oil contamination.
Inspect all sprockets for damage. Check belt tensioner for
signs of grease leakage or roughness in tensioner rota-
tion. Replace components if damaged.
Installation:
Rotate tensioner toward water pump and temporarily
tighten retaining nut. See Fig. 2. Ensure camshaft and crank-
shaft timing marks are aligned. See Fig. 1.
Apply pressure on tension side of belt and install timing belt
on oil pump sprocket and then on crankshaft sprocket. Apply
force on camshaft sprocket, in counterclockwise direction, to
apply tension on tension side of belt. Ensure all timing marks
are aligned.
Loosen belt tensioner bolt, then loosen nut to place tension
on timing belt. Rotate camshaft sprocket clockwise until tim-
ing mark is offset by 2 teeth to apply tension on belt. Ensure all
timing marks are aligned. Tighten tensioner nut, then tighten
bolt.
Check belt tension by applying slight thumb pressure to
timing belt in direction of timing belt lower rear cover. See
Fig. 3. Ensure distance between back of timing belt (smooth
side) and timing belt lower rear cover is approximately .23"
(6 mm). To complete installation, reverse removal proce-
dure. Adjust accessory drive belts to proper tension. See
Camshaft Sprocket Bolt .................................... 58-72 (79-98)
Crankshaft Sprocket Bolt ............................. 80-94 (109-127)
Damper Pulley Bolt ........................................... 11-13 (15-18)
Engine Support Bracket Bolt ............................. 22-30 (30-41)
Front Cover Bolt ................................................ 11-13 (15-18)
Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27)
Water Pump Bolt
8 X 70 mm ...................................................... 15-19 (20-26)
All Others .................................................................. 10 (14)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ...................................... 84-108 (9-12)
Valve Cover Bolt .................................................... 48-60 (5-7)
Water Pump Pulley Bolt ........................................ 72-84 (8-9)
Fig. 1: Aligning Timing Mark & Arranging Belt
Fig. 2: Positioning Timing Belt Tensioner
92
91G00816 Courtesy of Chrysler Corp.
CHRYSLER
1.8L 4-Cylinder VIN T (Cont)
93
NOTE: The following revised information regarding the tensioner
pulley pivot bolt is from Chrysler technical service bulletin 09-
06-96; March 29, 1996.
Timing Belt Tensioner Bracket Precaution:
On models with hydraulic timig belt tensioner, do not loosen,
tighten, or remove timing belt tensioner pivot bolt. Bolt is
installed at factory with special threadlocking compound
that is not reusable. If tensioner pivot bolt is disturbed,
entire bracket assembly must be replaced. The tensioner
pulley center bolt MAY be removed and installed.
2.0L 4-Cyl. SOHC
Breeze
1996-00................
1
2.4 Hours ................. 250245
Cirrus
2000.....................
1
2.4 Hours ................. 250245
Neon
1995-00................
1
2.4 Hours ................. 250245
Stratus
1995-00................
1
2.4 Hours ................. 250245
1
On Neon models, the manufacturer recommends the belt be
replaced at 105,000 mile intervals.
On Breeze, Cirrus and Stratus models, the manufacturer rec-
ommends the belt be replaced at 100,000 mile intervals on
vehicles with Federal emissions, and 105,000 mile intervals
with California emissions.
TIMING BELT
Removal (Hydraulic Tensioner):
Remove No. 1 spark plug. Using dial indicator, set number
one cylinder to TDC of compression stroke. Remove ac-
cess plug from top of timing belt cover. See Fig. 1. Ensure
timing mark on camshaft aligns with mark on rear cover.
See Fig. 2.
belts. Raise vehicle and remove right inner splash shield.
See Fig. 7. Remove crankshaft damper bolt. Use gear puller
to remove crankshaft damper.
Lower vehicle and place a jack under engine to support
weight. Remove right engine mount. On Breeze and Stra-
tus, remove generator (with wiring attached) and bracket,
and secure out of way. On Neon, remove power steering
pump with hoses attached, and secure out of way. Remove
upper and lower engine torque struts (2001-00 Neon). On
all models, remove right engine mount bracket from en-
gine. See Fig. 3.
Remove front timing belt cover. See Fig. 1. Rotate crank-
shaft so that timing marks are aligned. See Fig. 2. Loosen
timing belt tensioner bolts. If reusing timing belt, mark ar-
row on belt to indicate direction of rotation. Remove timing
belt and tensioner. DO NOT loosen, tighten, or remove
tensioner pulley pivot bolt.
CAUTION: To prevent pistons from hitting valves, do not rotate
camshaft or crankshaft after removing the timing belt.
NOTE: When tensioner is removed from engine, it is necessary
to compress plunger into tensioner body. Index tensioner in vise
the same way it is installed on engine to ensure proper pin orientation
when tensioner is installed on engine.
CHRYSLER
*2.0L 4-Cylinder SOHC, VIN C
Fig. 2: Aligning Timing Marks & Adjusting Belt Tension
(Hydraulic Timing Belt Tensioner)
Courtesy of DaimlerChrysler
96F14485 Courtesy of DaimlerChrysler
Oil Pump Body
94
96D14483 Courtesy of DaimlerChrysler
Fig. 3: Locating Right Engine Mount Bracket (Typical)
CHRYSLER
*2.0L 4-Cylinder SOHC, VIN C (Cont.)
Fig. 4: Compressing Hydraulic Timing Belt Tensioner
96I14488 Courtesy of DaimlerChrysler
Inspection:
Check belt teeth for damage or oil contamination. Inspect
belt for glossy, hardened or non-elastic surface. Ensure
the belt is not cracked, separated or showing canvas fiber.
Inspect all sprockets for damage. Check tensioner pulley
and idler pulley for signs of grease leakage or roughness
in rotation. Replace components if damaged.
Installation (Hydraulic Tensioner):
Place tensioner in soft-jawed vise and slowly compress
plunger. See Fig. 4. When plunger is compressed into
tensioner body, install a 5/16" (1.9 mm) hex wrench or lock-
ing pin through body and plunger to hold plunger in place
until tensioner is installed.
Set crankshaft sprocket to TDC by aligning sprocket with
arrow on oil pump housing, then back off to 3 notches be-
fore TDC.
Set camshaft to TDC by aligning mark on sprocket with
arrow on rear of timing belt cover. See Fig. 2. Move crank-
shaft to 1/2 notch mark before TDC for belt installation. See
Fig. 5. Install timing belt by starting at crankshaft, then around
water pump sprocket and then camshaft sprocket.
Move crankshaft sprocket to TDC to take up belt slack. In-
stall tensioner to block, but do not final tighten bolts. Using
a torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N.
m) of torque in clockwise direction. With torque applied to
tensioner pulley, move the tensioner up against the
tensioner pulley bracket. Final tighten tensioner bolts. See
Fig. 1.
Pull tensioner plunger locking pin. Pretension is correct
when pin can be removed and installed. Rotate crankshaft
2 revolutions. Check alignment of the timing marks. Install
front timing belt cover. Install engine mount bracket. Install
generator and bracket (Breeze and Stratus) or power steer-
ing pump (Neon).
Fig. 5: Aligning Crankshaft Sprocket Timing Marks
Courtesy of DaimlerChrysler Fig. 6: Aligning Timing Marks & Adjusting Belt Tension
(Mechanical Timing Belt Tensioner)
95
CHRYSLER
*2.0L 4-Cylinder SOHC, VIN C (Cont.)
Install right engine mount. Remove jack from under en-
gine. Install crankshaft damper and tighten bolt to specifi-
cation. See TORQUE SPECIFICATIONS.
Raise vehicle on hoist. Install right inner splash shield.
Lower vehicle. Install accessory drive belts. Adjust drive
ranges.
On Neon models, connect scan tool to Data Link Connec-
tor (DLC) under lower left edge of instrument panel. Follow
scan tool manufacturers instructions to access the cam/
crank relearn procedure. Perform cam/crank relearn pro-
cedure.
NOTE: Chrysler recommends replacing worn mechanical tensioners
with updated hydraulic tensioner kits. Information is from Chrysler
technical service bulletin 09-06-00; March 10, 2000.
Removal (Mechanical Tensioner):
Remove No. 1 spark plug. Using dial indicator, set number
one cylinder to TDC of compression stroke. Remove ac-
cess plug from top of timing belt cover. See Fig. 1. Ensure
timing mark on camshaft aligns with mark on rear cover.
See Fig. 6.
belts. Raise vehicle and remove right inner splash shield.
See Fig. 7. Remove crankshaft damper bolt. Use gear puller
to remove crankshaft damper.
On Breeze and Stratus, lower vehicle and place a jack un-
der engine to support weight. Remove right engine mount
from engine and body. Remove generator (with wiring at-
tached) and bracket, and secure out of way. Remove en-
gine mount bracket from engine. For 2000 Breeze and Stra-
tus, remove accessory drive belt idler pulley from genera-
tor bracket. Remove generator bracket-to-engine bolts.
Move bracket away from engine for clearance to remove
timing belt cover.
On 2000 Neon, remove lower torque strut. On all Neon
models, lower vehicle and place jack under engine to sup-
port weight. Remove power steering pump with hoses at-
tached, and secure out of way. Remove upper torque strut
(if equipped). Remove right engine mount-to-engine mount
bracket through bolt. Remove engine mount bracket from
engine.
On all models, remove timing belt cover. Rotate the crank-
shaft so that timing marks are aligned. See Fig. 6.
Install an 8 mm Allen wrench into timing belt tensioner. See
Fig. 6. Insert long end of a 3 mm Allen wrench into pin hole
in the front of tensioner. Slowly rotate tensioner counter-
clockwise with 8 mm Allen wrench while pushing lightly on
the 3 mm Allen wrench, until it slides into the locking hole.
If reusing old timing belt, mark belt with arrow to indicate
direction of rotation. Remove timing belt.
NOTE: Mechanical timing belt tensioner is serviced as an assembly.
To prevent premature timing belt failure and engine damage,
do NOT separate tensioner pulley from tensioner bracket.
Inspection:
Installation (Mechanical Tensioner):
Set crankshaft sprocket to TDC by aligning sprocket with
arrow on oil pump housing, then back off to 3 notches be-
fore TDC.
Set camshaft to TDC by aligning mark on sprocket with
arrow on rear of timing belt cover. See Fig. 6. Move crank-
shaft to 1/2 mark before TDC for belt installation. See Fig.
5. Install timing belt by starting at crankshaft, then around
water pump sprocket and then camshaft sprocket. See Fig.
6. Move crankshaft sprocket to TDC to take up belt slack.
Remove Allen wrench from timing belt tensioner pulley. Ro-
tate crankshaft clockwise 2 revolutions. Check alignment
of camshaft and crankshaft timing marks. If timing marks
do not align, remove timing belt and realign timing marks.
Install front timing belt cover. Install engine mount bracket
to engine. Continue installation in reverse of removal pro-
cedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS. Adjust accessory drive belts to proper
On 1998-00 Neon models, connect scan tool to Data Link
Connector under lower left edge of dash. Follow scan tool
manufacturers instructions to access the cam/crank re-
learn procedure. Perform cam/crank relearn procedure.
Camshaft Sprocket Bolt ............................................ 85 (115)
Crankshaft Damper Bolt ......................................... 105 (142)
Engine Mount Bolt .......................................................... 45 (61)
Engine Mount Bracket-to-Engine Bolts ....................... 45 (61)
Engine Torque Strut Bolts (2001-00 Neon) .................. 87 (118)
Generator Mounting Bolts............................................... 45 (61)
Power Steering Pump Mounting Bolts ............................ 40 (54)
Timing Belt Tensioner Bolt
Hydraulic Tensioner ................................................... 23 (31)
Timing Belt Tensioner Bracket Bolt
Mechanical Tensioner ................................................ 23 (31)
INCH Lbs. (N.m)
Timing Belt Cover Bolts (M6) .................................... 106 (12)
Water Pump Mounting Bolts ..................................... 106 (12)
Fig. 7: Exploded View Of Splash Shield Components
96
2.2L 4-Cyl. DOHC, Turbo III
Daytona (Includes Canadian)
1992-93 ..............
1
2.6 Hours ................. 250206
Spirit
1991-92................
1
4.1 Hours ................. 250206
1
TIMING BELT
Removal:
Remove PCV hose. Remove upper timing belt cover. Re-
move accessory drive belts. Rotate crankshaft so that cyl-
inder No. 1 is at TDC of compression stroke.
Raise vehicle on hoist and remove right wheel and inner
splash shield. Remove water pump pulley. Remove crank-
shaft pulley bolts and remove pulley. It is NOT necessary to
remove center bolt from the crankshaft.
Remove lower accessory drive belt idler pulley and
tensioner pulley. Remove lower timing belt cover. Remove
accessory drive belt idler pulley bracket.
Lower vehicle. Place floor jack under vehicle to support
weight of engine and transaxle assembly. Remove right
engine mount (timing belt end of engine). Note position
and number of shims for reassembly reference.
Remove air cleaner fresh air duct. Remove ignition sec-
ondary wire cover from top of engine. Remove valve covers.
Loosen center bolt of timing belt tensioner pulley to relieve
timing belt tension. If reusing old timing belt, mark belt with
arrow to indicate original direction of rotation. Remove tim-
ing belt.
Inspection:
Inspect timing belt for damaged teeth, cracking and oil con-
tamination. Check timing belt tensioner for worn bearing.
Check camshaft, crankshaft and intermediate shaft seals
for leaks. Replace damaged components.
Installation:
Loosen rocker arm assembly bolts about 3 turns. See Fig.
1. Align and pin both camshafts with 3/32 drill bits or pins.
See Fig. 2. Accessory drive shaft does not have to be timed.
Remove spark plugs.
Install a dial indicator in No. 1 spark plug hole. Rotate crank-
shaft until No. 1 piston is at TDC. Mark engine block for
TDC reference.
Install timing belt and idler pulley in correct sequence. See
Fig. 2. Remove dial indicator from cylinder head. Remove
drill bits or pins from camshaft sprockets.
CHRYSLER
2.2L 4-Cylinder DOHC, VIN A
Fig. 1: Rocker Arm Loosening & Tightening Sequence
Install a belt tension gauge on the timing belt. Install ten-
sion on the belt run between the 2 camshafts. Tension
gauge must contact timing belt between the teeth to get an
accurate reading. Rotate timing belt tensioner clockwise to
obtain a tension of 110 lbs. (445 N.) for a new belt, or 70
lbs. (311 N.) for a used belt. Tighten timing belt tensioner
center bolt to specification. See TORQUE SPECIFICA-
TIONS.
CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate
crankshaft using camshaft or intermediate shaft bolt.
Rotate crankshaft clockwise 2 revolutions. Check align-
ment of camshaft and crankshaft timing marks.
Recheck timing belt tension. Readjust, if necessary. Tighten
rocker arm shafts in sequence. See Fig. 1. See TORQUE
SPECIFICATIONS.
Install valve covers, spark plugs and ignition wire covers.
Install fresh air duct. To complete installation, reverse re-
97
CHRYSLER
2.2L 4-Cylinder DOHC, VIN A (Cont.)
Camshaft Sprocket Bolt .................................................. 65 (89)
Crankshaft Pulley-To-Sprocket Bolt ............................... 27 (31)
Crankshaft Sprocket Center Bolt .................................. 85 (115)
Intermediate Shaft Bolt ................................................... 65 (88)
Right Engine Mount
To-Engine Bracket Through Bolt .............................. 100 (136)
To-Frame Rail Bolts .................................................... 50 (68)
Water Pump Pulley Bolt .................................................. 21 (28)
Wheel Lug Nut ............................................................. 95 (129)
INCH Lbs. (N.m)
Rocker Arm Shaft Bolts
Step 1 ........................................................................ 106 (12)
Step 2 ......................................................................... 210 (24)
98
Belt
2.2L 4-Cyl. DOHC, Turbo
TC (Maserati)
1990............... 2.9 Hrs. ...... 2521530....... 250153
kits.
TIMING BELT
Removal:
Rotate crankshaft so that cylinder No. 1 is at TDC of com-
pression stroke. Raise vehicle on hoist and remove right
inner splash shield. Remove accessory drive belts.
Remove water pump pulley. Remove crankshaft pulley bolts
and remove pulley. It is NOT necessary to remove center
bolt from the crankshaft. Lower vehicle. Remove upper and
lower timing belt covers.
Place floor jack under vehicle to support weight of engine
and transaxle assembly. Remove right engine mount (tim-
ing belt end of engine). Remove valve cover.
Loosen center bolt of timing belt tensioner pulley. If reusing
old timing belt, mark belt with arrow to indicate original
Inspection:
Check camshaft, crankshaft and intermediate shaft seals
for leaks. Replace damaged components.
Installation:
Turn crankshaft and intermediate shaft until the alignment
marks on the sprockets are aligned. See Figs. 2 and 3. The
distributor rotor must be facing the No. 1 cylinder in the
distributor cap.
Position pin punches in intake and exhaust camshaft align-
ment holes. See Fig. 1. Position both camshafts so that the
2 alignment holes in the exhaust and intake camshaft
sprockets are below and adjacent to the centerline of the 2
sprockets. See Fig. 2. The 2 keyways not used must be
positioned at the top, outside of the vertical centerline of the
camshafts.
Turn crankshaft until the alignment mark on the sprocket is
in line with the crankshaft and intermediate shaft centerline.
Turn the intermediate shaft until the marking on the sprocket
(if there is one) is in line with the marking on the crankshaft
sprocket. If there is no marking on the intermediate shaft
sprocket, set timing hole on vertical line through center of
the axis, upper side, 2 degrees clockwise.
Position timing belt on the crankshaft sprocket first. Then,
install timing belt on intermediate shaft sprocket by turning
it slightly, if necessary. Repeat this procedure for the cam-
shaft sprockets.
CHRYSLER
2.2L 4-Cylinder DOHC, VIN R
Fig. 1: Installing Pin Punches In Camshafts
Remove the spark plugs. Remove the pin punches. Rotate
crankshaft to TDC. Place Tension Tool (C-4703) on large
hex nut in center of timing belt tensioner pulley. See Fig. 4.
Loosen tensioner pulley lock nut. Adjust tensioner tool in-
dex, if necessary, to position the axis within 15 degrees of
horizontal. See Fig. 4.
CAUTION: Do NOT rotate crankshaft counterclockwise or attempt
to rotate the engine using the camshaft or intermediate shaft
mounting bolt.
Rotate crankshaft clockwise from TDC 2 full revolutions
back to TDC. Tighten the locknut on the timing belt tensioner.
To complete installation, reverse removal procedure. Ad-
tension ranges.
Crankshaft Pulley-To-Sprocket Bolt ............................... 21 (28)
Crankshaft Sprocket Center Bolt ................................. 50 (68)
Generator Drive Belt Idle Pulley Bolt .............................. 40 (54)
Intermediate Shaft Bolt ................................................... 65 (88)
Right Engine Mount
To-Engine Bracket Through Bolt ................................ 75 (102)
To-Frame Rail Bolts .................................................... 21 (28)
INCH Lbs. (N.m)
Water Pump Pulley Bolt ............................................... 106 (12)
99
CHRYSLER
2.2L 4-Cylinder DOHC, VIN R (Cont.)
Fig. 3: Aligning Camshaft, Crankshaft & Intermediate Shafts
100
CHRYSLER
2.2L 4-Cylinder DOHC, VIN R (Cont.)
101
CHRYSLER
Belt
Application Time
1
Kit No. No.
2.2L 4-Cyl. SOHC
Aries & Reliant
1981-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989............... 2.2 Hrs. ...... 2521530........ 250153
Caravan, Town & Country & Voyager
1982-88.......... 2.2 Hrs. ...... 2520710........ 250071
Caravelle, New Yorker & 600
1983-88.......... 2.2 Hrs. ...... 2520710........ 250071
Charger & Turismo
1983-87.......... 2.2 Hrs. ...... 2520710........ 250071
Dakota
1987-88..........
2
1.1 Hrs. .... 2520710........ 250071
Daytona
1984-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989-93.......... 2.2 Hrs. ...... 2521530........ 250153
E Class
1983-84.......... 2.2 Hrs. ...... 2520710........ 250071
Executive Limo (Canadian)
1986............... 2.2 Hrs. ...... 2520710........ 250071
Expo (Canadian)
1987-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989............... 2.2 Hrs. ...... 2521530........ 250153
Horizon & Omni
1981-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989-90.......... 2.2 Hrs. ...... 2521530........ 250153
Lancer
1985-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989............... 2.2 Hrs. ...... 2521530........ 250153
Laser
1984-86.......... 2.2 Hrs. ...... 2520710........ 250071
1982-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989-90.......... 2.2 Hrs. ...... 2521530........ 250153
Mini Ram Van
1984-87.......... 2.2 Hrs. ...... 2520710........ 250071
New Yorker
1983-88.......... 2.2 Hrs. ...... 2520710........ 250071
Rampage
1982-84.......... 2.2 Hrs. ...... 2520710........ 250071
Scamp Pickup
1983............... 2.2 Hrs. ...... 2520710........ 250071
Shadow & Sundance
1987-88.......... 2.2 Hrs. ...... 2520710........ 250071
1989-94.......... 2.2 Hrs. ...... 2521530........ 250153
TC3
1981-82.......... 2.2 Hrs. ...... 2520710........ 250071
Turismo
1983-87.......... 2.2 Hrs. ...... 2520710........ 250071
024
1981-82.......... 2.2 Hrs. ...... 2520710........ 250071
TIMING BELT APPLICATION (Cont.)
Belt
Application Time
1
Kit No. No.
2.2 L 4-Cyl. SOHC (Cont.)
400
1982-83.......... 2.2 Hrs. ...... 2520710........ 250071
600
1983-88.......... 2.2 Hrs. ...... 2520710........ 250071
2.5L 4-Cyl. SOHC
Acclaim
1989-95.......... 2.2 Hrs. ...... 2521530........ 250153
Aries, Lancer & Reliant
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
1989............... 2.2 Hrs. ...... 2521530........ 250153
Caravan, Town & Country & Voyager
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
1989-95.......... 2.2 Hrs. ...... 2521530........ 250153
Caravelle & 600
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
Dakota
1989-95.......... 1.1 Hrs. ...... 2521530........ 250153
Daytona
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
1989-93.......... 2.2 Hrs. ...... 2521530........ 250153
Dynasty
1988............... 2.2 Hrs. ............................. 250132
1989-93.......... 2.2 Hrs. ...... 2521530........ 250153
Lancer
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
1989............... 2.2 Hrs. ...... 2521530........ 250153
Laser
1986............... 2.2 Hrs. ............................. 250114
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
1989-94.......... 2.2 Hrs. ...... 2521530........ 250153
Mini Ram Van
1987............... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
New Yorker
1986-87.......... 2.2 Hrs. ............................. 250114
1988............... 2.2 Hrs. ............................. 250132
Shadow & Sundance
1988............... 2.2 Hrs. ............................. 250132
1989-94.......... 2.2 Hrs. ...... 2521530........ 250153
Spirit
1989-1995 ...... 2.2 Hrs. ...... 2521530........ 250153
1
2
102
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove all accessory
drive belts. If necessary, remove alternator, mounting brack-
ets, and A/C compressor (if equipped). DO NOT discon-
nect refrigerant lines. Remove A/C belt idler pulley.
Raise and support vehicle. Remove right inner splash shield.
Remove water pump and crankshaft pulleys. Remove upper
and lower timing belt covers. See Fig. 1. Support engine using
a jack.
CAUTION: If timing belt is to be reused, mark direction of rotation
for reassembly reference.
Remove right engine mount bolt, and raise engine slightly.
Loosen the timing belt tensioner and remove timing belt. See
Fig. 2.
Installation:
Remove spark plugs. Place cylinder No. 1 on TDC. Align tim-
ing marks on crankshaft and intermediate shaft sprockets.
See Fig 3. Rotate camshaft sprocket until 2 marked arrows on
sprocket hub align with camshaft bearing cap-to-cylinder head
parting line. Small hole in camshaft sprocket must be at 12
oclock relative to cylinder head line. See Fig. 3.
Install timing belt. Ensure timing belt is installed in original
direction of rotation. Install Timing Belt Tensioner (C-4703)
horizontally on large hex of belt tensioner pulley. Loosen
tensioner lock nut (if necessary) to reset belt tensioner to
within a 15-degree axis of horizontal position of tool. See
Fig. 2. Tighten lock nut.
CAUTION: DO NOT rotate crankshaft counterclockwise. DO NOT
rotate engine using camshaft or intermediate shaft sprocket bolts.
Rotate crankshaft clockwise 2 complete revolutions to TDC.
Tighten tensioner retaining bolt to specification while hold-
ing belt tensioner wrench in position. See TORQUE SPECI-
FICATIONS. Check all timing marks for proper alignment.
tension ranges.
CHRYSLER
96I14660 Courtsey of Chrysler Corp.
Fig. 1: Removing Timing Belt Covers
Bracket-To-Block Bolt ................................................. 70 (95)
Damper Weight ............................................... 21-23 (28-30)
INCH Lbs. (N.m)
Balance Shaft Chain Guide Nut ................................ 106 (12)
Balance Shaft Chain Pivot & Tensioner Bolt ............. 106 (12)
Balance Shaft Cover Bolt .......................................... 106 (12)
Intermediate Shaft Retainer Bolt ............................... 106 (12)
Timing Belt Cover Bolt .................................................. 44 (5)
Valve Cover Bolt ........................................................ 106 (12)
Water Pump Pulley Bolt ............................................ 106 (12)
103
Fig. 4: Aligning Crankshaft, Intermediate Shaft &
Camshaft Timing Marks
CHRYSLER
104
Fig. 2: Installing Timing Belt Tensioner Assembly
2.4L 4-Cyl. DOHC, VIN B
Caravan & Voyager
1996-00 ..............
1
3.6 Hours ................. 250265
1
- With Pwr. Strng. add .2 hours.
120,000 miles.
TIMING BELT
Removal:
Raise vehicle on hoist and remove right front wheel. Re-
move right inner splash panel. Remove accessory drive
belts. Remove crankshaft vibration damper.
Remove generator drive belt idler pulley. Remove lower
timing belt cover. Lower vehicle and remove upper timing
belt cover.
Place floor jack under vehicle to support weight of engine
and transaxle assembly. Remove purge duty solenoid and
wiring harness from right engine mount bracket (timing
belt end of engine).
Remove 2 right engine mount vertical bolts from frame rail.
Remove the one horizontal fastener. DO NOT remove large
nut from center bolt of insulator rubber. Remove horizontal
and vertical fasteners from engine side of mount. Remove
right engine mount assembly. Rotate crankshaft to align
timing marks on camshafts and oil pump housing. See
Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing
edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth with oil pump housing mark will cause camshaft marks
to be misaligned.
On 1996 models equipped with hydraulic tensioner, re-
move hydraulic tensioner bolts and remove tensioner. Place
hydraulic tensioner in vise and SLOWLY compress
tensioner plunger. Align holes in tensioner body and plunger
and insert a pin through body and plunger to lock plunger
in place. Skip next step.
On models with a mechanical timing belt tensioner, insert
a 6 mm Allen wrench into tensioner. Insert long end of 3
mm Allen wrench into pin hole on front of tensioner. While
rotating the tensioner counterclockwise, push in lightly on
the 3 mm Allen wrench until it can be pushed into locking
hole. See Fig. 3.
On all models, if reusing old timing belt, mark belt with
ing belt.
Inspection:
Replace damaged components.
NOTE: If timing belt tensioner needs to be replaced, camshaft
sprockets and rear timing belt cover will need to be removed.
CHRYSLER
2.4L 4-Cylinder DOHC, VIN B
Installation:
aligned. See Fig. 1. Set camshafts timing marks together
by aligning notches on sprockets. Turn exhaust camshaft
sprocket clockwise about 1/2 notch below intake camshaft
Install timing belt starting at crankshaft, around water pump
sprocket, idler pulley, camshafts sprockets and then around
tensioner pulley.
Move exhaust camshaft counterclockwise to take out belt
slack and align timing marks. See Fig. 1.
105
Fig. 3: Adjusting Timing Belt Tension (Mechanical)
CHRYSLER
2.4L 4-Cylinder DOHC, VIN B (Cont.)
Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)
On 1996 models with hydraulic timing belt tensioner, in-
stall tensioner on engine block but do NOT final tighten
bolts. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley
in a clockwise direction. See Fig. 5. With torque applied to
tensioner pulley, push timing belt tensioner against
tensioner pulley bracket and final tighten tensioner bolts.
See TORQUE SPECIFICATIONS. Remove holding pin from
tensioner. Timing belt tension is correct when pin can be
removed and installed freely. Skip next step.
On models with mechanical timing belt tensioners, pull
locking Allen wrench from timing belt tensioner.
On all models, rotate crankshaft 2 revolutions and check
alignment of timing marks. If timing marks are not correct,
reposition timing belt.
Install right engine mount support and support bracket.
Install upper and lower timing belt covers. Install generator
idler pulley. Install crankshaft vibration damper.
tension ranges.
Crankshaft Vibration Damper ................................. 105 (142)
Engine Mount Bracket-To-Engine Bolts.......................... 45 (61)
Generator Drive Belt Idle Pulley Bolt .............................. 40 (54)
Lower Timing Belt Tensioner
Bracket Bolt .............................................................. 45 (61)
Right Engine Mount
Frame Rail Fasteners ................................................. 50 (68)
Horizontal Engine Fastener ..................................... 111 (150)
Vertical Engine Fastener ........................................... 75 (102)
Timing Belt Tensioner (Hydraulic)
Mounting Bolt ............................................................ 24 (28)
Timing Belt Tensioner (Mechanical)
Center Bolt ................................................................... 24 (28)
Timing Belt Tensioner Assembly Bolt ....................... 45 (61)
Wheel Lug Nut .......................................................... 100 (135)
INCH Lbs. (N.m)
Timing Belt Cover Bolts
M6 (Outer-To-Inner) ................................................. 40 (4.5)
M6 (Inner-To-Head) ................................................ 105 (12)
Water Pump Bolt ......................................................... 106 (12)
106
2.4L 4-Cyl. DOHC, VIN X
Breeze
1996-00................
1
3.6 Hours ................. 250265
Cirrus
1995-00................
1
3.6 Hours ................. 250265
Sebring Convertible
1996-99................
1
3.6 Hours ................. 250265
Stratus
1995-00................
1
3.6 Hours ................. 250265
1
Up to 1999 model year, the manufacturer recommends the
timing belt be replaced every 105,000 miles. For 2000 model
years, the manufacturer recommends the timing belt be re-
placed at 100,000 miles for Federal vehicles and at 105,000
miles for California vehicles.
TIMING BELT
Removal:
Raise vehicle on hoist and remove right front wheel. Re-
move right inner splash panel. Remove accessory drive
belts. Remove crankshaft vibration damper.
Remove generator drive belt idler pulley. Remove lower
timing belt cover.
Remove right engine support assembly vertical bolts from
bottom of frame rail (timing belt end of engine).
Lower vehicle. Remove upper timing belt cover. Place floor
jack under vehicle to support weight of engine and transaxle
assembly. Remove 3 bolts attaching engine mount assem-
bly to engine bracket.
Move A/C drier aside. Remove coolant reservoir tank. Re-
move right engine mount. Remove 3 bolts attaching en-
gine mount bracket to engine block.
CAUTION: Align timing marks by rotating crankshaft only. Do
not rotate camshaft after timing belt is removed or engine damage
may result.
Rotate crankshaft clockwise to align timing marks on cam-
shafts and oil pump housing. See Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing
edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth with oil pump housing mark will cause camshaft marks
to be misaligned.
On models equipped with hydraulic tensioner, remove hy-
draulic tensioner bolts and remove tensioner. Place hy-
draulic tensioner in vise and SLOWLY compress tensioner
plunger. Align the holes in the tensioner body and plunger
and insert a pin through the body and plunger to lock the
plunger in place. Skip next step.
On models with a mechanical timing belt tensioner, insert
a 6 mm Allen wrench into tensioner. Insert long end of 3
mm Allen wrench into pin hole on front of tensioner. While
rotating the tensioner counterclockwise, push in lightly on
the 3 mm Allen wrench until it can be pushed into locking
hole. See Fig. 3.
On all models, if reusing old timing belt, mark belt with
ing belt.
Inspection:
CHRYSLER
2.4L 4-Cylinder DOHC, VIN X
Fig. 2: Installing Timing Belt Tensioner Assembly
107
Fig. 3: Adjusting Timing Belt Tension (Mechanical)
CHRYSLER
2.4L 4-Cylinder DOHC, VIN X (Cont.)
Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position
NOTE: If timing belt tensioner needs to be replaced, camshaft
sprockets and rear timing belt cover will need to be removed.
Installation:
aligned. See Fig. 1. Set camshafts timing marks together
by aligning notches on sprockets. Turn exhaust camshaft
sprocket clockwise about 1/2 notch below intake camshaft
Install timing belt starting at crankshaft, around water pump
sprocket, idler pulley, camshafts sprockets and then around
tensioner pulley.
On models with hydraulic timing belt tensioner, install
tensioner on engine block but do NOT final tighten bolts.
Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a
clockwise direction. See Fig. 5. With torque applied to
tensioner pulley, push timing belt tensioner against
tensioner pulley bracket and final tighten tensioner bolts.
See TORQUE SPECIFICATIONS. Remove holding pin from
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)
tensioner. Timing belt tension is correct when pin can be
removed and installed freely. Skip next step.
On models with mechanical timing belt tensioners, pull
locking Allen wrench from timing belt tensioner.
On all models, rotate crankshaft 2 revolutions and check
alignment of timing marks. If timing marks are not correct,
reposition timing belt.
Install right engine mount and support bracket. Install up-
per and lower timing belt covers. Install generator idler pul-
ley. Install crankshaft vibration damper.
tension ranges.
Crankshaft Vibration Damper ................................. 105 (142)
Generator Drive Belt Idler Pulley Bolt ............................. 40 (54)
Right Engine Mount
Frame Rail Vertical Fasteners ..................................... 45 (61)
To-Engine Support Bracket ......................................... 45 (61)
Timing Belt Tensioner (Hydraulic)
Mounting Bolt ............................................................ 21 (28)
Timing Belt Tensioner (Mechanical)
Bracket Mounting Bolt ............................................... 45 (61)
Wheel Lug Nut .......................................................... 100 (135)
INCH Lbs. (N.m)
M6 (Outer-To-Inner) ................................................. 40 (4.5)
M6 (Inner-To-Head) ................................................ 105 (12)
Water Pump Bolt ......................................................... 106 (12)
108
CHRYSLER
*2.5L V6
2.5L V6
Avenger & Sebring Coupe
1995-00................
1
2.7 Hours ................ 250259
Cirrus & Stratus
1995-00................
1
2.7 Hours ................ 250259
Sebring Convertible
1997-00................
1
2.7 Hours ................ 250259
1
The manufacturer recommends the belt be replaced at 60,000
mile intervals, except in California, Connecticut, and Massa-
chusetts. In these states, inspect belt at 60,000 miles and
replace if necessary. If not replaced at 60,000 miles, replace
at 100,000 miles.
TIMING BELT
Removal (Cirrus, Sebring Convertible & Stratus):
Disconnect negative battery cable from jumper terminal.
Raise and support vehicle. Remove right front wheel. Re-
move accessory drive belt splash shield from right
wheelwell.
Remove accessory drive belts. Remove right engine sup-
port assembly vertical bolts from bottom side of frame rail
(timing belt end of engine).
weight of engine and transaxle assembly. Remove 3 bolts
attaching engine support assembly to engine block
bracket.
Move the A/C drier aside with hoses attached. Remove cool-
ant reservoir tank. Remove right engine support assembly.
Remove 3 bolts attaching engine support bracket to en-
gine block, and remove bracket.
Remove crankshaft vibration damper. Remove power steer-
ing pump (hoses attached) and bracket from engine block.
Remove timing belt covers.
Rotate crankshaft to align camshaft and crankshaft timing
marks. See Figs. 2 and 3.
If reusing old timing belt, mark timing belt direction of rota-
tion for installation reference. Loosen timing belt automatic
tensioner bolts. Remove timing belt. Remove automatic
tensioner.
CAUTION: DO NOT rotate crankshaft or camshaft with timing
belt removed.
NOTE: When automatic tensioner is removed from engine, it
is necessary to compress plunger into tensioner body.
Removal (Avenger & Sebring Coupe):
Disconnect negative battery cable. Remove coolant reser-
voir bottle. On models with cruise control, remove cruise
control actuator and set aside.
On all models, raise and support vehicle. Remove right
front wheel. Remove side panel from right wheelwell.
Remove accessory drive belts. Remove generator and
bracket from engine block and set aside. Remove crank-
shaft vibration damper.
weight of engine and transaxle assembly. Remove engine
mount-to-frame through bolt. Remove engine mount-to-en-
gine bracket nuts and bolt. Remove engine mount.
Remove 3 bolts attaching engine support bracket to en-
gine block. Top reamer bolt may be heat seized on engine
support bracket. Spray lubricant on bolt while removing.
NOTE: Reamer bolt head will have a R marking for identi-
fication.
Remove power steering pump (hoses attached) and
bracket from engine block and set aside. Remove timing
belt covers.
If reusing old timing belt, mark timing belt direction of rota-
tion for installation reference. Loosen timing belt tensioner
pulley bolt. Remove timing belt. Remove automatic
tensioner.
CAUTION: DO NOT rotate crankshaft or camshaft with timing
belt removed.
NOTE: When automatic tensioner is removed from engine, it
is necessary to compress plunger into tensioner body.
Installation (All Models):
Place automatic tensioner into vise and SLOWLY compress
plunger. When plunger is compressed into tensioner body,
install locking pin through body and plunger holes to retain
plunger until tensioner is installed. See Fig. 1.
Index tensioner in vise the same direction as installed.
This will ensure proper pin orientation when tensioner is
installed in engine. See Fig. 1.
Set crankshaft mark with timing mark on oil pump housing,
then back off 3 notches before TDC. See Fig. 2. Set cam-
shaft sprockets by aligning timing marks on sprockets with
marks on rear timing belt cover. See Fig. 3.
NOTE: If reusing old timing belt, install in original direction
of rotation.
Install timing belt on right (next to firewall) camshaft sprocket
first. Install a spring clip to keep belt in position. Keeping
belt taught, install belt under water pump pulley and then
around front camshaft sprocket. Install spring clip on front
sprocket and belt.
Rotate crankshaft clockwise to TDC. Continue routing belt
around idler pulley, crankshaft sprocket, and tensioner pul-
ley. Apply rotating force to crankshaft sprocket in clockwise
direction to tension belt. Ensure all timing marks are still
aligned.
Loosen tensioner pulley center bolt. Position tensioner pul-
ley with pin holes facing down. Install Adapter (MD998767)
or equivalent, and torque wrench, to tensioner pulley. See
Fig. 4. Apply 39 INCH Ibs. (4.4 N.m) in a counterclockwise
direction to tensioner. Tighten tensioner bolt to specifica-
tion, without letting tensioner pulley rotate.
With torque being applied to tensioner pulley, install auto-
matic tensioner (with locking pin in place) to tensioner pul-
ley bracket. Tighten bolts to specification. Pull tensioner
plunger locking pin.
109
CHRYSLER
*2.5L V6 (Cont.)
Fig. 2: Setting Crankshaft Sprocket
Fig. 3: Aligning Camshaft Sprockets
Fig. 1: Compressing Tensioner
Rotate crankshaft 2 revolutions clockwise, and check align-
ment of timing marks. Install tensioner locking pin into au-
tomatic tensioner. Pin should slide in and out with no re-
sistance. Even if locking pin cannot be easily inserted, belt
tension is okay if automatic tensioner plunger projection is
within .149-.177 (3.8-4.5 mm). Projection is measured
between top edge of automatic tensioner housing and arm
of tensioner pulley bracket. Retension timing belt, if neces-
sary.
Install timing belt covers. Install crankshaft vibration damper.
Tighten crankshaft damper bolt to specification.
NOTE: Reamer bolt head will have a R marking for identi-
fication.
Install engine mount bracket. On Avenger and Sebring
Coupe, when installing engine support bracket to engine
block, tighten top reamer bolt slowly while spraying it with
lubricant. Attach engine mount so arrow on side plate points
toward engine.
On all models, reverse removal procedure to complete in-
stallation. Adjust the drive belts to proper tension. See page
Crankshaft Vibration Damper Bolt .............................. 134 (182)
Engine Mount Bracket-To-Engine Block
Cirrus, Sebring Convertible & Stratus ....................... 33 (45)
Engine Mount-To-Engine Support Bracket Bolt/Nut
Avenger & Sebring Coupe.......................................... 64 (86)
Engine Mount-To-Frame Through Bolt
Avenger & Sebring Coupe................................ 72-87 (98-118)
Engine Support Assembly-To-Engine Mount Bracket
Avenger & Sebring .......................................... 47-54 (64-74)
Engine Support Assembly-To-Frame Rail
Avenger & Sebring ........................................... 47-54 (64-74)
Cirrus, Sebring Convertible & Stratus ......................... 45 (61)
Engine Support Bracket-To-Engine Block Bolt
Avenger & Sebring Coupe................................. 47-54 (64-74)
Generator Mount Bracket-To-Engine Block
Avenger & Sebring Coupe............................................ 30 (41)
Power Steering Pump Bracket-To-Engine Bolts
Avenger & Sebring Coupe............................................ 16 (22)
Cirrus, Sebring Convertible & Stratus ........................... 40 (54)
Timing Belt Tensioner Pivot Arm Bolt ............................ 33 (44)
Timing Belt Tensioner-To-Engine Bolt ........................ 17 (23)
Water Pump Bolt ........................................................ 18 (24)
Wheel Lug Nut
Avenger & Sebring Coupe.............................. 65-80 (88-108)
INCH Lbs. (N.m)
Timing Belt Cover Bolts.................................... 89-106 (10-12)
110
CHRYSLER
3.0L V6 SOHC
Belt
3.0L V6
Acclaim & Spirit
1989-95.......... 4.0 Hrs. ..... 2521390......... 250139
Caravan, Mini Ram Van & Voyager
1987-00..........
1
3.8 Hrs. ... 2521390......... 250139
Daytona (Includes Canadian)
1990-93.......... 4.0 Hrs. ..... 2521390......... 250139
Dynasty (Includes Canadian)
1988-93.......... 4.0 Hrs. ..... 2521390......... 250139
LeBaron
1990-95.......... 4.0 Hrs. ..... 2521390......... 250139
New Yorker
1988-89.......... 4.0 Hrs. ..... 2521390......... 250139
Raider
1989............... 3.5 Hrs. ..... 2521390......... 250139
Ram 50
1990-91.......... 3.5 Hrs. ..... 2521390......... 250139
Shadow & Sundance
1992-94.......... 4.0 Hrs. ..... 2521390......... 250139
Stealth
1991-96.......... 2.0 Hrs. ..... 2521390......... 250139
TC Maserati
1990-91.......... 4.0 Hrs. ..... 2521390......... 250139
1
kits.
timing belt be replaced at 60,000. For 1994-96 model years,
the manufacturer recommends the timing belt be replaced at
60,000 miles, except in California. In California, timing belt
replacement is recommended, but not required at 60,000
miles. Replace the timing belt at 100,000 miles, unless previ-
ously changed.
For 1997-00 model years, the manufacturer recommends the
belt be inspected at 60,000, and replaced if necessary.
Inspect belt at 90,000 miles, and replace if necessary. This
maintenance is NOT required if belt was replaced at 60,000.
Inspect belt at 120,000 miles, and replace if necessary. This
maintenance is NOT required if belt was replaced at 90,000
miles.
TIMING BELT REMOVAL
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New
Yorker, Shadow, Spirit & Sundance (1987-89):
Disconnect negative battery cable. Support engine and
transmission with floor jack. Remove front engine mount
bracket. Remove upper (front outer) timing belt cover. Align
timing marks on front and rear camshaft sprockets and
timing mark on crankshaft sprocket. See Fig. 1.
Remove crankshaft pulleys and vibration damper. Loosen
timing belt tensioner bolt and remove timing belt.
Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit,
Sundance & TC (1990-96):
belts. Remove A/C compressor and power steering pump
with hoses attached and secure aside (if equipped). Re-
move A/C compressor mounting bracket and drive belt
tensioner. Remove power steering/alternator belt tensioner.
Raise and support vehicle. Remove right inner fender
shield. Remove crankshaft pulleys and vibration damper.
Lower vehicle. Support engine with floor jack. Separate right
(timing belt side) engine mount from engine mount bracket
located in front of timing belt cover.
Slightly raise engine. Remove engine mount bracket. Re-
move timing belt covers, noting bolt length for installation
reference. Rotate engine and align timing marks on cam-
shaft sprockets and crankshaft sprocket. See Fig. 1. If re-
using timing belt, mark direction of timing belt rotation for
installation reference.
Loosen timing belt tensioner bolt. Move timing belt tensioner
away from timing belt. Remove timing belt. Note direction
of flange installation on front of crankshaft, in front of crank-
shaft sprocket. Remove flange and crankshaft sprocket from
crankshaft (if necessary).
If removing camshaft sprocket, hold camshaft by engaging
Camshaft Sprocket Holder (MB990775) in the holes on front
of camshaft sprocket. Remove camshaft sprocket bolt and
washer. Remove camshaft sprocket.
Caravan & Voyager:
Raise vehicle. Remove accessory drive belt splash shield.
Remove accessory drive belts. Remove crankshaft pulleys
and vibration damper.
Lower vehicle. Support engine weight with floor jack. Re-
move purge duty solenoid and wiring harness from right
engine mount bracket.
Remove 2 right engine mount insulator vertical bolts Re-
move the one horizontal fastener. DO NOT remove large
nut from center bolt of insulator rubber. Remove horizontal
and vertical fasteners from engine side of mount. Remove
engine mount.
Fig. 1: Locating Timing Belt & Sprockets
111
(Raider & Ram 50)
CHRYSLER
If timing belt is to be reused, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt
tensioner.
Stealth:
Remove lower splash shields. Remove cruise control ac-
tuator (if equipped). Remove all drive belts. Unplug electri-
cal connector at power steering pump. Remove A/C
tensioner pulley and mounting bracket.
Remove power steering pump, leaving hoses connected,
and wire aside. Support engine. Remove front engine mount
through-bolt and front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal
as bolt is sometimes seized in engine support bracket.
Remove engine support bracket bolts in proper sequence.
See Fig. 3. Remove engine support bracket. Remove tim-
ing cover cap, timing belt cover, and gaskets. Using Holder
(MB990767) and Adapter Bolts (MD998719), remove crank-
shaft pulley.
Remove lower timing belt cover, gaskets, and flange. Ro-
tate crankshaft to align all timing marks. See Fig. 1. Loosen
belt tensioner bolt. Rotate belt tensioner counterclockwise
to relieve belt tension.
If reusing timing belt, place arrow on belt to indicate belt
running direction. Remove timing belt and belt tensioner.
TIMING BELT INSPECTION
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for signs of oil contamination, cracks, separation, worn or
missing teeth, or hardened black surface. Replace belt if worn,
damaged or contaminated. Inspect belt tensioner for smooth
rotation. Replace if defective.
TIMING BELT INSTALLATION
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New
Yorker, Shadow, Spirit & Sundance (1987-89):
Install belt tensioner and tensioner spring. Install tensioner
spring between water pump retaining pin and tensioner
bracket with hook of spring facing outward. Turn tensioner
full counterclockwise in adjustment slot and tighten tem-
porarily to hold tensioner in position.
Install timing belt on crankshaft sprocket first while keep-
ing belt tight on tension side. See Fig. 1. Install belt on
radiator side camshaft sprocket. Then, install belt on water
pump pulley and rear camshaft sprocket and finally on tim-
ing belt tensioner.
Apply rotating force to front camshaft sprocket in opposite
direction of tension side of belt. Ensure all timing marks
are aligned. Install crankshaft sprocket flange. Loosen
Remove engine support bracket from front of engine. Re-
move timing belt covers, noting bolt length for installation
reference. Note direction of flange installation on front of
crankshaft, in front of crankshaft sprocket. Remove flange.
Rotate crankshaft and align timing marks on camshaft
sprockets and crankshaft sprocket. See Fig. 1. If reusing
timing belt, mark direction of timing belt rotation for instal-
lation reference.
Loosen timing belt tensioner bolt. Move timing belt tensioner
away from timing belt and temporarily tighten bolt. Remove
timing belt.
Raider & Ram 50:
Disconnect negative battery cable. Drain cooling system.
Disconnect upper radiator hose. Remove upper radiator
shroud. Remove cooling fan and fan clutch assembly. Re-
move cooling fan pulley. Remove all accessory drive belts.
Remove power steering pump with pressure and return
hoses connected and set aside.
Remove power steering pump brackets. Remove A/C
tensioner pulley and mounting bracket. Remove A/C com-
pressor with hoses connected and mounting bracket. Re-
move cooling fan bracket assembly. Remove timing belt
No. 1 upper outer cover and gaskets. See Fig. 2.
Remove timing belt No. 2 upper outer cover and gaskets.
Remove timing belt lower outer cover and gaskets. Using
Holder (MB998747) or equivalent, and a used V belt, re-
move crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine
V belt to hold crankshaft pulley unless belt is to be replaced.
Remove flange. See Fig. 2. Rotate crankshaft and align all
timing marks. See Fig. 1. Loosen belt tensioner bolt and
rotate belt tensioner counterclockwise to release belt ten-
sion.
Fig. 3: Engine Support Bracket (Stealth)
112
tensioner from temporary position and allow it to apply ten-
sion to timing belt. Turn crankshaft 2 full turns in a clock-
wise direction ONLY.
NOTE: Turn crankshaft smoothly and ONLY in a clockwise direction.
Again line up all timing marks and tighten tensioner against
belt. Tighten tensioner locking bolt to specification. See
TORQUE SPECIFICATIONS. To complete installation, re-
verse removal procedures. Adjust the drive belts to proper
CAUTION: When reusing timing belt, ensure timing belt is installed
in original direction of rotation.
Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit,
Sundance & TC (1990-96):
Rotate timing belt tensioner counterclockwise and tempo-
rarily tighten bolt. Ensure all timing marks are aligned. See
Fig. 1. Install timing belt on crankshaft sprocket while hold-
ing timing belt tight on tension side. If reusing timing belt,
ensure timing belt is installed in original direction of rota-
tion.
Install timing belt on front (radiator side) camshaft sprocket,
water pump pulley, rear camshaft sprocket and then on
timing belt tensioner. Ensure timing belt is installed in this
order.
Apply rotating force on front (radiator side) camshaft
sprocket in opposite direction to apply pressure on tension
side of timing belt. Ensure all the timing marks align. See
Fig. 1.
Install flange on front of crankshaft sprocket (if removed)
with flat side against timing belt and offset side toward
front of crankshaft. Loosen timing belt tensioner bolt, al-
lowing spring tension to be applied on timing belt tensioner
and timing belt.
Rotate crankshaft clockwise 2 full revolutions. DO NOT ro-
tate crankshaft counterclockwise. Realign all timing marks.
Tighten timing belt tensioner bolt to specification. See
Fig. 4: Identifying Timing Belt Cover Bolt Lengths
(Except Raider, Ram 50 & Stealth)
CHRYSLER
To install remaining components, reverse removal proce-
dure. Ensure timing belt cover bolts are installed in original
location. See Fig. 4. Tighten bolts to specification. Adust
ranges.
Caravan & Voyager:
If timing belt tensioner spring was removed, install spring
on tensioner arm with end of hook facing out (away from
engine).
Ensure all timing marks are aligned. See Fig. 1. Install
timing belt on crankshaft sprocket while holding timing belt
tight on tension side. See Fig. 1. If reusing timing belt, en-
sure timing belt is installed in original direction of rotation.
Install timing belt on front (radiator side) camshaft sprocket,
water pump pulley, rear camshaft sprocket and then on
timing belt tensioner. Ensure timing belt is installed in this
order and there is no slack in belt.
Install flange on front of crankshaft sprocket with fiat side
against timing belt and offset side toward front of crank-
shaft. Loosen timing belt tensioner bolt, allowing spring
tension to be applied on timing belt tensioner and timing
belt.
Slowly rotate crankshaft clockwise 2 full revolutions. DO
NOT rotate crankshaft counterclockwise. Realign all timing
marks. Tighten timing belt tensioner bolt to specification.
See TORQUE SPECIFICATIONS table.
Install timing belt covers. Ensure bolts are installed in origi-
nal locations. See Fig. 4. Install engine support bracket.
Install right side engine mount. Install crankshaft vibration
damper.
CAUTION: Engine support bracket reamer bolt must be tightened
slowly while spraying lubricant on bolt.
Raider & Ram 50:
Install belt tensioner and spring. Ensure spring is secured
on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing away from cylinder block.
Rotate belt tensioner counterclockwise as far as possible
and temporarily tighten bolt. Align all timing marks with No.
1 cylinder at TDC of compression stroke. See Fig. 1.
Install timing belt on crankshaft sprocket and then left cam-
shaft sprocket with all slack removed from tension side of
(Raider & Ram 50)
113
CHRYSLER
belt. Route timing belt onto water pump pulley, right cam-
shaft sprocket and tensioner. Remove any slack from belt
by rotating left and then right camshaft sprockets counter-
clockwise. Ensure all timing marks are aligned. Install
flange on crankshaft. Loosen belt tensioner bolts slightly
and allow tensioner to apply belt tension.
Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise.
Realign all timing marks. Tighten belt tensioner bolts to
specification. Using belt tension gauge, measure belt ten-
sion halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
Belt tension should be 57.3-83.8 Ibs. (26-38 kg). To install
remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers. See Fig. 5. Tighten
tension ranges.
Stealth:
on pin of water pump and engaged in hole of belt tensioner,
with hook of spring pointing away from cylinder block. Ro-
tate belt tensioner counterclockwise as far as possible.
Temporarily tighten bolt. Align all timing marks with No. 1
cylinder at TDC of compression stroke. See Fig. 1.
Install timing belt onto crankshaft sprocket, rear cylinder
bank camshaft sprocket, water pump pulley, front cylinder
bank camshaft sprocket, and timing belt tensioner. Ensure
belt is installed in original direction of rotation, and all tim-
ing marks are aligned. Install flange onto crankshaft.
Loosen belt tensioner bolts slightly, and allow tensioner to
apply belt tension.
Using Crankshaft Socket (MD998716) or equivalent, rotate
crankshaft 2 revolutions clockwise. DO NOT rotate coun-
terclockwise. Realign all timing marks. Tighten belt
tensioner bolts to specification. See TORQUE SPECIFICA-
TIONS. Using belt tension gauge, measure belt tension
halfway between crankshaft sprocket and camshaft
NOTE: Engine support bracket reamer bolt must be tightened
slowly. Apply lubricant onto bolt during installation.
Belt tension should be 44-66 lbs. (20-30 kg). To install
bolts into proper holes. Install covers and engine support
bracket. See Figs. 3 and 6. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper
TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 &
STEALTH)
A/C Compressor Drive Belt
Idler Pulley Bolt ......................................................... 40 (54)
Crankshaft Vibration Damper Bolt .......................... 100 (135)
Engine Bracket-To-Engine Bolt ................................... 35 (47)
Engine Mount-To-Frame Bolt ...................................... 50 (68)
Engine Mount Vertical Bolt ........................................ 75 (102)
Timing Belt Tensioner Pulley Bolt ....................... 18-21 (25-28)
Water Pump Bolts .......................................................... 20 (27)
(Stealth)
TORQUE SPECIFICATIONS (RAIDER & RAM 50)
Montero & Raider ................................... 108-116 (146-157)
Pickup .................................................... 130-137 (176-186)
Left Engine Support Bracket Bolt ...................... 15-21 (20-30)
Rear Engine Support Bracket Bolt .................... 13-18 (18-25)
Right Engine Support Bracket Bolt
10 X 22 mm .................................................... 25-36 (34-49)
10 X 40 mm .................................................... 25-36 (34-49)
12 X 22 mm & 12 X 32 mm ............................. 47-61 (64-83)
Timing Belt Tensioner Bolt ............................... 16-21 (22-29)
Water Pump Bolt .............................................. 14-20 (19-27)
INCH Lbs. (N.m)
Timing Belt Cover Cap Bolt .............................. 84-108 (9-12)
TORQUE SPECIFICATIONS (STEALTH)
Automatic Tensioner Bolt ............................................ 17 (23)
1991 ....................................................... 108-116 (146-157)
1992-94 ................................................................ 136 (185)
Engine Support Bracket Bolt
10 X 40 mm .................................................... 47-54 (64-73)
Except 10 X 40 mm ..................................... 76-83 (103-113)
Timing Belt Tensioner Arm Bolt .................................. 31 (42)
Water Pump Bolt ........................................................ 17 (23)
INCH Lbs. (N.m)
114
CHRYSLER & EAGLE
*1.5L 4-Cylinder SOHC
Belt
Application Time
1
Kit No. No.
1.5L 4-Cyl.
Colt
1985-86.......... 2.8 Hrs. ............................. 250073
1987-90.......... 2.8 Hrs. ...... 2521280........ 250128
1991-94.......... 2.4 Hrs. ...... 2521910........ 250191
Colt (Canadian)
1985-86.......... 2.8 Hrs. ............................. 250073
1989-91.......... 2.8 Hrs. ...... 2521280........ 250128
1992 & 1995... 2.4 Hrs. ...... 2521910........ 250191
Summit
1989-90.......... 2.8 Hrs. ...... 2521280........ 250128
1991-96.......... 2.4 Hrs. ...... 2521910........ 250191
Vista (Canadian)
1989-91.......... 2.8 Hrs. ...... 2521280........ 250128
1992............... 2.4 Hrs. ...... 2521910........ 250191
1
kits.
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner
assembly, then disconnect accelerator cable and oxygen
lead sensor. Mark position of spark plug wires for installa-
tion, then remove wires from spark plugs. Support engine
using a suitable engine support bar. Remove left engine
mount bracket. Remove all accessory drive belts and pul-
leys.
CAUTION: DO NOT rotate engine counterclockwise (as viewed
from timing belt end of engine). If reusing timing belt, place reference
mark on timing belt to indicate direction of rotation before removing.
Remove timing belt covers and gaskets, noting bolt lengths
and locations as they are removed. Rotate engine clock-
wise to align timing mark on camshaft sprocket with mark
on cylinder head. Ensure all timing marks are aligned. See
Fig. 1.
Loosen timing belt tensioner bolts. Move tensioner inward
toward water pump. Temporarily tighten bolt in slot side of
tensioner. Remove timing belt from camshaft sprocket. Re-
move crankshaft pulley, and timing belt.
Inspection:
Inspect belt teeth for cracks, damage, or oil contamination.
Inspect all sprockets for damage. Examine belt tensioner
for grease leakage and roughness when pulley is rotated.
Replace components if defective.
Installation:
Ensure crankshaft and camshaft timing marks are aligned.
See Fig. 1. If tensioner was removed, ensure spring is
installed correctly. See Fig. 2. Install timing belt onto crank-
shaft and camshaft sprockets. Ensure tension side is tight
and all timing marks are aligned when camshaft sprocket
is rotated. Install crankshaft pulley. Loosen tensioner mount-
ing bolts. See Fig. 3. Ensure timing belt is not out of posi-
tion and has not jumped a sprocket tooth. Tighten tensioner
bolts.
CAUTION: If pivot bolt is tightened before side bolt, belt tensioner
may rotate, causing belt to be over tightened.
Rotate crankshaft one full revolution clockwise, until crank-
shaft sprocket timing mark aligns with TDC position. Re-
check belt tension. To check belt tension, hold belt tensioner
and timing belt together. Apply slight thumb pressure at
center point of belt tensioner. A tension gauge can also be
used to check belt tension. See Fig. 4.
tension ranges.
1991-85 .......................................................... 47-54 (65-75)
1992-96 ........................................................ 52-74 (70-100)
1991-96 .......................................................... 10-11 (14-15)
Crankshaft Sprocket Bolt
1985 ............................................................... 37-43 (50-58)
1986-96 ........................................................ 52-74 (70-100)
Front Cover Bolt
1985-88 ............................................................ 9-10 (12-14)
Rocker Arm Adjuster Lock Nut
1989-96 .......................................................... 10-13 (14-18)
1985-96 .......................................................... 14-20 (19-27)
INCH Lbs. (N.m)
1985-1990 .................................................... 90-102 (10-11)
1987-88 ..................................................... 108-120 (12-14)
Front Cover Bolt
1989-96 .......................................................... 84-132 (9-15)
Fuel Rail Bolt
1992-96 .......................................................... 84-108 (9-12)
Rocker Cover Bolt
1989-96 ........................................................ 13-17 (1.5-1.9)
Timing Belt Cover Bolt
1989-96 .......................................................... 84-108 (9-12)
Water Pump Pulley Bolt
1986-88 ..................................................... 108-120 (12-14)
1989-96 .............................................................. 72-84 (8-9)
115
CHRYSLER & EAGLE
*1.5L 4-Cylinder SOHC (Cont.)
Fig. 4: Checking Timing Belt Tension With A Gauge
116
Belt
2.0L 4-Cyl. DOHC (4G6)
Laser & Talon
1990-94.......
1 & 2
3.6 Hrs. ... 2521670......
3
250167
1990-94.......
1 & 2
3.6 Hrs. ........................
4
250168
Talon Turbo
1995-98.......
1 & 2
3.6 Hrs. ... 2521670......
3
250167
1995-99.......
1 & 2
3.6 Hrs. ........................
4
250168
2000 GTX (Canadian)
1989-93.......
1 & 2
3.6 Hrs. ... 2521670......
3
250167
1989-93.......
1 & 2
3.6 Hrs. ........................
4
250168
1
- Balance shaft labor time included in camshaft
labor time.
2
3
Timing belt.
4
Balance shaft belt.
kits.
For 1990-94 vehicles, the manufacturer recommends the belt
be replaced every 60,000 miles.
be replaced every 60,000 miles except in California. In Califor-
nia, timing belt replacement is recommended, but not required,
at 60,000 miles. In California, replace timing belt at 100,000
miles.
For 1998 vehicles, the manufacturer recommends the belt be
replaced every 60,000 miles except in California, Connecticut
and Massachusetts, timing belt replacement is recommended
but not required at 60,000 miles. In these states, replace tim-
ing belt at 100,000 miles.
NOTE: Replacement procedures includ revised information from
Chrysler technical service bulletin 09-01-94; January 28, 1994.
TIMING BELT & BALANCE SHAFT BELT
Removal:
Disconnect negative battery cable. Remove engine under-
cover. Place wooden block between jack and oil pan and
raise engine slightly. Remove engine mount assembly near
timing belt cover.
Remove clamp for power steering return hose near timing
belt cover. Remove all drive belts and tensioner bracket.
See Fig. 1. Remove power steering and water pump pul-
leys. Rotate crankshaft clockwise so that No. 1 cylinder is
at TDC of compression stroke. Remove crankshaft pulley.
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
timing marks are aligned. If reusing timing belts, mark timing
belts for direction of rotation.
CHRYSLER & EAGLE
*2.0L 4-Cylinder DOHC, Except VIN Y
Fig. 1: Exploded View Of Timing Belts & Components
Courtesy of Mitsubishi Motor Sales of America
117
Fig. 2: Aligning Timing Belt A Marks (1990-93 Models)
Fig. 4: Timing Belt B (Balance Shaft Belt) Components
CHRYSLER & EAGLE
*2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)
118
Fig. 5: Holding Balance Shaft Stationary
Fig. 6: Inspecting Timing Belt Auto Tensioner
CHRYSLER & EAGLE
Fig. 7: Aligning Timing Belt B (1990-92 Models)
Remove upper timing belt cover and gasket. Remove stub
bolt of engine support bracket and remove center timing
belt cover. Remove lower timing belt cover.
NOTE: Camshaft sprocket dowel pins will be in 12 oclock position
when timing marks are correctly aligned.
Ensure camshaft, crankshaft and oil pump sprocket timing
marks are aligned. See Figs. 2 and 3. Loosen tensioner
pulley center bolt. Move tensioner to relieve timing belt ten-
sion. Remove timing belt. Remove timing belt auto
tensioner. See Fig. 1.
Remove plug from left side of cylinder block. Install a .31"
(8.0 mm) diameter Phillips screwdriver into the hole against
balance shaft. See Fig. 5. Screwdriver must go in at least
2.36 (60 mm) or more. If screwdriver will only go in about
.79-.98 (20-25 mm), turn sprocket one revolution and align
timing mark. Keep screwdriver in place until timing belt is
installed. This ensures that balance shaft driven by oil
pump sprocket remains in correct position.
To remove timing belt B (balance shaft belt), hold crank-
shaft sprocket stationary with a spanner wrench. Remove
crankshaft sprocket bolt. Using gear puller, remove outer
crankshaft sprocket.
Remove crankshaft sensing blade (if equipped). See Fig.
4. Loosen timing belt B tensioner bolt. If reusing timing
belt B, mark direction of belt rotation for reassembly refer-
ence. Remove timing belt B.
Inspection:
Inspect timing belts for damaged teeth and cracking. En-
sure belts are not contaminated with oil. Check tensioners
for free rotation and grease leakage. Replace components
if damaged or if grease leakage exists.
Check timing belt auto tensioner for leaks. Hold timing belt
auto tensioner upright. Measure rod protrusion above edge
of housing. See Fig. 6. Length should be .47 (12 mm).
Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto
tensioner rod moves more than .039 (1 mm), replace the
auto tensioner.
Installation:
Retract rod into auto tensioner housing by placing auto
tensioner assembly in a soft-jawed vise. Close vise
SLOWLY to push rod back into auto tensioner housing.
When pin hole in cylinder aligns with pin hole in rod, insert
set pin. Replace tensioner assembly if rod can be retracted
easily into housing. Install auto tensioner on engine with
set pin in place.
Align balance shaft and crankshaft timing marks with rear
cover. See Figs. 7 and 8. Install timing belt B on sprock-
ets. If using old belt, install belt in original direction of rota-
tion. Ensure there is no slack in tension side of belt.
CAUTION: Ensure tensioner pulley shaft does not rotate when
bolt is tightened or excessive pressure will be applied to tim-
ing belt.
Install timing belt B tensioner so center of tensioner pul-
ley is to the left and above of retaining bolt center. See Fig.
9. Rotate tensioner inward toward timing belt until belt is
tight. Tighten tensioner retaining bolt without letting
tensioner pulley rotate out of position. Check belt deflec-
tion at designated area. Belt deflection should be .20-.28"
(5.0-7.0 mm). Readjust timing belt if belt deflection is not
within specification.
119
CAUTION: Install crankshaft sensing blade and crankshaft sprockets
in correct positions or timing belt may be damaged.
Install crankshaft sensing blade (if equipped) in front of
crankshaft sprocket B, with offset in proper direction. See
Fig. 10. Install crankshaft sprocket A. Apply light coat of
engine oil to crankshaft sprocket bolt threads, and tighten
bolt to specification. See TORQUE SPECIFICATIONS. In-
stall idler pulley (if removed).
Ensure camshaft, crankshaft and oil pump timing marks
are still aligned. See Figs. 2 and 3. DO NOT remove screw-
driver from side of engine block until timing belt is installed.
NOTE: Intake and exhaust camshafts use same camshaft sprocket.
Camshaft sprockets are provided with 2 timing marks. For exhaust
camshaft sprocket, use timing mark on right with dowel pin facing
up. On intake camshaft sprocket, use timing mark on the left
with dowel pin hole on top.
Rotate camshaft sprocket so dowel pins are upward and
away from cylinder head and timing marks are aligned with
cylinder head surface. Timing marks should face each other.
See Figs. 2 and 3.
Install timing belt on intake camshaft sprocket. Install spring
clip to retain timing belt on sprocket. See Fig. 11. Place a
wrench on each camshaft sprocket retaining bolt. Rotate
camshafts so timing marks align with each other.
Install timing belt over exhaust camshaft. Install spring clip
to retain timing belt. Install timing belt over idler pulley, oil
pump sprocket, crankshaft sprocket and tensioner pulley.
Remove spring clips from camshaft sprockets.
Timing Belt Tension Adjustment (1990-92):
Position timing belt tensioner pulley so that the 2 pin holes
in the center eccentric are facing to the left (as viewed from
timing belt end of engine) of the center bolt. Hand tighten
center bolt.
Remove screwdriver from balance shaft hole in side of
engine block. Install plug.
Rotate crankshaft 1/4 turn counterclockwise, then rotate
crankshaft 1/4 clockwise until timing marks are aligned
again. No. 1 cylinder should be at TDC of compression
stroke.
Attach Adapter (MD998767) to tensioner pulley eccentric.
Attach torque wrench to adapter and apply 24 INCH lbs.
(2.7 N.m) of torque in a clockwise direction. See Fig. 15.
With torque applied to eccentric, tighten tensioner pulley
center bolt to 32-40 ft. lbs. (43-55 N.m).
Insert Set Screw (MD998738) through inner timing belt cover
until it contacts tensioner arm. See Fig. 12. Slowly rotate
set screw until set pin can be removed. Remove set screw
from engine.
Rotate crankshaft 6 complete turns clockwise. Wait 15 min-
utes without turning crankshaft. Measure distance between
top of auto tensioner body and tensioner arm. The distance
should be .15-.18 (3.8-4.5 mm). See Fig. 16, Dimension
A. If distance is not correct, timing belt tension will have to
be readjusted. If distance is correct, go to FINAL ASSEM-
BLY.
Lift tensioner pulley upward to apply tension on timing belt.
The 2 pin holes in the center of the tensioner must face
down. See Fig. 12. Screw the Set Screw (MD998738) into
engine support bracket until it makes contact with tensioner
arm. At that point, screw the set screw in a few more threads
and remove the set pin from the auto tensioner. Remove
the set screw. Tighten timing belt tensioner pulley center
bolt to 35 ft. lbs (48 N.m).
Remove screwdriver from side of engine block and install
plug. To tension timing belt, rotate crankshaft about 1/4
turn counterclockwise, then 1/4 turn clockwise until all tim-
ing marks align.
Loosen tensioner pulley center bolt. Install Adapter
(MD998767) or equivalent to tensioner eccentric. Install
torque wrench on adapter. See Fig. 13. Starting with eccen-
tric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m)
of torque counterclockwise on tensioner pulley.
Hold tensioner pulley at specified torque, and tighten
tensioner center bolt to specification. Do not let tensioner
pulley turn with bolt. See TORQUE SPECIFICATIONS.
Rotate crankshaft 2 full revolutions clockwise so that tim-
ing marks are aligned. Allow engine to stand for 15 min-
utes without turning crankshaft. Distance between top of
auto tensioner housing and tensioner arm should be .15-
.18" (3.8-4.5 mm). See Fig. 16, Dimension A. If distance
is incorrect, repeat tensioning procedure until distance is
correct. Once distance is correct, go to FINAL ASSEMBLY.
Final Assembly:
dure. Ensure proper length bolts are installed in timing belt
covers. See Fig. 14. See TIMING COVER BOLT LENGTH &
TORQUE table. Adjust drive belts to proper tension. See
TIMING COVER BOLT LENGTH & TORQUE
Bolt INCH Lbs. (N.m)
A 6 x 16 mm Flange Bolt .............................. 89-106 (10-12)
B 6 x 18 Flange Bolt ..................................... 89-106 (10-12)
C 6 x 25 Loose Washer Bolt ................................... 58 (6.5)
D 6 x 25 Flange Bolt .................................... 89-106 (10-12)
E 6 x 45 Flange Bolt ..................................... 89-106 (10-12)
Fig. 10: Installing Crankshaft Sprocket & Crankshaft
Sensing Blade
Fig. 9: Installing Timing Belt B Tensioner
CHRYSLER & EAGLE
120
CHRYSLER & EAGLE
Fig. 12: Installing Set Screw On Tensioner Pulley
Fig. 13: Adjusting Timing Belt Tension (1993-98)
Fig. 14: Installing Timing Belt Cover Bolts
Fig. 11: Installing Timing Belt On Intake Sprockets
Auto Tensioner Bolt .................................................... 17 (24)
Balance Shaft Sprocket Bolt ......................................... 33 (46)
Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26)
Engine Mount-To-Body
Through Bolt (1993-98) ..................................... 72-87 (98-118)
Through Bolt (1990-92) ...................................... 43-58 (60-80)
Engine Mount-To-Engine
Bolt/Nut (1993-98) ..................................................... 49 (67)
Bolt/Nut (1990-92) ........................................... 36-47 (50-65)
Idler Pulley Bolt ........................................................... 27 (38)
Timing Belt B (Balance Shaft)
Tensioner Bolt .................................................... 11-16 (15-20)
Timing Belt Tensioner Pulley Center Bolt ................... 35 (48)
Water Pump Bolt .......................................................... 10 (14)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................... 89-106 (10-12)
Water Pump Pulley Bolt ................................................ 80 (9)
Fig. 16: Measuring Timing Belt Auto Tensioner Protrusion
121
Belt
2.0L 4-Cyl. SOHC
Colt Vista
1984-86
Balance Shaft .....
1
.................................. 250090
Camshaft ............
2
2.8 Hrs. ..................... 250089
1987-91
Balance Shaft .....
1
.................................. 250159
Camshaft ............
2
2.8 Hrs. . 2521581..... 250158
Ram 50
1983-86
Balance Shaft ...
1
.................................. 250090
Camshaft ...........
3
2.3 Hrs. ..................... 250089
1987-89
Balance Shaft ...
1
.................................. 250159
3
2.3 Hrs. . 2521581..... 250158
Vista (Canada)
1989-91
Balance Shaft ...
1
.................................. 250159
2
2.8 Hrs .. 2521581..... 250158
2000GTX (Canada)
1989-92
Balance Shaft ..
1
.................................. 250159
Camshaft .........
2
2.8 Hrs. ..................... 250155
1
- Balance Shaft labor time included in camshaft
labor time.
2
3
kits.
mile intervals.
TIMING BELT
Removal:
Disconnect negative battery cable. On vehicles equipped
with A/C, remove upper radiator shroud and cooling fan/
clutch assembly. On 1989-91 models, support engine and
remove upper engine mount located near timing belt cover.
On all vehicles, position No. 1 cylinder at TDC of compres-
sion stroke. Loosen pulley bolts. Remove drive belts. Re-
move crankshaft, water pump and power steering pulleys.
Remove upper and lower front timing belt covers.
On 1989-91 models, remove tensioner pulley bracket.
Relieve camshaft timing belt tensioner pressure and se-
cure tensioner toward water pump. If camshaft timing belt
is to be reused, mark belt with an arrow indicating direction
of rotation and remove camshaft timing belt.
Rotate crankshaft in direction of rotation and align timing
marks. See Fig. 1. Remove crankshaft sprocket attaching
bolt. Loosen main tensioner pivot and disengage spring
from boss on water pump. Remove tensioner assembly.
Remove balance shaft belt (belt A).
Remove camshaft sprocket, then crankshaft sprocket and
flange. Remove plug from lower left side of cylinder block,
then insert screwdriver into hole to hold balance shaft in
position while removing oil pump sprocket nut. See Fig. 2.
Loosen right side balance shaft sprocket bolt, then remove
balance shaft belt tensioner. Remove balance shaft timing
belt (belt B).
Inspection:
Inspect back of belt for hardness, non-elasticity and glossy
surface. If no mark is produced when fingernail is forced
into it, replace belt. Check for rounded sides on belt, flak-
ing, peeling, cracking and separating rubber. Cracks are
most evident at base of tooth.
Installation:
Install timing belt B, ensuring tension side has no slack.
Align crankshaft and balance shaft sprocket timing marks
with marks on timing case. See Fig. 3. Install tensioner B
so only light pressure is on belt. Ensure flange on tensioner
is mounted away from engine and finger-tighten bolt. En-
sure that the pulley is to left of installation bolt and pulley
flange faces front of engine. See Fig. 4.
Lift tensioner with finger tip until slack is removed from
tension side of belt. Tighten tensioner bolt, being careful to
prevent turning shaft. Ensure timing marks are in align-
ment. Tighten right silent shaft bolt.
Check belt tension by pressing center of tension side in-
ward, using index finger and measuring belt deflection.
Deflection should be .195-.265" (5.0-7.0 mm). Readjust if
not within specification.
Ensure camshaft timing belt sprockets align with timing
marks. Ensure tensioner is fully toward water pump and
install camshaft timing belt (belt A) in order of crankshaft
sprocket, oil pump sprocket and camshaft sprocket. En-
sure tension side of belt has no slack. Loosen tensioner
mounting bolt and nut and allow tensioner spring to ten-
sion belt.
Tighten slot side bolt and then tighten nut. Ensure all timing
marks are in correct alignment. Turn crankshaft clockwise
one revolution. Loosen mounting nut and bolt to allow
tensioner to readjust. Tighten slot side bolt, then tighten nut.
Reverse removal procedure to complete reassembly. Adjust
drive belts to proper tension. See page A-60 for belt tensiion
ranges.
CHRYSLER & EAGLE
2.0L 4-Cylinder SOHC
122
Fig. 2: Locking Balance Shaft In Place
Fig. 3: Aligning Balance Shaft Sprocket
Fig. 4: Installing Balance Shaft Tensioning Pulley
Automatic Tensioner Bolt .................................. 14-20 (19-27)
1983-85 .......................................................... 11-15 (15-20)
1986-91 .......................................................... 15-21 (20-29)
Front Cover Bolts
1983-88 .......................................................... 15-19 (20-26)
1989 M8 X 30 Bolt ........................................... 20-26 (27-35)
Except 1989 M8 X 30 Bolt ............................... 14-20 (19-27)
Idler Pulley Bolt ................................................. 25-30 (34-41)
Tensioner Pulley Center Bolt ............................ 31-40 (42-54)
Left Lower Rear Cover Bolt ............................. 22-30 (30-41)
Timing Belt Tensioner Nut
1983-85 .......................................................... 16-21 (22-28)
1986-91 .......................................................... 32-39 (42-53)
Water Pump Bolt
Except 8 X 65 mm ............................................ 9-11 (12-15)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
All Except Left Lower Rear Cover Bolt ............ 84-108 (9-12)
CHRYSLER & EAGLE
2.0L 4-Cylinder SOHC (Cont.)
123
CHRYSLER & EAGLE
*3.2L & 3.5L V6
3.2L V6
Concord & Intrepid (Includes Canadian)
1998-00 ..............
1
2.8 Hours ................. 250295
3.5L V6
Concord & Intrepid (Includes Canadian)
1993-94 ..............
1
2.7 Hours ................. 250219
1995-97................
1
2.7 Hours ................. 250255
2000 ...................
1
2.7 Hours ................. 250295
LHS & 300M
1994 ...................
1
2.7 Hours ................. 250219
1995-97 ..............
1
2.7 Hours ................. 250255
1998-00 ..............
1
2.7 Hours ................. 250295
New Yorker
1994 ...................
1
2.7 Hours ................. 250219
1995-96 ..............
1
2.7 Hours ................. 250255
Vision
1993-94 ..............
1
2.7 Hours ................. 250219
1995-97 ..............
1
2.7 Hours ................. 250255
1
105,000 miles up to the 1999 model year. For 2000 model
years, the manufacturer recommends the timing belt be re-
placed at 100,000 miles for Federal vehicles, and 105,000
miles for California vehicles.
*NOTE: The 3.2L is an interference engine. See page
TIMING BELT
CAUTION: The following procedure can only be used if camshaft
sprockets have NOT been loosened or removed. If camshaft sprockets
have been removed, special tools and timing procedure are required.
Consult service information for procedure.
Removal:
Disconnect negative battery cable from jumper terminal.
Remove upper radiator crossmember. Remove electric cool-
ing fan module with fans.
Remove accessory drive belts. Hold crankshaft damper
stationary while removing center bolt. Use gear puller to
remove crankshaft damper.
Remove lower timing belt cover. Remove stamped steel
(right side) timing belt cover. DO NOT remove the sealer on
the stamped steel cover, it is reusable.
Remove cast (left side) timing belt cover. If reusing old tim-
ing belt, mark belt direction of rotation for reinstallation.
CAUTION: Align camshaft sprockets between marks on rear belt
covers before removing timing belt or damage to valves and
pistons may occur.
Rotate crankshaft to align crankshaft sprocket timing mark
with TDC mark on oil pump housing. Align camshaft sprock-
ets with marks on rear covers. See Figs. 1 and 2.
CAUTION: When timing belt tensioner is removed from engine,
always store tensioner with plunger facing up.
Remove timing belt tensioner. Store with plunger facing up.
Remove timing belt.
Installation:
When tensioner is removed from engine, it is necessary to
compress plunger into tensioner body. Place timing belt
tensioner in vise with holes in plunger and housing aligned.
SLOWLY compress plunger. See Fig. 3. Total bleed down
of plunger should take about 5 minutes. When pin holes
are aligned, install locking pin through tensioner and
plunger.
Ensure camshaft and crankshaft sprocket timing marks
are still aligned. If camshaft timing marks are not aligned,
always rotate camshafts towards nearest timing marks.
DO NOT turn camshafts a full revolution. This could cause
valves to contact pistons.
Install timing belt starting at crankshaft sprocket, going in a
counterclockwise direction. After belt is installed on right
camshaft sprocket, keep tension on belt until it is past
tensioner pulley.
Holding tensioner pulley against belt, install tensioner into
housing and tighten bolts to specification. See TORQUE
SPECIFCATIONS. When tensioner is in place, pull locking
pin to allow tensioner to extend to pulley bracket.
124
Fig. 3: Compressing Tensioner
Fig. 2: Removing/Installing Timing Belt
CHRYSLER & EAGLE
*3.2L & 3.5L V6 (Cont.)
Rotate crankshaft sprocket 2 revolutions and check timing
marks on camshafts and crankshaft. Marks should line up
within their respective locations. If marks do not line up,
repeat procedure. See Fig. 1.
Install timing belt covers and crankshaft damper. Install
accessory drive belts. To complete installation, reverse re-
Start engine and allow to idle for about one minute. If noise
is present in timing belt tensioner, air has possibly entered
tensioner. To remove air, run engine at 1600-2000 RPM for
10 minutes to purge air.
M8 ............................................................................ 21 (28)
M10 .......................................................................... 40 (54)
Timing Belt Tensioner Pulley Assembly ....................... 45 (61)
INCH Lbs. (N.m)
Timing Belt Cover Bolts (M6) .................................... 106 (12)
Upper Radiator Attaching Screws ............................. 123 (14)
Water Pump Bolts .................................................... 106 (12)
125
CHRYSLER, EAGLE & MITSUBISHI
*1.6L 4-Cylinder DOHC
1
Belt Part No.
1.6L 4-Cyl. DOHC
Colt & Summit
1989-90................. 3.6 Hours .................. 250165
Colt 100, Colt 200 & Vista (Canada)
1989-90................. 3.6 Hours .................. 250165
Mirage
1989 & 1991-92..... 3.6 Hours .................. 250165
1
60,000 miles.
NOTE: Replacement procedures include revised information
from Chrysler technical service bulletin 09-01-94; January 28,
1994.
TIMING BELT
Removal:
Raise and support vehicle. Remove lower left engine com-
partment splash shield. Support weight of engine from
above with Suppport Fixture (C-4852 or 7137) or equiva-
lent. On timing belt end of engine, remove engine mount
bracket connecting engine to body.
Loosen, but do not remove water pump pulley bolts. Re-
move generator and power steering pump drive belts. Re-
move water pump pulley.
NOTE: It is necessary to lower engine slightly to remove the crankshaft
pulley.
Remove accessory drive belt tensioner pulley bracket. See
Fig. 1. Remove A/C compressor drive belt (if equipped).
Remove water pump pulley. Remove crankshaft pulley-to-
crankshaft sprocket bolts. Remove crankshaft pulley. It is
NOT necessary to remove crankshaft pulley center bolt.
Remove upper and lower timing belt covers.
CAUTION: Crankshaft may need to be rotated up to 6 revolutions
before all sprockets are properly aligned.
Rotate engine clockwise (as viewed from timing belt end of
engine) to align all timing marks so No. 1 cylinder is at TDC
of compression stroke. See Fig. 2. If reusing belt, mark belt
with original rotation direction.
Remove rubber plug from inner timing belt cover. Install
Set Screw (MD998738) into engine support bracket until it
contacts auto tensioner arm. See Fig. 3. Remove auto
tensioner. Loosen timing belt tensioner pulley center re-
taining bolt.
Compress auto tensioner push rod by SLOWLY rotating
Set Screw (MD998738) until hole in auto tensioner aligns
with hole in auto tensioner body. Push rod may need to be
rotated to align holes. Insert a 1/16 Allen wrench or pin into
aligned holes to hold push rod in compressed position.
Remove timing belt.
Inspection:
Check belt teeth for cracks, damage and oil contamination.
and idler pulley for grease leakage and roughness in rota-
Inspect auto tensioner for leaks. Replace, if necessary. In-
spect tensioner pulley and idler pulley for smooth rotation.
Replace if bearings are worn.
CAUTION: Install flange and crankshaft sprocket in correct direction
to prevent damage to timing belt.
Installation:
Rotate timing belt tensioner pulley so that the 2 pin holes
are to the left of the center bolt. See Fig. 4. Tighten center
bolt finger tight. Leave Allen wrench or pin installed in auto
tensioner.
Rotate camshaft sprockets so dowel pins face upward and
timing marks on sprockets align. See Fig. 2. Outer marks
on sprockets should be aligned with cylinder head surface.
When exhaust camshaft sprocket is released, camshaft
will rotate one tooth in counterclockwise direction. When
installing timing belt, ensure this rotation is compensated
for.
Rotate crankshaft and align timing marks on crankshaft
and oil pump sprockets. If installing old timing belt, ensure
it is installed in original direction of rotation.
Install timing belt around intake camshaft sprocket. Install
spring-type paper clip on timing belt and camshaft sprocket
to hold belt on sprocket. Clip should be installed below
cylinder head surface, on outer side of camshaft sprocket.
Install box wrench on both camshaft sprocket bolts. Install
timing belt around exhaust camshaft sprocket while hold-
ing camshaft sprocket bolt to align timing mark on cam-
shaft sprocket with timing mark.
Install another spring-type paper clip on timing belt and
exhaust camshaft sprocket to hold belt on sprocket. Install
clip below cylinder head surface, on outer side of camshaft
sprocket.
Install timing belt in the following order: around idler pulley,
oil pump sprocket, crankshaft sprocket and tensioner pul-
ley. Remove both spring-type paper clips. Rotate tensioner
pulley inward toward timing belt until belt is NOT sagging.
Temporarily tighten center bolt on tensioner pulley. Ensure
all timing marks are aligned.
CAUTION: Ensure all timing belt teeth are engaged with teeth
on camshaft, oil pump and crankshaft sprockets.
To adjust belt tension, rotate crankshaft 1/4 turn counter-
clockwise, then rotate clockwise until No. 1 cylinder is at
TDC. Ensure timing marks are aligned. Loosen center bolt
on tensioner pulley.
Note pin holes in tensioner pulley. Use socket wrench to
rotate tensioner pulley. Using INCH lb. torque wrench and
Socket Wrench (MD998752), apply a clockwise torque of
24 INCH Ibs. (2.7 N.m) on tensioner pulley. See Fig. 5. With
torque applied to tensioner pulley, tighten tensioner pulley
center bolt to 32-41 ft. Ibs. (43-55 N.m).
SLOWLY rotate set screw until Allen wrench or pin can be
removed from auto tensioner. Remove set screw.
Rotate crankshaft clockwise 6 complete revolutions and
leave in this position for approximately 15 minutes. After 15
minutes, measure distance between bottom edge of
tensioner arm and top of auto tensioner body. Distance
should be .15-.18" (3.8-4.5 mm). See Fig. 7, Dimension
A.
126
*1.6L 4-Cylinder DOHC (Cont.)
127
Fig. 3: Retracting Auto Tensioner Rod
Fig. 4: Positioning Timing Belt Tensioner Pulley
If distance is not correct, loosen timing belt tensioner pul-
ley center bolt. Use Set Screw to compress auto tensioner
again. Readjust timing belt tension using Socket Wrench
(MD998752) and INCH lb. torque wrench until correct dis-
tance of .15-.18" (3.8-4.5 mm) is obtained.
Remove set screw. Install rubber plug in rear timing belt
cover. Install upper and lower timing belt covers. Ensure
timing belt cover bolts are installed in correct location. See
Fig. 6.
Install crankshaft pulley. Install A/C compressor belt (if
equipped). Install accessory drive belt tensioner bracket.
Install water pump pulley. Install generator and power steer-
ing pump drive belts. Adjust drive belts to correct tension.
Install engine mount bracket on timing belt end of engine.
Remove engine support fixture. Install lower splash shield.
Accessory Drive Belt
Tensioner Pulley Bracket Bolt ......................... 17-20 (23-27)
Auto Tensioner Bolt .......................................... 14-20 (19-27)
Crankshaft Pulley-To-Sprocket Bolt .................. 14-22 (19-30)
Crankshaft Sprocket Center Bolt .................. 80-94 (109-127)
Engine Mount Bracket
To-Body Through Bolt ........................................ 43-58 (60-80)
To-Engine Bracket Bolt/Nut ............................... 36-47 (50-65)
Timing Belt Cover
Left Lower Rear Cover Bolt ............................. 22-30 (30-41)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ....................................... 84-106 (10-12)
128
Belt
Application Time
1
Kit No. No.
1.8L 4-Cyl.
Eclipse & Laser
1990-94
Balance Shaft ....
2
................................ 250159
Camshaft ......... 2.4 Hrs. .. 2521580....... 250158
Talon
1993-94
Balance Shaft ....
2
................................ 250159
Camshaft ......... 2.4 Hrs. .. 2521580....... 250158
1
2
Balance shaft labor time included in
camshaft labor time.
kits.
60,000 miles.
TIMING BELT
CAUTlON: To prevent engine damage, DO NOT rotate crankshaft
Removal:
Disconnect negative battery cable. Disconnect power steer-
ing hose clamp. Remove engine undercover. Place wooden
block between jack and oil pan. Raise engine slightly.
Remove engine mount assembly near timing belt cover.
Remove all drive belts and tensioner pulley bracket. See
Fig. 1. Remove power steering, water pump and damper
pulleys. Remove adapter and crankshaft pulley.
NOTE: Ensure timing marks are aligned. Mark direction of rotation
of all timing belts.
Remove upper and lower timing belt covers and gas-
kets. Remove access cover. Remove crankshaft sprocket
A bolt and washer. Rotate crankshaft clockwise (as
viewed from timing belt side of engine), and align timing
mark on camshaft sprocket with timing mark on rear up-
per timing belt cover. See Fig. 2.
Loosen timing belt tensioner bolt for timing belt A. Move
tensioner toward water pump, and tighten tensioner bolt. Re-
move timing belt.
Remove timing belt tensioner, tensioner spacer and tensioner
spring. See Fig. 1. Remove camshaft sprocket. Remove plug
from side of cylinder block, and install a .31" (8.0 mm) diam-
eter Phillips screwdriver to hold left silent shaft. See Fig. 3.
Remove oil pump sprocket nut, and remove sprocket. Re-
move crankshaft sprocket A and flange. Remove timing
belt tensioner B. If timing belt B is to be reused, mark
direction of timing belt rotation for reassembly reference.
Remove timing belt B.
Inspection:
Inspect timing belts for damaged teeth or cracks. Ensure
belts are not contaminated by oil. Check tensioners for
freedom of rotation. Replace components if damaged.
Installation:
Coat outer diameter of right silent shaft spacer with engine
oil. Install spacer with chamfered side toward oil seal. In-
stall right silent shaft sprocket. Align crankshaft sprocket
B and right silent shaft timing marks. See Fig. 5. Install
timing belt B on sprockets. Ensure belt is installed in
original direction of rotation and no slack exists in belt.
CAUTION: Ensure right silent shaft spacer is installed with chamfered
side toward oil seal, or damage to oil seal will result.
CAUTION: When tightening bolt, ensure tensioner does not rotate,
or excessive pressure will be applied to timing belt.
Install timing belt tensioner B so center of pulley is lo-
cated left of tensioner bolt. See Fig. 6. Ensure flange on
tensioner pulley is toward front of engine. Rotate tensioner
inward toward timing belt until belt is tight. Tighten tensioner
bolt.
Check belt deflection at designated area. See Fig. 6. Belt
deflection should be .20-.28" (5.0-7.1 mm). Readjust tim-
ing belt if belt deflection is not within specification.
Install flange in front of crankshaft sprocket B, with offset
toward crankshaft. See Fig. 1. Install crankshaft sprocket
A. install camshaft and oil pump sprockets. Tighten bolts
Install tensioner spring, tensioner spacer and timing belt
A tensioner. Ensure upper end of tensioner spring con-
tacts water pump. Rotate tensioner toward water pump,
and temporarily tighten nut.
Ensure all timing marks are aligned. See Fig. 2. When
aligning oil pump sprocket timing marks, remove plug from
cylinder block. See Fig. 3. Insert a .31" (8.0 mm) diameter
Phillips screwdriver into plug hole.
If screwdriver can only be inserted .79-.98" (20.0-24.9 mm),
rotate oil pump sprocket one revolution, and realign timing
mark. Insert screwdriver, and ensure it can be inserted at
least 2.36" (59.9 mm). DO NOT remove screwdriver until tim-
ing belt is installed.
Install timing belt A on sprockets. Ensure no slack exists
on tension side of belt. See Fig. 2. Install timing belt on
crankshaft sprocket A, oil pump sprocket, and then on
camshaft sprocket. If reused, ensure belt is installed in
original direction of rotation.
Loosen tensioner nut to allow spring tension to be applied
to timing belt. Ensure all timing marks are aligned. Re-
move screwdriver and install plug. To apply tension on tim-
ing belt, rotate crankshaft clockwise so camshaft sprocket
moves 2 teeth past timing mark on rear timing belt cover.
See Fig 7. DO NOT rotate crankshaft counterclockwise.
CAUTION: DO NOT tighten tensioner spacer nut before tightening
tensioner bolt, or timing belt tensioner will rotate and apply
excessive pressure on timing belt.
Rotate tensioner inward toward timing belt. Ensure timing
belt fully engages camshaft sprocket. Tighten timing belt
tensioner bolt. Tighten tensioner spacer nut. At midway loca-
tion between camshaft sprocket and oil pump sprocket, push
timing belt A outward toward lower timing belt cover. Note
clearance between timing belt and cover. See Fig. 8. Clear-
ance should be .47" (12.0 mm). Timing belt may need to be
readjusted.
1.8L 4-Cylinder
129
Fig. 1: Exploded View Of Timing Belts & Related Components
To complete installation, reverse removal procedure. En-
sure proper length bolts are installed in designated areas
in timing belt covers. See Fig. 9. Adjust drive belts to proper
A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27)
Flywheel/Drive Plate Bolt ........................... 94-101 (127-137)
Front Cover Bolt ................................................ 11-13 (15-18)
Timing Belt A Tensioner Bolt .......................... 16-22 (22-30)
Timing Belt B Tensioner Bolt .......................... 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 48-60 (5-7)
Fig. 2: Aligning Timing Belt A Timing Marks
130
Fig. 5: Aligning Timing Belt B Timing Marks
Fig. 7: Applying Tension To Timing Belt A
Fig. 8: Checking Timing Belt A Tension
Fig. 9: Identifying Timing Belt Cover Bolt Locations
Fig. 4: Installing Crankshaft Sprockets
Fig. 3: Holding Silent Shaft In Stationary Position
90C02590 Courtesy of Chrysler Corp.
131
1.8L 4-Cylinder VINs C & D
1
Belt Part No.
1.8L 4-Cyl.
Colt
1992-94................ 2.4 Hours................. 250201
Colt Vista
1992-94................ 2.4 Hours................. 250201
Expo
1992-94................ 2.4 Hours................. 250201
Mirage
1993-96................ 2.4 Hours................. 250201
1997-01................ 2.4 Hours................. 250288
Summit
1992-96 .............. 2.4 Hours................. 250201
Summit Wagon
1992-96 .............. 2.4 Hours................. 250201
1
Chrysler & Eagle: The manufacturer recommends the belt be
replaced every 60,000 miles.
Mitsubishi: For 1992-93 models, the manufacturer recom-
mends the belt be replaced at 60,000 miles.
For 1994-96 models, the manufacturer recommends the belt
miles, unless previously changed.
be replaced every 60,000 miles except in California, Connecti-
cut, and Massachusetts. In California, Connecticut, and Mas-
sachusetts, timing belt replacement is recommended, but not
required, at 60,000 miles. In these states, replace timing belt
at 100,000 miles, unless previously changed.
For 2001 models, the manufacturer recommends the belt be
replaced every 60,000 miles except in California, Massachu-
setts and Vermont. In California, Massachusettes and Ver-
mont, timing belt replacement is recommended, but not re-
quired, at 60,000 miles. In these states, replace timing belt at
100,000 miles, unless previously changed.
TIMING BELT
Removal:
Disconnect negative battery cable. On Expo models, re-
move condenser tank. On all models, remove A/C and
power steering hose mounting bracket from upper en-
gine mount at timing belt cover. Remove all accessory
drive belts. Using End Yoke Holder (MB990767) and Crank-
shaft Pulley Holder (MD998718) or equivalent, remove
crankshaft pulley bolt and pulley.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed
from timing belt end of engine).
Remove upper and lower timing belt covers. Remove
flange. Rotate crankshaft clockwise (as viewed from tim-
Fig. 2: Installing Flange
ing belt end of engine) until cylinder No. 1 is at TDC of
compression stroke, and timing mark on camshaft sprocket
and crankshaft sprocket align with timing mark on engine.
See Fig. 1.
If timing belt is to be reused, mark direction of rotation be-
fore removing. Loosen timing belt tensioner bolt. Using a
screwdriver, move tensioner away from timing belt. Tighten
bolt to secure tensioner. Remove timing belt.
Inspection:
grease leakage or roughness in tensioner rotation. Re-
place components if damaged.
Installation:
Install timing belt tensioner, leaving bolt loose. Using a
screwdriver, push tensioner toward engine mount. Tighten
timing belt tensioner bolt.
Align camshaft sprocket and crankshaft sprocket timing
marks with timing marks on engine.
Install timing belt. Loosen timing belt tensioner to apply
spring pressure to timing belt. Ensure timing marks are
still aligned.
Tighten timing belt tensioner bolt. Rotate camshaft in re-
verse direction and ensure that there is no slack in timing
belt. Rotate crankshaft 2 complete revolutions clockwise
(as viewed from timing belt end of engine) and ensure
timing marks are still aligned.
132
1.8L 4-Cylinder VINs C & D (Cont.)
Fig. 4: Identifying Timing Belt Cover Bolt Locations
Ensure timing belt teeth are properly seated in sprockets.
Install flange. See Fig. 2. To complete installation, reverse
removal procedure. Ensure proper length bolts are installed
in designated areas in timing belt covers. See Fig. 4. Ad-
tension ranges.
Crankshaft Center Pulley Bolt ..................... 80-94 (109-127)
Front Cover Bolt ............................................... 11 -13 (15-18)
Timing Belt B Tensioner Bolt ......................... 11 -16 (15-24)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 48-60 (5-7)
133
2.0L 4-Cyl. DOHC, VIN Y
Avenger, Neon,
& Sebring Coupe
1995-99................
1
3.6 Hours ................. 250246
Eclipse (Non-Turbo)
1995-99................
1
3.6 Hours ................. 250246
Talon (Non-Turbo)
1995-98................
1
3.6 Hours ................. 250246
1
Chrysler: On Neon models, the manufacturer recommends
replacing the timing belt at 105,000 miles.
On Avenger and Sebring Coupe models, the manufacturer
recommends the belt be replaced every 60,000 miles except
in California, Connecticut, and Massachusetts. In California,
Connecticut, and Massachusetts, timing belt replacement is
recommended, but not required, at 60,000 miles. In these
states, replace timing belt at 100,000 miles.
Eagle: For 1995-96 model years, the manufacturere recom-
mends the belt be replaced every 60,000 miles, except in
California. In California, timing belt replacement is recom-
mended, but not required, at 60,000 miles. In California, re-
place timing belt at 100,000 miles, unless previously changed.
belt be replaced every 60,000 miles except in California, Con-
necticut, and Massachusetts. In California, Connecticut, and
Massachusetts, timing belt replacement is recommended,
but not required, at 60,000 miles. In these states, replace
timing belt at 100,000 miles, unless previously changed.
Mitsubishi: For 1995-97 model years, the manufacturer rec-
ommends the belt be replaced every 60,000 miles except in
California. In California, timing belt replacement is recom-
mended, but not required, at 60,000 miles. In California, re-
place timing belt at 100,000 miles, unless previously changed.
TIMING BELT
Removal (Mechanical Timing Belt Tensioner):
On Avenger and Sebring, remove coolant reservoir and place
out of way. On all models, raise and support vehicle. Re-
move right inner splash shield. Remove center bolt from
crankshaft pulley. Use gear puller to remove crankshaft
pulley.
mounting bracket from engine. Move out of way.
Lower vehicle. Place jack under engine for support. Re-
move right side engine mount. Remove engine mount
*2.0L 4-Cylinder DOHC, VIN Y
Fig. 1: Aligning Timing Marks & Adjusting Belt Tension
(Mechanical Timing Belt Tensioner)
bracket from front of engine. Remove timing belt cover. Ro-
tate engine clockwise to align the camshaft and crankshaft
timing marks. See Fig. 1.
Install 8 mm Allen wrench into timing belt tensioner. See
Fig. 1. Insert long end of a 3 mm Allen wrench into pin hole
in the front of tensioner. Slowly rotate tensioner counter-
clockwise with 8 mm Allen wrench while pushing lightly on
the 3 mm Allen wrench, until it slides into the locking hole.
NOTE: Mechanical timing belt tensioner is serviced as an assembly.
To prevent premature timing belt failure and engine damage,
do not separate tensioner pulley from tensioner bracket.
134
*2.0L 4-Cylinder DOHC, VIN Y (Cont.)
Loosen timing belt tensioner to remove timing belt. If reus-
ing old belt, mark belt with arrow to indicated direction of
rotateion. Remove timing belt.
Remove tensioner from engine. It will be necessary to com-
press the center plunger and lock it in place.
Place tensioner in a soft-jawed vise. Align the hole in the
end of the tensioner center plunger with the hole in the end
of the tensioner body. Slowly compress the tensioner, and
when holes are aligned, insert a locking pin in the tensioner.
NOTE: The following revised information regarding the tensioner
pulley pivot bolt is from Chrysler technical service bulletin 09-
06-96; March 29, 1996. Also Mitsubishi technical service bulletin
96-11-004; May 1996.
Timing Belt Tensioner Bracket Precaution:
On models with hydraulic timig belt tensioner, do not
loosen, tighten, or remove timing belt tensioner pivot bolt.
Bolt is installed at factory with special threadlocking com-
pound that is not reusable. If tensioner pivot bolt is dis-
turbed, entire bracket assembly must be replaced. The
tensioner pulley center bolt MAY be removed and installed.
Inspection:
Installation (Hydraulic Timing Belt Tensioner):
Ensure camshaft and crankshaft timing marks are aligned.
Rotate crankshaft pulley sprocket 1/2 tooth counterclock-
wise from TDC location. See Fig. 3.
Fig. 3: Aligning Crankshaft Timing Mark
(Hydraulic Timing Belt Tensioner Shown; Mechanical
Tensioner Similar)
Inspection:
Installation (Mechanical Timing Belt Tensioner):
Ensure camshaft and crankshaft timing marks are aligned.
Rotate crankshaft pulley sprocket 1/2 tooth counterclock-
wise from TDC location. See Fig. 3.
Install timing belt starting from crankshaft pulley sprocket,
go around water pump sprocket, idler pulley, camshaft
sprockets, and then around tensioner pulley. Move crank-
shaft sprocket to TDC to take up belt slack.
Remove Allen wrench from timing belt tensioner pulley. Ro-
tate crankshaft clockwise 2 revolutions. Check alignment
of camshaft and crankshaft timing marks. If timing marks
do not align, remove timing belt and realign timing marks.
Continue installation in reverse of removal procedure. Ad-
tension ranges.
On Neon models only, connect scan tool to Data Link Con-
nector (DLC) under lower left edge of instrument panel.
Follow scan tool instructions to access the cam/crank re-
Removal (Hydraulic Timing Belt Tensioner):
Raise and support vehicle. Remove right inner splash
shield. Remove center bolt from crankshaft pulley. Use gear
puller to remove crankshaft pulley.
mounting bracket from engine. Move out of way.
Lower vehicle. Place jack under engine for support. Re-
move right side engine mount. Remove engine mount
bracket from front of engine. Remove timing belt cover. Ro-
tate engine clockwise to align the camshaft and crankshaft
timing marks. See Fig. 2.
135
*2.0L 4-Cylinder DOHC, VIN Y (Cont.)
Install timing belt starting from crankshaft pulley sprocket,
go around water pump sprocket, idler pulley, camshaft
sprockets, and then around tensioner pulley. Move crank-
shaft sprocket to TDC to take up belt slack. Install timing
belt tensioner, but do not final tighten fasteners yet.
With 21 ft. lbs. (28 N.m) of torque applied to tensioner pul-
ley, move tensioner against pulley bracket and tighten all
bolts to specification. See TORQUE SPECIFICATIONS. See
Fig. 4.
Remove tensioner plunger locking pin. Pretension is cor-
rect when locking pin can be removed and installed again.
Rotate crankshaft clockwise 2 revolutions and check tim-
ing belt alignment marks. Reset belt if marks are not
aligned. Install timing belt covers.
Continue installation in reverse of removal procedure. Ad-
tension ranges.
On Neon models only, connect scan tool to Data Link Con-
nector (DLC) under lower left edge of instrument panel.
Follow scan tool instructions to access the cam/crank re-
Engine Mount Bracket-To-Engine Nut/Bolt ..................... 30 (41)
Engine Mount-To-Body Bracket
Through Bolt ..................................................... 72-87 (98-118)
Engine Mount-To-Engine Mount Bracket
Nut/Bolt ........................................................................ 64 (86)
Engine Mount-To-Frame Rail Bolt (Neon) ...................... 40 (54)
Power Steering Pump Bolts ........................................... 29 (39)
Hydraulic Belt Tensioner .............................................. 30 (41)
Mechanical Belt Tensioner ........................................... 21 (28)
Timing Belt Tensioner Pulley Bolt
Hydraulic Belt Tensioner ............................................... 50 (68)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................. 106 (12)
Water Pump Bolt ...................................................... 106 (12)
136
2.4L 4-Cyl.
Colt, Colt Vista & Colt Wagon (Canada)
1992
Balance Shaft ............
1
......................... 250159
2
2.4 Hours ................. 250204
1993
1
......................... 250159
2
2.4 Hours ................. 250230
1994
1
......................... 250168
2
2.4 Hours ................. 250230
Expo
1992
1
......................... 250159
2
2.4 Hours ................. 250204
1993-95
1
......................... 250168
2
2.4 Hours ................. 250230
Summit
1992
1
......................... 250159
2
2.4 Hours ................. 250204
1993-96
1
......................... 250168
Camshaft .........
2
2.4 Hours ................. 250230
1
- Balance Shaft labor time included in camshaft
labor time.
2
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Loosen left front wheel
lug nuts, then raise and support vehicle with jack stands.
Remove left front wheel and tire assembly. Remove left
front inner splash shield through the wheel well. Remove
coolant reservoir. Support engine with jack and wooden
block placed under the oil pan. Remove right side engine
mount.
Remove accessory drive belts and pulleys. Remove timing
belt upper and lower front covers. Rotate crankshaft in normal
direction of rotation and align timing marks. See Fig. 1. Re-
move auto-tensioner assembly, then remove camshaft tim-
ing belt.
Remove crankshaft sprocket bolt, then crankshaft sprocket
and flange. Remove balance shaft timing belt tensioner
pulley bolt, then remove tensioner pulley. Remove balance
shaft timing belt. Ensure balance shaft (silent shaft)
sprocket and crankshaft sprocket timing marks are prop-
erly aligned. See Fig. 2.
Installation:
Align crankshaft and balance shaft sprocket timing marks
with the marks on the timing case. See Fig. 2. Install bal-
ance shaft timing belt over crankshaft and balance shaft
sprockets. When installing timing belt, be sure tension side
of belt has no slack. Install balance shaft belt tensioner.
Assemble tensioner so that pulley is to the left of the instal-
lation bolt and pulley flange is facing the front of engine.
Raise the tensioner toward belt by hand. Apply sufficient
pressure so that tension side of belt is taut, then tighten
tensioner bolt. Ensure that tensioner does not rotate with
bolt as it is tightened, as excessive tension will be placed
on the belt. Ensure that timing marks are still aligned, then
check belt tension. See Fig. 2. There should be approxi-
mately .20-.28" (5.0-7.0 mm) slack on tension side of belt
when belt is moved by hand.
Install crankshaft sprocket flange with the raised side fac-
ing outward, then install crankshaft sprocket. Measure pro-
trusion of auto-tensioner plunger from tensioner housing.
Protrusion should be .47" (11.9 mm). Position timing belt
tensioner in a soft jawed vise, then carefully compress
plunger. After plunger has been compressed, insert a .055
(1.4 mm) pin or wire through tensioner body to hold plunger
in place.
Remove auto-tensioner from vise and install on engine.
See Fig. 1. With oil pump sprocket timing marks aligned,
remove plug from side of engine and insert a screwdriver,
with a shaft diameter of .31" (8.0 mm), into the hole. See
Fig. 3. If screwdriver can be inserted 2.4" (61.0 mm) or
more, alignment is correct.
If screwdriver can only be inserted .8-1" (20.3-25.4 mm),
rotate oil pump sprocket one revolution and realign timing
marks. Ensure screwdriver can be inserted 2.4" (61.0 mm)
or more. Leave screwdriver inserted in hole until after tim-
ing belt has been installed.
Install camshaft timing belt, first over crankshaft sprocket,
then oil pump sprocket, idler pulley, camshaft sprocket and
tensioner pulley. Hold belt so there is no slack on tension
side. Apply counterclockwise force on camshaft sprocket to
aid in tensioning belt. Ensure that all timing marks remain
aligned. Carefully position timing belt tensioner pulley
against timing belt, then tighten center bolt. Rotate crank-
shaft pulley 1/4 turn counterclockwise, then turn clockwise,
aligning crankshaft and camshaft timing marks.
Loosen tensioner pulley retaining bolt, then position socket
tool and a suitable torque wrench to the pulley. See Fig. 4.
Tighten to specification. Tighten retaining bolt while holding
the pulley in position. Install set screw tool through left hand
engine support bracket. Engine may need to be raised slightly
to install set screw tool. Tighten set screw tool until it contacts
tensioner arm, then tighten tool slightly more. Remove pin or
wire retaining auto-tensioner plunger, then remove set screw
tool.
Rotate engine in the clockwise direction two turns. After approxi-
mately 15 minutes, measure auto-tensioner plunger protrusion
from tensioner housing. Plunger protrusion should be .15-.18"
(3.8-4.6 mm). See Fig. 5, Dimension A. If protrusion is not within
limits, readjust timing belt tension.
Install timing belt lower and upper front covers, and tighten
bolts to specification. Install crankshaft pulley and water
pump pulley, and tighten attaching bolts to specification.
Install drive belt tensioner pulleys. Install A/C compressor,
power steering pump and alternator drive belts. Adjust drive
ranges. Check and adjust ignition timing as necessary.
2.4L 4-Cylinder
137
Fig. 3: Checking Oil Pump Sprocket Timing Mark
Alignment
Fig. 2: Aligning Balance Shaft Marks
Install right side engine mount, and tighten bolts/nuts to speci-
fication. After completing installation of engine mount, remove
jack and wooden block supporting engine. Install coolant res-
ervoir. Install left front inner splash shield. Install left front wheel
and tire assembly, then lower vehicle. Connect negative battery
cable.
Crankshaft Pulley Bolts .............................................. 18 (25)
Right Side Engine Mount Bolt/Nuts ............................ 42 (58)
Through Bolt Attaching Nuts ....................................... 25 (34)
Through Bolt Nut ........................................................ 51 (70)
INCH Lbs. (N.m)
Tensioner Pulley Bolt ................................................. 31 (3.5)
Timing Belt Front Cover Bolts ........................ 84-108 (9.6-12)
Water Pump Pulley Bolts ........................................... 78 (8.9)
Fig. 1: Aligning Camshaft Timing Belt Marks
Fig. 5: Measuring Timing Belt Auto-Tensioner Protrusion
Courtesy of Chrysler Corp.
138
CHRYSLER & MITSUBISHI
*2.3L 4-Cylinder Diesel
1
Belt Part No.
2.3L 4-Cyl. Turbo Diesel
Pickup
1983-85
Balance Shaft ...... 1.8 Hours .................. 250092
Camshaft ............. 1.8 Hours .................. 250091
Ram 50
1983-85
Balance Shaft ...... 1.8 Hours .................. 250092
Camshaft ............. 1.8 Hours .................. 250091
1
50,000 miles.
TIMING BELTS & SPROCKETS
Removal:
Disconnect negative battery cable. Remove drive belts, fan,
pulleys, and timing belt covers. Position cylinder No. 1 at
TDC of compression stroke and ensure timing marks are
in alignment. See Fig. 1.
Mark belts indicating direction of rotation. Loosen nuts and
bolts securing belt tensioners. Pivot tensioners toward water
pump and secure. Remove timing belts and all necessary
sprockets.
Remove silent shaft sprockets by removing plug from right
side of block and cover from left side of block. Insert screw-
driver and socket extension into holes to hold silent shafts
in place. See Fig. 2.
Fig. 2: Removing Silent Shaft Sprockets
Installation:
Install crankshaft sprocket and flange ensuring flange on
crankshaft sprocket B is installed correctly. See Fig. 3.
Mount injection pump sprocket, if removed, and tighten nut
to specifications.
Install flange to injection pump sprocket, noting flange holes
are offset to aid in correct installation. Lightly oil left silent
shaft spacer and insert spacer with chamfered end toward
seal.
Install both silent shaft sprockets. Tighten nut and bolt to
specifications. Keep silent shafts from turning by using
method described in removal procedure.
Position and secure tensioner B fully toward water pump.
Align timing marks on crankshaft sprocket and silent shaft
sprockets. See Fig. 4. Install timing belt B, noting refer-
ence mark if refitting old belt.
Check alignment of timing marks. Loosen tensioner B
mounting nut and bolt, and allow tensioner spring pressure
to adjust belt.
Tighten nut first, then tighten bolt. DO NOT tighten bolt first.
Using index finger, press belt at center of tension side inward
and measure belt deflection. Deflection should be .16-.20" (4-
5 mm).
Position and secure camshaft timing belt tensioner fully
toward water pump. Align camshaft, crankshaft and injec-
tion pump timing marks. See Fig. 1. Install timing belt on
pulleys in order of crankshaft sprocket, injection pump
sprocket and camshaft sprocket.
Ensure tension side of belt is taut and injection pump
sprocket does not turn. If reusing old belt, make certain belt
is installed according to rotation reference mark.
139
*2.3L 4-Cylinder Diesel (Cont.)
Fig. 4: Aligning Timing Belt B Marks
While keeping belt taut, loosen tensioner mounting bolts
and allow tensioner spring pressure to tighten belt. Ensure
timing belt and camshaft sprocket are still in mesh.
Tighten upper slot-side, bolt first. Then tighten lower ful-
crum-side, bolt. Tightening bolts out of specified sequence
will over-tighten belt. After tightening tensioner mounting
bolts, check sprocket alignment.
Turn crankshaft clockwise until second tooth past timing mark
on camshaft sprocket is in alignment with triangle timing
mark. Turn crankshaft counterclockwise and realign timing
marks.
Using forefinger, press belt on tension side of belt between
camshaft sprocket and injection pump sprocket. Measure
belt deflection. Deflection should be .16-.20 (4-5 mm).
tension ranges.
Belt Tensioner Bolts ......................................... 16-21 (22-29)
Camshaft Sprocket Bolts .................................. 47-54 (64-73)
Crankshaft Sprocket Bolt .......................... 123-137 (167-186)
Front Case Bolts
1983-84 .......................................................... 15-19 (20-26)
Silent Shaft Sprocket Bolt .................................. 25-28 (34-39)
INCH Lbs. (N.m)
Front Case Bolts
1985 .......................................................... 108-120 (12-14)
Valve Cover Bolts .................................................. 44-53 (5-6)
Fig. 3: Installing Crankshaft Sprocket
140
Belt
2.4L 4-Cyl. SOHC
Pickup
1990-92
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
2.3 Hrs. . 2521240........ 250124
1993-96
Balance Shaft ...
1
.................................. 250168
Camshaft ..........
2
2.3 Hrs. ....................... 250229
Ram 50
1990-92
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
2.3 Hrs. . 2521240........ 250124
1993
Balance Shaft ...
1
.................................. 250168
Camshaft ..........
2
2.3 Hours .................... 250229
1
- Balance Shaft labor time included in Camshaft
labor time.
2
kits.
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove radiator shroud,
cooling fan and pulley. Remove all drive belts and crank-
shaft pulley. Remove upper timing belt covers and gaskets.
Note bolt length and location.
from timing belt end of engine). If timing belt is to be reused,
mark direction of rotation before removing.
Remove crankshaft sprocket bolt and washer. Rotate
crankshaft clockwise (as viewed from timing belt end of
engine) until cylinder No. 1 is at TDC of compression
stroke. Align timing mark on camshaft sprocket with mark
on cylinder head. See Fig. 1.
Loosen timing belt tensioner adjustment bolt, and move
tensioner toward water pump. Tighten bolt to secure
tensioner. Remove front timing belt (belt A) and tensioner.
DO NOT rotate crankshaft after timing belt has been re-
moved.
Fig. 1: Aligning Front Timing Belt
Remove camshaft sprocket (if necessary). Remove oil pump
sprocket access plug from cylinder block. See Fig. 2. Insert a
.31 (8.0 mm) diameter Phillips screwdriver to block left silent
shaft.
Remove oil pump sprocket nut, and remove sprocket. Re-
move front crankshaft sprocket and flange. Note direction
and order of installation for reassembly reference.
Remove rear timing belt tensioner assembly. Remove rear
timing belt (belt B).
Inspection:
Check belt teeth for cracks, damage and contamination.
Inspect sprockets for damage. Check belt tensioner for
leakage and roughness in rotation. Replace components
if damaged.
Installation:
Install rear crankshaft sprocket and flange. Install right si-
lent shaft sprocket and spacer. Spacer should be installed
with chamfered end into oil seal. Align timing marks. See
Fig. 3. Install rear timing belt (belt B) on sprockets.
Install rear tensioner. Hold tensioner tightly against belt
while tightening bolts. Ensure deflection is .20-.28" (5.0-
7.1 mm). See Fig. 4. Install camshaft sprocket. Tighten
camshaft sprocket bolt to specification. See TORQUE
SPECIFICATIONS.
Install front timing belt tensioner, tension spring and spacer.
Ensure spring is properly engaged against water pump
case. Rotate tensioner toward water pump, and tempo-
rarily tighten bolts. Ensure timing marks are aligned. See
Fig. 1. Install front timing belt (belt A) on crankshaft.
Apply pressure on tension side of timing belt while install-
ing belt (in order) on crankshaft, oil pump and camshaft
sprockets. Loosen tensioner to apply spring pressure to
timing belt.
To apply tension to belt, rotate crankshaft clockwise until
camshaft sprocket timing mark is offset by 2 teeth. Tighten
tensioner bolt. Tighten tensioner spacer nut.
2.4L 4-Cylinder
141
Fig. 4: Installing Timing Belt B Tensioner (Typical)
Fig. 5: Checking Timing Belt A Tension (Typical)
Fig. 3: Aligning Rear Timing Belt
To check belt tension, apply slight thumb pressure and
measure deflection between camshaft and oil pump
sprocket. Belt deflection should be .55" (14.0 mm). See
Fig. 5. To complete installation, reverse removal proce-
dure.
tension ranges.
Engine Support Bracket Bolt ............................. 36-47 (49-64)
Timing Belt B Tensioner Bolt .......................... 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 48-60 (5-7)
142
*3.0L V6 DOHC
1
Belt Part No.
3.0L V6 DOHC
Diamante
1992-96................ 3.8 Hours................. 250195
Stealth
1991-96
Non-Turbo ........ 3.4 Hours................. 250195
Turbo................. 3.6 Hours................. 250195
3000GT
1991-98
Non-Turbo ........ 3.4 Hours................. 250195
Turbo................. 3.6 Hours................. 250195
1
Chrysler: Up to 1993 model year, the manufacturer recom-
mends the belt be replaced every 60,000 miles. For 1994-96
model years, the manufacturer recommends replacing the
timing belt at 60,000 miles, except in California. In California,
belt replacement is recommended, but not required at 60,000
miles. Replace belt at 100,000 miles, unless previously
changed.
Mitsubishi: For 1991-93 model years, the manufacturer rec-
ommends the belt be replaced every 60,000 miles.
belt be replaced every 60,000 miles except in California. In
California, timing belt replacement is recommended, but not
required, at 60,000 miles. Replace timing belt at 100,000
belt be replaced every 60,000 miles except in California and
Massachusetts. In California and Massachusetts, timing belt
replacement is recommended, but not required, at 60,000
miles. Replace timing belt at 100,000 miles, unless previ-
ously changed.
Fig. 1: Removing Engine Support Bracket Bolts
TIMING BELT
Removal (Diamante):
Disconnect negative battery cable. Remove left front and
left side splash shields. Using engine hoist, lift engine to
remove weight from engine mounts. Remove alternator
and drive belt tensioner assembly. Remove engine sup-
port bracket. Disconnect power steering connections. On
1993-96 models, remove camshaft position sensor and
crankshaft position sensor. Remove crankshaft pulley. On
vehicles with ABS, remove overflow tank and bracket. Re-
move generator/air conditioning idler pulley.
NOTE: Remove remaining engine mount bracket bolts in sequence.
Lubricate reamer bolt with penetrating oil before and during
removal. See Fig. 1.
Remove timing belt covers. Turn crankshaft clockwise to
align all timing marks. Loosen center bolt on tensioner
pulley to relieve belt tension. Remove timing belt. Mark ro-
tation direction if belt is to be reused.
143
Removal (Stealth & 3000GT):
Disconnect negative battery cable. Remove lower splash
shields. Remove cruise control actuator (if equipped). Re-
move drive belts. Remove alternator. Remove drive belt
tensioner.
Using Holder (MB990767) and Adapter Bolts (MD998754)
or equivalent, remove crankshaft pulley. See Fig. 2. Dis-
connect brake fluid level sensor. Remove upper timing belt
covers. Support engine. Remove front engine mount
through-bolt and front engine mount.
NOTE: Engine support bracket reamer bolt may be seized. Apply
penetrating lubricant to bolt during remove.
Remove drive belt idler pulley. Remove engine support
bracket bolts in sequence. See Fig. 1. Remove engine sup-
port bracket. Remove timing belt upper and lower covers,
noting length and location of cover bolts.
Rotate crankshaft to align all timing marks. See Fig. 3.
Loosen tensioner center bolt. Remove timing belt.
Installation (Diamante, Stealth & 3000GT):
Place automatic tensioner assembly in a soft-jawed vise.
Slowly close vise to press rod back into tensioner until both
rod and housing holes are aligned. Install a .055" (1.40
mm) diameter wire through both holes.
Remove tensioner from vise, and install assembly with
wire in place. Install crankshaft sprocket (if removed). Align
timing marks on crankshaft and camshaft sprockets. See
Fig. 3.
CAUTlON: Turning camshaft sprockets while No. 1 cylinder is
at TDC may damage valve and piston. Use care when aligning
timing marks.
To lower No. 1 piston from TDC and prevent valve and pis-
ton contact, turn crankshaft back 3 sprocket teeth (mea-
sured at timing mark). Starting with front bank of cylinders,
verify intake and exhaust camshaft timing marks are not
within shaded area of figure. See Fig. 4.
WARNING: Use care when aligning timing marks. When camshaft
sprocket timing marks are in indicated area, camshaft is under
valve spring pressure and may rotate suddenly, pinching hand
between sprockets.
If camshaft sprocket timing mark is within indicated area,
carefully rotate camshaft sprocket until timing mark is lo-
cated in nearest safe area. See Fig. 4.
Rotate either camshaft sprocket clockwise to align timing
marks as shown in illustration. See Fig. 5. If camshaft
sprocket is rotated past timing mark, rotate it counterclock-
wise to realign it. Repeat procedure for other front bank
camshaft sprocket.
NOTE: If necessary, crankshaft sprocket may be turned one tooth
counterclockwise to aid belt installation.
Repeat previous three steps and this step for rear cylinder
bank camshafts. Align crankshaft timing mark. Install tim-
ing belt onto sprockets in sequence. See Fig. 6. Use spring-
type paper clips to secure belt on sprockets. Use wrenches
on camshaft sprocket bolts to prevent camshafts from turn-
ing during belt installation.
*3.0L V6 DOHC (Cont.)
Rotate timing belt tensioner pulley until pin holes are lo-
cated above center bolt. See Fig. 7. Push tensioner pulley
against belt, and tighten center bolt. Ensure all timing marks
are aligned, and remove clips.
Rotate crankshaft 1/4 revolution counterclockwise. Rotate
crankshaft clockwise until timing marks are realigned.
Loosen tensioner center bolt. Using Tensioner Pulley
Socket (MD998767) or equivalent, apply approximately 90
INCH Ibs. (10 N.m) torque to tensioner pulley to prevent it
from turning. See Fig. 7. Retighten center bolt to specifica-
tion. See TORQUE SPECIFICATIONS. Ensure tensioner
pulley does not rotate while tightening center bolt.
Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes.
Verify wire can still be moved easily, or automatic tensioner
rod projects from tensioner body .15-.18" (3.8-4.5 mm). If
wire does not move easily, or rod projection is not to speci-
fication, repeat previous five steps. Remove wire.
NOTE: Lubricate engine support bracket reamer bolt while
it is tightened slowly.
To complete installation, reverse removal procedure. In-
stall bolts into correct timing belt cover holes. Install bolts
into engine support bracket in reverse order of removal
sequence. See Fig. 1. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper
10 X 40 mm .................................................... 47-54 (64-73)
Except 10 X 40mm ..................................... 76-83 (103-113)
Water Pump Bolt ........................................................ 17 (23)
INCH Lbs. (N.m)
144
Fig. 7: Adjusting Timing Belt Tensioner
Fig. 4: Aligning Timing Marks To Prevent Valve & Piston
Damage
Fig. 5: Aligning Timing Marks - Final Alignment
145
DAEWOO
1
Belt Part No.
1.6L 4-Cyl. DOHC
Lanos
1999-2001 ............. 2.3 Hours .................. 250310
1 With Air Cond. add .2 hours.
The manufacturer recommends replacing the belt at 60,000
miles, except in California. In California, inspect the belt at
60,000 miles and replace the belt at 102,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Disconnect intake air
temperature sensor connector from intake air duct. Dis-
connect the air intake tube from the throttle body. Discon-
nect the breather tube from the valve cover. Remove the air
filter housing.
Raise and support the vehicle. Remove right front wheel.
Remove right front splash shield from wheelwell. Remove
accessory drive belts. See Fig. 1.
Remove power steering pump pulley bolts (if equipped).
Remove power steering pump pulley. Remove crankshaft
pulley center bolt. Remove crankshaft pulley. Lower vehicle.
Remove upper and lower timing belt covers. See Fig. 2.
Remove power steering pump mount bolts (if equipped).
Set power steering pump aside with hoses attached.
Using crankshaft center bolt, rotate crankshaft one full turn
clockwise (as viewed from timing belt end of engine).
Align mark on crankshaft sprocket with notch at bottom of
rear timing belt cover. See Fig. 3. Ensure camshaft sprocket
timing marks face each other. See Fig. 4.
CAUTION: Engine damage could result if camshaft sprockets
are not properly aligned with notches on valve cover.
Slightly loosen water pump bolts. Using Timing Belt Ad-
juster (J-42492), rotate water pump counterclockwise to
relieve tension on the timing belt. See Fig. 5. Remove tim-
ing belt.
Installation:
Ensure crankshaft and camshaft timing timing marks are
still aligned. Install the timing belt. See Fig. 6. Turn water
pump clockwise until the adjust arm pointer on the auto-
matic tensioner aligns with the notch on the automatic
tensioner bracket. See Fig. 7. Tighen water pump bolts.
Using crankshaft center bolt, turn crankshaft clockwise (as
viewed from timing belt end of engine) 2 full revolutions.
Loosen water pump bolts.
Rotate water pump until the adjust arm pointer on the auto-
matic tensioner is aligned with the pointer on the auto-
matic tensioner bracket. See Fig. 8. Final tighten water pump
bolts. See TORQUE SPECIFICATIONS table.
Remove crankshaft sprocket center bolt. Install power steer-
ing pump (if equipped). Tighten bolts to specification. In-
stall timing belt covers. Install crankshaft pulley. Tighten
center bolt to specification.
Fig. 3: Aligning Crankshaft Sprocket Timing Mark
Fig. 1: Removing A/C Compressor Drive Belt
Fig. 2: Timing Belt Covers
Courtesy of Daewoo Motor America, Inc.
146
DAEWOO
Fig. 5: Moving Water Pump To Relieve Timing Belt Tension
Install power steering pump pulley (if removed). Install ac-
cessory drive belts. Install right front splash shield. Install
right front wheel. Install air filter housing. Connect air in-
take temperature sensor connector. Connect negative bat-
tery cable. Adjust drive belts to correct tension. See page A-
Step 1 ............................................................................ 70 (95)
Step 2 ............................................................ Plus 30 Degrees
Power Steering Pump Pulley Bolt ................................... 18 (25)
Timing Belt Automatic Tensioner Bolt ............................. 18 (25)
Water Pump Bolt ............................................................ 10 (89)
Wheel Lug Nuts ....................................................... 88 (120)
INCH Lbs. (N.m)
Fig. 7: Aligning Timing Belt Tensioner WIth Notch
Fig. 8: Aligning Timing Belt Tensioner With Pointer
147
DAEWOO
Belt
Application Time
1
Kit No. No.
1.6L 4-Cyl.
Optima
1988-91.......... 2.9 Hrs. ............................. 250148
2.0L 4-Cyl.
Optima
1988-89.......... 2.9 Hrs. ............................. 250081
1990-91.......... 2.9 Hrs. ...... 2521630........ 250163
1
kits.
TIMING BELT
Removal (1.6L):
belts. Remove power steering pump. Remove timing belt
cover. Remove air cleaner. Mark all hoses for installation
reference and disconnect hoses from valve cover. Remove
valve cover. Remove timing belt.
Installation (1.6L):
Align camshaft sprocket mark with mark on rear timing belt
cover. Install timing belt. To complete installation, reverse
Removal (2.0L):
Disconnect negative battery cable. Remove drive belt. Re-
move power steering pump and bracket. Remove serpen-
tine drive belt tensioner as an assembly. Remove timing
Fig. 1: Exploded View Of Timing Belt & Related Components
(2.0L)
Loosen water pump attaching bolts. On water pump ec-
centric, use special tool (J-33039-A) or equivalent to re-
lease tension. Remove crankshaft pulley. Remove timing
belt from camshaft and crankshaft sprockets.
Installation (2.0L):
Align timing marks on camshaft and crankshaft sprockets
with marks on timing belt rear cover. Place timing belt on
camshaft and crankshaft sprockets and tensioner. Use
special tool (J-33039-A) or equivalent to rotate water pump
eccentric until tensioner touches stop. Slightly tighten wa-
ter pump attaching bolts.
Rotate crankshaft clockwise 2 revolutions. Rotate water
pump eccentric counterclockwise until hole in tensioner
arm is in line with hole in base. Tighten water pump at-
taching bolts and make sure tensioner holes are still
aligned. To complete installation, reverse removal proce-
dure. Adjust drive belt to proper tension. See page A-60 for
Water Pump Bolts ..................................................... 18 (24)
148
DAEWOO
2.0L 4-Cyl. DOHC
Nubira
1999-2001 ............. 1.8 Hours .................. 250309
TIMING BELT
Removal:
nect the breather tube from the valve cover. Remove the air
filter housing.
serpentine accessory drive belt.
Remove crankshaft pulley bolts. It is NOT necessary to
remove crankshaft sprocket center bolt. Remove crankshaft
pulley. Lower vehicle.
Support engine assembly from above with Support Fixture
(J-28467-B). See Fig. 1. Remove engine mount bracket
from timing belt end of engine. See Fig. 2.
Remove front timing belt cover. Using crankshaft center
bolt, rotate crankshaft one full turn clockwise (as viewed
from timing belt end of engine).
rear timing belt cover. See Fig. 3. Align camshaft sprocket
timing marks with notches on valve cover. See Fig. 4.
Loosen the automatic tensioner bolt. Use an Allen wrench
to rotate tensioner and relieve tension on timing belt. See
Fig. 5. Remove timing belt.
Installation:
still aligned. Install the timing belt. See Fig. 6. Turn the
timing belt tensioner clockwise to tension the timing belt.
Turn tensioner until the pointer aligns with the notch on the
rear timing belt cover. Tighten automatic tensioner bolt. See
Ensure timing belt tensioner pointer is still aligned with
notch.
If timing belt tensioner is correctly aligned, install timing
belt cover. Install the engine mount bracket on the timing
belt end of engine. Install crankshaft pulley. Install serpen-
tine accessory drive belt. Install right front splash shield.
Install right front wheel.
Install air filter housing. Connect air intake temperature
sensor connector. Connect negative battery cable.
Fig. 1: Supporting Engine Assembly
Fig. 2: Removing Engine Mount Bracket
Daewoo Motor America, Inc.
149
DAEWOO
Fig. 5: Identifying Timing Belt Tensioner
Step 1 ............................................................................ 37 (50)
Step 1 .......................................................................... 96 (130)
Step 2 ....................................................... Plus 40-50 Degrees
Engine Mount Bracket Bolt ............................................. 44 (60)
Timing Belt Idler Pulley Bolt/Nut ..................................... 18 (25)
Water Pump Bolt ............................................................ 15 (20)
Wheel Lug Nuts ....................................................... 88 (120)
INCH Lbs. (N.m)
150
DAEWOO
2.2L 4-Cyl. DOHC
Leganza
1999-2001 ............. 1.8 Hours .................. 250305
TIMING BELT
Removal:
nect the breather tube from the valve cover. Remove reso-
nator from throttle body. Remove air filter housing.
serpentine accessory drive belt.
Remove crankshaft pulley bolts. It is NOT necessary to
remove crankshaft sprocket center bolt. Remove crankshaft
pulley. Lower vehicle.
Support engine assembly from above with Support Fixture
(J-28467-B). See Fig. 1. Remove engine mount bracket
from timing belt end of engine. See Fig. 2.
Remove power steering hose clamp bolt, and position hose
away from timing belt cover. Remove front timing belt cover.
See Fig. 7. Using crankshaft center bolt, rotate crankshaft
one full turn clockwise (as viewed from timing belt end of
engine).
rear timing belt cover. See Fig. 3. Align camshaft sprocket
timing marks with notches on valve cover. See Fig. 4.
Loosen the automatic tensioner bolt. Use an Allen wrench
to rotate tensioner and relieve tension on timing belt. See
Fig. 5. Remove timing belt.
Installation:
still aligned. Install the timing belt. See Fig. 6. Turn the
timing belt tensioner counterclockwise to tension the tim-
ing belt. Turn tensioner until the pointer aligns with the
notch on the rear timing belt cover. Tighten automatic
tensioner bolt. See TORQUE SPECIFICATIONS table.
Ensure timing belt tensioner pointer is still aligned with
notch.
If timing belt tensioner is correctly aligned, install timing
belt cover. Install the engine mount bracket on the timing
belt end of engine. Position power steering hose in place
and install clamp bolt. Install crankshaft pulley. Install ser-
pentine accessory drive belt.
Fig. 1: Supporting Engine Assembly
Fig. 2: Removing Engine Mount Bracket
Install right front splash shield. Install right front wheel.
Install air filter housing and resonator. Connect air intake
temperature sensor connector. Connect negative battery
cable.
151
DAEWOO
Fig. 7: Timing Belt Cover
Step 1 ............................................................................ 37 (50)
Step 1 .......................................................................... 96 (130)
Step 2 ....................................................... Plus 40-50 Degrees
Engine Mount Bracket Bolt ............................................. 44 (60)
Timing Belt Idler Pulley Bolt/Nut ..................................... 18 (25)
Water Pump Bolt ............................................................ 15 (20)
Wheel Lug Nuts ....................................................... 88 (120)
INCH Lbs. (N.m)
Power Steering Hose Clamp Bolt .................................... 71 (8)
152
1
Belt Part No.
1.0L 3-Cyl.
Charade
1988-92................. 1.8 Hours .................. 250178
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Loosen accelerator cable
lock nut. Remove accelerator cable from throttle body and
clamp. Remove vent hose from valve cover. Remove air
cleaner assembly, and mark all hoses for installation ref-
erence.
Remove alternator electrical connector. On models
equipped with A/C, loosen idler pulley mounting nut. Loosen
adjusting bolt, and remove drive belt. On all models, re-
move alternator drive belt.
Remove right lower engine cover. Using a wooden block
and jack, apply slight pressure to oil pan to release pres-
sure from front mounts. Remove front mount bracket-to-
mount nuts. Remove front mount bracket-to-cylinder head
bolts. Remove the 3 front engine mounting bracket-to-cyl-
inder head attaching bolts. See Fig. 1 and Fig. 2. Slightly
lower jack and remove front mount bracket.
Remove water pump pulley. Working from left side
fenderwell, place socket on crankshaft pulley bolt, and ro-
tate crankshaft so No. 1 cylinder is at TDC of compression
stroke. Ensure timing mark on flywheel aligns with mating
mark on bellhousing. See Fig. 3.
Remove oil filter cap. Ensure exhaust valve rocker on No. 1
cylinder is free. If rocker is not free, rotate crankshaft 360
degrees (1 turn), and align timing marks.
Insert screwdriver through bellhousing to hold ring gear,
and remove crankshaft pulley retaining bolt. Remove crank-
shaft pulley. Remove upper and lower timing belt covers.
Remove flange on front of crankshaft pulley. See Fig. 4.
If reusing timing belt, mark belt rotation direction. Loosen
idler pulley bolt. Position pulley as far left as possible, and
tighten pulley bolt. Remove timing belt. Remove idler pul-
ley and spring.
If replacing belt pulleys, remove crankshaft belt pulley and
flange. For camshaft belt pulley, remove pulley retaining
bolt. Pulley can be held by installing rod through pulley hole
and resting it against rib on cylinder head. Using Pulley
(09213-87701-000) remove camshaft belt pulley.
Inspection:
Inspect idler pulley for smooth rotation. Replace if neces-
sary.
Inspect idler pulley tension spring for damage. Check ten-
sion spring free length and tension. Replace spring if free
length and tension are not within specification. See TIM-
ING BELT PULLEY SPECIFICATIONS.
TIMING BELT PULLEY SPECIFICATIONS
Application Specification
Camshaft Belt Pulley Diamter .................... 4.72 (119.9 mm)
Crankshaft Belt Pulley Diameter ...................... 2.33 (59.3 mm)
Idler Pulley Tension Spring Free Length .......... 2.13 (54.0 mm)
Spring Tension ................................................ 3.6 Lbs. @ 2.56
Fig. 1: Removing Engine Front Mounting Bracket Nuts
Fig. 2: Removing Cylinder Head Mounting Bracket
DAIHATSU
*1.0L 3-Cylinder
153
Inspect all belt pulleys for wear in belt areas. Measure di-
ameter of crankshaft and camshaft belt pulleys. Replace
pulleys if measurements are not to specification.
Installation:
Install camshaft belt pulley. Tighten retaining bolt to speci-
fication. See TORQUE SPECIFICATIONS. Install crankshaft
belt pulley and inner flange in proper direction. See Fig. 4.
Install idler pulley and tension spring. Position pulley as far
left as possible. Align camshaft and crankshaft mating
marks. See Fig. 5. Install timing belt on engine. If installing
used belt, ensure it is installed in original rotation direc-
tion. If installing new belt, align the mark on back of belt
with mating mark on each pulley.
After belt is installed, loosen idler pulley to apply spring
tension on idler pulley. Temporarily tighten idler pulley bolt.
Temporarily install bolt in crankshaft and rotate crankshaft
COUNTERCLOCKWISE 2 complete revolutions until No. 1
piston is at TDC. The F mark on camshaft drive pulley
should be toward top when No. 1 piston is at TDC.
Loosen idler pulley bolt to apply spring tension against
timing belt. Tighten idler pulley bolt to specification. Ensure
all timing marks align.
Install outer flange on crankshaft pulley, with protruding
side toward crankshaft belt pulley. To complete installa-
tion, reverse removal procedure. Adjust drive belts to proper
Water Pump Bolts ............................................ 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ........................................ 18-36 (2-4)
Fig. 3: Aligning Flywheel Timing Marks
Fig. 4: Installing Crankshaft Pulley & Flanges
DAIHATSU
Fig. 5: Aligning Crankshaft & Camshaft Mating Marks
154
1
Belt Part No.
1.3L 4-Cyl.
Charade
1988-92................. 1.8 Hours .................. 250181
1.6L 4-Cyl.
Rocky
1990-92................. 2.3 Hours .................. 250182
1
60,000 miles.
TIMING BELT
Removal (1.3L):
Disconnect negative battery cable. Remove air conditioner
drive belt and idler assembly (if equipped). Remove air
conditioner compressor, leaving hoses attached.
Remove power steering pump from engine. Mark and re-
move all hoses attached to air cleaner. Remove air cleaner.
Remove oil pressure switch wire harness brackets, and
pull wire toward throttle body.
Loosen water pump pulley bolts. Remove water pump pul-
ley and belt. Slightly raise engine, and disconnect engine
mount bracket and insulators. Remove service hole cover
to access crankshaft pulley bolts. See Fig. 1. Remove crank-
shaft pulley by removing 4 small attaching bolts.
Remove upper and lower timing belt covers. Rotate engine
until F mark on camshaft sprocket aligns with timing mark
on cylinder head cover. See Fig. 2. If reusing belt, mark
arrow on belt to indicate direction of rotation.
Loosen timing belt tensioner bolt, and move tensioner away
from belt. Tighten timing belt tensioner. Remove timing belt
from engine. Remove cylinder head cover.
Removal (1.6L):
sembly. Loosen and remove drive belts. Remove radiator
reserve tank. Disconnect clutch cable clamps from upper
radiator shroud.
Disconnect fan clutch. Remove radiator fan shroud and fan
clutch. Remove water pump pulley and belt. Remove crank-
shaft pulley attaching bolts and remove pulley. Remove 8
timing belt cover bolts.
Remove timing belt cover. Rotate engine until F mark on
camshaft sprocket aligns with timing indicator on cylinder
head cover. See Fig. 2. If reusing belt, mark arrow on belt to
indicate direction of rotation.
Loosen timing belt tensioner bolt, and move tensioner away
from belt. Tighten timing belt tensioner, and remove timing
belt from engine.
Inspection (1.3L & 1.6L):
Inspect timing belt for wear and defects. Check timing belt
tensioner for smooth rotation. Ensure tensioner contact
surface is clean and not damaged. Check camshaft for
smooth rotation. Check sides of belt. If belt side is dam-
aged, check sprocket flange.
Fig. 1: Locating Service Hole Cover (Charade)
Fig. 2: Locating Timing Belt Alignment Marks
Fig. 3: Adjusting Timing Belt
DAIHATSU
155
Check for dirt or contamination on sprocket teeth. Measure
sprocket diameter. Camshaft sprocket should be 4.717"
(119.8 mm). Crankshaft sprocket should be 2.335' (59.37
mm). Clean and/or repair as necessary.
Installation (1.3L & 1.6L):
Install crankshaft timing belt sprocket (if removed). Ensure
recessed side of crankshaft sprocket flange faces engine
block. Ensure crankshaft sprocket timing notch (drilled mark)
aligns with timing indicator on engine. See Fig. 2. Tighten
crankshaft timing belt sprocket bolt to 65-72 ft. lbs. (88-98
N.m).
Install camshaft timing belt sprocket (if removed). Tighten
camshaft sprocket bolts to 11-16 ft. lbs. (15-22 N.m). Apply
Sealant (Three Bond 1104) or equivalent, to cylinder head
near camshaft bearing cap contact areas. Install cylinder
head cover. Ensure camshaft and crankshaft sprockets are
Install timing belt on sprockets. If installing used belt, en-
sure there are 35 teeth between sprocket timing notches
(drilled marks), and belt rotates in same direction. If install-
ing new belt, align marks on belt with timing notches (drilled
marks) on sprockets. See Fig. 2. Loosen tensioner lock
bolt to apply tension to timing belt. Tighten tensioner lock
bolt. Rotate crankshaft clockwise 1.9 turns until F mark
on camshaft comes within 3 teeth of indicator mark on
engine. See Fig. 3.
CAUTION: DO NOT allow engine to rotate counterclockwise during
timing belt adjustment.
Loosen tensioner lock bolt, and rotate crankshaft until F
mark aligns with indicator mark on engine. Tighten timing
belt tensioner lock bolt to 22-32 ft. lbs. (30-44 N.m). Ensure
both timing marks are aligned with indicators.
Check belt tension. At midpoint, belt should deflect 0.2" (5
mm) with a pushing force of 1.8-3.5 Ibs. (0.8-1.6 kg). To
complete installation, reverse removal procedure. Adjust
ranges.
A/C Idler Pulley Bolt .......................................... 23-35 (31-47)
Camshaft Sprocket Bolts .................................. 11-16 (15-22)
Crankshaft Pulley Bolts .................................... 15-22 (20-30)
Timing Belt Tensioner Bolt ................................. 2-32 (30-44)
Water Pump Bolts ............................................ 11-16 (15-22)
INCH Lbs. (N.m)
Fig. 4: Timing Belt Components - 1.3L
Fig. 5: Timing Belt Components - 1.6L
DAIHATSU
156
2.2L 4-Cyl.
Medallion
1989 ................... 2.3 Hours ................ 250140
TIMING BELT
Removal:
Remove hood. Disconnect negative battery cable. Drain
coolant and discharge A/C system. Remove grille, radiator
support and facia panel. Disconnect cooling fan and
thermoswitch wires. Remove radiator, cooling fan and A/C
condenser.
Loosen power steering pump belt. Remove timing belt
cover. Loosen serpentine drive belt adjustment bolt and
nut. Loosen belt and remove from water pump pulley. Re-
move water pump pulley bolt and pulley. Remove water
pump attaching bolts. Remove water pump, gasket, timing
belt and timing belt tensioner.
Installation:
Use feeler gauge to measure clearance between interme-
diate shaft cover and timing belt tensioner. Clearance should
be .004" (.10 mm). See Fig. 1. Turn adjusting screw to
adjust clearance. Position camshaft sprocket timing index
in line with static timing mark. Position crankshaft so No. 1
piston is at TDC of compression stroke. Remove plug in
cylinder block and insert TDC Rod (Mot. 861) into TDC hole
in crankcase. Install timing belt. See Fig. 2.
Position timing belt cover over sprockets and check cam-
shaft timing mark with index on cover. Remove TDC rod
and install plug in cylinder block. Rotate camshaft clock-
wise 2 complete revolutions. DO NOT rotate counterclock-
wise. Remove timing belt cover and loosen timing belt
tensioner bolts a maximum of 1/4 turn.
Spring loaded timing belt tensioner will automatically ad-
just to correct position. Ensure clearance between timing
belt tensioner and intermediate shaft cover is .004" (.10
mm). Tighten lower timing belt tensioner bolt. Tighten up-
per bolt. Test belt tension with Tension Gauge (Ele 343).
Deflection should be .216-.276" (5.5-7.0 mm). Install water
pump with new gasket. Loosen timing belt tensioner bolts
and allow tensioner spring to tighten timing belt. Retighten
timing belt tensioner bolts.
Install timing belt cover, water pump pulley and water pump
pulley bolt. Reverse removal procedures to complete in-
stallation. Adjust drive belts to proper tension. See page A-
EAGLE
2.2L 4-Cylinder
Fig. 1: Checking Timing Belt Tensioner Clearance
157
1
Belt Part No.
1.3L 4-Cyl.
128
1973-78................ 2.3 Hours ................. 250018
1979..................... 2.4 Hours ................. 250018
X1/9
1974-78................ 2.3 Hours ................. 250018
1.5L 4-Cyl.
Strada
1979-82................ 2.0 Hours ................. 250069
X1/9
1979-83................ 2.0 Hours ................. 250069
1
The manufacturer recommends the belt be replaced at the
following intervals:
On 1974-78 models, replace belt every 36,000 miles.
On 1979 1.3L 4-Cylinder, replace belt every 36,000 miles.
On 1979-83 1.5L 4-Cylinder, replace belt every 30,000 miles.
TIMING BELT
NOTE: This procedure is with engine in vehicle. If a timing belt
is loosened or removed to perform repair work, it should always
be replaced.
Removal (128 & Strada):
Disconnect negative battery cable. Remove right guard and
loosen timing belt cover retaining screws, from under ve-
hicle. Remove timing belt cover. Check timing by aligning
index marks on top and bottom of camshaft sprocket with
index marks on engine mounting and upper case. Index on
crankshaft sprocket should be in alignment with index on
crankshaft seal case.
Put vehicle in low gear and apply hand brake to prevent
crankshaft from turning. Remove fan belt, loosen tensioner
pulley retaining nut and relieve tension. Remove timing
belt.
Installation (128 & Strada):
Install new belt, making sure belt and sprocket teeth engage
correctly. Tighten pulley support nut. Recheck timing. Install
remaining components. Adjust drive belts to proper tension.
Removal (X1/9):
Disconnect negative battery cable. Rotate No. 4 cylinder
into firing position at top dead center. Position transmis-
sion into 4th gear, to prevent crankshaft from turning. Apply
parking brake.
NOTE: If camshaft is turned independently of engine, valves
may hit pistons causing engine damage.
Remove right guard from under engine. Remove timing
belt cover. Loosen alternator and remove alternator/water
pump drive belt. Loosen air pump and remove drive belt.
Remove valve cover and check that camshaft lobes of No. 4
cylinder are pointing up. Remove distributor. Loosen idler
pulley lock nut. Remove timing belt starting at idler pulley.
Installation (X1/9):
Install timing belt making sure that teeth are properly en-
gaged in sprockets. Start installation of timing belt at crank-
shaft pulley. Release idler pulley lock nut and retighten af-
ter tension is on belt.
NOTE: Never allow engine to rotate backwards, or slack will develop
in belt and belt will jump timing.
Rotate engine 2 turns in direction of engine rotation. Loosen
idler pulley lock nut to ensure all slack is removed. Re-
tighten lock nut. Rotate engine until No. 4 cylinder is in
firing position (cam lobe up). Install remaining components
in reverse of removal order. Adjust drive belts to proper
Crankshaft Pulley/Sprocket Nut .............................. 101 (137)
FIAT
158
1
Belt Part No.
1.6L 4-Cyl.
124
1971-74................ 1.9 Hours ................. 250020
1.8L 4-Cyl.
Brava
1974-78................ 2.4 Hours ................. 250020
124
1974-78................ 1.9 Hours ................. 250020
131
1975-78................ 1.9 Hours ................. 250020
1
The manufacturer recommends that belt be replaced every
25,000 miles or 24 months (1974-77 Models) or every 25,000
miles (1978 models).
TIMING BELT
Removal & Installation:
Disconnect negative battery cable. Drain cooling system
and remove upper radiator hose. Remove upper section of
air duct. Remove spark plugs. Rotate crankshaft until
marks on both camshaft sprockets are aligned with fixed
pointer on front of engine. See Fig. 1 or 2. Number 4 piston
should now be at TDC firing position. Place transmission in
4th gear and apply parking brake to prevent crankshaft from
turning.
CAUTION: Do not turn crankshaft or camshafts independent
of each other as valves may hit pistons.
Remove lower engine protection plate. Remove all drive
belts. Disconnect coolant extension union at cylinder head.
Loosen timing belt idler pulley nut and mounting bracket
bolt and release timing belt tension. On 1.6L engines be-
fore No. 42577, pry pulley to release tension. Tighten pul-
ley nut and bracket bolt, and remove belt.
Fig. 1: Camshaft & Crankshaft Timing Marks (1.8L)
FIAT
NOTE: Anytime tension is relieved from timing belt, timing belt
must be replaced.
Install timing belt make sure not to move sprockets. Ensure
hole in auxiliary shaft pulley is lined up with tensioner pulley
bolt.
To adjust timing belt tension, loosen idler pulley tensioner
nut and allow pulley to tension timing belt. Rotate crank-
shaft pulley 2 full turns and recheck timing marks. Tighten
tensioner nut and bracket bolt. Adjust drive belts to proper
Tensioner Nut ............................................................. 33 (45)
159
Fig. 2: Aligning Timing Marks (1.6L)
FIAT
Courtesy of Fiat Motor Co.
160
1
Belt Part No.
2.0L 4-Cyl.
Brava
1979-83................ 2.4 Hours ................. 250068
Spider 2000
1979-82................ 3.1 Hours ................. 250068
1
30,000 miles.
TIMING BELT
WARNING: Timing belts must not be reused once tension is relieved.
Crankshaft and/or camshafts must not be turned with belt removed
due to resultant valve and/or piston damage.
Removal:
Disconnect negative battery cable and drain cooling system.
Remove spark plugs and set engine to fire (TDC) on No. 4
cylinder. Crankshaft and camshaft timing marks must be
aligned with indicators. See Fig. 1. Remove upper radiator
hose from T union, then unbolt and remove union from the
cylinder head.
Remove hot air hose from exhaust manifold to air intake. Re-
move all drive belts from crankshaft pulley. Remove water pump
pulley bolts and remove pulley. Remove outer timing belt cover.
Lock crankshaft to prevent turning and remove crankshaft
pulley. Remove lower timing cover. Loosen belt tensioner
to release belt tension. Remove timing belt.
Installation:
Turn auxiliary sprocket to align hole in sprocket with sprocket
bolt and spring retaining bolt. Install belt and adjust
tensioner, then turn crankshaft 2 full turns and recheck ten-
sion and timing. To complete installation, reverse removal
procedures. Adjust drive belts to proper tension. See page
FIAT
*2.0L 4-Cylinder
Fig. 1: Camshaft & Crankshaft Timing Marks
Fig. 2: Sprocket Alignment For Timing Belt Installation
161
Belt
Application Time
1
Kit No. No.
1.3L 4-Cyl. VIN H
Aspire
1994-97.......... 2.0 Hrs. ............................. 250185
Festiva
1988-89.......... 2.0 Hrs. ...... 2521410........ 250141
1990-93.......... 2.0 Hrs. ............................. 250185
1
kits.
For Aspire, the manufacturer recommends the belt be replaced
every 60,000 miles on Federal vehicles, and 105,000 miles
on California vehicles. For Festiva, the manufacturer recom-
mends the belt be replaced every 60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove accessory belts.
Remove water pump pulley. Remove right inner fender panel
to gain access to crankshaft pulley. See Fig. 1. Remove
outer crankshaft pulley attaching bolts, then outer stiffener
and spacer. Remove inner pulley and baffle plate. Remove
bolts retaining upper and lower cover halves to engine front.
Remove both covers. See Fig. 2.
NOTE: Always rotate engine in direction of normal operation.
Rotating crankshaft backwards may cause belt to jump timing.
Mark timing belt direction of rotation for installation refer-
ence. Remove timing belt tensioner pulley bolt. Remove
tensioner pulley, spring, and spring cover. Remove timing
belt.
CAUTION: Never twist, turn inside out, or bend timing belt. Keep
belt away from grease and oil.
Installation:
Ensure timing belt and sprockets are clean and not worn or
damaged. Align crankshaft and camshaft timing marks.
See Fig. 3. Position belt onto sprockets, in original running
direction. Install timing belt tensioner spring, spring cover,
and pulley. To complete installation, reverse removal pro-
cedure. Tighten all bolts and nuts to specification. See
FORD
1.3L 4-Cylinder
Fig. 1: Removing Right Inner Fender Panel
Fig. 2: Timing Belt Upper & Lower Covers
A/C Compressor Bolt ....................................... 29-40 (39-54)
Camshaft Pulley Bolt .......................................... 9-13 (12-17)
Crankshaft Sprocket Bolt .............................. 80-87 (108-118)
Power Steering Adjuster Nut ............................. 27-38 (37-52)
Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26)
Water Pump Pulley Bolts .................................. 36-45 (49-61)
INCH Lbs. (N.m)
Camshaft Cover ................................................. 71-97 (8-11)
Timing Belt Cover Bolt ........................................ 71-97 (8-11)
Valve Cover Bolt .................................................... 44-79 (5-9)
162
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks
FORD
163
Belt
1.6L 4-Cyl. -- DOHC
Capri
1991-94 ........ 3.6 Hrs. ...... 2521790....... 250179
kits.
60,000 miles.
TIMING BELT
NOTE: Always rotate engine in direction of normal operation.
Rotating crankshaft backwards may cause belt to jump timing.
Removal:
hicle. Remove right front tire and wheel assembly. Remove
right front splash guard. Lower vehicle. Remove spark plugs
and set No. 1 cylinder to TDC of compression stroke. Re-
move accessory drive belts. Remove dipstick. Remove wa-
ter pump pulley. Remove crankshaft pulley, damper and
baffle plate. See Fig. 2.
Remove upper timing belt cover. Remove center and lower
timing belt covers. Remove timing belt tension spring.
Loosen timing belt tension pulley. Support engine with floor
jack. Remove right engine mount. After marking timing belt
direction of rotation, remove timing belt. See Fig. 2.
Installation:
Ensure sprockets, tensioner, and idler pulleys are clean
and not worn, deformed, or damaged. Align timing marks
on camshafts and crankshaft. Intake cam should have let-
ter I aligned with arrow on belt cover. Exhaust cam should
have letter E aligned with arrow on belt cover. Crankshaft
key should align with arrow. See Fig. 1.
CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with
solvents. Wipe them clean only.
Unloaded free length of timing belt tension spring should
be 2.315" (58.8mm). Replace spring as necessary. Tighten
tension pulley with tension spring fully extended. If reusing
timing belt, install belt in original direction of rotation. Keep
tension on opposite side of tensioner as tight as possible.
Rotate crankshaft 2 full turns. Inspect alignment of timing
marks. If any mark is not aligned, remove timing belt and
reset timing. Loosen tension pulley retaining bolt to allow
tension spring to tighten belt. Tighten tension pulley to speci-
fication. See TORQUE SPECIFICATIONS. Rotate engine 2
full turns. Verify timing mark alignment.
Measure timing belt tension between camshaft pulleys.
Belt deflection should be 0.33-0.45" (8.5-11.5 mm). See
Fig. 3. If incorrect, loosen tension pulley and repeat proce-
dure. If correct tension cannot be achieved, replace ten-
sion spring. To complete installation, reverse removal pro-
cedure. Adjust drive belts to proper tension. See page A-60
Camshaft Pulley Bolt ........................................ 37-45 (49-61)
Crankshaft Pulley Center Bolt ................... 115-123 (157-167)
Power Steering Adjuster Nut ............................. 27-38 (37-52)
Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26)
NCH Lbs. (N.m)
Camshaft Cover ................................................. 71-97 (8-11)
Valve Cover Bolt .................................................... 44-79 (5-9)
Water Pump Pulley Bolt ...................................... 71-97 (8-11)
FORD
1.6L 4-Cylinder DOHC
TECHNICAL SERVICE BULLETIN
REVISION
NOTE: Information on revised service procedure is from Ford
technical service bulletin 94-17-5; August 24, 1994. This bulletin
supercedes 94-15-10; July 21, 1993.
SWISH NOISE FROM TIMING BELT
Issue: Some 1990 1.6L and 1.6L engines built up to 10/1/
1990 may exibit a swish noise from the timing belt. This is
caused be a belt guide plate that does not maintain correct
timing belt alignment.
Action: A revised timing belt guide plate and pulley boss is
available to correct the noise. See Fig. 4. This procedure will
also require replacement of the crankshaft and associated
hardware.
This procedure is also recommended when replacing a dam-
aged crankshaft to prevent timing belt noise.
164
FORD
1.6L 4-Cylinder DOHC (Cont.)
Courtesy of Ford Motor Co.
Fig. 4: New & Revised Timing Belt Pulley
When replacing the timing belt and crankshaft, all associated
parts MUST be replaced as a set. See TIMING BELT PULLEY
PARTS (1990) table for reference. The crankshaft pulley cen-
ter bolt listed in the TORQUE SPECIFICATION table is the
revised bolt torque. Use Crankshaft Pulley Holder (T92C-6316-
AH).
TIMING BELT PULLEY PARTS (1990)
Part Name Part No.
Crankshaft ............................................................ F1JY-6303-A
Crankshaft Accessory Pulley (With FEAD Belt)
With A/C & Power Steering ................................ F1JY-6A312-A
Crankshaft Damper Pulley (With V Belt)
Generator & Water Pump ................................. F1JY-6A312-A
Crankshaft Pulley Boss w/Pin ........................... F1CZ-6C337-A
Crankshaft Pulley Plate ........................................ F1CZ-6378-A
Crankshaft Timing Pulley ..................................... F1CZ-6306-B
Oil Pan Gasket ..................................................... F1CZ-6701-B
Oil Pump Assembly.............................................. F2CZ-6600-A
Oil Pump Body-To-Inlet Tube Gasket ................... E7GZ-6626-A
Oil Pump-To-Cylinder Block Gasket ..................... E7G7-6659-A
Timing Pulley Bolt ............................................... F1CZ-6A340-A
Timing Pulley Key.............................................. F1CZ-6B316-B
165
165
Belt
Application Time
1
Kit No. No.
1.6L 4-Cyl. SOHC
Escort, EXP, Lynx, LN7
1981-85............... 2.2 Hrs. ..... 2520670... 250067
Tracer
1987-90............... 2.2 Hrs. ..... 2521410... 250141
1.9L 4-Cyl. SOHC
Escort, EXP
1985-90............... 2.2 Hrs. ..... 2520670... 250067
1991
thru: 3-25-91 ..... 2.2 Hrs. ..... 2520670... 250067
from: 3-26-91 .... 2.2 Hrs. ..... 2521940... 250194
1992-96............... 2.2 Hrs. ..... 2521940... 250194
Lynx
1985-87............... 2.2 Hrs. ..... 2520670... 250067
Tracer
1991-96
to: 3-25-91......... 2.2 Hrs. ..... 2520670... 250067
from: 3-26-91 .... 2.2 Hrs. ..... 2521940... 250194
1
kits.
60,000 miles.
* NOTE: The 1.6L engine is an interference engine.
TIMING BELT
Removal:
belt. Remove timing belt cover. Rotate crankshaft clockwise,
and align timing mark on camshaft sprocket with timing mark
on cylinder head. See Fig. 1. Ensure crankshaft sprocket tim-
ing mark aligns with oil pump housing timing mark.
Loosen timing belt tensioner bolt. Pry timing belt tensioner
away from timing belt, and tighten tensioner bolt. Remove
spark plugs. Support engine with floor jack. Remove en-
gine mount at timing belt end of engine.
Raise and support vehicle. Remove right front splash shield.
Remove retaining bolt and crankshaft pulley. Remove timing
belt.
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt
removed. If camshaft must be rotated, install crankshaft pulley
and position crankshaft with cylinder No. 1 at 90 degrees BTDC.
Installation:
Install timing belt over sprockets in counterclockwise di-
rection, starting at crankshaft.
CAUTION: Maintain tension on timing belt between crankshaft
and camshaft sprockets when installing belt over remaining sprockets.
Loosen belt tensioner bolt. Allow belt tensioner to apply
tension on timing belt. Rotate crankshaft 2 full revolutions
clockwise and realign timing marks. DO NOT rotate crank-
shaft counterclockwise. Tighten belt tensioner bolt to speci-
fication. To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension. See
FORD
91H07180 Courtesy of Ford Motor Co.
166
FORD
Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)
96E14831 Courtesy of Ford Motor Co.
Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)
Fig. 3: Releasing Timing Belt Tension (Except Tracer)
A/C Compressor Mounting Bolt ........................ 15-22 (20-30)
Belt tensioner Bolt ............................................ 17-22 (23-30)
Crankshaft Pulley Bolt .................................. 81-96 (110-130)
Power Steering Pump Bolt ................................ 30-41 (41-56)
Water Pump Bolt .............................................. 15-22 (20-30)
INCH Lbs. (N.m)
Timing Belt Cover Nut .......................................... 44-62 (5-7)
Valve Cover Bolt ................................................ 44-106 (5-12)
167
FORD
(Tracer)
Fig. 6: Installing Timing Belt (Tracer)
168
1
Belt Part No.
1.6L 4-Cyl.
Capri
1972...................... 1.3 Hours .................. 250013
2.0L 4-Cyl.
Capri
1971-74................. 1.3 Hours .................. 250013
Pinto
1971-74................. 1.3 Hours .................. 250013
1
TIMING BELT
Removal:

belts. Ensure that crankshaft is at TDC of No. 1 cylinder
compression stroke. See Fig. 1. Remove camshaft belt
cover. Loosen belt tensioner adjustment bolt and force
tensioner to one side to relieve belt tension. Hold tensioner
in this position and tighten bolt to hold tensioner. Lift belt off
sprockets.
NOTE: DO NOT rotate crankshaft or camshaft with belt removed.
Installation:
Place new belt over sprockets and loosen tensioner ad-
justment bolt to place tension on belt. Rotate crankshaft 2
complete turns to place timing marks in proper position
and to remove all slack from belt. Torque tensioner adjust-
FORD
1.6L & 2.0L 4-Cylinder Capri & Pinto
ment bolt and pivot bolt to specification. Adjust drive belts to
proper tension. See page A-60 for belt tension ranges.
Belt Tensioner .................................................. 32-36 (42-48)
Crankshaft Pulley ............................................. 39-43 (54-60)
Timing Belt Cover ................................................. 7-9 (10-12)
Water Pump Bolts
8 mm .............................................................. 12-15 (15-21)
10 mm ............................................................ 26-31 (35-41)
Fig. 1: Visual Camshaft Timing Check
169
Belt
1.8L 4-Cyl.
Escort & Tracer
1991-96.......... 2.8 Hrs. ...... 2521790........ 250179
1
kits.
60,000 miles.
TIMING BELT
NOTE: Mark direction of timing belt rotation if timing belt is
to be reused.
FORD
170
Removal:
belts. Remove upper timing belt cover. See Fig. 1. Remove
water pump pulley. Raise and support vehicle. Remove right
front wheel. Remove right upper and lower splash shield.
Remove middle and lower timing belt covers. Rotate crankshaft
clockwise until No. 1 piston is at TDC. Ensure camshaft timing
marks are aligned. See Figs. 2 and 6.
Remove crankshaft pulley and hub. Mark direction of timing belt
rotation if timing belt is to be reused. Loosen timing belt tensioner
bolt, and remove timing belt.
CAUTION: DO NOT rotate camshafts with timing belt removed,
as engine damage could result.
Installation:
Temporarily position belt tensioner with spring fully extended,
and tighten tensioner bolt. Ensure timing marks on crank-
shaft sprocket and oil pump align. See Fig. 3.
CAUTION: Ensure I and E camshaft sprocket timing marks
are facing up. Camshaft sprockets may be stamped with more
than one mark.
Ensure camshaft sprocket timing marks are still aligned.
See Figs. 2 and 6. Install timing belt. If reusing timing belt,
ensure belt is installed in original direction of rotation.
Loosen tensioner bolt. Position tensioner so slack is re-
moved from timing belt. Tighten tensioner bolt. Rotate crank-
shaft clockwise 2 full revolutions. Ensure all timing marks
are aligned. If timing marks are not aligned, remove timing
belt and repeat timing belt tensioning procedure.
Fig. 5: Checking Timing Belt Deflection
Fig. 4: Identifying Crankshaft Pulley & Guide Plates
FORD
Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft
timing mark with tension set mark (at approximately 10 oclock
position). See Fig. 3. Loosen tensioner bolt. Apply tension to the
tensioner. Tighten tensioner bolt to 27-38 ft. lbs. (37-52 N.m).
Rotate crankshaft clockwise 2 1/6 revolutions. Ensure tim-
ing marks align. If timing marks are not aligned, repeat
installation procedure. Measure timing belt deflection by
applying 22 lbs. (10 kg) of pressure on timing belt at a point
halfway between camshaft sprockets. See Fig. 5.
Fig. 6: Identifying Camshaft Sprocket Timing Marks
171
FORD
Timing belt deflection should be .35-.45" (8.9-11mm). If
deflection is not within specification, loosen tensioner bolt.
Using a pry tool, tighten or loosen tensioner to obtain proper
timing belt deflection. Tighten tensioner bolt.
Belt Tensioner Bolt ........................................... 17-22 (23-30)
Water Pump Bolt .............................................. 15-22 (20-30)
INCH Lbs. (N.m)
Timing Belt Cover Nut .......................................... 44-61 (5-7)
Valve Cover Bolt ................................................ 48-106 (5-12)
172
1
Belt Part No.
2.0L 4-Cyl. Diesel
Escort & Lynx
1984-87
Camshaft ............ 6.2 Hours .................. 250103
Injection Pump... 1.3 Hours .................. 250102
Tempo & Topaz
1984-86
Camshaft ............ 6.2 Hours .................. 250103
1
100,000 miles.
ENGINE REMOVAL
NOTE: Engine/transaxle must be removed to replace timing belt.
The engine/transaxle is removed as an assembly.
Removal & Installation:
Disconnect negative battery cable. Mark hinges for reinstallation
and remove hood. Remove air cleaner assembly. Drain coolant.
Remove upper and lower radiator hoses.
Disconnect wiring at cooling fan. Remove shroud and cooling fan
as an assembly. Remove radiator. Discharge A/C system (if
equipped). Disconnect hoses at compressor. Remove cable at
starter.
Disconnect all vacuum lines as necessary. Disconnect
clutch cable at transaxle, injection pump throttle linkage,
and fuel hoses at engine.
Disconnect both engine harness connectors and glow plug
relay connectors at dash panel. Connectors are located un-
der plastic shield on dash panel. Remove and save plastic
retainer pins. Disconnect alternator connector on right-hand
fender apron.
Disconnect power steering hoses at pump (if equipped).
Remove hose bracket from cylinder head. Attach engine
support tool to lifting eye. Raise vehicle. Disconnect ex-
haust bracket at oil pan. Disconnect both exhaust pipes
from manifold. Pull exhaust system from grommets and
set aside. Disconnect speedometer cable from transaxle.
Disconnect heater hoses at water pump inlet tube and at
oil cooler.
Disconnect control arms at body. Remove stabilizer bar
brackets. Remove half-shaft assemblies and install align-
ment plugs in differential side gears. On manual transaxle
models, remove shift stabilizer bar-to-transaxle bolts. Re-
move shift mechanism-to-shift shaft attaching bolt at
transaxle.
Remove left-hand rear insulator mount bracket from body
bracket. Remove left-hand front insulator-to-transaxle bolts.
Lower vehicle. Attach engine hoist to lifting eyes. Remove
engine support tool. Disconnect right-hand insulator inter-
mediate bracket from engine bracket and insulator. Re-
move bracket. Lower engine and transaxle assembly to
floor.
To install engine, reverse removal procedures.
CAUTION: DO NOT allow front wheels to touch ground.
TIMING BELT
Removal:
With engine out of vehicle, remove front upper timing belt
cover and flywheel timing mark case.
Rotate crankshaft in normal direction of rotation to align
timing marks of flywheel and front camshaft sprocket with
pointers. Loosen tensioner pulley lock bolt to slide timing
belt off water pump and camshaft.
NOTE: DO NOT allow crankshaft to rotate with timing belt removed.
Installation:
Align camshaft and crankshaft sprockets with their respective
timing marks. See Fig. 1. Remove tensioner spring from front
timing belt upper cover pocket and install in tensioner lever slot
and over crankcase stud. See Fig. 4. Push tensioner lever as far
as possible toward water pump and tighten lock bolt.
Install timing belt. With tensioner pulley loose, adjust belt ten-
sion by rotating crankshaft pulley in direction of rotation twice
until No. 1 cylinder is at TDC (camshaft timing marks aligned).
Tighten tensioner lock bolt. Adjust belt tension to 33-44 lbs.
(15-20 kg). Remove tensioner spring and place in front cover
pocket.
Fig. 1: Cross Section Of 2.0L Diesel Engine
FORD
173
FORD
Fig. 4: Installing Front Timing Belt Tensioner Spring
Install front upper cover and flywheel timing mark case.
Install front timing belt lower cover. Install crankshaft pulley
and front timing belt upper cover. Adjust drive belts to proper
tension. See page 381 for belt tension ranges.
REAR TIMING BELT
Removal:
Remove rear timing belt cover and flywheel timing mark
case. Rotate crankshaft until No. 1 cylinder is at TDC (fly-
wheel timing mark at TDC, camshaft sprocket and injec-
tion pump timing marks aligned). See Figs. 2 and 5.
Loosen tensioner lock nut. Turn tensioner clockwise with a screw-
driver to loosen timing belt. Tighten lock nut and remove timing
belt.
Installation:
Install timing belt and adjust belt tension as follows: with
tensioner pulley loose, rotate crankshaft twice until flywheel
TDC timing mark aligns with pointer. Tighten tensioner lock
nut and adjust belt tension to 22-33 lbs. (10-15 kg). Install
timing belt cover and flywheel timing mark case. Adjust drive
belts to proper tension.See page A-60 for belt tension ranges.
Camshaft Sprocket (Front & Rear) .............................. 45 (61)
Crankshaft Pulley ................................................... 119 (165)
CV Hub Nut ............................................... 180-200 (244-271)
Insulator Brkt.-To-Body Brkt. Bolts ............. 75-100 (102-136)
Inter. Brkt.-To-Engine Brkt. Bolts ................ 75-100 (102-136)
Roll Restrictor-To-Transaxle Bolts .................... 25-45 (35-61)
Shifter-To-Input Shaft Bolts ................................. 7-10 (10-14)
Shift Stabilizer-To-Transaxle Bolts .................... 23-35 (31-47)
Water Pump ............................................................... 29 (39)
Fig. 2: Aligning Camshaft & Injection Pump Timing Marks
174
FORD
Fig. 6: Aligning Camshaft Timing Mark
Fig. 7: Installing Rear Timing Belt
175
2.0L 4-Cyl. VIN 3
Escape
2001...................... 3.6 Hours .................. 250294
120,000 miles.
TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing
belt removed, damage to valves and pistons may result.
Removal:
belt. Remove air cleaner outlet pipe and ignition wires from
spark plugs. Disconnect throttle cables and cruise control
actuator cable. Disconnect accelerator cable. Remove valve
cover. See Fig. 1.
Remove spark plugs. Remove catalytic converter. Remove
coolant tube bolt and nut. Position coolant tube to side.
Rotate crankshaft to just before No. 1 cylinder TDC. See
Fig. 2. Remove stud and install Crankshaft TDC Timing
Peg (303-574). See Fig. 3.
NOTE: Make sure second notch in pulley is indexed to lower
cylinder block. See Fig. 2.
Rotate crankshaft clockwise against peg to bring it to TDC.
Loosen water pump pulley bolts.
Remove timing belt cover by removing crankshaft pulley,
then remove lower timing belt cover bolts and lower timing
belt cover. See Fig. 4. Install Engine Support Bar (303-F072).
See Fig. 5.
Remove ground strap and engine mount upper bracket
and studs. See Fig. 6. Remove upper timing belt cover
bolts and cover. See Fig. 7.
Remove water pump pulley and accessory drive belt idler
pulley. Install Camshaft Alignment Tool (303-465) and align
NOTE: Installation of Camshaft Alignment Tool (303-465) into
exhaust camshaft may require camshafts to be rotated slightly
clockwise.
Raise and support vehicle. Remove engine mount lower
bracket. See Fig. 9.
Loosen timing belt tensioner pulley and allow it to slide
down to bottom of its travel. Slide timing belt off of camshaft
and crankshaft sprockets.
CAUTION: DO NOT reuse old timing belt. Replace with a new
belt.
FORD
2.0L 4-Cylinder DOHC, Escape
Fig. 1: Removing Valve Cover
Fig. 3: Removing Stud For Installation Of Crankshaft TDC
Timing Peg (303-574)
Fig. 4: Removing Lower Timing Belt Cover
Fig. 2: Aligning Crankshaft Timing Marks Before TDC
176
FORD
2.0L 4-Cylinder DOHC, Escape (Cont.)
Fig. 5: Installing Engine Support Bar (303-F072)
Fig. 6: Removing Engine Mount Upper Bracket
Fig. 7: Removing Upper Timing Belt Cover
Installation:
Slide crankshaft pulley onto crankshaft. Ensure crankshaft
position is at No, 1 TDC by rotating it clockwise against
Crankshaft TDC Timing Peg (303-574). Ensure second
notch in pulley is indexed to lower cylinder block. See Fig.
2. Remove crankshaft pulley.
Ensure timing belt tensioner is installed correctly with tab
positioned in slot in inner timing cover. See Fig. 10.
Install new timing belt onto timing belt sprockets and ad-
just timing belt tensioner by using a 6 mm Allen wrench to
rotate adjuster counterclockwise and align marks. See
Figs. 11 and 12. Tighten tensioner pulley bolt to specifica-
tion. See TORQUE SPECIFICATIONS table.
Install front engine mount lower bracket. Install accessory
drive belt idler pulley. Install water pump pulley, but hand
tighten only. Install timing belt covers. Install crankshaft
pulley. Tighten water pump pulley bolts to specification.
See TORQUE SPECIFICATIONS.
Remove Crankshaft TDC Timing Peg (303-574). Install stud.
Install engine mount upper bracket and ground strap. Re-
move Engine Support Bar (303-F072). Install coolant tube,
catalytic converter and remove Camshaft Alignment Tool
(303-465).
Install valve cover and spark plugs. Reconnect accelerator
cable and cruise control actuator cable. Reinstall ignition
wires, air cleaner outlet pipe and accessory drive belt. Re-
connect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)
Fig. 9: Removing Engine Mount Lower Bracket
177
FORD
2.0L 4-Cylinder DOHC, Escape (Cont.)
Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45)
Coolant Tube Attachments ............................................. 15 (20)
Engine Mount Lower Bracket Nuts ................................. 37 (50)
Engine Mount Upper Bracket Nuts ................................. 61 (83)
Engine Mount Upper Bracket Studs .............................. 25 (34)
Exhaust Camshaft Center Plug..................................... 27 (37)
Ground Strap .................................................................. 25 (34)
Spark Plugs................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) .......................... 18 (24)
Timing Belt Tensioner Bolt ............................................ 18 (25)
Water Pump Pulley Bolt ................................................. 18 (24)
INCH Lbs. (N.m)
Lower Timing Belt Cover Bolt ....................................... 62 (7)
Upper Timing Belt Cover Bolt ....................................... 71 (8)
Valve Cover ...................................................................... 80 (9)
178
2.0L 4-Cyl.
Contour & Mystique
1995-97.................. 2.6 Hours .................. 250258
TIMING BELT
belt removed, damage to valve/piston may result.
Removal:
Noting position for installation reference, disconnect second-
ary wires from spark plugs. Remove spark plugs.
Disconnect negative battery cable. Remove air intake resona-
tors. Remove power steering pressure hose bracket from
lifting eye, and position aside.
Support engine from above using Three Bar Engine Support
(D88L-6000-A) or equivalent. Remove upper timing belt cover.
Mark position of upper front engine mount before removal.
Remove upper front mount. If equipped, disconnect cool-
ant level sensor connector from coolant recovery reservoir.
Remove retainers attaching recovery reservoir, and posi-
tion aside. Remove upper front mount insulator.
Loosen water pump pulley bolts. Remove serpentine drive
belt. Remove drive belt idler pulley from alternator mount-
ing bracket. Remove water pump pulley.
Remove center timing belt cover. Raise and support ve-
hicle. Remove crankshaft pulley. Remove lower timing belt
cover. Remove valve cover.
Temporarily install crankshaft pulley. Rotate crankshaft to align
timing mark on block with larger notch on pulley. See Fig. 1. Use
Camshaft Alignment Tool (T94P-6256-CH) or equivalent to align
camshafts. See Fig. 2. Install tool in slots on camshafts at rear of
engine.
Loosen timing belt tensioning pulley. See Fig. 4. Move pulley
to relieve tension on timing belt, and retighten pulley. If reus-
ing timing belt, mark direction of rotation before removal. Re-
move timing belt.
Installation:
Temporarily install crankshaft pulley. Ensure crankshaft pul-
ley timing marks are aligned. See Fig 1. Ensure camshaft
alignment tool is still installed.
Install tensioner and retaining bolt (if necessary). Remove
crankshaft pulley.
Install timing belt on crankshaft sprocket. Working in a clock-
wise direction, install timing belt around camshaft sprockets.
Ensure timing belt span between crankshaft sprocket and
exhaust camshaft is not loose. Ensure timing belt is aligned
on all sprockets.
Install lower timing belt cover. Apply Silicone Gasket Sealer
(F1AZ 9562-A) or equivalent to crankshaft keyway. Install
crankshaft pulley. Tighten bolt to specification. See TORQUE
SPECIFICATIONS.
Ensure crankshaft timing marks are aligned. See Fig. 1.
Loosen timing belt tensioner pulley, and allow spring to
pull pulley against timing belt. Remove camshaft align-
ment tool. Rotate crankshaft clockwise 2 full revolutions.
Tighten timing belt tensioner pulley to specification. See
TORQUE SPECIFICATIONS. Align crankshaft timing marks.
See Fig. 1. Ensure camshafts are still aligned by installing
Camshaft Alignment Tool (T94P-6256-CH) on rear of camshafts.
If crankshaft and camshaft alignment is correct, continue
with installation procedure.
If camshaft alignment tool cannot be installed on camshafts
with crankshaft at TDC, hold camshaft sprocket with Cam-
shaft Sprocket Holding Tool (T74P-6256-B) or spanner
wrench. Loosen, but do not remove, camshaft sprocket
center bolt. Rotate camshafts until camshaft alignment tool
can be installed on rear of camshafts. Crankshaft MUST
remain at TDC when aligning camshafts. Tighten cam-
shaft sprocket center bolts to specification. Continue with
installation procedure.
Install timing belt covers. Install crankshaft pulley. Tighten bolt
to specification. Install valve cover. Install spark plugs.
Install upper front engine mount. Remove engine support
tool. Install water pump pulley. Install serpentine belt idler
pulley and serpentine bolt.
Install coolant recovery reservoir. Continue installation in re-
verse of removal procedure.
Alternator Mounting Bolt .................................... 30-41 (41-56)
Timing Belt Tensioner Bolt .................................. 26-30 (35-40)
Upper Front Engine Mount Nuts .......................... 52-70 (70-95)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Center Timing Belt Cover Bolt .............................. 53-71 (6-8)
Lower Timing Belt Cover Bolt ............................... 53-71 (6-8)
Spark Plug ................................................... 106-156 (12-18)
Upper Timing Belt Cover Bolt ............................... 27-44 (3-5)
Valve Cover ........................................................... 53-71 (6-8)
Water Pump Pulley Bolt .................................. 89-124 (10-14)
FORD
2.0L 4-Cylinder VIN 3, 1995-97
179
FORD
2.0L 4-Cylinder VIN 3, 1995-97 (Cont.)
Fig. 2: Installing Camshaft Alignment Tool
Courtesy of For Motor Co.
180
2.0L 4-Cyl. VIN 3
Cougar
1999-01................. 3.2 Hours .................. 250294
Contour & Mystique
1998-00................. 3.2 Hours .................. 250294
Escort ZX2
1998-01................. 2.8 Hours .................. 250294
Focus
2000-01................. 2.8 Hours ................. 250294
belt be inspected every 120,000 miles. Replace, if necessary.
For 2001 model year, the manufacturer recommends the belt
TIMING BELT
belt removed, damage to valve/piston may result.
Removal (Contour, Cougar & Mystique):
hicle. Remove right front wheel. Remove engine splash
shield from right wheelwell. Remove engine undercover, if
equipped.
Loosen, but do not remove, water pump pulley bolts. Turn
serpentine drive belt tensioner clockwise and remove ser-
pentine drive belt. If belt is to be reused, mark belt with
arrow to indicate direction of rotation.
Remove water pump pulley. Remove serpentine belt idler
pulley. Remove crankshaft pulley center bolt and remove
pulley.
Remove lower timing belt cover. Working from under ve-
hicle, loosen center bolt of left-hand and right-hand engine
support insulators 2 turns. DO NOT remove center bolts.
Lower vehicle. Remove coolant reservoir tank with hoses
attached, and set aside. Disconnect cruise control cable (if
equipped) from coolant reservoir.
Position floor jack under engine. Raise engine slightly to
release pressure from mounting insulator on front of en-
gine. Marking installed position for installation reference,
remove engine front support insulator from timing belt end
of engine.
Remove power steering pressure hose bracket from en-
gine lifting eye, and position aside. Remove upper and
center timing belt covers.
NOTE: Spark plug removal is necessary for final timing adjustment.
Remove top engine appearance cover from between valve
covers. Remove secondary wires from spark plugs. Work-
ing from the outer ends to the center, loosen valve cover
bolts. Remove valve cover. Remove spark plugs.
Temporarily install crankshaft pulley. Rotate crankshaft to
align timing mark on block with larger notch on pulley. See
Fig. 1. Cylinders No. 1 and No. 4 are at TDC when crank-
shaft pulley Woodruff key points straight up.
Loosen timing belt tensioner center attaching bolt about 4
turns. Position tensioner locating tab at approximately the
4 oclock position. See Fig. 4. Line up hex key slot in
tensioner adjusting washer with pointer that is located be-
hind pulley. See Fig. 4.
CAUTION: To achieve proper tension when installing timing belt,
camshaft sprocket bolts must be loose enough to allow sprockets
to turn freely on the camshafts.
Remove plug from center of exhaust camshaft pulley. Hold
exhaust camshaft with open end wrench on hex portion of
camshaft. See Fig. 3. Loosen, but do not remove, exhaust
camshaft sprocket bolt. Loosen, but do not remove, intake
camshaft sprocket bolt.
If reusing timing belt, mark direction of rotation before re-
moval. Remove timing belt.
To lock crankshaft in correct position, remove plug from
lower, left part of engine block. See Fig. 1.
Rotate crankshaft to a few degrees before TDC position.
Install locking Crankshaft Position Timing Peg (T97P-6000-
A) into plug hole. Rotate crankshaft clockwise to lock crank-
shaft against timing peg.
Removal (Escort):
hicle. Remove right front wheel. Remove engine splash
shield from right wheelwell.
Disconnect HO2S electrical connectors. Unbolt catalytic
converter from exhaust manifold and from muffler inlet pipe.
Remove crossmember bolts and crossmember. Remove
catalytic converter bracket bolts. Remove catalytic converter.
Lower vehicle. Remove center trim cover from valve cover.
Noting installed position for installation reference, discon-
nect spark plug wires. Remove spark plugs. Remove valve
cover bolts (10). Remove valve cover.
serpentine drive belt tensioner clockwise and remove ser-
FORD
2.0L 4-Cylinder VIN 3, 1998-01
181
FORD
Fig. 2: Timing Belt Installed Position
Fig. 3: Installing Camshaft Alignment Tool
Fig. 4: Aligning Timing Belt Tensioner For Belt Removal
pentine drive belt. If belt is to be reused, mark belt with
arrow to indicate direction of rotation.
pulley. Remove crankshaft pulley center bolt and pulley.
Remove lower timing belt cover. Lower vehicle. Position
floor jack under engine. Raise engine slightly to release
pressure from mounting insulator on front of engine. Mark-
ing installed position for installation reference, remove en-
gine front support insulator.
Remove upper and center timing belt covers.
Fig. 1. To lock crankshaft in correct position, remove plug
from lower, left part of engine block. See Fig. 1. Rotate crank-
shaft to a few degrees before TDC position. Install locking
Crankshaft Position Timing Peg (T97P-6000-A) into plug
hole. Rotate crankshaft clockwise to lock crankshaft against
timing peg.
Remove plug from center of exhaust camshaft pulley. Hold
exhaust camshaft with open end wrench on hex portion of
camshaft. See Fig. 3. Loosen, but do not remove, exhaust
camshaft sprocket bolt. Loosen, but do not remove, intake
camshaft sprocket bolt.
Removal (Focus):
Raise and support vehicle. Remove serpentine belt cover
from under vehicle.
serpentine drive belt tensioner clockwise. If serpentine drive
belt is to be reused, mark belt with arrow to indicate rota-
tion direction. Remove serpentine drive belt.
pulley. Remove crankshaft pulley center bolt and remove
pulley.
Remove lower timing belt cover. Lower vehicle. Remove
coolant expansion tank and set aside. Remove power steer-
ing reservoir from shock tower and set aside with hoses
attached.
Position floor jack under engine. Raise engine slightly to
release pressure from mounting insulator on front of en-
gine. Marking installed position for installation reference,
remove engine front support insulator from timing belt end
of engine.
Remove upper and center timing belt covers. Remove top
engine appearance cover from between valve covers. Work-
ing from the outer ends to the center, loosen valve cover
bolts. Remove valve cover. Remove secondary wires and
spark plugs. Remove PCV hose.
Fig. 1. To lock crankshaft in correct position, remove plug
from lower, left part of engine block. See Fig. 1. Rotate crank-
shaft to a few degrees before TDC position. Install locking
Crankshaft Position Timing Peg (T97P-6000-A) into plug
timing peg.
182
Holding exhaust camshaft stationary with Holding Tool (303-
098) or spanner wrench, loosen, but do not remove, ex-
haust camshaft sprocket bolt. Holding intake camshaft
sprocket stationary, loosen, but do not remove, intake cam-
shaft sprocket bolt.
NOTE: Revised installation and timing belt tensioning procedures
are from Ford technical service bulletin 99-25-4; December 13,1999.
Ensure crankshaft pulley timing marks are still aligned and
Crankshaft Position Timing Peg (T97P-6000-A) is still in
place. See Fig 1. Ensure crankshaft remains resting against
timing peg during timing belt installation.
Position cylinder No. 4 to valves overlap position. Install
Camshaft Alignment Tool (T94P-6256-CH) or equivalent to
align camshafts. See Fig. 3. Camshafts may be turned
slightly with open end wrench, in normal direction of rota-
tion, to install tool in slots on camshafts at rear of engine.
CAUTION: Timing belt tensioner locating tab should NOT be
hooked in sheet metal cover during timing belt installation. See
Fig. 4.
Tensioner locating tab should be at approximately the 4
oclock position. See Fig. 4. Line up hex key slot in tensioner
adjusting washer with pointer that is located behind pulley.
See Fig. 4.
Starting from crankshaft pulley, install timing belt on sprock-
ets in counterclockwise direction. Remove all slack from
belt during installation.
CAUTION: Incorrect timing belt tension will cause incorrect valve
timing.
To tension the timing belt, rotate timing belt tensioner tab
counterclockwise and insert tab into slot in rear cover. Po-
sition hex key slot in tensioner adjusting washer to the 4
oclock position. See Fig. 5.
Tighten attaching bolt enough to seat the tensioner firmly
against rear timing cover, BUT still allow the tensioner ad-
justing washer to be rotated with a 6 mm hex key.
Working counterclockwise, tension the timing belt. Ensure
all slack is removed from belt. Using a 6 mm hex key, rotate
adjusting washer until notch in pointer is centered over
index line on locating tab. See Fig. 6. Pointer will move
clockwise during adjustment.
While holding adjusting washer in position so that it does
not rotate, tighten tensioner center attaching bolt to 18 ft.
lbs. (25 N.m).
NOTE: DO NOT use Camshaft Alignment Tool (T94P-6256-CH) to hold
camshafts stationary while tightening camshaft sprocket bolts.
On Focus models, hold intake camshaft sprocket station-
ary, and tighten intake camshaft sprocket bolt to 50 ft. lbs.
FORD
(68 N.m). Hold exhaust camshaft stationary and tighten
exhaust camshaft sprocket bolt to 50 ft. lbs. (68 N.m).
On Escort ZX2, Contour, Cougar and Mystique, hold intake
camshaft with Holding Tool (303-098) or spanner wrench,
and tighten camshaft sprocket bolt to 50 ft. lbs. (68 N.m).
On Escort ZX2, Contour, Cougar and Mystique, hold ex-
haust camshaft with open end wrench. Tighten exhaust
camshaft sprocket bolt to 44 ft. lbs. (60 N.m). Final tighten
exhaust camshaft sprocket bolt to 88 ft. lbs. (120 N.m).
On all models, remove camshaft alignment tool. Remove
timing peg from side of engine block.
Rotate crankshaft 2 revolutions in normal direction of rota-
tion. Align crankshaft pulley with timing mark. Install lock-
ing Crankshaft Position Timing Peg (T97P-6000-A) into plug
timing peg.
Camshaft Alignment Tool (T94P-6256-CH) should slide into
slots in rear of camshafts. If not, readjust camshaft pulley
positions.
Fig. 5: Positioning Tensioner Hex Key Slot
Fig. 6: Final Timing Belt Tensioning
183
FORD
On all models except Focus, install NEW center plug into
exhaust camshaft sprocket after all timing marks are
aligned and belt is tensioned.
On all models, install valve covers. Install spark plugs and
secondary wiring. Install appearance cover between valve
covers. Connect solenoid valve electrical connector in ap-
pearance cover (if equipped) and press in rubber seal.
Install upper and center timing belt covers. Install front en-
gine front support insulator. Remove floor jack.
On Contour, Cougar, and Mystique, attach power steering
pipe bracket to engine lifting eye. Install coolant reservoir
tank. Raise and support vehicle. Verify that center bolt is
centered in right-hand and left-hand lower engine support
insulators. Tighten center bolt to specification. See TORQUE
SPECIFICATIONS.
On Escort, install catalytic converter and crossmember.
On all models, install lower timing belt cover. Install crank-
shaft pulley and tighten bolt to specification. Install serpen-
tine drive belt idler pulley. Install water pump pulley. Install
serpentine drive belt.
Install engine splash shield and undercover (if equipped).
Install right front wheel. Tighten lug nuts to specification.
When battery is disconnected, some abnormal driveability
symptoms may occur until the PCM relearns its adaptive
strategy. The vehicle may need to be driven 10 miles or
more to complete a relearn cycle.
Camshaft Sprocket Bolt (Except Focus)
Intake .......................................................................... 50 (68)
Exhaust
Step 1 ....................................................................... 44 (60)
Step 2 ..................................................................... 88 (120)
Camshaft Sprocket Bolt (Focus)
Intake & Exhaust ......................................................... 50 (68)
Catalytic Converter (Escort)
Bracket Bolts ..................................................... 41-47 (55-64)
To-Exhaust Manifold Bolts ................................. 41-47 (55-64)
To-Muffler Pipe Flange Bolts ............................. 34-39 (46-54)
Crossmember Bolts (Escort) ............................ 69-93 (94-126)
Engine Front Support
Insulator Bolt/Nut (Except Focus) ................................. 61 (83)
Engine Front Support (Focus)
To-Engine Bracket Nut ................................................ 59 (80)
To-Frame Bolts ............................................................ 42 (48)
Engine Lower Support Insulators (Contour, Cougar & Mystique)
Right-Hand
Auto. Trans. ............................................................. 88 (120)
Man. Trans. ............................................................... 42 (48)
Left-Hand
All Vehicles .............................................................. 88 (120)
Serpentine Drive Belt Idler Pulley Bolt ............................ 35 (40)
Spark Plugs ................................................................... 11 (15)
Timing Belt Tensioner Attaching Bolt ............................. 18 (25)
Water Pump Bolt ........................................................ 13 (18)
Wheel Lug Nut
Escort (Alloy Wheel) .................................... 74-100 (100-135)
Escort (Steel Wheel) ......................................... 66-87 (89-117)
Except Escort ............................................................. 94 (128)
INCH Lbs. (N.m)
Center Timing Belt Cover Bolt .............................. 53-71 (6-8)
Upper Timing Belt Cover Bolt
Except Escort ............................................................... 89 (10)
Escort ............................................................................. 35 (4)
Valve Cover ................................................................... 62 (7)
Valve Cover Appearance Cover ....................................... 62 (7)
184
2.0L 4-Cyl. VIN P
Escort & Tracer
1997-01................. 2.2 Hours .................. 250283
Focus
2000-01................. 2.2 Hours .................. 250283
Up to 2000 model year, the manufacturer recommends that
the timing belt be inspected at 120,000 miles. Replace, if nec-
essary. For 2001 model year, the manufacturer recommends
that the timing belt be replaced at 120,000 miles.
TIMING BELT
Removal (Escort & Tracer):
Disconnect negative battery cable. Place cylinder No. 1 to
TDC of compression stroke. Remove accessory drive belt
and tensioner. Remove timing belt cover. Raise and sup-
port vehicle. Remove right hand splash guard. Remove
crankshaft pulley. Align timing marks. See Fig. 1.
Loosen timing belt tensioner. Using an 8 mm hex wrench,
turn tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit
to lock tensioner in place. See Fig. 2. If reusing old belt,
mark belt with arrow to indicate original direction of rota-
tion. Remove timing belt.
Installation (Escort & Tracer):
Ensure timing marks are still aligned. Install timing belt. If
reusing old belt, ensure it is installed in original direction of
rotation.
Remove drill bit and tighten tensioner bolt. Rotate crank-
shaft clockwise 2 revolutions. Recheck timing mark align-
ment. To complete installation, reverse removal procedure.
Removal (Focus)
Disconnect negative battery cable. Detach coolant expan-
sion tank and set to one side. Remove power steering fluid
reservoir from shock tower and set aside with hoses at-
tached.
Turn serpentine belt tensioner clockwise to relieve tension
and remove serpentine drive belt. Remove power steering
drive belt.
Hold power steering pump pulley stationary and remove
power steering pump center nut. Remove power steering
pump pulley. Remove power steering pump mounting nuts.
Set power steering pump aside with hoses attached.
move the lower drive belt cover.
Remove the crankshaft pulley and vibration damper. Lower
vehicle. Noting position for reassembly reference, discon-
nect spark plug secondary cables from spark plugs.
Remove spark plugs. Place jack under engine to support
weight. Remove front engine mount and upper timing belt
cover from timing belt end of engine. Remove center timing
belt cover. Remove engine mount bracket from timing belt
end of engine.
Turn the crankshaft so that timing marks are aligned. See
Fig. 1. Loosen timing belt tensioner. Using an 8 mm hex
wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/
8 drill bit to lock tensioner in place. See Fig. 2. If reusing old
belt, mark belt with arrow to indicate original direction of
rotation. Remove timing belt.
Installation (Focus):
Ensure timing marks are still aligned. Install timing belt in
a counterclockwise direction starting at crankshaft sprocket.
Keep slack out of belt span from crankshaft to camshaft
sprocket. If reusing old belt, ensure it is installed in original
Remove drill bit and tighten tensioner bolt. Rotate crank-
shaft clockwise 2 revolutions. Recheck timing mark align-
ment. If not correct, readjust timing belt.
Install engine mount bracket and upper timing belt cover to
engine. Tighten bolts to specification. See TORQUE SPECI-
FICATIONS table. Install lower timing belt cover. Install en-
gine mount to engine and frame. Tighten nuts and bolts to
specification. Remove jack from under engine.
Install spark plugs and secondary cables. Raise vehicle.
Install crankshaft pulley and vibration damper. Tighten cen-
ter bolt to specification.
Install lower drive belt cover. Lower vehicle. Install power
steering pump. Install power steering pump pulley. Tighten
center bolt to specification. See TORQUE SPECIFICATIONS
table. Install serpentine drive belts. Install power steering
fluid reservoir and coolant expansion tank. Connect nega-
tive battery cable.
FORD
2.0L 4-Cylinder SOHC, VIN P
185
FORD
2.0L 4-Cylinder SOHC, VIN P (Cont.)
Camshaft Sprocket Bolt ................................. 70-85 (95-115)
Engine Mount (Focus)
Bracket-To-Engine ....................................................... 35 (48)
To-Engine Nuts ............................................................ 59 (80)
To-Frame Bolts ............................................................ 35 (48)
Power Steering Pump (Focus)
Mount Bolt .................................................................... 17 (23)
Pulley Bolt ..................................................................... 37 (47)
Spark Plugs .................................................................... 11 (15)
Timing Belt Tensioner Bolt .............................. 15-22 (20-30)
Wheel Lug Nut (Focus) ................................................ 94 (128)
INCH Lbs. (N.m)
Timing Belt Cover Bolt Lower ............................. 71-97 (8-11)
186
Belt
Application Time
1
Kit No. No.
2.0L 4-Cyl.
Probe
1993-97.......... 2.5 Hrs. ...... 2522280....... 250228
2.2L 4-Cyl.
Probe
1989-92.......... 2.3 Hrs. ...... 2521340....... 250134
1
kits.
For the 2.0L engine, the manufacturer recommends the belt
be replaced at every 60,000 miles, except in California. For
California 2.0L engine, replace belt at 105,000 miles. For the
2.2L engine, the manufacturer recommends the belt be re-
placed at every 60,000 miles.
Fig. 2: Exploded View Of Timing Belt Components (2.2L)
FORD
*2.0L & *2.2L 4-Cylinder Probe
Fig. 1: Exploded View Of Timing Belt Components (2.0L)
187
Fig. 5: Timing Belt Tensioner & Spring (2.2L)
FORD
*2.0L & *2.2L 4-Cylinder Probe (Cont.)
TIMING BELT
belt removed. Damage to valve/piston may result.
Removal:
belts. Remove spark plug wires and valve cover. Install
Three Bar Engine Support (014-00750) or equivalent.
Slightly raise engine with a jack. Remove right engine
mount. Remove dipstick bolt. Remove upper timing belt
cover.
Remove water pump pulley. Raise and support vehicle.
Remove right front wheel. Remove right upper and lower
splash shield. Remove crankshaft pulley, crankshaft pulley
guide plate. Remove lower timing belt cover. Temporarily
install crankshaft pulley bolt.
NOTE: Mark direction of timing belt rotation if reusing belt.
Rotate crankshaft clockwise and align crankshaft sprocket
timing notch with line on oil pump. Ensure camshaft sprocket
timing marks align. Install Camshaft Pulley Holder (T92C-
6256-AH) or equivalent. Using an Allen wrench, turn timing
chain tensioner and remove tensioner spring. Remove tim-
ing belt.
Installation:
Install timing belt. Rotate tensioner clockwise with an Allen
wrench, and install tensioner spring. Ensure timing marks on
crankshaft sprocket and engine block align.
Remove camshaft pulley holder, and ensure camshaft
sprocket timing marks are still aligned. Rotate crankshaft
clockwise 2 full revolutions. Ensure all timing marks align.
If timing marks do not align, remove timing belt. Repeat
previous two steps. To complete installation, reverse re-
moval procedure. Tighten bolts to specification. See
188
FORD
*2.0L & *2.2L 4-Cylinder Probe (Cont.)
Alternator Mounting Bolt ......................................... 27-38 (52)
Tensioner Bolt .................................................. 27-38 (39-50)
Water Pump Bolt .............................................. 14-19 (19-26)
INCH Lbs. (N.m)
Valve Cover ........................................................... 53-62 (6-7)
189
Belt
2.0L 4-Cyl. OHC
Ranger
1983-88..........
1
2.2 Hrs. ..... 2520140........ 250014
2.3L 4-Cyl. OHC
Aerostar
1987...............
1
2.2 Hrs. ..... 2520140........ 250014
Cougar
1981...............
1
1.3 Hrs. ..... 2520140........ 250014
1984-86..........
1
1.3 Hrs. ..... 2520140........ 250014
Courier
1977-82..........
2
2.2 Hrs. ..... 2520140........ 250014
Fairmont & Zephyr
1978-83..........
2
1.6 Hrs. ..... 2520140........ 250014
Granada
1981-82..........
2
1.6 Hrs. ..... 2520140........ 250014
LTD & Marquis
1983-86..........
2
1.5 Hrs. ..... 2520140........ 250014
Merkur XR4Ti
1985-89..........
1
1.5 Hrs. ..... 2520140........ 250014
Mustang, Mustang II & Capri
1974-91..........
2
1.6 Hrs. ..... 2520140........ 250014
1992
With Round Tooth
Sprockets ...
1
1.5 Hrs. ............................ 250210
With SquareTooth
Sprockets ...
1
1.5 Hrs. ..... 2520140........ 250014
Mustang
1993...............
2
1.5 Hrs. ............................ 250210
Pinto & Bobcat
1974-80..........
2
2.0 Hrs. ..... 2520140........ 250014
Ranger
1983-91..........
1
2.2 Hrs. ..... 2520140........ 250014
1992
With Round Tooth
Sprockets ...
1
2.2 Hrs. ............................ 250210
With SquareTooth
Sprockets ...
1
2.2 Hrs. ..... 2520140........ 250014
1993-94..........
1
2.2 Hrs. ............................ 250210
Thunderbird
1983-88..........
2
1.3 Hrs. ..... 2520140........ 250014
1
- With Air Cond. add 1.0 hours.
2
- With Air Cond. add .5 hours
kits.
TIMING BELT
CAUTION: Rotate crankshaft clockwise (in normal rotation direction)
only. Timing belt may come off if engine is rotated counterclockwise.
Removal:
Disconnect negative battery cable. Rotate engine clock-
wise and position cylinder No. 1 on TDC of compression
stroke. Ensure O mark on crankshaft pulley aligns with
O mark on outer timing belt cover.
Looking through plug hole of outer timing belt cover, ensure cam-
shaft sprocket timing mark aligns with cover pointer. See Fig 1.
Remove fan guard, cooling shroud, cooling fan and fan
shroud. Remove drive belt, water pump pulley and auto-
matic belt tensioner. Discharge A/C System (if equipped)
using approved refrigerant recovery equipment. Remove A/
C compressor mounting bracket with power steering pump
attached, and position aside. Drain cooling system. Re-
move upper radiator hose. Remove thermostat housing
and gasket.
Remove retaining bolt and crankshaft pulley. Remove hub
assembly retaining bolt from crankshaft. Remove outer tim-
ing belt cover. Ensure camshaft sprocket timing mark aligns
with cover pointer. See Fig. 1.
Loosen belt tensioner bolts. Using Camshaft Belt Tensioner
(T74P-6254-A) or equivalent, release spring tension on belt
tensioner. Rotate belt tensioner away from timing belt and
tighten bolts.
Remove retaining bolts and pull crankshaft sensor from
dowel pins. See Fig. 1. Remove hub assembly and belt
guide. Note direction of belt guide installation. Remove tim-
ing belt.
Installation:
Install crankshaft sprocket (if removed) with recessed area
toward crankshaft. See Fig. 1. Install belt guide with flat
side toward camshaft sprocket. Install camshaft sprocket
with timing mark outward.
Install NEW camshaft sprocket bolt and tighten to specifi-
cation while holding camshaft with camshaft sprocket
holder. See TORQUE SPECIFICATIONS.
CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt.
Align camshaft sprocket timing mark with pointer. Properly
position crankshaft so timing mark aligns with notch in
front cover casting. See Fig. 3. Install timing belt over crank-
shaft sprocket, then counterclockwise over auxiliary shaft
and camshaft sprockets. Loosen belt tensioner bolt, allow-
ing tension to be applied on timing belt.
NOTE: It may be necessary to push belt tensioner against timing belt,
as spring tension may not move belt tensioner against timing belt.
FORD
190
Fig. 2: Positioning Crankshaft Sensor
FORD
Remove one spark plug from each cylinder. Rotate engine
clockwise (viewed from front of engine) 2 complete revolu-
tions. Tighten timing belt tensioner bolts to specification.
See TORQUE SPECIFICATIONS. Ensure all timing marks
align properly. Install belt guide on crankshaft.
Install crankshaft sensor over dowel pins. Tighten long crank-
shaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). Rotate crankshaft
counterclockwise approximately 45 degrees so outer vane of hub
assembly does not engage with crankshaft sensor positioner.
Install hub assembly and crankshaft pulley. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Install crank-
shaft sensor positioner. See Fig. 2. Rotate crankshaft clock-
wise approximately 90 degrees so outer vane of hub assem-
bly engages with crankshaft sensor positioner. Tighten short
crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m).
dure. Tighten bolts to specification. See TORQUE SPECI-
FICATIONS.
Disconnect heater hose from fitting on thermostat housing to
bleed air from cooling system when filling. Fill cooling system
with Ford Coolant (E2FZ-19549-AA) or equivalent, until cool-
ant flows from fitting. Install heater hose. Refill radiator. Adjust
drive belts to proper tension. See page a-60 for belt tension
ranges.
Auxiliary Shaft Sprocket Bolt .............................. 29-40 (39-54)
Belt Tensioner
Adjusting Bolt ................................................. 14-22 (19-30)
Pivot Bolt ....................................................... 29-40 (39-54)
Camshaft Plug ................................................. 12-18 (16-24)
1
.................................. 52-70 (71-95)
Crankshaft Pulley-To-Hub Assembly Bolt ......... 15-22 (20-30)
Water Pump Bolt
2
............................................ 14-21 (19-29)
Water Pump Pulley Bolt .................................... 14-22 (19-30)
INCH Lbs. (N.m)
Auxiliary Shaft Cover Bolt .................................. 72-108 (8-12)
Auxiliary Shaft Retainer Plate Bolt ..................... 72-108 (8-12)
Camshaft Retainer Thrust Plate Box ................ 72-108 (8-12)
Outer Timing Belt Cover Bolt ............................ 72-108 (8-12)
Valve Cover Bolt .................................................. 60-96 (6-11)
1
- Install NEW bolt. DO NOT reuse bolt.
2
- Apply thread sealant on bolt threads.
191
Fig. 4: Aligning Camshaft & Oil Pump Timing Marks
Fig. 3: Positioning Crankshaft
FORD
192
1
Belt Part No.
2.3L 4-Cyl. Diesel
Ranger
1985-87
Balance Shaft ..... 2.2 Hours .................. 250092
Camshaft ............. 2.2 Hours .................. 250091
1
TIMING BELT
Removal:
Disconnect negative battery cable. Remove drive belts. Re-
move 5 upper front timing belt cover retaining bolts. Re-
move upper front cover. Remove cooling fan and shroud.
Remove water pump pulley. Remove crankshaft pulley at-
taching bolt. Rotate crankshaft until No. 1 piston is at TDC
on compression stroke.
Remove vibration damper using Damper Remover (T58P-
6316-D) or equivalent. Remove 5 lower front timing belt
cover attaching bolts and remove cover. Loosen timing belt
tensioners and remove belts. Mark direction of rotation on
timing belts before removal.
Check timing belts for missing teeth, cracking or excessive
wear. Replace timing belt if necessary. Camshaft/injection
pump timing belt must be removed to access silent shaft
timing belt.
NOTE: DO NOT loosen nut near timing scale unless removing
silent shaft timing belt. This nut is for silent shaft timing belt
tensioner. Loosening this nut may change silent shaft timing
belt tension. See Fig. 1.
Installation:
Fabricate timing belt tensioner, using a pivot nut from rear
brake adjuster and bar stock. See Fig. 3. Release tension
on tensioner spring, using belt tensioner. Rotate tensioner
toward water pump and tighten top bolt.
Install camshaft/injection pump timing belt. Ensure belt is
installed to rotate in original rotation. Maintain tension on
belt. Loosen top tensioner bolt to tension timing belt. See
Fig. 4. Tighten tensioner hold-down bolts. To complete in-
stallation, reverse removal procedure. Adjust drive belts to
Fig. 3: Timing Belt Tensioner
Fig. 2: Timing Mark Alignment
FORD
Fig. 1: Silent Shaft Timing Belt Tensioner Nut
193
Fig. 4: Loosening Belt Tensioner Bolts
Fig. 6: Removing Tensioner Bolt Access Cover
Fig. 5: Aligning Mark On Timing Cover With Mark On
Camshaft Sprocket
FORD
Crankshaft Pulley Bolts ............................ 123-137 (167-186)
Injection Pump Sprocket Nut ............................ 40-50 (54-68)
Timing Belt Tensioner Nut ................................ 16-21 (22-29)
INCH Lbs. (N.m)
Front Case Bolts ......................................... 108-120 (12-14)
Rocker Cover Bolts ............................................... 48-60 (5-7)
Silent Shaft Chamber Cover Bolts ........................ 36-48 (4-5)
Test
194
1
Belt Part No.
2.3L 4-Cyl.
Ranger
1995-97................. 2.2 Hours .................. 250276
1
60,000 miles.
TIMING BELT
Removal:
Remove spark plugs. Ensure crankshaft is set at TDC and
camshaft sprocket timing mark and oil pump sprocket timing
mark are aligned with inner cover timing marks. See Fig. 1.
Remove fan guard. Remove fan shroud and position aside.
Remove fan retaining screws, and remove fan and shroud.
Rotate drive belt tensioner and remove belt.
Remove cooling fan and water pump pulley. Discharge A/C
system (if equipped) using approved refrigerant recovery/
recycling equipment. Remove A/C compressor and posi-
tion aside. Remove A/C compressor mounting bracket with
power steering pump attached, and position aside.
Remove timing belt outer cover retaining bolt. Release 7
cover interlocking tabs. Remove timing belt cover. Holding
timing belt tensioner with Camshaft Belt Tension Adjuster
(T74P-6254-A) or equivalent, loosen adjusting bolt and slowly
release tension. See Fig. 2. Pry tensioner away from timing
belt and tighten bolt to hold tensioner in place. Remove timing
belt.
CAUTION: Always rotate engine in direction of normal rotation
(clockwise as viewed from front of engine). Reverse rotation may
cause timing belt to jump time, causing engine damage.
Installation:
Ensure crankshaft is set at TDC and camshaft sprocket
timing mark and oil pump sprocket timing mark are aligned
with inner cover timing marks.
Install NEW timing belt. Loosen tensioner bolt. Allow
tensioner to adjust itself, and retighten bolt. Rotate crank-
shaft clockwise 2 complete revolutions to remove slack
from belt.
Loosen tensioner bolt. Allow tensioner to adjust itself and
retighten bolt. To complete installation, reverse removal
A/C Compressor Bolts ..................................... 15-21 (21-28)
Alternator Bracket Bolts .................................... 30-40 (41-54)
Alternator Retaining Bolts ................................. 30-40 (41-54)
Cooling Fan Bolts ............................................. 13-16 (17-23)
Crankshaft Damper Bolt ........................... 103-133 (140-180)
Oil Pump Sprocket Bolt ..................................... 28-40 (38-54)
Timing Belt Tensioner Adjusting Bolt ................ 14-21 (35-45)
Timing Belt Tensioner Pivot Bolt ....................... 28-40 (40-55)
INCH Lbs. (N.m)
Engine Timing Belt Cover Bolt .......................... 71-106 (8-12)
Spark Plug ........................................................ 80-177 (9-20)
Valve Cover Bolt ................................................ 80-115 (9-13)
FORD
2.3L 4-Cylinder
Fig. 1: Aligning Camshaft & Oil Pump Timing Marks
195
1
Belt Part No.
2.5L 4-Cyl.
Ranger
1998-01................. 2.2 Hours .................. 250276
1
belt be inspected at 120,000 miles and replaced if necessary.
be replaced at 120,000 miles.
TIMING BELT
Removal:
Disconnect battery ground cable. Remove exhaust side
spark plugs.
Remove fan shroud bolts and position over fan blades.
Loosen, but do not remove, water pump pulley bolts. Re-
move accessory drive serpentine belt.
Remove fan and clutch assembly retaining screws. Re-
move fan and clutch assembly. Remove fan shroud. Re-
move water pump pulley.
On models with A/C, discharge A/C system using approved
refrigerant recovery/recycling equipment. Remove A/C com-
pressor from mounting bracket. Remove A/C compressor
mounting bracket with power steering pump attached, and
position aside.
cover interlocking tabs. Remove timing belt cover.
Rotate crankshaft in normal direction of rotation so that No. 1
cylinder is at TDC of compression stroke. Align camshaft,
crankshaft and oil pump timing marks. See Fig. 1. Crankshaft
keyway should be pointing straight up and circle on crank-
shaft sprocket must align with notch in engine front cover.
Holding timing belt tensioner with Camshaft Belt Tension Ad-
juster (T74P-6254-A) or equivalent, loosen adjusting bolt and
pivot bolt. Slowly release spring tension. Pry tensioner away
from timing belt and tighten bolt to hold tensioner in place.
Remove timing belt.
Installation:
with inner cover timing marks.
Install timing belt on crankshaft sprocket, oil pump sprocket
and then the camshaft sprocket. Loosen timing belt
tensioner bolt.
Allow tensioner to adjust itself against timing belt. DO NOT
tighten belt tensioner. Slowly rotate crankshaft clockwise 2
complete turns clockwise (as viewed from front of engine)
so No. 1 cylinder is at TDC of compression stroke.
Recheck timing alignment marks. If timing marks are not
al i gned, reposi ti on ti mi ng bel t. Repeat ti mi ng bel t
tensioning procedure.
Tighten timing belt tensioner adjusting and pivot bolts to
specification. See TORQUE SPECIFICATIONS. Install
crankshaft pulley. Tighten center bolt to specification.
Install timing belt cover. Install exhaust side spark plugs.
Install A/C compressor mounting bracket to engine. Install
A/C compressor to mounting bracket. To complete installa-
tion, reverse removal procedure. Recharge A/C system.
A/C Compressor Mount Bolts ............................. 15-21 (21-28)
A/C Compressor Mounting Bracket-To-Engine
M8 Bolt ......................................................................... 18 (25)
M10 Bolt & Stud ............................................................ 35 (48)
Alternator Bracket Bolts .................................... 30-40 (41-54)
Alternator Retaining Bolts ................................. 30-40 (41-54)
Cooling Fan-To-Water Pump Bolts ................... 13-16 (17-23)
Crankshaft Damper Bolt ............................... 93-121 (125-165)
INCH Lbs. (N.m)
Spark Plug ........................................................ 80-177 (9-20)
Valve Cover Bolt ................................................ 80-115 (9-13)
FORD
2.5L 4-Cylinder
196
1
Belt Part No.
2.5L V6
Probe
1993-97................. 4.0 Hours .................. 250214
1
60,000 miles for Federal vehicles and 105,000 miles for Cali-
fornia vehicles.
TIMING BELT
belt removed. Damage to valve/piston may result.
Fig. 2: Checking & Compressing Automatic Belt Tensioner
FORD
2.5L V6
197
Compress automatic belt tensioner until hole in piston aligns
with second hole in housing. Insert a .06" (1.5 mm) diameter pin,
or drill through hole to keep piston in compressed position. See
Fig. 1.
Ensure camshafts and crankshaft timing marks align. See Fig. 3.
Turn crankshaft counterclockwise until crankshaft timing sprocket
is offset from TDC by one tooth. See Fig. 4. Install timing belt.
Turn crankshaft clockwise until crankshaft timing mark is
back to TDC. This should put slack on tensioner portion of
belt. Install automatic timing belt tensioner, and tighten bolts
to specification. See TORQUE SPECIFICATIONS. Remove
pin from automatic tensioner.
Turn crankshaft 2 complete revolutions. Recheck timing marks
to ensure timing is still correct. See Fig. 3. To complete instal-
lation, reverse removal procedure. Tighten bolts to specifi-
cation. Check ignition timing. Adjust drive belts to proper
A/C Compressor Bracket-To-Cylinder
Block Bolt ........................................................ 28-38 (38-51)
Camshaft Sprocket Bolt ............................. 90-103 (122-140)
Crankshaft Pulley Bolt .............................. 116-122 (157-165)
Engine Mount Nuts ......................................... 54-76 (73-103)
Engine Mount Through-Bolts .......................... 50-68 (86-116)
Front Suspension Crossmember Bolt ........... 69-93 (94-126)
Knock Sensor ................................................... 14-25 (20-34)
Power Steering Pump Bracket Bolt ................... 24-33 (32-46)
Spark Plug ....................................................... 11 -16 (15-23)
Tensioner Pulley Bolt ........................................ 27-33 (37-45)
Water Pump Bolt .............................................. 14-18 (19-24)
Wheel Lug Nut ................................................ 65-87 (88-118)
INCH Lbs. (N.m)
Valley Cover Bolts .............................................. 71 -88 (8-10)
Valve Cover Bolt .................................................... 43-78 (5-8)
Fig. 3: Aligning Camshaft & Crankshaft To TDC
Fig. 4: Positioning Crankshaft To Remove Slack From
Timing Belt
FORD
2.5L V6 (Cont.)
Removal:
Disconnect negative battery cable. Disconnect engine cool-
ant temperature sensor and temperature gauge sender
connectors from coolant elbow. Disconnect crankshaft po-
sition sensor connector. See Fig. 2. Remove accessory
drive belts. Raise and support vehicle.
Remove A/C belt tensioner bracket. Remove crankshaft
damper bolt using Crankshaft Pulley Holder (T92C-6316-
AH) or equivalent. Remove crankshaft damper. Remove 2
timing belt cover bolts from behind crankshaft damper.
Remove timing belt cover lower bolts. Using Power Steer-
ing Pump Pulley Remover (D85L-6000-A) or equivalent,
remove power steering pump pulley.
Using Water Pump Pulley Remover (T92C-631 2-AH) or
equivalent, remove water pump pulley bolts and pulley.
Lower vehicle. Remove oil dipstick tube. Remove upper
timing belt cover bolts. Remove A/C-alternator belt idler
bracket. Remove left timing belt cover then right cover.
Remove 3 nuts and through-bolt from right engine mount.
Remove right engine mount. Align crankshaft timing
sprocket by turning crankshaft in normal direction of en-
gine rotation only. Remove timing belt tensioner arm by
removing lower and then upper tensioner arm bolts.
Mark direction of timing belt rotation if reusing belt. Using an Allen
wrench, loosen timing belt tensioner bolt. Remove timing belt.
CAUTION: DO NOT rotate camshafts or crankshaft with timing
belt removed, as engine damage could result.
Inspection:
tamination. Ensure upper and lower timing belt idlers ro-
tate freely. Replace damaged components.
Inspect timing belt tensioner for signs of oil leakage. Re-
place timing belt tensioner if oil leakage exists.
Measure timing belt tensioner rod protrusion (free length)
from end of rod to edge of housing. See Fig. 1. Replace
timing belt tensioner if distance is not .55-.63" (14-16 mm).
Installation:
Place timing belt tensioner in a press, using a flat washer to
prevent damage to timing belt tensioner plug.
198
FORD
*3.0L V6 SOHC, Villager
Belt
3.0L V6 SOHC
Villager (Mercury)
1993...............
1
3.5 Hrs. .... 2521040....... 250104
1994-98..........
1
3.5 Hrs. .......................... 250249
1
this application. See page.... for information on component
kits.
105,000 miles.
TIMING BELT
Removal:
hicle. Remove covers from below engine. Drain cooling
system. Remove right front wheel and engine side cover.
Remove accessory drive belts. Remove crankshaft pulley
bolt and pulley.
Remove upper radiator hose and water inlet hose. Re-
move A/C compressor idler pulley and bracket. Remove
water pump pulley. Remove upper and lower timing belt
front covers.
Temporarily install crankshaft pulley bolt so crankshaft can
be rotated. Set cylinder No. 1 at TDC of compression stroke
by rotating crankshaft until marks on camshaft sprockets
align with marks on timing belt upper rear cover, and mark
on crankshaft sprocket aligns with mark on front cover hous-
ing. See Fig. 2.
Loosen timing belt tensioner nut. Release tension on belt.
Remove timing belt. Check timing belt tensioner, spring
and timing belt.
Installation:
Ensure cylinder No. 1 is at TDC of compression stroke.
See Fig. 2. Install tensioner and return spring if removed. If
return spring stud was removed, apply thread lock sealant
to threads before installing stud. Insert an Allen wrench
into hole in tensioner, turn tensioner fully clockwise, and
temporarily tighten lock nut.
Install timing belt with arrow on timing belt facing front of
engine. Align White lines on timing belt with marks on cam-
shaft sprockets and crankshaft sprocket. White lines en-
sure correct number of teeth exist between timing marks
on sprockets.
Loosen tensioner lock nut. Using Allen wrench, rotate
tensioner by turning Allen wrench clockwise 70-80 degrees.
Temporarily tighten lock nut. Rotate crankshaft clockwise
at least 2 revolutions.
Return cylinder No. 1 to TDC of compression stroke. Using
Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs.
(10.0 kg) pressure to timing belt between right camshaft
sprocket and tensioner. Hold tensioner in position with Allen
wrench, and loosen tensioner lock nut.
Fig. 2: Installing Timing Belt & Sprocket
199
FORD
*3.0L V6 SOHC, Villager (Cont.)
Place a .0138" (.351 mm) feeler gauge at tensioner pulley
and timing belt, and rotate crankshaft until feeler gauge is
centered between tensioner pulley and timing belt. See
Fig. 3. Tighten tensioner lock nut to specification. See
Rotate crankshaft to remove feeler gauge. Rotate crank-
shaft clockwise at least 2 revolutions until cylinder No. 1 is
at TDC of compression stroke. Measure timing belt deflec-
tion halfway between camshaft sprockets.
If deflection is not .51-.59" (13-15 mm), readjust timing belt
tension. To complete installation, reverse removal proce-
dure.
tension ranges.
Crankshaft Pulley Bolt ................................. 90-98 (122-133)
Rocker Shaft Bolts ............................................ 13-16 (16-20)
Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58)
Water Pump Bolt .............................................. 13-16 (16-20)
INCH Lbs. (N.m)
200
3.0L V6 SHO
Taurus
1989-95................ 3.0 Hours ................. 250248
3.2L V6 SHO
Taurus
1993-95................ 3.0 Hours ................. 250248
100,000 miles.
TIMING BELT
Removal (3.0L SHO):
Remove battery. Remove engine roll damper, located near
timing belt cover. Disconnect ignition control module. Re-
move intake manifold crossover tube. See Fig. 4. Remove
accessory drive belts. Remove alternator belt tensioner pul-
ley and bracket.
Remove water pump tensioner pulley. Disconnect crank-
shaft sensor wiring assembly at lower timing belt cover.
Remove upper timing belt cover. Ensure transaxle is in
Neutral.
Rotate crankshaft until No. 1 piston is at TDC. Ensure White
mark on crankshaft damper aligns with 0 mark on lower
timing belt cover and camshaft timing marks align with
marks on timing belt cover. See Fig. 1.
Raise and support vehicle. Remove right front wheel and
splash shield. Using Puller (T67L-3600-A) or equivalent,
remove crankshaft damper. Remove timing belt covers. Dis-
connect crankshaft position sensor wire and grommet from
slot near water pump.
Ensure timing marks align. See Fig. 2. If reusing timing
belt, place reference mark on timing belt, camshaft sprock-
ets, and crankshaft sprocket. Mark direction of belt rotation
Loosen timing belt tensioner lock nut. Rotate tensioner
pulley 180 degrees clockwise using 6mm Allen wrench.
See Fig. 6. Tighten lock nut to hold tensioner in unloaded
position. Lower vehicle. Remove timing belt.
NOTE: To prevent timing belt whine on models with 3.0L engine
and manual transaxle, the timing belt must be correctly tensioned.
The revised tensioning procedure is from Ford technical service
bulletin 95-22-10; November 6, 1995.
Installation (3.0L SHO):
Ensure No. 1 piston is at TDC of compression stroke. En-
sure camshaft timing marks align with timing belt cover
marks and crankshaft sprocket timing mark aligns with
mark on oil pump housing. See Fig. 2.
Install timing belt on crankshaft and route around left cam-
shaft and onto right camshaft sprockets. Ensure used tim-
ing belt is installed in original direction of rotation. Loosen
timing belt tensioner lock nut and leave nut loose.
Raise and support vehicle. Install center timing belt cover
and ensure crankshaft sensor wiring is properly routed.
Install lower timing belt cover. Install crankshaft damper.
Tighten bolt to specification. See TORQUE SPECIFICA-
TIONS table.
Rotate crankshaft until Yellow mark on crankshaft damper
aligns with 0 mark on lower timing belt cover. See Fig. 1.
Remove plastic access cover in lower timing belt cover.
Tighten timing belt tensioner lock nut to 25-37ft. lbs. (34-50
N.m). Install plastic access cover.
Rotate crankshaft clockwise 60 degrees until White mark
on crankshaft damper aligns with 0 mark on lower timing
belt cover. Lower vehicle.
Ensure camshaft timing marks align with timing belt cover
marks. See Fig. 2. Install upper timing belt cover. Install
intake manifold crossover tubes. Connect ignition electri-
cal connector.
Install splash shield and right front wheel. To install re-
maining components, reverse removal procedure. Adjust
ranges.
FORD
3.0L & 3.2L V6 SHO
Fig. 2: Aligning Timing Marks Fig. 1: Crankshaft Pulley Timing Marks
G93G56966
201
Removal (3.2L SHO):
Remove battery. Remove engine roll damper, located near
timing belt cover. Disconnect ignition control module. Re-
move intake manifold crossover tube. See Fig. 4. Remove
serpentine drive belt and tensioner.
Remove upper and lower idler pulleys. Using a strap wrench
to hold power steering pump pulley, remove power steer-
ing pump pulley nut and pulley. Remove upper and center
timing belt covers. Disconnect crankshaft sensor wiring
assembly at lower timing belt cover.
Ensure transaxle is in Neutral. Rotate crankshaft until No.
1 piston is at TDC. Ensure White mark on crankshaft damper
aligns with 0 mark on lower timing belt cover and cam-
shaft timing marks align with marks on timing belt cover.
See Fig. 2.
splash shield. Using Puller (T67L-3600-A), remove crank-
shaft damper. Remove lower timing belt cover. Remove
timing belt guide located in front of crankshaft sprocket.
Ensure timing marks align. See Fig. 2.
If reusing timing belt, place reference mark on timing belt,
camshaft sprockets, and crankshaft sprocket. Mark direc-
tion of belt rotation for reassembly reference. Slowly loosen
timing belt tensioner bolt and remove tensioner. Lower ve-
hicle. Remove timing belt.
Installation (3.2L SHO):
Ensure No. 1 piston is at TDC of compression stroke. En-
sure camshaft timing marks align with timing belt cover
marks and crankshaft sprocket timing mark aligns with
mark on oil pump housing. See Fig. 2. Place timing belt
tensioner in a soft jawed vise. Compress tensioner until
hole in tensioner rod aligns with hole in tensioner housing.
Install a 1.5 mm Allen wrench through hole, and lock
tensioner in retracted position. See Fig. 3.
Install timing belt on crankshaft and route belt around left
camshaft and onto right camshaft sprockets. Ensure used
timing belt is installed in original direction of rotation.
Install timing belt tensioner while pushing tensioner pulley
toward belt. Install rubber grommets between tensioner
and oil pump. See Fig. 5. Remove Allen wrench from
tensioner. If installing used belt, skip the next step. If in-
stalling new timing belt, go to next step.
Mount Timing Belt Tensioner Tool (T93P-6254B) or equiva-
lent, using power steering pump bracket bolt holes. Using
INCH-lb. torque wrench and Torque Wrench Attachment
(T93P-6254-A) or equivalent, rotate tensioner clockwise to
4.3 INCH lbs. (.5 N.m.). Tighten belt tensioner bolt. Re-
move tensioner tool. Tighten bolts to specification.
Raise and support vehicle. Install timing belt guide and
lower timing belt cover. Install crankshaft damper. Rotate
crankshaft clockwise 60 degrees until White mark on crank-
shaft damper aligns with 0 mark on lower timing belt cover.
Ensure camshaft timing marks align with timing belt cover
marks. See Fig. 2. Ensure crankshaft sensor wiring is prop-
erly routed. Install remaining timing belt covers. To install
remaining components, reverse removal procedure. Ad-
tension ranges.
FORD
3.0L & 3.2L V6 SHO (Cont.)
Fig. 5: Installing Rubber Grommets (3.2L SHO)
Fig. 4: Exploded View Of Intake Manifold & Brackets
Fig. 3: Compressing Timing Belt Tensioner (3.2L)
202
FORD
3.0L & 3.2L V6 SHO (Cont.)
Fig. 6: Adjusting Timing Belt Tension (3.0L)
G93F566965
Camshaft Pulley Bolts ...................................... 15-18 (20-24)
Camshaft Timing Belt Sprocket Bolt ................. 15-18 (20-24)
Engine Damper Bracket Bolt ............................ 21-30 (28-41)
Idler Pulley Nut ................................................. 25-37 (34-50)
Intake Manifold Crossover Tube Bolt ................... 11-16 (15-22)
Timing Belt Upper Cover Bolt (3.2L) ................. 12-17 (16-23)
Timing Belt Tensioner Arm Nut (3.2L) ............... 27-37 (36-50)
Timing Belt Tensioner Bolt (3.2L) ..................... 12-17 (16-23)
Timing Belt Tensioner Lock Nut (3.0L ) ............ 25-37 (34-50)
Water Pump Pulley Bolt .................................... 12-17 (16-23)
Wheel Lug Nut .............................................. 85-105 (115-142)
INCH Lbs. (N.m)
Camshaft Sensor Bolt ........................................ 62-97 (7-11)
Crankshaft Sensor ............................................... 18-27 (2-3)
Timing Belt Cover Bolt (3.0L) ................................. 62-97 (7-11)
Valve Cover Bolt .............................................. 89-142 (10-16)
203
GEO
1.6L 4-Cylinder DOHC, Prizm GSI
1.6L 4-Cyl. DOHC
Prizm GSI
1990-92................
1
3.1 Hours ................. 250176
1
The manufacturer recommends the belt be inspected and
adjusted at 30,000 mile intervals, and replaced at 60,000 mile
intervals.
TIMING BELT
Removal:
hicle. Turn front wheels all the way to the right. Remove
right front wheel. Remove right lower stone shield from
under vehicle. Remove accessory drive belts.
Remove center bolt and crankshaft pulley. Lower vehicle.
Label spark plug secondary cables for reassembly refer-
ence. Disconnect spark plug cables from spark plugs.
Remove PCV valvefrom valve cover. Disconnect accelera-
tor cable from valve cover. Disconnect wiring harness from
valve cover. Remove valve covers.
Remove windshield washer reservoir. Remove engine wir-
ing harness from upper timing belt cover.
Support engine from above using Engine Support Bar (J
28467-A) or equivalent. Remove engine mount through bolt
from mount on timing belt end of engine.
Remove water pump pulley. Remove upper, center and lower
timing belt covers. Remove timing belt guide. Turn crank-
shaft so that camshaft and crankshaft timing marks are
aligned. See Fig. 2. Loosen timing belt idler pulley bolt.
Remove timing belt.
CAUTION: If timing belt is to be reused, mark direction of timing
belt rotation. Place mating marks on belt and sprockets for reference.
Inspection:
Inspect timing belt for cracks or damaged teeth. Ensure
timing belt is not contaminated with oil. Check belt tensioner
pulley for smooth rotation or grease leaks. Replace dam-
aged components.
Remove spring from timing belt idler pulley. Check free
length of belt tensioner spring. Free length is measured
between inside diameters of hooked portion of spring (not
coil length). Replace spring if free length is greater than
1.618 (41.09 mm). See Fig. 3.
Installation:
timing belt. If reusing old timing belt, ensure belt is in-
stalled in original rotating direction.
If removed, installed timing belt idler pulley spring. Loosen
timing belt idler pulley bolt to allow tension to be applied on
timing belt.
Temporarily install crankshaft pulley center bolt. Rotate crank-
shaft clockwise 2 revolutions, to TDC. Ensure all timing
marks are aligned.
Final tighten timing belt idler pulley bolt to specification.
See TORQUE SPECIFICATIONS. Apply about 4.5 lbs. (2.04
kg) of downward pressure to timing belt between camshaft
sprockets. Belt deflection should be about .16 (4 mm) if
timing belt tension is correct.
Remove crankshaft bolt. Install timing belt guide. Install
upper, center, and lower timing belt covers. Install crank-
shaft pulley. Tighten center bolt to specification. Install wa-
ter pump pulley.
Install engine mount through-bolt and tighten to specifica-
tion. Remove engine support bar. Install valve cover with
new gaskets. Apply GM sealant (part no. 1052917) or
equivalent to valve cover mating surfaces.
Install accessory drive belts. Adjust drive belts to proper
tension. See page A-60 for belt tension ranges. To install
remaining components, reverse removal procedure.
Courtesy of Toyota Motor Sales, U.S.A., Inc.
204
GEO
1.6L 4-Cylinder DOHC, Prizm GSI (Cont.)
Camshaft Sprocket Bolts ............................................... 35 (47)
Engine Mount Through-Bolt ............................................ 64 (87)
Water Pump Pulley Bolt .............................................. 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Nut ............................................................ 53 (6)
Fig. 3: Checking Timing Belt Tensioner Spring Free Length
205
GEO
*1.6L 4-Cylinder Storm SOHC
1
Belt Part No.
1.6L 4-Cyl. SOHC
Storm
1990-93................ 1.5 Hours ................. 250177
1
mile intervals.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator and
power steering pump drive belts. Using Engine Support
Fixture (J-26900-9) or equivalent, support engine from
above.
Remove engine mount located at timing belt cover. Rotate
crankshaft and position No. 1 cylinder at TDC of compres-
sion stroke. Ensure timing mark on crankshaft pulley aligns
with O timing mark on timing belt cover. Remove timing
Ensure locating dowel on camshaft sprocket is at 12 oclock
position and timing mark is aligned with cylinder head sur-
face. See Fig. 2.
Raise and support vehicle. Remove right side undercover.
Remove crankshaft pulley-to-sprocket bolts. See Fig. 1.
Lower vehicle. Ensure timing mark (notch) on rear of crank-
shaft sprocket is aligned with timing mark on oil pump. See
Fig. 4. Loosen belt tensioner bolt 1/2 turn. Rotate belt
tensioner and remove timing belt.
Inspection:
Inspect timing belt for damaged teeth, cracking or oil con-
tamination. Ensure belt tensioner bearing rotates freely.
Replace components if damaged.
NOTE: Revised timing belt tensioning procedure is from GEO
technical service bulletin 91-487-6A; February 26, 1992.
Installation:
Rotate camshaft so locating dowel on camshaft sprocket
is at 12 oclock position and timing mark aligns with cylin-
der head surface. See Fig. 2.
Ensure timing mark (notch) on rear of crankshaft sprocket
aligns with timing mark on oil pump. See Fig. 4. Install
timing belt over crankshaft sprocket, tensioner pulley, wa-
ter pump and camshaft sprocket.
Insert a hex wrench into the tensioner pulley hexagonal
hole. Rotate pulley counterclockwise to tension the belt.
Hold pulley stationary and temporarily tighten the tensioner
pulley bolt.
Rotate crankshaft 2 revolutions counterclockwise and align
crankshaft and camshaft timing marks. See Figs. 2 and 4.
Fig. 1: Timing Belt Components
Courtesy of General Motors Corp.
Loosen belt tensioner pulley bolt. Insert a hex key wrench
into tensioner pulley hexagonal hole. Rotate the tensioner
pulley counterclockwise to tension the timing belt. Tighten
tensioner pulley bolt to 37 ft. lbs. (50 N.m).
Rotate crankshaft back to about 50 degrees BTDC and
back to TDC of No. 4 cylinder. Align crankshaft sprocket
timing mark with mark on oil pump housing. Align cam-
shaft sprocket timing mark with upper surface of cylinder
head.
206
GEO
*1.6L 4-Cylinder Storm SOHC (Cont.)
Fig. 4: Crankshaft Sprocket Timing Mark
Measure timing belt deflection by applying 22 lbs. (98 N) of
force to belt. See Fig. 5. Defection must be .63-.79 (16-20
mm). If deflection is not correct, retension timing belt. En-
sure camshaft sprocket is still aligned correctly.
Install timing belt cover. Install crankshaft pulley. Install
engine undercover. Install right engine mount.
Crankshaft Pulley-To-Sprocket Bolt ................................ 17 (23)
Crankshaft Sprocket Center Bolt ............................... 87 (118)
Engine Mount
Right Bracket Bolt ..................................................... 29 (39)
Right Through-Bolt ................................................... 50 (68)
Timing Belt Tensioner Pulley Bolt ................................... 37 (50)
Water Pump Bolt ............................................................ 18 (25)
Wheel Lug Nut .......................................................... 87 (118)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Flange Bolt ............................... 89 (10)
Valve Cover Bolt .......................................................... 89 (10)
207
GEO
*1.6L & 1.8L 4-Cylinder DOHC, Prizm
Belt
1.6L 4-Cyl. DOHC, VIN 6
Prizm (Except GSI)
1989-97..........
1
2.2 Hrs. .... 2522360........ 250236
1.8L 4-Cyl. DOHC, VIN 8
Prizm (Except GSI)
1993-97..........
1
2.2 Hrs. ........................... 250235
1
kits.
The manufacturer recommends the belt be inspected and
adjusted at 30,000 mile intervals, and replaced at 60,000 mile
intervals.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove windshield
washer reservoir.
On vehicles equipped with cruise control, remove cruise
control actuator cover. Disconnect cruise control electrical
connector and actuator cable. Remove cruise control ac-
tuator from vehicle.
On all vehicles, raise and support vehicle. Remove right
front wheel. Remove right wheel housing. Loosen, but do
not remove, water pump pulley bolts.
Lower vehicle. Remove accessory drive belts. Disconnect
A/C compressor electrical connector. Remove A/C com-
pressor mounting bolts. Set compressor aside with hoses
attached. Remove mounting bracket from engine.
Remove wiring harness from valve cover. Noting position
for reassembly reference, remove spark plug secondary
cables from spark plugs. Remove spark plugs.
Remove PCV valve from valve cover. Remove valve cover.
Turn crankshaft so that 0 mark on crankshaft pulley aligns
with mark on timing case cover. Ensure No. 1 piston is at
TDC of compression stroke. If not, turn crankshaft one full
revolution.
Using Support Fixture (J028467-A) or equivalent, support
engine from above. Remove engine mount from timing belt
end of engine. Remove water pump pulley.
Remove crankshaft pulley. Remove timing belt covers. Not-
ing installed position, remove timing belt guide from crank-
shaft.
belt rotation and place reference marks on timing belt and sprockets
for installation reference.
Remove timing belt tensioner bolt, tensioner and tensioner
spring. Remove timing belt.
Inspection:
Inspect timing belt for damaged teeth or cracking. Ensure
timing belt is not contaminated with oil. Check tensioner
pulley for rotation freedom or grease leaks. Replace com-
ponents if damaged.
Check free length of idler pulley spring. Free length is mea-
sured between inside edge of hooked portions of spring
(not the coil area). See Fig. 4. Replace spring if free length
is not as specified. See TENSIONER SPRING FREE
LENGTH.
TENSIONER SPRING FREE LENGTH
Maximum Free Length
Year In. (mm)
1989-92.................................................................. 1.512 (38.4)
1993-94.................................................................. 1.390 (35.3)
1995-97.................................................................. 1.453 (36.9)
Installation:
Ensure all timing marks are still aligned. See Fig. 3. Install
timing belt tensioner and spring. Move tensioner to the left
and temporarily tighten bolt.
Install timing belt. If old timing belt is reused, ensure belt is
installed in original rotating direction. Ensure marks on
belt align with camshaft and crankshaft sprockets.
Loosen timing belt tensioner bolt and allow tension to be
applied on timing belt. Rotate crankshaft CLOCKWISE 2
revolutions. DO NOT turn crankshaft counterclockwise. En-
sure all timing marks are aligned. Tighten timing belt
tensioner bolts to specification. See TORQUE SPECIFICA-
TIONS.
208
Fig 3: Aligning Camshaft & Crankshaft Timing Marks
Fig. 2: Aligning Timing Marks & Checking Belt Deflection
GEO
*1.6L & 1.8L 4-Cylinder DOHC, Prizm (Cont.)
Measure timing belt deflection at midway point between
camshaft and crankshaft sprockets. See Fig. 2. With 4.4
Ibs. (1.9 kg) applied on timing belt, defection should be
.20-.24" (5.1-6.9 mm). If belt deflection is not within specifi-
cation, repeat previous step.
CAUTION: Ensure all timing marks are aligned once timing belt
is adjusted.
Install timing belt guide with cupped side facing out. Install
timing belt covers, starting with bottom cover. Install crank-
shaft pulley. Tighten center bolt to specification.
Install water pump pulley. Install engine mount. Install en-
gine ground wire (if equipped) to right fender apron. Install
valve cover with new gasket. Install spark plugs and spark
plug secondary wires.
Install PCV valve and wiring harness on valve cover. Install
A/C compressor mounting bracket (if removed). Install A/C
compressor to bracket. Install accessory drive belts.
Install cruise control actuator (if equipped). Install wind-
shield washer reservoir. To install remaining components,
reverse removal procedure. Adjust accessory drive belts to
A/C Compressor Bracket-To-Engine Bolt ................... 35 (47)
A/C Compressor-To-Bracket Bolt ............................... 18 (25)
Timing Belt Tensioner Bolt ............................................. 27 (37)
Water Pump Bolt ........................................................ 11 (15)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Cap Nuts ................................................... 53 (6)
Fig. 4: Checking Timing Belt Tensioner Spring Free Length
209
GEO
1.6L & 1.8L 4-Cylinder DOHC, Storm
1.6L 4-Cyl. DOHC
Storm
1990-91................
1
2.0 Hours ................. 250169
1.8L 4-Cyl. DOHC
Asuna Sunfire (Canadian)
1993.....................
1
2.4 Hours ................. 250205
Storm
1992-93................
1
2.4 Hours ................. 250205
1
mile intervals.
TIMING BELT
Removal:
belts or serpentine belt. Raise and support vehicle. Re-
move right splash shield.
Rotate crankshaft so that No. 1 cylinder is at TDC of com-
pression stroke. Remove crankshaft pulley.
Lower vehicle. Support weight of engine from above or with
floor jack. Remove engine mount from timing belt end of
engine. Remove timing belt upper cover. On 1.6L engine,
remove timing belt lower cover.
On 1.8L engine, remove serpentine drive belt idler pulley.
Remove exhaust heat shield. Remove power steering
pump mounting bolts. Move pump forward to gain access
to serpentine drive belt tensioner. Remove serpentine drive
belt tensioner from mounting bracket.
On 1.6L and 1.8L engines, remove engine mount bracket
from timing belt end of engine. Remove timing belt lower
cover.
See Fig. 1. Loosen timing belt tensioner pulley bolt 1/2
turn. If timing belt is to be reused, mark direction of timing
belt rotation, and place reference marks on timing belt and
sprockets for installation reference. Remove timing belt.
Inspection:
Inspect timing belt for cracks or damage. Ensure belt is not
contaminated with oil. Check belt tensioner pulley for
smooth rotation. Replace damaged components.
Installation:
timing belt. If reusing old timing belt, ensure belt is in-
stalled in original rotating direction.
Install timing belt on crankshaft pulley, then water pump
pulley, timing belt idler pulley, exhaust camshaft sprocket,
intake camshaft sprocket and timing belt tensioner pulley.
See Fig. 2. Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
Loosen belt tensioner bolt to allow tension to be applied
on timing belt. Rotate crankshaft clockwise 2 revolutions.
Ensure all timing marks are still aligned. Tighten timing
belt tensioner pulley bolt to specification. See TORQUE
SPECIFICATIONS.
Install lower timing belt cover. Install engine mount bracket
on engine. Install crankshaft pulley and tighten center bolt
to specification. Install upper timing belt cover. Install en-
gine mount.
dure. Adjust drive belts to proper tension. See page A-60
1.6L ............................................................................ 87 (118)
1.8L .......................................................................... 108 (147)
Engine Mount Bracket-To-Engine Bolt ............................ 37 (50)
Engine Mount Through-Bolt ............................................ 50 (68)
Power Steering Pump Mounting Bolt .............................. 15 (20)
Serpentine Drive Belt Tensioner Bolt ............................. 30 (40)
Water Pump Bolt
1.6L .............................................................................. 11 (15)
1.8L .............................................................................. 18 (24)
Wheel Lug Nut .......................................................... 87 (118)
INCH Lbs. (N.m)
210
GEO
1.6L & 1.8L 4-Cylinder DOHC, Storm (Cont.)
Fig. 2: Timing Belt Installation
211
GEO/CHEVROLET
1.0L 3-Cylinder
Belt
1.0L 3-Cyl.
Firefly (Canadian)
1985-88..........
1
2.2 Hrs. ........................... 250095
1989-91..........
1
2.2 Hrs. ........................... 250166
1994-95..........
1
2.2 Hrs. ........................... 250241
1996-00..........
1
1.8 Hrs. .... 2521941........ 250194
Metro
1989-92..........
1
2.2 Hrs. ........................... 250166
1993...............
1
2.2 Hrs. .........................
2
250166
1993...............
1
2.2 Hrs. .........................
3
250241
1994-95..........
1
2.2 Hrs. ........................... 250241
1996-97..........
1
2.2 Hrs. .... 2521941........ 250194
1996-00..........
1
1.8 Hrs. .... 2521941........ 250194
Sprint (Includes Canadian)
1985-88..........
1
2.2 Hrs. ........................... 250095
1989-91..........
1
2.2 Hrs. ........................... 250166
1
2
Four bolt sprocket.
3
Five bolt sprocket.
kits.
belt be replaced at 60,000 mile intervals. For 1998-00 model
years, the manufacturer recommends the belt be inspected at
60,000 miles and replaced at 100,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner. Re-
move A/C suction pipe bracket (if equipped). Raise and
support vehicle. Remove lower right engine undercover.
Remove lower generator cover plate. Remove all acces-
sory drive belts.
Remove outer bolts retaining crankshaft pulley. Remove
crankshaft pulley. DO NOT remove crankshaft pulley center
bolt. Remove wire harness from timing belt cover.
Remove timing belt cover and seal. See Fig. 1 or 4. Rotate
crankshaft and align timing marks. See Fig. 2 or 5. Remove
tensioner spring and tensioner stud. Loosen, but DO NOT
remove, tensioner bolt.
If reusing timing belt, mark rotation direction. Remove belt
tensioner, tensioner plate, tensioner spring, spring damper
and timing belt.
CAUTION: DO NOT rotate crankshaft or camshaft when timing
belt is removed or piston damage may result. Note direction of
timing belt guide for installation. Ensure concave side of timing
belt guide faces away from timing belt.
Inspection:
tamination. Ensure tensioner rotates freely. Replace dam-
aged components.
CAUTION: Ensure concave side of timing belt guide faces oil
pump. Flat side of timing belt guide goes against crankshaft
sprocket.
CAUTION: Ensure tensioner plate moves when tensioner is moved
toward timing belt. If tensioner plate does not move, ensure lug
is engaged in hole on tensioner.
Installation:
If tensioner was removed, install tensioner plate on
tensioner. Ensure tensioner plate lug engages hole on rear
of tensioner. Install tensioner assembly on cylinder block.
Tighten tensioner bolt finger tight to allow movement of
tensioner.
Ensure all timing marks align. See Fig. 2 or 5. If timing
marks are not aligned, rotate camshaft or crankshaft to
align timing marks. DO NOT rotate camshaft or crankshaft
so timing mark moves more than 90 degrees or engine
damage may occur. See Fig. 3.
CAUTION: Install timing belt so arrow on timing belt, or mark
made during removal, points in direction of crankshaft rotation.
Crankshaft rotates clockwise.
Install tensioner spring and spring damper, push tensioner
plate upward and tighten tensioner bolt. Install timing belt
so arrow on timing belt, or mark made during removal,
points in direction of crankshaft rotation. Ensure no slack
exists on drive side of timing belt. Loosen tensioner bolt
and allow spring tension to remove slack in timing belt.
Tighten tensioner bolt.
212
Fig. 2: Aligning Timing Marks (1985-97)
Fig. 3: Rotating Camshaft & Crankshaft
GEO/CHEVROLET
Rotate crankshaft 2 revolutions clockwise to ensure all slack
is removed from timing belt. Tighten tensioner stud and
tensioner bolt. See TORQUE SPECIFICATIONS. Ensure all
timing marks are aligned. To install remaining components,
reverse removal procedure. Adjust drive belts to proper ten-
A/C Compressor Mounting Bolt
12 mm ...................................................................... 21 (29)
14 mm ........................................................................ 33 (45)
Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16)
Tensioner Bolt ............................................................ 20 (27)
INCH Lbs. (N.m)
Timing Belt Tensioner Stud ........................................ 97 (11)
Valve Cover Bolt ............................................................ 44 (5)
Water Pump Bolt (1998-00) .......................................... 115 (13)
Water Pump Bolt (1995-97) ......................................... 97 (11)
213
GEO/CHEVROLET
1.3L 4-Cylinder
Belt
1.3L 4-Cyl.
Firefly (Canadian)
1995-97..........
1
2.6 Hrs. ........................... 250272
1998-00..........
1
2.6 Hrs. .... 2521941........ 250194
Metro
1992-93..........
1
2.6 Hrs. ........................... 250095
1994...............
1
2.6 Hrs. ........................... 250243
1995-97..........
1
2.6 Hrs. ........................... 250272
1998-01..........
1
2.6 Hrs. .... 2521941........ 250194
1
kits.
belt be replaced at 60,000 mile intervals. For 1998-01 model
years, the manufacturer recommends the belt be inspected at
60,000 miles and replaced at 100,000 miles.
TIMING BELT
Removal:
hicle. Remove right side fender apron extension. Do not
push center pin in too far as it may fall into fender.
Remove alternator/water pump drive belt and water pump
pulley. Lock flywheel and loosen crankshaft pulley outer
bolts. See Figs. 1 and 2. It is NOT necessary to remove
crankshaft pulley center bolt. Remove crankshaft pulley.
Remove timing belt outside cover. Rotate crankshaft to align
camshaft and crankshaft timing marks. See Figs. 3 and 6.
Loosen tensioner bolt and stud. Push tensioner plate fully
upward and temporarily tighten tensioner bolt. Remove tim-
ing belt from sprockets.
Inspection:
NOTE: Ensure tensioner plate moves when tensioner is moved
is engaged in hole on rear of tensioner.
Installation:
Ensure that tensioner rotates smoothly. Install tensioner
plate on tensioner. Lug of tensioner plate must fit in hole of
tensi oner. Instal l tensi oner assembl y. Hand ti ghten
tensioner bolt. Plate movement in upward direction should
cause tensioner to move in same direction.
On 1992-97 models only, remove air cleaner and valve cover,
then completely loosen all valve screws and lock nuts on
intake and exhaust rocker arms. Turn camshaft pulley clock-
wise until timing mark on pulley aligns with V mark on belt
inside cover. See Fig. 3.
Turn crankshaft pulley bolt clockwise until punch mark on
sprocket aligns with arrow mark on oil pump case. See
Fig. 3.
Install timing belt on sprockets with drive-side of belt free of
any slack when tensioner plate is pushed up with fingers.
Loosen tensioner bolt and allow tensioner to remove slack
in timing belt. Skip the next step to continue.
NOTE: On 1998-01 models, camshaft sprocket is marked with
a raised E for a timing mark.
On 1998-01 models, ensure camshaft and crankshaft tim-
ing marks are still aligned. See Fig. 6. If timing marks are
not aligned, rotate camshaft or crankshaft to align timing
marks. DO NOT rotate camshaft or crankshaft more than
90 degrees or engine damage may result. Install timing
belt. Ensure no slack exists on drive-side of timing belt.
Loosen tensioner bolt and allow tensioner to remove slack
in timing belt. Go to next step.
Turn crankshaft 2 rotations clockwise to take up slack. En-
sure timing marks are still aligned. Tighten tensioner ad-
justment stud nut and tensioner bolt. Ensure seal is be-
tween water pump and oil pump case. See Fig. 5. Install
timing belt outside cover.
Fig. 1: Using Screwdriver To Lock Flywheel
Fig. 2: Locking Flywheel In Position
214
Fig. 3: Identifying Timing Marks (Up To 1997)
Fig. 4: Adjusting Valve Lash
GEO/CHEVROLET
Fig. 5: Locating Oil Case Seal
On 1992-97 models, rotate crankshaft to position camshaft
lobe and rocker arm to adjust valve lash. See Fig. 4. En-
sure clearance is .010" ( .25 mm) at intake valves and .011"
(.28 mm) at exhaust valves. To adjust clearance, turn ad-
justing screw until correct clearance is obtained. Tighten
lock nut to 11-13.5 ft. lbs. (15-18 N.m).
On all models, to complete installation, reverse removal
Crankshaft Pulley Bolt (1998-01) ................................ 12 (16)
Crankshaft Sprocket Bolt (1992-97) ......................... 79 (110)
Crankshaft Sprocket Bolt (1998-01) ......................... 96 (130)
Valve Adjustment Lock Nut ................................ 11-13 (15-18)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt (1992-97) ................................ 97 (11)
Tensioner Stud ........................................................... 97 (11)
Timing Belt Cover Nut/Bolts ....................................... 97 (11)
Valve Cover Nuts .......................................................... 44 (5)
Fig. 6: Identifying Timing Marks (1998-01)
215
GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 8-Valve
1.6L 4-Cyl. SOHC, VIN U
Tracker & Sunrunner (Asuna & Pontiac, Canada)
1989-95................
1
3.6 Hours ...............
2
250164
1989-95................
1
3.6 Hours ...............
3
250212
1
2
Except California.
3
California.
TIMING BELT
Removal:
belts. Remove cooling fan, fan shroud and water pump
pulley. Remove outer bolts retaining crankshaft pulley.
Remove 5 crankshaft pulley-to-sprocket bolts. Remove
crankshaft pulley. DO NOT remove center bolt from crank-
shaft pulley. The center bolt holds crankshaft sprocket to
crankshaft.
Remove timing belt cover and seal. See Fig. 1. Loosen
tensioner stud and remove tensioner spring from tensioner
plate and tensioner screw.
If reusing timing belt, mark timing belt with arrow to indi-
cate rotation direction. Remove timing belt.
Inspection:
for freedom of rotation. Replace components if damaged.
Installation:
If tensioner was removed, install tensioner plate on
tensioner. Ensure lug of tensioner plate engages in hole
on rear of tensioner. Install tensioner, tensioner plate and
tensioner spring on engine block. Tighten tensioner bolt
finger tight to allow movement of tensioner.
CAUTION: Ensure tensioner plate moves when tensioner is moved
engages in tensioner bolt.
Remove valve cover. Loosen all valve adjusting screws fully
before installing timing belt. Ensure camshaft rotates freely
during belt tension adjustment. Rotate camshaft clockwise,
and align timing mark on camshaft sprocket with V timing
mark on timing belt inside cover. See Fig. 3.
Rotate crankshaft clockwise, and align timing mark on crank-
shaft sprocket with timing mark on oil pump housing. See
Fig. 3. Install timing belt on engine. If installing old belt,
ensure arrow on timing belt aligns with direction of crank-
shaft rotation. Ensure no slack exists on side of timing belt
opposite tensioner.
Install tensioner spring to tensioner plate and tensioner
screw. Finger tighten tensioner stud. Rotate crankshaft 2
revolutions clockwise to ensure all slack is removed from
timing belt.
aligned. Tighten tensioner stud to specification. Tighten
tensioner bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure all timing marks align.
Adjust valve lash between rocker arm adjusting screw and
valve stem. See VALVE LASH SPECIFICATIONS. Turn crank-
shaft so No. 1 piston is at TDC of compression stroke.
Ensure camshaft timing mark is aligned with V timing
mark on rear timing belt cover.
Adjust valve lash on No. 1 and No. 2 intake valves. Adjust
valve lash on No. 1 and No. 3 exhaust valves. Rotate crank-
shaft one full revolution (360 degrees). Adjust remaining
intake and exhaust valves.
Install timing belt cover. Install crankshaft pulley. To com-
plete installation, reverse removal procedures. Adjust drive
ranges.
VALVE LASH SPECIFICATIONS
Clearance Clearance
Valve Cold, In. (mm) Hot, In. (mm)
Intake ................... .051-.067 (.13-.17) ......... .009-.011 (.23-.27)
Exhaust .............. .0063-.0075 (.15-.19) .. .0102-.0114 (.25-.29)
216
GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 8-Valve (Cont.)
Fig. 2: Locking Camshaft During Sprocket Removal
A/C Compressor
8 mm Bolt ................................................................. 21 (29)
10 mm Bolt ............................................................... 33 (45)
Crankshaft Pulley-To-Sprocket Bolts .......................... 12 (16)
Power Steering Pump Mounting Bolt .......................... 21 (29)
Valve Adjusting Screw Locknut ....................................... 13 (17)
INCH Lbs. (N.m)
Fan Clutch Nuts ......................................................... 97 (11)
Tensioner Stud ........................................................... 97 (11)
Valve Cover Bolt ............................................................ 44 (5)
Water Pump Bolt ...................................................... 106 (12)
217
GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 16-Valve
1.6L 4-Cyl. SOHC, VIN 6
Tracker & Sunrunner (Canadian)
1994-98................
1
4.0 Hours ...............
2
250164
1994-98................
1
4.0 Hours ...............
3
250212
1999-01................
1
4.0 Hours ................

250212
1
2
Except California.
3
California.
mile intervals.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove cooling fan nuts
and fan shroud fasterners. Remove accessory drive belts.
Raise and support vehicle. Remove front skid plate (if
equipped). Remove 2 lower radiator shroud bolts. Remove
5 outer bolts retaining crankshaft pulley to crankshaft. Re-
move crankshaft pulley. DO NOT remove center bolt from
crankshaft pulley. The center bolt holds crankshaft sprocket
to crankshaft.
Lower vehicle. On models with air conditioning, remove A/
C suction line bracket bolts from radiator support. On all
models, remove upper radiator shroud bolts and remove
radiator shroud with cooling fan and water pump pulley.
NOTE: It may be necessary to drain cooling system and disconnect
upper radiator hose to remove fan shroud.
Disconnect wiring harness from timing belt cover. Remove
timing belt cover. See Fig. 1.
Rotate crankshaft clockwise to align crankshaft and cam-
shaft timing marks. Stamped E on camshaft sprocket must
face up and align with mark on rear cover. See Fig. 2.
Loosen timing belt tensioner pulley center bolt and stud
nut. Remove tensioner spring. Push tensioner plate up-
ward to relieve tension on timing belt.
original direction of rotation. Remove timing belt.
CAUTION: DO NOT rotate crankshaft or camshaft when timing
belt is removed or piston damage may result.
Inspection:
for freedom of rotation. Replace components if damaged.
Installation:
If tensioner was removed, install tensioner plate, spring,
and tensioner pulley on engine. Tighten tensioner bolt and
stud nut finger tight to allow movement of tensioner.
aligned. Install timing belt. If reusing old belt, ensure it is
installed in original rotation direction.
Loosen timing belt tensioner bolt and nut so it places ten-
sion on belt. Rotate crankshaft clockwise 2 revolutions.
Ensure timing marks still align. See Fig. 2.
Tighten tensioner stud nut and tensioner pulley bolt to speci-
fication. See TORQUE SPECIFICATIONS. Install timing belt
cover.
To complete installation, reverse removal procedures. Ad-
tension ranges. If cooling system was drained, refill and
bleed air from system.
Crankshaft Pulley Center Bolt ..................................... 81 (110)
Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16)
Front Skid Plate Bolt ...................................................... 40 (55)
INCH Lbs. (N.m)
Cooling Fan-To-Pulley Nut .......................................... 97 (11)
Timing Belt Tensioner Stud Nut ................................... 97 (11)
218
GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 16-Valve (Cont.)
Fig. 3: Timing Belt Tensioner Assembly
219
GEO & ISUZU
*1.5L 4-Cylinder
1
Belt Part No.
1.5L 4-Cyl.
I-Mark
1985-87
Thru 6/30/86 ....... 1.5 Hours ..................... T118
From 7/1/86......... 1.5 Hours ..................... T162
1988-89................. 1.5 Hours ..................... T162
Spectrum (Chevrolet & Geo)
1985-87
Thru 4/30/87 ....... 1.5 Hours ..................... T118
From 5/1/87........ 1.5 Hours ..................... T162
1988-89................. 1.5 Hours ..................... T162
Sunburst (Canada)
1985-88................. 1.5 Hours ..................... T118
1
60,000 miles.
TIMING BELT & SPROCKETS
Removal:
Place small piece of wood on jack under oil pan and care-
fully raise motor. Remove rear side torque rod and right
engine mount. Remove body side and engine side mounts.
Remove drive belts, crank pulley and timing belt cover. En-
sure timing marks are aligned with TDC. Use Crank Holder
(J-37376) or equivalent, to remove timing belt crankshaft
pulley. Confirm crankshaft is at TDC before removing belt.
See Fig. 1. Rotate crankshaft so camshaft pulley dowel is at
12 oclock and alignment mark aligns with edge of cylinder
head. See Fig. 2.
NOTE: The rear of timing belt crankshaft pulley has a small indent
which aligns with small triangle on engine block at 12 oclock.
Loosen belt tensioner attaching bolt. Insert Allen wrench
into pulley tensioner attaching bolt. Loosen timing belt
tensioner by rotating pulley clockwise. Remove timing belt.
Installation:
Ensure camshaft pulley mark is aligned with upper surface
of head and dowel pin is at 12 oclock position. Ensure
Woodruff key of crankshaft is in 12 oclock position. Install
timing belt. Tighten tensioner bolt, and rotate crankshaft 2
revolutions.
Check timing marks. Loosen tensioner bolt and remove
slack from timing belt. There must be no slack in the belt
after it has been installed.
tension ranges.
Water Pump Bolts ...................................................... 17 (24)
INCH Lbs. (N.m)
Timing Cover Bolts ..................................................... 86 (10)
Fig. 1: Crankshaft Sprocket Timing Marks
220
GEO & ISUZU
221
1
Belt Part No.
1.4L 4-Cyl.
Acadian, Chevette
1976...................... 1.4 Hours .................. 250037
1977...................... 1.4 Hours .................. 250039
1.6L 4-Cyl.
Acadian, Chevette, T-1000, 1000
1976...................... 1.4 Hours .................. 250037
1977-78................. 1.4 Hours .................. 250039
1979-87................. 1.4 Hours .................. 250061
1
TIMING BELT
Removal:
Disconnect negative battery cable. Remove radiator upper
mounting panel. On A/C equipped vehicles, remove upper
half of fan shroud. Remove drive belts and engine fan. Re-
move front cover retaining screws and nuts. Remove cover.
Rotate crankshaft until timing mark on pulley is at zero de-
grees (No. 1 cylinder at TDC). Remove A/C compressor
and brackets if necessary.
Insert 1/8" drill bit or rod through hole in upper rear cover
and through hole in camshaft drive sprocket. This is pro-
vided to verify camshaft timing. Remove timing belt front
and lower cover. Loosen idler pulley and allow pulley to
rotate clockwise. See Fig. 2. Remove timing belt from sprock-
ets.
Installation:
With No. 1 piston at TDC, install belt on sprockets and use 1/
4" Allen wrench to move idler pulley counterclockwise until all
slack is removed from belt. Tighten idler pulley bolt. Rotate
crankshaft clockwise a minimum of one revolution. Stop with
No. 1 piston at TDC. DO NOT let timing belt back up.
Use belt tension gauge between camshaft sprocket and
idler pulley. See Fig. 3. Be sure gauge finger is engaged in
slot between teeth of timing belt. Use 1/4" Allen wrench on
idler pulley to obtain correct tension. Reverse removal pro-
GENERAL MOTORS
TIMING BELT ADJUSTMENT SPECIFICATIONS
Belt Size Operating Range Specification
3/4" (19 mm) ......... 50-80 Ibs. .......................... 63-77 Ibs.
(110-176 kg) (140-160 kg)
Fig. 1: Sprocket Timing Marks
Camshaft Sprocket Bolts .......................................... 75 (101)
Idler Pulley Bolts ......................................................... 15 (20)
Water Pump Bolts ...................................................... 15 (20)
INCH Lbs. (N.m)
Front Cover (Nuts & Bolts) ............................................ 70 (8)
222
GENERAL MOTORS
Fig. 2: Timing Belt Idler Pulley
223
GENERAL MOTORS
*1.6L 4-Cylinder LeMans
1
Belt Part No.
1.6L 4-Cyl.
Le Mans
1988-89................. 2.0 Hours .................. 250148
1990
With Tensioner
Pulley................. 2.0 Hours .................. 250203
Without Tensioner
Pulley................. 2.0 Hours .................. 250148
1991-93................. 2.0 Hours .................. 250203
1
*NOTE: For 1990-93 models, this application is an
interference engine. See page A-59 for interference
engine cautions.
TIMING BELT
Removal:
drive belts. Remove power steering pump and lines. Re-
move crankshaft pulley. Remove timing belt covers starting
with upper cover.
Rotate engine to align timing marks on crankshaft and cam-
shaft sprockets with reference mark on lower timing belt
cover. See Fig. 1. Loosen water pump bolt to release belt
tension. Remove timing belt.
CAUTION: Rotate engine and align reference mark on crankshaft
and camshaft sprockets with reference mark on lower timing
belt cover before removing belt. Use proper reference mark. Reference
marks may be difficult to locate.
Installation:
Install timing belt. Align all timing marks. Carefully rotate
water pump to remove slack from timing belt. Tighten water
pump bolts.
Using Belt Tension Gauge (J-26486-B) or equivalent, mea-
sure belt tension between water pump and camshaft
sprocket. Adjust belt tension to 35 Ibs. (16 kg). To install
INCH Lbs. (N.m)
Timing Belt Cover Bolt (Front & Rear) ......................... 88 (10)
Water Pump Bolt .......................................................... 71 (8)
Fig. 1: Timing Belt & Pulley Alignment
224
Belt
Application Time
1
Kit No. No.
1.6L 4-Cyl.
Nova
SOHC
1985-88 ........ 3.1 Hours.. 2520700......... 250070
DOHC
1988 ............. 3.1 Hours.......................... 250112
1
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Drain cooling system. Re-
move fan shroud on models with power steering. On models
with air conditioning, loosen idler pulley nut, adjusting bolt and
remove drive belt. On DOHC models, raise and support vehicle
and remove right front wheel and right side engine undercover.
Remove radiator and air cleaner assembly. If equipped with cruise
control, remove actuator and ignition coil. Remove drive belts, fan,
water pump drive pulley and valve cover with gasket. Set No. 1
piston at TDC on compression stroke. On DOHC models, use
jack to raise engine slightly, then remove right side engine mount
through-bolt and mount. Remove crankshaft pulley No. 2 (power
steering only).
GENERAL MOTORS
1.6L 4-Cylinder Nova
Fig. 2: Timing Belt & Pulley Alignment
Fig. 1: Camshaft Sprocket Alignment (DOHC)
Fig. 3: Timing Belt Deflection Points
225
Using puller, remove crankshaft pulley. Remove upper and
lower engine front cover mount bolts, gasket and covers.
Mark timing belt location. Loosen idler pulley mount bolt,
position pulley at far left and retighten mount bolt. Remove
timing belt.
Installation:
Loosen timing belt idler pulley mount bolt, move pulley as
far left as possible and retighten bolt. If reusing old belt,
align marks made during removal. Install belt with arrow
pointing in direction of rotation. DO NOT bend or twist belt.
Release idler pulley and place tension on belt.
GENERAL MOTORS
1.6L 4-Cylinder Nova (Cont.)
If installing new belt, align camshaft(s) timing marks and
crankshaft timing marks. See Fig. 1 and Fig. 2. Install tim-
ing belt. Release idler pulley and place tension on belt.
After installing new or used belt, slowly turn crankshaft 2
revolutions clockwise. Recheck timing marks. Adjust belt
tension and deflection. See Fig. 3. Belt tension should be
4.4 Ibs. (2 kg), with a deflection of .24-.28" (6-7 mm) on 8-
valve engines and .16" (4 mm) on 16-valve engines. To
ranges.
8-Valve .................................................................... 87 (117)
16-Valve ................................................................ 137 (186)
Timing Belt Idler Mount Bolt .............................. 26-36 (36-49)
226
1
Belt Part No.
1.8L 4-Cyl. Diesel
Acadian (Canadian)
1981-85................. 3.1 Hours .................. 250076
Chevette
1981-86................. 3.1 Hours .................. 250076
1
TIMING BELT
Removal:
Remove fan shroud, V-belt and pulley. Remove upper dust
cover. Disconnect by-pass hose.
With No. 1 piston at TDC of compression stroke, check that
timing mark on injection pump pulley is in alignment with
front plate pointer. Align injector gear by inserting 8 mm x 1.25
mm bolt through gear alignment hole and front flange plate.
See Fig. 1.
Remove valve cover. Attach Fixing Plate (J-29761) or equiva-
lent, to slot in rear of camshaft. This will prevent camshaft
from rotating. Remove damper pulley and timing belt holder.
Recheck to be sure No. 1 cylinder is at TDC.
Remove lower dust cover and timing belt holder. Remove tension
spring from behind front plate, next to injection pump. Loosen
tension pulley and plate bolts. Remove timing belt.
Installation:
Remove bolt attaching camshaft gear. Using Gear Puller
(J-22888) or equivalent, remove cam gear. Reinstall cam
gear loosely so it can be turned by hand. Install timing belt
in proper sequence. See Fig. 2.
Belt should be properly tensioned between pulleys. Cogs
on belt and pulley should engage properly. Crankshaft
should not be turned. Concentrate belt looseness on ten-
sion pulley. Depress tension pulley with finger and install
tension spring.
Finger tighten tensioner bolts in sequence to prevent move-
ment of tensioner pulley. See Fig. 3. Tighten camshaft pulley
bolt. Remove injection pump gear lock bolt. Remove fixing
plate on end of camshaft.
Install damper pulley on hub and check that No. 1 cylinder
is at TDC. DO NOT turn crankshaft if adjustment is needed.
Be sure mark on injection pump pulley aligns with mark on
plate. See Fig. 1. Fixing plate should fit smoothly into slot at
rear of camshaft. Remove fixing plate.
Loosen tensioner pulley and plate bolts. Concentrate belt loose-
ness on tensioner and tighten bolts in sequence. See Fig. 3. Belt
tension should be checked at point between camshaft gear
and injection pump gear using Belt Tension Gauge (J-29771)
or equivalent. Belt tension should be 46-63 lbs (20-28 kg).
Remove damper pulley and install belt holder in position away
from timing bolt. Install by-pass hose, dust covers, and damper
pulley. Install cooling fan, belt and pulley. Install fan shroud.
Refill system with coolant and connect battery. Adjust drive
belts to proper tension. See page A-60 for belt tension ranges.
Damper Pulley Bolt ..................................................... 12 (20)
Tension Pulley
Center Bolt ................................................................ 54 (73)
Side Bolts ................................................................. 15 (20)
Water Pump Bolts ...................................................... 15 (20)
GENERAL MOTORS
Fig. 1: Injection Pump Alignment Marks & Lock Bolt
96E14856 Courtesy Of General Motors Corp.
Courtesy Of General Motors Corp.
227
Fig. 3: Locating/Tightening Tensioner Bolts
Courtesy Of General Motors Corp.
GENERAL MOTORS
*1.8L 4-Cylinder Diesel (Cont)
228
GENERAL MOTORS
1.8L 4-Cylinder
1
Belt Part No.
1.8L 4-Cyl. OHC
J2000, 2000, 2000 Sunbird
1982-84................. 2.7 Hours .................. 250081
Firenza
1982-86................. 2.7 Hours .................. 250081
Skyhawk
1982-86................. 2.7 Hours .................. 250081
Sunbird
1985-86................. 2.7 Hours .................. 250081
1
TIMING BELT
Removal:
Disconnect negative battery cable. Remove belts, brackets
and shields necessary to gain access to crankshaft pulley.
Remove timing belt front cover.
Rotate crankshaft so timing mark on crankshaft pulley lines
up with 10 BTDC mark on indicator scale. Mark on cam-
shaft sprocket must align with mark on camshaft carrier.
Remove timing probe holder. Verify timing marks are aligned
and loosen water pump retaining bolts to remove timing
belt.
Installation:
Install new timing belt on sprockets. Install crankshaft pul-
ley and check for alignment of timing marks. Using Ad-
juster (J-33039) or equivalent , rotate water pump clock-
wise until slack is removed from timing belt. Tighten water
pump bolts. See Fig. 1.
NOTE: If new timing belt has been installed, check final ten-
sion with engine at operating temperature. If new head gasket
is installed, cylinder head must be retightened AFTER initial
warm up. Timing belt tension MUST then be rechecked.
Using Cam Drive Belt Tension Gauge (J-26486-A) or
equivalent, check belt tension between water pump and
camshaft sprocket. Initial new belt tension should be 38
lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16
kg).
Reassemble components and run engine to operating tem-
perature (thermostat open). As new belt takes a set posi-
tion, substantial tension loss will occur. After belt has been
run, recheck tension with gauge on belt.
If belt tension is incorrect, loosen water pump bolts and
rotate pump until correct tension is obtained. Hot timing
belt tension specification is 30 lbs. (13 kg).
DO NOT leave tension gauge on belt during retightening or
reading will be inaccurate. Tighten water pump bolts. Re-
verse removal procedure to complete installation. Adjust
ranges.
Crankshaft Sprocket Retaining Bolt ........................ 115 (156)
Timing Belt Rear Cover Bolt ....................................... 19 (25)
Water Pump Retaining Bolts ...................................... 19 (25)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt .......................................... 72 (8)
Timing Belt Front Cover Bolt ......................................... 60 (7)
Fig. 1: Timing Belt Tension Adjustment
229
GENERAL MOTORS
2.0L 4-Cylinder
Belt
Application Time
1
Kit No. No.
2.0L 4-Cyl. OHC
Firenza
1987-88............ 2.7 Hrs. ........................... 250081
Grand Am
1987-88............ 2.7 Hrs. ........................... 250081
1989................. 2.7 Hrs. ..... 2521630....... 250163
Le Mans
1989
1st Design..... 2.7 Hrs. ........................... 250081
2nd Design ... 2.7 Hrs. ..... 2521630....... 250163
1990................. 2.7 Hrs. ..... 2521630....... 250163
Skyhawk
1987-88............ 2.7 Hrs. ........................... 250081
Sunbird
1987-88............ 2.7 Hrs. ........................... 250081
1989-94............ 2.7 Hrs. ..... 2521630....... 250163
1
kits.
TIMING BELT & SPROCKETS
Removal (1987-88):
Disconnect negative battery cable. Remove belts, brackets
and shields necessary to gain access to crankshaft pulley.
Remove timing belt front cover.
Rotate crankshaft so timing mark on crankshaft pulley lines
up with 10 degrees BTDC mark on indicator scale. Mark on
camshaft sprocket must align with mark on camshaft car-
rier. Remove crankshaft pulley.
Remove timing probe holder. Verify timing marks are aligned
and loosen water pump retaining bolts to remove timing
belt.
Install new timing belt on sprockets. Install crankshaft pulley
and check for alignment of timing marks. Using Adjuster (J-
33039) or equivalent, rotate water pump clockwise until slack
is removed from timing belt. Tighten water pump bolts. See
Fig. 1.
NOTE: If new timing belt has been installed, check final ten-
sion with engine at operating temperature. If new head gasket
is installed, cylinder head must be retightened AFTER initial
warm up. Timing belt tension MUST then be rechecked.
Fig. 1: Timing Belt Tension Adjustment
Using Cam Drive Belt Tension Gauge (J-26486-A) or
equivalent, check belt tension between water pump and
camshaft sprocket. Initial new belt tension should be 38
lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16
kg).
Reassemble components and run engine to operating tem-
perature (thermostat open). As new belt takes a set posi-
tion, substantial tension loss will occur. After belt has been
run, recheck tension withgauge on belt.
If belt tension is incorrect, loosen water pump bolts and
rotate pump until correct tension is obtained. Hot timing
belt tension specification is 30 lbs. (13 kg).
DO NOT leave tension gauge on belt during retightening or
reading will be inaccurate. Tighten water pump bolts. Re-
ranges.
Removal (1989-94):
Disconnect negative battery cable. Remove serpentine belt,
brackets, and shields necessary to gain access to crank-
shaft pulley. Remove front timing belt cover. See Fig. 2.
Remove crankshaft pulley. Loosen water pump retaining
bolts. Using Timing Belt Adjuster (J-33039-A) or equiva-
lent, rotate water pump to release timing belt tension. Re-
move timing belt.
To install camshaft and crankshaft sprockets (if removed),
reverse removal procedure. Tighten retaining bolts to speci-
fication. See TORQUE SPECIFICATIONS.
230
Rotate crankshaft and camshaft clockwise to align timing
marks on sprockets with marks on rear cover. Install new
timing belt on sprockets. Ensure belt has tension on it be-
tween the camshaft sprocket and crankshaft sprocket.
NOTE: Adjust timing belt with engine coolant temperature at
68F (20C).
Using timing belt tension adjuster, rotate water pump clock-
wise until tensioner contacts the high torque stop. See Fig.
3. Slightly tighten water pump retaining bolts.
Using crankshaft sprocket bolt, rotate engine clockwise 2 revo-
lutions to fully seat timing belt. Rotate water pump eccentric
counterclockwise until hole in tensioner arm aligns with hole
in base.
Tighten water pump bolts to specification. See TORQUE
SPECIFICATIONS. Ensure tensioner holes remain in align-
ment as stated. Ensure all timing marks are properly
aligned. To install remaining components, reverse removal
Fig. 3: Timing Belt Tensioner (1989-94)
GENERAL MOTORS
Camshaft Pulley-To-Sprocket Bolt
1987-88 .................................................................... 20 (27)
1989-92 .................................................................... 15 (20)
Serpentine Belt Tensioner Bolt ................................... 35 (47)
Water Pump Bolt ........................................................ 18 (24)
INCH Lbs. (N.m)
Camshaft Carrier Cover Bolt ...................................... 84 (10)
231
GENERAL MOTORS
*3.0L V6 DOHC, Catera
Fig. 2: Positioning Crankshaft At 60 Degrees BTDC
3.0L V6 DOHC
Catera
1997-01................. 2.6 Hours .................. 250285
The manufacturer recommends the belt be replaced at
100,000 mile intervals.
Using scan tool, check cold start counter (also called a heavy
duty register). If there were any cold starts below -20F (-28C),
visually inspect timing belt for cracks. If there are cracks
present, DO NOT reuse the belt. Replace belt. If belt is okay
and reused, DO NOT clear the cold start counter.
TIMING BELT
Precautions:
When servicing timing belt, always turn crankshaft in nor-
mal direction of rotation (clockwise).
Install timing belt with engine at room temperature.
Never remove timing belt without first setting camshaft gears
and crankshaft drive gear to TDC and locking them in place.
Guide marks on timing belt are to aid in timing belt installa-
tion. If guide marks cannot be identified, a new belt must
be installed.
Removal:
Disconnect negative battery cable. Remove air intake reso-
nator and ducting from throttle body.
Raise and support vehicle. Remove lower front splash
shield. Remove AIR injection crossover pipe clamps and
bushing nut from front cover. See Fig. 1. Separate air injec-
tion crossover pipe from hoses and front cover.
Lower vehicle. Remove air injection crossover pipe from
front cover.
Loosen, but do not remove water pump pulley bolts.
Loosen, but do not remove, power steering pump pulley
bolts. Remove A/C compressor hose strap from AIR injec-
tion crossover bracket. Remove accessory drive serpen-
tine belt.
Release plastic retaining tabs, and remove wiring harness
channel cover from front of engine. Move wiring harness
out of way.
Remove water pump pulley bolts and pulley. Remove power
steering pump pulley bolts and pulley. Remove accessory
drive serpentine belt tensioner.
Remove front timing belt cover. Remove 6 harmonic bal-
ancer-to-crankshaft bolts. Remove harmonic balancer. It is
NOT necessary to remove crankshaft center bolt.
Rotate crankshaft clockwise to 60 degrees before TDC.
See Fig. 2. Ensure timing marks are not 180 degrees from
TDC.
Install Crankshaft Holder (J-42069-10) and rotate crank-
shaft clockwise until holder contacts water pump. See Fig.
3. Secure moveable lever of tool to water pump pulley flange.
Camshaft timing marks should be aligned with marks on
rear cover. See Figs. 4 and 5. If not aligned, crankshaft 180
degrees (one half turn) off.
Fig. 3: Installing Crankshaft Holder
Fig. 1: Timing Belt Front Cover
232
Fig. 6: Installing Camshaft Gear Holders
Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley
To lock camshafts in place, install Camshaft Gear Holders
(J42069-1 and J-42069-2). See Fig. 6. It may be necessary
to loosen timing belt idler pulley and turn eccentric until
holder can be inserted.
Loosen timing belt tensioner and idler pulley bolts. If reus-
ing timing belt, mark belt with arrow to indicate original
CAUTION: Do not move camshafts with belt removed. Do not remove
Camshaft Holders (J-42069) with timing belt removed.
Inspection:
Check timing belt for excessive wear, cracks, or missing
teeth. Inspect timing belt tensioner and idler pulleys for
worn bearings. Replace as necessary.
GENERAL MOTORS
*3.0L V6 DOHC, Catera (Cont.)
Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks
(Up To 1999 Early Design)
(From 1999 Late Design)
NOTE: Install timing belt at room temperature. NEW timing belts
are marked with direction of rotation arrow and mating marks.
Make sure belt is installed with arrows pointing in correct direction
or rotation.
Installation:
To install timing belt, remove crankshaft holder. Raise and
support vehicle. Start installation of belt at crankshaft pul-
ley. Install timing belt with double dash marks aligned with
oil pump and drive gear marks. See Fig. 7. Install Timing
Belt Holder (J42069-30) or equivalent plastic wedge to hold
belt against crankshaft sprocket.
NOTE: Timing belt configuration changed in mid-1999 model
year. For both designs, use the marks on each side of the direction
of rotation arrows to line up the left (drivers side) camshaft sprockets.
For early design (up to mid-1999), use the remaining 3 White
marks on the NAPA timing belt. For later design (mid-1999 to
present), use the remaining 3 Yellow marks on the NAPA timing
belt. Correct belt application MUST be used on each engine design.
Lower vehicle. Route timing belt around tensioner, right
bank (passengers side) camshaft gears, idler pulley, and
left bank (drivers side) camshaft pulleys. Ensure timing
belt marks are aligned with marks on camshaft sprockets
and notches on rear timing belt cover. Keep timing belt
taught between idler pulley and left bank camshaft pulleys.
See Figs. 4 and 5.
233
Fig. 9: Adjusting Timing Belt Tension (New Design Engine
Shown; Early Design Engine Tensioner Is The Same)
GENERAL MOTORS
Fig. 8: Measuring Timing Belt Deflection
Ensure timing belt tension is taught (no slack). Measure
timing belt deflection midway between left bank camshafts
(viewed from rear of engine) and left side idler pulley (viewed
from rear of engine). See Fig. 8. Deflection should be no
more than 0.40 (10 mm). If initial timing belt deflection is
okay, go to TIMING BELT TENSION ADJUSTMENT. If timing
belt deflection is not correct, go to TIMING BELT DEFLEC-
TION ADJUSTMENT.
Timing Belt Deflection Adjustment:
If timing belt deflection adjustment is necessary, loosen
left (drivers) side idler pulley bolt. (This is NOT the idler
pulley positioned between camshaft sprockets in top, cen-
ter of engine). Turn left idler pulley counterclockwise until
high point of eccentric nut is in about 12 oclock position.
See Fig 5. Snug idler pulley bolt while holding eccentric so
it does not move. Go to next step.
Apply additional tension to timing belt by loosening bolt for
idler pulley located between camshaft sprockets (top, cen-
ter of engine). Rotate high point of eccentric to 9 oclock
position. Tighten idler pulley bolt while holding eccentric
so it does not rotate. Go to TIMING BELT TENSION AD-
JUSTMENT.
Loosen timing belt tensioner lock nut. Turn tensioner ec-
centric counterclockwise to full stop. Turn eccentric back
until reference mark is .039 (1 mm) from belt tension set-
ting flange. See Fig 9. Tighten timing belt tensioner lock nut
until snug. Lock nut will be final tightened after final adjust-
ments are made. Go to CHECKING CAMSHAFT
SPROCKET ALIGNMENT.
Checking Camshaft Sprocket Alignment:
Ensure timing belt alignment marks are still aligned with
reference points on camshaft sprockets and rear timing
belt cover. Remove all locking tools from camshafts and
timing belt.
Rotate crankshaft clockwise 2 revolutions, stopping at 60
degrees before TDC mark. See Fig. 2. Install Crankshaft
Holder (J42069-10) to crankshaft flange. Secure moveable
lever of tool to water pump pulley flange.
NOTE: Alignment marks on timing belt will no longer align with
camshaft sprocket marks after one or more crankshaft revo-
lutions.
Ensure crankshaft timing mark aligns with mark on oil pump
housing. Ensure camshaft timing marks align with notches
on rear cover.
Use Checking Gauge (J42069-20) to inspect alignment of
left bank and right bank camshaft gears. See Fig. 10. The
reference marks on both sets of camshaft sprockets must
match exactly with marks on Checking Gauge (J42069-
20).
If timing belt readjustment is NOT necessary, go to FINAL
TIMING BELT TENSIONING & INSTALLATION. If timing belt
readjustment IS necessary, go to TIMING BELT READJUST-
MENT.
NOTE: When readjusting timing belt tension, Crankshaft Holder
(J42069-10) must be in position on engine.
Timing Belt Readjustment (Left Bank Camshafts):
If timing belt readjustment is required, always start with left
bank (drivers side) camshafts first. Install Checking Gauge
(J42069-20) to left bank camshafts.
Loosen idler pulley on drivers side of engine. This is idler
pulley below camshaft sprockets. Using Wrench (J42069-
40) or equivalent, turn idler pulley eccentric COUNTER-
CLOCKWISE until timing marks on camshaft sprockets
and checking gauge are in alignment. High point of idler
pulley eccentric should be in about the 12 oclock position.
Tighten idler pulley bolt while holding eccentric from turn-
ing.
234
GENERAL MOTORS
Remove checking gauge and crankshaft holder. Rotate
crankshaft clockwise 2 revolutions, stopping at 60 degree
BTDC. Install Crankshaft Holder (J42069-10) to crankshaft
drive gear. Rotate crankshaft to secure lever of holder to
water pump flange. Install Checking Gauge (J42069-20) to
left bank camshafts. If camshaft sprockets are now prop-
erly aligned, go to FINAL TIMING BELT TENSIONING & IN-
STALLATION. If not, repeat readjustment procedure.
Timing Belt Readjustment (Right Bank Camshafts)
If timing belt readjustment is required, always start with left
bank (drivers side) camshafts first. Install Checking Gauge
(J42069-20) to right bank (passengers side) camshafts.
Loosen bolt on idler pulley that is located the center and
below the left bank and right bank camshafts.
Using Wrench (J42069-40) or equivalent, turn idler pulley
eccentric COUNTERCLOCKWISE until timing marks on
camshaft sprockets and checking gauge are in alignment.
High point of idler pulley eccentric should be in about the 9
oclock position. Tighten idler pulley bolt while holding ec-
centric from turning.
Remove checking gauge and crankshaft holder. Rotate
crankshaft clockwise 2 revolutions, stopping at 60 degree
BTDC. Install Crankshaft Holder (J42069-10) to crankshaft
drive gear. Rotate crankshaft to secure lever of holder to
water pump flange. Install Checking Gauge (J42069-20) to
right bank camshafts. If camshaft sprockets are now prop-
erly aligned, go to FINAL TIMING BELT TENSIONING & IN-
STALLATION. If not, repeat readjustment procedure.
Final Timing Belt Tensioning & Installation
To set final timing belt tension, loosen timing belt tensioner
eccentric lock nut. Turn timing belt eccentric counterclock-
wise to full stop. Turn tensioner back until reference mark
is .079-.157 (2-4 mm) ABOVE reference mark on flange.
See Fig. 9. Tighten tensioner eccentric lock nut to specifi-
cation.
If timing belt idler pulley bolts were loosened, final tighten
them to specification. See TORQUE SPECIFICATIONS. In-
spect high points of timing belt tensioner eccentrics. Left
side idler pulley (viewed from rear of engine) eccentric high
point should be in about the 12 oclock position. Top center
idler pulley eccentric high point should be in about the 9
oclock position. See Fig. 5.
Remove crankshaft holding tool. Rotate crankshaft clock-
wise 2 revolutions, stopping at 60 degrees before TDC
mark. Install Crankshaft Holder (J-42069-10) to crankshaft
drive gear.
Turn crankshaft clockwise until lever of holder firmly con-
tacts water pump pulley flange. Secure moveable lever of
tool to water pump pulley flange.
Ensure camshaft timing marks align with notches on rear
cover and crankshaft timing mark align with mark on oil
pump housing. Use Checking Gauge (J42069-20) to in-
spect alignment of left bank and right bank camshaft gears.
Adjust timing belt position, if necessary. Ensure all tools
are removed from engine. Install timing belt front cover.
Install crankshaft harmonic balancer. Tighten bolt to speci-
fication.
Install timing belt cover. Install accessory drive belt tensioner.
Install water pump and power steering pump pulleys. In-
stall serpentine drive belt.
Install air injection crossover pipe to front of engine. Install
air intake resonator and ducting. Install engine splash
shield.
Step 1 ........................................................................... 37 (50)
Step 2 ................................................... Additional 60 Degrees
Crankshaft Harmonic Balancer Bolt ............................... 15 (20)
Step 1 ....................................................................... 184 (250)
Generator Bolt ............................................................... 30 (40)
Power Steering Pump Pulley Bolt .................................. 15 (20)
Serpentine Drive Belt Tensioner Bolt ............................ 30 (40)
Timing Belt Tensioner Bracket Bolt ................................ 30 (40)
Timing Belt Tensioner Eccentric
Lock Nut ....................................................................... 15 (20)
INCH Lbs. (N.m)
Timing Belt Front Cover Bolt ............................................. 71 (8)
Fig. 10: Installing Checking Gauge on Camshaft Sprockets
Timing Belt
235
GENERAL MOTORS
*3.0L V6 DOHC, Saturn
Fig. 1: Positioning Crankshaft At 60 Degrees BTDC
3.0L V6 DOHC
Saturn L Series
2000-01................. 4.0 Hours .................. 250285
TIMING BELT
Removal:
sembly.
move lower front splash shield.
NOTE: Right engine mount must be removed before accessory
drive belt can be removed from vehicle.
Lower vehicle. Loosen, but do not remove water pump pul-
ley bolts. Loosen, but do not remove power steering pump
pulley bolts. Rotate accessory serpentine belt tensioner
clockwise, and remove accessory serpentine belt from
pulleys.
Support weight of engine from above or below with floor
jack. Remove front engine mount (timing belt end of en-
gine) from engine and frame. Remove engine mount bracket
from engine block.
Remove water pump pulley bolts and pulley. Remove power
steering pump pulley bolts and pulley. Remove accessory
drive belt tensioner front engine block.
Remove 6 harmonic balancer-to-crankshaft bolts. Remove
harmonic balancer. It is NOT necessary to remove crank-
shaft center bolt.
Remove wiring harness channel from front timing belt cover
and secure away from engine. Remove front timing belt
cover. Inspect sealing strip on outer edge of cover for cracks
or tears. Replace, if necessary.
Rotate crankshaft clockwise to 60 degrees before TDC.
See Fig. 1. Ensure timing marks are not 180 degrees from
TDC. Camshaft timing marks should be aligned with marks
on rear cover. See Fig. 5.
Install Crankshaft Holder (J-42069-10) and rotate crank-
shaft clockwise until holder contacts the water pump. See
Fig. 2. Secure moveable lever of tool to water pump pulley
flange.
To lock camshafts in place, install Camshaft Gear Holders
(J42069-1 and J-42069-2). See Fig. 3. It may be necessary
to loosen timing belt idler pulley and turn eccentric until
holder can be inserted.
Loosen timing belt tensioner and idler pulley bolts. If reus-
ing timing belt, mark belt with arrow to indicate original
NOTE: DO NOT move camshafts with belt removed. DO NOT remove
Camshaft Holders (J-42069) with timing belt removed.
Fig. 2: Installing Crankshaft Holder
NOTE: Install timing belt at room temperature.
Inspection:
Check timing belt for excessive wear, cracks, or missing
teeth. Inspect timing belt tensioner and idler pulleys for
grease leaks or worn bearings. Replace as necessary.
NOTE: Upper timing belt idler pulley uses a narrow .20 (5 mm)
thick spacer and a Black bolt. The lower timing belt idler pulley
uses a .40 (11 mm) thick spacer and a Silver bolt.
Installation:
To install timing belt, remove crankshaft holder. Using a felt
pen, mark the face of the upper and lower timing belt idler
pulleys. The mark should line up with point farthest away
from the Torx head mounting bolt. See Fig. 7. The idler
pulleys provide adjustment by rotating on an eccentric circle
around the mounting bolt.
Loosen lower idler pulley mounting bolt just enough so
that pulley will rotate with slight resistance. Remove upper
timing belt pulley.
NOTE: Use the marks on each side of the direction of rotation
arrows to line up the left (drivers side) camshaft sprockets. For
this design (idler pulley located above crankshaft) engine, use
the remaining 3 White marks on the NAPA timing belt. Correct
belt marks MUST be used.
236
Remove camshaft holders from camshaft sprockets. In-
stall Checking Gauge (J42069-20) to left hand (drivers side)
camshafts. See Fig. 8. Pull timing belt between timing belt
tensioner and crankshaft sprocket to take up slack between
left hand camshaft sprocket and lower idler pulley.
Ensure left hand camshaft timing marks are about 1 mm
(about the width of the timing marks on the sprockets) on
the retard side. See Fig. 8. If they are not, turn lower idler
pulley clockwise to allow retard of left hand camshafts. Pull
timing belt between timing belt tensioner and crankshaft
sprocket to take up slack between left hand camshaft
sprocket and lower idler pulley.
CAUTION: If TDC is passed while rotating crankshaft, DO NOT
turn crankshaft counterclockwise. This will take out correct timing
belt tension between timing belt tensioner and crankshaft sprocket.
To correct for this, rotate crankshaft 2 additional turns.
Remove Crankshaft Holder (J42069-10). Rotate crankshaft
clockwise 1 3/4 revolutions. Install Crankshaft Holder
(J42069-10) to crankshaft flange, and then stop at TDC.
Tighten lever arm to water pump pulley flange.
NOTE: Alignment marks on timing belt will no longer align with
camshaft sprocket marks after one or more crankshaft revo-
lutions. Timing marks on timing belt are used for initial installation
only.
Install timing belt onto left hand camshafts (as viewed from
rear of engine), matching marks on timing belt with corre-
sponding marks on camshaft sprockets. See Fig. 5. Keep-
ing slack out of belt, route timing belt around lower idler
pulley and around crankshaft sprocket. Ensure mark on
timing belt mates with mark on crankshaft sprocket face.
Hold timing belt in place against crankshaft sprocket using
Plastic Wedge (J-42069-30). Route timing belt around right
hand camshaft pulleys (as viewed from rear of engine).
Ensure timing belt dash marks are aligned with marks on
right hand camshaft sprockets.
Install upper idler pulley. Tighten mounting bolt just enough
so that the pulley will rotate with slight resistance. Install
Timing Belt Holder (J42069-30) or equivalent to crankshaft.
Tighten lever arm to water pump pulley flange.
Ensure timing belt tension is taught (no slack). Loosen
timing belt tensioner lock nut. Turn tensioner eccentric until
center alignment mark is about .118 (3 mm) above align-
ment mark on spring loaded idler pulley. See Fig. 6. Re-
move plastic wedge holding timing belt against crankshaft
sprocket. Tighten timing belt tensioner lock nut until snug.
Lock nut will be final tightened after final adjustments are
made.
Adjust upper timing belt idler pulley so that the largest part
of the eccentric is above and to the left of the mounting Torx
bolt. Temporarily tighten Torx mounting bolt. See Fig. 7.
Adjust lower idler pulley so that the largest part of the ec-
centric is above and to the left of the mounting Torx bolt.
Temporarily tighten Torx mounting bolt. See Fig. 7.
Fig. 3: Installing Camshaft Gear Holders
Fig. 4: Aligning Timing Belt Marks On Crankshaft Pulley
Fig. 6: Setting Timing Belt Tension Setting
GENERAL MOTORS
*3.0L V6 DOHC, Saturn (Cont.)
237
GENERAL MOTORS
*3.0L V6 DOHC, Saturn (Cont.)
Fig. 7: Positioning Timing Belt Idler Pulleys
Fig. 8: Positioning Timing Belt On Left Hand Camshafts
CAUTION: If TDC is passed while rotating crankshaft, do NOT
turn crankshaft counterclockwise. This will take out correct timing
belt tension between timing belt tensioner and crankshaft sprocket.
To correct for this, rotate crankshaft 2 additional turns.
Remove Camshaft Gear Holder (J42069-2, Green) from
left hand camshaft sprockets. Remove Crankshaft Holder
(J42069-10) from crankshaft. Rotate crankshaft clockwise
1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to
crankshaft flange, and then stop at TDC. Tighten lever arm
to water pump pulley flange.
Recheck both camshaft timing marks on both banks with
Checking Gauge (J42069-20). If timing marks are NOT
aligned, readjust timing belt. It is NOT necessary to remove
timing belt. If camshaft timing marks are aligned, final tighten
upper and lower timing belt idler pulley Torx mounting bolts
to 30 ft. lbs. (40 N.m).
Adjust timing belt tensioner so that the center alignment
mark is about 3 mm above alignment mark on spring loaded
idler. See Fig. 6. Tighten timing belt tensioner pulley nut.
Verify all timing marks are still aligned.
Remove Crankshaft Holder (J42069-10). Remove Check-
ing Gauge (J42069-20). Install timing belt front cover. In-
stall crankshaft harmonic balancer. Tighten bolts to speci-
fication.
Install water pump and power steering pump pulleys. In-
stall accessory drive belt tensioner. Install accessory drive
belt. Install engine mount. Connect negative battery cable.
Raise vehicle. Install splash shield. Install wheel. Lower
vehicle and install air cleaner assembly.
Step 1 ........................................................................... 37 (50)
Crankshaft Harmonic Balancer Bolt ............................... 15 (20)
Step 1 ....................................................................... 184 (250)
Engine Mount-To-Bracket Bolt ........................................ 41 (55)
Engine Mount Bracket-To-Engine Bolt ............................ 41 (55)
Generator Bolt ............................................................... 30 (40)
Serpentine Drive Belt Tensioner Unit Bolt ..................... 30 (40)
Timing Belt Idler Pulley Torx Bolt ................................... 30 (40)
Timing Belt Tensioner Bracket Bolt ................................ 30 (40)
Timing Belt Tensioner Eccentric
Lock Nut ....................................................................... 15 (20)
Water Pump Bolt ............................................................ 18 (25)
Wheel Lug Nut ............................................................. 92 (125)
INCH Lbs. (N.m)
Timing Belt Front Cover Bolt ............................................. 71 (8)
Rotate lower timing belt idler pulley counterclockwise until
the left hand camshaft timing marks on the sprockets are
lined up with marks on the Checking Gauge (J42069-20).
While holding lower idler pulley in this position, tighten lower
idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m).
Remove Crankshaft Holder (J42069-10). Rotate crankshaft
1 3/4 turns clockwise. DO NOT rotate crankshaft counter-
clockwise. Install Crankshaft Holder (J42069-10) to crank-
shaft flange, and then stop at TDC. Tighten lever arm to
water pump pulley flange.
Inspect left hand camshaft timing marks for alignment.
Sprocket timing marks should align with marks on rear
cover. Realign, if necessary.
Remove Checking Gauge (J42069-20) from left hand cam-
shaft sprockets. Install checking gauge on right hand
sprockets (passenger side). Install Camshaft Gear Holder
(J42069-2, Green) between left hand camshaft sprockets.
Turn upper timing belt idler pulley counterclockwise until
the right hand camshaft sprocket timing marks are aligned
with marks on Checking Gauge (J42069-20). While hold-
ing idler pulley eccentric in this position, tighten upper idler
pulley Torx mounting bolt to 15 ft. lbs. (20 N.m).
238
GENERAL MOTORS
*3.4L V6
3.4L V6 DOHC
Cutlass Supreme & Grand Prix
1991-95 ............
1
4.5 Hours ..................... 250192
1996 .................
1
4.5 Hours ..................... 250273
Lumina
1991-95 ............
1
4.5 Hours ..................... 250192
1997-96 ............
1
4.5 Hours ..................... 250273
Monte Carlo
1995 .................
1
4.5 Hours ..................... 250192
1996-97 ............
1
4.5 Hours ..................... 250273
1
With Air. Cond. add .4 hours.
mile intervals.
TIMING BELT
NOTE: Revised repair procedure are from GM technical service
bulletin 47-61-34; December, 1994.
Removal:
Disconnect negative battery cable. Remove air cleaner and
duct assembly. Drain engine coolant.
Remove accelerator and cruise control cables from throttle
body. Remove fuel rail cover. Relieve fuel pressure. Re-
move fuel lines from fuel rail. Remove fuel mounting
bracket.
Remove heater hose and bracket from lower intake mani-
fold. Remove PCV valve and vacuum line from throttle body.
Remove electrical connectors from EGR valve, canister
purge solenoid and MAP sensor. Remove vacuum lines
from upper intake manifold tee.
Remove wiring loom bracket for rear spark plug wires. Re-
move upper intake manifold. Remove coolant recovery tank.
Remove serpentine drive belt and drive belt tensioner.
Siphon fluid from power steering pump. Disconnect power
steering lines and remove power steering pump.
On 1993-91 vehicles only, reposition PCM out of way. Re-
move PCM mounting bracket. On 1995-94 vehicles only,
disconnect PCM connectors and secure out of way.
On all vehicles, note position for reassembly reference and
remove spark plug wires from spark plugs. Remove wiring
harness cover at right side (passenger) strut tower. Re-
move fuel line bracket.
Remove timing belt covers. Remove breather hose from
rear camshaft cover and crankcase vent from breather mani-
fold. Remove camshaft carrier covers.
NOTE: Actuator assembly uses a tapered bushing between the
actuator and mounting base. DO NOT lose or damage the bushing
when removing the actuator assembly.
Remove side plate bolts securing timing belt tensioner
actuator. Rotate actuator assembly from tensioner pulley
socket and out of mounting base. Remove timing belt
tensioner pulley. See Fig. 1.
Position timing belt tensioner actuator in vise with rod tip
(rubber boot end) pointing down.
Fig. 1: Timing Belt Assembly
Fig. 2: Measuring Timing Belt Tensioner Actuator Length
Fig. 3: Reworking Paper Clip
239
GENERAL MOTORS
*3.4L V6 (Cont.)
Fig. 4: Installing Camshaft Hold-Down Tools (J 38613-A)
CAUTION: Allow oil to flow towards boot end of actuator for at
least 5 minutes prior to refilling.
NOTE: Tensioner actuator is oil filled. Removal of plug may allow
oil to escape. DO NOT remove vent plug.
Straighten out a standard paper clip (.032 with no serra-
tions) and form a loop at one end. See Fig. 3. Remove
rubber end plug from rear of tensioner actuator. Push pa-
per clip through end of vent plug and into pilot hole. Insert a
small screwdriver into the screw slot inside actuator, be-
hind rubber end plug.
Retract actuator plunger by rotating screw in a clockwise
direction, until it is fully retracted. Push on paper clip and
slowly rotate screw counterclockwise until paper clip en-
gages. Remove timing belt.
NOTE: Remove timing marks from camshaft and intermediate
shaft sprockets.
pression stroke. Mark the timing indicator with White paint
or equivalent on the crankshaft balancer and front cover.
Position camshafts so that flat spots are UP for installa-
tion of Camshaft Hold-Down Tools (J 38613-A). Install Cam-
shaft Hold-Down Tools (J 38613-A) on both camshaft carri-
ers. See Fig. 4.
Remove camshaft sprocket center bolts. Note difference
between early and late designs. See Fig. 5. Lightly tap on
rear of sprockets to remove from camshaft.
Inspection:
To determine if timing belt length is within specifications,
measure tensioner actuator from centerline of tensioner
actuator to end of rubber boot. See Fig. 2. If measurement
is 3.2-3.7 (80.5-94.0 mm) for a used belt, the belt is in
acceptable range. Replace belt is measurement is more
than 3.7 (94 mm).
Inspect belt teeth and back side of belt for cracks, tears or
other damage. Inspect components for excessive wear or
unusual conditions. Note any evidence of oil or other fluid
intrusion.
Installation:
Install camshaft sprockets with bolts and locks. Tighten
bolts finger tight. Install timing belt onto camshaft sprock-
ets in a counterclockwise direction. Continue installing tim-
ing belt, making sure timing belt teeth are fully engaged
with all sprockets.
Install timing belt tensioner pulley. Tighten timing belt
tensioner pulley bolt to 37 ft. lbs. (50 N.m).
Fig. 5: Identifying Camshaft Sprocket Designs
240
NOTE: If tensioner oil has been lost, fill tensioner with Mobil
1 SAE 5W-30 synthetic engine oii through plug hole. Fill to bottom
of plug hole only when plunger is fully retracted and pin is installed.
Install rubber end plug in rear of tensioner assembly until
flush. Ensure plug is sealed against case.
NOTE: Ensure actuator bushings and appropriate holes in side
plate are clean. DO NOT lubricate bushings.
Install actuator bushing into side plate. Install timing belt
actuator and actuator side plate. Tighten side plate bolt to
20 ft. lbs. (27 N.m).
Rotate pulley assembly into timing belt a maximum of 11 ft.
lbs. (15 N.m) to allow engagement of actuator shaft into
pulley pocket arm socket. Pull the paper clip from the ac-
tuator. Retighten pulley assembly counterclockwise to seat
pulley into belt.
Tighten both right hand camshaft sprockets (bank closest
to firewall) to 96 ft. lbs. (130 N.m). Remove camshaft hold-
down from right hand camshaft carrier.
Rotate crankshaft one full turn (360 degrees) clockwise,
as viewed from front of engine. Align crankshaft reference
marks. Make sure both right hand camshaft flat spots are
down. Tighten both left hand camshaft sprockets (bank
closest to radiator) to 96 ft. lbs. (130 N.m). Remove cam-
shaft hold-down from left hand camshaft carrier.
Rotate engine clockwise (as viewed from front) 2 times to
seat belt and verify correct valve timing. DO NOT reverse
rotation. Make sure both camshaft flat spots are up on one
bank and down on opposing bank.
Install camshaft carrier covers. Install breather hose and
crankcase vent onto rear cover. Install timing belt covers.
Continue installation in reverse of removal procedure. Re-
fill cooling system with 50/50 mix of water and coolant.
Open air bleed valve on thermostat housing while filling
cooling system. Adjust drive belts to proper tension. See
Crankshaft Balancer Bolt .......................................... 79 (107)
EGR Valve Bolts ............................................................. 18 (25)
Front Cover Bolts
Large Bolts ............................................................... 35 (47)
Small Bolts ............................................................... 18 (25)
Intermediate Shaft Belt Sprocket Bolt ........................ 96 (130)
Timing Belt Actuator Side Plate Bolt ............................... 20 (27)
Timing Chain Tensioner Bolt ...................................... 18 (24)
Upper Intake Manifold Bolts & Nuts................................ 22 (27)
INCH Lbs. (N.m)
Camshaft Carrier Cover Bolts ........................................ 97 (11)
Timing Belt Cover Bolts.................................................. 89 (10)
Water Pump Bolt ........................................................ 97 (11)
GENERAL MOTORS
*3.4L V6 (Cont.)
241
HONDA
*1.2L 4-Cylinder
1
Belt Part No.
1.2L 4-Cyl.
Civic
1973-79................. 1.5 Hours .................. 250028
1
TIMING BELT
Removal:
Disconnect negative battery cable. Remove wheelwell
splash shield. Remove air conditioning compressor ad-
justment pulley complete with bracket drive belt. Remove
remaining accessory drive belt(s). Remove valve cover. Re-
move water pump pulley and crankshaft pulley. See Fig. 1.
Ensure that cylinder No. 1 is at TDC of compression stroke
and camshaft is aligned with mark. See Fig. 3.
Remove upper timing belt cover from cylinder head. Re-
move lower timing belt cover from engine block. Loosen
(do not remove) timing belt adjusting and pivot bolts. Slide
belt off pulleys.
Installation:
To install, reverse removal procedure using care not to ex-
cessively bend or twist timing belt. Do not expose belt to
engine oil as this will cause belt rubber to swell. Install belt
in same direction of rotation to prevent premature wear or
failure. Adjust drive belts to proper tension. See page A-60
Application Ft. lbs (N.m)
A/C Pulley Bolt ............................................................ 17 (23)
Alternator
Through-Bolt ............................................................. 33 (45)
Adjustment Bolt ........................................................ 17 (23)
Engine Support Bolts/Nut ........................................... 40 (55)
Side Bracket ............................................................... 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover ...................................................... 84 (9.7)
Valve Cover ................................................................ 84 (9.7)
242
HONDA
Fig. 2: Aligning Camshaft Marks
243
HONDA
*1.3L 4-Cylinder
Belt
1.3L 4-Cyl.
Civic
1980-83
Canada ........
2
2.0 Hrs. ............................ 250028
US ...............
2
2.0 Hrs. ............................ 250073
1984-85..........
2
2.0 Hrs. ............................ 250099
1986-87..........
2
2.0 Hrs. ..... 2521610........ 250161
Civic CRX
1984...............
2
2.0 Hrs. ............................ 250099
1
2
kits.
TIMING BELT
Removal:
splash shield. Remove A/C compressor or adjusting pul-
ley and bracket. Remove A/C belt. Remove accessory drive
belts. Remove engine support bolts and nut. Remove side
mount rubber. Rotate crankshaft counterclockwise to posi-
tion No. 1 cylinder to TDC of compression stroke.
See Figs. 2 and 4. Ensure camshaft timing marks are
aligned with valve cover surface and UP or ROUND mark
is upward. See Figs. 1 and 5.
Remove crankshaft pulley. Remove lower timing belt cover
from engine block. Loosen timing belt tensioner to relieve
timing belt tension.
If timing belt is being reused, mark direction of belt rotation
before removing. Remove timing belt from camshaft and
crankshaft gears.
Inspection:
Inspect timing belt for wear on rounded edges of drive teeth.
Inspect belt for signs of oil contamination. Replace belt if
damaged or contaminated. Inspect all drive gears for wear
in drive belt area. Replace as necessary.
Installation :
Ensure No. 1 piston is at TDC of compression stroke. Ensure
camshaft timing marks are aligned with valve cover surface
and UP or ROUND mark is upward. See Figs. 1 and 4.
Install timing belt. Use care not to excessively bend or twist
belt. Ensure belt is installed in original direction of rotation.
Belt tension must be adjusted. Rotate crankshaft counter-
clockwise 3 teeth on camshaft pulley to create tension on
belt. Tighten tensioner adjustment bolt to specification.
CAUTION: Belt tension must be adjusted when engine temperature
is cold.
Install washer on crankshaft bolt with flat side toward the
pulley. See Figs. 2 and 4.Tighten retaining bolt to specifica-
tion. Reverse removal procedure to complete installation.
Tighten all bolts to specification. On specified Civic mod-
els, valve cover bolts must be tightened in proper sequence.
See Fig. 3. Adjust drive belts to proper tension. See page A-
Alternator Adjustment Bolt .......................................... 17 (23)
Alternator Bracket Bolt ................................................ 33 (45)
1980-83 .................................................................... 61 (81)
1984-87 .................................................................. 83 (112)
Timing Belt Adjuster Bolt ............................................. 35 (48)
INCH Lbs. (N.m)
Valve Cover Bolt ........................................................ 108 (12)
Valve Cover Nut ............................................................ 84 (9)
Water Pump Bolt ...................................................... 108 (12)
244
HONDA
Fig. 3: Valve Cover Tightening Sequence
245
HONDA
246
HONDA
*1.5L 4-Cylinder
Belt
Application Time
1
Kit No. No.
1.5L 4-Cyl.
Civic CVCC
1975............... 2.0 Hrs. ...... 2520360........ 250036
1976-79.......... 2.0 Hrs. ............................. 250041
Civic
1980-83.......... 2.0 Hrs. ............................. 250041
1984-85.......... 2.0 Hrs. ............................. 250099
1986-87.......... 2.0 Hrs. ...... 2521610........ 250161
1988-95.......... 2.0 Hrs. ...... 2521430........ 250143
Civic VX
1992-95.......... 2.0 Hrs. ............................. 250223
Civic CRX
1984-85.......... 2.0 Hrs. ............................. 250099
1986-87.......... 2.0 Hrs. ...... 2521610........ 250161
Civic Del Sol
1993-95
Exc. VX ........ 2.0 Hrs. ...... 2521430........ 250143
VX ................ 2.0 Hrs. ............................. 250223
1
kits.
scheduled maintenance interval for 1975-89 models, belt
manufacturers suggest the belt be replaced at 60,000 mile
intervals. On 1990-94 models, the manufacturer recommends
the belt be replaced at 90,000 mile intervals. For 1995 mod-
els, the manufacturer recommends the belt be replaced at
90,000 mile intervals for normal service and 60,000 miles for
severe service.
TIMING BELT
Removal (1975-79):
splash shield. Remove A/C compressor adjusting pulley
together with bracket and A/C belt. Remove alternator
bracket and belt. Remove engine support bolts and nut.
Remove rubber mount. Remove valve cover. Remove crank-
shaft pulley. Remove upper timing belt cover from cylinder
head and remove lower timing belt cover from engine block.
Ensure that No. 1 cylinder is at TDC on compression stroke
with camshaft aligned with marks. Remove timing belt.
aligned. See Figs. 1 and 5. Reverse removal procedure
using care not to excessively twist or bend belt. Adjust drive
ranges.
Removal (1980-95):
terclockwise until No. 1 cylinder is at TDC of compression
stroke. Remove splash shield. Remove power steering
pump, leaving hoses attached. Remove A/C belt idler pul-
ley bracket and belt. Remove alternator belt. Remove power
steering pump bracket.
Remove cruise control actuator (if equipped). Remove
power steering reservoir bracket. Remove engine mount
nuts. Loosen engine mount bolt. Pivot side engine mount
cushion aside.
Remove valve cover. Remove upper timing belt cover. Re-
move crankshaft pulley. Loosen timing belt tension adjuster
bolt 180 degrees. Push tensioner to release belt tension.
Retighten tension adjuster bolt. Disengage timing belt from
pulleys. See Figs. 1, 2 and 3.
Install timing belt onto crankshaft pulley, tension adjuster
pulley, water pump pulley, and camshaft sprocket. DO NOT
bend or twist belt excessively. Ensure crankshaft pulley tim-
247
HONDA
ing mark aligns with pointer on lower timing belt cover. See
Figs. 5, 6, 7, 8 or 9.
Adjust timing belt tension. See TIMING BELT ADJUSTMENT.
Before installing valve cover gasket, apply non-hardening
sealant to rounded surfaces of front and rear camshaft
caps. To complete installation, reverse removal procedure.
TIMING BELT ADJUSTMENT
Remove cylinder head cover. Remove upper timing belt
cover. Rotate crankshaft counterclockwise until No. 1 cylin-
der is at TDC of compression stroke. Loosen but do not
remove, timing belt adjuster bolt. See Fig. 4.
Rotate crankshaft 3 teeth counterclockwise on camshaft
sprocket to create tension on timing belt. Tighten adjuster
bolt to specification. Retighten crankshaft pulley bolt to
specification if it loosened during crankshaft rotation. See
248
HONDA
A/C Compressor Bracket Bolt .................................... 33 (45)
SOHC
1975-79 ................................................................. 22 (30)
1980-95 ................................................................. 28 (33)
1
SOHC ................................................................... 134 (185)
Power Steering Pump Bracket Bolt ............................. 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Water Pump Bolt ...................................................... 108 (12)
1
- Lubricate bolt threads. Do not lubricate washer or washer
mating surface of bolt.
249
HONDA
(1988-91: Dual Point Injection)
Fig. 8: Aligning Timing Marks (1988-91 Civic Si & 4WD
Civic Wagon; Multipoint Injection)
250
HONDA
251
HONDA
1.6L 4-Cyl. DOHC
Civic Del Sol
1994-97................
1
2.0 Hours ................. 250227
1
replaced at 90,000 miles. For 1995-96 vehicles, the manufac-
turer recommends the belt be replaced at 90,000 miles for
normal service and 60,000 miles for severe service.
For 1997 vehicles, normal replacement interval is at 105,000
miles or 84 months. Replace at 60,000 miles if car is regularly
driven in extreme temperatures (over 110 degrees F, or under
-20 degrees F).
TIMING BELT
Removal:
If the radio has a theft protection circuit, be sure to get the
customers code before disconnecting battery. Disconnect
negative battery cable. Remove engine lower splash shield.
Remove power steering, alternator, and A/C compressor
drive belts. Remove power steering pump and hang out of
way, leaving hoses connected. Rotate crankshaft counter-
clockwise to TDC of compression stroke. See Fig. 1.
remove engine mount bracket nuts and bracket. Remove
power steering pump lower bracket and heat shield from
engine. Remove the crankshaft pulley.
Remove valve cover. Remove middle and lower covers.
See Fig. 3. Loosen timing belt tension adjusting bolt 180
if it is to be reused. Remove timing belt from pulleys.
Installation:
on oil pump housing. See Fig. 2. Set intake and exhaust
camshaft pulleys to TDC. The TDC marks should align
with each other with UP marks pointing up. See Fig. 2.
tension adjusting pulley, water pump pulley, intake cam-
shaft pulley, and exhaust camshaft pulley. See Fig. 4. DO
NOT bend or twist belt excessively. Ensure arrow on used
belt points in original rotation direction. Ensure crankshaft
and camshaft pulleys remained aligned with TDC marks.
Install lower and middle covers. Install crankshaft pulley.
Tighten pulley bolt to specification. See TORQUE SPECIFI-
CATIONS. Rotate crankshaft pulley 5-6 turns counterclock-
wise so timing belt seats on pulleys.
cover). See Fig. 1. Loosen adjusting bolt 180 degrees.
pulley. Tighten adjusting bolt. If necessary, retorque crank-
shaft pulley bolt.
tioned. To complete installation, reverse removal proce-
dure. When installing valve cover gasket, apply liquid gas-
ket to 8 corners where gasket meets camshafts. Tighten
fasteners to specification. See TORQUE SPECIFICATIONS.
tension ranges.
Fig. 1: Setting Crankshaft Pulley To TDC
Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
252
HONDA
1
............................................ 130 (177)
Power Steering Pump-To-Bracket Bolts ......................... 17 (24)
Timing Belt Adjusting Bolt ............................................. 40 (54)
Water Pump Bolt (10 x 1.25 mm) ................................... 33 (44)
INCH Lbs. (N.m)
Valve Cover Nuts
2
..................................................................................................... 89 (10)
Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
1
- Lubricate bolt threads and bottom shoulder of bolt head.
2
- Tighten nuts in 2-3 steps, starting from center outward. Fig. 4: Timing Belt Installation Sequence
253
HONDA
*1.6L 4-Cylinder SOHC, 1976-95
1
Belt Part No.
1.6L 4-Cyl.
Accord (Includes Canadian)
1976-78................. 2.0 Hours .................. 250041
1980-83................. 2.0 Hours .................. 250041
Civic & Civic del Sol
1988-91................. 2.1 Hours .................. 250145
1992
(Except Si) ......... 2.1 Hours .................. 250145
(Si) ...................... 2.0 Hours .................. 250224
1993-95................. 2.1 Hours .................. 250224
Civic CRX
1988-91................. 2.1 Hours .................. 250145
Prelude (Canadian)
1980-82................. 2.1 Hours .................. 250041
1
scheduled maintenance interval for 1975-89 models, belt
intervals. On 1990-94 models, normal replacement interval is
at 90,000 miles. For 1995 models, recommended replace-
ment interval is 90,000 for normal service and 60,000 for se-
vere service.
TIMING BELT
Removal:
Disconnect battery negative cable. Rotate crankshaft coun-
terclockwise until No. 1 cylinder is at TDC of compression
stroke. Remove wheelwell splash shield. Remove power
steering pump, leaving hoses attached.
Remove A/C belt idler pulley bracket, and belt. Remove
alternator belt. Remove power steering pump bracket. Re-
move cruise control actuator (if equipped).
Remove power steering reservoir bracket. Use jack to sup-
port engine and then remove engine mount nuts. Loosen
engine mount bolt. Pivot side engine mount-cushion aside.
Remove valve cover. Remove upper timing belt cover. Re-
move crankshaft pulley. Remove crankshaft position sen-
sor from oil pump (if equipped). Loosen timing belt tension
adjuster bolt 180 degrees. See Fig. 2. Push tensioner to
release belt tension. Retighten tension adjuster bolt. Mark
rotation direction of timing belt if it is to be reused. Remove
timing belt from pulleys. See Figs. 1 and 5.
Installation:
Crankshaft keyway will be at 12 oclock position, and
sprocket groove or mark will align with pointer on oil pump
housing.
Install timing belt onto crankshaft pulley, tension adjuster
pulley, water pump pulley, and camshaft sprocket. DO NOT
bend or twist belt excessively. Ensure arrow on used belt
points in original rotation direction. Ensure crankshaft and
camshaft timing marks are still aligned.
Adjust timing belt tension. See TIMING BELT ADJUSTMENT.
Before installing valve cover gasket, apply non-hardening
sealant to rounded surfaces of front and rear camshaft
caps. To complete installation,reverse removal procedure.
TIMING BELT ADJUSTMENT
Remove valve cover. Remove upper timing belt cover. Ro-
tate crankshaft counterclockwise until cylinder No. 1 is at
TDC of compression stroke. Loosen but do not remove,
timing belt adjuster bolt. See Fig. 2.
Rotate crankshaft 3 teeth counterclockwise on camshaft
sprocket to create tension on timing belt. Tighten adjuster
bolt. Retighten crankshaft pulley bolt to specification if it loos-
ened during crankshaft rotation. See TORQUE SPECIFICA-
TIONS.
Fig. 1: Exploded View Of Timing Belt Components (Accord
& Prelude)
254
HONDA
*1.6L 4-Cylinder SOHC, 1976-95 (Cont.)
(Prelude, 1980-82)
(Accord, 1976-82)
DOHC ....................................................................... 38 (51)
SOHC ....................................................................... 28 (38)
1
SOHC ................................................................... 130 (180)
SOHC ................................................................... 134 (185)
Timing Belt Adjuster Bolt
DOHC ....................................................................... 41 (55)
SOHC ....................................................................... 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Water Pump Bolt ...................................................... 108 (12)
1
- Lubricate bolt threads but do not lubricate washer or mat
ing surface of bolt.
255
HONDA
Fig. 5: Exploded View Of Timing Belt Components (1992-95 Civic)
256
Fig. 6: Aligning Timing Belt Marks (Civic, 1988-95)
HONDA
257
HONDA
*1.6L 4-Cylinder SOHC, 1996-2000
1.6L 4-Cyl. SOHC
Civic
1996-00................
1
2.0 Hours ................. 250224
Civic Del Sol
1996-97................ `
1
2.0 Hours ................ 250224
1
For 1996 vehicles, manufacturer recommends replacing belt
at 90,000 miles for normal service and 60,000 miles for se-
vere service. For 1997-00 vehicles, normal replacement inter-
val is at 105,000 miles or 84 months. Replace at 60,000 miles
if car is regularly driven in extreme temperatures (over 110
degrees F, or under -20 degrees F).
TIMING BELT
Removal:
Disconnect negative battery cable. Remove engine lower
splash shield. Remove power steering, alternator, and A/C
compressor drive belts. Rotate crankshaft counterclock-
wise to TDC of compression stroke. See Fig. 3.
Remove engine oil dipstick. Remove power steering pump
and set aside with hoses attached. Remove timing belt
upper cover and A/C drive belt idler pulley bracket.
remove engine mount bracket nuts. Remove crankshaft
pulley. Remove lower cover and dipstick tube.
Remove Crankshaft Speed Fluctuation (CKF) sensor from
oil pump. Loosen the timing belt tension adjusting bolt 180
if it is to be reused. Remove timing belt from pulleys. See
Fig. 1.
258
HONDA
NOTE: The following revised timing belt tensioner information
is from Honda technical service bulletin 96-057; August 4, 1998.
Inspection:
Inspect timing belt tensioner pulley for worn bearing. Re-
place as necessary.
If there was a customer complaint of a whine or chirping
noise from the front of the engine at idle, or just above idle,
this may be caused by a timing belt that is tensioned too
tight. A revised timing belt tensioner and spring are avail-
able for all 1996, 1997 and some 1998 engines.
The timing belt tensioner kit is available under part number
14520-P2A-305.
Installation:
top surface of cylinder head. See Fig. 3.
tension adjusting pulley, water pump pulley, and camshaft
pulley. See Fig. 4. DO NOT bend or twist belt excessively.
Ensure arrow on used belt points in original rotation direc-
tion. Ensure crankshaft and camshaft pulley timing mark
are aligned with TDC marks.
Install lower cover. Install crankshaft pulley. Tighten pulley
bolt to specification. See TORQUE SPECIFICATIONS. Ro-
tate crankshaft pulley 5-6 turns counterclockwise so timing
belt seats on pulleys.
cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Ro-
tate crankshaft counterclockwise 3 teeth on camshaft pul-
ley. Tighten adjusting bolt. If necessary, retorque crankshaft
pulley bolt.
tioned. To complete installation, reverse removal proce-
259
HONDA
1
Step 1 ....................................................................... 14 (20)
Timing Belt Tensioner Adjusting Bolt ........................... 33 (45)
INCH Lbs. (N.m)
CKF Sensor Bolt ....................................................... 106 (12)
Water Pump Bolt ...................................................... 106 (12)
1
260
HONDA
1.6L 4-Cyl. SOHC
Civic
2001.....................
1
2.7 Hours ................. 250312
1
-20 degrees F).
TIMING BELT
Removal:
Disconnect negative battery cable. Remove engine lower
splash shield. Rotate crankshaft counterclockwise to TDC
of compression stroke. See Fig. 2. Remove front wheels.
Remove splash shield. Remove power steering adjusting
plate mounting bolt, then remove power steering pump
belt and pump without disconnecting hoses. Remove al-
ternator.
Remove four (4) ignition coils, throttle cable clamps and
harness holder from cylinder head cover. Remove cylinder
head cover. See Fig. 1.
261
HONDA
Hold crankshaft pulley with Holder Handle (07JAB-
001020A), Holder Attachment (07JAA-001020A) and use a
heavy duty 19 mm socket and breaker bar to remove pulley
bolt. See Fig. 3. Support engine with a jack and wood block
under oil pan. Remove upper engine bracket from timing
belt end of engine.
Remove grommet from upper timing belt cover and dis-
connect TDC sensor connector. Remove both upper and
lower timing belt covers. See Fig. 4.
Fig. 3: Removing Crankshaft Pulley
Fig. 5: Removing CKP Sensor From Oil Pump
Fig. 6: Removing Tension From Timing Belt
262
HONDA
1.7L 4-Cylinder SOHC, (Cont.)
Fig. 8: Aligning Camshaft TDC Marks
Remove side engine mount bracket. Remove CKP sensor
from oil pump without disconnecting connector. See Fig. 5.
Move auto tensioner to remove tension from timing belt
and remove timing belt. See Fig. 6.
Installation:
top surface of cylinder head. See Fig. 8
tensioner pulley, water pump pulley, and camshaft pulley.
See Fig. 9. DO NOT bend or twist belt excessively. Ensure
arrow on used belt points in original rotation direction. En-
sure crankshaft and camshaft pulley timing marks are
aligned with TDC marks.
Install CKP sensor, side engine mount bracket, lower tim-
ing belt cover, and crankshaft pulley. Tighten bolts to speci-
fication. See TORQUE SPECIFICATIONS. Rotate crankshaft
pulley 5-6 turns counterclockwise so timing belt positions
on pulley.
Turn crankshaft pulley so No. 1 piston is at TDC (White
TDC mark on crankshaft pulley aligns with pointer on
cover). See Fig. 2.
Ensure camshaft pulley marks are aligned at TDC. See
Fig. 8. If not, timing belt will need to be removed and repo-
sitioned. To complete installation, reverse removal proce-
dure. Tighten all nuts and bolts to specification. See
Auto Tensioner Mounting Bolt ..................................... 33 (44)
1
Step 1 ....................................................................... 14 (20)
Engine Side Mount Bracket Nuts .................................... 33 (44)
Engine Upper Bracket Nuts............................................ 40 (54)
INCH Lbs. (N.m)
CKP Sensor Bolt ...................................................... 106 (12)
Harness Holder & Cable Clamps .................................. 89 (10)
Water Pump Bolt ...................................................... 106 (12)
1
263
HONDA
*1.8L 4-Cylinder
Belt
1.8L 4-Cyl.
Accord
1979-83..........
1
2.0 Hrs. ............................ 250041
1984-85..........
1
2.0 Hrs. ..... 2521600........ 250094
Prelude
1979-82..........
1
2.0 Hrs. ............................ 250041
1983-85..........
1
2.0 Hrs. ..... 2521600........ 250094
1986-87..........
1
2.0 Hrs. ..... 2521600........ 250160
1
kits.
Although the manufacturers does not recommend a specific
TIMING BELT
Removal (1979-81):
Disconnect negative battery cable. Remove engine sup-
port bolts and nuts. Remove side rubber mount. Remove
side mount bracket. Remove cruise control actuator. Re-
move engine splash guard. Remove water pump drive belt,
water pump pulley and crankshaft pulley. Remove alterna-
tor, belt, A/C compressor and belt.
Remove valve cover. Ensure cylinder No. 1 is at TDC of
compression stroke and camshaft is aligned to mark. Re-
move upper timing belt cover from cylinder head and re-
move lower timing belt cover from engine block. Loosen,
do not remove, timing belt adjusting and pivot bolts. If reus-
ing belt, mark direction of belt rotation. Slide belt off pulleys.
To install, reverse removal procedure using care not to ex-
cessively bend or twist belt. If re-installing old belt, install
belt so same direction of rotation will be maintained. Ad-
just drive belts to proper tension.
Removal (1982-87):
Disconnect negative battery cable. Remove engine sup-
port bolts and nuts. Remove side rubber mount. Remove
side mount bracket. Remove cruise control actuator. Re-
move engine splash guard. Remove water pump drive belt,
water pump pulley. Remove alternator, belt, A/C compres-
sor and belt. Rotate crankshaft counterclockwise to posi-
tion No. 1 cylinder to TDC of compression stroke. Remove
all drive belts.
Ensure camshaft timing marks are aligned with valve cover
surface and UP or ROUND mark is upward. See Fig. 2,
Fig. 3 or Fig. 4.
(Accord, 1984-85)
(Accord & Prelude, 1979-83)
264
HONDA
(Accord, 1979-83)
Remove crankshaft pulley. Remove lower timing belt cover
from engine block. Loosen timing belt tensioner to relieve
before removing. Remove timing belt from camshaft and
crankshaft gears.
Inspection (1982-87):
Inspect timing belt for wear or rounded edges of drive teeth.
Inspect belt for signs of oil contamination. Replace belt if dam-
aged or contaminated. Inspect all drive gears for wear in drive
belt area. Replace as necessary.
Ensure camshaft timing marks are aligned with valve cover
surface and UP or ROUND mark is upward. See Fig. 2,
Fig. 3 or Fig. 4.
Install timing belt. Use care not to excessively bend or twist
belt. Ensure belt is installed in original direction of rotation.
Belt tension must be adjusted. Rotate crankshaft counter-
clockwise 3 teeth on camshaft pulley to create tension on
belt. Tighten tensioner adjustment bolt to specification.
CAUTION: Belt tension must be adjusted when engine temperature
is cold.
(Prelude, 1984-87)
Install washer on crankshaft bolt with flat side toward the
pulley. Tighten retaining bolt to specification. Reverse re-
moval procedure to complete installation. Tighten all bolts
to specification. Apply non-hardening sealant to rounded
surfaces of front and rear camshaft caps before installing
valve cover gasket. Adjust drive belts to proper tension. See
A/C Compressor Bracket Bolts ................................... 35 (47)
Alternator Adjustment Bolt ........................................... 17 (23)
Alternator Bracket Bolt ................................................. 33 (45)
Camshaft Pulley Bolt
1983-87 ..................................................................... 27 (37)
1979-82 ..................................................................... 22 (30)
Crankshaft Pulley Bolt ............................................... 83 (112)
Timing Belt Adjuster Bolt .............................................. 32 (44)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................... 84 (9)
Valve Cover Bolt ......................................................... 108 (12)
Valve Cover Nut ............................................................. 84 (9)
Water Pump Bolt ....................................................... 108 (12)
265
HONDA
Fig. 5: Exploded View Of Timing Belt & Components (Accord, 1984-85 & Prelude, 1984-87)
266
HONDA
*2.0L 4-Cylinder CR-V
2.0L 4-Cyl.
CR-V
1997-01 ..............
1
3.0 Hours ................. 250184
1
- With Cruise Control add .3 hours.
TIMING BELT
Removal:
Disconnect battery negative cable. Remove engine guard
bar and lower splash shield. Remove power steering, al-
ternator, and A/C compressor drive belts. Remove cruise
control actuator and vacuum tank from left side fenderwell
(if equipped) and hang out of way. Rotate crankshaft coun-
terclockwise to TDC of compression stroke. See Fig. 1.
remove engine mount bracket nuts and bracket. Remove
the crankshaft pulley.
Remove cylinder head cover. Remove middle and lower
covers. See Fig. 3. Loosen timing belt tension adjusting
bolt 180 degrees. Push tensioner to release belt tension.
Retighten tension adjusting bolt. Mark rotation direction of
timing belt if it is to be reused. Remove timing belt from
pulleys.
Installation:
Set intake and exhaust camshaft pulleys to TDC. The TDC
marks should align with cylinder head surface with UP
marks pointing up. See Fig. 2.
tension adjusting pulley, water pump pulley, exhaust cam-
shaft pulley, and intake camshaft pulley. See Fig. 4. DO
NOT bend or twist belt excessively. Ensure arrow on used
belt points in original rotation direction. Check that crank-
shaft and camshaft pulleys remained aligned with TDC
marks.
Install lower and middle covers. Install crankshaft pulley.
Tighten pulley bolt to specification. See TORQUE SPECIFI-
CATIONS. Rotate crankshaft pulley 5-6 turns counterclock-
wise so timing belt positions on pulley.
cover). See Fig. 1. Loosen adjusting bolt 180 degrees.
Fig. 1: Setting Crankshaft Pulley To TDC
Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
267
HONDA
*2.0L 4-Cylinder CR-V (Cont.)
pulley. Tighten adjusting bolt. If necessary, retorque crank-
shaft pulley bolt.
tioned.
installing cylinder head cover gasket, apply liquid gasket
(Part No. 08718-0001 or -0003) to 8 corners where gasket
meets camshafts. Tighten fasterners to specification. See
268
HONDA
*2.0L 4-Cylinder CR-V (Cont.)
Alternator Adjusting Lock Nut ......................................... 17 (24)
1
............................................ 130 (177)
Engine Underguard Bar Bolts ........................................ 17 (24)
Power Steering Pump-To-Bracket Bolts ......................... 17 (24)
Timing Belt Adjusting Bolt ............................................. 40 (54)
INCH Lbs. (N.m)
Cylinder Head Cover Nuts
2
.......................................... 89 (10)
Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and bottom shoulder of bolt head.
2
- Tighten nuts in 2-3 steps, starting from center outward.
269
HONDA
*2.0L 4-Cylinder SOHC, Accord & Prelude
Belt
2.0L 4-Cyl. SOHC
Accord
1986-89..........
1
2.7 Hrs. .... 2521600........ 250160
Prelude
1985...............
1
2.7 Hrs. .... 2521600........ 250094
1986-87..........
1
2.7 Hrs. .... 2521600........ 250160
1988-90..........
1
2.7 Hrs. ........................... 250144
1
kits.
For 1985-89 vehicles, although the manufacturer does not
recommend a specific scheduled maintenance interval, belt
manufacturers suggest the belt be replaced every 60,000
miles. For 1990 vehicles, the manufacturer recommends the
belt be replaced at 90,000 miles.
TIMING BELT
Removal (Except 1988-90 Prelude):
stroke. Remove drive belts. Remove left engine mount bolts/
nuts, engine mount and bracket. Remove cruise control
actuator (if equipped). See Fig. 1.
Remove splash shield. Remove power steering adjusting
pulley. Remove power steering pump with hoses attached
and set aside. Remove alternator. Remove A/C compres-
sor (if equipped). Remove engine valve cover and upper
timing belt cover. Ensure timing marks align and UP mark
is facing upward. See Fig. 3.
Remove crankshaft pulley. Remove lower timing belt cover.
If timing belt is going to be reused, mark belt rotation direc-
tion before removing. Loosen timing belt tensioner adjust-
ment bolt. Push tensioner to release belt tension, retighten
adjustment bolt. Remove timing belt.
Inspection:
Inspect timing belt for wear and for signs of oil contamina-
tion. Replace belt if damaged or contaminated. Inspect all
drive gears for wear. Inspect water pump for excessive bear-
ing play or coolant leakage. Replace as necessary.
Installation (Except 1988-90 Prelude):
Ensure cylinder No. 1 is still at TDC. Install timing belt on
sprockets. DO NOT excessively bend or twist belt. Ensure
arrow on used belt points in original rotation direction.
Adjust timing belt tension by rotating crankshaft counter-
clockwise until cylinder No. 1 is at TDC of compression
stroke. Loosen, but do not remove timing belt adjustment
bolt. Rotate crankshaft counterclockwise 3 teeth on cam-
(Except 1988-90 Prelude)
Fig. 2: Timing Belt Installed Position
(1988-90 Prelude)
shaft pulley to create tension on timing belt. Tighten adjust-
ment bolt to specification. See TORQUE SPECIFICATIONS.
Apply non-hardening sealant to rounded surfaces of front
and rear camshaft caps before installing valve cover gas-
ket. To complete installation, reverse removal procedure.
TIONS. Adjust drive belts to proper tension.
Removal (1988-90 Prelude):
Turn crankshaft counterclockwise (as viewed from timing
belt end of engine) so that No. 1 cylinder is at TDC of com-
pression stroke. TDC mark (White paint) is at rear of en-
gine on transaxle mating flange. See Fig. 3.
270
HONDA
*2.0L 4-Cylinder SOHC, Accord & Prelude (Cont.)
(1985-87 Prelude, Others Similar)
(1988-90 Prelude)
Remove engine lower splash shield. Support weight of
engine from above or with floor jack. Remove engine mount
from timing belt end of engine. Remove cruise control ac-
tuator (if equipped).
Remove accessory drive belts. Remove generator and set
aside. Remove power steering pump with hoses attached
and set aside. Remove A/C compressor (if equipped) with
hoses attached and set aside.
Remove valve cover. Remove crankshaft pulley center bolt.
Remove crankshaft pulley. Remove upper and lower tim-
ing belt covers. Noting installed position for reassembly
reference, remove timing belt guide plate from crankshaft.
Loosen timing belt tensioner bolt and remove timing belt.
Inspection:
drive gears for wear. Inspect water pump for excessive
bearing play or coolant leakage. Replace as necessary.
Installation (1988-90 Prelude):
Ensure crankshaft is still at TDC. Ensure camshaft sprocket
is correctly aligned. See Fig. 3. UP mark on camshaft
should be facing straight up and grooves on sprocket
should align with top surface of cylinder head.
Install timing belt on engine. Move tensioner toward belt
and temporarily tighten tensioner bolt. Without moving
crankshaft, install timing belt guide plate (concave side
faces away from engine). Install lower timing belt cover.
Install crankshaft pulley. Apply engine oil to bolt threads
and install crankshaft pulley bolt and washer. Tighten to
Loosen, but DO NOT remove, timing belt adjusting bolt
through access hole in timing belt cover. See Fig. 4. Rotate
crankshaft counterclockwise 3 teeth on camshaft pulley to
tension timing belt. Tighten adjusting bolt to 31 ft. lbs. (43
N.m). Install upper timing belt cover. Install valve cover.
Install generator, power steering pump and A/C compres-
sor. Install accessory drive belts and adjust to proper ten-
sion. Install engine mount and cruise control actuator.
TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE)
Alternator Bracket Adjustment Bolt .............................. 51 (69)
INCH Lbs. (N.m)
Valve Cover Nut ............................................................ 84 (9)
Water Pump Bolt ...................................................... 106 (12)
TORQUE SPECIFICATIONS (1988-90 PRELUDE)
A/C Compressor Mounting Bolt .................................. 18 (25)
Engine Mount-To-Engine Nut ......................................... 47 (65)
Generator Lower Mount Bolt ....................................... 33 (45)
Generator Upper Mount Bolt ....................................... 20 (27)
Power Steering Pump Upper Mount Bolt ........................ 20 (27)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Water Pump Bolt ...................................................... 106 (12)
271
HONDA
*2.0L & 2.1L 4-Cylinder DOHC, Prelude
2.0L 4-Cyl. DOHC
Prelude
1988-91................
1
3.3 Hours ................. 250142
2.1L 4-Cyl. DOHC
Prelude
1990-91................
1
3.3 Hours ................. 250142
1
scheduled maintenance interval for 1989 models, belt manu-
facturers suggest the belt be replaced at 60,000 mile inter-
vals. On 1990-91 models, the manufacturer recommends belt
TIMING BELT
Removal:
stroke. Remove drive belts. Remove left engine mount bolts/
nuts, engine mount and bracket. Remove cruise control
actuator (if equipped).
Remove engine splash shield. Remove power steering
adjusting pulley. Remove power steering pump with hoses
attached and set aside. Remove alternator.
Remove A/C compressor (if equipped). Remove engine
valve cover and upper timing belt cover. See Fig. 2. Ensure
timing marks align, and UP marks on camshaft sprockets
are positioned at the top. See Fig. 1.
Remove crankshaft pulley. Remove lower timing belt cover.
If reusing timing belt, mark belt rotation direction before
removing. Loosen timing belt tensioner adjustment bolt
and push tensioner to release belt tension. Tighten adjust-
ment bolt and remove timing belt.
Inspection:
drive gears for wear in drive belt area. Inspect water pump
for excessive bearing play or coolant leakage. Replace if
necessary.
Installation:
Ensure cylinder No. 1 is still at TDC. Install timing belt on
sprockets. DO NOT bend or twist belt excessively. Ensure
arrow on used belt points in original rotation direction.
clockwise until cylinder No. 1 is at TDC of compression
To complete installation, reverse removal procedure. Apply
non-hardening sealant to rounded surfaces of front and
rear camshaft caps before installing valve cover gasket.
Alternator Bracket Adjustment Bolt .............................. 20 (27)
Power Steering Adjustment Nut .................................. 31 (42)
Timing Belt Adjustment Bolt ....................................... 31 (42)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 90 (10)
Water Pump Bolt ...................................................... 108 (12)
272
HONDA
*2.0L & 2.1L 4-Cylinder DOHC, Prelude (Cont.)
273
HONDA
*2.2L 4-Cylinder DOHC, Prelude
Belt
2.2L 4-Cyl. DOHC, H22A
Prelude
1993-01 .........
1
3.3 Hrs. .... 2521860......
2
250226
1993-01.............................. 2521860......
3
250186
1
- Balancer shaft belt included in camshaft belt
labor time.
2
3
Balancer shaft belt.
kits.
For 1993-94 vehicle, the manufacturer recommends camshaft
and balancer shaft belts be replaced at 90,000 miles. For
1995-96 vehicles, the manufacturer recommends the belt be
replaced at 90,000 miles for normal service or 60,000 miles
for severe service.
For 1997-01 vehicles, normal replacement interval is at
TIMING & BALANCER SHAFT BELTS
Removal:
Disconnect the negative battery cable. Rotate crankshaft
counterclockwise so that cylinder No. 1 is at TDC of com-
pression stroke. Timing marks are viewed through window
on transaxle-to-engine mating flange. See Fig. 1.
Remove engine lower splash shield. Remove power steer-
ing pump and alternator drive belts. Remove alternator ter-
minal and connector. If equippped, disconnect cruise con-
trol actuator electrical connector. Move cruise control actua-
tor out of way with cable attached.
Support engine with floor jack. Remove engine side mount
and bracket from front of engine. Remove dipstick tube
from front of engine. Remove cylinder head cover.
Remove middle timing belt cover. Remove crankshaft pul-
ley. Loosen belt tension adjusting nut. Push belt tensioner
to release tension from balancer belt. Tighten adjusting
nut. Remove balancer shaft and camshaft timing belts.
Inspection:
With belt or belt covers removed, inspect belts for wear,
cracks, or oil soaking. Inspect belt teeth for wear. Replace
belt if worn, oil soaked, or cracked. Inspect water pump for
leaks.
Installation:
Remove balancer belt drive pulley. Ensure crankshaft drive
pulley TDC (White) mark is aligned with pointer on oil pump
housing. See Fig. 3. Align camshaft pulleys at TDC posi-
tion. See Fig. 1.
Remove the auto-tensioner from front of engine. Place auto-
tensioner in soft-jawed vise with maintenace bolt facing
up. See Fig. 4. DO NOT grip housing.
Remove maintenace bolt from top of auto-tensioner. Use a
flat blade screwdriver to compress auto-tensioner to bot-
tomed out position. Place stopper on auto-tensioner. Refill
any oil that may have spilled out, and install maintenance
bolt with new gasket.
Install auto-tensioner on engine with stopper in place. In-
stall timing belt around crankshaft drive pulley, adjusting
pulley, water pump, exhaust camshaft pulley, then intake
camshaft pulley. Ensure crankshaft and camshaft pulleys
remain aligned at TDC.
Remove the auto-tensioner stopper. Install balancer belt
drive pulley. Temporarily install lower cover, crankshaft pul-
ley, and crankshaft pulley bolt. Tighten bolt.
Rotate crankshaft about 5-6 times counterclockwise so that
timing belt positions on the pulleys. Place crankshaft and
camshaft pulleys at TDC positions. If either crankshaft or
camshaft pulley is not positioned at TDC, timing belt will
have to be repositioned.
Fig. 1: Identifying Camshaft & Crankshaft TDC Marks
274
HONDA
*2.2L 4-Cylinder DOHC, Prelude (Cont.)
Remove crankshaft pulley and lower cover. Loosen belt
tension adjusting nut about 1 turn. Verify balancer belt ad-
juster moves freely. Retighten tension adjusting nut.
Remove sealing bolt from maintenance hole in side of en-
gine block. See Fig. 5. Insert a 6x100 mm bolt into mainte-
nance hole to lock rear balancer shaft in place. Ensure bolt
inserts at least 2.9 (74 mm). Align groove on front balancer
shaft with pointer on oil pump housing. See Fig. 6.
Install balancer belt. Loosen adjusting nut to tension bal-
ancer belt. Remove 6 x 100 mm bolt from side of engine
block. Install sealing bolt.
Install lower cover and crankshaft pulley. Lubricate crank-
shaft pulley bolt and underside of bolt shoulder. Install and
tighten bolt to specification.
Turn crankshaft pulley about 1 turn counterclockwise.
Tighten belt tension adjusting nut. Install rubber seal around
adjusting nut. Install accessory drive belts and adjust ten-
sion.
Install middle cover. When installing cylinder head cover
gasket, apply liquid gasket (Part No. 08718-001 or -0003)
to 8 corners where gasket meets camshafts. Reverse re-
moval procedure to complete installation.
275
HONDA
*2.2L 4-Cylinder DOHC, Prelude (Cont.)
Fig. 3: Aligning Timing Belt Drive Pulley With TDC Mark
Fig. 4: Compressing Auto-Tensioner
Fig. 5: Aligning & Locking Balancer Shaft
Fig. 6: Aligning Balancer Shaft Pulley
Auto-Tensioner Mount Bolts ........................................... 16 (22)
Balance Shaft Pulley Bolt ............................................ 22 (30)
Camshaft Pulley Bolt .................................................... 37 (51)
Crankshaft Pulley Bolt ...........................................
1
181 (245)
Maintenance Hole Sealing Bolt ...................................... 22 (29)
Power Steering Pump Bolt/Lock Nut ........................... 16 (22)
Timing Belt Tension Adjusting Nut .............................. 33 (45)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ............................................ 90 (10)
Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and underside of bolt shoulder.
276
HONDA
*2.2L 4-Cylinder SOHC, Odyssey
Belt
2.2L 4-Cyl. RA1
Odyssey
1997-95
Balance Shaft ..................... 2521860.... 250186
Camshaft ........
1
2.7 Hrs. ... 2521860...

250187
1
- Balance shaft belt included in camshaft belt
labor time.
kits.
1995-96 vehicles, the manufacturer recommends the belt be
replaced at 90,000 miles for normal service or 60,000 miles
for severe service.
-20 degrees F).
TIMING BELT
Removal:
signs of seal leakage. Remove accessory drive belts. Re-
move alternator terminal and connector. Raise and sup-
port vehicle. Remove wheelwell splash shield. Use a jack,
with cushion between oil pan and jack, to support engine.
Remove side engine mount.
Remove cylinder head cover. Remove crankshaft pulley.
Remove upper and lower timing belt covers. Loosen tim-
ing belt tensioner adjuster bolt 145-180 degrees. Push
tensioner to release belt tension from timing belt and bal-
ancer belt. Retighten tensioner adjuster bolt. Mark rotation
direction of timing belt if it is to be reused. Remove timing
belt from pulleys.
Installation:
Install timing belt in sequence shown. See Fig. 6. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. To
ranges.
96H14628 Courtesy of American Honda Motor Co., Inc.
Fig. 1: Timing Belt, Balance Belt & Related Components
96I14629 Courtesy of American Honda Motor Co., Inc.
Fig. 2: Removing/Installing Timing Belt Covers
277
96B14630 Courtesy of American Honda Motor Co., Inc.
Fig. 3: Loosening Tensioner Adjusting Nut
96C14631 Courtesy of American Honda Motor Co., Inc.
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
Fig. 5: Aligning Camshaft Pulley TDC Marks
HONDA
*2.2L 4-Cylinder SOHC, Odyssey (Cont.)
Power Steering Pump Mounting Nut ........................... 16 (22)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7)
Valve Cover Nut ......................................................... 86 (9.8)
278
HONDA
*2.2L & 2.3L 4-Cylinder DOHC & SOHC
Belt
2.2L 4-CYL. SOHC
Accord
1990-93
Balance Shaft ..................... 2521860...

250186
1
3.1 Hrs. .. 2521860.... 250187
1994-95
EX Model
Balance Shaft ....................................... 250186
Camshaft ..........
1
3.1 Hrs. ..................... 250244
Except EX Model
Balance Shaft .................... 2521860.... 250186
Camshaft ..........
1
3.1 Hrs. .. 2521860.... 250187
1996-97
w/VTEC
Balance Shaft ....................................... 250186
Camshaft ..........
1
3.1 Hrs. ..................... 250244
w/o VTEC
Balance Shaft .................... 2521860.... 250186
Camshaft ..........
1
3.1 Hrs. .. 2521860.... 250187
Prelude
1992-96
Balance Shaft ..................... 2521860.... 250186
1
3.1 Hrs. .. 2521860.... 250187
2.3L 4-Cyl. DOHC
Prelude
1992-96
Balance Shaft .......................................

250186
1
3.3 Hrs. ..................... 250216
1
labor time. With Air Cond. add .5 hours.
kits.
For 1990-94 vehicle, the manufacturer recommends camshaft
and balance shaft belts be replaced at 90,000 miles. For 1995-
96 vehicles, the manufacturer recommends the belt be re-
placed at 90,000 miles for normal service or 60,000 miles for
severe service.
-20 degrees F).
TIMING & BALANCE SHAFT BELTS
Removal:
Disconnect negative battery cable. Position crankshaft with
cylinder No. 1 at TDC of compression stroke. See Figs. 1, 2,
or 3. Disconnect battery negative cable. Remove splash
shield. Remove cruise control actuator, leaving cable con-
nected. Remove power steering pump, leaving hoses con-
nected.
Disconnect alternator wiring. Remove wiring harness from
valve cover. Remove alternator and A/C belts (if equipped).
Remove valve cover and upper timing belt cover. Remove
side engine mount. Remove engine oil dipstick and tube.
Support engine. Remove 2 rear bolts from engine center
support beam. Lower engine enough to permit removal of
lower timing belt cover. Remove rubber seal from belt ten-
sion adjuster nut. Remove lower timing belt cover.
Lock timing belt adjuster arm into position by installing one
lower cover retaining bolt. Loosen belt tension adjuster
bolt. Push belt tensioner to release tension from belt.
Tighten adjuster bolt. Remove balance shaft and camshaft
timing belts.
Fig. 1: Positioning Camshaft Sprocket For Valve
Adjustment (Prelude 2.2L SOHC)
279
HONDA
*2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)
Fig. 2: Positioning Camshaft Sprocket For Valve
Adjustment (Accord 2.2L SOHC)
Fig. 3: Positioning Camshaft Sprockets For Valve Adjustment (Prelude 2.3L DOHC)
CAUTION: DO NOT rotate crankshaft or camshaft when removing
timing belts.
Inspection:
With belt or belt covers removed, inspect belts for wear,
cracks, or oil soaking. Inspect belt teeth for wear. Replace
belt if worn, oil soaked, or cracked.
Installation:
Align White mark on flywheel or drive plate (flexplate) with
pointer on block. Ensure camshaft(s) is at TDC for No. 1
cylinder. See Figs. 1, 2, or 3. Install camshaft timing belt.
See Fig. 4. Align rear timing balance shaft belt pulley by
inserting a 6X100 mm bolt 2.9 inches (74 mm) into align-
ment access hole. Align groove on front balance shaft pul-
ley with pointer on oil pump body.
clockwise until No. 1 piston is at TDC of compression
Reverse removal procedure to complete installation.
Tighten crankshaft pulley bolt to specification. See TORQUE
280
HONDA
Fig. 4: Removing/Installing Timing & Balance Shaft Belts
Fig. 5: Locating Timing Belt Adjuster Nut (Typical)
Alternator Bracket Adjuster Bolt ................................... 16 (22)
Balance Shaft Pulley Bolt ............................................ 22 (30)
2.2L DOHC ............................................................... 37 (51)
2.2L SOHC & 2.3L .................................................... 27 (37)
Power Steering Belt Adjuster Nut ................................ 11 (15)
Shift Cable Bracket Bolt .............................................. 16 (22)
Timing Belt Tension Adjuster ...................................... 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 90 (10)
Water Pump Bolt ...................................................... 108 (12)
281
Fig. 7: Aligning Balancer Belt Driven Pulley
HONDA
Fig. 6: Installing Crankshaft Pulley (Typical)
282
HONDA
2.3L 4-Cyl. F23A, SOHC
Accord
1998-01
Balance Shaft .......................................

250186
1
3.6 Hours................

250244
Odyssey
1998
Balance Shaft .......................................

250186
1
4.0 Hours................

250244
1
labor time.
Replace at 60,000 miles if vehicle is regularly driven in ex-
treme temperatures (over 110 degrees F, or under -20 de-
grees F).
Removal:
signs of seal leakage. Raise and support vehicle. Remove
engine lower splash shield.
Remove accessory drive belts. Remove alternator terminal
and connector. Remove alternator and alternator bracket.
Use a jack, with cushion between oil pan and jack, to sup-
port engine. Remove side engine mount from front of en-
gine. Remove dipstick tube from front of engine.
Remove upper and lower timing belt covers. See Fig. 1 and
2.
Insert a 6 mm timing cover bolt through the hole in the end
of the timing belt adjuster arm. This will temporarily lock
the arm in place.
Loosen belt tensioner adjusting nut about 1 turn. See Fig.
3. Push outer balancer shaft belt tensioner pulley up to
take tension off of the balancer belt. Retighten belt tensioner
adjusting nut. Remove balancer shaft belt.
Loosen belt tensioner adjusting nut about 1 turn. See Fig.
3. Push camshaft timing belt tensioner pulley down to take
tension off of camshaft timing belt. Retighten belt tensioner
adjusting nut. Remove camshaft timing belt.
Installation:
Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by
aligning dimple on timing belt drive pulley with pointer on
oil pump housing. See Fig. 4. Ensure camshaft pulley TDC
marks are aligned. See Fig. 5.
Fig. 1: Timing Belt, Balancer Belt & Related Components
283
HONDA
Install camshaft timing belt in sequence shown. See Fig.
6. Loosen and retighten tensioner adjusting nut to tension
camshaft timing belt. Install balancer belt drive pulley and
lower cover. Install crankshaft pulley. Install bolt.
Rotate crankshaft pulley COUNTERCLOCKWISE about 5-
6 turns so timing belt positions on pulley. Set No. 1 piston
at TDC of compression stroke. Loosen belt tensioner ad-
justing nut about 1 turn. Rotate crankshaft counterclock-
wise 3 teeth on camshaft pulley. Tighten belt tensioner ad-
justing nut to specification. See TORQUE SPECIFICA-
TIONS.
Rotate crankshaft so that crankshaft and camshaft pulleys
are at TDC position. Ensure camshaft UP mark is facing
up. If they are not, timing belt will have to be repositioned.
Remove crankshaft pulley and lower cover. Set timing belt
drive pulley to TDC position.
Lock camshaft timing belt adjuster arm in place by install-
ing a 6x10 mm timing cover bolt. Loosen belt tensioner
adjusting nut about 1 turn. See Fig. 3. Verify balancer belt
tensioner pulley moves freely. Push balancer belt tensioner
up then retighten belt tensioner adjusting nut.
Remove sealing bolt from maintenance hole on side of
engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from
end of of 6x100 mm bolt. Install 6x100 mm bolt into sealing
bolt hole to lock balancer shaft in place.
284
Align front balancer shaft pulley groove with pointer on oil
pump housing. See Fig. 8. Install balancer belt. Loosen
tensioner adjusting nut about 1 turn to tension balancer
shaft belt. Remove 6x100 mm bolt from rear of balancer
shaft. Install sealing bolt with new washer.
Temporarily install crankshaft pulley and bolt. Turn crank-
shaft pulley about 1 turn counterclockwise, then tighten
tensioner adjusting nut. Remove the 6x10 mm bolt that
locked camshaft timing belt adjuster arm in place.
Remove crankshaft pulley. Install lower cover with new gas-
ket or liquid gasket. Install rubber seal around belt
tensioner adjusting nut. DO NOT loosen nut. Install crank-
shaft pulley. Lubricate crankshaft pulley bolt and underside
of bolt shoulder. Install and tighten crankshaft pulley bolt to
specification.
Install dipstick tube with new O ring. When installing cyl-
inder head cover gasket, apply liquid gasket (Part No. 08718-
0001 or -0003) to 4 corners where gasket meets cam-
shafts.
Install alternator and harness. Install accessory drive belts.
Install engine mount bracket to engine and frame. Connect
negative battery cable. Adjust drive belts to proper tension.
Alternator Adjusting Lock Nut ......................................... 16 (22)
Engine Block Sealing Bolt .............................................. 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt
Accord .......................................................................... 40 (54)
Engine Side Mount Through-Bolt
Odyssey ....................................................................... 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt
Odyssey ....................................................................... 47 (64)
Timing Belt Tensioner Adjusting Nut .......................... 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ........................................... 86 (9.8)
Dipstick Tube Bolt ........................................................ 106 (12)
Water Pump Bolts ........................................................ 106 (12)
HONDA
Fig. 7: Locking Balancer Shaft In Place
Fig. 8: Aligning Balancer Belt Drive Pulley
285
HONDA
*2.6L 4-Cylinder
1
Part No.
2.6L 4-Cyl.
Passport
1994-96
M/T .................... 1.6 Hours ................ 250147
A/T ..................... 1.9 Hours ................ 250147
1
60,000 miles.
TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
Removal:
Disconnect negative battery cable. Remove all necessary
air ducts. Position No. 1 cylinder at TDC of compression
stroke. Align timing marks. See Fig. 3. Remove fan and fan
shroud. Remove accessory drive belts. Remove water pump
pulley. If necessary, remove radiator and splash guard.
Prevent engine from rotating and remove crankshaft timing
pulley. Remove upper and lower timing belt covers. See
Fig. 2. Remove spring from tension pulley. Loosen adjust-
ing bolt and move pulley toward water pump. Remove tim-
ing belt.
CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft
or damage may result.
Inspection:
Handle timing belt carefully. Avoid twisting or kinking belt.
Do not allow belt to become contaminated by water, oil, dirt
or other contaminates. Inspect belt for cracks or damage.
Replace, if necessary.
Measure tensioner pulley spring length and force. Spring
length should not exceed 2.76" (70.2 mm) and spring force
should not be less than 197-343 lbs. (27-48 kg).
Replace tensioner pulley spring if not within specification.
TIMING SPROCKET SPECIFICATIONS
Application Standard Limit
In. (mm) In. (mm)
Camshaft ....................... 5.202 ................................ 5.198
(132.03) ......................... (131.93)
Crankshaft ...................... 2.574 ................................ 2.570
(65.33) ............................. (65.23)
Oil Pump ........................ 4.485 ................................ 4.481
(113.84) ......................... (113.74)
Installation:
Pull tensioner fully toward water pump side and tempo-
rarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC
on compression stroke by rotating crankshaft until keyway
aligns with mark on front crankshaft seal housing (12
oclock).
Rotate camshaft until timing mark on cam gear (arrow) aligns
with mark on upper camshaft cover (notch). See Fig. 1.
Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order.
Ensure belt is positioned in sequence given and without
slack between sprockets. Loosen tensioner pulley adjust-
ing bolt allowing spring tension to tighten belt. Tighten ad-
justing bolt temporarily.
Temporarily install crankshaft pulley bolt and rotate crank-
shaft 2 complete revolutions in opposite direction of en-
gine rotation, until marks on crankshaft and front oil seal
retainer are aligned again. See Fig. 1. Loosen tensioner
lock bolt, allowing tensioner spring to fully adjust tension.
Tighten tensioner lock bolt.
Install timing belt covers. To complete installation, reverse
removal procedures. Tighten all bolts to specification. See
Front Cover ................................................................. 14 (19)
Tensioner Pulley
Bolts ......................................................................... 18 (24)
Nut ............................................................................ 10 (14)
Water Pump Bolt .......................................................... 14 (19)
INCH Lbs. (N.m)
286
HONDA
Fig 3: Installing Belt Guide
287
HONDA
*2.7L V6
1
Belt Part No.
2.7L V6
Accord
1996-97.................. 4.0 Hours .................. 250263
1
1996 vehicles, the manufacturer recommends the belt be re-
placed at 90,000 miles for normal service or 60,000 miles for
severe service.
-20 degrees F).
TIMING BELT
Removal:
Disconnect negative battery cable. Remove front wheels
and splash shield. Support engine with cushioned jack.
Remove 3 bolts attaching side engine mount to engine,
then loosen mount center bolt and pivot mount out of way.
Remove A/C, P/S and alternator belt. Remove dipstick and
pipe. Remove crankshaft pulley. Remove timing belt covers.
See Fig. 2.
Fig. 1: Identifying TDC Marks, Timing Belt Adjusting Bolt
& Installation Sequence
Fig. 2: Identifying Lower & Upper Timing Belt Covers
before removing. Rotate crankshaft clockwise until No. 1
piston is at TDC of compression stroke. See Fig. 1.
Loosen timing belt adjusting bolt 180 degrees and push
tensioner to remove tension from timing belt. Retighten
adjusting bolt and remove timing belt. Inspect camshaft
and crankshaft seals, replace if leaking.
Inspection:
Inspect timing belt for wear or rounded edges of drive teeth.
damaged or contaminated.
Installation:
Clean timing belt covers and ensure No. 1 piston is at TDC
of compression stroke. Ensure crankshaft and camshaft
pulleys are at TDC and install timing belt in sequence
shown. See Fig. 1.
To adjust timing belt, rotate crankshaft clockwise 5-6 revo-
lutions to seat belt and then rotate crankshaft until No. 1
piston is at TDC of compression stroke. Loosen adjusting
bolt 180 degrees then retighten adjusting bolt. See Fig. 1.
tension ranges.
A/C Compressor Bracket Bolt
8 mm Bolts ............................................................... 16 (22)
10 mm Bolts ............................................................. 33 (44)
A/C Idler Pulley Center Nut ......................................... 33 (44)
Alternator Bracket Bolts
8 mm Bolts ............................................................... 16 (22)
10 mm Bolts ............................................................. 33 (44)
Idler Pulley Center Nut ................................................ 33 (44)
INCH Lbs. (N.m)
Dipstick Bracket Bolts .................................................. 84 (9)
Timing Belt Cover Bolts ................................................ 84 (9)
288
3.0L V6 (J30A1)
Accord
1998-01................. 4.7 Hours .................. 250286
3.5L V6 (J35A1)
Odyssey
1999-01.................. 4.0 Hours .................. 250286
HONDA
*3.0L & 3.5L V6
TIMING BELT
Removal:
Disconnect negative battery cable. Turn crankshaft pulley
so that No. 1 piston is at TDC on compression stroke.
White mark on crankshaft pulley should align with pointer
on front cover. Remove lower engine splash shield. Re-
move the generator and power steering pump drive belts.
Remove dipstick tube from front of engine. Support engine
with a jack, and remove engine side mount from front of
engine. Remove crankshaft pulley.
Remove upper and lower timing belt covers. See Fig. 1. If
reusing timing belt, mark direction of belt rotation for instal-
lation reference.
Remove one of the battery clamp bolts from battery tray.
Grind threaded end of bolt to a partial point (about 45 de-
gree chamfer). Thread battery bolt into rear cover to hold
timing belt adjuster in installed position. Hand tighten ONLY.
See Fig. 2.
289
HONDA
*3.0L & 3.5L V6 (Cont.)
Remove side engine mount bracket from front of engine
(above water pump pulley). Loosen timing belt idler pulley
bolt 5-6 turns. Remove timing belt.
Installation:
Ensure that engine is at TDC. Align dimple on timing belt
drive pulley with pointer on oil pump. See Fig. 3. Align cam-
shaft pulleys with pointers on back covers.
CAUTION: Handle auto-tensioner carefully so oil does not spill
or leak out. Replace any oil that may leak out.
Remove battery clamp bolt from back cover. Remove the
timing belt auto-tensioner.
For auto-tensioner with removeable bolt, hold auto-
tensioner with maintenance bolt pointing up. Remove main-
tenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed
vise. DO NOT grip auto-tensioner housing. Insert flat blade
screwdriver into maintenance hole. Place stopper on auto-
tensioner while turning screwdriver clockwise to compress
tensioner to bottom.
Replace any oil that may have spilled out of auto-tensioner.
Reinstall maintenance bolt with NEW gasket. Ensure no
oil is leaking around maintenance bolt, then reinstall auto-
tensioner onto engine with stopper in place.
On 2000-01 models with sealed auto-tensioner, place
tensioner in press. SLOWLY compress tensioner until pin
can be inserted through tensioner body and insert pin. See
Fig. 5. Install auto-tensioner onto engine.
On all models, install timing belt in following sequence:
Crankshaft pulley, idler pulley, front camshaft pulley, water
pump pulley, rear camshaft pulley and tension adjust pul-
ley. See Fig. 6. Ensure crankshaft and camshaft pulleys
remained aligned with marks on back cover. Tighten idler
pulley bolt.
Remove stopper or pin from auto-tensioner. Install engine
side mount bracket to the front of engine (above water pump
pulley). Install upper and lower covers. Install crankshaft
pulley. Lubricate crankshaft pulley bolt threads and install
bolt. Tighten crankshaft pulley bolt to specification. See
Rotate crankshaft about 5-6 turns clockwise to position
timing belt on pulleys. Ensure crankshaft and camshaft
pulleys are aligned at TDC. Crankshaft pulley White mark
should be aligned with pointer on front cover. Remove rub-
ber plugs from upper covers to check camshaft pulley posi-
tions.
If either camshaft is not at TDC, remove timing belt and
readjust position. To complete installation, reverse removal
procedure. Tighten all fasteners to specification. See
Camshaft Sprocket Center Bolt ...................................... 67 (90)
Engine Side Mount Bracket-To-Mount Through-Bolt
Accord & Odyssey ......................................................... 40 (54)
Engine Side Mount-To-Engine Bolts .............................. 33 (44)
Power Steering Pump Lock Nut ..................................... 17 (24)
INCH Lbs. (N.m)
Auto-Tensioner Mount Bolts ......................................... 106 (12)
Lower Engine Splash Shield Bolts ............................... 106 (12)
Water Pump Bolts .................................................... 106 (12)
Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner
290
Fig. 4: Compressing Auto-Tensioner
(Accord; 1999 Odyssey)
HONDA
*3.0L & 3.5L V6 (Cont.)
Fig. 5: Compressing Auto-Tensioner (2000-01 Odyssey)
291
HONDA
3.2L V6 DOHC
3.2L V6
Passport
1998-01.................

2.8 Hours.................. 250303
Normal replacement interval is at 75,000 miles for 1998-99
model years. For 2000-01 model year vehicles, recommended
replacement interval is 105,000 miles.
TIMING BELT
Removal:
drive belt.
Installation:
tensioner rod.
Fig. 5.
are still aligned.
292
Fig. 3: Installing Timing Belt On Right Hand Camshaft
Sprocket
HONDA
3.2L V6 DOHC (Cont.)
Fig. 4: Installing Timing Belt On Left Hand Camshaft
Sprocket
Fig. 5: Installing Locking Pin In Timing Belt Tensioner
nect battery.
M8 Bolt ......................................................................... 16 (22)
M10 Bolt ...................................................................... 34 (46)
Water Pump Bolt ......................................................... 18 (25)
293
1.5L 4-Cyl.
Accent
1995-97................
1
2.2 Hours ................. 250282
1
replaced every 60,000 miles, except in California. In Califor-
nia, timing belt replacement is recommended, but not required
at 60,000 miles.
TIMING BELT
Removal:
move all accessory drive belts. Remove pulleys from crank-
shaft and water pump.
CAUTION: DO NOT rotate engine counterclockwise. If reusing
timing belt, place reference mark on timing belt to indicate direction
of rotation before removal.
Remove timing belt covers and gaskets, noting bolt length
and location. Rotate crankshaft clockwise to align timing
marks on crankshaft and camshaft sprockets. See Fig. 1.
If reusing old belt, place mark on belt to indicate direction of
belt rotation. Loosen timing belt tensioner bolts, and move
tensioner inward toward water pump. Temporarily tighten
bolt in slotted side of tensioner. Remove timing belt.
Inspection:
Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner and idler
pulley for worn bearing.
Installation:
aligned. See Fig. 1. Move timing belt tensioner toward wa-
ter pump and tighten bolt. Install crankshaft sprocket (if
removed) with chamfer (flange) toward engine.
Make sure there is no slack in belt. If reusing old belt, en-
sure belt is installed in original direction of rotation.
Apply counterclockwise force on camshaft sprocket to ap-
ply tension on tension side of belt. Ensure all timing marks
are aligned. See Fig. 1.
CAUTION: Slot-side timing belt tensioner bolt must be tightened
before pivot-side to prevent belt tensioner from rotating, causing
belt to be over tightened.
Loosen timing belt tensioner bolts to place tension on tim-
ing belt. See Fig. 2. Tighten timing belt tensioner bolts to
Smoothly rotate crankshaft clockwise for one full revolu-
tion. Realign crankshaft and camshaft timing marks.
Loosen pivot-side bolt and then slot-side bolt. Tighten slot-
side bolt, and then pivot-side bolt to specification.
To check belt tension, hold belt tensioner and timing belt
together and apply slight thumb pressure at center point of
belt tensioner. This about 11 lbs. See Fig. 2.
Ensure belt cog will reach half the width of timing belt
tensioner bolt on slot-side of belt tensioner. Install crank-
shaft flange. Install timing belt cover. To install remaining
components, reverse removal procedure. Adjust drive belts
to proper tension. See page A-60 for belt tension ranges.
Camshaft Sprocket ......................................... 59-74 (80-100)
Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150)
Crankshaft Sprocket Center Bolt ............... 103-111 (140-150)
Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55)
INCH Lbs. (N.m)
HYUNDAI
Fig. 1: Aligning Tlming Marks Fig. 2: Checking Tlming Belt Tension
Courtesy of Hyundai Motor Co.
294
Belt
1.5L 4-Cyl.
Accent
1995-01..........
1
2.2 Hrs. .... 2521910........ 250191
Excel
1986-89..........
1
2.2 Hrs. ........................... 250073
1990-94..........
1
2.2 Hrs. .... 2521280........ 250128
Scoupe
1991-93..........
1
2.2 Hrs. .... 2521280........ 250128
1994-95..........
1
2.2 Hrs. .... 2521910........ 250191
1
kits.
be replaced every 60,000 miles, except in California. In Cali-
fornia, timing belt replacement is recommended, but not re-
quired at 60,000 miles.
TIMING BELT
Removal:
Remove all accessory drive belts. Remove pulleys from
crankshaft and water pump.
belt rotation. Move tensioner inward toward water pump,
and temporarily tighten bolt in slotted side of tensioner.
Remove timing belt.
Inspection:
separating canvas. Inspect timing belt tensioner for worn
bearing.
Installation:
ter pump and tighten bolt.
HYUNDAI
Fig. 3: Locating Camshaft & Crankshaft Sprocket Marks
295
HYUNDAI
tion. Realign crankshaft and camshaft timing marks. Loosen
pivot-side bolt and then slot-side bolt. Tighten slot-side
bolt, and then pivot-side bolt to specification.
belt tensioner. This is about 11 lbs. (4.98 kg). See Fig. 2.
tensioner bolt on slot-side of belt tensioner. Install timing
belt cover. To install remaining components, reverse re-
INCH Lbs. (N.m)
Water Pump Pulley Bolt ............................... 106-133 (12-15)
296
1.6L 4-Cyl.
Accent
2001.....................
1
2.0 Hours ................. 250282
1
1
- With Pwr. Strg. add .2 hours.
inspected every 30,000 miles. Manufacturer recommends the
belt be replaced every 60,000 miles, except in California. In
California, timing belt replacement is recommended, but not
required at 60,000 miles.
TIMING BELT
Removal:
move all accessory drive belts. Remove pulleys from crank-
shaft and water pump.
belt rotation. Loosen timing belt tensioner bolts, and move
bolt in slotted side of tensioner. Remove timing belt.
Inspection:
pulley for worn bearing.
Installation:
ter pump and tighten bolt. Install crankshaft sprocket (if
removed) with chamfer (flange) toward engine.
tion. Realign crankshaft and camshaft timing marks.
Loosen pivot-side bolt and then slot-side bolt. Tighten slot-
side bolt, and then pivot-side bolt to specification.
belt tensioner. This about 11 lbs. See Fig. 2.
tensioner bolt on slot-side of belt tensioner. Install crank-
shaft flange. Install timing belt cover. To install remaining
components, reverse removal procedure. Adjust drive belts
Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150)
Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55)
INCH Lbs. (N.m)
HYUNDAI
Fig. 1: Aligning Tlming Marks Fig. 2: Checking Tlming Belt Tension
297
Belt
Application Time
2
Kit No. No.
1.6L 4-Cyl. DOHC
Elantra
1992.....................
1
3.0 Hrs. ..................... 250165
1993-95
Balance Shaft ........................................ 250168
1
3.0 Hrs. ..................... 250165
1.8L 4-Cyl. DOHC
Elantra
1993-95
Balance Shaft ...................... 2521670 ... 250168
1
3.0 Hrs. ... 2521670 ... 250167
1
2
labor time.
kits.
SCHEDULED MAINTENANCE SCHEDULE
60,000 miles.
TIMING BELT
Removal:
Remove cover from under engine (if equipped). Support
engine weight with floor jack. Remove engine mount lo-
cated near timing belt cover. Remove all accessory drive
belts. Remove water pump pulley and crankshaft pulley.
and locations.
Rotate engine clockwise to align all timing marks so No. 1
cylinder is at TDC of compression stroke. See Fig. 7. Re-
move automatic tensioner. Place mark on timing belt to
indicate direction of belt rotation. Remove timing belt.
On models equipped with balance shaft, remove outer
crankshaft sprocket. Align oil pump sprocket timing mark
with mark on oil pump case. See Fig. 7.
CAUTION: Leave screwdriver inserted in block until timing belt
is installed. This will lock left side balance shaft in correct position.
HYUNDAI
*1.6L & 1.8L 4-Cylinder DOHC
Remove plug at left side of cylinder block. See Fig. 6. Insert
screwdriver to hold left balance shaft in place. Screwdriver
should insert at least 2.4 (60 mm) into hole. If not, rotate oil
pump sprocket one full turn and align timing mark. Ensure
screwdriver inserts correct amount.
Loosen balance belt tensioner bolt. Remove balance belt.
Inspection:
Check end of automatic tensioner rod for wear. Measure
distance from end of automatic tensioner rod to top of auto-
matic tensioner housing. Distance should be .47" (12 mm).
If out of specification, replace automatic tensioner.
Compressing Automatic Tensioner:
Check if plug at bottom of tensioner protrudes past
tensioner housing. If plug protrudes past housing, place a
washer over plug to prevent plug from contacting vise when
pushing rod into tensioner housing. Place tensioner as-
sembly in a soft-faced vise.
SLOWLY squeeze rod back into automatic tensioner. Re-
place tensioner if rod can be retracted easily into automatic
tensioner. Align holes in rod and automatic tensioner body.
See Fig. 3. Insert drill bit or pin through holes to retain rod in
retracted position.
NOTE: If right (viewed from rear of engine) balance shaft sprocket
was removed, ensure right balance shaft spacer is installed with
chamfer toward engine. Before installation, apply light coat
of engine oil to spacer.
Installation (Balance Shaft Belt):
Ensure crankshaft sprocket and right side balance shaft
sprocket timing marks are aligned with marks on oil pump
housing. See Fig. 1. Install balance shaft belt. If removed,
install balance shaft tensioner pulley and center bolt.
Install balance shaft belt (timing belt B). No slack should
be present in belt. Lift tensioner toward belt so that large
part of center eccentric is to the left and above the center
bolt. See Fig. 2.
While tightening balance shaft tensioner center bolt, en-
sure tensioner and sprockets DO NOT rotate. Ensure tim-
ing marks are still aligned. Check belt tension by applying
finger pressure to side of belt opposite tensioner. See Fig.
2. Deflection should be .20-.28" (5-7 mm). If not, readjust
belt tension.
Install crankshaft flange and outer sprocket. Install flange
in correct direction to prevent damage to timing belt. See
Fig. 5.
Fig. 1: Aligning Crankshaft & Balance Shaft Sprockets
298
Fig. 3: Retracting Automatic Tensioner Rod
Fig. 4: Installing Flange & Crankshaft Sprocket
(Engines Without Balance Shaft Belt)
HYUNDAI
*1.6L & 1.8L 4-Cylinder DOHC (Cont.)
Fig. 9: Removing Timing Belt Automatic Tensioner Lock
Wire
Fig. 8: Installing Tensioner Pulley
Fig. 2: Balance Shaft Tension Pulley Alignment
Fig. 5: Installing Flange & Crankshaft Sprocket
(Engines With Balance Shaft Belt)
299
Rotate camshaft sprockets so dowel pins face up and tim-
ing marks on sprockets align. See Fig. 7. Inner marks on
sprockets should be aligned with cylinder head surface.
will rotate one tooth in counterclockwise direction. When
installing timing belt, compensate for rotation.
Rotate crankshaft and align timing marks on crankshaft
and oil pump sprockets. If installing old timing belt, ensure
it is installed in original direction of rotation.
Install timing belt on tensioner pulley and crankshaft
sprocket. Hold belt in place using left hand. Pull belt around
oil pump sprocket using right hand. Pull belt around idler
pulley.
HYUNDAI
Fig. 10: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)
Installation (Camshaft Timing Belt):
If crankshaft sprocket was removed, ensure sprocket,
spacer and flange are installed correctly. See Fig. 4.
Remove automatic tensioner from vise, and install onto
engine with wire in place. Install tensioner arm. Position
tensioner pulley so that pin holes are left of center bolt. See
Fig. 8. Temporarily tighten camshaft tension pulley center
bolt.
CAUTION: The same camshaft sprocket is used on intake and
exhaust camshafts. Each has two timing marks. Both camshaft
sprockets are positioned correctly when the center dowel pin
holes face up (12 oclock position).
300
HYUNDAI
Fig. 12: Adjusting Camshaft Belt Tension
Install timing belt around intake camshaft sprocket. En-
sure exhaust timing mark on camshaft sprocket aligns with
cylinder head surface. See Fig. 7. Using both hands, install
timing belt around exhaust camshaft sprocket.
Rotate tensioner pulley in toward timing belt until belt does
not sag. Temporarily tighten center bolt on tensioner pulley.
Ensure all timing marks are still aligned.
To adjust camshaft belt tension, rotate crankshaft 1/4 turn
counterclockwise, and then rotate until No.1 cylinder is at
TDC. Loosen center bolt on camshaft belt tensioner pulley.
Install Socket Wrench (MD998752) into pin holes offset to
left center of pulley. See Fig. 12. Using INCH lb. torque
wrench and socket wrench, apply a clockwise torque of 23-
25 INCH Ibs. (2.6-2.8 N.m) on tensioner pulley. With torque
applied to tensioner pulley, tighten tensioner pulley center
bolt to 31-40 ft. Ibs. (42-54 N.m). DO NOT allow pulley to
rotate while tightening center bolt.
NOTE: If engine is in vehicle, it may be necessary during tensioner
pulley adjustment to jack up engine slightly for clearance.
Install Set Screw (09244-28000) or equivalent, in left en-
gine support bracket until screw end contacts tensioner
arm. See Fig. 9. Turn set screw further until wire can be
removed from automatic tensioner. Remove set screw.
Rotate crankshaft clockwise 2 complete revolutions, and
leave in this position for approximately 15 minutes. After 15
minutes, measure distance between bottom of tensioner
arm and top of automatic tensioner body (automatic
tensioner rod extension). Distance should be .15-.18" (3.8-
4.5 mm). See Fig. 13, Dimension A. Repeat timing belt
tensioning procedure until correct distance is obtained. If
correct distance can be measured, go to last step. If correct
distance CANNOT be measured, go to next step.
If engine is in vehicle or distance cannot be measured due
to lack of clearance, an alternate method can be used.
Install Set Screw (09244-28000) until it contacts tensioner
arm.
Turn set screw inward, counting number of turns until
tensioner arm contacts automatic tensioner housing. Set
screw should rotate 2 1/2 - 3 turns inward if belt tension is
correct. Repeat timing belt tensioning procedure until cor-
rect distance is obtained. Remove set screw.
Install rubber plug in rear timing belt cover. To complete
installation, reverse removal procedure. Ensure timing belt
cover bolts are installed in proper location. See Fig. 11.
tension ranges.
Camshaft Sprocket Bolt .................................. 58-72 (80-100)
Crankshaft Sprocket Center Bolt ................... 80-94 (110-130)
Front Cover Bolt
8 x 30 mm Bolt ................................................ 20-26 (27-35)
Except 8 x 30 mm Bolt .................................... 14-20 (19-27)
Timing Belt Cover
Left Lower Rear .............................................. 22-30 (30-42)
Except Left Lower Rear ......................................................
1
1
- Tighten to 89-106 INCH lbs. (10-12 N.m).
Fig. 13: Measuring Timing Belt Tensioner Protrusion
301
1.8L 4-Cyl. DOHC
Elantra
1996-98................
1
2.4 Hours ................. 250278
Tiburon
1997.....................
1
2.4 Hours ................. 250278
2.0L 4-Cyl. DOHC
Elantra
1999-01................
1
2.4 Hours ................. 250284
Tiburon
1997-01................
1
2.4 Hours ................. 250284
1
The manufacturer requires that the belt be replaced every
miles.
TIMING BELT
Removal:
Remove all drive belts and drive pulleys from crankshaft
and water pump. Remove crankshaft pulley and water pump
pulleys.
and locations. DO NOT rotate engine counterclockwise, as
viewed from timing belt side of engine.
Rotate engine clockwise to align all timing marks so No. 1
cylinder is at TDC of compression stroke. See Fig. 1. Move
timing belt tensioner out of way to relieve belt tension. If
reusing belt, place mark on timing belt to indicate direction
of belt rotation. Remove timing belt.
Inspection:
Check belt teeth for cracks, damage, and oil contamina-
tion. Inspect all sprockets for damage. Check tensioner
pulley and idler pulley for grease leakage and worn bear-
ings. Replace components if damaged.
Installation:
aligned. Outer marks on sprockets should be aligned with
rocker cover surface. Install timing belt. If reusing old belt,
ensure belt is installed in original direction of rotation.
Loosen timing belt tensioner bolt, allowing tensioner pul-
ley to contact belt. Tighten timing belt tensioner pulley bolt.
Rotate crankshaft one turn clockwise. Realign camshaft
and crankshaft timing marks.
HYUNDAI
*1.8L & 2.0L 4-Cylinder Elantra & Tiburon
Camshaft Sprocket Bolt ............................... 77-89 (100-120)
Timing Belt Idler Bolt .......................................... 31-41 (43-55)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ............................................ 71-86 (8-10)
Adjust timing belt tension until .15-.24 (4-6 mm) deflection
is present midway between idler pulley and camshaft
sprocket, with a force of 4.4 lbs. (2 kg) applied to belt.
Rotate engine clockwise 2 revolutions. Ensure timing marks
are still aligned and proper belt tension still exists. Install
timing belt covers. Install crankshaft pulley. To complete
installation, reverse removal procedure.
Adjust drive belt tension. See page A-60 for belt tension
ranges.
TIMING BELT NOISE: FRONT CASE
Description: Some 1999-00 Elantras and Tiburons produced
before Sept. 22, 1999, may exhibit an unusual noise at the
front of the engine. The noise may be caused by the timing
belt rubbing against the front of the engine.
Some timing belt idler pulley mounting surfaces were ma-
chined incorrectly. This can cause the timing belt to ride off of
the timing belt sprockets and into the front cover.
Service Procedure: If this condition exists, the forward edge
of the timing belt will shredded and the inside of the upper
timing belt cover will be worn. Replace the front case, idler
pulley, timing belt and any other damaged components.
NOTE: This information is from the Hyundai technical service
bulletin 00-20-002-1; May, 2000.
302
Belt
2.0L 4-Cyl. DOHC
Sonata
1992-98
Balance Shaft ................. 2521670........... T168
Camshaft .....
1
3.8 Hrs. .... 2521670........... T167
1
labor time. With Air Cond. add .4 hours.
kits.
miles.
TIMING BELT
Removal:
Remove all drive belts. Remove crankshaft pulley and wa-
ter pump pulley. Remove upper and lower timing belt cov-
ers, noting bolt lengths and locations.
Turn crankshaft clockwise and align timing marks so No. 1
cylinder is at TDC. Timing marks on camshaft sprockets
should be aligned at upper surface of cylinder head. See
Fig. 2. Camshaft sprocket dowel pins should face upward.
from timing belt end of engine). If reusing timing belt, mark direction
of belt rotation before removing.
Remove timing belt automatic tensioner. See Fig. 1. Mark
timing belt to indicate original direction of rotation. Remove
timing belt.
Remove balance shaft access plug from cylinder block.
Insert Phillips screwdriver to block left balance shaft. See
Fig. 3. Balance shaft is correctly locked in place if screw-
driver can be inserted at least 2.36 (60 mm). If not, rotate
oil pump sprocket so screwdriver can be inserted to cor-
rect depth.
Loosen balance shaft belt tensioner bolt. Remove front
crankshaft sprocket and flange. Remove balance shaft tim-
ing belt.
Inspection:
Check belt teeth for damage and oil contamination. Inspect
belt is not cracked, separated or showing canvas fiber.
Inspect automatic tensioner for leaks. Check rod end of
automatic tensioner for wear. Measure distance from
tensioner rod end to tensioner housing. Distance should
be .47" (12 mm). If not, replace automatic tensioner.
NOTE: If plug at bottom of tensioner protrudes past tensioner
housing, place a washer over plug to prevent contacting vise
when pushing rod into tensioner housing.
Retract rod into tensioner housing by placing automatic
tensioner assembly in a soft-faced vise. Close vise
SLOWLY to push rod back into tensioner. See Fig. 4.
Replace automatic tensioner assembly if rod can be easily
pushed into automatic tensioner. While automatic tensioner
is in vise, align holes in end of tensioner rod and housing.
Install pin through holes to lock tensioner in position.
Installation:
Align timing marks on balance shaft sprockets with timing
marks on engine case. See Fig. 5. Install balance shaft
timing belt and crankshaft flange. Install crankshaft flange
in correct direction. See Fig. 6.
Position balance shaft tensioner so that the center of the
pulley is to the left and above the tensioner bolt. See Fig.
5. Hold tensioner tightly against belt. Tighten tensioner
pulley bolt without letting tensioner rotate.
To check balance shaft belt tension, depress belt with fin-
ger midway between sprockets (opposite tensioner pul-
ley). Deflection should be between .20-.29 (57 mm). If not,
readjust belt tension.
Place crankshaft sprocket on crankshaft. Tighten bolt to
Ensure screwdriver is still installed through left side of cyl-
inder block to hold balance shaft in place. Install automatic
tensioner on engine block with rod locked in place.
Rotate camshaft sprockets so dowel pins face upward and
timing marks on sprockets align. See Fig. 2. Outer marks
on sprockets should be aligned with cylinder head surface.
NOTE: The same camshaft sprockets are installed on intake and
exhaust camshafts. Timing marks are correctly aligned when
dowel pin holes are facing straight up.
HYUNDAI
*2.0L 4-Cylinder Sonata
303
HYUNDAI
*2.0L 4-Cylinder Sonata (Cont.)
Fig. 3: Locking Balance Shaft In Place
Fig. 5: Aligning Balance Shaft Timing Marks
Fig. 6: Installing Crankshaft Flange
Fig. 7: Tensioning Camshaft Timing Belt
304
HYUNDAI
*2.0L 4-Cylinder Sonata (Cont.)
Fig. 8: Adjusting Timing Belt Tensioner Pulley
Align crankshaft sprocket timing marks and oil pump
sprocket timing marks. See Fig. 2. Install timing belt around
tensioner pulley and crankshaft sprocket. Hold timing belt
on tensioner pulley using left hand. Pulling belt with right
hand, install belt around oil pump sprocket.
Install belt around idler pulley. Align timing mark on ex-
haust camshaft sprocket with top of cylinder head. Pulling
belt with both hands, install it around exhaust camshaft
sprocket.
Gently raise tensioner pulley so belt does not sag. Position
timing belt tensioner pin holes so that they face up. Tempo-
rarily tighten center bolt. See Fig. 7.
clockwise, and then rotate clockwise until No. 1 cylinder is
at TDC. Ensure all timing marks are aligned.
Loosen center bolt on tensioner pulley. Note location of pin
holes in tensioner pulley.
Using INCH lb. torque wrench and Socket Wrench (09224-
28100), apply a torque of 22-24 INCH Ibs. (2.6-2.8 N.m) on
tensioner pulley. With torque applied to tensioner pulley,
tighten tensioner pulley center bolt to specification. See
Fig. 8.
Install Set Screw (09244-28000) or equivalent, in left en-
gine support bracket until set screw end contacts tensioner
arm. Rotate set screw further until locking pin can be re-
moved from automatic tensioner. See Fig. 7. Remove set
screw.
Rotate crankshaft clockwise 2 complete revolutions. Allow
engine to sit in this position for about 15 minutes. Measure
distance between tensioner arm and automatic tensioner
body. Distance should be .15-.18" (3.8-4.5 mm). See Fig.
10, Dimension A. If distance is incorrect, repeat Timing
belt tensioning procedure. If distance is okay, go to next to
last step.
If distance between automatic tensioner and tensioner arm
cannot be measured easily, use this alternate method. In-
stall Set Screw (09244-28000) until it contacts tensioner
arm.
Rotate set screw inward while counting number of turns
until tensioner arm contacts automatic tensioner housing.
Turn set screw 2 1/2 -3 turns to correctly tension belt. Re-
move set screw.
Install rubber plug in rear timing belt cover. Install timing
belt covers. Install timing belt cover bolts in correct loca-
tions. See Fig. 9.
sealant to contact areas on semi-circular packing and rocker
cover before installing. Ensure correct bolts are installed in
proper location in timing belt covers. Adjust drive belts to
Balance Shaft Sprocket Bolt ............................. 32-36 (43-49)
Balance Shaft Tensioner Retaining Bolt .......... 11 -16 (15-22)
Crankshaft Sprocket Center Bolt ................... 81-96 (110-130)
Front Tensioner Pulley Bolt ............................... 32-41 (43-55)
Oil Pump Sprocket Nut ..................................... 37-44 (50-60)
Water Pump Mounting Bolt ................................... 9-11 (12-15)
INCH Lbs. (N.m)
Fig. 10: Measuring Automatic Tensioner Protrusion
305
HYUNDAI
*2.4L 4-Cylinder
Belt
2.4L 4-Cyl.
Sonata
1989-91
Balance Shaft ....
1
.............. 2521240..... 250159
Camshaft ............ 2.7 Hrs. .. 2521240..... 250124
1
- Balance Shaft Belt included in Camshaft Belt
labor time.
kits.
60,000 miles.
TIMING BELTS
Removal:
Disconnect negative battery cable. Remove all drive belts
and crankshaft pulley. Remove upper timing belt cover and
gasket. Remove timing belt lower cover and gasket, noting
bolt lengths and locations.
Remove crankshaft sprocket bolt access cover. Remove
crankshaft sprocket bolt and washer. Rotate engine clock-
on cylinder head. See Fig. 1. Loosen front timing belt
tensioner adjustment bolt, and move tensioner toward water
pump.
Tighten bolt to secure tensioner. Remove front timing belt.
Remove camshaft sprocket. Remove oil pump sprocket
access plug from cylinder block. Insert 8 mm Phillips screw-
driver to block left silent (counterbalance) shaft. See Fig. 3.
Remove oil pump sprocket nut to remove sprocket.
Remove front crankshaft sprocket and flange. Remove rear
timing belt tensioner assembly. Remove rear timing belt.
Remove right silent shaft sprocket with spacer. Remove
rear crankshaft sprocket with key and inner cover.
Inspection:
Check belt teeth for cracks, damage or oil contamination. Inspect
all sprockets for damage. Check belt tensioner for damage. Check
belt tensioner for signs of grease leakage or roughness in
tensioner rotation. Replace components if damaged.
Installation:
Install rear timing belt gear on crankshaft. Install spacer to
right silent shaft with chamfer of spacer facing toward engine
block. Properly install flange on crankshaft. Install rear belt
and align rear belt marks. See Fig. 5. Install crankshaft gear,
camshaft timing belt, washer and bolt. Align timing marks.
See Fig. 1.
Install rear tensioner. Hold tensioner tight against belt while
tightening bolts. Depress belt with finger to ensure deflec-
tion is between .20-30 (5-7 mm). Install camshaft and oil
pump sprocket (if removed). Tighten camshaft sprocket
retaining bolt to specification while holding hexagon area
of camshaft.
Install belt tensioner, tension spring and spacer. Ensure
spring is properly engaged against front case. Rotate
tensioner toward water pump and temporarily tighten re-
taining bolts. Ensure camshaft and crankshaft timing marks
are aligned. See Fig. 1. Install timing belt on crankshaft.
Apply pressure on tension side of belt while installing
belt on camshaft sprocket. Loosen tensioner to allow
spring pressure to timing belt. Rotate camshaft sprocket
clockwise until timing mark is offset by 2 teeth to apply
tension on belt. Ensure all timing marks are aligned.
Tighten tensioner bolt.
Tighten tensioner spacer. To check belt tension, apply slight
thumb pressure to measure deflection between camshaft
and oil pump sprocket. Belt deflection should be .55 (14 mm).
To install remaining components, reverse removal procedure.
Adjust drive belts to proper tension. See page A-60 for belt tension
ranges.
INCH Lbs. (N.m)
Crank Angle Sensor Nut ................................... 84-108 (9-12)
Left Lower Rear Cover Bolt ................................. 44-61 (5-7)
All Exc. Left Lower Rear Cover Bolt ................. 84-108 (9-12)
Fig. 1: Aligning Front Timing Belt Marks
306
HYUNDAI
Fig. 3: Blocking Left Silent Shaft
Fig. 4: Positioning Timing Belt Crankshaft Flange
307
HYUNDAI
Fig. 5: Aligning Rear Timing Belt Marks
308
HYUNDAI
*3.0L V6
Belt
3.0L V6
Sonata
1990-98..........
1
3.1 Hrs. .... 2521390........ 250139
1
kits.
The manufacturer requires the belt be replaced every 60,000
miles, except for 1998 California vehicles. For 1998 California
vehicles, timing belt replacement is recommended, but not
required at 60,000 miles.
TIMING BELT
Removal:
Support engine oil pan with jack and block of wood. Re-
move all drive belts. Remove power steering pump with
hoses connected and set aside. Remove engine mount on
timing belt end of engine. Remove engine support bracket
bolts in sequence. Slowly remove reamer bolt. See Fig. 1.
NOTE: Reamer bolt may sometimes become seized on engine support
bracket. Remove reamer bolt carefully without damaging threads.
Fig. 1: Engine Support Bolt Loosening & Tightening
Sequence
Ensure engine is on No. 1 cylinder compression stroke
and timing marks are aligned. Remove crankshaft pulley
and timing belt covers.
Rotate crankshaft clockwise to align camshaft and crank-
shaft timing marks. See Fig. 3. Loosen timing belt tensioner
bolt and pivot tensioner counterclockwise. Lock tensioner
in retracted position. If reusing timing belt, mark rotation
direction on belt. Remove timing belt.
Inspection
separating canvas. Inspect timing belt tensioner for worn
bearing.
Installation:
Align camshaft and crankshaft timing marks. See Fig. 3. If
tensioner spring has been removed, install spring on
tensioner so hook faces away from engine block.
Route timing belt on crankshaft sprocket and then onto
rear camshaft sprocket. Run timing belt under water pump
pulley, over front camshaft sprocket and then over tensioner
pulley.
Apply force counterclockwise to rear camshaft sprocket,
applying tension to right side of belt. Ensure timing marks
are aligned.
Loosen tensioner bolt allowing tensioner to take up slack
in left side of timing belt. Tighten tensioner bolt. Rotate
crankshaft 2 turns clockwise.
Realign timing marks. Measure timing belt tension using
belt tension gauge midway between crankshaft and cam-
shaft sprockets, on side opposite tensioner. For new belt,
tension should be 57-84 lbs. (26-38 kg).
Install flange on crankshaft sprocket with flat side facing
timing belt. Install front timing belt cover. Install crankshaft
pulley and tighten bolt to specification.
Install engine support bolts and tighten in sequence. See
Fig. 1. To complete installation, reverse removal proce-
dure. Tighten nuts and bolts to specification. See TORQUE
Water Pump Bolt
Headmark 4 Bolt ............................................... 9-11 (12-15)
Headmark 7 Bolt ............................................. 15-20 (20-27)
INCH Lbs. (N.m)
309
HYUNDAI
*3.0L V6 (Cont.)
310
INFINITI
*3.0L V6 J30
Installation:
Ensure crankshaft sprocket, camshaft sprockets, idler pul-
leys and timing belt are dry and clean. Ensure No. 1 cylin-
der is at TDC of compression stroke and all timing marks
are still aligned. See Fig. 2. Remove all spark plugs. Install
timing belt with White marks on timing belt aligned with
timing mark on crankshaft sprocket and camshaft sprock-
ets. Ensure arrow on timing belt points toward front of en-
gine.
CAUTION: Timing belt must be installed so White marks on timing
belt align with timing mark on crankshaft sprocket and camshaft
sprockets. Arrow on timing belt must point toward front of engine.
DO NOT bend or twist timing belt during installation.
CAUTION: Ensure stopper bolt is removed before adjusting clearance
on automatic tensioner or stopper bolt and automatic tensioner
may be damaged.
Remove stopper bolt from automatic tensioner. Using vise,
adjust tensioner arm on automatic tensioner so .16" (4.0 mm)
clearance exists between pusher and tensioner arm. See
Fig. 4. Once correct clearance is obtained, reinstall stopper
bolt. Install automatic tensioner on cylinder block with bolts
finger tight.
Slightly push automatic tensioner inward against timing
belt to prevent timing belt from slipping. DO NOT push to
hard or timing belt will be adjusted too tight. Rotate crank-
shaft 10 degrees clockwise. Tighten automatic tensioner
retaining nut and then the bolts to specification in sequence.
See Fig. 4. See TORQUE SPECIFICATIONS.
Rotate crankshaft 120 degrees counterclockwise. Loosen
automatic tensioner retaining bolts and nut 1/2 turn. Rotate
automatic tensioner back as far as possible. Rotate crank-
shaft clockwise until No. 1 cylinder is at TDC on compres-
sion stroke and all timing marks are aligned. See Fig. 5.
Using Push-Pull Gauge (J-38387) or equivalent and Hook
(KV10112000) or equivalent, push end of pusher on auto-
matic tensioner inward against timing belt with a force of
13.2 lbs. (6 kg). See Fig. 6. Tighten automatic tensioner
retaining nut and then the bolts to specification in sequence.
See Fig. 4. See TORQUE SPECIFICATIONS.
3.0L V6
J30
1993....................... 4.4 Hours ................ 250180
1994-97.................. 4.4 Hours ................ 250251
60,000 miles.
TIMING BELT
Removal:
hicle. Remove lower engine cover. Drain radiator and cylin-
der block. Remove air intake ducts, radiator, drive belts,
cooling fan assembly and starter. Remove crankshaft pul-
ley bolt. Using puller, remove crankshaft pulley. Remove
coolant inlet and outlets for access to timing belt cover.
NOTE: Crankshaft position sensor is mounted on front of exhaust
camshaft on driver side. Crankshaft position sensor removal
may be required for timing belt cover removal. Mark location
of crankshaft position sensor before removing to ensure proper
installation during reassembly.
Install a 6x16 mm stopper bolt on automatic tensioner to
prevent tensioner from pushing outward. See Fig. 1. Ro-
tate engine so No. 1 cylinder is at TDC on compression
stroke. No. 1 cylinder is front cylinder on right side when
viewed from rear of engine. Ensure timing marks on cam-
shaft sprockets and crankshaft sprocket are aligned. See
Fig. 2. Remove bolts and automatic tensioner. Remove
timing belt. DO NOT rotate crankshaft or camshafts with
timing belt removed or engine damage may result.
Inspection:
Inspect timing belt for cracks, worn teeth or oil contamina-
tion. Inspect crankshaft sprocket and camshaft sprockets
for damaged teeth. Inspect automatic tensioner for signs
of oil leakage around the shaft that pushes the pulley out-
ward. Check all idler pulleys for smooth rotation. Replace
components if damaged.
Fig. 1: Installing Stopper Bolt On Automatic Tensioner
311
INFINITI
*3.0L V6 J30 (Cont.)
Courtesy of Nissan Motor Co., U.S.A.
Rotate crankshaft clockwise 120 degrees clockwise from
No. 1 cylinder TDC position. Rotate crankshaft counter-
clockwise 120 degrees back to No. 1 cylinder TDC posi-
tion. Fabricate belt tension plate to proper specification.
See Fig. 7. Using belt tension plate and push-pull gauge,
check timing belt deflection at mid-way distance between
sprockets and idler pulleys using 11 Ibs. (5 kg) force. See
Fig. 7. Timing belt deflection should be .24-.28" (6.0-7.0
mm).
If timing belt deflection is not within specification, repeat
previous four steps until proper timing belt deflection is
obtained. Ensure automatic tensioner retaining nut and
bolts are tightened to specification. See TORQUE SPECI-
FI CATI ONS. Remove st opper bol t f rom aut omat i c
tensioner.
Fig. 4: Adjusting Automatic Tensioner Clearance &
Identifying Bolt/Nut Tightening Sequence
312
INFINITI
*3.0L V6 J30 (Cont.)
Fig. 6: Adjusting Automatic Timing Belt Tensioner
Fig. 7: Fabricating Belt Tension Plate & Checking
Timing Belt Deflection
NOTE: If timing belt deflection does not meet specification, it
may be necessary to apply more or less tension against the pusher
on automatic belt tensioner in previous step.
After 5 minutes, ensure clearance between tensioner arm
and pusher on automatic tensioner is .138-.205" (3.50-
5.20 mm). Ensure timing belt will not slip at any point on
camshaft sprockets and crankshaft sprocket.
dure. Tighten all fasteners to specification. See TORQUE
Automatic Tensioner Bolt/Nut ........................... 12-15 (16-20)
Exhaust .......................................................... 11-14 (15-19)
Intake ......................................................... 91-97 (123-132)
Crankshaft Position Sensor Brackets .............. 12-15 (16-20)
Engine Mount-To-Frame Nut ............................ 41-49 (56-66)
Idler Pulley Nut ................................................. 32-43 (45-58)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt .................................. 44 (5)
Rear Cover Bolt .......................................................... 53 (6)
Upper & Lower ........................................................... 27 (3)
Valve Cover Bolt/Screw
Exhaust Camshaft Cover ........................................... 71 (8)
Intake Camshaft Cover ............................................... 27 (3)
313
INFINITI
*3.0L V6 M30
Belt
Application Labor Kit No. No.
3.0L V6
M30
1990-92.......... 4.0 Hours... 2521040........ 250104
kits.
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove lower engine
covers. Drain cooling system. Remove radiator, cooling fan
and accessory drive belts. Remove water pump pulley, spark
plugs and distributor cover. Remove fresh air tube from
rocker arm cover.
Remove A/C drive belt idler bracket. Disconnect coolant
inlet hose from thermostat housing. Remove crankshaft
pulley retaining bolt. Using puller, remove crankshaft pul-
ley. Remove front upper and lower timing belt covers. See
Fig. 2.
Temporarily install crankshaft pulley retaining bolt. Using
crankshaft pulley retaining bolt, rotate crankshaft until No.
1 cylinder is at TDC on compression stroke and all timing
marks are aligned See Fig. 1. Loosen timing belt tensioner
retaining nut. Rotate timing belt tensioner to release timing
belt tension. Remove timing belt.
NOTE: No. 1 cylinder is front cylinder on left when viewed from
front of engine.
belt removed or engine damage may result.
Inspection:
tamination. Ensure timing belt tensioner rotates smoothly.
Inspect tensioner spring for damage. Replace components
if damaged.
Installation:
Ensure No. 1 cylinder is TDC on compression stroke and
all timing marks are aligned. See Fig. 1. Install timing belt
tensioner and tensioner spring (if removed). If tensioner
spring stud was removed from cylinder block, apply thread
sealant to threads before installing.
Rotate timing belt tensioner fully outward (away from tim-
ing belt area) and temporarily tighten retaining nut. Align
White marks on timing belt with timing marks on camshaft
and crankshaft sprocket and install timing belt.
CAUTION: Install timing belt with arrow pointing toward timing
belt cover. With timing belt installed, 40 teeth should be between
timing marks on right and left camshafts and 43 teeth between
timing mark on left camshaft sprocket and timing mark on crankshaft
Using an Allen wrench, hold tension on timing belt tensioner
and loosen retaining nut. Rotate timing belt tensioner clock-
wise 70-80 degrees and tighten retaining nut. Rotate crank-
shaft clockwise 2 full revolutions and realign timing marks
so No. 1 cylinder is at TDC on compression stroke. Apply
22 lbs (10 kg) of pressure on timing belt at midway point
between timing belt tensioner and camshaft sprocket. See
Fig. 2.
Loosen timing belt tensioner retaining nut while maintaining
pressure on timing belt tensioner using an Allen wrench. In-
sert a .0138" (.350 mm) thick and 1/2" wide feeler gauge be-
tween timing belt tensioner and timing belt. Perform first step
of installation. See Fig. 3.
Rotate crankshaft clockwise until feeler gauge is properly
positioned between timing belt and timing belt tensioner.
Perform second step of installation. See Fig. 3. Timing belt
should move approximately 2 1/2 teeth. Maintain steady
pressure on timing belt tenisoner. Tighten timing belt
tensioner retaining nut to specification. See TORQUE
SPECIFICATIONS.
Rotate crankshaft clockwise and remove feeler gauge. Ro-
tate crankshaft clockwise 2 full revolutions and realign tim-
ing marks so No. 1 cylinder is at TDC on compression
stroke. Timing belt deflection should be .51-.59" (13.0-15.0
mm) when applying 22 lbs. (10 kg) pressure on timing belt
at midway poing between camshaft sprockets.
dure. Tighten all bolts and nuts to specification. See
TORQUE SPECIFICATIONS. Fill and bleed cooling system.
tension ranges.
Fig. 1: Aligning Timing Marks & Checking Belt Tension
314
INFINITI
*3.0L V6 M30 (Cont.)
Fig. 3: Checking Timing Belt Clearance
Camshaft Locating Plate Bolt ........................... 58-65 (79-88)
Crossmember-To-Body Bolt ............................. 32-41 (43-56)
Timing Belt Tensioner Nut ................................ 32-43 (43-58)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Rocker Arm Cover Bolt ............................................ 9-27 (1-3)
Timing Belt Cover Bolt .......................................... 27-44 (3-5)
315
ISUZU
1
Belt Part No.
1.6L 4-Cyl. DOHC
I-Mark
1989......................... 2.0 Hours ............... 250169
Impulse
1990-92 Non-Turbo. 2.0 Hours ............... 250169
1991-92 Turbo ....... 2.4 Hours ............... 250169
Stylus
1991......................... 2.0 Hours ............... 250169
1.6L 4-Cyl. SOHC
Stylus
1991-93.................... 3.0 Hours ............... 250177
1.8L 4-Cyl. SOHC
Impulse
1992......................... 2.4 Hours ............... 250205
Stylus
1992-93.................... 2.4 Hours ............... 250205
1
60,000 miles.
*NOTE: The 1991-93 1.6L (SOHC) engine used in
the Stylus is an interference engine. See page A-
59 for interference engine cautions.
TIMING BELT
Removal (DOHC):
belts. Remove upper timing belt cover. See Fig. 1. Support
engine. Remove engine mounting bracket located at tim-
ing belt cover. Rotate crankshaft and position No. 1 cylinder
at TDC of compression stroke. Ensure timing mark on crank-
shaft pulley aligns with 0 timing mark on timing belt cover.
Ensure timing marks on camshaft sprockets are aligned
with cylinder head surface. See Fig. 3. Disconnect front
exhaust pipe. Remove bolts attaching torque rod bracket to
cylinder block. Remove bolt attaching torque rod to vehicle
frame. Remove torque rod and bracket as an assembly.
Remove engine stiffener brace. See Fig. 2. Remove fly-
wheel dust cover. Hold flywheel while removing crankshaft
pulley bolt. Remove crankshaft pulley. Remove lower tim-
ing belt cover.
Ensure timing mark (notch) on crankshaft sprocket aligns
with timing mark on oil pump. See Fig. 3. Loosen tensioner
pulley bolt 1/2 turn. Rotate tensioner pulley clockwise. Mark
timing belt direction of rotation if reusing old belt. Remove
timing belt.
Inspection (DOHC):
tamination. Ensure tensioner pulley and idler pulley rotate
freely. Replace components if damaged.
Installation (DOHC):
Rotate camshafts so timing marks align with cylinder head
surface. Install 6 mm bolts in lock bolt holes to secure
camshafts. Ensure timing mark (notch) on crankshaft
sprocket aligns with timing mark on oil pump. See Fig. 3.
Install timing belt in the following order: over crankshaft
sprocket, water pump, idler pulley, exhaust camshaft, in-
take camshaft and belt tensioner. Ensure no slack exists in
belt.
Loosen bolt and allow tensioner pulley to apply tension on
timing belt. Hold tensioner pulley and tighten tensioner pulley
bolt.
CAUTION: On new timing belts, push tensioner pulley sightly
inward to apply more pressure on timing belt. On used timing
belts, allow only spring tension to be applied to timing belt.
Rotate crankshaft 2 revolutions in direction of engine rota-
tion. Ensure all timing marks align. Rotate crankshaft 60
degrees. Measure timing belt deflection at midpoint be-
tween camshaft sprockets. Ensure timing belt defection is
within specification. See TIMING BELT DEFLECTION
SPECIFICATIONS. If belt deflection is not within specifica-
tion, repeat the last two steps.
CAUTION: Ensure timing marks align after belt adjustment.
FICATIONS. Adjust drive belts to proper tension.
TIMING BELT DEFLECTION SPECIFICATIONS
Application In. (mm)
DOHC
New Belt ..................................................... .28-.33 (7.1-8.4)
Used Belt ................................................. .35-.41 (8.9-10.4)
SOHC
New Or Used Belt ........................................ .63-.79 (16-20)
Removal (SOHC):
Disconnect negative battery cable. Support engine. Remove
right side engine mount. Remove alternator and power steer-
ing pump drive belts. Ensure engine is supported. Remove
engine mounting bracket located at timing belt cover.
Remove crankshaft pulley bolts. Remove crankshaft pulley
from crankshaft pulley hub. Remove timing belt cover. Ro-
tate crankshaft and position No. 4 cylinder at TDC of com-
pression stroke. Ensure timing mark on camshaft pulley
aligns with cylinder head. See Fig. 4 .
Ensure timing mark (notch) on crankshaft sprocket aligns
with timing mark on oil pump. See Fig. 4. Loosen tensioner
pulley bolt. Rotate tensioner pulley to loosen timing belt
tension. Mark timing belt direction of rotation if reusing belt.
Remove timing belt.
Inspection (SOHC):
tamination. Ensure tensioner pulley rotates freely. Replace
components if damaged.
Installation (SOHC):
Rotate camshaft so timing mark aligns with cylinder head
surface. Ensure dowel pin on camshaft pulley is in the up
position. See Fig. 4. Ensure timing mark (notch) on crank-
shaft sprocket aligns with timing mark on oil pump. See
Fig. 4. Install timing belt in the following order: over crank-
shaft sprocket, camshaft pulley, water pump and belt
tensioner.
316
Insert a hex wrench into belt tensioner. Rotate tensioner
pulley counterclockwise to tension belt. Hold tensioner
pulley, and tighten pulley bolt. Rotate crankshaft back to
approximately 50 degrees BTDC and back to TDC for No. 4
cylinder. Ensure all timing marks align. Measure timing
belt deflection. See Fig. 5. Ensure timing belt defection is
within specification. If belt deflection is not within specifica-
tion, repeat thisstep.
CAUTION: Ensure timing marks align after belt adjustment.
DOHC ................................................................... 109 (148)
SOHC ....................................................................... 62 (84)
Left Engine Mount Bolt ................................................ 51 (69)
Right Engine Mount Bolt ........................................... 89 (121)
Right Engine Mount Nut ............................................. 37 (50)
Right Engine Mount Through-Bolt .............................. 51 (69)
Tensioner Pulley Bolt
DOHC ....................................................................... 31 (42)
SOHC ....................................................................... 37 (50)
Water Pump Bolt ........................................................ 17 (23)
Wheel Lug Nut .......................................................... 87 (118)
INCH Lbs. (N.m)
ISUZU
Fig. 1: Routing Timing Belt (DOHC)
Fig. 3: Aligning Timing Marks (DOHC)
Fig. 2: Engine Stiffener Brace
Fig. 4: Aligning Timing Marks (SOHC)
317
ISUZU
Fig. 5: Checking Timing Belt Tension (SOHC)
Fig. 6: Tightening Sequence For Valve Cover Bolts (DOHC)
Fig. 7: Routing Timing Belt (SOHC)
318
ISUZU
Application
1
1.8L 4-Cyl. Diesel
I-Mark
1981-84................. 3.1 Hours .................. 250076
1
60,000 miles.
TIMING BELT & VALVE TIMING
Removal:
cover. Drain engine coolant. Remove fan shroud, fan, drive
belt and pulley. Remove crankshaft pulley. Remove upper
timing belt cover. Remove coolant by-pass hose.
With piston of No. 1 cylinder at TDC of compression stroke,
check that timing marks on injection pump sprocket and
front plate are aligned. Lock sprocket in place by inserting
a bolt through sprocket and into block. See Fig. 1.
Remove air cleaner and PCV valve hose. Remove valve cover.
Loosen adjusting screws on rocker arms to relieve tension
on camshaft. Lock camshaft in place by installing Fixing
Plate (J-29761) or equivalent, in slot at rear of camshaft.
See Fig. 2.
Ensure that No. 1 piston is still at TDC, then remove crank-
shaft pulley. Remove lower timing belt cover. Remove tim-
ing belt holder. See Fig. 3. Remove tension spring located
behind front plate. Loosen tensioner pulley and pivot bolts.
Remove timing belt.
Installation:
Remove camshaft sprocket center bolt. Using Puller (J-29801)
or equivalent, remove camshaft sprocket. Install sprocket on
camshaft. Lightly tighten center bolt so that sprocket can
be turned smoothly by hand. Starting at crankshaft sprocket
and working in a counterclockwise direction, engage new
timing belt over each sprocket and pulley. Check that belt is
properly engaged on all sprockets and pulleys. See Fig. 4.
Take up belt slack at tensioner pulley by depressing pulley
and installing tension spring. Tighten tensioner pulley pivot
bolts just enough to prevent pulley movement. See Fig. 5.
DO NOT tighten pulley center bolt at this time.
Tighten camshaft sprocket bolt. Remove bolt used to lock
injection pump sprocket in place. Remove fixing plate used
to lock camshaft in place. Install crankshaft pulley on hub.
Check that No.1 piston is still at TDC. DO NOT turn crank-
shaft in an attempt to adjust timing mark on pulley. Ensure
that timing marks on injection pump sprocket and front
plate are still aligned.
Check that fixing plate fits smoothly into slot at rear of cam-
shaft, then remove fixing plate. Loosen tensioner pulley
pivot bolts and take up timing belt slack. Tighten tensioner
pulley center bolt, then tighten pivot bolts. Using Tension
Gauge (J-29771) or equivalent, check for 47-64 Ibs. (21-29
kg) tension between camshaft and injection pump sprock-
ets.
Remove crankshaft pulley and install timing belt holder.
Ensure that timing belt holder does not rubagainst timing
belt. Reverse removal procedure to complete installation.
tension ranges.
Crankshaft Pulley ............................................. 11-18 (15-24)
Injection Pump Timing Pulley ........................... 42-52 (57-71)
Tensioner Pulley
Center Bolt ...................................................... 47-64 (64-87)
Pivot Bolt ......................................................... 11-18 (15-24)
Fig. 1: Aligning Injection Pump Timing Marks
Fig. 2: Camshaft Fixing Plate
319
ISUZU
Fig. 5: Location Of Tensioner Pulley
Fig. 3: Location Of Timing Belt Holder
320
ISUZU
*2.0L, 2.3L & 2.6L 4-Cylinder
2.0L 4-Cyl. Turbo
Impulse
1985-89
A/T .....................
1
3.6 Hours ................. 250121
M/T ....................
1
3.4 Hours ................. 250121
2.3L 4-Cyl.
Amigo
1989-93
A/T .....................
1
1.9 Hours ................. 250122
M/T ....................
1
1.6 Hours ................. 250122
Impulse
1988-89
A/T .....................
1
3.6 Hours ................. 250122
M/T ....................
1
3.4 Hours ................. 250122
Pickup
1986-95
A/T .....................
1
1.9 Hours ................. 250122
M/T ....................
1
1.6 Hours ................. 250122
Trooper II
1986-87
A/T .....................
1
1.9 Hours ................. 250122
M/T ....................
1
1.6 Hours ................. 250122
2.6L 4-Cyl.
Amigo
1989-94
A/T .....................
1
1.9 Hours ................. 250147
M/T ....................
1
1.6 Hours ................. 250147
Pickup
1988-95
A/T .....................
1
1.9 Hours ................. 250147
M/T ....................
1
1.6 Hours ................. 250147
Rodeo
1991-97
A/T .....................
1
1.9 Hours ................. 250147
M/T ....................
1
1.6 Hours ................. 250147
Trooper
1990-91
A/T .....................
1
1.9 Hours ................. 250147
M/T ....................
1
1.6 Hours ................. 250147
Trooper II
1988-89
A/T .....................
1
1.9 Hours ................. 250147
M/T ....................
1
1.6 Hours ................. 250147
1
60,000 miles.
TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
Removal:
Disconnect negative battery cable. Remove all necessary
air ducts. Position No. 1 cylinder at TDC of compression
stroke. Align timing marks. See Fig. 1. Remove fan and fan
shroud. Remove accessory drive belts. Remove water pump
pulley. If necessary, remove radiator and splash guard.
Prevent engine from rotating and remove crankshaft timing
pulley. Remove upper and lower timing belt covers. Re-
move spring from tension pulley. Loosen adjusting bolt
and move pulley toward water pump. Remove timing belt.
CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft
or damage may result.
Inspection:
Handle timing belt carefully. Avoid twisting or kinking belt.
DO NOT allow belt to become contaminated by water, oil,
dirt or other contaminates. Inspect belt for cracks or dam-
age. Replace, if necessary.
On 2.0L engines, measure outside diameter of crankshaft,
camshaft and oil pump sprockets. If specifications are ex-
ceeded, replace sprocket(s). See TIMING SPROCKET
SPECIFICATIONS table.
On all engines, measure tension pulley spring length and
force. On 2.3L and 2.6L engine, spring length should not
exceed 2.76" (70.2 mm) and spring force should not be
less than 60-106 lbs. (27-48 kg).
On 2.0L, spring length should not exceed 3.11" (79 mm)
and spring force should not be less than 53-57 lbs. (24-26
kg). On all engines, replace tension pulley spring if not
TIMING SPROCKET SPECIFICATIONS
Application Standard Limit
In. (mm) In. (mm)
Camshaft ....................... 5.202 ................................ 5.198
(132.03) ......................... (131.93)
Crankshaft ...................... 2.574 ................................ 2.570
(65.33) ............................. (65.23)
Oil Pump ........................ 4.485 ................................ 4.481
(113.84) ......................... (113.74)
Installation:
Pull tensioner fully toward water pump side and tempo-
rarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC
on compression stroke by rotating crankshaft until keyway
aligns with mark on front crankshaft seal housing (12
oclock). Rotate camshaft until timing mark on cam gear
(arrow) aligns with mark on upper camshaft cover (notch).
See Fig. 3.
Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order.
Ensure belt is positioned in sequence given and without
slack between sprockets. Loosen tensioner pulley adjust-
ing bolt allowing spring tension to tighten belt. Tighten ad-
justing bolt temporarily.
Temporarily install crankshaft pulley bolt and rotate crank-
shaft 2 complete revolutions in opposite direction of en-
gine rotation, until marks on crankshaft and front oil seal
retainer are aligned again. See Fig. 3. Loosen tensioner
lock bolt, allowing tensioner spring to fully adjust tension.
Tighten tensioner lock bolt.
321
ISUZU
*2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
Install timing belt covers. To complete installation, reverse
removal procedures. Tighten all bolts to specification. See
Front Cover ................................................................. 14 (19)
Tensioner Pulley
Bolts ......................................................................... 18 (24)
Nut ............................................................................ 10 (14)
Water Pump ............................................................... 14 (19)
INCH Lbs. (N.m)
322
Fig. 3: Timing Alignment Marks
Fig. 2: Installing Belt Guide
ISUZU
*2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
323
ISUZU
1
Belt Part No.
2.2L 4-Cyl. Diesel
LUV (Chevrolet)
1981-82................. 2.7 Hours .................. 250075
Pickup (Isuzu)
1983-85................. 2.7 Hours .................. 250075
PUP
1981-87................. 2.7 Hours .................. 250075
S10 & S15 Pickup (Chevrolet/GMC)
1983-85................. 2.7 Hours .................. 250075
Trooper II
1984-87................. 2.7 Hours .................. 250075
1
60,000 miles.
TIMING BELT
Removal:
cover. Drain cooling system. Remove battery. Remove fan,
fan shroud, top radiator hose and drive belts. Remove 4
crankshaft pulley bolts and crankshaft pulley. Remove tim-
ing belt covers. See Fig. 1.
Remove tension spring. See Fig. 2. Position No. 1 cylinder
at TDC of compression stroke. Ensure injection pump and
camshaft sprocket timing marks are aligned. See Fig. 3.
Remove injection pump pulley flange bolts and remove
flange. Remove tensioner spring without using excess force
on spring. Remove tension pulley nut and tensioner as-
sembly. Remove timing belt.
Installation:
Ensure that timing marks on injection pump, camshaft
sprockets, crankshaft pulley and timing pointer are aligned.
See Fig. 4. Install timing belt over crankshaft sprocket, cam-
shaft sprocket and injection pump sprocket.
Install tensioner assembly so that end of tensioner is in
contact with 2 pins on timing pulley housing. See Fig. 5.
Hand tighten nut. Install tension spring. Tighten nut to 22-
36 ft. Ibs. (30-49 N.m). Turn crankshaft 2 complete revolu-
tions in normal direction of rotation, then turn crankshaft 90
degrees past TDC. Loosen tensioner nut completely and
allow tensioner to take up slack. Tighten nut.
Install and tighten injection pump pulley flange. Ensure
hole in flange lines up with triangular timing mark on pump
sprocket. See Fig. 3. Turn crankshaft 2 more turns, bring-
ing No. 1 cylinder to TDC on compression stroke. Check
timing mark alignment. Check timing belt tension with Ten-
sion Gauge (J-29771) or equivalent. Tension should be
33-55 Ibs. (15-25 kg). Reverse removal procedure to com-
plete installation. Adjust drive belts to proper tension. See
Injection Pump Timing Pulley Bolt .................... 42-52 (57-71)
Tension Spring Nut ........................................... 22-36 (30-49)
Timing Belt Tensioner Bolts ........................ 79-94 (107-127)
Fig. 2: Removing Tension Spring
324
Fig. 3: Timing Belt Sprocket Alignment
Fig. 5: Timing Belt Tensioner Installation
Fig. 6: Injection Pump Timing Alignment Marks
ISUZU
325
2.2L 4-Cyl. DOHC
Amigo
1998-00
Auto. Trans. .......
1
1.9 Hours ................. 250305
Man. Trans. .......
1
1.6 Hours ................. 250305
Rodeo
1998-01
Auto. Trans. .......
1
1.9 Hours ................. 250305
Man. Trans. .......
1
1.6 Hours ................. 250305
1
replaced every 75,000 miles. For 1999-00 vehicles, the manu-
facturer recommends the belt be replaced every 100,000 miles
for normal service, or 75,000 miles for severe service.
replaced every 75,000 miles for normal service, or 60,000
miles for severe service.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove serpentine drive
belt. Remove engine wiring harness cover, and disconnect
3 connectors from left rear side of engine compartment.
Remove 4 crankshaft pulley bolts and remove pulley from
crankshaft. It is NOT necessary to remove the crankshaft
center bolt. Remove engine harness cover from front of
engine.
Remove timing belt cover. If reusing old belt, place mark
on belt to indicate direction of belt rotation.
Rotate crankshaft so camshaft and crankshaft timing marks
are aligned. See Fig. 1. Loosen timing belt tensioner pulley
bolt, and move tensioner away from timing belt. Remove
timing belt.
Inspection:
pulley for worn bearings.
Installation:
aligned. See Fig. 1. Place Camshaft Locking Tool (J-43037)
between camshafts to prevent movement.
Install timing belt on engine. If reusing old belt, install belt
in original position. Ensure there is no slack in belt. Loosen
tensioner pulley center bolt. Move timing belt tensioner to-
ward belt.
NOTE: Adjust timing belt tension with engine cold.
To tension timing belt, align timing belt tensioner arrow in
correct position for new or used belt. See Fig. 2. Tighten
timing belt tensioner to specification. See TORQUE SPECI-
FICATIONS.
Remove camshaft locking tool. Turn crankshaft 2 turns in
normal direction of rotation until No. 1 cylinder is at TDC.
Check alignment of timing belt tensioner pointer. If marks
do NOT align, repeat timing belt tensioning procedure.
Install timing belt cover. Install engine harness cover. Con-
nect engine harness electrical connectors. Continue in-
stallation in reverse of removal procedure.
ISUZU
Fig. 1: Aligning Timing Marks Fig. 2: Adjusting Timing Belt Tension
326
ISUZU
1
Step 1 ........................................................................... 36 (50)
Step 2 ................................................................ + 60 Degrees
Step 3 (1998-00 Engines Only) ......................... +15 Degrees
1
Step 1 ......................................................................... 94 (130)
Step 2 ................................................................ + 45 Degrees
Water Pump Bolt ........................................................... 18 (25)
INCH Lbs. (N.m)
Engine Harness Cover-To-Engine .................................. 53 (6)
1
Replace bolt if loosened or removed.
327
ISUZU
*2.2L 4-Cylinder Oasis
Belt
2.2L 4-Cyl. RA1
Oasis
1996-97
Balancer Shaft .................. 2521860.....

250186
Camshaft .......
1, 2
2.7 Hrs. .. 2521860...... 250187
1
- Balancer shaft belt included in camshaft belt
labor time.
2
kits.
replaced every 90,000 miles for normal service or 60,000 miles
for severe service. For 1997 vehicles, normal replacement
interval is at 105,000 miles or 84 months. Replace at 60,000
miles if vehicle is regularly driven in extreme temperatures
(over 110 degrees F, or under -20 degrees F).
TIMING BELT
Removal:
signs of seal leakage.
and connector. Raise and support vehicle. Remove
wheelwell splash shield. Using a jack with block of wood
to support engine, remove side engine mount.
Remove upper and lower timing belt covers. Loosen tim-
ing belt tension adjuster bolt 145-180 degrees. Push
tensioner to release belt tension from timing belt and bal-
ancer belt. Retighten tension adjuster bolt. Mark rotation
direction of timing belt if it is to be reused. Remove timing
belt from pulleys.
Installation:
Install timing belt in sequence shown. See Fig. 6. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. To
ranges.
328
ISUZU
*2.2L 4-Cylinder Oasis (Cont.)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7)
Valve Cover Nut ......................................................... 86 (9.8)
329
ISUZU
*2.3L 4-Cylinder Oasis
2.3L 4-Cyl. F23A, SOHC
Oasis
1998-99
Balancer Shaft ..
1
4.0 Hours ................

250186
1
4.0 Hours ................

250244
1
labor time.
Replace at 60,000 miles if vehicle is regularly driven in ex-
treme temperatures (over 110 degrees F, or under -20 de-
grees F).
Removal:
signs of seal leakage. Raise and support vehicle. Remove
engine lower splash shield.
and connector. Remove alternator and alternator bracket.
Using a jack with a block of wood to support engine, re-
move side engine mount from front of engine. Remove
dipstick tube from front of engine.
Insert a 6 mm timing cover bolt through the hole in the end
of the timing belt adjuster arm. This will temporarily lock
the arm in place.
Loosen belt tension adjusting nut about 1 turn. See Fig. 3.
Push outer balancer shaft belt tensioner pulley up to take
tension off of the balancer belt. Retighten belt tension ad-
justing nut. Remove balancer shaft belt.
Loosen belt tension adjusting nut about 1 turn. See Fig. 3.
Push camshaft timing belt tensioner pulley down to take
tension off of camshaft timing belt. Retighten belt tension
adjusting nut. Remove camshaft timing belt.
Installation:
Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by
aligning dimple on timing belt drive pulley with pointer on
oil pump housing. See Fig. 4. Ensure camshaft pulley TDC
marks are aligned. See Fig. 5.
Install camshaft timing belt in sequence shown. See Fig.
6. Loosen and retighten tensioner adjusting nut to tension
camshaft timing belt. Install balancer belt drive pulley and
lower cover. Install crankshaft pulley. Install bolt.
330
ISUZU
Rotate crankshaft pulley COUNTERCLOCKWISE about 5-
6 turns so timing belt positions on pulley. Set No. 1 piston
at TDC of compression stroke. Loosen belt tensioner ad-
justing nut about 1 turn. Rotate crankshaft counterclock-
wise 3 teeth on camshaft pulley. Tighten belt tensioner ad-
justing nut to specification. See TORQUE SPECIFICA-
TIONS.
Rotate crankshaft so that crankshaft and camshaft pulleys
are at TDC position. Ensure camshaft UP mark is facing
up. If they are not, timing belt will have to be repositioned.
Remove crankshaft pulley and lower cover. Set timing belt
drive pulley to TDC position.
Lock camshaft timing belt adjuster arm in place by install-
ing a 6x10 mm timing cover bolt. Loosen belt tension ad-
justing nut about 1 turn. See Fig. 3. Verify balancer belt
tensioner pulley moves freely. Push balancer belt tensioner
up then retighten belt tensioner adjusting nut.
Remove sealing bolt from maintenance hole on sideof en-
gine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end
of of 6x100 mm bolt. Install 6x100 mm bolt into mainte-
nance hole to lock balancer shaft in place.
Align front balancer shaft pulley groove with pointer on oil
pump housing. See Fig. 8. Install balancer belt. Loosen
tensioner adjusting nut about 1 turn to tension balancer
shaft belt. Remove 6x100 mm bolt from rear of balancer
shaft. Install sealing bolt with new washer.
331
Temporarily install crankshaft pulley and bolt. Turn crank-
shaft pulley about 1 turn counterclockwise, then tighten
tensioner adjusting nut. Remove the 6x10 mm bolt that
locked camshaft timing belt adjuster arm in place.
Remove crankshaft pulley. Install lower cover with new gas-
ket or liquid gasket. Install rubber seal around belt
tensioner adjusting nut. DO NOT loosen nut. Install crank-
shaft pulley. Lubricate crankshaft pulley bolt and underside
of bolt shoulder. Install and tighten crankshaft pulley bolt to
specification.
Install dipstick tube with new O ring. When installing cyl-
inder head cover gasket, apply liquid gasket (Part No. 08718-
0001 or -0003) to 4 corners where gasket meets cam-
shafts.
Install alternator and harness. Install accessory drive belts.
Install engine mount bracket to engine and frame. Connect
negative battery cable. Adjust drive belts to proper tension.
ISUZU
Fig. 7: Locking Balancer Belt Shaft In Place
Fig. 8: Aligning Balancer Belt Drive Pulley
Alternator Adjusting Locknut ........................................... 16 (22)
Engine Block Sealing Bolt .............................................. 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt
Oasis ........................................................................... 40 (54)
Engine Side Mount Through-Bolt
Oasis ........................................................................... 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt
Oasis ........................................................................... 47 (64)
Timing Belt Tensioner Adjusting Nut .......................... 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ........................................... 86 (9.8)
Dipstick Tube Bolt ........................................................ 106 (12)
Engine Lower Splash Shield ......................................... 89 (10)
Water Pump Bolts ........................................................ 106 (12)
332
ISUZU
3.2L V6 1993-97
3.2L V6 DOHC
Trooper
1992-95................
1
2.6. Hours ................ 250220
3.2L V6 SOHC
Rodeo
1993-97................
1
2.8 Hours ................. 250221
Trooper
1992-97................
1
2.8 Hours ................. 250221
1
60,000 miles.
TIMING BELT
Removal:
sembly. Remove upper fan shroud. Remove cooling fan
assembly. Remove all accessory drive belts.
Remove fan pulley assembly. Remove crankshaft pulley
bolt. Using Puller (J-8614-01) or equivalent, remove crank-
shaft pulley pulley. Remove oil cooler hose from timing
cover. Remove timing belt cover. Align all timing marks prior
to belt removal. See Figs. 1, 2 and 3. Remove belt tensioner
pusher and timing belt.
Installation:
Ensuring all timing marks are aligned. Install belt over one
pulley at a time staring at crankshaft sprocket working coun-
terclockwise. Belt should go over tensioner last. Secure
belt at each pulley during installation with pinch clips. See
Fig. 4.
CAUTION: To ensure correct timing belt installation, ensure
direction of rotation arrows are pointing in proper direction.
If timing belt is being reused, install belt in original direction
of rotation.
Compress timing belt tensioner pusher and insert pin to
retain pusher. Apply pressure to tensioner against belt and
install tensioner pusher. Tighten bolts to specification. See
Loosen tensioner pulley bolt. Apply pressure on belt by
rotating tensioner. Tighten tensioner pulley bolt to specifi-
cation. Remove pin from timing belt tensioner pusher.
Remove pinch clips from timing belt, (if used). Install crank-
shaft pulley, tightening center bolt finger tight. Rotate crank-
shaft 2 turns clockwise. Ensure timing belt tensioner pusher
rod protrudes proper amount. See Fig. 5.
If timing belt tensioner pusher rod protrusion is not within
specification, remove pusher, loosen tensioner pulley bolt
and readjust. Reset timing belt tensioner pusher rod and
repeat step 3). Remove crankshaft pulley and install timing
belt cover. To complete installation, reverse removal proce-
dure. Tighten nuts and bolts to specification. See TORQUE
Fan Pulley Bolt ............................................................ 16 (22)
Front Plate Bolt ........................................................... 14 (19)
Idler Arm Retaining Bolt .............................................. 33 (44)
Timing Belt Tensioner Pusher Bolt ............................. 14 (19)
Upper Intake Manifold Bolt .......................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ........................................ 87 (10)
Cooling Fan Assembly Nut ........................................... 69 (8)
Fig. 1: Aligning Timing Marks (DOHC)
Fig. 2: Aligning Camshaft Timing Marks (SOHC)
333
Fig. 4: Installing Pinch Clip On Timing Belt
Fig. 5: Adjusting Timing Belt Tensioner Pusher
ISUZU
3.2L V6 1993-97 (Cont.)
Fig. 6: Exploded View Of SOHC Cylinder Head Components
(DOHC Is Similar)
Fig. 7: Aligning Timing Belt Sprockets (DOHC)
Fig. 3: Aligning Crankshaft Timing Marks (All Models)
334
ISUZU
3.2L & 3.5L V6 DOHC, 1998-01
3.2L V6
Amigo
1998-99................
1
2.8 Hours ................. 250303
Rodeo
1998-01................
1
2.8 Hours ................. 250303
3.5L V6
Trooper
1998-01................
1
2.4 Hours ................. 250303
VehiCROSS
1999-01................
1
2.0 Hours ................. 250303
1
TIMING BELT REPLACEMENT INTERVALS
Application Miles
3.2L V6
Amigo
1998 ...................................................................... 75,000
1999
Normal Service .................................................... 100,000
Severe Service....................................................... 75,000
Rodeo
1998 ...................................................................... 75,000
1999-01
Normal Service .................................................... 100,000
Severe Service....................................................... 75,000
3.5L V6
Trooper
1998 ...................................................................... 75,000
1999-01
Normal Service .................................................... 100,000
Severe Service....................................................... 75,000
VehiCROSS
1999-01
Normal Service .................................................... 100,000
Severe Service ...................................................... 75,000
TIMING BELT
Removal:
drive belt.
Installation:
335
Sprocket
ISUZU
3.2L & 3.5L V6 DOHC, 1998-01 (Cont.)
Fig. 4: Installing Timing Belt on Left Hand Camshaft
Sprocket
Fig. 5: Installing Locking Pin in Timing Belt Tensioner
tensioner rod.
Fig. 5.
are still aligned.
nect battery.
M8 Bolt ......................................................................... 16 (22)
M10 ............................................................................. 34 (46)
Water Pump Bolt ......................................................... 18 (25)
336
KIA
Belt
1.6L 4-Cyl.
Sephia
1996-97..........
1
2.4 Hrs. .... 2521790........ 250179
1.8L 4-Cyl.
Sephia
1995-97..........
1
2.4 Hrs. .... 2521790........ 250179
1
With Pwr. Strng. add . 2 hours.
kits.
California Models The manufacturer recommends inspect-
ing the belt at 60,000 miles, 90,000 miles, and replacing belt
at 105,000 miles.
Except California Models The manufacturer recommends
TIMING BELT
Removal:
drive belts. Remove water pump pulley. Remove crank-
shaft pulley bolts, and remove pulley only.
Disconnect spark plug wires and remove spark plugs.
Rotate crankshaft clockwise until No. 1 cylinder is at TDC
of compression stroke. Ensure camshaft sprockets and
crankshaft sprocket timing marks align. See Fig. 2.
If timing belt is to be reused, mark direction of timing belt
rotation. Loosen timing belt tensioner lock bolt. Tempo-
rarily secure tensioner away from belt with spring fully ex-
tended. Remove timing belt.
Inspection:
Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or rough-
ness of rotation. Inspect tensioner spring for stretching.
Replace parts as necessary.
Installation:
aligned. See Fig. 2. Install belt around crankshaft sprocket.
Keeping belt pulled tight on right side (facing engine), route
belt around camshaft sprockets.
Loosen timing belt tensioner lock bolt, and allow spring to
apply tension on belt. Snug tensioner lock bolt. Rotate crank-
shaft clockwise 2 complete turns. Ensure timing marks
align. If timing marks are not aligned, remove belt, realign
all timing marks, and repeat installation procedure.
Check timing belt deflection. Check timing belt deflection
with 22 lbs. (10 kg) of pressure applied to belt. Timing belt
deflection should be .36-45" (9.0-10.7 mm). If timing belt
deflection is not within specification, repeat timing belt
tensioning procedure or replace tensioner spring. If timing
belt deflection is within specification, reverse removal pro-
cedure to complete installation.
Before installing valve cover, apply silicone sealer to areas
next to front camshaft journals and rear distributor mount-
ing cap. Also apply thin bead of silicone sealer around
spark plug holes on underside of valve cover. Adjust drive
ranges.
Spark Plug ........................................................ 14-17 (19-23)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ..................................... 69-97 (7.8-11)
Valve Cover Bolt .............................................. 44-78 (5.0-8.8)
Water Pump Pulley Bolt ................................... 69-97 (7.8-11)
Fig. 1: Identifying Timing Belt Covers
Courtesy of Kia Motors of America, Inc.
337
KIA
*1.6L & 1.8L 4-Cylinder SOHC
1
Belt Part No.
1.6L 4-Cyl.
Sephia
1994-95................. 2.0 Hours .................. 250185
1.8L 4-Cyl
Sephia
1996-97................. 2.0 Hours .................. 250185
1
ing the belt at 60, 000 miles, 90,000 miles, and replacing belt
at 105,000 miles.
TIMING BELT
Removal:
drive belts. Remove water pump pulley. Remove crankshaft
pulley bolts, and remove pulley only. See Fig. 2. Remove
upper and lower timing belt covers. Disconnect spark plug
wires and remove spark plugs. Rotate crankshaft clock-
wise until No. 1 cylinder is at TDC of compression stroke.
Ensure camshaft sprocket and crankshaft sprocket timing
marks align. See Fig. 1.
Loosen timing belt tensioner lock bolt. Temporarily secure
tensioner away from belt with spring fully extended. Re-
move timing belt.
Inspection:
Installation:
aligned. See Fig. 1. Install belt around crankshaft sprocket.
Keeping belt pulled tight on right side (facing engine), route
belt around camshaft sprocket.
shaft clockwise 2 complete turns. Ensure timing marks
align. If timing marks are not aligned, remove belt, realign
all timing marks, and repeat installation procedure.
Rotate crankshaft clockwise 2 more turns, and check tim-
ing belt deflection. Check timing belt deflection with 22 lbs.
(10 kg) of pressure applied to belt, midway between cam-
shaft and crankshaft pulleys, on side opposite tensioner.
Timing belt deflection should be .43-51" (10.9-13.0 mm).
procedure or replace tensioner spring. If timing belt de-
flection is within specification, reverse removal proce-
dure to complete installation. Adjust drive belts to proper
Crankshaft Pulley Lock Bolt ...................... 116-123 (157-167)
Spark Plug ........................................................ 14-17 (19-23)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt .......................................... 71 (8)
Water Pump Pulley Bolt ................................... 69-97 (7.8-11)
Courtesy of Kia Motors America, Inc.
338
KIA
*1.6L & 1.8L 4-Cylinder SOHC (Cont.)
Courtesy of Kia Motors America, Inc.
339
KIA
1.8L 4-Cyl.
Sephia
1998-01................
1
2.4 Hours ................. 250302
Spectra
2000-01................
1
2.4 Hours ................. 250302
1
at 105,000 miles.
Fig. 1: Removing Timing Belt Guide Plate
TIMING BELT
Removal:
drive belts. Remove water pump pulley. Remove crank-
shaft pulley bolt, and remove pulley and timing belt guide
plate. See Fig. 1.
Remove upper and lower timing belt covers. Rotate crank-
stroke. Ensure camshaft sprockets and crankshaft sprocket
timing marks align. See Figs. 2 and 3. Camshaft sprocket
I and E marks must face up and align with marks on
rear timing belt cover.
original direction of rotation. Remove timing belt tensioner
pulley. See Fig. 4. Remove timing belt.
Inspection:
damage. Check tensioner and idler pulley bearings for
looseness or roughness of rotation. Inspect tensioner
spring for stretching. Replace parts as necessary.
NOTE: Manufacturer recommends replacing timing belt tensioner
spring whenever timing belt is replaced. See Fig. 5.
Installation:
Install tensioner pulley with NEW spring. Move tensioner
away from timing belt and tighten center bolt. Ensure cam-
shaft and crankshaft timing marks are still aligned. See
Figs. 2 and 3.
Install timing belt around crankshaft sprocket. If reusing
old belt, ensure belt is installed in original direction of rota-
tion. Keeping belt pulled tight on right side (facing engine),
route belt around idler pulley, camshaft sprockets, and
tensioner pulley.
Loosen timing belt tensioner center bolt, and allow spring
to apply tension on belt. Tighten tensioner center bolt. Ro-
tate crankshaft clockwise 2 complete revolutions. Ensure
timing marks align. If timing marks are not aligned, remove
belt, realign all timing marks, and repeat installation proce-
dure.
Check timing belt deflection with 22 lbs. (10 kg) of down-
ward pressure applied to belt, midway between camshaft
sprockets. Timing belt deflection should be .36-.45 (9.0-
11 mm).
340
KIA
Fig. 5: Cross-Section Of Timing Belt Tensioner
Fig. 4: Timing Belt Tensioner & Idler Pulley
timing belt tensioning procedure. If timing belt deflection is
within specification, Install timing belt covers. Install crank-
shaft and water pump pulleys. Continue installation in re-
verse of removal procedure.
tension ranges.
INCH Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft Bolt .......... 106-152 (12-17)
Water Pump Pulley Bolt ............................... 106-152 (12-17)
341
KIA
2.0L 4-Cyl.
Sportage
1995-01................
1
3.2 Hours ................. 250281
1
at 105,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove 2 air ducts
mounting bolts from radiator. Loosen fresh air duct clamp
at intake housing. Remove hose at resonance chamber.
Remove fresh air duct. Remove cooling fan shroud. Re-
move cooling fan clutch-to-pulley nuts.
Remove accessory drive belts. Remove cooling fan and
pulley. Remove lower engine splash guard. Remove crank-
shaft pulley from crankshaft. It is NOT necessary to remove
center bolt. Remove upper and lower timing belt covers.
See Fig. 1.
marks. See Figs. 3 and 4. Camshaft I and E marks
should align with marks on rear cover.
Loosen tensioner pulley bolt. Pivot tensioner pulley out-
ward to remove tension from timing belt, then retighten
tensioner lock bolt. See Fig. 2. Mark timing belt rotation
direction if old belt is to be reinstalled. Remove timing belt.
Installation:
Ensure crankshaft and camshaft pulleys are still aligned.
Install timing belt so that there is no looseness at tension
side, and at camshaft pulleys. If reusing old belt, ensure
belt is installed in original direction of rotation. Loosen
tensioner pulley bolt.
Turn crankshaft 2 revolutions in normal direction of rota-
tion. Check that timing marks are correctly aligned. If timing
marks are not correctly aligned, remove belt and realign.
Turn crankshaft to align S mark of exhaust camshaft pul-
ley with rear cover mating mark. Tighten tensioner pulley
bolt.
Check that belt deflection is .30-.33" (7.5-8.5 mm) with 22
lbs. (10 kg) of downward pressure on belt, midway be-
tween two camshaft pulleys.
Install timing belt guide plate with flat side toward belt.
Install timing belt covers.
tension ranges.
Camshaft Pulley Center Bolt .............................. 35-48 (47-65)
Cooling Fan Clutch-To-Pulley Nuts ............................ 24 (32)
Crankshaft Center Bolt ........................................... 120 (162)
Crankshaft Pulley-to-Crankshaft Bolts .................. 9-13 (12-17)
Generator Mount Bolts
Top Generator Bolt .................................................... 16 (22)
Bottom Generator Bolt ................................................ 32 (45)
Power Steering Pump Bolts ................................ 27-34 (37-46)
Water Pump Bolt ............................................................ 16 (22)
INCH Lbs. (N.m)
Cooling Fan Shroud Bolts ............................................ 74 (8)
Fresh Air Duct Mounting Bolts ..................................... 84 (10)
Timing Belt Cover Bolts........................................ 61-87 (7-10)
96D14491 Courtesy of Kia Motors America, Inc.
Fig. 1: Timing Belt & Related Components
96E14492 Courtesy of Kia Motors America, Inc.
Fig. 2: Loosening Tensioner
342
96F14493 Courtesy of Kia Motors America, Inc.
Fig. 3: Aligning Crankshaft Pulley Timing Marks
96G14494 Courtesy of Kia Motors America, Inc.
Fig. 4: Aligning Camshaft Pulley Mating Marks
KIA
343
KIA
Appication Labor Time Belt Part No.
2.0L 4-Cyl. SOHC
Sportage
1995.....................
1
2.3 Hours ................. 250264
1
at 105,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove timing belt cover.
Remove accessory drive belts. Turn crankshaft and align
timing mark on front housing and arrow at 2 on camshaft
pulley. See Fig. 1. Remove damper pulley. Remove timing
belt guide plate from timing belt pulley.
Loosen tensioner lock bolt. Pry tensioner outward as far as
possible from timing belt. Temporarily tighten tensioner
lock bolt. Mark timing belt rotation direction if old belt is to
be reinstalled. Remove timing belt.
Installation:
Check that timing belt tensioner spring has a free length of
2.24" (56.5 mm). Replace if necessary. Ensure timing belt
pulley mark is aligned with timing mark. Ensure that arrow
at 2 on camshaft pulley is aligned with timing mark on
front housing. Install timing belt so that there is minimal
slack from timing belt pulley to water pump and from water
pump to camshaft pulley.
Loosen tensioner bolt to apply tension to timing belt. Turn
crankshaft 2 turns clockwise and verify that timing marks
are correctly aligned. If not, repeat installation procedure.
Tighten belt tensioner lock bolt. Check that belt deflection
is .43-.51" (11-13 mm) at 22 lbs. (10 kg) pressure on belt
between camshaft pulley and crankshaft pulley. To com-
plete installation, reverse removal procedure. Adjust drive
ranges.
Accessory Belt Lock Bolts .................................. 24-30 (32-42)
Cooling Fan Assembly ............................................... 27 (37)
Cooling Fan Nuts ....................................................... 16 (22)
Crankshaft Damper Bolts ......................................... 132 (15)
Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52)
INCH Lbs. (N.m)
Cooling Fan Shroud Bolts ............................................ 74 (8)
Fresh Air Duct Mounting Bolts ..................................... 84 (10)
96A14498 Courtesy of Kia Motors America, Inc.
Fig. 1: Timing Belt & Related Components
Fig. 2: Camshaft Pulley Mating Marks
96J14497 Courtesy of Kia Motors America, Inc.
Fig. 3: Crankshaft Pulley Mating Marks
96J14497 Courtesy of Kia Motors America, Inc.
344
1
Belt Part No.
1.8L 4-Cyl.
Beta
1976-78................. 2.7 Hours .................. 250020
1
25,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove timing gear
cover, spark plugs, and valve covers. Install handles
(88013344) or equivalent, on flywheel. Turn crankshaft in
direction of rotation until holes in camshaft drive gears align
with timing reference pointers. See Fig. 1.
Remove reference pointers bracket. Attach locking fixture
(88013039) or equivalent, by engaging dowel pins in cam-
shaft gear timing holes. Attach fixture to cylinder head. Re-
move belt tensioner nut and bolt and release tension from
belt. Remove timing belt.
Installation:
Align reference mark on crankshaft pulley with timing mark
on locking fixture (88013039) or equivalent. When both
marks correspond exactly, cylinders No. 1 and No. 4 will be
at TDC. Fixture reference hole should also line up with
ancillary drive shaft reference hole. Check alignment by
inserting dowel pin.
Install timing belt. Unlock the belt stretcher bolt applying
pressure to the belt. Tighten bolt and nut to 33 ft. lbs. (45
N.m). Once tensioning bolt is torqued, remove locking fix-
ture. Turn the crankshaft a few times, partially release the
belt stretcher and finally relock it properly. Install timing
reference pointers bracket. Adjust drive belts to proper ten-
VALVE TIMING
To check valve timing, turn crankshaft until reference mark
on sheave aligns with long mark on timing gear cover. See
Fig. 2. Check that the holes in camshaft gears (one in each)
are aligned with reference marks on front camshaft bear-
ings. See Fig. 2. If adjustment is necessary, use locking
fixture (88013039) or equivalent, as instructed under TIM-
ING BELT.
LANCIA
*1.8L 4-Cylinder
Fig. 1: Align Camshaft Timing Marks With Bearing
Reference Marks When Installing Timing Belt
Fig. 2: Valve Timing Reference Marks
Application Ft. Lbs. (N. m)
Camshaft Housing Nuts ............................................ 16 (22)
345
2.5L V6
ES250
1990-91................. 3.8 Hours .................. 250157
3.0L V6
ES300
1992-93................. 3.0 Hours .................. 250200
1994-98................. 3.0 Hours .................. 250257
scheduled maintenance interval for normal operating condi-
tions, belt manufacturers suggest the belt be replaced at 60,000
mile intervals. The manufacturer recommends the belt be re-
placed at 60,000 miles or 96 months for severe operating
conditions.
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
TIMING BELT
Removal (2.5L & 1992-93 3.0L V6):
Disconnect negative battery cable. Remove cruise control
actuator and vacuum pump. Remove power steering res-
ervoir with hoses attached, and secure them aside. Raise
and support vehicle. Remove right front wheel. Remove
right lower engine cover. Remove all drive belts.
Remove top braces on right engine mount at timing belt
cover. Slightly raise engine to remove weight from right
engine mount. Remove retaining bolts/nuts and right en-
gine mount assembly. Remove spark plugs. Remove re-
taining bolts, No. 2 timing belt cover, gasket and right en-
gine mount bracket. See Fig. 1. Note bolt length and loca-
tion of No. 2 timing belt cover bolts for reassembly refer-
ence.
belt rotation and location on camshaft sprockets for reassembly
reference. Also place reference mark on timing belt at upper
edge of No. 1 timing belt cover.
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of
compression stroke. Ensure timing mark on crankshaft
pulley aligns with 0 mark on No. 1 timing belt cover. En-
sure timing marks on camshaft sprockets are aligned with
timing marks on No. 3 timing belt cover. See Fig. 2. Re-
move retaining bolts and timing belt tensioner.
LEXUS
2.5L & 3.0L V6 1990-98
346
Install Camshaft Sprocket Holder (SST 09278-54012) or
equivalent, in holes on front of right camshaft sprocket.
Slightly rotate right camshaft sprocket clockwise to release
tension on timing belt between camshaft sprockets. Re-
move timing belt from camshaft sprockets.
Using Pulley Holder (SST 09213-54014) or equivalent, and
Handle (SST 0933000021), hold crankshaft pulley, and re-
move retaining bolt. If timing belt is to be reused, ensure
reference mark placed on timing belt aligns with upper
edge of No. 1 timing belt cover when timing mark on crank-
shaft pulley is aligned with 0 mark on No.1 timing belt
cover.
Using puller, remove crankshaft pulley. DO NOT allow crank-
shaft to rotate. Remove No. 1 timing belt cover and gasket.
If timing belt is to be reused, mark direction of belt rotation,
and place reference marks on timing belt and crankshaft
sprocket for reassembly reference. Note direction of timing
belt guide installation for reassembly reference. See Fig.
1. Remove timing belt guide and timing belt. Remove idler
pulleys (if necessary).
Removal (1994-98 3.0L V6):
voir. Raise and support vehicle. Remove right side front
wheel. Remove right lower engine cover. Remove acces-
sory drive belts.
Remove engine stabilizer rod, engine mounting bracket
and right engine mount brace, located near timing belt
cover. Remove the alternator bracket for access to timing
belt covers. Remove No. 2 timing belt cover. See Fig. 1.
Use Pulley Holder (SST 09213-54015) or equivalent, and
Handle (SST 0933000021) or equivalent, to hold crank-
shaft pulley. Remove crankshaft pulley bolt. Using puller,
remove crankshaft pulley. Remove No. 1 timing belt cover.
See Fig. 1.
Remove engine mounting bracket. Note direction of timing
belt guide installation for reassembly reference. Remove
timing belt guide.
Temporarily install crankshaft pulley bolt in crankshaft. Us-
ing crankshaft pulley bolt, rotate crankshaft clockwise until
timing mark on crankshaft sprocket aligns with timing mark
on oil pump body. See Fig. 3. Ensure timing marks on cam-
shaft sprockets are aligned with timing mark on No. 3 tim-
ing belt cover. See Fig. 3. If timing marks are not aligned,
rotate crankshaft clockwise one full revolution (360 de-
grees).
Remove retaining bolts, timing belt tensioner and dust boot.
Remove crankshaft pulley bolt from crankshaft. Install cam-
shaft sprocket holder (SST 09278-54012) or equivalent, in
holes on front of right camshaft sprocket. Slightly rotate
right camshaft sprocket clockwise to release tension on
timing belt between camshaft sprockets. Remove timing
belt from camshaft sprockets.
Inspection (2.5L & 3.0L V6):
tamination. Ensure idler pulleys rotate freely. Replace dam-
aged components. Inspect timing belt tensioner for signs
of oil leakage. Replace timing belt tensioner if oil leakage
exists. Hold timing belt tensioner body. Press rod against
solid surface. Replace timing belt tensioner if rod moves.
Measure timing belt tensioner rod protrusion from end of
rod to edge of timing belt tensioner housing. See Fig. 5. On
2.5L engines, replace timing belt tensioner if distance is
not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace
timing belt tensioner if distance is not .394-.413" (10.01-
10.49 mm).
Installation (2.5L & 1992-93 3.0L V6):
Install No. 1 idler pulley (if removed). Apply Loctite 242 on
threads of No. 1 idler pulley retaining bolt. Install and tighten
retaining bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure idler pulley is clean, and pulley rotates
smoothly.
Install timing belt on crankshaft sprocket with installation
mark on timing belt aligned with timing mark on crankshaft
sprocket. See Fig. 2. Install timing belt guide with cupped
side away from crankshaft sprocket. Install No. 1 timing
belt cover and gasket. Align crankshaft key with key groove
of crankshaft pulley and install crankshaft pulley. Tighten
retaining bolt to specification.
CAUTION: If reusing timing belt, ensure timing mark on crankshaft
sprocket is aligned with reference mark placed on timing belt,
and timing belt is installed in original direction of rotation.
Install No. 2 idler pulley. Tighten retaining bolt to specifica-
tion. Ensure idler pulley rotates smoothly. Rotate crank-
shaft pulley so timing mark on crankshaft pulley aligns with
0 mark on No. 1 timing belt cover. Rotate left camshaft so
timing mark on camshaft sprocket aligns with timing mark
on No. 3 timing belt cover. See Fig. 2.
Rotate right camshaft so knock pin hole in camshaft aligns
with timing mark on No. 3 timing belt cover. See Fig. 2. If
reusing timing belt, ensure reference mark placed on tim-
ing belt aligns with upper edge of No. 1 timing belt cover
when timing mark on crankshaft pulley is aligned with 0
mark on No. 1 timing belt cover.
Using camshaft sprocket holder, slightly rotate left cam-
shaft sprocket clockwise, and install timing belt on cam-
shaft sprocket. Ensure reference mark on timing belt aligns
with timing mark on camshaft sprocket.
LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
347
shaft sprocket, and align timing mark on camshaft sprocket
with timing mark on No. 3 timing belt cover. Ensure tension
exists on timing belt between crankshaft sprocket and left
camshaft reference mark on timing belt with timing mark
on right camshaft sprocket. Install right camshaft sprocket
on camshaft with flange side toward cylinder head. Ensure
timing mark on right camshaft sprocket aligns with timing
mark on No. 3 timing belt cover. See Fig. 2.
Using camshaft sprocket holder, slightly rotate right cam-
shaft sprocket so knock pin hole in camshaft sprocket aligns
with knock pin hole in camshaft. Install knock pin in right
camshaft. Install right camshaft sprocket retaining bolt, and
tighten it to specification. See TORQUE SPECIFICATIONS.
LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Place washer on bottom side of timing belt tensioner. Us-
ing press, apply pressure on rod of timing belt tension until
rod is retracted, and holes in rod and housing are aligned.
Install hexagon wrench through holes in housing and rod
to hold rod in retracted position. See Fig. 6. Release press,
and install dust boot on timing belt tensioner. Install timing
belt tensioner. Tighten retaining bolts to specification. See
Remove hexagon wrench from timing belt tensioner. Ro-
tate crankshaft clockwise 2 full revolutions from TDC to
TDC. Ensure timing marks on camshaft sprockets align
with those on No. 3 timing belt cover. See Fig. 2.
CAUTION: Crankshaft must always be rotated clockwise. DO
NOT rotate crankshaft counterclockwise.
Installation (1994-98 3.0L V6):
Install timing belt plate. Install and tighten bolt to specifica-
tion. Install No. 1 and No. 2 idler pulleys (if removed). Install
and tighten bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure idler pulleys are clean and rotate
smoothly.
on oil pump body. See Fig. 3.
Using camshaft sprocket holder, rotate each camshaft
sprocket so timing mark on camshaft sprocket aligns with
timing mark on No. 3 timing belt cover. See Fig. 3. Align
reference marks on timing belt with dot on crankshaft
sprocket and timing marks on camshaft sprocket. Ensure
front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing
mark on camshaft sprockets and dot on crankshaft sprocket
when installing timing belt. Front mark must face toward timing
belt end of engine.
Install timing belt on crankshaft sprocket, water pump pul-
ley, left camshaft sprocket, No. 2 idler pulley, right camshaft
sprocket, and then on No. 1 idler pulley. Using press, apply
pressure on rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. Install hexagon
wrench through holes in housing and rod to hold rod in
retracted position. See Fig. 6. Release press and install
dust boot on timing belt tensioner. Install timing belt
tensioner. Install and alternately tighten bolts to specifica-
tion. See TORQUE SPECIFICATIONS.
tate crankshaft clockwise until timing mark on crankshaft
sprocket aligns with timing mark on oil pump body. See
Fig. 3. Ensure timing mark on each camshaft sprocket is
aligned with timing mark on No. 3 timing belt cover. See
Fig. 3. If all timing marks are not aligned, remove timing
belt and reinstall. Remove crankshaft pulley bolt.
Install timing belt guide with cupped side away from crank-
shaft sprocket and flat side toward timing belt. Install en-
gine mounting bracket on front of cylinder block. Install and
tighten bolts to specification. Using new gaskets, install
No. 1 and No. 2 timing belt covers. Install and tighten bolts
Fig. 3: Aligning Timing Marks (1994-98 3.0L)
Fig. 4: Identifying Timing Belt Reference Marks (1994-98 3.0L)
348
LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Fig. 6: Retracting Timing Belt Tensioner Rod
Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion
Align crankshaft key with key groove of crankshaft pulley.
Install crankshaft pulley. Install and tighten crankshaft pul-
ley bolt to specification. To install remaining components,
reverse removal procedure. Tighten fasteners to specifica-
tion. See TORQUE SPECIFICATIONS. Adjust drive belts to
TORQUE SPECIFICATIONS (2.5L V6)
Engine Crossmember-To-Body Bolt .......................... 29 (39)
Engine Mount Through-Bolt ........................................ 64 (87)
Crossmember Bolt .................................................. 54 (73)
Idler Pulley Bolt
No. 1 Idler Pulley ....................................................... 25 (34)
No. 2 Idler Pulley ....................................................... 29 (39)
Idler Pulley Support Bolt ............................................. 13 (18)
Right (Timing Belt Side) Engine Mount
Bolt ........................................................................... 47 (64)
Nut
Bracket Side .......................................................... 38 (52)
Body Side .............................................................. 65 (88)
Water Pump Bolt ........................................................ 14 (19)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
No. 3 Timing Belt Cover Bolt ......................................... 65 (7)
Valve Cover Nut ............................................................ 52 (6)
Front Engine Mount-To-Crossmember Bolt
Toyota Motor Corporation Bolt .................................. 59 (80)
Toyota Motor Manufacturing Bolt ............................... 49 (66)
Front Engine Mount-To-Cylinder
Block Bolt .................................................................. 47 (64)
Power Steering Pump Bracket
To-Cylinder Head Bolt .............................................. 32 (43)
Pulsation Damper ...................................................... 24 (33)
Right Engine Mount Brace Bolt ................................... 23 (31)
Stabilizer Bar Link-To
Lower Control Arm Nut ............................................. 29 (39)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt ............................................... 25 (34)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
No. 1 & 2 Timing Belt Cover Bolt ................................ 75 (8.5)
No. 3 Timing Belt Cover Bolt ...................................... 75 (8.5)
Timing Belt Plate Bolt ................................................ 71 (8.0)
Valve Cover Bolt ......................................................... 71 (8.0)
Water Pump Bolt/Nut ................................................. 71 (8.0)
349
3.0L V6 1MZFE
ES300
1999-01................. 3.0 Hours .................. 250257
RX300
1999-01................. 4.4 Hours .................. 250257
TIMING BELT
Removal (ES300):
Raise and support vehicle. Remove right side front wheel.
Remove right fender apron seal. Remove accessory drive
belts. Lower vehicle. Disconnect engine coolant reservoir
hose from water outlet. Disconnect ground strap connec-
tors.
cover. Remove generator-to-engine bracket for access to
timing belt covers.
Handle (SST 09330-00021) or equivalent, hold crankshaft
pulley. Remove crankshaft pulley bolt. Using puller, remove
crankshaft pulley. Remove No. 1 and No. 2 timing belt cov-
ers and gaskets. See Fig. 1. Remove engine mounting
bracket from front of engine. Note direction of timing belt
guide installation for reassembly reference. Remove tim-
ing belt guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing
belt side of engine.
timing marks are not aligned, rotate crankshaft clockwise
one full revolution (360 degrees).
If reusing old belt, ensure there are 3 installation marks
and front arrow marked on belt. See Fig. 3. If not, place
mating mark on belt where it contacts the crankshaft and
camshaft sprockets. Also, mark belt with arrow showing
Alternately loosen 2 bolts, and remove timing belt tensioner
and dust boot. DO NOT hold tensioner with push rod facing
downward. Remove timing belt.
Inspection (ES300):
tamination. Ensure idler pulleys rotate freely and are not
leaking oil. Replace damaged components. Check water
pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing
downward.
place timing belt tensioner if oil leakage exists. Hold timing
belt tensioner body with push rod facing upward. Press rod
against solid surface. Replace timing belt tensioner if push
rod moves.
Measure timing belt tensioner push rod protrusion from
end of rod to edge of timing belt tensioner housing. See
Fig. 4. Replace timing belt tensioner if distance is not .394-
.425" (10.01-10.8 mm).
NOTE: Engine should be cold when installing timing belt.
Installation (ES300):
Install No. 1 and No. 2 idler pulleys (if removed). On No. 1
idler pulley bolt, coat threads with Loctite 242 or equivalent.
Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Ensure idler pulleys are clean and ro-
tate smoothly.
Temporarily install crankshaft pulley bolt in crankshaft. If
necessary, use crankshaft pulley bolt to rotate crankshaft
clockwise until timing mark on crankshaft sprocket aligns
with timing mark on oil pump body. See Fig. 2.
Using spanner wrench, rotate each camshaft sprocket so
ley, left camshaft sprocket (front of vehicle side), No. 2 idler
pulley, right camshaft sprocket (firewall side), and then on
No. 1 idler pulley. If reusing old belt, ensure belt installation
marks align with camshaft and crankshaft sprocket marks.
Ensure front (or rotation direction mark) points in correct
direction.
Using press, SLOWLY apply about 200-2200 lbs. of pres-
sure on push rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. See Fig. 5. Align
holes in housing and push rod to hold rod in retracted
position. Install hexagon wrench through housing and push
rod hole to secure push rod. Release press and install
dust boot on timing belt tensioner.
LEXUS
3.0L V6 1999-01
350
Install timing belt tensioner. Install and alternately tighten
Remove hexagon wrench from timing belt tensioner. Slowly
rotate crankshaft clockwise 2 revolutions until timing mark
on crankshaft sprocket aligns with timing mark on oil pump
body.
Ensure timing mark on each camshaft sprocket is aligned
with timing mark on No. 3 timing belt cover. See Fig. 2. If all
timing marks are not aligned, remove timing belt and rein-
stall. Remove crankshaft pulley bolt.
tighten bolts to specification.
LEXUS
3.0L V6 1999-01 (Cont.)
Fig. 3: Identifying Timing Belt Reference Marks & Front Mark
Using new gaskets, install No. 1 and No. 2 timing belt
covers. Ensure there are no gaps in gasket. Cut off any
excess gasket. Install and tighten bolts to specification.
ley bolt to specification. See TORQUE SPECIFICATIONS.
Install generator bracket. Install engine mount brace and
stabilizer rod. Install fender apron seal and right front wheel.
dure. Tighten fasteners to specification. Connect engine
ground strap. Adjust drive belts to proper tension. See page
Removal (RX300):
Remove the outer cowl top panel along with ventilation lou-
vers and windshield wiper arm assembly. See Fig. 6. Re-
move shock tower suspension brace. Raise and support
vehicle.
Remove right side front wheel. Remove right fender apron
seal. Remove accessory drive belts. Lower vehicle. Re-
move cruise control actuator from right side engine com-
partment.
Disconnect engine coolant reservoir hose from water out-
let. Disconnect ground strap connectors.
Remove engine stabilizer rod and engine mounting bracket,
located near timing belt cover. Remove generator-to-en-
gine bracket for access to timing belt covers.
crankshaft pulley. Remove No. 1 and 2 timing belt covers
and gaskets. See Fig. 1. Remove engine mounting bracket
from front of engine. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt
guide.
351
LEXUS
3.0L V6 1999-01 (Cont.)
Fig. 5: Retracting Tlming Belt Tensloner Rod
and dust boot. DO NOT hold tensioner with push rod facing
Inspection (RX300):
leaking oil. Replace damaged components. Inspect water
CAUTION: Never hold timing belt tensioner with push rod facing
downward.
belt tensioner body with push rod facing upward. Press rod
rod moves.
.425" (10.01-10.8 mm).
Installation (RX300):
Install No. 1 and No. 2 idler pulleys (if removed). On No. 1
idler pulley bolt, coat threads with Loctite 242 or equivalent.
Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Ensure idler pulleys are clean and ro-
tate smoothly.
ley, left camshaft sprocket (front of vehicle side), No. 2 idler
pulley, right camshaft sprocket (firewall side), and then on
direction.
sure on push rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. See Fig. 5. Align
holes in housing and push rod. Install hexagon wrench
through housing and push rod hole to secure push rod.
Release press and install dust boot on timing belt tensioner.
Fig. 6: Exploded View Of Outer Cowl Top Panel (RX300)
Remove hexagon wrench from timing belt tensioner. Slowly
rotate crankshaft clockwise 2 revolutions until timing mark
body.
tighten bolts to specification. See TORQUE SPECIFICA-
TIONS.
covers. Ensure there are no gaps in gasket. Cut off excess
gasket. Install and tighten bolts to specification.
Install generator bracket. Connect engine ground strap.
Install engine mount brace and stabilizer rod. Install cruise
control actuator (if equipped).
Install right hand fender apron seal. Install front wheel. In-
stall shock tower suspension brace. Install outer cowl top
panel.
dure. Tighten fasteners to specification. Adjust drive belts
352
Left Hand (Front End of Vehicle Side) ......................... 94 (125)
Right Hand (Firewall Side of Vehicle) ........................... 65 (88)
Engine Stabilizer Rod Bolts ............................................ 47 (64)
Generator Adjusting Lock Bolt ........................................ 13 (18)
Generator Pivot Bolt ........................................................ 41 (56)
Right Engine Mount Brace-To-Body Bolt ..................... 23 (31)
Shock Tower Brace-To-Shock Tower Nuts .................... 59 (80)
No. 1 Idler Pulley Bolt ..............................................
1
25 (34)
Wheel Lug Nut .......................................................... 76 (103)
Wiper Arm Nuts .............................................................. 18 (24)
INCH Lbs. (N.m)
Water Pump Bolt/Nut ........................................................ 71 (8)
1
- Apply Loctite 242 or equivalent to bolt threads.
LEXUS
3.0L V6 1999-01 (Cont.)
353
3.0L 6-Cyl.
GS300
1993-97................. 3.4 Hours .................. 250215
SC300
1993-97................. 3.4 Hours .................. 250215
conditions.
TIMING BELT
Removal:
Disconnect battery cables and remove battery. Drain cool-
ing system. Place reference mark on fan clutch and water
pump for reassembly reference. Remove drive belt, cool-
ing fan, fan clutch and water pump pulley.
Remove radiator and lower engine cover. Remove oil filler
cap, No. 2 and No. 3 timing belt covers, gaskets and drive
belt tensioner. See Fig. 1.
Rotate crankshaft clockwise so cylinder No. 1 (front cylin-
der) is at TDC on compression stroke. Ensure timing mark
on crankshaft pulley aligns with 0 mark on timing belt
cover.
Timing marks on camshaft sprockets must align with tim-
ing marks on No. 4 timing belt cover. See Fig. 2. If condi-
tions are not as described, rotate crankshaft clockwise one
complete revolution clockwise.
CAUTION: If reusing timing belt, place arrow on timing belt to
indicate direction of rotation. Place reference mark on timing
belt and each camshaft sprocket for reassembly reference.
Alternately loosen timing belt tensioner bolts. Remove bolts,
timing belt tensioner and dust boot. See Fig. 1. Remove
timing belt from camshaft sprockets.
Using Handle (SST 09330-00021) or equivalent, and Pul-
ley Holder (SST 0921370010), or equivalent, hold crank-
shaft pulley and remove crankshaft pulley bolt. Using puller,
remove crankshaft pulley.
Remove No. 1 timing belt cover and gaskets. Note direc-
tion of timing belt guide installation for reassembly refer-
ence. See Fig. 1. Remove timing belt guide.
CAUTION: If reusing timing belt, place reference mark on timing
belt and crankshaft sprocket tor reassembly reference.
Remove timing belt. Remove bolt, idler pulley and plate
washer (if necessary).
Inspection:
tamination. Replace timing belt if damaged or contami-
nated. Check idler pulley and drive belt tensioner for smooth
rotation. Replace idler pulley or drive belt tensioner if de-
fective.
place timing belt tensioner if oil leakage exists.
Hold timing belt tensioner body, and press rod against solid
surface. Replace timing belt tensioner if rod moves.
rod to edge of housing. See Fig. 3. Replace timing belt
tensioner if distance is not .315-.343" (8.00-8.80 mm).
NOTE: Tlming belt tensioner may have a small amount of oil
on rod seal under normal conditions. If excessive amount of oil
exists, replace timing belt tensioner
Installation:
Install idler pulley and plate washer (if removed). Apply Loctite
242 on threads of idler pulley bolt. Install and tighten bolt to
specification. See TORQUE SPECIFICATIONS. Ensure idler
pulley is clean and rotates smoothly, and idler pulley bracket
moves freely.
Using crankshaft pulley bolt, rotate crankshaft and align
timing mark on crankshaft sprocket with timing mark on oil
pump body. See Fig. 2. Install timing belt on crankshaft
sprocket.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and crankshaft sprocket align and timing belt is installed
shaft sprocket and flat side against timing belt. Install gas-
kets and No. 1 timing belt cover.
Align crankshaft pulley key groove with crankshaft key. In-
stall crankshaft pulley. Install and tighten crankshaft pulley
bolt to specification. See TORQUE SPECIFICATIONS.
If installing camshaft sprocket, align hole in camshaft
sprocket with dowel pin in camshaft. Install camshaft
sprocket. Hold camshaft sprocket with sprocket holder, and
tighten bolt to specification. See TORQUE SPECIFICA-
TIONS.
cover.
Using sprocket holder, rotate camshaft sprockets so tim-
ing marks on camshaft sprockets align with timing marks
on No. 4 timing belt cover. See Fig. 2. Install timing belt on
camshaft sprockets. Ensure tension exists on timing belt
between camshaft sprockets.
belt and camshaft sprockets align and timing belt is installed
Using press, apply pressure on rod of timing belt tensioner
until rod is retracted and holes in rod and housing are
to hold rod in retracted position. See Fig. 4. Release press.
Install dust boot on timing belt tensioner. Install timing belt
tensioner. Alternately tighten timing belt tensioner bolts to
LEXUS
3.0L 6-Cylinder 1993-97
354
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
TDC. DO NOT rotate crankshaft counterclockwise.
Ensure timing marks on camshaft sprockets align with tim-
ing marks on No. 4 timing belt cover, and timing mark on
crankshaft pulley aligns with 0 mark on timing belt cover.
See Fig. 2. If timing marks are not aligned, remove timing
belt and reinstall.
dure. Use care when installing drive belt tensioner bolts to
avoid dropping bolts into timing belt cover. Adjust drive belts
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Air Intake Chamber Bolt/Nut ....................................... 13 (18)
Distributor Housing Bolt ............................................. 13 (18)
Drive Belt Idler Pulley Bolt ........................................... 27 (37)
Drive Belt Tensioner Bolt/Nut ...................................... 12 (16)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Power Steering Pump Pulley Nut ................................ 32 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt/Nut .................................................. 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ............................... 57 (6.4)
Valve Cover Bolt ......................................................... 52 (5.9)
LEXUS
3.0L 6-Cylinder 1993-97 (Cont.)
Courtesy of Toyota Motor Sales, U.S.A, Inc.
355
3.0L 6-Cyl. 2JZ-GE
GS300
1998-01.................

3.4 Hours.................. 250215
SC300
1998-00.................

3.4 Hours.................. 250215
TIMING BELT
Removal:
Raise and support vehicle. Remove engine undercover.
Drain cooling system.
On GS300, remove air cleaner inlet, air cleaner, and MAF
assembly. Remove radiator and electric cooling fan as-
sembly. On 1999-98 models, rotate serpentine drive belt
tensioner counterclockwise and remove belt. Tensioner bolt
is left-hand threaded. On 2001-00 models, rotate tensioner
clockwise to remove serpentine belt.
On SC300, remove battery and battery tray. Drain coolant.
Remove lower fan shroud. Remove radiator. Loosen 4 nuts
holding fan clutch to water pump. Rotate serpentine drive
belt tensioner bolt clockwise, and remove drive belt. Re-
move cooling fan, fan clutch, and water pump pulley.
On all models, remove power steering pump front bracket.
Remove pump with hoses attached, and hang out of way.
Remove No. 2 and No. 3 timing belt covers and gaskets.
See Fig. 2. Remove serpentine drive belt tensioner.
Using Handle (SST 09330-00021) and Pulley Holder (SST
09213-70010) or equivalent to hold crankshaft pulley,
loosen crankshaft pulley bolt. Rotate crankshaft clockwise
so cylinder No. 1 (front cylinder) is at TDC on compression
stroke. Ensure timing mark on crankshaft pulley aligns with
0 mark on timing belt cover. See Figs. 1 and 3.
Timing marks on camshaft timing pulleys must align with
timing marks on timing belt cover. See Fig. 1. If not, rotate
crankshaft clockwise one complete revolution (360 de-
grees).
CAUTION: Crankshaft must be correctly positioned by aligning
sub-timing mark with 0 mark on timing belt cover to prevent
valves from contacting pistons.
Rotate crankshaft pulley 60 degrees counterclockwise. Align
sub-timing mark with 0 mark on timing belt cover. See
Fig. 3, STEP 1. Ensure the dot marks of camshaft timing
pulleys are aligned with the timing marks of No. 4 timing
belt cover. See Fig. 3, STEP 2.
CAUTION: It reusing timing belt, place arrow on timing belt to
belt and each camshaft timing pulley for reassembly reference.
DO NOT allow the crankshaft pulley to rotate, and remove
crankshaft pulley bolt.
timing belt tensioner, and dust boot. See Fig. 2. Remove
Remove crankshaft pulley using gear puller. Remove No. 1
timing belt cover and gaskets. Note direction of timing belt
guide installation for reassembly reference (flat side to-
ward timing belt). See Fig. 2. Remove timing belt guide. If
reusing timing belt, place mating reference marks on tim-
ing belt and crankshaft sprocket. Remove timing belt.
Inspection:
nated. Check idler pulley and drive belt tensioner pulley for
smooth rotation. Replace idler pulley or drive belt tensioner
if defective. Inspect timing belt tensioner for signs of oil
leakage. Replace timing belt tensioner if oil leakage ex-
ists.
NOTE: Timing belt tensioner may have a small amount of oil
exists, replace timing belt tensioner.
Hold timing belt tensioner body, and press push rod against
solid surface. Replace timing belt tensioner if push rod
moves. Measure timing belt tensioner push rod protrusion
from end of rod to edge of housing. See Fig. 4. Replace
8.80 mm).
Installation:
242 or equivalent on threads of idler pulley pivot bolt. Install
and tighten bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure idler pulley is clean and rotates smoothly,
and idler pulley bracket moves freely.
timing mark on crankshaft timing pulley with timing mark
on oil pump body. See Fig. 3, STEP 3. Clean oil or water off
of crankshaft timing pulley, and install timing belt on crank-
shaft timing pulley and around idler pulley.
belt and crankshaft timing pulley align, and timing belt is installed
shaft timing pulley and flat side against timing belt. Install
gaskets and No.1 timing belt cover. Align crankshaft pulley
key groove with crankshaft key. Install crankshaft pulley.
LEXUS
3.0L 6-Cylinder 1998-2001
356
Ensure sub-timing mark (60 degrees BTDC) of crankshaft
pulley is aligned with 0 timing mark of No. 1 timing belt
cover. See Fig. 3, STEP 4. Temporarily install crankshaft
pulley bolt.
belt and camshaft timing pulleys align and timing belt is in-
stalled in original direction of rotation.
If necessary, use spanner wrench to rotate camshaft tim-
ing pulleys so timing marks on camshaft timing pulleys
align with timing marks on No. 4 timing belt cover. See Fig.
1. Install timing belt on camshaft timing pulleys. Ensure
tension exists on timing belt between camshaft timing pul-
leys.
Using press, SLOWLY apply pressure on push rod of tim-
ing belt tensioner until rod is retracted and holes in rod and
housing are aligned. See Fig. 5.
Fig. 2: Exploded View Of Typical Timing Belt & Components
LEXUS
3.0L 6-Cylinder 1998-2001 (Cont.)
357
Fig. 3: Aligning Sub-Timing Marks
LEXUS
3.0L 6-Cylinder 1998-2001 (Cont.)
TDC.
Ensure timing marks on camshaft timing pulleys align with
timing marks on timing belt cover, and timing mark on crank-
shaft pulley aligns with 0 mark on timing belt cover. If
stall.
Tighten crankshaft pulley bolt to specification. Install drive
belt tensioner. Install No. 2 and No. 3 timing belt covers. To
install remaining components, reverse removal procedure.
Use care when installing drive belt tensioner bolts to avoid
dropping bolts into timing belt cover.
Tighten fasteners to specification. See TORQUE SPECIFI-
CATIONS. Fill and bleed air from cooling system.
Camshaft Timing Pulley Bolt ...................................... 60 (81)
Drive Belt Tensioner Bolt ............................................ 15 (21)
Fan Clutch-To-Water Pump Nut (SC300) ..................... 12 (16)
Idler Pulley Bolt ...........................................................
1
26 (35)
Power Steering Pump-To-Front Bracket ......................... 42 (58)
Water Pump Bolt ........................................................ 15 (21)
INCH Lbs. (N.m)
Fan-To-Fan Clutch Nuts (SC300) .................................. 65 (7.5)
No. 1 & No. 2 Timing Belt Cover Bolt ................................ 71 (8)
1
358
4.0L V8
LS400
1990-97................. 4.5 Hours .................. 250190
SC400
1992-97................. 4.8 Hours .................. 250190
For 1990-94 model years, although the manufacturer does
not recommend a specific scheduled maintenance interval
for normal operating conditions, belt manufacturers suggest
the belt be replaced at 60,000 mile intervals. The manufac-
turer recommends the belt be replaced at 60,000 miles or 96
months or severe operating conditions.
belt be replaced at 90,000 miles for normal service and 60,000
miles for severe service.
TIMING BELT
Removal:
Remove battery. Remove lower engine cover Drain cooling
system. On LS400, remove air duct located above top of
radiator and air cleaner cover. Remove air cleaner assem-
bly. Remove V-bank cover. Remove drive belt, fan clutch
assembly and fan pulley. On SC400, rotate drive belt
tensioner counterclockwise. Remove drive belt. Remove
coolant reservoir.
On all models, remove radiator. Remove A/C compressor
with hoses attached and secure aside. Remove air intake
pipe between air cleaner hose and throttle body. Remove
upper spark plug wiring cover. Remove engine wiring cov-
ers located near valve covers. Remove No. 3 (upper) timing
belt covers. Remove spark plug wire clamps. Disconnect
spark plug wires from distributor caps.
Disconnect high-tension wire from ignition coils. Remove
spark plug wires and clamps. See Fig. 2. Remove bolt,
plate and drive belt idler pulley. Remove left (drivers side)
ignition coil. Disconnect cam position sensor electrical
connector from clamp on No. 2 timing belt cover. Remove
bolts, No. 2 timing belt covers and gaskets. See Fig. 3. It
may be necessary to remove coolant pipe to access No. 2
timing belt covers.
Remove bolts, distributor caps and rotors. Mark compo-
nent location for reassembly reference. Disconnect electri-
cal connector at distributor housings. Remove bolts and
distributor housings. See Fig. 3. Remove alternator, drive
belt tensioner and spark plugs.
CAUTION: If reusing timing belt, ensure the 4 installation marks
exist on timing belt. If installation marks do not exist, place installation
mark on timing belt, all sprockets and edge of fan bracket (LS400)
or hydraulic pump (SC400).
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on
compression stroke. Cylinder No. 1 is front cylinder on left
side when viewed from rear of engine. Ensure timing mark
on crankshaft pulley aligns with 0 mark on No. 1 timing
ing marks on timing belt rear plates. See Fig. 1. If timing
marks are not aligned, rotate crankshaft clockwise one
complete revolution. Alternately loosen timing belt tensioner
bolts. Remove bolts, timing belt tensioner and dust boot.
See Fig. 3. Using Sprocket Holder (SST 09278-54012) or
equivalent, slightly rotate right camshaft sprocket clockwise
to release tension on timing belt. Remove timing belt from
camshaft sprockets.
Using Pulley Holder (SST 09213-70010) or equivalent and
Handle (SST 0933000021) or equivalent, hold crankshaft
crankshaft pulley. On LS400, remove bolts/nuts and fan
bracket. On SC400, remove bolts/nuts and hydraulic pump.
On all models, remove No. 1 timing belt cover, gaskets,
timing belt cover spacer and gasket. See Fig. 3.
Note direction of timing belt guide installation for reassem-
bly reference. Remove timing belt guide. Remove timing
belt. Remove bolt, idler pulleys and plate washer (if neces-
sary).
CAUTION: If reusing timing belt, ensure installation mark exists
at crankshaft sprocket. If installation mark does not exist, place
installation mark on timing belt and crankshaft sprocket.
Inspection:
nated. Check idler pulleys for smooth rotation. Replace
idler pulleys if defective. Inspect timing belt tensioner for
signs of oil leakage. Replace timing belt tensioner if oil
leakage exists.
NOTE: Timing belt tensioner may weep a small amount of oil
Hold timing belt tensioner body and press rod against solid
surface. Replace timing belt tensioner if rod moves. Mea-
sure timing belt tensioner rod protrusion from end of rod to
edge of housing. See Fig. 4. Replace timing belt tensioner
if distance is not .413-.453" (10.50-11.50 mm).
LEXUS
4.0L V8 1990-97
Fig. 1: Checking Camshaft Timing Mark Alignment
359
Installation:
Install No.1 idler pulley and plate washer (if removed). Ap-
ply Loctite 242 on threads of idler pulley bolt. Install and
TIONS. Install No. 2 idler pulley and bolt. Tighten bolt to
pulleys are clean and rotate smoothly. Ensure idler pulley
bracket moves freely.
pump body. Install timing belt on crankshaft sprocket so
CR installation mark on timing belt aligns with dot on crank-
shaft sprocket. See Fig. 5. Install timing belt on No.1 and
then No. 2 idler pulley.
shaft sprocket. Flat side should be against timing belt. In-
stall gasket and timing belt cover spacer. Install gaskets
and No. 1 timing belt cover. On LS400, install fan bracket.
Install and tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS.
On SC400, install hydraulic pump. Install and tighten bolts/
nuts to specification. See TORQUE SPECIFICATIONS. On
all models, align crankshaft key with key groove of crank-
shaft pulley. Using hammer and Pulley Installer (SST 09223-
46011) or equivalent, install crankshaft pulley. Install and
tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS.
CAUTION: Ensure camshaft sprocket is installed with identification
mark facing forward, toward timing belt end of engine. Identification
mark is located on camshaft sprocket, below timing belt area.
Right camshaft sprocket contains an R identification mark,
and left camshaft sprocket contains an L identification mark.
pulley aligns with 0 mark on timing belt cover. Using
sprocket holder, rotate camshaft sprockets and align tim-
ing marks on camshaft sprockets with timing marks on
timing belt rear plate. See Fig. 1. Align installation mark on
timing belt with end of fan bracket (LS400) or hydraulic
pump (SC400).
Ensure timing mark on camshaft sprockets align with tim-
ing mark on timing belt rear plate. See Fig. 1. Align installa-
tion mark on timing belt with timing mark on left camshaft
sprocket. See Fig. 1. Install timing belt on left camshaft
sprocket.
Ensure timing mark on left camshaft sprocket still aligns
with timing mark on timing belt rear plate. Ensure tension
exists on timing belt between left camshaft sprocket and
crankshaft sprocket. Ensure timing mark on right camshaft
sprocket still aligns with timing mark on timing belt rear
plate.
Align installation mark on timing belt with timing mark on
right camshaft sprocket. See Fig. 1. Install timing belt on
right camshaft sprocket. Ensure timing mark on right cam-
shaft sprocket still aligns with timing mark on timing belt
rear plate. Ensure tension exists on timing belt between
right and left camshaft sprockets. Using press, apply pres-
sure on rod of timing belt tensioner until rod is retracted
and holes in rod and housing arealigned. See Fig. 6.
tensioner. Alternately tighten bolts to specification. See
CAUTION: Always rotate crankshaft clockwise as viewed from
front of engine. DO NOT rotate crankshaft counterclockwise.
tate crankshaft 2 full revolutions clockwise from TDC to
with timing marks on timing belt rear plate. See Fig. 1. If
stall. To install remaining components, reverse removal
procedure.
Ensure distributor housings are installed in correct loca-
tion according to identification mark on front of distributor
housing. Right distributor housing (viewed from rear of
engine) contains an R identification mark. Left distributor
housing contains an L identification mark.
Install rotors so rotor protrusion aligns with camshaft
sprocket groove. See Fig. 7. Ensure spark plug wires are
properly positioned and installed in retainers. See Fig. 2.
Tighten all bolts/nuts to specification. See TORQUE SPECI-
LEXUS
4.0L V8 1990-97 (Cont.)
Fig. 2: Removing/Installing Spark Plug Wires & Retainers
360
LEXUS
4.0L V8 1990-97 (Cont.)
361
LEXUS
4.0L V8 1990-97 (Cont.)
Fig. 7: Installing Rotors
Fig. 5: Identifying Timing Belt Installation Marks
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Distributor Housing Bolt ............................................. 13 (18)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Spark Plug .................................................................. 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ............................... 57 (6.4)
Valve Cover Bolt ......................................................... 52 (5.9)
362
4.0L V8
GS400
1998-00................. 4.5 Hours .................. 250298
LS400
1998-00................. 4.5 Hours .................. 250298
SC400
1998-00................. 4.8 Hours .................. 250298
miles or 72 months.
TIMING BELT
Removal:
cover. Drain cooling system. Remove air cleaner inlet. Re-
move V bank cover from top of engine. Remove air cleaner
assembly and intake air connector pipe.
On all models, drain engine coolant. Remove upper radia-
tor hose.
On GS400 and LS400, remove serpentine drive belt by turn-
ing drive belt tensioner pulley bolt counterclockwise.
Tensioner pulley bolt is LEFT HAND threaded. On SC400,
turn serpentine drive belt tensioner bolt CLOCKWISE to
relieve tension.
On LS400, remove fan and fan clutch and fan pulley. On
GS400, remove electric cooling fan assembly. On SC400,
disconnect hydraulic fan motor pressure and return pipes
from fan. Disconnect cooling fan inlet pipe and reservoir
tank from fan shroud.
On all models, remove the radiator assembly. Remove No.
2 drive belt idler pulley. See Fig. 2. Disconnect camshaft
position sensor wiring connector from No. 3 left side belt
cover. Move engine wiring harness out of way and remove
No. 3 left side (driver side) belt cover. See Fig. 2.
On GS400 and LS400, disconnect power steering air hose
from clamp on No. 3 right side belt cover. On LS400, dis-
connect coolant reservoir-to-engine pipe from in front of
No. 3 right side belt cover. On all models, remove No. 3
right side (passenger side) belt cover. See Fig. 2.
Remove A/C compressor from engine mount with hoses
attached. Move A/C compressor out of way. On GS400, re-
move No. 1 drive belt idler pulley and mount from engine.
See Fig. 2. On LS400, remove fan bracket from front of
engine. On SC400, remove fan hydraulic pump from front
of engine. See Fig. 7.
CAUTION: If reusing timing belt, check that there are 3 mating
marks on belt to show installed position on crankshaft and camshaft
timing pulleys. If marks are missing, place installation mating
marks on timing belt and camshaft and crankshaft pulleys. Also,
mark belt with arrow to indicate original direction of rotation.
Using Pulley Holder (SST 09213-70010) or equivalent and
pulley. Loosen, but do not remove crankshaft pulley bolt.
compression stroke. Cylinder No. 1 is front cylinder on left
on crankshaft pulley aligns with 0 mark on No. 1 timing
ing marks on timing belt rear plates. See Fig. 1. If timing
marks are not aligned, rotate crankshaft CLOCKWISE one
complete revolution.
Rotate crankshaft clockwise about 50 degrees clockwise.
Place timing mark on crankshaft pulley in line with centers
of crankshaft pulley bolt and No. 2 timing belt idler pulley
bolt. See Fig. 3.
CAUTION: If timing belt is disengaged, having crankshaft at incorrect
angle can cause piston to contact valves while removing crankshaft
pulley.
LEXUS
*4.0L V8 1998-00
Fig. 1: Crankshaft & Camshaft Timing Mark Alignment
Without moving crankshaft pulley, remove pulley bolt. Alter-
nately loosen 2 bolts, and remove timing belt tensioner.
DO NOT hold timing belt tensioner with push rod facing
downward. See Fig. 2.
Using spanner wrench, slightly rotate right side camshaft
pulley clockwise to relieve tension on timing belt. Remove
timing belt from camshaft pulleys.
On GS400, remove power steering pump pulley bolt and
pulley. On all models, remove generator. Remove serpen-
tine drive belt tensioner. Using gear puller, remove crank-
shaft pulley without rotating crankshaft.
Remove No. 1 timing belt cover. See Fig. 4. Noting installed
direction for reassembly reference, remove timing belt
guide from end of crankshaft. Remove timing belt cover
spacer.
363
Fig. 2: Exploded View Of Timing Belt Covers (GS400 Shown; Others Similiar)
LEXUS
*4.0L V8 1998-00 (Cont.)
364
If reusing timing belt, place mating mark on timing belt and
crankshaft timing pulley. Remove timing belt.
Inspection:
nated. Check idler pulleys for smooth rotation and oil seal
leakage. Replace idler pulleys if defective.
CAUTION: Never hold timing belt tensioner facing downward.
place timing belt tensioner if there are excessive oil leaks.
Hold timing belt tensioner body with push rod facing UP-
WARD. Press push rod against solid surface. Replace tim-
ing belt tensioner if push rod moves. Measure timing belt
tensioner push rod protrusion from end of rod to edge of
housing. See Fig. 5. Replace timing belt tensioner if dis-
tance is not .413-.453" (10.50-11.50 mm). Inspect water
pump for leaks or worn bearing.
Installation:
Install No.1 idler pulley and plate washer (if removed). Ap-
ply Loctite 242 or equivalent on threads of idler pulley pivot
bolt. Install and tighten bolt to specification. See TORQUE
SPECIFICATIONS.
If removed, install No. 2 idler pulley and bolt. Tighten bolt to
pulleys are clean and rotate smoothly. Ensure idler pulley
bracket moves freely.
Clean any oil or water off of crankshaft timing pulley. DO
NOT use solvent. Temporarily Install timing belt on crank-
shaft timing pulley, No. 1 idler pulley, and No. 2 idler pulley.
If reusing old belt, ensure mating mark on timing belt aligns
with mark on crankshaft timing pulley.
Install timing belt guide in original direction on end of crank-
shaft. Install gasket and timing belt cover spacer. Install
gaskets and No. 1 timing belt cover.
Without rotating crankshaft, align crankshaft key with key
groove of crankshaft pulley. Using hammer and Pulley In-
staller (SST 09223-46011) or equivalent, install crankshaft
pulley.
Install serpentine drive belt tensioner. Tighten bolts to speci-
fication. See TORQUE SPECIFICATIONS. Install generator.
On GS400, install power steering pump pulley. On all mod-
els, ensure crankshaft is still at 50 degrees ATDC position.
See Fig. 3.
Ensure camshaft timing pulleys are still aligned with mat-
ing marks on rear plate. See Fig. 1. Clean camshaft timing
pulleys (do not use solvent). Install timing belt on left side
(drivers side) camshaft pulley. If reusing old timing belt,
ensure mating mark on belt aligns with mark on left side
camshaft pulley.
Using spanner wrench, turn left side camshaft pulley until
there is tension on timing belt between crankshaft timing
pulley and left side camshaft pulley.
Install timing belt on right side camshaft pulley. If reusing
old belt, ensure mating mark on belt aligns with mark on
right side camshaft pulley. Ensure there is tension on tim-
ing belt between left side and right side camshaft pulleys.
sure on push rod of timing belt tensioner until rod is re-
tracted. Ensure timing belt tensioner is held with push rod
facing upward. Holes in push rod and housing must be
tensioner. Alternately tighten bolts to specification. See
CAUTION: Always rotate crankshaft clockwise as viewed from
front of engine. DO NOT rotate crankshaft counterclockwise.
Remove hexagon wrench from timing belt tensioner. Tem-
porarily install crankshaft pulley bolt. Slowly rotate crank-
shaft 2 full revolutions clockwise from TDC to TDC. Ensure
LEXUS
*4.0L V8 1998-00 (Cont.)
Fig. 3: Setting Crankshaft At 50 Degrees ATDC
Fig. 4: Exploded View Of Timing Belt & Idler Pulleys
365
LEXUS
*4.0L V8 1998-00 (Cont.)
timing marks on camshaft sprockets align with timing marks
on timing belt rear plate. See Fig. 1. If timing marks are not
aligned, remove timing belt and reinstall.
Tighten crankshaft pulley bolt to specification. On GS400,
install No. 1 drive belt idler pulley. On LS400, install fan
bracket. On SC400, install fan hydraulic pump and attach
lines.
On all models, install A/C compressor. Install No. 2 timing
belt cover. Install No. 3 timing belt covers. Connect cam-
shaft position sensor electrical connectors. Install serpen-
tine drive belt idler pulley.
Install radiator assembly. Install air cleaner assembly. Fill
and bleed cooling system. Start engine and open heater
water valve. Maintain engine speed at 2000-2500 RPM un-
til engine is warm. Stop engine. When engine is cool, refill
coolant reservoir.
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Fan Bracket-To-Engine Bolts (LS400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
Generator Pivot & Lock Bolt ............................................ 29 (39)
Hydraulic Pump-To-Engine Bolts (SC400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
No. 2 Timing Belt Cover Bolt .......................................... 12 (16)
No. 1 Timing Belt Idler Pulley Pivot Bolt ........................
1
25 (35)
No. 2 Timing Belt Idler Pulley Bolt .................................. 25 (35)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Power Steering Pump Pulley Center Nut
GS400 .......................................................................... 32 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt
GS400 & SC400........................................................... 15 (21)
LS400........................................................................... 13 (18)
INCH Lbs. (N.m)
Camshaft Timing Pulley Bolt ......................................... 66 (7.5)
No. 3 Camshaft Belt Cover Bolts ................................... 66 (7.5)
1
Use Loctite 242 on bolt threads.
Fig. 7: Timing Belt Components (LS400 & SC400)
Courtesy ofToyota Motor Sales, U.S.A., Inc.
Courtesy ofToyota Motor Sales, U.S.A., Inc.
366
4.7L V8
Land Cruiser
1998-01................. 4.5 Hours .................. 250298
LX470
1998-01................. 4.5 Hours .................. 250298
Tundra
2000-01................. 4.5 Hours .................. 250298
miles or 72 months.
TIMING BELT
Removal (Land Cruiser & LX470):
Raise and support vehicle. Remove lower engine cover.
Drain cooling system. Remove intake manifold cover lo-
cated on top of engine. Remove air cleaner assembly with
air intake hose that goes to throttle body.
Loosen 4 bolts holding fluid coupling to cooling fan bracket.
See Fig. 1. Remove serpentine drive belt, cooling fan fluid
coupling assembly, and fan pulley.
Remove radiator assembly. Remove accessory drive belt
idler pulley. Remove No. 3 timing belt cover from front of
passengers side camshaft.
Disconnect engine wiring harness clamps for access to
No. 3 timing belt cover at front of drivers side camshaft.
Disconnect electrical connectors from camshaft position
sensor on No. 3 timing belt cover. Remove No. 3 timing belt
cover. See Fig. 1.
Remove oil cooler pipe. Remove No. 2 timing belt cover.
Remove A/C compressor with hoses attached and set
aside. Remove cooling fan bracket.
Using Pulley Holder (SST 09213-70010) and Handle (SST
9330-00021), hold crankshaft pulley. Loosen crankshaft
pulley bolt.
at crankshaft and camshaft sprockets. If installation mark does
not exist, place mating marks on timing belt and crankshaft sprocket.
See Fig. 2. Also, place arrow on belt indicating direction of rotation.
Rotate crankshaft clockwise (viewed from front of engine)
so crankshaft pulley groove aligns with 0 timing mark on
No. 1 (lower) timing belt cover. See Fig. 7. Ensure timing
marks on camshaft sprockets align with marks on the tim-
ing belt rear plates. See Fig. 2. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution.
Realign crankshaft pulley groove with 0 timing mark on
No. 1 (lower) timing belt cover.
CAUTION: Crankshaft must be properly positioned BEFORE removing
timing belt to prevent pistons from hitting valves. DO NOT allow
engine to rotate when removing crankshaft pulley bolt.
LEXUS & TOYOTA
*4.7L V8
367
LEXUS & TOYOTA
*4.7L V8 (Cont.)
Fig. 2: Locating Timing Belt Alignment Marks
Using crankshaft pulley bolt, rotate crankshaft clockwise
(viewed from front of engine) about 50 degrees ATDC. This
will align crankshaft pulley groove with centerline of crank-
shaft pulley bolt and No. 2 idler pulley bolt. See Fig. 3. This
prevents valves from contacting pistons. Remove crank-
shaft pulley bolt.
Alternately loosen bolts and remove timing belt tensioner
and dust boot. Using spanner wrench in holes in camshaft
sprocket, slightly rotate passengers side camshaft
sprocket clockwise to release timing belt tension. Remove
Remove serpentine drive belt tensioner. See Fig. 1. Re-
move generator. Without letting crankshaft rotate, use puller
to remove crankshaft pulley. Remove No. 1 timing belt cover.
Noting direction of timing belt guide for installation refer-
ence, remove timing belt guide and timing belt cover spacer.
Remove timing belt.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft
sprockets. Wipe clean only.
Inspection (Land Cruiser & LX470):
leakage exists.
exists, replace timing belt tensioner. NEVER hold timing belt tensioner
with push rod facing DOWNWARD.
DO NOT allow tensioner push rod to face downward. Hold
timing belt tensioner body and press rod against solid sur-
face. Replace timing belt tensioner if rod moves.
Inspect water pump for leaks or bearing failure.
NOTE: Install timing belt with engine cold.
Installation (Land Cruiser & LX470):
If No. 1 idler pulley was removed, apply Loctite 242 or equiva-
lent to bolt threads. Ensure pulley bracket moves freely.
Install timing belt on crankshaft sprocket. If reusing old
belt, ensure match marks made on removal are properly
aligned.
Place timing belt around No. 1 and No. 2 idler pulleys.
Install gasket and timing belt cover spacer. Install timing
belt guide with cupped side away from crankshaft sprocket
and flat side toward timing belt.
Install No. 1 timing belt cover. Align groove of crankshaft
pulley with key in crankshaft. Tap crankshaft pulley until
seated on crankshaft.
Install serpentine drive belt tensioner. Install generator.
FICATIONS. Ensure crankshaft pulley groove aligns with
centerline of crankshaft and No. 2 idler pulley bolts. See
Fig. 3.
Ensure timing mark on drivers side camshaft sprocket is
correctly aligned. See Fig. 6. Install timing belt on drivers
side camshaft sprocket. If reusing old belt, ensure match-
ing marks are aligned. Rotate drivers side camshaft
sprocket counterclockwise until tension exists on timing
belt between crankshaft sprocket and drivers side cam-
shaft sprocket.
Fig. 3: Positioning Crankshaft Pulley
368
LEXUS & TOYOTA
*4.7L V8 (Cont.)
Fig. 6: Installing Timing Belt On Camshaft Sprocket
Ensure passengers side camshaft sprocket timing mark
is still aligned. Install timing belt on passengers side cam-
shaft sprocket. If reusing old belt, ensure matching marks
sure on timing belt tensioner rod until rod is retracted and
holes in rod and housing are aligned. See Fig. 5. Install
hexagon wrench through holes in housing and rod to hold
rod in retracted position.
Install timing belt tensioner on engine. Install and alter-
nately tighten bolts to specification.
CAUTION: When checking valve timing, only rotate crankshaft
clockwise as viewed from front of engine. DO NOT rotate crankshaft
counterclockwise.
Remove hexagon wrench from timing belt tensioner. To
check valve timing, rotate crankshaft pulley clockwise 2 full
revolutions from TDC to TDC. Crankshaft pulley groove
must align with 0 timing mark on No. 1 (lower) timing belt
cover.
With crankshaft at TDC position, ensure camshaft sprock-
ets align with timing marks on rear plates. If installing old
belt, ensure belt matching marks are aligned with cam-
shaft sprockets. If timing marks are not aligned, timing belt
will have to be removed and repositioned.
Tighten crankshaft pulley bolt to specification. Install fan
bracket. Install A/C compressor to engine mount bracket.
Install No. 2 and No. 3 timing belt covers. Install drive belt
idler pulley. Install radiator. Install cooling fan assembly.
dure. Tighten all fasteners to specification. Fill and bleed
air from cooling system.
Cooling System Bleeding:
Fill cooling system. Install radiator cap. Move heater con-
trol to warmest position. Start engine. Maintain engine speed
at 2000-2500 RPM until engine is at normal operating tem-
perature.
Shut engine off. Allow engine to cool. Recheck coolant level.
Fill coolant level to FULL line on coolant reservoir if neces-
sary.
Removal (Tundra):
Raise and support vehicle. Remove lower engine cover.
Drain cooling system. Remove radiator assembly. Remove
throttle body cover. Remove intake air connector assembly.
Loosen 4 bolts holding fluid coupling to cooling fan bracket.
See Fig. 1. Remove serpentine drive belt, cooling fan fluid
coupling assembly, and fan pulley.
Remove power steering pump from engine with hoses at-
tached and secure out of way. Remove serpentine drive
belt idler pulley. Remove No. 3 timing belt cover from front
of passengers side camshaft.
Disconnect engine wiring harness clamps for access to
No. 3 timing belt cover at front of drivers side camshaft.
Disconnect electrical connectors from camshaft position
sensor on No. 3 timing belt cover. Remove No. 3 timing belt
cover. See Fig. 1.
Remove oil cooler pipe. Remove No. 2 timing belt cover.
Remove A/C compressor with hoses attached and set
aside. Remove cooling fan bracket.
Using Pulley Holder (SST 09213-70010) and Handle (SST
9330-00021), hold crankshaft pulley. Loosen crankshaft
pulley bolt.
at crankshaft and camshaft sprockets. If installation mark does
not exist, place matching marks on timing belt and crankshaft
sprocket. See Fig. 2. Also, place arrow on belt indicating direction
of rotation.
Rotate crankshaft clockwise (viewed from front of engine)
so crankshaft pulley groove aligns with 0 timing mark on
No. 1 (lower) timing belt cover. See Fig. 7.
369
LEXUS & TOYOTA
*4.7L V8 (Cont.)
Ensure timing marks on camshaft sprockets align with
marks on the timing belt rear plates. See Fig. 2. If timing
marks are not aligned, rotate crankshaft clockwise one full
revolution. Realign crankshaft pulley groove with 0 timing
mark on No. 1 (lower) timing belt cover).
Alternately loosen bolts and remove timing belt tensioner
and dust boot. Using spanner wrench in holes in camshaft
sprocket, slightly rotate passengers side camshaft
sprocket clockwise to release timing belt tension. Remove
Remove serpentine drive belt tensioner. See Fig. 1. With-
out letting crankshaft rotate, use puller to remove crank-
shaft pulley. Remove No. 1 timing belt cover. Noting direc-
tion of timing belt guide for installation reference, remove
timing belt guide and timing belt cover spacer. Remove
timing belt.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft
sprockets. Wipe clean only.
Inspection (Tundra):
leakage exists.
exists, replace timing belt tensioner. NEVER hold timing belt tensioner
with push rod facing DOWNWARD.
DO NOT allow tensioner push rod to face downward. Hold
timing belt tensioner body and press rod against solid sur-
face. Replace timing belt tensioner if rod moves.
Inspect water pump for leaks or bearing failure.
NOTE: Install timing belt with engine cold.
Installation (Tundra):
If No. 1 idler pulley was removed, apply Loctite 242 or equiva-
lent to bolt threads. Ensure pulley bracket moves freely.
Install timing belt on crankshaft sprocket. If reusing old
belt, ensure match marks made on removal are properly
aligned.
Place timing belt around No. 1 and No. 2 idler pulleys.
Install gasket and timing belt cover spacer. Install timing
belt guide with cupped side away from crankshaft sprocket
and flat side toward timing belt.
Install No. 1 timing belt cover. Align groove of crankshaft
pulley with key in crankshaft. Tap crankshaft pulley until
seated on crankshaft.
Install serpentine drive belt tensioner. Install generator.
FICATIONS. Ensure the crankshaft pulley groove aligns with
0 timing mark on No. 1 timing belt cover. See Fig. 7.
Ensure timing mark on drivers side camshaft sprocket is
correctly aligned. See Fig. 6. Install timing belt on drivers
side camshaft sprocket. If reusing old belt, ensure match-
ing marks are aligned. Rotate drivers side camshaft
sprocket counterclockwise until tension exists on timing
belt between crankshaft sprocket and drivers side cam-
shaft sprocket.
Ensure passengers side camshaft sprocket timing mark
is still aligned. Install timing belt on passengers side cam-
shaft sprocket. If reusing old belt, ensure matching marks
sure on timing belt tensioner rod until rod is retracted and
holes in rod and housing are aligned. See Fig. 5. Install
hexagon wrench through holes in housing and rod to hold
rod in retracted position.
Install timing belt tensioner on engine. Install and alter-
nately tighten bolts to specification.
CAUTION: When checking valve timing, only rotate crankshaft
clockwise as viewed from front of engine. DO NOT rotate crankshaft
counterclockwise.
Remove hexagon wrench from timing belt tensioner. To
check valve timing, rotate crankshaft pulley clockwise 2 full
revolutions from TDC to TDC. Crankshaft pulley groove
must align with 0 timing mark on No. 1 (lower) timing belt
cover.
With crankshaft at TDC position, ensure camshaft sprock-
ets align with timing marks on rear plates. If installing old
belt, ensure belt matching marks are aligned with cam-
shaft sprockets. If timing marks are not aligned, timing belt
will have to be removed and repositioned.
Tighten crankshaft pulley bolt to specification. Install fan
bracket. Install A/C compressor to engine mount bracket.
Install No. 2 and No. 3 timing belt covers. Install drive belt
idler pulley. Install radiator. Install cooling fan assembly.
dure. Tighten all fasteners to specification. Fill and bleed
air from cooling system.
Cooling System Bleeding:
Fill cooling system. Install radiator cap. Move heater con-
trol to warmest position. Start engine. Maintain engine speed
at 2000-2500 RPM until engine is at normal operating tem-
perature.
Shut engine off. Allow engine to cool. Recheck coolant level.
Fill coolant level to FULL line on coolant reservoir if neces-
sary.
Accessory Drive Belt Tensioner Bolt ............................... 12 (16)
A/C Compressor-To-Mount Bolt ................................. 36 (49)
Cooling Fan Bracket
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
Cooling Fan Fluid Coupling-To-Cooling
Fan Bracket .................................................................. 16 (21)
Generator Bolt/Nut .......................................................... 12 (16)
No. 1 & No. 2 Idler Pulley Bolts .....................................
1
25 (35)
No. 2 Timing Belt Cover Bolt .......................................... 12 (16)
Radiator Bracket-To-Body Bolts...................................... 12 (18)
Spark Plug .................................................................. 13 (18)
Water Pump
Stud Bolt & Nut ........................................................... 13 (18)
Bolt ............................................................................... 15 (21)
INCH Lbs. (N.m)
No. 3 Timing Belt Cover Bolts .................................... 66 (7.5)
1
- Apply Loctite 242 or equivalent to No. idler pulley bolt
threads.
370
MAZDA
1.5L 4-Cylinder
1.5L 4-Cyl.
Protege
1995-97................. 2.4 Hours ................. 250266
1998
Up To Engine No.
194742 ............... 2.4 Hours ................. 250266
From Engine No.
194743 ............... 2.4 Hours ................. 250308
mile intervals for vehicles sold outside of California and Mas-
sachusetts. For vehicles sold in California and Massachu-
setts, inspect timing belt at 60,000 and 90,000 miles, and
replace timing belt at 105,000 miles.
TIMING BELT
Removal:
hicle. Remove right front wheel. Remove right side cover
and undercover.
Remove dri ve bel ts and water pump pul l ey.
Align crankshaft pulley timing mark with cylinder No. 1 at
TDC of compression stroke. Hold crankshaft stationary.
Remove crankshaft pulley bolts and pulley. Remove crank-
shaft pulley hub bolt and hub.
Remove spark plug wires. Remove valve cover bolts in
reverse order of tightening sequence. See Fig. 1. Remove
valve cover. Remove dipstick tube.
Remove upper timing belt cover. Support engine with jack.
Remove engine mount bracket from timing belt end of en-
gine. If timing belt is to be reused, mark timing belt rotation
direction. Ensure timing marks on camshaft and crank-
shaft sprockets are aligned. See Fig. 2.
Remove lower and middle timing belt covers. Loosen tim-
ing belt tensioner lock bolt, and move tensioner away from
belt with spring fully expanded. Remove timing belt.
Inspection:
ness of rotation. Inspect tensioner spring free length. Speci-
fied length is 2.80 (71mm). Replace parts as necessary.
Installation:
Position notch on crankshaft sprocket to 12 oclock posi-
tion (aligned with mark on oil pump). Align timing marks on
camshaft sprocket and crankshaft. See Fig. 2. Ensure crank-
shaft timing mark is at TDC of compression stroke. Install
belt around crankshaft sprocket. Working in a counterclock-
wise direction, route belt around pulleys and camshaft
sprocket.
Loosen timing belt tensioner lock bolt and allow spring to
shaft 2 complete turns in direction of normal engine rota-
tion. Ensure timing marks align.
Letter Z on camshaft pulley and pin on crankshaft pulley
boss should face upward. If timing marks are not aligned,
remove belt, realign all timing marks, and repeat installa-
tion procedure.
Fig. 1: Valve Cover Bolt Tightening Sequence
Courtesy of Mazda Motors Corp.
Check timing belt deflection with 22 lbs. (10 kg) of pres-
sure applied to belt. See Fig. 3. Ensure timing belt deflec-
tion is .28-.35 (7.0-9.0mm).
Ensure grooves on valve cover are free of oil, water, and
dirt. Using new valve cover gasket, install valve cover.
Tighten valve cover bolts in sequence. See Fig. 1. Com-
plete installation in reverse of removal procedure.
Crankshaft Pulley-to-Pulley Boss Bolt ............... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ..................... 116-123 (157-167)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Chain Adjuster Bolt ................................. 71-97 (8-11)
Timing Cover Bolt ................................................... 71-97 (8-11)
Valve Cover Bolt ...................................................... 62-97 (7-11)
371
MAZDA
1.6L 4-Cyl. DOHC
Protege
1999-01................
1
2.7 Hours ................. 250308
1
For 1999-00 vehicles, the manufacturer recommends belt re-
placement interval at 60,000 miles except for vehicles regis-
tered in California, Connecticut, Delaware, Maine, Maryland,
Massachusetts, New Hampshire, New Jersey, New York, Penn-
sylvania, Rhode Island, Vermont, and Washington D.C. For
these states, inspect timing belt at 60,000 and 90,000 miles,
and replace timing belt at 105,000 miles.
For 2001 vehicles, the replacement interval is 105,000 miles,
UNLESS the vehicle is operated in outside temperatures un-
der 0F (-18C). Under this condition, replace timing belt at
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove camshaft po-
sition sensor from left side (exhaust) of engine. Remove
ignition coils. Remove valve cover.
Remove accessory drive belts and water pump pulley. Align
crankshaft pulley timing mark with cylinder No. 1 at TDC of
compression stroke. Groove in crankshaft pulley should
align with T mark on timing belt cover.
Remove crankshaft pulley from pulley boss. See Fig. 1.
Note installed position, and remove plate from pulley boss.
Holding crankshaft , loosen crankshaft pulley boss bolt.
Support engine with jack or from above with support bar.
Remove engine mount from timing belt end of engine.
Remove timing belt covers. See Fig. 1. If timing belt is to be
reused, mark timing belt rotation direction.
Ensure camshaft and crankshaft timing marks are aligned
correctly. See Fig. 2. Pulley boss position pin on crankshaft
should be facing up. If not, rotate crankshaft until marks are
aligned. Remove crankshaft pulley boss.
Loosen timing belt tensioner lock bolt. Temporarily secure
tensioner away from belt with spring fully expanded. Re-
move timing belt.
Inspection:
Tensioner spring free length should be 2.43 (61.8 mm).
Installation:
Install tensioner spring with damper rubber closing face
on side away from tensioner. See Fig. 3.
aligned. See Fig. 2. Temporarily secure tensioner with
spring fully extended. Install belt around crankshaft sprocket,
idler pulley, exhaust camshaft, intake camshaft, then
tensioner.
Temporarily install crankshaft pulley boss and bolt. Loosen
timing belt tensioner lock bolt, and allow spring to apply
tension on belt. Rotate crankshaft clockwise almost 2 com-
plete turns.
Remove the crankshaft pulley boss bolt and pulley boss.
Ensure the crankshaft timing belt pulley mark is aligned
with tensioner set mark. See Fig. 4. If not, rotate crankshaft
to align.
While holding timing belt tensioner, tighten lock bolt to speci-
Install crankshaft boss and tighten bolt to specification.
Turn crankshaft clockwise 2 revolutions. Face pin on crank-
shaft pulley boss straight up. Ensure camshaft sprocket
timing marks are correctly aligned. See Fig. 2. If timing
marks are not aligned, remove belt, realign all timing
marks, and repeat installation procedure.
Check timing belt deflection with 22 lbs. (10 kg) of down-
ward pressure applied to belt, midway between camshaft
sprockets. Timing belt deflection should be 0.24-0.29 (6.0-
7.5 mm). If not, readjust timing belt tension.
installing valve cover, tighten valve cover bolts in correct
sequence. See Fig. 5.
Adjust air gap between crankshaft plate and Crankshaft
Position (CKP) sensor. With a plate tooth directly centered
over CKP sensor, air gap should be 0.020-0.059 (0.5-1.54
mm). Adjust accessory drive belts to proper tension. See
372
MAZDA
Fig. 3: Installing Timing Belt Tensioner Spring
Fig. 4: Aligning Timing Belt At Tensioner Set Mark
Crankshaft Pulley Boss Bolt ....................... 116-123 (157-167)
Engine Mount Nut/Bolt ......................................... 44-59 (59-80)
Engine Mount-To-Engine Bolt .............................. 50-68 (67-93)
Idler Pulley Bolt ................................................... 28-38 (38-52)
INCH Lbs. (N.m)
Camshaft Position Sensor Bolt ............................. 69-95 (8-11)
Crankshaft Position Sensor Bolt ........................ 69-95 (8-11)
Crankshaft Pulley-To-Pulley Boss Bolt ....... 109-151 (12.3-17.1)
Water Pump Pulley Bolt .......................................... 69-95 (8-11)
373
(1989 SOHC)
MAZDA
1.6L & 1.8L 4-Cylinder 1988-95
Belt
1.6L 4-Cyl. DOHC
MX-3
1994-95..........
1
2.9 Hrs. .... 2521790........ 250179
MX-5 Miata
1990-93 .........
1
3.0 Hrs. .... 2521790........ 250179
323
1988-89..........
1
2.8 Hrs. ........................... 250149
1.6L 4-Cyl. SOHC
MX-3
1992-93..........
1
2.0 Hrs. ........................... 250185
323
1986...............
1
2.0 Hrs. ........................... 250123
1987-89..........
1
2.0 Hrs. .... 2521410........ 250141
1990-94..........
1
2.0 Hrs. ........................... 250185
1.8L 4-Cyl. DOHC
Protege
1990-95..........
1
2.8 Hrs. .... 2521790........ 250179
1.8L 4-Cyl. SOHC
Protege
1990-94..........
1
2.0 Hrs. ........................... 250185
1
kits.
For 1992 and earlier model years, the manufacturer recom-
belt be replaced at 60,000 mile intervals for vehicles sold
outside of California. For vehicles sold in California, inspect
timing belt at 60,000 and 90,000 miles, and replace timing
belt at 105,000 miles.
TIMING BELT
Removal (MX-5 Miata):
Remove radiator hose and by-pass hoses from thermo-
stat housing. Remove air cleaner intake duct assembly
from throttle body to air cleaner filter housing. Remove
splash shield.
Remove drive belt(s) and water pump pulley. Align crank-
shaft pulley timing mark with cylinder No. 1 at TDC of com-
pression stroke. Hold crankshaft pulley stationary. Remove
crankshaft pulley bolts. Remove pulley. Remove crankshaft
pulley hub bolt and hub.
Remove cylinder head cover. Remove upper, center and
lower timing belt cover. If timing belt is to be reused, mark
timing belt rotation direction. Ensure timing marks on cam-
shaft sprockets are aligned. See Fig. 5. Loosen timing belt
tensioner lock bolt, and move tensioner away from belt
with spring fully expanded. Remove timing belt.
Removal (MX-3, Protege & 323):
hicle. Remove right front wheel. Remove right splash pan-
els.
Remove drive belts and water pump pulley. Align crank-
pression stroke. Hold crankshaft stationary, and remove
crankshaft pulley bolts and pulley. Remove crankshaft pul-
ley hub bolt and hub.
Remove timing belt covers. If timing belt is to be reused,
mark timing belt rotation direction. Align timing marks on
camshaft sprocket(s). See Figs. 5 and 6. Loosen timing
belt tensioner lock bolt. Temporarily secure tensioner away
from belt with spring fully expanded. Remove timing belt.
Inspection (All Models):
tion (aligned with mark on oil pump). Align timing marks on
camshaft sprocket(s). See Figs. 5 and 6. Ensure crank-
shaft timing mark is at TDC. Install belt around crankshaft
sprocket then working in a counterclockwise direction, route
belt around camshaft sprocket(s).
shaft 2 complete turns in direction of normal engine rota-
tion. Ensure timing marks align. If timing marks are not
aligned, remove belt, realign all timing marks, and repeat
installation procedure.
On all engines, check timing belt deflection with 22 lbs. (10
kg) of pressure applied to belt. See Fig. 7. Ensure timing
belt deflection is within specification. See TIMING BELT
DEFLECTION. Adjust drive belts to proper tension. See page
374
MAZDA
1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
(1990 & Later SOHC)
Fig. 3: Exploded View Of Timing Belt Components (DOHC)
Fig. 4: Exploded View Of Timing Belt Components (Miata)
TIMING BELT DEFLECTION
Application
1
Deflection in. (mm)
1989-87 .................................................... .47-.51 (11.9-13.0)
1995-90
DOHC ........................................................ .35-.45 (9.0-11.5)
SOHC ..................................................... .43-.51 (11.0-13.0)
1
- Deflection measurement is with 22 lbs. (10 kg) of pressure
applied to timing belt. See Fig. 7.
A/C Compressor Bracket
MX-5 Miata ...................................................... 11-16 (15-22)
MX-3, Protege & 323 ....................................... 17-26 (23-35)
Alternator Top Bolt ............................................ 27-38 (37-52)
Crankshaft/Timing Belt Sprocket Bolt
1991-86 ...................................................... 80-87 (109-118)
1996-92 .................................................. 116-123 (157-167)
Power Steering Pump-To-Bracket Bolt
MX-3, Protege & 323 ....................................... 27-38 (37-52)
DOHC ............................................................. 27-38 (37-52)
SOHC ............................................................. 14-19 (19-26)
INCH Lbs. (N.m)
Camshaft/Rocker Cover Bolt
DOHC & SOHC (Top) ......................................... 43-78 (5-9)
SOHC
(Timing Belt Cover-To-Camshaft Cover) ........... 69-95 (8-11)
Crankshaft Pulley Bolts ............................... 109-152 (12-17)
375
MAZDA
1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
Fig. 5: Aligning Camshaft Timing Marks (DOHC Engines)
Fig. 6: Aligning Camshaft Timing Marks (SOHC Engines)
376
MAZDA
1.8L 4-Cylinder DOHC, BP Engine
Belt
1.8L 4-Cyl. DOHC
MX-5 Miata
1994-01..........
1
2.6 Hrs. .... 25211790 ...... 250179
Protege
1995-98..........
1
2.4 Hrs. .... 2521790........ 250179
1
kits.
NOTE: Engine identification code is on machined pad at left
rear end of engine, at transmission mating flange.
be replaced at 60,000 mile intervals for vehicles sold outside
of California. For vehicles sold in California, inspect timing
belt at 60,000 and 90,000 miles, and replace timing belt at
105,000 miles.
of California and Massachusetts. For vehicles sold in Califor-
nia and Massachusetts, inspect timing belt at 60,000 and
90,000 miles, and replace timing belt at 105,000 miles.
For 1999-00 vehicles, the replacement interval is 60,000 miles
except for vehicles registered in California, Connecticut, Dela-
ware, Maine, Maryland, Massachusetts, New Hampshire, New
Jersey, New York, Pennsylvania, Rhode Island, Vermont, Vir-
ginia and Washington D.C. For these states, inspect timing
belt at 60,000 and 90,000 miles, and replace timing belt at
105,000 miles.
For 2001 MX-5 Miata, the replacement interval is 60,000 miles.
TIMING BELT
Removal (MX-5 Miata):
Remove radiator hose and by-pass hoses from thermo-
stat housing. If equipped with an control valve and pipe,
remove oil pipe and cover with a shop rag to prevent oil
spill. Remove oil control valve case. Remove Crankshaft
Position (CKP) and Camshaft Position (CMP) sensors from
front of engine (if equipped).
Keeping ignition wires attached, remove ignition coil pack
from front (timing belt end) of engine. Remove spark plugs.
Remove air cleaner intake duct assembly from throttle body
to air cleaner filter housing.
Remove drive belt(s) and water pump pulley. See Fig. 1.
Remove valve cover. Align crankshaft pulley timing mark
with cylinder No. 1 at TDC of compression stroke.
Remove crankshaft pulley from crankshaft pulley boss. Re-
move plate with crankshaft pulley. Ensure crankshaft pul-
ley boss locating pin faces straight up. Holding crankshaft
pulley boss stationary, remove crankshaft pulley boss bolt.
Remove pulley boss.
Remove upper, middle, and lower timing belt covers. If tim-
ing belt is to be reused, mark timing belt with arrow to
indicate rotation direction.
Ensure timing marks on camshaft sprockets and crank-
shaft sprockets are aligned. See Fig. 4 . Loosen timing belt
tensioner lock bolt. Move tensioner away from belt with
spring fully expanded, and tighten lock bolt. Remove timing
belt.
Removal (Protege):
hicle. Remove right front wheel. Remove right splash shield
from wheelwell.
Remove drive belts and water pump pulley. Align crank-
pression stroke. Hold crankshaft stationary, and remove
crankshaft pulley pulley from crankshaft pulley boss. See
Fig. 2 and 3.
Remove spark plug wires from spark plugs. Remove valve
cover. Remove dipstick pipe. and stay. Remove upper tim-
ing belt cover. If timing belt is to be reused, mark timing belt
rotation direction.
Support engine from above and remove engine mount
bracket from timing belt end of engine. Remove middle
and lower timing belt covers.
Holding crankshaft stationary, remove crankshaft pulley
boss. Align timing marks on crankshaft and camshaft
sprocket(s). See Fig. 4. Loosen timing belt tensioner lock
bolt. Temporarily secure tensioner away from belt with spring
fully expanded. Remove timing belt.
damage. Check tensioner and idler pulley bearing for loose-
ness or roughness of rotation. Replace parts as neces-
sary.
Fig. 1: Exploded View Of Timing Belt Components (Miata)
377
Fig. 2: Exploded View Of Timing Belt Components (Protege)
MAZDA
1.8L 4-Cylinder DOHC, BP Engine (Cont.)
Inspect tensioner spring for stretching. Replace tensioner
spring if free length is not greater than 2.33 (59.2 mm).
Free length is measured between inside edge to inside of
hooked portion of spring.
tion (aligned with mark on oil pump). See Fig. 4. Align tim-
ing marks on camshaft sprocket(s).
NOTE: Timing mark on intake camshaft sprocket is an I; timing
mark on exhaust camshaft is an E.
Install timing belt tensioner spring with damper rubber clos-
ing face away from tensioner. See Fig. 5. Temporarily se-
cure the timing belt tensioner with tensioner spring fully
expanded.
Install timing belt around crankshaft sprocket, then work-
ing in a counterclockwise direction, route belt around idler
pulley, camshaft sprocket(s), and tensioner pulley. Ensure
there is no slack in belt between crankshaft sprocket, idler
pulley, and camshaft sprockets.
378
MAZDA
Fig. 3: Exploded View Of Timing Belt Components (Miata With Oil Control Valve - Protege Similar)
Temporarily install the crankshaft pulley boss and bolt. Ro-
tate crankshaft about 2 turns in direction of normal engine
rotation. Align timing belt pulley boss mark with tensioner
set mark for correct timing belt tension adjustment. See
Fig. 6.
Holding crankshshaft stationary, remove the crankshaft
pulley boss and bolt. Ensure the crankshaft and camshaft
timing marks are still aligned. Loosen timing belt tensioner
lock bolt to apply tension to timing belt. Without moving
tensioner, tighten tensioner lock bolt to specification. See
Install crankshaft pulley boss and final tighen bolt to speci-
fication. Rotate crankshaft 2 1/6 times. Camshaft timing
marks should be aligned with marks on rear cover, and the
crankshaft pulley boss locating pin should point straight
up. If timing marks are not aligned, remove belt, realign all
timing marks, and repeat installation procedure.
Check timing belt deflection with 22 lbs. (10 kg) of pres-
sure applied to belt. See Fig. 7. Ensure timing belt deflec-
tion is within specification. See TIMING BELT DEFLECTION
table.
TIMING BELT DEFLECTION
Application
1
Deflection in. (mm)
DOHC, BP Engine ....................................... .35-.45 (8.5-11.5)
1
- Deflection measurement is with 22 lbs. (10 kg) of pressure
applied to timing belt. See Fig. 6.
dure. While installing valve cover gasket, apply light bead
of silicone sealer to 6 corners where gasket meets ends of
camshafts. Tighten all valve cover bolts in the correct se-
quence. See Fig. 8.
379
MAZDA
Fig. 5: Installing Timing Belt Tensioner Spring
Fig. 6: Aligning Timing Belt Tensioner Set Mark
Fill and bleed cooling system. Fill with 50/50 mix of water
and coolant. To bleed system, fill system. Run engine at
2500 RPM for 5 minutes. Run engine 3000 RPM for 5 min-
utes. Recheck coolant level and fill as necessary. On Pro-
tege, check ignition timing.
Crankshaft Pulley-To-Pulley Boss .......................... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ....................... 116-123 (157-167)
Engine Mount Bracket (Protege)
Nuts ................................................................ 55-77 (75-104)
Alternator Top Bolt ............................................ 14-18 (19-25)
Alternator Pivot Bolt ............................................. 28-38 (38-51)
Idler Pulley Bolt ................................................... 28-38 (38-51)
Spark Plugs .......................................................... 11-16 (15-22)
Timing Belt Tensioner Bolt ................................. 28-38 (38-51)
Wheel Lug Nut (Protege) .................................. 66-94 (89-127)
INCH Lbs. (N.m)
Valve Cover Bolt ...................................................... 43-78 (5-9)
380
MAZDA
1.8L 4-Cylinder FP Engine
1.8L 4-Cyl. DOHC
Protege
1999-00................
1
2.4 Hours ................. 250316
1
NOTE: Engine code is stamped on machined pad on lower left
end of engine, on transaxle mating flange.
The replacement is 60,000 miles except for vehicles regis-
tered in California, Connecticut, Delaware, Maine, Maryland,
Massachusetts, New Hampshire, New Jersey, New York, Penn-
sylvania, Rhode Island, Vermont, and Washington D.C. For
TIMING BELT
Removal:
Disconnect negative battery cable. Remove Crankshaft Po-
sition (CKP) and Camshaft Position (CMP) sensors from
front of engine.
Remove accessory drive belt. Remove the water pump pul-
ley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on
TDC of compression stroke.
CAUTION: Crankshaft position sensor rotor is on rear of crankshaft
pulley. DO NOT damage rotor when removing crankshaft pulley.
Remove crankshaft pul l ey and gui de pl ate (l arge
washer). Loosen valve cover bolts in 2-3 steps. See Fig. 3.
Remove valve cover and gasket.
Remove dipstick tube. Remove upper and lower timing
belt covers. Support engine from above. Remove engine
mount at timing belt end of engine.
If reusing timing belt, mark arrow on belt to indicate direc-
tion of rotation. Install crankshaft pulley bolt finger-tight to
retain crankshaft sprocket. Rotate crankshaft clockwise (as
viewed from timing belt end of engine) until cylinder No. 1
piston is at TDC of compression stroke and timing marks
Turn tensioner clockwise with a hex wrench to relieve spring
tension, and then disconnect spring. Remove timing belt.
Remove tensioner and idler pulley (if necessary).
Inspection:
Installation:
Install tensioner, and idler pulley (if removed). Temporarily
tighten tensioner with spring fully retracted. Ensure cam-
shaft and crankshaft timing marks are aligned. See Fig. 1.
Install timing belt around crankshaft sprocket, water pump
sprocket, idler pulley, and camshaft sprockets. Ensure
slack does not exist on idler side of timing belt.
Complete timing belt installation on slack (tensioner) side.
Allow tensioner to ride against timing belt. Turn crankshaft
2 revolutions in normal direction of rotation. Ensure cam-
shaft and crankshaft timing marks are still correctly aligned.
If not, timing belt will have to be removed and repositioned.
If all timing marks are okay, turn tensioner clockwise by
using a hex wrench. Connect tensioner spring to pin on
engine block. Turn crankshaft 2 revolutions. Ensure cam-
shaft and crankshaft timing marks are still aligned.
dure. Tighten valve cover bolts in correct sequence. See
Fig. 3. Install water pump pulley with stamped F mark
away from engine. Adjust drive belts to proper tension. See
Inspect crankshaft position sensor air gap. Air gap between
outer edge of crankshaft pulley rotor tooth and center of
CKP sensor should be 0.029-0.059 (0.5-1.5 mm). Air gap
is not adjustable. If gap is incorrect, check for damage parts.
Timing Belt Idler Pulley Bolt .............................. 28-38 (38-52)
INCH Lbs. (N.m)
CKP & CMP Sensor Bolts ...................................... 71-97 (8-11)
Timing Belt Covers ............................................. 61-87 (7-10)
Water Pump Pulley Bolts ....................................... 71-97 (8-11)
381
MAZDA
1.8L 4-Cylinder FP Engine (Cont.)
Fig. 3: Valve Cover Bolt Loosening & Tightening Sequence
Loosening Sequence Tightening Sequence
382
MAZDA
*2.0L 4-Cylinder DOHC, Except Tribute
Belt
2.0L 4-Cyl. DOHC
MX-6
1993-97..........
1
2.5 Hrs. .... TCK228 ....... 250228
Protege
2001...............
1
2.4 Hrs. .... TCK228 ....... 250228
626
1993-01..........
1
2.5 Hrs. .... TCK228 ....... 250228
1
kits.
For 1994-96 models years, the manufacturer recommends
the belt be replaced at 60,000 mile intervals for vehicles sold
For 1997-98 model years, the manufacturer suggests the belt
of California and Massachusetts. For vehicles sold in Califor-
nia and Massachusetts, inspect timing belt at 60,000 and
belt be replaced at 60,000 mile intervals except for vehicles
registered in California, Connecticut, Delaware, Maine, Mary-
land, Massachusetts, New Hampshire, New Jersey, New York,
Pennsylvania, Rhode Island, Vermont, Virginia and Washing-
ton D.C. For these states, inspect timing belt at 60,000 and
replaced at 105,000 miles, UNLESS the vehicle is operated in
temperatures under 0F (-18C). Under this condition, replace
TIMING BELT
Removal:
Disconnect negative battery cable. Remove Crankshaft Po-
sition (CKP) and Camshaft Position (CMP) sensors from
front of engine (if equipped). Remove spark plugs.
Remove accessory drive belts. Leaving hoses attached,
remove power steering pump and position aside. Remove
the water pump pulley. Rotate crankshaft so No. 1 cylinder
is on TDC of compression stroke.
CAUTION: On models with a crankshaft position sensor, rotor
is on rear of crankshaft pulley. DO NOT damage rotor when removing
crankshaft pulley.
Remove crankshaft pul l ey and gui de pl ate (l arge
washer). Loosen valve cover bolts in 2-3 steps. See Fig. 2.
Remove valve cover and gasket.
Remove dipstick tube. Remove upper and lower timing
belt covers. Support engine from above. Remove engine
If reusing timing belt, mark arrow on belt to indicate direc-
tion of rotation. Install crankshaft pulley bolt finger-tight to
retain crankshaft sprocket. Rotate crankshaft clockwise (as
viewed from timing belt end of engine) until cylinder No. 1
piston is at TDC of compression stroke and timing marks
Turn tensioner clockwise with a hex wrench to relieve spring
tension, and then disconnect spring. Remove timing belt.
Remove crankshaft sprocket, tensioner and idler pulley (if
necessary).
Inspection:
Measure spring free length from inside edge to inside edge
of hooked portion of spring. Replace parts as necessary.
Installation:
Install crankshaft sprocket, tensioner, and idler pulley (if
removed). Temporarily tighten tensioner. DO NOT install
tensioner spring yet. Ensure all timing marks are aligned.
See Fig. 1.
Install timing belt around crankshaft sprocket, water pump
sprocket, idler pulley, and camshaft sprockets. Ensure
slack does not exist on idler pulley side of timing belt.
Complete timing belt installation on slack (tensioner) side.
With tensioner spring removed, allow tensioner to ride
against timing belt. Turn crankshaft 2 revolutions in normal
direction of rotation. Ensure camshaft and crankshaft tim-
ing marks are still correctly aligned. If not, timing belt will
have to be removed and repositioned.
If all timing marks are okay, turn tensioner clockwise using
a hex wrench. Connect tensioner spring to pin on engine
block. Turn crankshaft 2 revolutions. Ensure camshaft and
crankshaft timing marks are still aligned.
383
MAZDA
*2.0L 4-Cylinder DOHC, Except Tribute (Cont.)
Fig. 2: Valve Cover Bolt Loosening & Tightening Sequences
Loosening Sequence
Tightening Sequence
dure. When installing valve cover gasket apply small amount
of silicone sealer to 4 corners of gasket where the front of
both camshafts go through cylinder head. Tighten valve
cover bolts in correct sequence. See Fig. 2. Adjust drive
ranges.
Inspect crankshaft position sensor air gap. Air gap between
outer edge of crankshaft pulley rotor tooth and center of
CKP sensor should be 0.029-0.059 (0.5-1.5 mm). Air gap
is not adjustable. If gap is incorrect, check for damage parts.
Timing Belt Idler Pulley Bolt .............................. 28-38 (38-51)
INCH Lbs. (N.m)
CKP & CMP Sensor Bolts ...................................... 71-97 (8-11)
Water Pump Pulley Bolts ....................................... 71-97 (8-11)
384
2.0L 4-Cyl. VIN 3
Tribute
2001...................... 3.6 Hours .................. 250294
120,000 miles.
TIMING BELT
belt removed, damage to valves and pistons may result.
Removal:
belt. Remove air cleaner outlet pipe and ignition wires from
spark plugs. Disconnect throttle cables and cruise control
actuator cable. Disconnect accelerator cable. Remove valve
cover. See Fig. 1.
Remove spark plugs. Remove catalytic converter. Remove
coolant tube bolt and nut. Position coolant tube to side.
Rotate crankshaft to just before No. 1 cylinder TDC. See
Fig. 2. Remove stud and install Crankshaft TDC Timing
Peg (303-574). See Fig. 3.
NOTE: Make sure second notch in pulley is indexed to lower
cylinder block. See Fig. 2.
Rotate crankshaft clockwise against peg to bring it to TDC.
Loosen water pump pulley bolts.
Remove timing belt cover by removing crankshaft pulley,
then remove lower timing belt cover bolts and lower timing
belt cover. See Fig. 4. Install Engine Support Bar (303-F072).
See Fig. 5.
Remove ground strap and engine mount upper bracket
and studs. See Fig. 6. Remove upper timing belt cover
bolts and cover. See Fig. 7.
Remove water pump pulley and accessory drive belt idler
pulley. Install Camshaft Alignment Tool (303-465) and align
NOTE: Installation of Camshaft Alignment Tool (303-465) into
exhaust camshaft may require camshafts to be rotated slightly
clockwise.
Raise and support vehicle. Remove engine mount lower
bracket. See Fig. 9.
Loosen timing belt tensioner pulley and allow it to slide
down to bottom of its travel. Slide timing belt off of camshaft
CAUTION: DO NOT reuse old timing belt. Replace with a NEW
belt.
MAZDA
2.0L 4-Cylinder DOHC, Tribute
Fig. 1: Removing Valve Cover
Fig. 3: Removing Stud For Installation Of Crankshaft TDC
Timing Peg (303-574)
Fig. 4: Removing Lower Timing Belt Cover
Fig. 2: Aligning Crankshaft Timing Marks Before TDC
385
MAZDA
2.0L 4-Cylinder DOHC, Tribute (Cont.)
Fig. 5: Installing Engine Support Bar (303-F072)
Fig. 6: Removing Engine Mount Upper Bracket
Fig. 7: Removing Upper Timing Belt Cover
Installation:
Slide crankshaft pulley onto crankshaft. Ensure crankshaft
position is at No. 1 TDC by rotating it clockwise against
Crankshaft TDC Timing Peg (303-574). Ensure second
notch in pulley is indexed to lower cylinder block. See Fig.
2. Remove crankshaft pulley.
Ensure timing belt tensioner is installed correctly with tab
positioned in slot in inner timing cover. See Fig. 10.
Install new timing belt onto timing belt sprockets and ad-
just timing belt tensioner using a 6 mm Allen wrench to
rotate adjuster counterclockwise and align marks. See
Figs. 11 and 12. Tighten tensioner pulley bolt to specifica-
Install front engine mount lower bracket. Install accessory
drive belt idler pulley. Install water pump pulley but hand
tighten only. Install timing belt covers. Install crankshaft
pulley. Tighten water pump pulley bolts to specification.
Remove Crankshaft TDC Timing Peg (303-574). Install stud.
Install engine mount upper bracket and ground strap. Re-
move Engine Support Bar (303-F072). Install coolant tube,
catalytic converter and remove Camshaft Alignment Tool
(303-465).
Install valve cover and spark plugs. Reconnect accelerator
cable and cruise control actuator cable. Reinstall ignition
wires, air cleaner outlet pipe and accessory drive belt. Re-
connect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)
Fig. 9: Removing Engine Mount Lower Bracket
386
MAZDA
2.0L 4-Cylinder DOHC, Tribute (Cont.)
Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45)
Coolant Tube Attachments ............................................. 15 (20)
Engine Mount Lower Bracket Nuts ................................. 37 (50)
Engine Mount Upper Bracket Nuts ................................. 61 (83)
Engine Mount Upper Bracket Studs .............................. 25 (34)
Ground Strap .................................................................. 25 (34)
Spark Plugs................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) ......................... 18 (24)
INCH Lbs. (N.m)
Valve Cover ...................................................................... 80 (9)
387
Fig. 1: Timing Belt Reference Marks & Deflection
MAZDA
*2.0L & 2.2L 4-Cylinder SOHC
Belt
Application Time
1
Kit No. No.
2.0L 4-Cyl. SOHC
B2000
1986
Thru: Chassis No.
568707 ......... 2.6 Hrs. ............................. 250113
From: Chassis No.
568708 ......... 2.6 Hrs. ............................. 250117
1987............... 1.6 Hrs. ............................. 250117
626
1983............... 1.6 Hrs. ............................. 250088
626 Coupe
1984-85
Thru: VIN JM1GC221E
1617 ............. 1.6 Hrs. ...........................
2
250088
From:VIN JM1GC221E
16176 ........... 1.6 Hrs. ...........................
3
250113
626 Hatchback
1984-85
Thru: VIN JM1GC
241E1.......... 1.6 Hrs. ...........................
2
250088
From: VIN JM1GC
241E1.......... 1.6 Hrs. ...........................
3
250113
626 Sedan
1984-85
Thru: VIN JM1GC221E163
5511 ............. 1.6 Hrs. ...........................
2
250088
From: VIN JM1GC221E163
5511 ............. 1.6 Hrs. ...........................
3
250113
1986-87 ........ 1.6 Hrs. ........................... 250117
2.2L 4-Cyl. Non-Turbo & Turbo
B2200
1987-93.......... 2.6 Hrs. ...... 2521340........ 250134
MX-6
1988-92.......... 2.3 Hrs. ...... 2521340........ 250134
626
1988-92.......... 1.6 Hrs. ...... 2521340........ 250134
1
2
With square tooth sprocket.
3
With round tooth sprocket.
kits.
60,000 miles.
*NOTE: These applications are interference en-
gines. See page A-59 for interference engine cautions.
TIMING BELT
Removal:
Remove cooling fan and shroud. Remove distributor from
front housing. Remove cooling fan pulley and bracket. Re-
move secondary air pipe assembly (carbureted engines).
Remove alternator drive belt and A/C and P/S drive belts (if
equipped). Remove crankshaft pulley and baffle plate. Re-
move timing belt covers. Align camshaft pulley with front
housing timing mark. See Fig. 1. Mark an arrow on timing
belt to indicate direction of travel. Remove tensioner lock
bolt, tensioner and spring. Remove timing belt. On 2.2L
engines, measure free length of tensioner spring. Replace
spring if free length is not 2.48 inch (63 mm). See Fig. 2.
NOTE: Never twist, turn inside out, or bend timing belt.
Installation:
Align camshaft pulley with front housing timing mark. Align
crankshaft pulley with pointer on oil pump body. See Fig. 1.
Install tensioner, lock bolt and tensioner spring. Position
timing belt tensioner to its limit of travel toward the intake
manifold side and partially tighten lock bolt.
388
MAZDA
*2.0L & 2.2L 4-Cylinder SOHC (Cont.)
Fig. 2: Measuring Free Length Of Tensioner Spring
Install timing belt onto crankshaft pulley and then camshaft
pulley. Install timing belt from tension side (right side, as
viewed from engine front). If timing belt is being reused,
ensure that arrow is pointing in direction of travel.
Loosen tensioner lock bolt to apply tension. To apply equal
tension to each side of timing belt, turn crankshaft 2 revolu-
tions in direction of travel. Tighten tensioner lock bolt. Check
for proper alignment of timing marks.
Check for proper belt tension by measuring amount of de-
flection midway between crankshaft and camshaft pulleys
when force of 22 lbs. (10 kg) is applied. See Fig. 1. Deflec-
tion should be .43-.51" (11-13 mm). If tension is incorrect,
repeat timing belt tensioning procedure.
tension ranges.
TORQUE SPECIFICATIONS (2.0L)
Torque Stopper Bolts ........................................ 45-56 (61-76)
INCH Lbs. (N.m)
Valve Cover ........................................................... 26-35 (3-4)
TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo)
Coolant Inlet Pipe Bolt ...................................... 14-19 (19-26)
Timing Belt Idler Pulley ..................................... 27-38 (37-52)
Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52)
Water Pump Bolt .............................................. 14-19 (19-26)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft
Sprocket Bolt ................................................. 109-152 (13-7)
Rocker Cover Bolt ................................................. 26-35 (3-4)
Timing Belt Cover ............................................... 61-87 (7-10)
389
MAZDA
1
Belt Part No.
2.0L 4-Cyl. Diesel
626
1984-85
Camshaft ........... 1.9 Hours................. 250103
1
100,000 miles.
TIMING BELT (FRONT)
Removal:
Disconnect negative battery cable. Remove right side
splash shield (if equipped). Remove drive belts and crank-
shaft pulley. Remove timing belt covers and rubber seals.
Turn crankshaft in a clockwise direction until mark on front
camshaft pulley and front seal plate timing mark align.
Loosen tensioner lock bolt, and push tensioner as far back
as it will go. Snug tensioner lock bolt.
Remove torque bracket from right fender apron. If reusing
timing belt, mark an arrow on timing to indicate direction of
travel, then remove timing belt. Check belt for premature wear,
missing teeth, or cracks. Check turning smoothness of belt
tensioner.
Installation:
Ensure that timing mark on camshaft pulley is aligned with
mark on front seal plate. Make sure that notch on crank-
shaft pulley is aligned with timing mark on oil pump hous-
ing. See Fig. 1.
If tensioner was removed, install tensioner, lock bolt, and
spring. Push tensioner as far left as it will go. Snug tensioner
lock bolt. Install timing belt. Release tensioner lock bolt
and allow tensioner to contact belt.
Turn crankshaft in a clockwise direction (as viewed from
front) for 2 complete revolutions. Tighten tensioner lock
bolt. Check timing marks on front camshaft and crankshaft
pulleys.
Fig. 2: Rear Camshaft & Injection Pump Pulley Timing
Marks
Check timing belt deflection using 22 lbs. (10 kg) of force
between front camshaft and water pump pulleys. Deflection
should be .413-.472" (10.49-11.99 mm) Reverse removal pro-
tension.
TIMING BELT (REAR)
Removal:
Remove rear timing belt cover. Turn crankshaft to align rear
camshaft pulley with rear seal plate timing mark. Loosen
belt tensioner lock nut. Rotate belt tensioner clockwise, us-
ing a screwdriver, as far as it will go. Snug tensioner lock nut.
If reusing timing belt, mark an arrow on timing belt to indi-
cate direction of travel. Remove rear timing belt. Check belt
for premature wear, missing teeth, or cracks. Check turn-
ing smoothness of belt tensioner.
Installation:
Check timing marks on rear camshaft and injection pump
pulleys. See Fig. 2. Secure injection pump pulley to engine
using two 8 x 1.5 x 45 mm bolts.
NOTE: DO NOT remove bolts securing injection pump pulley
at this time. Remove bolts after installing timing belt.
Fig. 1: Front Camshaft & Crankshaft Pulley Timing Marks
390
MAZDA
If tensioner was removed, install tensioner lock nut, and
spring in fully released position. Rotate belt tensioner clock-
wise, using a screwdriver, as far as it will go. Snug tensioner
lock nut.
Install rear timing belt on injection pump pulley, around
tensioner, and then on camshaft pulley. Remove bolts se-
curing injection pump pulley. Loosen tensioner lock nut
until tension is applied on belt. Turn crankshaft in a clock-
wise direction for 2 complete revolutions.
Check timing marks on rear camshaft and injection pump
pulleys. See Fig. 2. Tighten tensioner lock nut. Check tim-
ing belt deflection using 22 lbs. (10 kg) of force between
injection pump and camshaft pulleys. Deflection should be
0.375" (9.53 mm). Install rear timing belt cover. Adjust drive
ranges.
Fuel Injection Pump Pulley Bolts ...................... 43-51 (58-69)
Timing Belt (Front) Pulley Bolt .................. 116-123 (157-167)
Front ............................................................... 23-34 (31-46)
Rear ............................................................... 15-20 (20-27)
Water Pump Bolts ............................................ 23-34 (31-46)
INCH Lbs. (N.m)
Rear Cover Bolts .................................................. 60-84 (7-9)
391
MAZDA
2.3L 4-Cylinder
2.3L 4-Cyl.
B2300
1994.....................
1
2.2 Hours ................. 250210
1995-97................
1
2.2 Hours ................. 250276
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Ensure crankshaft is
set at TDC and camshaft sprocket timing mark is aligned
with cover pointer. See Fig. 2. Disconnect negative battery
cable.
Drain cooling system and remove upper radiator hose. Re-
move alternator. Loosen water pump pulley bolts. Remove
accessory drive belt(s). Remove spark plugs to ensure belt
does not jump time during rotation.
Remove cooling fan and water pump pulley. Remove crank-
shaft pulley, hub and belt guide. Remove crankshaft posi-
tion sensor. Remove dipstick and pipe. Remove timing belt
cover retaining bolt. Release 8 cover interlocking tabs.
Remove timing belt cover. Loosen timing belt tensioner
pulley bolt. Pry tensioner away from timing belt and tighten
bolt to hold tensioner in place. Remove timing belt.
(clockwise as viewed from front of engine).
Installation:
timing mark is aligned with cover pointer. See Fig. 1. Install
belt guide with flat side toward the camshaft sprocket. See
Fig. 2.
Install timing belt. Loosen tensioner bolt, allowing tensioner
to apply pressure on belt. Tighten tensioner bolt. Rotate
crankshaft clockwise 2 complete turns to remove slack from
belt.
Loosen tensioner bolt. Apply additional pressure to
tensioner as spring pressure is insufficient. Retighten
tensioner lock bolt. To complete installation, reverse re-
moval procedure. Fill and bleed cooling system. Adjust drive
ranges.
Crankshaft Damper Bolt ........................... 103-133 (140-180)
Water Pump Bolt
1
............................................ 14-21 (19-29)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................. 62-97 (7-11)
1
- Apply sealant to bolt threads.
392
2.5L 4-Cyl.
B2500
1998-00................
1
2.2 Hours ................. 250276
1
The manufacturer recommends the belt be inspected at
120,000 miles and replaced if necessary.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove exhaust side
spark plugs. Rotate crankshaft clockwise so No. 1 piston
is at TDC of compression stroke.
Remove fan shroud. Loosen fan clutch-to-pulley bolts. Re-
move accessory drive belt. Remove fan clutch and pulley.
Remove crankshaft center bolt and remove crankshaft pul-
ley.
Using recycling equipment, recover refrigerant from air con-
ditioning system (if equipped). Disconnect A/C clutch con-
nector from A/C clutch. Remove A/C compressor from mount-
ing bracket. Remove A/C compressor mounting bracket
with hoses attached, and position out of way.
cover interlocking tabs. Remove timing belt cover. Ensure
crankshaft and camshaft timing marks are aligned. See
Fig. 1.
Holding timing belt tensioner with Camshaft Belt Tension
Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt
and slowly release tension. See Fig. 2. Pry tensioner away
from timing belt and tighten bolt to hold tensioner in place.
(clockwise as viewed from front of engine). Reverse rotation may
cause timing belt to jump time, causing engine damage.
Installation:
with inner cover timing marks. See Fig. 1.
Install timing belt on crankshaft sprocket. Working clock-
wise, install belt over oil pump sprocket, camshaft sprocket,
and tensioner pulley.
Loosen tensioner bolt and allow tensioner to adjust itself.
Rotate crankshaft clockwise 2 complete revolutions to re-
move slack from belt. Recheck timing mark alignment.
Readjust as necessary. Tighten timing belt tensioner bolts.
Install timing belt cover. Install crankshaft pulley. Install A/C
compressor bracket with power steering pump. Install A/C
compressor and recharge system (if equipped).
tension ranges.
A/C Compressor Bracket Mount Bolts
M8 Bolt ......................................................................... 18 (25)
M10 Bolt ....................................................................... 35 (48)
A/C Compressor-To-Bracket Bolt ........................ 16-20 (21-28)
Cooling Fan-To-Pulley Bolts ............................. 13-16 (17-23)
Crankshaft Damper Bolt ............................ 92-122 (125-165)
INCH Lbs. (N.m)
Spark Plug ........................................................ 80-115 (9-13)
MAZDA
2.5L 4-Cylinder
Fig. 2: Exploded View Of Timing Belt & Components Fig. 1: Aligning Camshaft & Oil Pump Timing Marks
393
MAZDA
1.8L V6
1.8L V6
MX-3
1992-93...............
1
3.8 Hours................ 250214
MX-3 (Canadian)
1995....................
1
3.8 Hours................ 250214
1
be replaced every 60,000 miles. For 1993-95 model years,
the manufacturer recommends the belt be replaced at 60,000
mile intervals for vehicles sold outside of California. For ve-
hicles sold in California, inspect timing belt at 60,000 and
TIMING BELT
Removal:
Disconnect negative battery cable. Drain coolant. Raise and
support vehicle and remove right front wheel. Remove lower
engine covers. Remove accessory drive belts. Remove water
pump pulley. Remove drive belt idler pulley bracket. See
Fig. 1. Disconnect necessary clamps and power steering
pressure switch connector to remove power steering res-
ervoir. Remove retaining bolts and power steering reser-
voir with hoses attached, and secure reservoir aside.
Remove retaining nut and power steering pump pulley. Re-
move retaining bolts and power steering pump with hoses
attached, and secure pump aside. Remove crankshaft pul-
ley retaining bolt. Using puller, remove crankshaft pulley.
CAUTION: DO NOT damage crank angle sensor rotor on rear
of crankshaft pulley during crankshaft pulley removal.
394
Unplug crank angle sensor and unclip wires from oil dip-
stick tube. Remove oil dipstick and oil dipstick tube. Re-
move crank angle sensor harness bracket. Remove en-
gine wiring harness, located along top of timing belt cover.
Support engine using hoist or floor jack. Remove right front
wheel. Remove through-bolt, retaining nuts and right (tim-
ing belt side) engine mount. Remove retaining bolts, tim-
ing belt covers and gaskets. See Fig. 1.
Install crankshaft pulley retaining bolt in crankshaft. Rotate
crankshaft so No. 1 cylinder is at TDC on compression
stroke. Ensure grove on crankshaft sprocket aligns with
indicator on oil pump body. See Fig. 2.
If reusing timing belt, place reference mark on timing belt
to indicate direction of rotation. Hold timing belt tensioner
and remove lower retaining bolt first, then remove upper
bolt. Remove timing belt tensioner. Remove No. 2 timing
belt pulley and timing belt. Remove No. 1 idler pulley and
tensioner pulley (if necessary).
Inspection:
tamination. Ensure idler pulleys No. 1 and No. 2 and
tensioner pulley rotate freely. Replace damaged compo-
nents. Inspect timing belt tensioner for signs of oil leak-
age. Replace timing belt tensioner if oil leakage exists.
rod to edge of the housing. See Fig. 3. Replace timing belt
Installation:
Place timing belt tensioner in a press using a flat washer
to prevent damage to timing belt tensioner. See Fig. 4. Com-
press tensioner rod until holes in rod and housing are
aligned and install .06" (1.5 mm) diameter pin through holes
in housing and rod to hold rod in retracted position. See
Fig. 4.
Install timing belt tensioner on cylinder block with the up-
per retaining bolt only, do not fully tighten upper bolt. Install
No. 2 idler pulley and tighten to specification. See TORQUE
SPECIFICATIONS. Ensure all timing marks align. See Fig.
2. Install timing belt on sprockets. Ensure all slack is on
tensioner side. Ensure the timing belt fully engages all
sprockets.
CAUTION: If reusing timing belt, ensure timing belt is installed
Push outward at bottom of timing belt tensioner and install
lower retaining bolt in timing belt tensioner. Tighten both
timing belt tensioner retaining bolts to specification. Re-
move pin from timing belt tensioner, allowing tension to be
applied on timing belt. Rotate crankshaft 2 full revolutions
clockwise from TDC to TDC. Ensure timing marks on cam-
shaft sprockets and crankshaft sprockets are properly
aligned. See Fig. 2. If timing marks are not aligned, repeat
entire timing belt installation procedure.
Check timing belt deflection by applying 22 lbs (10 kg) of
force at designated area on timing belt. Check timing belt
deflection. See Fig. 6. Timing belt deflection should be .24-
.31" (6.0-8.0 mm). If timing belt deflection is not within speci-
fication, replace timing belt tensioner.
Install timing belt covers using NEW gaskets. Tighten re-
taining bolts to specification. See TORQUE SPECIFICA-
TIONS. Install dipstick tube with new O ring. To install
Tighten fasteners to specification. Adjust drive belts to proper
No. 1 Idler Pulley Bolt ........................................ 28-38 (38-52)
No. 2 Idler Pulley Bolt ........................................ 28-38 (38-52)
Power Steering Pump Bracket Bolt .......................................
1
Power Steering Pump Pulley Nut ...................... 49-69 (66-93)
Nut ................................................................ 55-75 (74-102)
Through-Bolt .................................................... 50-68 (67-92)
Water Pump Bolt .............................................. 14-19 (19-26)
INCH Lbs. (N.m)
Crank Angle Sensor Bracket Bolt ........................ 69-95 (8-11)
Cylinder Block Valley Cover Bolt ......................... 69-95 (8-11)
Valve Cover Bolt
2
.................................................. 43-78 (5-9)
1
- Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs.
(31-46 N.m.). Tighten lower bolt on front of bracket to 14-19
ft. lbs. (19-26 N.m). Tighten rear bracket-to-cylinder
block bolt to 24-33 ft. lbs. (32-45 N.m).
2
- Tighten bolts to specification in sequence. See Fig. 5.
MAZDA
1.8L V6 (Cont.)
395
MAZDA
1.8L V6 (Cont.)
396
MAZDA
2.3L V6
2.3L V6
Millenia
1995-00................
1
4.5 Hours ................ 250267
1
For 1996-95 vehicles, the manufacturer suggests the belt be
replaced at 60,000 mile intervals for vehicles sold outside of
California. For vehicles sold in California, inspect timing belt
at 60,000 and 90,000 miles, and replace timing belt at 105,000
miles.
For 1998-97 vehicles, the manufacturer suggests the belt be
replaced at 60,000 mile intervals for vehicles sold outside of
California and Massachusetts. For vehicles sold in California
and Massachusetts, inspect timing belt at 60,000 and 90,000
miles, and replace timing belt at 105,000 miles.
For 2000-99 vehicles, the replacement is 60,000 miles except
for vehicles registered in California, Connecticut, Delaware,
Maine, Maryland, Massachusetts, New Hampshire, New Jer-
sey, New York, Pennsylvania, Rhode Island, Vermont, and
Washington D.C. For these states, inspect timing belt at 60,000
and 90,000 miles, and replace timing belt at 105,000 miles.
For 2001 vehicles, the replacement is 60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Drain coolant. Raise
lower engine covers. Remove accessory drive belts.
Remove crankshaft pulley retaining bolt. Using puller, re-
move crankshaft pulley. Remove power steering pump pul-
ley. Remove water pump pulley. Remove generator drive
belt auto tensioner. See Fig. 1. Remove camshaft position
sensor from right hand camshaft.
Remove engine oil dipstick and pipe. Remove vacuum pipe.
Remove upper radiator hose. Support engine using hoist.
Remove No. 3 engine mount and brackets from timing belt
end of engine. Remove retaining bolts, timing belt covers
and gaskets. Remove power steering belt auto tensioner.
See Fig. 1.
CAUTION: DO NOT damage crank angle sensor rotor on rear
of crankshaft pulley during crankshaft pulley removal.
stroke. The crankshaft and camshaft timing marks should
align. See Fig. 2.
to indicate direction of rotation. Hold timing belt tensioner
and remove lower retaining bolt first, then remove upper
bolt. Remove timing belt tensioner. Remove timing belt.
397
MAZDA
2.3L V6 (Cont.)
Inspection:
tamination. Inspect timing belt auto tensioner for signs of
oil leakage. Replace timing belt auto tensioner if oil leak-
age exists. Measure timing belt auto tensioner rod protru-
sion from end of rod to edge of the housing. See Fig. 3.
Replace timing belt auto tensioner if distance is not .563-
.594" (14.3-15.1 mm).
NOTE: The following information on repairing the front engine
oil leaks is from Mazda technical service bulletin MT0596-07;
May, 1996.
Oil leaking from the front of the engine on 1995-96 models
may be caused by the No. 3 engine mount bracket stud.
See Fig. 6.
To repair the oil leak, remove No. 3 engine mount bracket.
Remove mounting stud from engine. Clean all threads thor-
oughly. Apply Loctite PST Pipe Sealant with Teflon (No. 565)
to stud threads. Install stud on engine block.
Installation
Place timing belt auto tensioner in a press using a flat
washer to prevent damage to timing belt tensioner. See
Fig. 4. Using no more than 2200 lbs., compress tensioner
rod until holes in rod and housing are aligned. Install .063"
(1.6 mm) diameter pin through holes in housing and rod to
hold rod in retracted position. See Fig. 4.
Install timing belt on sprockets and around idler pulleys.
See Fig. 5. Ensure all slack is on tensioner pulley side.
Install timing belt auto tensioner. Tighten timing belt auto
tensioner bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure all timing marks align. See Fig. 2.
398
MAZDA
2.3L V6 (Cont.)
Fig. 6: Locating Engine Mount Bracket Stud
Remove pin from timing belt tensioner, allowing tension to
be applied on timing belt. Rotate crankshaft 2 full revolu-
tions clockwise from TDC to TDC. Ensure timing marks on
camshaft sprockets and crankshaft sprockets are properly
aligned. See Fig. 2. If timing marks are not aligned, remove
and repeat entire timing belt installation procedure.
Install timing belt covers using NEW gaskets. Tighten re-
taining bolts to specification. See TORQUE SPECIFICA-
TIONS. Install dipstick tube with new O ring.
dure. Tighten fasteners to specification. Check ignition tim-
ing. Adjust drive belts to proper tension. See page A-60 for
Camshaft Position Sensor Bolt ........................... 14-18 (19-25)
Engine Mount
Nuts ................................................................ 55-77 (75-104)
Bolts .................................................................. 32-44 (44-60)
Generator Drive Belt Auto Tensioner Bolt ............ 14-18 (19-25)
No. 1 & No. 2 Idler Pulley Bolt ........................... 28-38 (38-52)
Tensioner Pulley Pivot Bolt ............................... 28-32 (38-44)
Timing Belt Auto Tensioner Bolt ........................ 14-19 (19-26)
Water Pump Bolt .............................................. 14-19 (19-26)
Wheel Lug Nut ................................................. 66-94 (89-127)
INCH Lbs. (N.m)
399
MAZDA
2.5L V6
2.5L V6
Millenia
1995-01...............
1
3.4 Hours................ 250214
MX-6
1993-97...............
1
4.0 Hours................ 250214
626
1993-01...............
1
4.0 Hours................ 250214
1
For 1994-96 models years. the manufacturer recommends
of California and Massachusettes. For vehicles sold in Cali-
fornia and Massachusetts, inspect timing belt at 60,000 and
For 1999 626 models and 1999-00 Millenia models, the manu-
facturer recommends the belt be replaced at 60,000 mile in-
tervals except for vehicles registered in California, Connecti-
cut, Delaware, Maine, Maryland, Massachusetts, New Hamp-
shire, New Jersey, New York, Pennsylvania, Rhode Island,
Vermont, Virginia and Washington D.C. For these states, in-
spect timing belt at 60,000 and 90,000 miles, and replace
timing belt at 105,000 miles.
For 2000 626 models, the manufacturer recommends the belt
be replaced at 60,000 mile intervals except for vehicles regis-
tered in California, Maine, Massachusettes and Vermont. For
For 2001 model year, replace timing belt at 105,000 miles,
UNLESS the vehicle is operated in temperatures that are un-
der 0F (-18C). In this case, replace timing belt at 105,000
miles.
TIMING BELT
Removal:
Disconnect negative battery cable. On Millenia, raise and
support vehicle. Remove right front wheel. Remove lower
engine covers.
On all models, remove accessory drive belts. Remove wa-
ter pump pulley. Remove drive belt idler pulley bracket. Re-
move retaining bolts and power steering pump with hoses
attached, and secure pump out of way.
Holding crankshaft stationary, remove the crankshaft pul-
ley retaining bolt. Using gear puller, remove crankshaft
pulley.
CAUTION: DO NOT damage crankshaft position sensor rotor
on rear of crankshaft pulley during crankshaft pulley removal.
Remove oil dipstick and oil dipstick tube. Remove crank-
shaft position sensor from front of engine. See Fig. 2. Sup-
port engine using hoist or floor jack. Remove right (timing
belt side) engine mount. Remove retaining bolts, timing
belt covers, and gaskets. See Fig. 2.
stroke. Ensure grove on crankshaft sprocket aligns with
indicator on oil pump body. See Fig. 1. Ensure camshaft
sprocket timing marks are aligned with marks on rear cover.
If reusing timing belt, place reference mark on timing belt to
indicate direction of rotation. Loosen the 2 timing belt
tensioner bolts. Hold timing belt tensioner and remove
lower retaining bolt. Remove No. 1 idler pulley and timing
belt.
Inspection:
tamination. Ensure idler pulleys No. 1 and No. 2, and
tensioner pulley rotate freely. Replace damaged compo-
nents.
place timing belt tensioner if oil leakage exists. Measure
timing belt tensioner rod protrusion from end of rod to edge
of housing. See Fig. 3. There are 2 types of tensioner used
on this engine. See Fig. 4. Replace timing belt tensioner if
rod protrusion distance is not as specified. See TIMING
BELT TENSIONER ROD PROTRUSION table.
TIMING BELT TENSIONER ROD PROTRUSION
Application In. (mm)
Type A (2001) ................................... 0.511-0.551 (13.0-14.0)
Type A (1993-00) .............................. 0.473-0.511 (12.0-13.0)
Type B ............................................ 0.563-0.594 (14.3-15.1)
Installation:
Place timing belt tensioner in a press using a flat washer to
prevent damage to timing belt tensioner. See Fig. 5. Using
no more than 2200 lbs. pressure, SLOWLY compress
400
MAZDA
2.5L V6 (Cont.)
Fig. 4: Identifying Timing Belt Tensioner Types
401
MAZDA
2.5L V6 (Cont.)
tensioner rod until holes in rod and housing are aligned.
Install 0.055" (1.4 mm) diameter pin through holes in hous-
ing and rod to hold rod in retracted position.
Install timing belt tensioner on cylinder block with the up-
per retaining bolt only, do not fully tighten upper bolt.
Ensure crankshaft and camshaft timing marks align. See
Fig. 1. Install timing belt on sprockets in order. See Fig. 6.
Ensure tension exists on belt between crankshaft pulley
and camshaft pulleys. See Fig. 6. While applying pressure
on timing belt, install No. 1 idler pulley.
Push outward at bottom of timing belt tensioner and install
lower retaining bolt in timing belt tensioner. Tighten both
timing belt tensioner retaining bolts to specification. See
TORQUE SPECIFICATIONS. Remove pin from timing belt
tensioner, allowing tension to be applied on timing belt.
Rotate crankshaft 2 full revolutions clockwise (as viewed
from timing belt end of engine) from TDC to TDC. Ensure
timing marks on camshaft sprockets and crankshaft sprock-
ets are properly aligned. See Fig. 1. If timing marks are not
aligned, remove and repeat entire timing belt installation
procedure.
Install right (timing belt side) engine mount. Install timing
belt covers using NEW gaskets. Tighten retaining bolts to
Install dipstick tube with new O ring. To install remaining
components, reverse removal procedure. Tighten fasten-
ers to specification. Adjust drive belts to proper tension.
Check crankshaft position sensor air gap. Gap between
center of sensor and outer edge of rotor tooth should be
0.020-0.059 (0.5-1.5 mm). If not, check for damaged com-
ponents. Air gap is not adjustable.
No. 1 & No. 2 Idler Pulley Bolt ........................... 28-38 (38-52)
Power Steering Pump Bracket Bolt .......................................
1
Nut (Millenia & 626) ....................................... 55-75 (74-102)
Through-Bolt
626 ............................................................ 63-86 (86-116)
Water Pump Bolt .............................................. 14-18 (19-25)
Wheel Lug Nut
Millenia ........................................................... 66-94 (89-127)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bracket Bolt ........... 69-95 (8-11)
1
- Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs.
(31-46 N.m.). Tighten lower bolt on front of bracket to 14-19
ft. lbs. (19-26 N.m).
402
MAZDA
*3.0L V6 DOHC
Application
1
3.0L V6 DOHC
929
1990-95................. 3.9 Hours .................. 250183
Serenia (Canadian)
1992-95................. 3.9 Hours .................. 250183
1
60,000 miles for Federal vehicles, and 105,000 miles on Cali-
fornia vehicles.
TIMING BELT
Removal:
Disconnect negative battery cable. Drain engine coolant.
Remove spark plug cables and spark plugs. Remove air
intake hose. Remove cooling fan and fan shroud.
Remove drive belts. Remove A/C and P/S idler pulleys (if
equipped). Remove crankshaft pulley, baffle plate (if
equipped), and sensor rotor (if equipped). DO NOT dam-
age sensor rotor. Remove coolant by-pass and upper ra-
diator hoses.
Remove distributor. Remove timing belt covers and gas-
ket. See Fig. 1. Turn crankshaft to align pulley match marks.
See Fig. 2. Remove timing belt upper idler pulley. If reusing
timing belt, mark rotation direction. Remove timing belt and
timing belt automatic tensioner.
Inspection:
Check automatic tensioner rod projection. Rod should
project .47-.55" (12-14 mm) from tensioner body. Replace
tensioner if projection is not within specification.
Installation:
Using flat washer to prevent damage to tensioner body
plug, place automatic tensioner in vise or arbor press. Com-
press tensioner rod until a pin can be inserted into tensioner
rod through hole in tensioner body. Install tensioner with
pin installed.
CAUTION: DO NOT exceed 2200 lbs (1000 kg) pressure on tensioner
rod.
Ensure match marks on pulleys align with marks on heads.
See Fig. 2. With upper idler pulley removed, install timing
belt on pulleys. Keep slack toward automatic tensioner side.
Install upper idler pulley. Rotate crankshaft twice in direc-
tion of rotation, and ensure match marks still align. Re-
move automatic tensioner pin, and repeat steps to confirm
match marks are still in alignment.
Check timing belt deflection between right cam pulley and
lower idler. Deflection should be .20-.28" (5-7 mm) at 22
lbs. (10 kg). If deflection is not correct, repeat installation
procedure. If deflection is still not correct, check for faulty
automatic tensioner or stretched timing belt.
403
MAZDA
Fig. 2: Aligning Timing Belt Match Marks
CATIONS. Adjust drive belts to proper tension. See page A-
A/C Compressor-To-Bracket Bolt ..................... 21-29 (29-39)
Alternator-To-Bracket Bolt ................................. 27-38 (37-52)
Left Head ........................................................ 14-18 (19-25)
Right Head ..................................................... 52-59 (71-80)
Power Steering
Idler Bolt ......................................................... 14-18 (19-25)
Pulley Nut ....................................................... 29-43 (39-58)
Pump Mount Bolt .............................................. 23-34 (31-46)
Radiator Bolt ..................................................... 14-18 (19-25)
Timing Belt Lower Idler Bolt ............................. 32-45 (43-61)
Timing Belt Upper Idler Bolt ............................. 27-38 (37-52)
Water Pump Bolt/Nut ........................................ 14-18 (19-25)
INCH Lbs. (N.m)
1
...................................... 71-97 (8-11)
Valve Cover Bolt .............................................. 30-39 (3.4-4.4)
1
- Exc. 3 top bolts on right side cover: 14-18 ft. Lbs. (19-25 N.m).
404
MAZDA
*3.0L V6 SOHC
Belt
Application Time
1
Kit No. No.
3.0L V6 SOHC
929
1988-91.......... 3.1 Hrs. ...... 2521460........ 250146
MPV
1989-98.......... 3.0 Hrs. ...... 2521460........ 250146
1
kits.
the belt be replaced at 60,000 miles.
belt be replaced at 60,000 mile intervals for vehicles sold
outside of California and Massachusetts. For vehicles sold in
California and Massachusetts, inspect timing belt at 60,000
and 90,000 miles, and replace timing belt at 105,000 miles.
Removal:
Remove spark plug wires and spark plugs. Remove air
intake hose. Remove cooling fan and fan shroud. Remove
drive belts. Remove A/C compressor drive belt idler pulley.
Remove retaining bolt and crankshaft pulley. Remove cool-
ant bypass and upper radiator hoses. Remove timing belt
covers and gaskets. See Fig. 1. Rotate crankshaft and align
all timing marks. See Fig. 2.
to indicate direction of timing belt rotation. Remove upper
idler pulley. See Fig. 1. Remove timing belt. Remove timing
belt tensioner, tensioner pulley and lower idler pulley (if
necessary).
Inspection:
rod to edge of timing belt tensioner housing. Replace tim-
ing belt tensioner if distance is not .47-.55" (12.0-14.0 mm).
tamination. Ensure idler pulleys and tensioner pulley ro-
tate freely. Inspect timing belt tensioner for signs of oil leak-
age. Replace worn components.
NOTE: The following information on tensioner pulley inspection
is from Mazda technical service bulletin 002/00R; March 9,2000.
During the 60,000 mile inspection or timing belt replace-
ment on MPV models, inspect tensioner pulley pivot bush-
ing for a bronze color (wear) on the Teflon coating. If the
bushing is worn, the tensioner pulley and spacer must be
replaced with the timing belt. This is to prevent a torn or
jumped timing belt.
Installation:
Install tensioner pulley and lower idler pulley (if removed).
Install retaining bolts, and tighten to specification. See
TORQUE SPECIFICATIONS. Ensure all pulleys are clean
and rotate smoothly.
CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure
on timing belt tensioner rod.
405
Place timing belt tensioner in press with flat washer to
prevent damage to timing belt tensioner plug. Apply pres-
sure on rod of timing belt tensioner until rod is retracted
and holes in rod and housing are aligned. See Fig. 3. In-
stall pin through holes in housing and rod to hold rod in
retracted position. Release press and remove timing belt
tensioner.
Install timing belt tensioner on cylinder block with pin in-
stalled. Tighten retaining bolts to specification. See
TORQUE SPECIFICATIONS. Rotate camshafts and crank-
shaft to ensure all timing marks are aligned. See Fig. 2.
With upper idler pulley removed, install timing belt on crank-
shaft sprocket, lower idler pulley, left camshaft sprocket,
right camshaft sprocket and tensioner pulley in sequence.
Install upper idler pulley. Tighten retaining bolt to specifica-
tion. See TORQUE SPECIFICATIONS. Rotate crankshaft 2
full revolutions clockwise from TDC to TDC. Ensure all tim-
ing marks are aligned. See Fig. 2. If timing marks are not
aligned, remove timing belt and reinstall.
Remove pin from timing belt tensioner, allowing pressure
to be applied to timing belt. Rotate crankshaft 2 full revolu-
tions clockwise from TDC to TDC. Ensure all timing marks
are aligned. Check timing belt deflection by applying 22 lbs.
(10 kg) of force at midpoint between right camshaft sprocket
and tensioner pulley. Timing belt deflection should be .20-.28"
(5.0-7.0 mm).
installation procedure. To install remaining components,
tion. See TORQUE SPECIFICATIONS. Fill and bleed cool-
ing system. Adjust drive belts to proper tension. See page
MAZDA
*3.0L V6 SOHC (Cont.)
A/C Compressor Bracket-To-Cylinder
Block Bolt ........................................................ 27-38 (37-52)
Lower Idler Pulley Bolt ...................................... 27-38 (37-52)
6 mm Bolt ...........................................................................
1
10 mm Bolt ..................................................... 27-38 (37-52)
Upper Idler Pulley Bolt ...................................... 27-38 (37-52)
Water Pump Bolt/Nut ........................................ 14-19 (19-26)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 30-39 (3-4)
1
- Tighten to 69-95 INCH lbs. (8-11 N.m).
406
MITSUBISHI
Belt
Application Time
1
Kit No. No.
1.5L 4-Cyl.
Mirage
1985-86.......... 2.8 Hrs. ............................. 250073
1987-90.......... 2.8 Hrs. ...... 2521280........ 250128
1991-96.......... 2.4 Hrs. ...... 2521910........ 250191
1997-01.......... 2.4 Hrs. ............................. 250289
Precis
1987-89.......... 2.2 Hrs. ............................. 250073
1990-93.......... 2.2 Hrs. ...... 2521280........ 250128
1
kits.
setts and Vermont. In California, Massachusetts and Vermont,
timing belt replacement is recommended, but not required, at
60,000 miles. In these states, replace timing belt at 100,000
TIMING BELT
Removal (1985-96):
Disconnect negative battery cable. Remove air cleaner
assembly, then disconnect accelerator cable and oxygen
lead sensor. Mark position of spark plug wires for installa-
tion, then remove wires from spark plugs. Support engine
using a suitable engine support bar. Remove left engine
mount bracket. Remove all accessory drive belts and pul-
leys.
and locations as they are removed. Rotate engine clock-
on cylinder head. Ensure all timing marks are aligned. See
Fig. 1.
Loosen timing belt tensioner bolts. Move tensioner inward
toward water pump. Temporarily tighten bolt in slot side of
tensioner. Remove timing belt from camshaft sprocket. Re-
move crankshaft pulley, and timing belt.
Inspection:
See Fig. 1. Install timing belt onto crankshaft and camshaft
sprockets. Ensure tension side is tight and all timing marks
are aligned when camshaft sprocket is rotated. Install crank-
Fig. 2: Installing Timing Belt Tensioner (1985-96)
407
MITSUBISHI
shaft pulley. Loosen tensioner mounting bolts. See Fig. 2.
Ensure timing belt is not out of position and has not jumped
a sprocket tooth. Tighten tensioner bolts.
CAUTION: If pivot bolt is tightened before side bolt, belt tensioner
may rotate, causing belt to be over tightened.
Rotate crankshaft one full revolution clockwise, until crank-
shaft sprocket timing mark aligns with TDC position. Re-
check belt tension. To check belt tension, hold belt tensioner
and timing belt together. Apply slight thumb pressure at
center point of belt tensioner. See Fig. 3. A tension gauge
can also be used to check belt tension. See Fig. 4.
tension ranges.
Removal (1997-01):
Disconnect negative battery cable. Remove all accessory drive
belts. Rotate crankshaft clockwise so that No. 1 cylinder is at
TDC of compression stroke. Holding crankshaft stationary,
Place jack under engine. Support engine so there is no
weight on engine mount bracket (timing belt end of en-
gine). On vehicles equipped with A/C, move A/C relay box
and drier assembly (hoses attached) out of way to remove
Fig. 4: Checking Timing Belt Tension (1985-96)
engine mount bracket. On all vehicles, remove engine mount
bracket-to-engine bolt and nut. Remove engine mount
bracket-to-body through bolt. Remove engine mount
bracket.
Remove water pump pulley. Remove power steering pump
and bracket with hoses attached and secure out of way.
Remove oil dipstick tube. Remove timing belt upper and
lower covers.
Rotate crankshaft clockwise to align timing mark on cam-
shaft sprocket with mark on cylinder head. Ensure crank-
shaft sprocket timing marks are aligned. See Fig. 6.
Loosen timing belt tensioner adjusting bolt. Move tensioner
toward water pump to relieve tension on timing belt. Tem-
porarily tighten tensioner adjusting bolt. Remove timing
belt.
Inspection:
408
MITSUBISHI
See Fig. 6. If timing belt tensioner and spring were removed,
install with tensioner spring in correct position. See Fig. 7.
Install timing belt onto crankshaft sprocket, camshaft
sprocket, and tensioner pulley. Ensure tension side is tight
and all timing marks are aligned. See Fig. 6.
After installing timing belt, ensure timing belt is tensioned
between crankshaft and camshaft sprockets. Check that
all timing marks are still aligned.
Loosen tensioner adjusting bolt. Rotate crankshaft one
full revolution clockwise, until crankshaft sprocket timing
mark aligns with TDC position. Tighten tensioner adjust-
ing bolt.
Ensure timing belt teeth are fully seated in camshaft
sprocket. Install timing belt covers. Install crankshaft pul-
ley. Tighten bolt to specification. See TORQUE SPECIFICA-
TIONS table.
tension ranges.
TORQUE SPECIFICATIONS (1985-96 MIRAGE)
1985-91 .......................................................... 47-54 (65-75)
1992-96 ........................................................ 52-74 (70-100)
1991-96 .......................................................... 10-11 (14-15)
1985 ............................................................... 37-43 (50-58)
1986-96 ...................................................... 52-74 (70-100))
Front Cover Bolt
1985-88 ............................................................ 9-10 (12-14)
Rocker Arm Adjuster Lock Nut
1989-96 .......................................................... 10-13 (14-18)
1985-96 .......................................................... 14-20 (19-27)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt ................................... 108-120 (12-14)
Front Cover Bolt ................................................ 84-132 (9-15)
Fuel Rail Bolt
1992-96 .......................................................... 84-108 (9-12)
Rocker Cover Bolt ........................................... 13-17 (1.5-1.9)
Water Pump Pulley Bolt
1988-85 ..................................................... 108-120 (12-14)
1996-89 .............................................................. 72-84 (8-9)
TORQUE SPECIFICATIONS (1991-94 PRECIS)
Camshaft Thrust Case Bolt .............................. 14-20 (19-27)
Crankshaft Sprocket Bolt ................................ 52-74 (70-100)
Front Cover Bolt ................................................ 10-11 (14-15)
INCH Lbs. (N.m)
Camshaft Rear Cover Bolts ................................. 70-86 (7-10)
Rocker Cover Bolt ........................................... 13-18 (1.5-2.0)
TORQUE SPECIFICATIONS (1997-01)
Crankshaft Pulley Center Bolt ...................................
1
93 (125)
Engine Mount Bracket-To-Engine ................................... 25 (35)
Engine Mount
Bracket-To-Engine Bracket Bolt/Nut ............................. 42 (57)
Bracket-To-Body Through Bolt ....................................
2
72 (98)
Power Steering Pump
Bracket-To-Engine Bolt ................................................ 16 (22)
Timing Belt Tensioner Adjusting Bolt .......................... 17 (24)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................... 89-106 (10-12)
1
Apply engine oil to bolt thread before installation.
2
Final tighten with full weight of engine on bolt.
409
MITSUBISHI
1.6L 4-Cyl. SOHC
Mirage
1985-88 ..............
1
2.8 Hours ................ 250093
1
60,000 miles.
TIMING BELT
Removal:
Remove splash panel in left side wheel house. Remove
air intake duct to air cleaner housing. Noting installed posi-
tion for reassembly reference, remove spark plug cables
from spark plugs.
Remove all accessory drive belts. Place jack under engine.
Support engine so there is no weight on engine mount
bracket (timing belt end of engine). Remove left side en-
gine mount.
Remove power steering pump pulley (if equipped). Re-
move water pump pulley. See Fig. 1. Remove upper timing
belt cover.
Rotate crankshaft clockwise so that No. 1 cylinder is at
TDC of compression stroke. Ensure camshaft sprocket
timing mark aligns with mark on under upper cover. See
Fig. 2. Holding crankshaft stationary, remove crankshaft
pulley. Remove lower timing belt cover.
Loosen timing belt tensioner adjusting bolt and nut. Move
tensioner adjusting bolt. Remove timing belt.
Inspection:
Installation:
If crankshaft sprocket was removed, ensure flange and
spacer are correctly installed. See Fig. 3. If timing belt
tensioner was removed, ensure end of tensioner spring is
seated under water pump housing. See Fig. 4. Move
tensioner towards water pump and temporarily tighten
mounting bolt and nut.
See Fig. 2. Install timing belt onto crankshaft sprocket, and
keeping tension tight, install timing belt on camshaft
sprocket.
After installing timing belt, ensure timing belt is tensioned
between crankshaft and camshaft sprockets. Check that
Loosen tensioner adjusting bolt and nut about 1 turn so
that timing belt tensioner contacts timing belt. Turn crank-
shaft clockwise by 2 teeth of the camshaft sprocket. See
Fig. 5. This is to give adequate tension to the timing belt.
DO NOT turn crankshaft counterclockwise.
Push timing belt tensioner to the right (as viewed from front
of engine) so that belt engages completely with camshaft
sprocket without any slack. Tighten tensioner bolt first, and
then the tensioner nut. See TORQUE SPECIFICATIONS.
Turn crankshaft one full revolution.
aligned. To check timing belt final tension, hold timing belt
between thumb and forefinger midway between camshaft
sprocket and oil pump sprocket. See Fig. 6. Distance from
back of timing belt to to edge of timing belt cover must be
.23 (6 mm). Readjust belt tension, if necessary.
Install timing belt covers. Ensure bolts are installed in cor-
rect position. See Fig. 7. Install crankshaft pulley. Tighten
tension ranges.
Crankshaft Pulley Center Bolt .......................
1
80-96 (110-130)
Engine Mount
To-Engine Bracket Bolt/Nut ............................... 37-50 (50-65)
Bracket-To-Body Through Bolt ......................... 66-81 (90-110)
Timing Belt Tensioner Adjusting Bolt/Nut ................... 17 (24)
Vibration Damper-To-Adapter Bolts..................... 11-13 (15-18)
INCH Lbs. (N.m)
Power Steering Pump Pulley Bolt ................................. 80 (9)
Timing Belt Cover Bolt ................................... 89-106 (10-12)
1
Apply engine oil to bolt thread before installation.
410
MITSUBISHI
Fig. 3: Crankshaft Sprocket, Flange & Spacer Installation
Fig. 4: Installing Tensioner Spring
Fig. 5: Camshaft Sprocket Position For Tension Adjustment
Fig. 6: Checking Timing Belt Tension Adjustment
Fig. 7: Timing Belt Cover Bolt Length
411
MITSUBISHI
Belt
1.8L 4-Cyl.
Cordia & Tredia
1983-84
Balance Shaft ...
1
.................................. 250090
Camshaft ..........
2
3.2 Hrs. .................... 250089
1985-86
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
3.2 Hrs. .................... 250089
1987-88
Balance Shaft ...
1
.................................. 250159
Camshaft ............
2
3.2 Hrs. . 2521580.... 250158
2.0L 4-Cyl.
Cordia & Tredia
1984,
Balance Shaft ...
1
.................................. 250090
Camshaft ..........
2
3.2 Hrs. .................... 250089
1985-86
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
3.2 Hrs. .................... 250089
1987-88,
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
3.2 Hrs. .................... 250158
Galant
1989-92
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
2.4 Hrs. . 2521550.... 250155
1993,
Balance Shaft ...
1
.................................. 250168
Camshaft ..........
2
2.4 Hrs. . 2522320.... 250232
Pickup
1983-86
Balance Shaft ...
1
.................................. 250090
Camshaft ..........
2
2.3 Hrs. .................... 250089
1987-89
Balance Shaft ...
1
.................................. 250159
Camshaft ..........
2
2.3 Hrs. . 2521581.... 250158
1
- Balance Shaft Belt labor time included in
Camshaft Belt labor time.
2
kits.
60,000 miles.
TIMING BELT
Removal (1983-88):
Disconnect negative battery cable. On models equipped
with A/C, remove upper radiator shroud and cooling fan/
clutch assembly. On models equipped with power steer-
ing, remove power steering pump and pulley. On all mod-
els, position No. 1 cylinder at TDC of compression stroke.
Loosen pulley bolts. Remove drive belts.
Remove crankshaft, water pump and power steering pul-
leys. Remove upper and lower front timing belt covers. Re-
lieve camshaft timing belt tensioner pressure and secure
tensioner toward water pump. If camshaft timing belt is to be
reused, mark belt with an arrow indicating direction of rotation
and remove belt. Remove camshaft and crankshaft sprocket
bolts. Remove camshaft sprocket, crankshaft sprocket and
crankshaft flange.
Remove plug on left side of cylinder block. Insert a screw-
driver to keep left silent shaft in position. See Fig. 3. Re-
move oil pump sprocket. Loosen right silent shaft sprocket
mounting bolt until it can be turned by hand. Remove belt
tensioner B and timing belt B.
Inspect back of belt for hardness, non-elasticity and glossy
surface. If no mark is produced when fingernail is forced
into it, replace belt. Check for rounded sides on belt, flak-
ing, peeling, cracking and separating rubber. Cracks are
most evident at base of tooth.
Install timing belt B ensuring tension side has no slack.
Install tensioner B so only light pressure is on belt. En-
sure flange on tensioner is mounted away from engine
and finger-tighten bolt. Lift tensioner with finger tip until slack
is removed from tension side of belt. Tighten tensioner bolt,
being careful to prevent turning shaft. Ensure timing marks
are in alignment. Tighten right silent shaft bolt.
Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not
within specification. Align camshaft timing belt sprockets
with corresponding timing marks. See Fig. 1 or Fig. 2. To
ensure oil pump sprocket is in correct alignment, insert
screwdriver shaft in hole on left side of block. See Fig. 3.
If screwdriver cannot be inserted at least 2.4" (60.0 mm),
turn oil pump sprocket one revolution and realign marks.
Insert screwdriver. Leave screwdriver inserted until timing
belt installation is complete. With tensioner secured fully
toward water pump, install timing belt in order of crank-
shaft sprocket, oil pump sprocket and camshaft sprocket.
Ensure tension side of belt has no slack. Loosen tensioner
mounting bolt and nut to allow only tensioner spring pres-
sure to tighten belt.
Check belt to ensure each tooth is in proper mesh with
camshaft sprocket. Tighten slot-side bolt before tightening
nut. Otherwise, tension bracket will turn and belt will be too
tight. Ensure all timing marks are in correct alignment. Re-
move screwdriver and install plug in block. Turn crankshaft,
clockwise only, one revolution. Loosen mounting nut and
bolt to allow tensioner to readjust and tighten slot-side bolt,
then tighten nut.
Hold belt and seal line of undercover, between thumb and
forefinger, at center of tension side. Measure clearance
between belt and seal line. Clearance should be .55" (14.0
mm). Reverse removal procedure to complete reassembly.
tension ranges.
412
Removal (1989-93):
Disconnect negative battery cable. Remove A/C and power
steering hose mounting bracket or oxygen sensor connec-
tor bracket from upper engine mount at timing belt cover.
Support engine, and remove upper engine mount. Remove
all drive belts and drive pulleys from crankshaft and water
pump.
Remove drive belt tensioner. Remove upper and lower tim-
ing belt covers. Note bolt lengths and locations. Longer (2)
bolts are located above crankshaft seal. Remove crank-
shaft sprocket bolt access cover, crankshaft sprocket bolt
and washer. If necessary, remove rocker arm cover for clear-
ance.
Rotate crankshaft clockwise (as viewed from timing belt
end of engine) until cylinder No. 1 is at TDC of compres-
sion stroke. Align timing mark on camshaft sprocket with
timing mark on cylinder head. See Fig. 1 or Fig. 2. Loosen
timing belt tensioner adjustment bolt, and move tensioner
toward water pump. Tighten bolt to secure tensioner. Re-
move front timing belt and camshaft sprocket.
If oil pump sprocket removal is necessary, remove left si-
lent shaft access plug from cylinder block. Insert .31" (8.0
mm) diameter Phillips screwdriver to block left silent shaft.
Remove oil pump sprocket nut and sprocket. Remove front
crankshaft sprocket and flange. Note direction and order of
installation. Remove rear timing belt tensioner assembly.
Remove rear timing belt.
Check belt teeth for cracks, damage and contamination.
Inspect sprockets for damage. Check belt tensioner for
leakage or roughness in rotation. Replace components as
necessary.
If reusing rear timing belt, install in original direction of rotation.
Ensure timing marks are aligned. See Fig. 4. Install rear timing
belt tensioner. Hold tensioner tightly against belt while tightening
bolts. Depress belt between sprockets to ensure deflection is
.20-28" (5-7 mm). Adjust as necessary.
Install crankshaft front sprocket. Install oil pump sprocket.
Hold left silent shaft using a .31 (8.0 mm) diameter Phillips
screwdriver through access hole. Ensure screwdriver can
be inserted at least 2.36 (59.9 mm). Remove screwdriver
if it cannot be inserted at least 2.36" (59.9 mm), and rotate
oil pump sprocket one revolution. Align timing mark. Insert
screwdriver, and ensure it can be inserted at least 2.36"
(59.9 mm).
DO NOT remove screwdriver until timing belt is installed.
Install camshaft sprocket. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install front timing belt
tensioner, tension spring and spacer(s). Ensure spring is
properly engaged against water pump case. Rotate
tensioner toward water pump, and temporarily tighten bolts.
Ensure timing marks are aligned. See Fig. 1 or Fig. 2.
If reused, install timing belt in original direction of rotation.
Apply pressure on tension side of belt while installing belt
on camshaft sprocket. Loosen timing belt tensioner to ap-
ply spring pressure to timing belt. Ensure timing marks are
still aligned. To apply tension on belt, rotate crankshaft clock-
wise until camshaft sprocket timing mark is offset by 2
teeth. Tighten tensioner bolt. Tighten tensioner nut.
To check belt tension, apply slight thumb pressure and
measure deflection between camshaft and oil pump
MITSUBISHI
(8-Valve Engine)
sprocket. Belt deflection should be .55" (14 mm). To com-
ranges.
1983-85 .......................................................... 11-15 (15-20)
1986-93 .......................................................... 15-21 (20-29)
Front Cover Bolts
M8 X 30 Bolt .................................................... 20-26 (27-35)
Except M8 X 30 Bolt ........................................ 14-20 (19-27)
Rear Timing Belt Tensioner ............................. 11-16 (15-22)
Silent Shaft Sprocket Bolt
.08" (2.0 mm) Washer .................................... 25-29 (34-39)
.10" (2.5 mm) Washer .................................... 31-35 (42-47)
Left Lower Rear Cover .................................... 22-30 (30-41)
All Others ............................................................................
1
1983-85 .......................................................... 16-21 (22-28)
1986-93 .......................................................... 32-39 (42-53)
Water Pump Bolt
Except 8 X 65 mm ............................................ 9-11 (12-15)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
All Except Left Lower Rear Cover Bolt ............. 84-108 (9-12)
1
- All except Left Lower Rear Cover Bolt tighten to 84-108
INCH Lbs. (9-12 N.m).
413
Fig. 3: Aligning Oil Pump Sprocket
MITSUBISHI
(16-Valve Engine)
Courtesy of Chrysler Corp.
414
Belt
2.0L 4-Cyl. DOHC (4G6)
Eclipse Turbo & Non-Turbo
1990-94......
1 & 2
3.6 Hrs. .... 2521670......
3
250167
1990-94......
1 & 2
3.6 Hrs. .........................
4
250168
Eclipse Turbo
1995-99......
1 & 2
3.6 Hrs. .... 252167 ......
03
250167
1995-99......
1 & 2
3.6 Hrs. .........................
4
250168
Galant
1989-92......
1 & 2
3.6 Hrs. .... 2521670......
3
250167
1989-92......
1 & 2
3.6 Hrs. .........................
4
250168
1993...........
1 & 2
3.6 Hrs. .... 2522320......
3
250232
1993...........
1 & 2
3.6 Hrs. .........................
4
250168
1
- Balance shaft labor time included in camshaft
labor time.
2
3
4
Balance shaft belt.
kits.
be replaced every 60,000 miles, except in California. In Cali-
fornia, timing belt replacement is recommended but not re-
quired at 60,000 miles. In California, replace belt at 100,000
be replaced every 60,000 miles, except in California, Con-
necticut and Massachusetts. In California, Connecticut and
Massachusetts, timing belt replacement is recommended but
not required at 60,000 miles. In California, replace belt at
TIMING BELT & BALANCE SHAFT BELT
Removal:
cover. Place wooden block between jack and oil pan and
raise engine slightly. Remove engine mount assembly near
timing belt cover.
Remove clamp for power steering return hose near timing
belt cover. Remove all drive belts and tensioner pulley
bracket. See Fig. 1. Remove power steering and water
pump pulleys. Rotate crankshaft clockwise so that No. 1
cylinder is at TDC of compression stroke. Remove crank-
shaft pulley.
MITSUBISHI
*2.0L 4-Cylinder DOHC, Eclipse & Galant
Fig. 1: Exploded View Of Timing Belts & Components
415
Fig. 4: Timing Belt B (Balance Shaft Belt) Components
MITSUBISHI
*2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)
416
Fig. 5: Holding Balance Shaft Stationary
MITSUBISHI
2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
timing marks are aligned. If reusing timing belts, mark timing
belts for direction of rotation.
Remove upper timing belt cover and gasket. Remove stub
bolt of engine support bracket and remove center timing
belt cover. Remove lower timing belt cover.
NOTE: Camshaft sprocket dowel pins will be in 12 oclock position
when timing marks are correctly aligned.
Ensure camshaft, crankshaft and oil pump sprocket timing
marks are aligned. See Figs. 2 and 3. Loosen tensioner
pulley center bolt. Move tensioner to relieve timing belt ten-
sion. Remove timing belt. Remove timing belt auto
tensioner. See Fig. 1.
Remove plug from left side of cylinder block. Install a .31"
(8.0 mm) diameter Phillips screwdriver into the hole against
balance shaft. See Fig. 5. Screwdriver must go in at least
2.36 (60 mm) or more. If screwdriver will only go in about
.79-.98
(20-25 mm) before striking balance shaft, turn sprocket
one revolution and align timing mark. Keep screwdriver in
place until timing belt is installed. This ensures balance
shaft driven by oil pump sprocket remains in correct posi-
tion.
To remove timing belt B (balance shaft belt), hold crank-
shaft sprocket stationary with a spanner wrench. Remove
crankshaft sprocket bolt. Using gear puller, remove outer
crankshaft sprocket.
Remove crankshaft sensing blade (if equipped). See Fig.
4. Loosen timing belt B tensioner bolt. If reusing timing
belt B, mark direction of belt rotation for reassembly refer-
ence. Remove timing belt B.
Inspection:
Inspect timing belts for damaged teeth and cracking. En-
sure belts are not contaminated with oil. Check tensioners
for free rotation and grease leakage. Replace components
if damaged or if grease leakage exists.
NOTE: The following revised information for timing belt tensioner
inspection is from Mitsubishi technical service bulletin 96-11-
006; June, 1996.
Apply 22-44 lbs. (10-20 kg) of force to end of rod. If auto
tensioner rod moves more than 0.39 (1 mm), replace the
auto tensioner.
Installation:
Retract rod into auto tensioner housing by placing auto
tensioner assembly in a soft-jawed vise. Close vise
SLOWLY to push rod back into auto tensioner housing.
When pin hole in cylinder aligns with pin hole in rod, insert
set pin. Replace tensioner assembly if rod can be retracted
easily into housing. Install auto tensioner on engine with
set pin in place.
Align balance shaft and crankshaft timing marks with rear
cover. See Figs. 7 and 8. Install timing belt B on sprock-
ets. If using old belt, install belt in original direction of rota-
tion. Ensure there is no slack in tension side of belt.
CAUTION: Ensure tensioner pulley shaft does not rotate when
bolt is tightened or excessive pressure will be applied to tim-
ing belt.
417
Install timing belt B tensioner so center of tensioner pul-
ley is to the left and above of retaining bolt center. See Fig.
9. Rotate tensioner inward toward timing belt until belt is
tight. Tighten tensioner retaining bolt without letting
tensioner pulley rotate out of position. Check belt deflec-
tion at designated area. Belt deflection should be .20-.28"
(5.0-7.0 mm). Readjust timing belt if belt deflection is not
CAUTION: Install crankshaft sensing blade and crankshaft sprockets
in correct positions or timing belt may be damaged.
Install crankshaft sensing blade (if equipped) in front of
crankshaft sprocket B, with offset in proper direction. See
Fig. 10. Install crankshaft sprocket A. Apply light coat of
engine oil to crankshaft sprocket bolt threads, and tighten
bolt to specification. See TORQUE SPECIFICATIONS. In-
stall idler pulley (if removed).
Ensure camshaft, crankshaft and oil pump timing marks
are still aligned. See Figs. 2 and 3. Do not remove screw-
driver from side of engine block until timing belt is installed.
NOTE: Intake and exhaust camshafts use same camshaft sprocket.
Camshaft sprockets are provided with 2 timing marks. For exhaust
camshaft sprocket, use timing mark on right with dowel pin facing
up. On intake camshaft, sprocket, use timing mark on the left,
with dowel pin hole on top.
Rotate camshaft sprocket so dowel pins are upward and
away from cylinder head and timing marks are aligned with
cylinder head surface. Timing marks should face each other.
See Figs. 2 and 3.
Install timing belt on intake camshaft sprocket. Install spring
clip to retain timing belt on sprocket. See Fig. 11. Place a
wrench on each camshaft sprocket retaining bolt. Rotate
camshafts so timing marks align with each other.
Install timing belt over exhaust camshaft. Install spring clip
to retain timing belt. Install timing belt over idler pulley, oil
pump sprocket, crankshaft sprocket and tensioner pulley.
Remove spring clips from camshaft sprockets.
Timing Belt Tension Adjustment (1990-92)
Position timing belt tensioner pulley so that the 2 pin holes
in the center eccentric are facing to the left (as viewed from
timing belt end of engine) of the center bolt. Finger tighten
center bolt.
Remove screwdriver from balance shaft hole in side of
engine block. Install plug.
Rotate crankshaft 1/4 turn counterclockwise, then rotate
crankshaft 1/4 clockwise until timing marks are aligned
again. No. 1 cylinder should be at TDC of compression
stroke.
Attach Adapter (MD998767) to tensioner pulley eccentric.
Attach torque wrench to adapter and apply 24 INCH lbs.
(2.7 N.m) of torque in a clockwise direction. See Fig. 15.
With torque applied to eccentric, tighten tensioner pulley
center bolt to 32-40 ft. lbs. (43-55 N.m).
Insert Set Screw (MD998738) through inner timing belt cover
until it contacts tensioner arm. See Fig. 12. Slowly rotate
set screw until set pin can be removed. Remove set screw
from engine.
Rotate crankshaft 6 complete turns clockwise. Wait 15 min-
utes without turning crankshaft. Measure distance between
top of auto tensioner body and tensioner arm. The distance
should be .15-.18 (3.8-4.5 mm). If distance is not correct,
timing belt tension will have to be readjusted. Go to FINAL
ASSEMBLY.
Lift tensioner pulley upward to apply tension on timing belt.
The 2 pin holes in the center of the tensioner must face
down. See Fig. 12. Screw the Set Screw (MD998738) into
engine support bracket until it makes contact with tensioner
arm. At that point, screw the set screw in a few more threads
and remove the set pin from the auto tensioner. Remove
the set screw. Tighten timing belt tensioner pulley center
bolt to 35 ft. lbs (48 N.m).
Remove screwdriver from side of engine block and install
plug. To tension timing belt, rotate crankshaft about 1/4
turn counterclockwise, then 1/4 turn clockwise until all tim-
ing marks align.
Loosen tensioner pulley center bolt. Install Adapter
(MD998767) or equivalent to tensioner eccentric. Install
torque wrench on adapter. See Fig 13. Starting with eccen-
tric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m)
of torque counterclockwise on tensioner pulley.
Hold tensioner pulley at specified torque, and tighten
tensioner center bolt to specification. DO NOT let tensioner
pulley turn with bolt. See TORQUE SPECIFICATIONS.
Rotate crankshaft 2 full revolutions clockwise so that tim-
ing marks are aligned. Allow engine to stand for 15 min-
utes without turning crankshaft. Distance between top of
auto tensioner housing and tensioner arm should be .15-
.18" (3.8-4.5 mm). See Fig. 16, Dimension A. If distance
is incorrect, repeat tensioning procedure until distance is
correct. Go to FINAL ASSEMBLY.
Final Assembly:
dure. Ensure proper length bolts are installed in timing belt
covers. See Fig. 14. See TIMING COVER BOLT LENGTH &
TORQUE. Adjust drive belts to proper tension. See page A-
Fig. 10: Installing Crankshaft Sprocket & Crankshaft
Sensing Blade
MITSUBISHI
*2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)
418
MITSUBISHI
2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)
Fig. 11: Installing Timing Belt On Intake Sprockets
TIMING COVER BOLT LENGTH & TORQUE
Bolt Length INCH Lbs. (N.m)
A : 6 x 16 mm Flange Bolt ............................. 89-106 (10-12)
B : 6 x 18 Flange Bolt .................................... 89-106 (10-12)
C: 6 x 25 Loose Washer Bolt .................................. 58 (6.5)
D: 6 x 25 Flange Bolt .................................... 89-106 (10-12)
E : 6 x 45 Flange Bolt .................................... 89-106 (10-12)
Balance Shaft Sprocket Bolt ......................................... 33 (46)
Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26)
Bolt/Nut (1993-98) ..................................................... 49 (67)
Bolt/Nut (1990-92) ........................................... 36-47 (50-65)
Through-Bolt (1993-98) ..................................... 72-87 (98-118)
Through-Bolt (1990-92) ...................................... 43-58 (60-80)
Timing Belt B (Balance Shaft)
Tensioner Bolt .................................................... 11-16 (15-20)
Timing Belt Tensioner Pulley Center Bolt ................... 35 (48)
Water Pump Bolt .......................................................... 10 (14)
INCH Lbs. (N.m)
419
Belt
Application Time
1& 2
Kit No. No.
2.4L 4-Cyl. DOHC
Galant
1994
Balance Shaft ..............
1
......................... 250168
Camshaft
Thru 5/94 ..... 3.6 Hrs. ...... 2522560........ 250256
From 6/94 .... 3.6 Hrs. ............................. 250230
1995-96
Balance Shaft
1
...................................... 250168
Camshaft ....... 3.6 Hrs. ............................. 250230
1
-Balance Shaft included in Camshaft labor time.
2
kits.
TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft
Removal:
Disconnect negative battery cable. Remove protective cover
from below engine. Remove A/C and power steering hose
mounting bracket. Support engine. Remove upper engine
mount located near timing belt cover. Remove all drive belts.
Remove tensioner pulley bracket. Remove pulleys from
crankshaft, water pump and power steering.
Remove drive belt tensioner. Remove upper and lower tim-
ing belt cover with gasket. Note bolt lengths and locations.
Remove breather hose, PCV hose and center shield from
valve cover. Disconnect spark plug wires from spark plugs.
Remove rocker cover and semi-circular packing (located at
rear of rocker cover). Remove rubber plug. Rotate crank-
shaft clockwise (as viewed from timing belt end of engine)
until all timing marks align and cylinder No. 1 is at TDC of
compression stroke. See Fig. 1.
Remove automatic tensioner. See Fig. 2. If timing belt is to be
reused, mark timing belt to indicate original direction of rota-
tion. Remove timing belt. Remove tensioner pulley, tensioner
arm and idler pulley (if necessary). Inspect sprockets for dam-
age.
To remove camshaft sprockets, hold camshaft hexagon
(between camshaft journals No. 2 and 3) while removing
camshaft sprocket bolt. Remove camshaft sprockets. Remove
silent shaft access plug from cylinder block. Insert .31" (8.0 mm)
diameter Phillips screwdriver to block left silent shaft. See Fig. 3.
Remove oil pump sprocket nut and sprocket.
Remove bolt, washer, crankshaft sprocket and flange. Note
direction of flange installation. Remove rear timing belt
tensioner assembly. Remove rear timing belt.
Inspection:
Check belt teeth for damage and oil contamination. Inspect
belt is not cracked, separated or showing canvas fiber. In-
spect all sprockets fordamage. Check tensioner pulley and
idler pulley for grease leakage and roughness in rotation.
Replace components if damaged.
Inspect automatic tensioner for leaks. Check rod end of auto-
matic tensioner for wear. Measure distance from tensioner
rod end to tensioner housing. Distance should be .47" (11.9
mm).
Retract rod into tensioner housing by placing automatic
tensioner assembly in a soft-jawed vise. Close vise to push
rod back into tensioner. Replace automatic tensioner as-
sembly if rod can be easily pushed into automatic tensioner.
NOTE: lf plug at bottom of tensioner protrudes past tensioner
housing, place a washer over plug to prevent it from contacting
vise when pushing rod into tensioner housing.
Installation:
Align timing marks on silent shaft rear crankshaft sprock-
ets with timing marks on engine case.
Install rear timing belt and tensioner. Hold tensioner tightly
against belt while tightening bolts. To check tension, de-
press belt with finger midway between sprockets. Deflec-
tion should be .20-.28" (5.0-7.1 mm). Install crankshaft
sprocket, oil pump sprocket and camshaft sprocket. Tighten
camshaft sprocket bolts to specification while holding hexa-
gon area of camshaft. See TORQUE SPECIFICATIONS.
Install idler pulley.
Retract automatic tensioner rod into tensioner housing by
placing tensioner assembly in a soft-jawed vise. Push rod
back into automatic tensioner in small increments until
both rod and housing holes are aligned. See Fig. 6. Install
a .055" (1.39 mm) diameter wire into holes. Remove auto-
matic tensioner from vise with wire attached.
Install tensioner and arm. Install tensioner pulley on
tensioner arm. Ensure pin holes of tensioner pulley shaft
are left of pulley center bolt. Tighten center bolt. Rotate
camshaft sprockets so dowel pins face upward and timing
marks on sprockets align. See Fig. 1. Outer marks on
sprockets should be aligned with cylinder head surface.
will rotate one tooth in counterclockwise direction. Ensure
this rotation is compensated for when installing timing belt.
Rotate crankshaft and oil pump sprockets to align timing
marks.
If reusing old timing belt, ensure belt is installed in original
direction of rotation. Remove silent shaft access plug from
cylinder block. Insert .31" (8.0 mm) diameter Phillips screw-
driver. See Fig. 3. If screwdriver can be inserted 2.36" (59.9
mm) or more, timing mark alignment is okay.
MITSUBISHI
420
remove screwdriver and rotate oil pump sprocket one full
turn. Reinsert screwdriver. Leave screwdriver in place until
timing belt is installed. Install timing belt on intake cam-
shaft sprocket. Use spring clip to hold belt on sprocket.
See Fig. 7.
Install wrench on both camshaft sprocket bolts. Install tim-
ing belt around exhaust camshaft sprocket while holding
camshaft sprocket bolt so timing mark on camshaft sprocket
is aligned with timing mark. Install another spring clip on
timing belt and camshaft sprocket to hold belt on sprocket.
Install timing belt in following sequence: around idler pul-
ley, oil pump sprocket, crankshaft sprocket and tensioner
pulley.
Remove both spring clips. Rotate tensioner pulley inward to-
ward timing belt until belt does not sag. Temporarily tighten
center bolt on tensioner pulley. Ensure all timing marks are
aligned. Remove Phillips screwdriver from silent shaft ac-
cess hole. Install plug. Remove wrench from camshaft
sprocket bolts.
clockwise, and then rotate clockwise until cylinder No. 1 is
at TDC. Ensure timing marks are aligned. Loosen center
bolt on tensioner pulley. Note location of pin holes in
tensioner pulley. Using INCH-lb. torque wrench and Socket
Wrench (MD998767) or equivalent, apply 22 INCH Ibs. (2.6
N.m) on tensioner pulley. See Fig. 5. With torque applied to
tensioner pulley, tighten tensioner pulley center bolt to 35 ft.
Ibs. (48 N.m).
Install set screw in support bracket until set screw end
contacts tensioner arm. See Fig. 8. Rotate set screw fur-
ther until wire can be removed from automatic tensioner.
Remove set screw. Rotate crankshaft clockwise 2 com-
plete revolutions, and allow to remain in this position for
about 15 minutes. Measure distance between tensioner
arm and automatic tensioner body. Distance should be
.15-.18" (3.8-4.5 mm). See Fig. 9, Dimension A.
If distance cannot be measured due to lack of clearance,
use alternate method. Install set screw until it contacts
tensioner arm. Rotate set screw inward while counting
number of turns until tensioner arm contacts automatic
tensioner housing. Number of turns should be 2 1/2-3 if
belt tension is correct. Remove set screw. Install rubber
plug in rear timing belt cover.
sealant to contact areas on semi-circular packing and rocker
cover before installing. Ensure correct bolts are installed in
proper location in timing belt covers. Adjust drive belts to
Fig. 4: Installing Crankshaft Sprockets
MITSUBISHI
421
Fig. 7: Installing Timing Belt On Camshaft Sprockets
MITSUBISHI
Fig. 8: Measuring Timing Belt Adjustment
Fig. 5: Adjusting Timing Belt Tensioner Pulley
Auto Tensioner Bolt .......................................... 14-20 (19-27)
Front ............................................................... 36-51 (49-69)
Left .................................................................. 22-30 (30-41)
Front Cover Bolt ................................................ 14-16 (19-22)
Front Tensioner Pulley Bolt ............................... 31-40 (42-54)
Rear Tensioner Retaining Bolt ......................... 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Crankshaft Position Sensor Nut ....................... 84-108 (9-12)
Valve Cover Bolt .................................................... 24-36 (3-4)
Fig. 9: Measuring Automatic Tensioner Protrusion
422
MITSUBISHI
2.4L 4-Cylinder 1985-90 Galant & Van
Belt
2.4L 4-Cyl. SOHC
Galant
1985-87........
1 & 2
2.4 Hrs. .. 2521240......
3
250124
1985-87........
1 & 2
2.4 Hrs. .......................
4
250159
Van
1990-87........
1 & 2
3.2 Hrs. .. 2521240......
3
250124
1990-87........
1 & 2
3.2 Hrs ........................
4
250159
1
- Balance shaft belt labor time included in
camshaft belt labor time.
2
3
4
Balance shaft belt.
kits.
60,000 miles.
TIMING BELT REMOVAL
Removal:
Disconnect negative battery cable. Position No. 1 cylinder
at TDC of compression stroke. Remove crankshaft and
water pump pulleys. Remove upper and lower front timing
belt covers Relieve camshaft timing belt tensioner pres-
sure and secure tensioner toward water pump.
If camshaft timing belt is to be reused, mark belt with an
arrow indicating direction of rotation and remove belt. Re-
move camshaft and crankshaft sprocket bolts. Remove cam-
shaft sprocket, crankshaft sprocket and crankshaft flange.
Remove plug on left side of cylinder block. Insert a screw-
driver to keep left silent shaft in position. See Figs. 4 and 5.
Remove oil pump sprocket. Loosen right silent shaft
sprocket mounting bolt until it can be turned by hand. Re-
move belt tensioner B and timing belt B.
Inspect back of belt for hardness, non-elastic and having a
glossy surface. If no mark is produced when fingernail is
forced into it, replace belt. Check for rounded sides on belt.
Sides of belt should be straight and clear-cut. Flaking, peel-
ing, cracking and rubber from canvas also indicates belt
warrants replacement. Cracks are most evident at base of
tooth.
Abnormal wear most often occurs on load side of tooth.
Fluffy canvas, unclear canvas texture, belt color changed to
White from rubber missing, reduced tooth width or a miss-
ing tooth warrant belt replacement.
Installation:
Lightly oil right silent shaft spacer and insert spacer with
chamfered end toward seal. Install right silent shaft
sprocket (if removed) and finger-tighten bolt. Align crank-
shaft sprocket and silent shaft sprocket timing marks with
corresponding marks on front case. See Figs. 2 and 7.
Install tensioner B so only light pressure is on belt. En-
sure flange on tensioner is mounted away from engine
and finger-tighten bolt.
Lift tensioner with finger tip until slack is removed from
tension side of belt. Tighten tensioner bolt, being careful to
prevent turning shaft. Ensure timing marks are in align-
ment. Tighten right silent shaft bolt.
Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not
Align camshaft timing belt sprockets with corresponding
timing marks. See Fig. 6. To ensure oil pump sprocket is in
correct alignment, insert screwdriver shaft in hole on left
side of block. See Figs. 4 and 5.
turn oil pump sprocket one revolution and realign marks.
Insert screwdriver. Leave screwdriver inserted until timing
belt installation is complete. Install crankshaft sprocket.
See Figs. 1 and 8.
Fig. 1: Installing Crankshaft Sprockets (Galant)
Fig. 2: Aligning Timing Marks For Timing Belt B
423
MITSUBISHI
2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)
With tensioner secured fully toward water pump, install tim-
ing belt in order of crankshaft sprocket, oil pump sprocket
and camshaft sprocket. Ensure tension side of belt has no
slack. Loosen tensioner mounting bolt and nut to allow
only tensioner spring pressure to tighten belt. Check belt to
ensure each tooth is in proper mesh with camshaft
sprocket.
Tighten slot-side bolt before tightening nut. Otherwise, ten-
sion bracket will turn and belt will be over tensioned. En-
sure all timing marks are in correct alignment. Remove
screwdriver and install plug in block. Turn crankshaft, clock-
wise only, one revolution. Loosen mounting nut and bolt to
allow tensioner to readjust and tighten slot-side bolt, then
tighten nut.
Hold belt and seal line of undercover, between thumb and
forefinger, at center of tension side. Measure clearance
between belt and seal line. Clearance should be .55" (14.0
mm). See Fig. 9. Reverse removal procedure to complete
reassembly. Adjust drive belts to proper tension. See page
Fig. 4: Aligning Oil Pump Sprocket
424
Fig. 8: Installing Crankshaft Sprockets (Van)
Fig. 9: Checking Timing Belt A Tension
MITSUBISHI
2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)
Fig. 6: Aligning Camshaft Timing Marks (8-Valve Engine)
Crankshaft Pulley Bolt ........................................ 14-22 (19-30)
Front ............................................................... 36-51 (49-69)
Left .................................................................. 22-30 (30-41)
Engine Support Bracket Bolts .......................... 29-36 (39-49)
Front Cover Bolts .............................................. 15-19 (20-26)
Front Roll Stopper Bracket Nuts ....................... 22-36 (30-49)
Front Roll Stopper Insulator Nut ....................... 36-41 (49-56)
Left Mounting Bracket-To-Engine
Bolts & Nuts ................................................... 36-47 (49-64)
Rear Roll Stopper Bracket-To-Rear
Roll Stopper Insulator Nut .............................. 22-29 (30-39)
Roll Stopper Stay Bolt ..................................... 11-15 (15-20)
Rear Roll Stopper-To-No. 2
Crossmember Nuts ....................................... 43-58 (58-79)
Rear Tensioner Retaining Bolt ....................... 11-16 (15-22)
Silent Shaft Sprocket Bolt
1985-87 .......................................................... 25-28 (34-38)
1986-85 .......................................................... 16-21 (22-28)
1987-90 .......................................................... 32-39 (42-53)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt ................................................ 84-108 (9-12)
425
MITSUBISHI
*2.4L 4-Cylinder SOHC, VIN G
2.4L 4-Cyl. SOHC
Eclipse
2000-01...............
1 & 2
2.4 Hours .............
3
250232
1996-98...............
1 & 2
2.4 Hours .............
3
250230
1996-01...............
1 & 2
2.4 Hours .............
4
250168
Galant
1999-01...............
1 & 2
2.4 Hours .............
3
250232
1994-98...............
1 & 2
2.4 Hours .............
3
250230
1994-01...............
1 & 2
2.4 Hours .............
4
250168
Montero Sport
1997-99...............
1 & 2
1.8 Hours .............
3
250230
1997-99...............
1 & 2
1.8 Hours .............
4
250168
1 -
Balance shaft belt labor time included in
camshaft belt labor time.
2 -
With Air Cond. add .7 hours for Galant.
With Air Cond. add .2 hours for Eclipse.
3
4
Balance shaft belt.
NOTE: Engine VIN is eight character of vehicle VIN.
at 100,000 miles.
miles.
TIMING BELT REMOVAL
Eclipse & Galant:
Raise and support vehicle. Remove engine splash shield
from right side wheelwell.
Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Except Montero Sport)
426
MITSUBISHI
*2.4L 4-Cylinder SOHC, VIN G (Cont.)
Lower vehicle. Support weight of engine with floor jack.
Remove upper engine mount located near timing belt cover.
Remove all drive belts. On all except 1999 Galant, remove
drive belt tensioner pulley bracket and power steering pump
pulley. See Fig. 1. On all models, remove water pump pul-
ley.
Remove crankshaft pulley. Noting bolt lengths and loca-
tions, remove upper and lower timing belt cover with gas-
ket.
Rotate crankshaft clockwise (as viewed from timing belt
end of engine) until cylinder No. 1 is at TDC of compres-
sion stroke. Align timing mark on camshaft sprocket with
timing mark on cylinder head. See Fig. 2.
Loosen timing belt tensioner center bolt, and move
tensioner toward water pump. Tighten center bolt to secure
tensioner. Remove front timing belt. Remove timing belt
auto tensioner.
Fig. 2: Aligning Front Timing Belt Marks
Fig. 3: Locking Balance Shaft
To remove balance shaft belt, remove left balance shaft
access plug from cylinder block. Insert .31" (8.0 mm) diam-
eter Phillips screwdriver to block left silent shaft. See Fig. 3.
Ensure screwdriver can be inserted at least 2.36 (59.9
mm). Remove screwdriver if it cannot be inserted at least
2.36" (59.9 mm). Rotate balance shaft one revolution and
realign timing mark.
If reusing old balance shaft timing belt, mark belt with ar-
row to indicate rotation direction. Holding crankshaft sta-
tionary, remove front crankshaft sprocket bolt. Use gear
puller to remove crankshaft sprocket from crankshaft.
Noting direction of installation, remove crankshaft sensing
blade. Loosen balance shaft tensioner pulley center bolt.
Remove balance shaft timing belt.
Fig. 5: Aligning Balance Shaft Timing Marks
(Montero Sport)
427
MITSUBISHI
Montero Sport:
Drain engine coolant. Remove upper radiator hose. Loosen
the cooling fan clutch-to-pulley nuts. Remove accessory
drive belts. Remove fan shroud and cooling fan clutch with
pulley.
CAUTION: Never rotate crankshaft counterclockwise.
Rotate crankshaft clockwise so that No. 1 piston is at TDC
of compression stroke. Leaving secondary wires attached,
remove distributor cap and set aside.
Note installed position of distributor and distributor rotor.
Unplug distributor electrical connector. Remove distbutor
housing and set aside.
Disconnect ignition power transistor and ignition coil con-
nector. Remove ignition coil. Remove timing belt upper
cover.
Holding crankshaft stationary, remove crankshaft pulley bolt.
Remove crankshaft pulley. Remove distributor bracket. See
Fig. 4.
Remove timing belt lower cover. Align timing mark on cam-
shaft sprocket with timing mark on cylinder head. See Fig.
2.
Loosen timing belt tensioner center bolt, and remove
tensioner toward water pump. Tighten center bolt to secure
tensioner. If reusing old timing belt, mark belt with arrow to
indicate original direction of rotation. Remove timing belt.
Remove timing belt auto tensioner.
To remove balance shaft timing belt, remove left balance
shaft access plug from cylinder block. Insert .31" (8.0 mm)
diameter Phillips screwdriver to block left silent shaft. See
Fig. 3. Ensure screwdriver can be inserted at least 2.36
(59.9 mm). Remove screwdriver if it cannot be inserted at
least 2.36" (59.9 mm). Rotate balance shaft one revolution
and realign timing mark.
If reusing old balance shaft timing belt, mark belt with ar-
row to indicate rotation direction. Loosen balance shaft
tensioner pulley center bolt. Remove balance shaft timing
belt.
Inspect back of belt for being hard, non-elastic and having
a glossy surface. Check for rounded sides on belt. Sides of
belt should be straight and clear-cut. Flaking, peeling, crack-
ing rubber from canvas also indicates belt warrants re-
placement. Cracks are most evident at base of tooth.
Abnormal wear most often occurs on load side of tooth.
Fluffy canvas, unclear canvas texture, belt color changed to
White from rubber missing, reduced tooth width or a miss-
ing tooth warrant belt replacement.
Fig. 8: Installing Crankshaft Sensing Blade
(Eclipse & Galant)
Check timing belt and balance shaft belt tensioner pulleys
for worn bearings. Replace as necessary.
Apply 22-44 lbs. (20 kg) of force to end of rod. If auto
tensioner rod moves more than 0.39 (1 mm), replace the
auto tensioner.
Eclipse & Galant:
Align crankshaft rear sprocket and balance shaft sprocket
timing marks. See Fig. 5. Install balance shaft timing belt. If
reusing old belt, install in original direction of rotation.
Fig. 7: Adjusting Balance Shaft Timing Belt Tensioner
428
Fig. 11: Timing Belt Cover Bolt Installation Guide
Move the balance shaft tensioner pulley so that the center
of the tensioner pulley is above and to the left of the
centerline of the tensioner center bolt. See Fig. 7. The
tensioner pulley flange should face toward the front of the
engine.
Using your hand, place pressure on balance shaft tensioner
pulley in direction of balance shaft timing belt. Loosen bal-
ance shaft tensioner pulley center bolt. Ensure balance
shaft timing belt is taut (no slack), and tighten balance shaft
tensioner pulley center bolt.
NOTE: When tightening balance shaft tensioner pulley center
bolt, ensure tensioner pulley shaft does not rotate with bolt. This
will place excessive tension on belt.
Press balance shaft belt on side opposite tensioner to check
belt deflection. See Fig. 5. Balance shaft belt deflection
should be .20-.28" (5.0-7.0 mm). Adjust as necessary.
Install crankshaft sensing blade in correct direction. See
Fig. 8. Install crankshaft sprocket. Apply engine oil to threads
of crankshaft sprocket bolt. Install and tighten bolt to speci-
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed.
Using a soft-jawed vise, SLOWLY compress the timing belt
auto tensioner push rod until rod pin hole aligns with pin
hole in tensioner body. Insert a locking pin through tensioner
body and tensioner push rod pin holes to lock auto tensioner
in position. Install auto tensioner on engine with locking
pin in place.
timing belt on engine. If reusing old timing belt, ensure belt
is installed in original direction of rotation. Make sure there
is no slack in timing belt between sprockets.
Set the timing belt tensioner pulley so that pin holes are at
the bottom of the pulley. See Fig. 9. Press tensioner pulley
lightly against the timing belt. Temporarily tighten tensioner
pulley center bolt.
CAUTION: To prevent breaking auto tensioner push rod, turn
Set Screw (MD998738) by hand only.
Install Set Screw (MD998738) into rear timing belt cover.
See Fig. 9. Screw in set screw until tensioner bracket arm
makes contact with auto tensioner push rod end.
Remove Phillips screwdriver from engine block and install
plug. To adjust timing belt tension, turn crankshaft 1/4 revo-
lution counterclockwise. Turn crankshaft clockwise until all
timing marks are aligned.
Loosen the tensioner pulley center bolt. Install Adapter
(MD998767) and torque wrench on tensioner pulley. See
Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tight-
ening tensioner pulley center bolt to specification. See
TORQUE SPECIFICATIONS. DO NOT let tensioner pulley
turn while tightening center bolt.
Remove locking pin from auto tensioner. Remove set screw.
Turn crankshaft 2 revolutions clockwise. Align all timing
marks. Let vehicle sit for 15 minutes. Measure auto
tensioner rod protrusion between auto tensioner housing
and point where it contacts tensioner arm. Protrusion
should be .150-.177 (3.8-4.5 mm). If protrusion is not as
specified, repeat timing belt tensioning procedure.
Install timing belt covers. Ensure bolts are installed in origi-
nal locations. See Fig. 11. Continue installation in reverse
order of removal procedure. Adjust drive belts to proper
Montero Sport:
Align crankshaft sprocket and balance shaft sprocket tim-
ing marks. See Fig. 5. Install balance shaft timing belt. If
reusing old belt, install in original direction of rotation.
Move the balance shaft tensioner pulley so that the center
of the tensioner pulley is above and to the left of the
centerline of the tensioner center bolt. See Fig. 7. The
tensioner pulley flange should face toward the front of the
engine.
Using your hand, place pressure on balance shaft tensioner
pulley in direction of balance shaft timing belt. Loosen bal-
ance shaft tensioner pulley center bolt. Ensure balance
shaft timing belt is taut (no slack), and tighten balance shaft
tensioner pulley center bolt.
NOTE: When tightening balance shaft tensioner pulley center
bolt, ensure tensioner pulley shaft does not rotate with bolt. This
will place excessive tension on belt.
Press balance shaft belt on side opposite tensioner to check
belt deflection. See Fig. 5. Balance shaft belt deflection
should be .20-.28" (5.0-7.0 mm). Adjust as necessary.
Using a soft-jawed vise, SLOWLY compress the timing belt
auto tensioner push rod until rod pin hole aligns with pin
hole in tensioner body. Insert a locking pin through tensioner
body and tensioner push rod pin holes to lock auto tensioner
in position. Install auto tensioner on engine with locking
pin in place.
timing belt on engine. If reusing old timing belt, ensure belt
is installed in original direction of rotation. Make sure there
is no slack in timing belt between sprockets.
MITSUBISHI
429
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed.
Set the timing belt tensioner pulley so that pin holes are at
the bottom of the pulley. See Fig. 9. Press tensioner pulley
lightly against the timing belt. Temporarily tighten tensioner
pulley center bolt.
CAUTION: To prevent breaking auto tensioner push rod, turn
Set Screw (MD998738) by hand only.
Install Set Screw (MD998738) into rear timing belt cover.
See Fig. 9. Screw in set screw until tensioner bracket arm
makes contact with auto tensioner push rod end.
Remove Phillips screwdriver from engine block and install
plug. To adjust timing belt tension, turn crankshaft 1/4 revo-
lution counterclockwise. Turn crankshaft clockwise until all
timing marks are aligned.
Loosen the tensioner pulley center bolt. Install Adapter
(MD998767) and torque wrench on tensioner pulley. See
Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tight-
ening tensioner pulley center bolt to specification. See
TORQUE SPECIFICATIONS. DO NOT let tensioner pulley
turn while tightening center bolt.
Remove locking pin from auto tensioner. Remove set screw.
Turn crankshaft 2 revolutions clockwise. Align all timing
marks. Let vehicle sit for 15 minutes. Measure auto
tensioner rod protrusion between auto tensioner housing
and point where it contacts tensioner arm. See Fig. 12,
Dimension A. Protrusion should be .150-.177 (3.8-4.5
mm). If protrusion is not as specified, repeat timing belt
tensioning procedure.
Install timing belt lower cover, distributor bracket, and tim-
ing belt upper cover. Install distributor, distributor cap, and
ignition coil.
Install cooling fan clutch, pulley, fan shroud, and upper ra-
diator hose. Continue installation in reverse order of re-
moval procedure. Fill and bleed cooling system. Adjust ig-
nition timing.
MITSUBISHI
TORQUE SPECIFICATIONS (ECLIPSE & GALANT)
Crankshaft Drive Belt Pulley Bolt ................................ 18 (25)
Crankshaft Sprocket Bolt ............................
1
80-94 (108-127)
Drive Belt Tensioner Pulley Bracket Bolt .............. 17-20 (23-26)
Engine Upper Mount
Mount-To-Engine Bracket Nut/Bolt ................................ 49 (67)
Mount-To-Body Through Bolt ............................ 71-85 (98-118)
Tensioner Pulley Center Bolt
Balance Shaft Belt Pulley ............................................ 14 (19)
Camshaft Belt Pulley ................................................... 35 (48)
Water Pump Bolt ........................................................ 10 (14)
INCH Lbs. (N.m)
6 mm (Except Flange Bolts) .................................... 78 (8.8)
6 mm (Flanged Bolt) ...................................... 89-106 (10-12)
8 mm Bolt .................................................................. 120 (14)
1
Apply engine oil to bolt threads.
TORQUE SPECIFICATIONS (MONTERO SPORT)
Crankshaft Drive Belt Pulley Bolt ................................ 18 (25)
Distributor Bracket Bolt (M6 x 18 mm) ......................... 17 (24)
Tensioner Pulley Center Bolt
Balance Shaft Belt Pulley ............................................ 14 (19)
Camshaft Belt Pulley ................................................... 35 (48)
Water Pump Bolt ........................................................ 10 (14)
INCH Lbs. (N.m)
Cooling Fan Clutch-To-Stud Nut ....................... 89-106 (10-12)
Distributor Bracket Bolt
Except M6 x 18 mm..................................................... 97 (11)
Distributor Housing Hold-Down Bolt ........................... 115 (13)
Timing Belt Cover
Lower Cover Bolt ..................................................... 78 (8.8)
Upper Cover Bolt ......................................................... 97 (11)
Water Pump Pulley Bolt ............................................ 117 (13)
430
MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine
Belt
Application Time
1
Kit No. No.
3.0L V6 SOHC
Diamante
1992-96.......... 3.8 Hours... 2521390........ 250139
Galant
1988............... 3.8 Hrs. ...... 2521390........ 250139
Montero (12-Valve Engine)
1989-94.......... 3.5 Hrs. ...... 2521390........ 250139
Pickup (4WD)
1990-94.......... 3.5 Hrs. ...... 2521390........ 250139
Sigma
1989-90.......... 3.8 Hrs. ...... 2521390........ 250139
3000GT
1997-98.......... 3.4 Hours... 2521390........ 250139
1
kits.
TIMING BELT REMOVAL
Diamante:
Disconnect negative battery cable. Remove left front and
left side splash shields. Using engine hoist, lift engine just
enough to remove weight from engine mounts. Remove
drive belts. Remove A/C tensioner pulley and bracket.
CAUTION: Apply spray lubricant on reamer bolt during removal
as bolt is sometimes seized in engine support.
Remove engine mount bracket bolts in sequence. Lubri-
cate reamer bolt with penetrating oil before and during re-
moval. See Fig. 2. Remove power steering pump, leaving
hoses attached. On 1996 models, remove crankshaft po-
sition sensor and right oxygen sensor. Remove crankshaft
pulley. On vehicles with ABS, remove overflow tank and
bracket.
On all models, remove engine support bracket. Remove
crankshaft pulley. Remove timing belt covers. Remove
flange from crankshaft. See Fig. 3. Rotate crankshaft to
align all timing marks. See Fig. 4. Loosen belt tensioner
bolt, and rotate belt tensioner counterclockwise to release
belt tension.
If reusing timing belt, mark belt to indicate direction of belt
rotation. Loosen tensioner bolt. Pry tensioner counterclock-
wise to relieve belt tension. While holding tensioner, tighten
tensioner bolt. Remove timing belt.
Galant:
drive belts. Disconnect connector and pressure hoses at
power steering pump. Remove power steering pump with
return hose connected. Remove through-bolt from front
engine mount.
CAUTION: Apply spray lubricant on reamer bolt during removal
as bolt is sometimes seized in engine support.
Support engine and remove front engine mount. Remove
engine mount bracket bolts in sequence. Lubricate reamer
bolt with penetrating oil before and during removal. See
Fig. 2.
Remove A/C tensioner pulley and mounting bracket. Re-
move No. 1 upper outer cover and gaskets. See Fig. 3.
Remove engine support bracket bolts in proper sequence.
See Fig. 2. Remove engine support bracket.
Fig. 1: Locating Timing Belt & Sprocket
Remove cover cap and No. 2 upper outer cover and gas-
kets. Remove under cover. Using Holder (MB990767-01)
and Adapter Bolts (MD998719) or equivalent, remove crank-
shaft pulley.
Remove lower outer cover, gaskets and flange. See Fig. 3.
Rotate crankshaft and align all timing marks. See Fig. 4.
Loosen belt tensioner bolt and rotate belt tensioner coun-
terclockwise to release belt tension.
tensioner.
431
MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine (Cont.)
Fig. 2: Removal & Installation Of Engine Support Bracket
Montero & Pickup:
Disconnect upper radiator hose. Remove upper radiator
shroud. Remove cooling fan and fan clutch assembly. Re-
move cooling fan pulley. Remove all accessory drive belts.
Remove power steering pump with pressure and return
hoses connected and set aside.
Remove power steering pump brackets. Remove A/C
tensioner pulley and mounting bracket. Remove A/C com-
pressor with hoses connected and mounting bracket. Re-
move cooling fan bracket assembly. Remove timing belt
No. 1 upper outer cover and gaskets. See Fig. 3.
Remove timing belt No. 2 upper outer cover and gaskets.
Remove timing belt lower outer cover and gaskets. Using
Holder (MB998747) or equivalent, and a used V belt, re-
move crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine
V belt to hold crankshaft pulley unless belt is to be replaced.
Remove flange. See Fig. 3. Rotate crankshaft and align all
timing marks. See Fig. 4. Loosen belt tensioner bolt and
rotate belt tensioner counterclockwise to release belt ten-
sion.
tensioner.
Sigma:
drive belts. Disconnect connector and pressure hose at
power steering pump. Remove power steering pump with
return hose connected. Support engine. Remove through-
bolt from front engine mount. Remove front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal
as bolt is sometimes seized in engine support bracket.
Remove A/C tensioner pulley and mounting bracket. Re-
move timing belt No. 1 upper outer cover and gaskets. See
Fig. 3. Remove engine support bracket bolts in proper se-
quence. See Fig. 2. Remove engine support bracket.
Remove cover cap and timing belt No. 2 upper outer cover
and gaskets. Remove under cover. Usi ng Hol der
(MB990767-01) and Adapter Bolts (MD998719) or equiva-
lent, remove crankshaft pulley.
Remove lower outer cover, gaskets and flange. See Fig. 3.
Rotate crankshaft and align all timing marks. See Fig. 4.
Loosen belt tensioner bolt and rotate belt tensioner coun-
terclockwise to release belt tension. If timing belt is to be
reused, place arrow on belt to indicate rotation direction.
432
3000GT:
Remove engine lower splash shields. Remove cruise con-
trol actuator (if equipped) from right side fenderwell.
Remove all drive belts. Remove A/C drive belt tensioner
pulley assembly. Remove power steering and generator
drive belt tensioner pulley bracket.
Place floor jack under engine to support weight of engine.
Remove engine-to-body mount from timing belt end of en-
gine.
Unplug power steering pump pressure switch electrical
connector. Remove power steering pump with hoses at-
tached and set out of way.
Remove engine support bracket bolts, in specified se-
quence, from front of engine. Fig. 2. Note position of reamer
bolt for reassembly reference.
CAUTION: Reamer bolt may be heat-seized to engine support
bracket. Reamer bolt has R marking on bolt head.
bolt. Remove crankshaft pulley.
Remove all timing belt covers. See Fig. 6. Noting position
for reassembly reference, remove front flange from crank-
shaft. See Fig. 7.
Rotate crankshaft to align all timing marks. See Fig. 4.
Loosen belt tensioner bolt. Rotate belt tensioner pulley
counterclockwise to relieve belt tension. Tighten tensioner
pulley bolt.
If reusing timing belt, place arrow on belt to indicate belt
running direction. Remove timing belt.
All Models:
belt for signs of oil contamination, cracks, separation, worn
or missing teeth, or hardened black surface. Replace belt
if worn, damaged or contaminated. Inspect belt tensioner
for smooth rotation. Replace parts, if defective.
Diamante:
Install timing belt onto crankshaft sprocket, then around
left camshaft sprocket, with all slack removed from tension
side of belt. Route timing belt onto water pump pulley, right
camshaft sprocket, and tensioner. Apply torque to rear cam-
shaft pulley to tighten belt. Ensure all timing marks are
aligned.
Install flange onto crankshaft. Loosen belt tensioner bolts
slightly, and allow tensioner to apply belt tension. Using
Crankshaft Socket (MD998716-01) or equivalent, rotate
tensioner bolts to specification. Using belt tension gauge,
measure belt tension halfway between crankshaft sprocket
and camshaft sprocket on side opposite belt tensioner.
Belt tension should be 44-66 Ibs. (20-30 kg).
Install proper length bolts in timing belt covers. See Fig. 6.
Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS.
Install engine support bracket and tighten bolts in sequence.
See Fig. 2. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. To install remaining components, re-
verse removal procedure. Adjust drive belts to proper ten-
Galant:
Install timing belt. Ensure belt is installed in original direc-
tion of rotation and all timing marks are aligned. Install
measure belt tension half way between crankshaft sprocket
CAUTION: Engine support bracket reamer bolt must be tightened
proper length bolts in timing belt covers and engine sup-
port bracket. See Figs. 2 and 6. Tighten bolts to specifica-
Montero & Pickup:
Install timing belt on crankshaft sprocket and then left cam-
shaft sprocket with all slack removed from tension side of
belt. Route timing belt onto water pump pulley, right cam-
shaft sprocket and tensioner. Remove any slack from belt
by rotating left and then right camshaft sprockets counter-
clockwise. Ensure all timing marks are aligned. Install
Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise.
Realign all timing marks. Tighten belt tensioner bolts to
specification. Using belt tension gauge, measure belt ten-
sion halfway between crankshaft sprocket and camshaft
MITSUBISHI
Fig. 5: Identifying Timing Belt Cover Bolt Lengths (Pickup)
433
MITSUBISHI
Fig. 6: Timing Belt Cover Bolt Length Identification
(Diamante, Galant & Sigma)
proper length bolts in timing belt covers. See Fig. 5. Tighten
tension ranges.
CAUTION: The sealing washer under the cooling system air bleed
bolt was reduced to .85mm from 2.0mm. The .85 mm washer CANNOT
be reused. Replace washer if bolt is loosened or removed. This
information is from Mitsubishi technical service bulletin 96-
00-003; February, 1996.
Before refilling cooling system, remove air bleed bolt on
top of thermostat housing. Refill cooling system with 50/50
mix of water and coolant until it overflows from air bleed
bolt hole. Install air bleed bolt with new .85 mm washer (if
equipped).
Start engine and run to normal operating temperature. Race
engine to 3000 RPM several times. Stop engine. After en-
gine cools, refill radiator.
Sigma:
and temporarily tighten bolt. Align all timing marks with No.1
cylinder at TDC of compression stroke. See Fig. 4.
Install timing belt on crankshaft sprocket, rear head cam-
shaft sprocket, water pump pulley, front head sprocket and
timing belt tensioner. Ensure belt is installed in original
direction of rotation and all timing marks are aligned on
crankshaft. Loosen belt tensioner bolts slightly and allow
tensioner to apply belt tension.
measure belt tension halfway between crankshaft sprocket
Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install
proper length bolts in timing belt covers. See Fig. 6.
Install engine support bracket . Tighten bolts in sequence
to specification. See Fig. 2. See TORQUE SPECIFICATIONS.
tension ranges.
3000GT:
Ensure all timing belt marks are aligned. See Fig. 4. If not
already done, loosen tensioner center bolt. Turn tensioner
counterclockwise. Temporarily tighten tensioner center bolt.
Install timing belt on crankshaft sprocket, left hand cam-
shaft sprocket (side away from tensioner pulley), water
pump pulley, right hand camshaft sprocket, and timing belt
tensioner. Apply counterclockwise force to right hand cam-
Fig. 8: Identifying Timing Belt Cover Bolts (3000GT)
(3000GT SOHC)
434
shaft sprocket (camshaft closest to firewall) to remove any
belt slack. Ensure all timing marks are still aligned.
Install front flange on crankshaft. Loosen timing belt
tensioner pulley center bolt. Allow the tensioner spring
force to tension timing belt. Turn crankshaft 2 revolutions
clockwise. DO NOT turn counterclockwise.
Align all timing belt marks. Final tighten tensioner pulley
center bolt. Using a belt tension gauge, measure timing
belt tension midway between crankshaft sprocket and left
hand camshaft sprocket (side opposite belt tensioner pul-
ley). Belt tension should be 46.3-68.3 lbs. (21-31 kg).
Install flange onto crankshaft. Loosen belt tensioner bolts
slightly, and allow tensioner to apply belt tension.
Install timing belt covers. Install timing belt cover bolts in
correct locations. See Fig. 8.
NOTE: When installing engine support bracket reamer bolt, tighten
it slowly while spraying lubricant on reamer bolt. Reamer bolt
has R marking on bolt head.
Install crankshaft pulley. Tighten crankshaft pulley bolt to
specification. See TORQUE SPECIFICATIONS. Install en-
gine support bracket on engine block. Install bolts in cor-
rect location, and tighten in sequence. See Fig. 2.
TORQUE SPECIFICATIONS (DIAMANTE)
1991 ....................................................... 108-116 (146-157)
1994-92 ................................................................ 136 (185)
10 X 40 mm .................................................... 47-54 (64-73)
Except 10 X 40 mm ..................................... 76-83 (103-113)
Water Pump Bolt ........................................................ 17 (23)
INCH Lbs. (N.m)
TORQUE SPECIFICATIONS (GALANT)
10 X 40 mm .................................................... 25-36 (34-49)
10 X 53 mm .................................................... 47-54 (64-73)
12 X 56 mm ................................................ 76-83 (103-113)
Water Pump Bolt .............................................. 14-19 (19-26)
INCH Lbs. (N.m)
MITSUBISHI
TORQUE SPECIFICATIONS (MONTERO & PICKUP)
Montero .................................................. 108-116 (146-157)
Pickup .................................................... 130-137 (176-186)
Left Engine Support Bracket Bolt ...................... 15-21 (20-30)
Rear Engine Support Bracket Bolt .................... 13-18 (18-25)
Right Engine Support Bracket Bolt
10 X 22 mm .................................................... 25-36 (34-49)
10 X 40 mm .................................................... 25-36 (34-49)
12 X 22 mm .................................................... 47-61 (64-83)
12 X 32 mm .................................................... 47-61 (64-83)
Water Pump Bolt .............................................. 14-20 (19-27)
INCH Lbs. (N.m)
TORQUE SPECIFICATIONS (SIGMA)
Engine Mount Bracket Nut ................................ 44-57 (60-77)
10 X 40 mm .................................................... 25-36 (34-49)
10 X 53 mm .................................................... 47-54 (64-73)
12 X 56 mm
1989 ........................................................ 76-83 (103-113)
1990 ............................................................ 47-61 (65-85)
Water Pump Bolt .............................................. 14-20 (19-27)
INCH Lbs. (N.m)
TORQUE SPECIFICATIONS (3000GT)
Engine Mount
To-Body Through-Bolt ................................................. 51 (70)
To-Engine Support Bracket ......................... 72-87 (100-120)
Engine Support Bracket-To-Engine Bolt
1
M10 Bolt ..................................................................... 51 (70)
M12 Bolt ................................................................... 80 (110)
Generator/Power Steering Tensioner Pulley
Bracket Bolt ................................................................. 30 (42)
Power Steering Pump Mount Bolt
Short Bolt ................................................................... 29 (40)
Long, Shoulder Bolt .................................................... 16 (22)
Timing Belt Tensioner Pulley Center Bolt ......... 16-22 (22-30)
Water Pump Bolt ........................................................ 17 (23)
INCH Lbs. (N.m)
1
Spray lubricant on reamer bolt while tightening.
435
MITSUBISHI
*3.0L V6 SOHC, 24 Valve Engine
3.0L V6 SOHC
Eclipse
2000-01................
1
3.0 Hours ................. 250259
Galant
1999-01................
1
2.4 Hours ................. 250259
Montero (24-Valve Engine)
1995-96................
1
3.5 Hours ................. 250259
Montero Sport
1997-01................
1
3.5 Hours ................. 250259
1
- With Air Cond. add .2 hours for Eclipse, and .6
hours for Galant and Montero Sport.
TIMING BELT REMOVAL
Eclipse & Galant:
hicle. Remove engine splash shield from right wheelwell.
Remove generator and A/C compressor drive belt. Remove
dipstick tube from front of engine. Remove generator with
wires attached and secure out of way. Remove power steer-
ing pump drive belt.
Lower vehicle. Support weight of engine with jack. Remove
engine mount from timing belt end of engine. Holding crank-
shaft pulley stationary, remove crankshaft pulley bolt. Re-
move crankshaft pulley.
Remove engine support bracket from front of engine.
CAUTION: Always turn crankshaft in clockwise direction (as viewed
from front of engine).
direction of belt rotation. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks. See Fig. 2. Loosen
center bolt of timing belt tensioner pulley, and remove tim-
ing belt. Remove timing belt auto-tensioner from engine
block.
Montero & Montero Sport:
Disconnect upper radiator hose from engine. Remove up-
per radiator shroud. Loosen cooling fan clutch-to-pulley
nuts. Relieve tension on accessory drive belts.
Remove cooling fan and fan clutch assembly. Remove cool-
ing fan pulley. Remove all accessory drive belts. Remove
generator with wires attached and secure out of way.
Remove power steering pump with hoses connected, and
set aside. Remove A/C compressor with hoses connected,
and set aside. Remove A/C compressor bracket. Remove
accessory mount assembly. See Fig. 4.
Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner)
Fig. 1: Exploded View Of Timing Belt Components (Galant)
436
(Montero Sport)
Remove upper timing belt upper cover. See Fig. 3. Holding
crankshaft pulley stationary, remove crankshaft pulley bolt.
Remove lower timing belt cover. Turn crankshaft clockwise
to align camshaft and crankshaft timing marks. See Fig. 2.
Loosen belt tensioner pulley center bolt.
Fig. 4: Exploded View Of Accessory Mount Assembly
(Montero & Montero Sport)
MITSUBISHI
*3.0L V6 SOHC, 24 Valve Engine (Cont.)
direction of belt rotation. Remove timing belt. Remove tim-
ing belt auto-tensioner.
All Models:
pulley for smooth rotation. Replace if defective.
Check timing belt auto -tensioner for leaks. Hold timing
belt auto-tensioner upright. Measure rod protrusion above
edge of housing. See Fig. 5. Length should be .47 (12
mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If
auto tensioner rod moves more than 0.39 (1 mm), replace
the auto-tensioner.
Eclipse & Galant:
Place auto-tensioner in soft-jawed vise to SLOWLY com-
press the push rod. If there is a plug at the base of the auto-
tensioner body, place flat washer around plug so it will not
contact vise jaw.
CAUTION: Never compress the auto-tensioner too fast or the push
rod will be damaged.
Slowly compress auto-tensioner push rod until holes in
push rod and auto-tensioner housing are aligned. Insert a
locking pin into the alignment holes. Install auto-tensioner
on engine.
timing belt on crankshaft sprocket, idler pulley, left bank
camshaft sprocket, water pump pulley, right bank camshaft
sprocket, and tensioner pulley. Take all slack out of timing
belt.
Loosen the tensioner pulley center bolt. Rotate tensioner
pulley against timing belt. Temporarily tighten tensioner
pulley center bolt. Turn crankshaft 1/4 turn counterclock-
wise. Turn crankshaft 1/4 turn clockwise. Ensure all timing
belt marks are still aligned.
For 1999-00 models, loosen tensioner pulley center bolt.
Position tensioner pin holes at BOTTOM of tensioner. In-
stall Adapter (MD998767) on tensioner pulley. See Fig. 6. U
se a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque
(counterclockwise direction) to tensioner pulley. Tighten
tensioner center bolt to specification while holding tensioner
stationary.
For 2001 models, loosen tensioner pulley center bolt. Po-
sition tensioner pin holes at TOP of tensioner. Install
Adapter (MD998767) on tensioner pulley. See Fig. 8. Us e
a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque
(clockwise direction) to tensioner pulley. Tighten tensioner
center bolt to specification while holding tensioner station-
ary.
On all models, remove locking pin from auto-tensioner.
Turn crankshaft 2 revolutions clockwise and align all tim-
ing marks. DO NOT rotate counterclockwise.
Wait for at least 5 minutes, then check auto-tensioner push
rod protrusion. To check push rod protrusion, measure
clearance between body of auto-tensioner and bottom of
tensioner pulley bracket arm. Clearance should be 0.15-
0.20 (3.8-5.0 mm). If protrusion is not correct, repeat tim-
ing belt tensioning procedure.
437
Install power steering pump. Install A/C compresor bracket
and A/C compressor. Install water pump pulley and cooling
fan. To install remaining components, reverse removal pro-
CAUTION: The sealing washer under the cooling system air bleed
bolt was reduced to .85mm from 2.0mm. The .85 mm washer CANNOT
be reused. Replace washer if bolt is loosened or removed. This
information is from Mitsubishi technical service bulletin 96-
00-003; February, 1996.
Before refilling cooling system, remove air bleed bolt on
top of thermostat housing. Refill cooling system with 50/50
mix of water and coolant until it overflows from air bleed
bolt hole. Install air bleed bolt with new .85 mm washer (if
equipped).
TORQUE SPECIFICATIONS (ECLIPSE & GALANT)
Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24)
Crankshaft Pulley Bolt .............................
1
131-137 (177-186)
Dipstick Tube Bolt ......................................................... 10 (14)
Engine Mount
To-Engine Support Bracket Nut/Bolt ......................... 63 (86)
To-Body Through Bolt ................................................
2
61 (83)
Engine Support Bracket-to-Engine Bolt ......................... 32 (44)
Generator Pivot Bolt ....................................................... 32 (44)
Generator Top Bolt ........................................................ 15 (21)
Power Steering Pump Belt Tensioner Bolt .................... 32 (44)
Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44)
Water Pump Bolt
M8 Bolt .......................................................................... 17 (23)
M10 Bolt ....................................................................... 30 (41)
INCH Lbs. (N.m)
1
Apply engine oil to bolt threads before installation.
2
Final tighten bolt with full weight of engine on mount.
Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse &
(Galant; 1997-01 Montero & Montero Sport)
MITSUBISHI
Install engine support bracket on engine block. Tighten top
bolt first, then working in a counterclockwise direction,
tighten the remaining bolts. See Fig. 7. Install timing belt
covers. Install crankshaft pulley. Apply engine oil to crank-
shaft pulley bolt, then tighten bolt to specification. See
contact vise jaw.
SLOWLY compress auto-tensioner push rod until holes in
on engine.
belt.
Loosen tensioner pulley center bolt. Position tensioner pin
holes at bottom of tensioner. Install Adapter (MD998767)
on tensioner pulley. See Fig. 6. Using torque wrench, apply
39 INCH lbs. (4.4 N.m) of torque (counterclockwise direc-
tion) to tensioner pulley. Tighten tensioner center bolt to
specification while holding tensioner stationary.
Remove locking pin from auto-tensioner. Turn crankshaft 2
revolutions clockwise and align all timing marks. DO NOT
rotate counterclockwise.
Install timing belt covers. Install crankshaft pulley. Install
accessory mount assembly on front of engine.
Fig. 5: Checking Timing Belt Auto-Tensioner Movement
438
MITSUBISHI
Fig. 7: Engine Support Bracket Tightening Sequence
(Eclipse & Galant)
(2001 Eclipse & Galant)
TORQUE SPECIFICATIONS (MONTERO & MONTERO
SPORT)
Accessory Mount Assembly Bolt .................................... 33 (44)
Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24)
Crankshaft Pulley Bolt ............................................
1
134 (181)
Generator Pivot (Upper) Bolt ......................................... 38 (52)
Generator Bottom Bolt ................................................... 16 (22)
Power Steering Pump Bolt .................................. 29-33 (39-44)
Water Pump Bolt ............................................................ 18 (24)
INCH Lbs. (N.m)
Cooling Fan Clutch-to-Pulley Nut ..................... 89-106 (10-12)
M6 Bolt ......................................................................... 97 (11)
M8 Bolt ....................................................................... 117 (13)
1
439
Application LaborTime Belt Part No.
3.5L V6
Montero
1994-96................
1
4.5 Hours ................. 250253
1
The manufacturer requires the belt be replaced every 60,000
miles, except in California. In California, belt replacement is
recommended, but not required. In California, replace belt at
TIMING BELT
NOTE: Ensure timing marks are aligned. Mark timing belt direction
of rotation
Removal:
Disconnect negative battery cable. Drain engine coolant.
Remove engine coolant reservoir tank, fan shroud and ra-
diator.
Remove generator with wires attached and secure out of
way. Remove battery and battery tray. Remove engine lower
splash shields.
Remove accessory drive belts. Remove cooling fan clutch
assembly. See Fig. 2. Remove cooling fan pulley. Remove
A/C compressor with hoses attached and secure out of
way. Remove A/C compressor bracket.
Remove power steering pump mount cover. Remove power
steering pump with hoses attached and secure out of way.
Remove accessory mount. See Fig. 2.
Remove timing belt upper cover. Disconnect crankshaft po-
sition sensor connector. Using Holder (MB990767) and
Bolts (MB998754) or equivalents, hold crankshaft station-
ary while remove crankshaft pulley center bolt.
If reusing timing belt, place arrow on belt to indicate run-
ning direction. Rotate crankshaft to align all timing marks.
See Fig. 3. Loosen timing belt tensioner center bolt. Re-
move timing belt and timing belt automatic tensioner.
NOTE: Revised auto-tensioner procedure is from Mitsubishi technical
service bulletin 96-11-006; June, 1996.
Inspection:
pulley for smooth rotation.
Check timing belt automatic tensioner for leaks. Hold tim-
ing belt auto-tensioner upright. Measure rod protrusion
above edge of housing. Length should be .461-.484 (11.7-
12.3 mm). Apply 40-44 lbs. (18-20 kg) of force to end of rod.
If automatic tensioner rod moves more than 0.39 (1 mm),
replace the automatic tensioner.
Installation:
Place automatic tensioner assembly in a soft-jawed vise.
SLOWLY close vise to press rod back into tensioner until
both rod and housing holes are aligned. Install a .055"
(1.40 mm) diameter wire or drill bit through both holes.
Remove automatic tensioner from vise, and install assem-
bly on engine with wire in place. Install crankshaft sprocket
(if removed). Align timing marks on crankshaft and cam-
shaft sprockets. See Fig. 3.
CAUTION: Turning camshaft sprockets while No. 1 piston is at
TDC may damage valve and piston. Use care when aligning timing
marks.
To lower No. 1 piston from TDC and prevent valve and pis-
ton contact, turn crankshaft back 3 sprocket teeth (mea-
sured at timing mark). See Fig. 4.
MITSUBISHI
*3.5L V6 DOHC
Courtesy of Mitsubishi Motor Sales of America, Inc.
Fig. 2: Exploded View Of Accessory Mount Components
440
Starting with left (drivers side) bank of cylinders, verify in-
take and exhaust camshaft timing marks are correctly
aligned with marks on rear timing belt cover. See Fig. 3.
Rotate either camshaft sprocket clockwise to align timing
marks.
WARNING: Use care when aligning timing marks. Camshaft is
under valve spring pressure and may rotate suddenly, pinching
hand between sprockets.
Align camshaft timing marks on right (passengers side)
camshaft sprockets. See Fig. 3. Using box end wrenches,
hold camshaft sprocket center bolts to prevent sprockets
from turning. With right bank camshaft sprocket timing
marks aligned with marks on rear timing belt cover, install
timing belt on right bank camshaft sprockets. Hold cam-
shaft sprockets in place with spring clips. See Fig. 5.
Install timing belt around water pump pulley. With left bank
camshaft sprockets correctly aligned, install timing belt on
left hand camshaft sprocket. Secure timing belt onto sprock-
ets with spring clips.
MITSUBISHI
Install timing belt on the idler pulley. Realign the crankshaft
sprocket timing mark with mark on oil pump housing. Turn
crankshaft ONE turn counterclockwise (as viewed from front
of engine). Set timing belt on crankshaft sprocket, then onto
tensioner pulley.
Rotate timing belt tensioner pulley until pin holes are lo-
cated above center bolt. See Fig. 6. Push tensioner pulley
against belt, and temporarily tighten center bolt. Ensure all
timing marks are still aligned, and remove spring clips.
Rotate crankshaft 1/4 revolution counterclockwise. Rotate
crankshaft clockwise until timing marks are realigned.
Loosen tensioner center bolt.
Using Tensioner Pulley Socket (MD998767) or equivalent,
apply approximately 83 INCH Ibs. (9.4 N.m) torque to
tensioner pulley in a clockwise direction. Holding tensioner
pulley to prevent it from turning, final tighten center bolt to
35 ft. lbs. (48 N.m). Ensure tensioner pulley does not rotate
while tightening center bolt.
Remove set pin or drill bit from automatic tensioner. Rotate
crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify
wire or drill bit can still be easily removed and installed.
Even if set pin or drill bit cannot be easily installed, the
automatic tensioner is normal if its push rod protrusion is
within .15-.18" (3.8-4.5 mm). Measure push rod protrusion
between top of tensioner body and lever arm of tensioner
pulley lever. See Fig. 7.
If push rod protrusion is out of specification, timing belt
tension adjustment will have to be repeated.
Install timing belt covers. Install crankshaft pulley. Tighten
crankshaft pulley bolt to specification. See TORQUE SPECI-
FICATIONS.
Install generator. Install accessory mount. Install power
steering pump and A/C compressor. Install cooling fan.
Install accessory drive belts.
CAUTION: On later model years, the sealing washer under the
cooling system air bleed bolt was reduced to .85 mm from 2.0
mm. The .85 mm washer CANNOT be reused. Replace washer if
bolt is loosened or removed. This information is from Mitsubishi
technical service bulletin 96-00-003; February, 1996.
Install radiator. Before refilling cooling system, remove air
bleed bolt on top of thermostat housing. Refill cooling sys-
tem with 50/50 mix of water and coolant until it overflows
from air bleed bolt hole. Install air bleed bolt with new .85
mm washer (if equipped).
Fig. 5: Securing Timing Belt With Spring Clips
Fig. 4: Positioning Crankshaft For Timing Belt Installation
441
MITSUBISHI
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS.
tension ranges.
Application Ft. Lbs. (N,m)
Automatic Tensioner Bolt ............................................... 17 (24)
Accessory Mount Bolts
10 x 80 mm ..................................................... 28-30 (38-41)
10 x 100 mm ................................................... 32-34 (43-46)
12 x 100 mm ................................................... 53-55 (72-75)
Timing Belt Tensioner Arm Pivot Bolt ............................. 33 (44)
INCH Lbs. (N.m)
Coolant Air Bleed Bolt ............................................. 80-97 (9-11)
Cooling Fan-To-Pulley Bolt ............................. 89-106 (10-12)
Crankshaft Position Sensor ........................................... 80 (9)
Radiator Mounting Bolt/Nut .............................................. 62 (7)
Fig. 7: Measuring Push Rod Protrusion
442
MITSUBISHI
*3.5L V6 SOHC
3.5L V6 SOHC
Diamante
1997-01................
1
3.4 Hours ................. 250287
Montero
1997-00................
1
3.5 Hours ................. 250287
Montero Sport
2000-01................
1
3.5 Hours ................ 250287
1
- With Air Cond. add .6 hours for Montero and
Montero Sport.
NOTE: Replacement procedure for Diamante includes revised
information from Mitsubishi technical service bulletin No. 00-
11-005; April, 2000.
TIMING BELT REMOVAL
Diamante:
belts. Remove generator with wires attached and secure
out of way.
Holding crankshaft pulley stationary, remove crankshaft
pulley bolt. Remove crankshaft pulley.
Remove timing belt covers. See Fig. 1. Support weight of
engine with floor jack. Remove engine mount from front
(timing belt end) of engine. Remove engine support bracket
from front of engine.
direction of belt rotation. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks. See Fig. 2. Loosen
center bolt of timing belt tensioner pulley, and remove tim-
ing belt. Remove timing belt auto-tensioner from engine
block.
(Diamante Shown; Others Similar)
Remove upper radiator hose. Remove radiator shroud.
Loosen cooling fan clutch-to-pulley nuts. Relieve tension
on accessory drive belts.
Remove cooling fan and fan clutch assembly. Remove cool-
ing fan pulley. Remove all accessory drive belts. Remove
generator with wires attached and secure out of way.
Remove power steering pump with hoses connected, and
set aside. Remove A/C compressor from bracket ( hoses
connected), and set aside. Remove A/C compressor
bracket. On Montero Sport, remove timing mark indicator
plate from front of engine. On Montero and Montero sport,
remove accessory mount assembly. See Fig. 4.
Remove upper timing belt upper cover. See Fig. 3. Holding
crankshaft pulley stationary, remove crankshaft pulley bolt.
443
Remove lower timing belt cover. Turn crankshaft clockwise
to align camshaft and crankshaft timing marks. See Fig. 2.
Loosen belt tensioner pulley center bolt.
direction of belt rotation. Remove timing belt. Remove tim-
ing belt auto-tensioner.
All Models:
pulley for smooth rotation. Replace if defective.
Check timing belt auto-tensioner for leaks. Hold timing belt
auto-tensioner upright. Measure rod protrusion above edge
of housing. See Fig. 5. Length should be .461-.484 (11.7-
12.3 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod.
If auto tensioner rod moves more than 0.39 (1 mm), re-
place the auto-tensioner.
Diamante:
contact vise jaw.
on engine.
WARNING: Right bank camshaft can easily turn from valve spring
pressure. Be careful not to pinch fingers when installing timing
belt.
Fig. 4: Exploded View Of Accessory Mount Assembly
MITSUBISHI
444
MITSUBISHI
belt.
specification while holding tensioner pulley stationary.
Install engine support bracket on engine block. Tighten top
bolt first, then working in a counterclockwise direction,
tighten the remaining bolts. See Fig. 7. Install timing belt
covers. Install crankshaft pulley. Apply engine oil to crank-
shaft pulley bolt, then tighten bolt to specification. See
contact vise jaw.
on engine.
Fig. 5: Checking Timing Belt Auto-Tensioner Movement
belt.
specification while holding tensioner pulley stationary.
crankshaft pulley bolt to specification. See TORQUE SPECI-
FICATIONS table. Install accessory mount assembly on
front of engine.
Install A/C compressor. Install generator. Install upper ra-
diator hose. Adjust drive belts to proper tension. See page
dure. When filling cooling system, use 50/50 mix of coolant
and water. Open bleed screw on top of thermostat housing.
Slowly fill cooling system until coolant flows out of bleed
hole. Install bleed screw. Start engine and run to normal
operating temperature. Race engine to 3000 RPM several
times. Stop engine. After engine cools, refill radiator and
coolant reservoir tank.
TORQUE SPECIFICATIONS (DIAMANTE)
Auto-Tensioner Bolt ....................................................... 17 (23)
1
134 (181)
Engine Mount
To-Engine Support Bracket Nut/Bolt ............. 73-87 (98-118)
To-Body Through Bolt
2
..................................... 73-87 (98-118)
Engine Support Bracket-to-Engine Bolt ......................... 32 (44)
Generator Pivot Bolt ....................................................... 32 (44)
Generator Top Bolt ........................................................ 15 (21)
Power Steering Pump Belt Tensioner Bolt .................... 32 (44)
Water Pump Bolt
M8 Bolt .......................................................................... 17 (23)
M10 Bolt ....................................................................... 30 (41)
INCH Lbs. (N.m)
Timing Mark Indicator Plate Bolt ..................................... 97 (11)
1
2
Arrow on engine mount plates must face toward front
of vehicle.
445
MITSUBISHI
(MONTERO & MONTERO SPORT)
Accessory Mount Assembly Bolt .................................... 33 (44)
Auto-Tensioner Bolt ....................................................... 18 (24)
1
134 (181)
Generator Pivot (Upper) Bolt ......................................... 38 (52)
Generator Bottom Bolt ................................................... 16 (22)
Power Steering Pump Bolt ............................................ 17 (24)
Water Pump Bolt ............................................................ 17 (23)
INCH Lbs. (N.m)
Cooling Fan Clutch-to-Pulley Nut ..................... 89-106 (10-12)
1
Fig. : Engine Support Bracket Tightening Sequence
(Diamante)
446
NISSAN
*1.5L & *1.6L 4-Cylinder SOHC
Belt
Application Time
1
Kit No. No.
1.5L 4-Cyl. SOHC
Sentra
1982-83.......... 2.8 Hrs. ...... 2520770........ 250077
Pulsar NX
1983-84.......... 3.0 Hrs. ...... 2520770........ 250077
310
1982............... 5.8 Hrs. ...... 2520770........ 250077
1.6L 4-Cyl. SOHC
Pulsar & Pulsar NX
1983-88.......... 2.3 Hrs. ...... 2520770........ 250077
Sentra
1983-88.......... 2.8 Hrs. ...... 2520770........ 250077
1
kits.
On 1982-85 models, although the manufacturer does not rec-
intervals. On 1986 and later models, the manufacturer recom-
TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshaft separately
with timing belt removed. Valves will contact piston and may
cause damage.
Removal:
Disconnect negative battery cable. Place crankshaft on TDC
of compression stroke. Remove spark plugs. Remove right
front under engine cover and splash cover. Remove acces-
sory drive belts. Remove water pump pulley and crankshaft
pulley. On 1988 models, support engine with a jack under
oil pan and remove right side engine mount.
On all models remove upper and lower timing belt cover.
Check timing mark alignment. See Fig. 2. Mark timing belt
rotation direction for installation reference. Loosen timing
belt tensioner and retain tensioner away from timing belt.
Remove timing belt. Remove tensioner and spring (if nec-
essary). See Fig. 1.
CAUTION: Camshaft sprockets have 2 marks on them. Ensure
the correct mark is aligned. See Fig. 2.
Installation:
Ensure camshaft and crankshaft sprocket timing marks
are aligned at TDC on compression stroke. See Fig. 2.
Install timing belt tensioner so no tension will be applied to
belt during installation (if removed). If installing removed
belt, properly position rotation direction mark made at re-
moval.
Install timing belt, keeping belt tight on jackshaft and cam-
shaft sprockets side. Loosen tensioner and allow tension
to be applied to timing belt. Rotate camshaft sprocket 20
degrees (2 cogs) clockwise.
Fig. 1: Exploded View Of Timing Belt Components Fig. 2: Timing Mark Alignment
447
NISSAN
*1.5L & *1.6L 4-Cylinder SOHC (Cont.)
Using a screwdriver, prevent tensioner from turning and
tighten tensioner lock nut. Recheck timing mark alignment.
Ensure ignition rotor is firing No. 1 cylinder. To complete
installation, reverse removal procedure. Adjust drive belts
Camshaft Sprocket Bolt ................................... 29-35 (39-48)
Crankshaft Pulley Damper Bolt .................... 90-98 (123-132)
INCH Lbs. (N.m)
Camshaft Lockplate ............................................. 35-43 (4-5)
Timing Belt Tensioner ......................................... 52-70 (6-8)
Timing Belt Tensioner Lock Nut ...................... 12-15 (16-21)
INCH Lbs. (N.m)
Camshaft Sprocket Bolt .............................. 78-104 (8.8-11.8)
Jackshaft Sprocket Bolt ............................... 78-104 (8.8-11.8)
Valve Cover Bolt
1st Step ....................................................... 17-35 (1.9-4.0)
2nd Step ...................................................... 35-52 (4.0-5.9)
Timing Belt Cover .......................................... 46-58 (5.2-6.6)
Water Pump Pulley Bolt ............................... 74-96 (8.4-10.9)
Water Pump Bolt ........................................... 46-58 (5.2-6.6)
448
NISSAN
*1.6L & *1.8L 4-Cylinder DOHC
1
Belt Part No.
1.6L 4-Cyl. DOHC
Pulsar
1987...................... 3.8 Hours .................. 250137
1.8L 4-Cyl. DOHC
Pulsar NX
1988-89................. 3.8 Hours .................. 250137
1
60,000 miles.
TIMING BELT
Removal:
Remove upper radiator hose. Remove undertray from right
side. Remove accessory drive belts. Remove water pump
pulley.
Place reference mark on crank angle sensor and timing
belt cover for reassembly reference. See Fig. 1. Remove
crank angle sensor. Support engine and remove front engine
mount support.
Remove upper timing belt cover. See Fig. 1. Align timing
marks on camshaft sprockets. See Fig. 2. Remove right
side inner fender panel. Remove crankshaft pulley and lower
timing belt cover. Loosen tensioner pulley nut and release
tension. Remove timing belt.
Using dial indicator, check camshaft sprocket runout. Re-
place sprocket if runout exceeds .004" (.10 mm). To re-
move camshaft sprocket, remove camshaft cover and hold
hex area of camshaft. Remove sprocket retaining bolts.
See Fig. 3.
Remove camshaft sprocket. If crankshaft sprocket requires
removal, note direction of sprocket plates prior to removal.
See Fig. 1. Remove plates and sprocket.
Inspection:
damaged or contaminated.
Check tensioner and idler pulleys for smooth rotation. In-
spect tensioner pulley return spring for distortion or corro-
sion.
Installation:
Install crankshaft sprocket and sprocket plates. Sprocket
plates must be installed with flat side against crankshaft
sprocket.
Align camshaft and crankshaft sprockets. See Fig. 2. In-
stall timing belt. Ensure 39 teeth exist between marks on
camshaft sprockets and 48 teeth between crankshaft and
camshaft sprockets. See Fig. 2.
Loosen tensioner pulley nut. Install crankshaft bolt and a
spacer. Rotate crankshaft 2 revolutions. Tighten tensioner
pulley nut to specification. Ensure all marks are aligned.
Install timing belt covers.
Install crankshaft pulley and washer. Install engine mount.
Install crank angle sensor and water pump pulley. Ensure
reference marks on crank angle sensor are aligned. Tighten
bolts to specification.
tension. See page A-60 for belt tension ranges. Install up-
per radiator hose and refill cooling system.
Engine Mount Bolt ............................................ 29-40 (39-54)
Idler Nut ............................................................ 23-31 (31-42)
Tensioner Pulley Nut ........................................ 16-22 (22-30)
Timing Belt Tensioner Pulley Nut ..................... 16-22 (22-30)
Water Pump Bolt .............................................. 12-14 (16-19)
INCH Lbs. (N.m)
Crank Angle Sensor Bolt ....................................... 61-70 (7-8)
Rear Timing Belt Cover Bolt ................................. 61-70 (7-8)
449
NISSAN
*1.6L & *1.8L 4-Cylinder DOHC
Fig. 3: Removing Camshaft Sprocket
450
NISSAN
1
Belt Part No.
1.7L 4-Cyl. Diesel
Sentra
1983-87
Camshaft ............ 4.0 Hours .................. 250096
1
intervals. On 1986-87 models, the manufacturer recommends
TIMING BELT
Removal:
Disconnect negative battery cable. Ensure No. 1 cylinder is
at TDC of compression stroke. Remove accessory drive
belts. Remove crankshaft pulley. Remove timing belt cover.
Loosen tensioner. Remove timing belt.
Installation:
Install timing belt ensuring timing marks are aligned. See
Fig. 1. Ensure reference marks are 39 cogs apart.
tion. Tighten tensioner bolt while holding it to keep it from
rotating. To complete installation, reverse removal proce-
dure.
tension ranges.
INJECTION PUMP BELT
Removal:
Disconnect negative battery cable. Remove timing belt cover
from rear of engine. Loosen injection timing belt tensioner.
Remove injection timing belt.
Installation:
Install injection timing belt. Ensure reference marks are 23
cogs apart. See Fig. 2. Rotate crankshaft 2 revolutions in
normal direction of rotation. Tighten tensioner bolt while
holding it to keep it from rotating. To complete installation,
reverse removal procedure.
Fig. 1: Installing Camshaft Timing Belt
Fig. 2: Installing Injection Timing Belt
Front Tensioner Bolt ......................................... 27-33 (36-34)
Rear Tensioner Bolt ......................................... 12-15 (16-21)
INCH Lbs. (N.m)
451
NISSAN
1.8L & *2.0L 4-Cylinder
1.8L 4-Cyl. Turbo
200SX (Includes Canadian)
1984-87................
1
2.0 Hours ................. 250100
2.0L 4-Cyl.
Stanza & Stanza Wagon
1982-89................
1
4.4 Hours ................. 250078
200SX
1984-88................
1
2.0 Hours ................. 250078
1
On 1985-82 models, the manufacturer does not recommend a
specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. On 1986
and later models, the manufacturer recommends the belt be
replaced every 60,000 miles.
A59 for interference engine cautions.
TIMING BELT
Removal (1982-88):
Disconnect negative battery cable. Turn crankshaft until No.
1 cylinder is at TDC on compression stroke. Remove cool-
ing fan, radiator shroud and accessory drive belts.
NOTE: After timing belt is removed, do not rotate crankshaft
or camshaft.
Remove upper and lower dust cover mount bolts. Remove
upper and lower covers and gaskets. Remove timing belt
tensioner, bracket, and timing belt.
Removal (1989):
hicle. Remove right front wheel. Remove exhaust side spark
plugs. Turn crankshaft until No. 1 cylinder is at TDC on
compression stroke. Remove dust cover and undercovers.
Remove belts.
Support engine with a chain hoist. Remove right side en-
gine mount and bracket. Remove upper and lower timing
belt covers and gaskets. Remove timing belt tensioner,
bracket and timing belt.
Do not tighten tensioner bolts to final specification before
drive belt is installed. Install timing belt. Align belt mark to
camshaft and crankshaft sprocket marks. See Fig. 1.
Tighten belt tensioner and assemble spring. To set spring,
hook one end on bolt B side and hook the other end on
tensioner bracket pawl. Tighten bolt B and then bolt A.
See Fig. 2.
Belt tension will automatically be at the specified value.
Install lower front cover with gaskets and tighten mount
bolts. Install plate and front pulley damper. Complete in-
stallation by reversing removal procedure. Adjust drive belts
TORQUE SPECIFICATIONS (1982-88)
Idler Nut ............................................................ 23-31 (31-42)
Water Pump Bolt .............................................. 12-14 (16-19)
INCH Lbs. (N.m)
Front Cover Bolts .................................................. 27-43 (3-5)
TORQUE SPECIFICATIONS (1989)
Camshaft Lock Plate Bolt ................................. 58-65 (78-88)
INCH Lbs. (N.m)
Front Cover Bolts .................................................. 27-43 (3-5)
Fig. 1: Timing Belt Alignment Procedure
452
NISSAN
*3.0L V6 DOHC
1
Belt Part No.
3.0L V6 DOHC
300ZX
1990-93................. 4.6 Hours .................. 250180
1994-96................. 4.6 Hours .................. 250251
1
60,000 miles.
TIMING BELT
Removal:
cover. Drain coolant from radiator and cylinder block. Re-
move radiator. Remove accessory drive belts. Remove cool-
ing fan and coupling. Remove starter.
Lock flywheel/flexplate to prevent crankshaft from rotating.
Remove crankshaft pulley bolt and pulley. Remove water
inlet and outlet hoses. Remove timing belt front covers.
Remove spark plugs.
Install a stopper bolt (M6 x 16) into timing belt tensioner
arm to maintain tensioner position. See Fig. 1. Set cylinder
No. 1 at TDC of compression stroke by rotating crankshaft
until timing marks align. Remove timing belt tensioner and
timing belt.
Inspection:
Replace timing belt if cracked, worn or saturated with oil or
coolant. Replace tensioner if it leaks oil.
Installation:
See Fig. 1. Measure clearance between tensioner arm and
tensioner body (distance pusher rod protrudes from
tensioner body). If clearance is .16" (.4 mm), go to step
after next. If clearance is not .16" (.4 mm), go to next step.
Remove tensioner. Remove stopper bolt. Using a vise, ad-
just clearance until it is as specified. Install stopper bolt in
tensioner to maintain clearance. Install tensioner. Hand-
tighten tensioner nut and bolts.
shaft sprockets and crankshaft sprocket. White lines ensure
correct number of teeth exist between timing marks on sprock-
ets.
Push tensioner gently toward timing belt to prevent belt
from slipping (excessive pressure will overtighten belt). Main-
tain light pressure on tensioner.
Turn crankshaft clockwise 10 degrees. Tighten tensioner
bolts and nut. See TORQUE SPECIFICATIONS. Turn crank-
shaft counterclockwise 120 degrees. Turn crankshaft clock-
wise until cylinder No. 1 is at TDC of compression stroke.
Loosen tensioner nut and bolts 1/2 turn. Move tensioner as
far pack as possible. Using Push/Pull Gauge (J-38387) or
equivalent, apply 15.2-18.3 lbs. (6.9-8.3 kg) pressure to
end of pusher. See Fig. 2. Tighten tensioner nut and bolts.
Turn crankshaft 120 degrees clockwise, then turn it 120 de-
grees counterclockwise to TDC. Fabricate a small steel plate.
See Fig. 3. Set plate at each position shown (A, B, C and
D).
Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Mea-
sure and record timing belt deflection in each position. Divide
sum of measurements (A + B + C + D) by 4 to obtain
average.
Average timing belt deflection should be .24-.28" (6-7 mm).
If deflection is not as specified, repeat last five (5) steps. If
timing belt deflection is excessive, change amount of push-
ing force applied in third step back.
Remove tensioner stopper bolt. After 5 minutes, ensure
clearance between pusher rod and tensioner arm is .138-
.205" (3.5-5.2 mm). Check for slippage or misplacement of
timing belt at each sprocket. Install timing belt covers. To
ranges.
Camshaft Sprocket Bolts
Exhaust .......................................................... 10-14 (14-19)
Intake ......................................................... 90-98 (122-133)
Timing Belt Idler Pulley Nut .............................. 32-43 (43-58)
Timing Belt Tensioner Lock Nut ....................... 12-15 (16-20)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Fig. 1: Installing Timing Belt & Tensioner
453
NISSAN
Fig. 3: Checking Timing Belt Deflection
454
NISSAN
*3.0L V6 SOHC
Belt
Application Time
1
Kit No. No.
3.0L V6 SOHC
Maxima
1985-88.............. 6.0 Hrs. .... 2521040...... 250104
1989-91.............. 5.7 Hrs. .... 2521040...... 250104
1992-94
With Square Tooth
Sprocket ........ 5.7 Hrs. .... 2521040...... 250104
With Round Tooth
Sprocket ........ 5.7 Hrs. ......................... 250249
Pathfinder & Pickup
1986-92.............. 4.5 Hrs. .... 2521040...... 250104
1993-94
With Square Tooth
Sprocket ........ 4.5 Hrs. .... 2521040...... 250104
With Round Tooth
Sprocket ........ 4.5 Hrs. ......................... 250249
1995-96.............. 4.5 Hrs. ......................... 250249
Quest
1993-94
With Square Tooth
Sprocket ....... 3.5 Hrs. .... 2521040...... 250104
With Round Tooth
Sprocket ....... 3.5 Hrs. ......................... 250249
1995-98.............. 3.5 Hrs. ......................... 250249
200SX
1987-88.............. 4.8 Hrs. .... 2521040...... 250104
300ZX
1984-89.............. 6.0 Hrs. .... 2521040...... 250104
1
kits.
ommend a specific scheduled maintenance interval, belt manu-
vals. On 1986 and later models, the manufacturer recom-
TIMING BELT
Removal (200SX, 300ZX):
Disconnect negative battery cable. Release fuel pressure
from system. Raise and support vehicle. Remove right wheel
and engine side cover (if necessary). Drain cooling sys-
tem. Remove cooling fan duct. Remove engine coolant res-
ervoir. Remove actuator and remove radiator hoses. Do not
allow coolant to contact drive belts.
Remove front upper and lower belt covers. Remove drive
belts and set No. 1 cylinder at TDC of compression stroke.
Remove idler bracket of compressor drive belt and crank-
shaft pulley. Remove timing belt by removing timing belt
tensioner and return spring.
Inspection:
Visually inspect condition of timing belt. Inspect for cracks,
wear, breaks, and oil/coolant saturation.
Installation:
Ensure that piston No. 1 is at TDC of compression stroke.
Remove valve covers and loosen all rocker shaft bolts. Do not
bend timing belt. Install tensioner and return spring.
Turn tensioner clockwise and temporarily tighten lock nut.
Install timing belt. Align White lines on timing belt with punch
mark on camshaft pulleys and crankshaft pulley. Arrow on
timing belt must be pointing toward front belt covers.
Using Allen wrench, slowly turn tensioner clockwise and
counterclockwise 2 or 3 times. When camshafts and crank-
shaft marks are aligned, tighten tensioner lock nut. See
Fig. 3. Ensure that camshaft lobes are correctly positioned.
Tighten rocker shaft bolts in 2 stages.
Refill and bleed air from from cooling system. To complete
installation, reverse removal procedures. Adjust drive belts
Removal (Maxima & Quest):
hicle. Remove covers from below engine. Drain cooling
system. Remove right front wheel and engine side cover.
Remove accessory drive belts. Remove crankshaft pulley
bolt and pulley.
Remove upper radiator hose and water inlet hose. Re-
move A/C compressor idler pulley and bracket. Remove
water pump pulley. Remove upper and lower timing belt
front covers.
Temporarily install crankshaft pulley bolt so crankshaft can
be rotated. Set cylinder No. 1 at TDC of compression stroke
by rotating crankshaft until marks on camshaft sprockets
align with marks on timing belt upper rear cover, and mark
on crankshaft sprocket aligns with mark on front cover hous-
ing. See Fig. 2.
Fig. 1: Exploded View Of Timing Belt & Related omponents
455
Loosen timing belt tensioner nut. Release tension on belt.
Remove timing belt. Check timing belt tensioner, spring
and timing belt.
Removal (Pathfinder & Pickup):
Disconnect negative battery cable. Remove covers from be-
low engine. Drain and remove radiator. Remove cooling fan
and water pump pulley. Remove accessory drive belts. Re-
move spark plugs. Remove distributor protector. Remove A/C
compressor idler pulley and bracket.
Remove fresh air tube from cylinder head cover. Remove
thermostat housing coolant hose. Remove crankshaft pul-
ley bolt and pulley. Remove upper and lower timing belt front
covers. Temporarily install crankshaft pulley bolt to rotate crank-
shaft.
Set cylinder No. 1 at TDC of compression stroke by align-
ing marks on camshaft sprockets with marks on timing
belt upper rear cover and mark on crankshaft sprocket with
mark on front cover housing. See Fig. 1. Loosen timing
belt tensioner. Remove timing belt. Check timing belt
tensioner, spring and timing belt.
Installation:
See Fig. 2. Install tensioner and return spring if removed. If
return spring stud was removed, apply thread lock sealant
to threads before installing stud. Insert an Allen wrench
into hole in tensioner, turn tensioner fully clockwise, and
temporarily tighten lock nut.
shaft sprockets and crankshaft sprocket. White lines en-
sure correct number of teeth exist between timing marks on
sprockets.
Loosen tensioner lock nut. Using Allen wrench, rotate
tensioner by turning Allen wrench clockwise 70-80 degrees.
Temporarily tighten lock nut. Rotate crankshaft clockwise
at least 2 revolutions.
Return cylinder No. 1 to TDC of compression stroke. Using
Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs.
(10.0 kg) pressure to timing belt between right camshaft
sprocket and tensioner. Hold tensioner in position with Allen
wrench, and loosen tensioner lock nut.
Place a .0138" (.351 mm) feeler gauge at tensioner pulley
and timing belt, and rotate crankshaft until feeler gauge is
centered between tensioner pulley and timing belt. See
Fig. 3. Tighten tensioner lock nut to specification. See
Rotate crankshaft to remove feeler gauge. Rotate crank-
shaft clockwise at least 2 revolutions until cylinder No. 1 is
at TDC of compression stroke. Measure timing belt deflec-
tion halfway between camshaft sprockets. If deflection is
not .51-.59" (13-15 mm), repeat procedure. To complete
installation, reverse removal procedure.
Refill and bleed air from cooling system. Adjust drive belts
NISSAN
Fig. 2: Installing Timing Belt & Sprocket
Rocker Shaft Bolts ............................................ 13-16 (16-20)
Water Pump Bolt .............................................. 13-16 (16-20)
INCH Lbs. (N.m)
456
NISSAN
3.3L V6 SOHC
3.3L V6 VG33E (SOHC)
Frontier
1999-01................
1
3.1 Hours ................. 250249
Pathfinder
1996-00................
1
2.8 Hours ................. 250249
QX4
1997-00................. 3.9 Hours .................. 250249
Quest
1999-01................
1
2.6 Hours ................. 250249
Xterra
2000-01................
1
3.1 Hours ................. 250249
1
With Supercharger add .2 hours.
*NOTE: The 1996-00 3.3L engine used in the Pathfinder
is an interference engine. See page A-59 for interference
engine cautions.
TIMING BELT
Removal (Frontier, Pathfinder, QX4 & Xterra):
Disconnect negative battery cable. Remove the engine un-
der cover. Drain coolant and remove the radiator. Remove
engine cooling fan and water pump pulley. Remove acces-
sory drive belts. Remove spark plugs.
Remove distributor protector. Remove A/C compressor drive
belt idler bracket. Remove fresh air intake tube from rocker
cover. Remove thermostat housing hose.
Rotate crankshaft to set No. 1 cylinder at TDC on compres-
sion stroke. See Fig. 2. Remove crankshaft pulley bolt and
remove crankshaft pulley. Remove front upper and lower
belt covers.
Align punch mark on left camshaft sprocket with punch
mark on timing belt upper rear cover. Align punch mark on
crankshaft sprocket with notch on oil pump housing. See
Fig. 3. Install crankshaft pulley bolt so that crankshaft can
be rotated.
Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner,
and remove timing belt.
Inspection (Frontier, Pathfinder, QX4 & Xterra):
Check timing belt for cracks and broken or worn teeth.
Check belt tensioner for smooth turning. Check condition
of tensioner spring. Replace parts as necessary.
Installation (Frontier, Pathfinder, QX4 & Xterra):
Install timing belt when engine is cold. Ensure No. 1 cylin-
der is at TDC on compression stroke. Crankshaft sprocket
mark should align with mark on rear cover. See Fig. 5. If
removed, install timing belt tensioner and tensioner spring.
NOTE: If stud for tensioner spring is removed, apply thread sealant
to stud threads before installing.
Turn tensioner clockwise fully outward with hexagon wrench
and temporarily tighten lock nut. Align White lines on timing
belt with punch marks on camshaft sprockets and crank-
shaft sprocket. See Fig. 6. Point arrow on timing belt to-
ward front belt cover. There should be 40 teeth between left
and right camshaft sprockets and 43 teeth between left
camshaft sprocket and crankshaft sprocket.
Loosen tensioner lock nut. Using hex wrench, turn
tensioner clockwise and counterclockwise at least 2 times.
Tighten tensioner lock nut. Turn crankshaft clockwise at
least 2 revolutions, then slowly set No. 1 cylinder at TDC on
compression stroke. Apply 22 lbs. (10 kg) of force to belt
(downward direction) midway between camshaft sprock-
ets. Belt deflection should be 0.51-0.59 (13-15 mm). If not,
Install lower and upper belt covers. Install crankshaft pul-
ley. Tighten bolt to specfication. See TORQUE SPECIFICA-
TIONS. To complete installation, reverse removal proce-
dures. Fill and bleed cooling system.
96B14499 Courtesy of Nissan Motor Co., U.S.A.
96E14500 Courtesy of Nissan Motor Co., U.S.A.
Fig. 2: Setting Crankshaft To TDC
457
NISSAN
96F14501 Courtesy of Nissan Motor Co., U.S.A.
Fig. 3: Aligning Camshaft & Crankshaft Punch Marks
96G14502 Courtesy of Nissan Motor Co., U.S.A.
Fig. 4: Loosening Timing Belt Tensioner Nut
Fig. 5: Positioning Camshaft & Crankshaft Sprockets
96H14503 Courtesy of Nissan Motor Co., U.S.A.
If vehicle is equipped with manual A/C, move temperature
control lever to full HOT position. If vehicle is equipped with
automatic A/C, turn ignition on. Remove air relief plug on
intake manifold collector. See Fig. 7. Remove heater hose
from heater core inlet. See Fig. 8. Fill radiator slowly until
coolant starts to drip from air relief plug. Tighten air relief
plug to 61-69 INCH lbs. (7-8 N.m).
Fill radiator and coolant reservoir tank to MAX mark. Install
and tighten radiator cap. Start and run engine until warm.
Run engine at 3000 RPM for at least 10 seconds (repeat 2-
3 times). Stop engine and allow it to cool. Refill radiator and
coolant reservoir as necessary.
Repeat previous step at least 3 times with temperature
control lever at several different positions between full COLD
and full HOT positions. System is full when water noise is
no longer heard at heater core and coolant level no longer
drops. Adjust drive belts to proper tension. See page A-60
Removal (Quest):
Raise and support vehicle. Remove the engine under cover.
Remove right side wheel and engine side cover. Drain cool-
ant from radiator. Remove accessory drive belts.
Rotate crankshaft to set No. 1 cylinder at TDC on compres-
sion stroke. See Fig. 2. Remove crankshaft pulley bolt and
remove crankshaft pulley using a gear puller.
Remove upper radiator hose and water inlet hose from
timing belt end of engine. Remove A/C compressor drive
belt idler bracket. Remove water pump pulley. Remove
breather pipe from timing belt front upper cover. Remove
front upper and lower belt covers.
Align punch mark on left camshaft sprocket with punch
mark on timing belt upper rear cover. Align punch mark on
crankshaft sprocket with notch on oil pump housing. See
Fig. 3. Install crankshaft pulley bolt so that crankshaft can
be rotated.
Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner,
NOTE: After removing timing belt, DO NOT turn crankshaft or
camshaft separately or valves will strike pistons.
458
NISSAN
Inspection (Quest):
Check timing belt for cracks and broken or worn teeth.
Check belt tensioner for smooth turning. Check condition
of tensioner spring. Replace parts as necessary.
Installation (Quest):
Install timing belt when engine is cold. Ensure No. 1 cylin-
der is at TDC on compression stroke. Crankshaft sprocket
mark should align with mark on rear cover. See Fig. 5. If
removed, install timing belt tensioner and tensioner spring.
NOTE: If stud for tensioner spring is removed, apply thread sealant
to stud threads before installing.
Turn tensioner clockwise fully outward with hexagon wrench
and temporarily tighten lock nut. Align white lines on timing
belt with punch marks on camshaft sprockets and crank-
shaft sprocket. See Fig. 6. Point arrow on timing belt to-
ward front belt cover. There should be 40 teeth between left
and right camshaft sprockets and 43 teeth between left
camshaft sprocket and crankshaft sprocket.
Loosen tensioner lock nut. Using hex wrench, turn
tensioner clockwise and counterclockwise at least 2 times.
Tighten tensioner lock nut. Turn crankshaft clockwise at
least 2 revolutions, then slowly set No. 1 cylinder at TDC on
compression stroke. Apply 22 lbs. (10 kg) of force to belt
(downward direction) midway between camshaft sprock-
ets. Belt deflection should be 0.51-0.59 (13-15 mm). If not,
Install lower and upper belt covers. Install crankshaft pul-
ley. Tighten bolt to specfication. See TORQUE SPECIFICA-
TIONS. To complete installation, reverse removal proce-
dures. Fill and bleed cooling system.
If vehicle is equipped with manual A/C, turn ignition on.
Move temperature control lever to full COOL position. Se-
lect any fan speed and mode except OFF. If vehicle is also
equipped with rear heater, set rear controls to the full HOT
position.
If vehicle is equipped with automatic A/C, turn ignition on.
Move temperature control lever to full HOT position. Select
any fan speed and mode except OFF. If vehicle is also
equipped with rear heater, set rear control to the full HOT
position.
On all models, loosen radiator and engine air relief plugs.
Remove heater pipe air relief cap. See Fig. 9. Connect one
end of 40 clear, heat resistant hose to heater pipe air re-
lief. Fill coolant reservoir to MAX mark and place hose from
heater pipe air relief into reservoir. Ensure hose is below
coolant level at all times.
Slowly add coolant through radiator filler neck allowing
several minutes for air to escape. When coolant starts to
drip from radiator air relief plug, close plug. Tighten radia-
tor air relief plug to 15-19 ft. lbs. (20-26 N.m).
Continue adding coolant while gently moving upper radia-
tor hose up and down until coolant no longer lowers in filler
neck. Place wire under radiator filler cap negative pressure
relief valve. See Fig. 10. DO NOT install cap at this time. If
vehicle is equipped with rear heater, ensure rear fan is ON
and rear temperature control lever is in full HOT position.
Start and run engine at 2000 RPM for 10-15 minutes or until
lower radiator hose becomes hot. If coolant comes out of
engine air relief plug, close plug. Tighten plug to 15-19 ft.
lbs. (20-26 N.m). If coolant in radiator neck lowers, add
coolant. If coolant overflows filler neck, install radiator cap
(with wire installed).
NOTE: Ensure coolant level in reservoir tank is maintained at
MAX mark for the following steps.
On vehicles without rear heater, ensure temperature con-
trol lever is in full HOT position. Select any fan speed and
mode except OFF. Ensure A/C control unit is in ON position.
Run engine at 3000 RPM for 5 minutes or until outlet air is
hot. Repeat this step at least 3 times. Ensure no water
noise is present in heater core.
On vehicles with rear heater, run engine at 3000 RPM with
front temperature control lever in full COLD position. Move
rear temperature control lever to full HOT position. Select
any fan speed except OFF. Ensure A/C control unit is in ON
position. Start and run engine for 5 minutes or until rear
outlet air is hot.
Move rear temperature control lever to full COLD position.
Move front temperature control lever to full HOT position.
Select any fan speed and mode except OFF. Start and run
engine for 5 minutes or until front outlet air is hot. Repeat
previous step and this step at least 3 times. Ensure no
water noise is present in front or rear heater core.
On all models, stop engine. Fill coolant reservoir to MAX
mark. Let engine cool down. Remove radiator cap and re-
move wire from negative pressure valve. Fill radiator as
necessary and reinstall radiator cap. Remove hose from
heater pipe air relief and quickly install cap on pipe. Fill
reservoir as necessary and install reservoir cap. Adjust drive
ranges.
Spark Plugs ......................................................... 14-22 (20-29)
Water Pump Bolt .............................................. 12-15 (16-20)
Wheel Lug Nut
Quest ............................................................... 72-87 (98-118)
INCH Lbs. (N.m)
Cooling Fan & Water Pump Pulley Bolts ............ 52-89 (6-10)
Radiator Mounting Bolts ................................. 34-42 (3.8-4.8)
459
NISSAN
Fig. 8: Locating Heater Core Inlet Hose
(Frontier, Pathfinder, QX4 & Xterra)
Fig. 10: Holding Pressure Relief Valve Open
(Quest)
Fig. 9: Locating Air Relief Plugs (Quest)
Fig. 7: Locating Air Relief Plug
(Frontier, Pathfinder, QX4 & Xterra)
460
PEUGEOT
1.9L 4-Cylinder
1.9L 4-Cyl.
405
1989-91
DOHC................. 4.0 Hours .................. 250188
SOHC ............... 4.0 Hours .................. 250189
TIMING BELT
Removal (DOHC):
Disconnect negative battery cable. Raise and support front
of vehicle. Remove A/C compressor drive belt. Remove A/C
compressor from mounting bracket with refrigerant hoses
attached. Suspend compressor from lower frame at bot-
tom of engine compartment.
Remove alternator drive belt, then alternator. Support en-
gine. Remove upper engine mount and two upper cover
bolts. Tilt engine and transmission assembly as far as
possible. Disconnect wiring harnesses from relay box, then
pull up on clip and lift upper cover upward.
Remove lower flywheel housing cover. Hold flywheel in po-
sition with Peugeot Lock Tool (J-36358) or equivalent. Re-
move right mud shield. Remove 4 crankshaft pulley retain-
ing bolts, then crankshaft pulley. Remove lower cover. Re-
move flywheel locking tool.
Rotate engine, using crankshaft pulley bolt, to align crank-
shaft lock pin hole with engine lock pin hole. See Fig. 1.
Insert Peugeot Lock Pin (No.0153-G) or equivalent through
crankshaft lock pin holes, remove pin. Insert Peugeot Lock
Pins (No. 0153-M) or equivalent through camshaft sprocket
lock pin holes.
Loosen timing belt tensioner bolts, then turn tensioner to
relieve tension on timing belt. Remove timing belt from sprock-
ets.
Installation (DOHC):
Ensure that camshaft and crankshaft locking pins are in
position. See Fig. 1. Install belt in order, observing direction
of engine rotation. Start with camshaft sprockets, tensioner,
crankshaft sprocket, water pump sprocket and tensioner.
See Fig. 3.
Lift and tilt engine and transmission assembly as far as
possible, then position belt tensioning tool on indicated
section of timing belt and lock in position. Rotate tensioner
one full turn. Using Peugeot Tensioner Tool (No. 0153-P)
or equivalent, rotate tensioner counterclockwise until 19
SEEM units are displayed on belt tensioning tool meter.
See Fig. 3. Without changing tensioner position, torque
tensioner bolt to 18 ft. lbs., then remove belt tensioning
meter.
Rotate tensioner counterclockwise until 21 SEEM units are
displayed on belt tensioning tool meter. See Fig. 3. Without
changing tensioner position, torque tensioner bolt to 18 ft.
lbs. Remove three locking pins and rotate crankshaft two
turns in normal direction of engine rotation.
Insert Peugeot Lock Pin Tool (0153-G) or equivalent through
crankshaft lock pin holes. Both camshaft lock pins should
be able to be inserted through lock pin holes without effort.
See Fig. 1. If not, timing belt must be removed and rein-
stalled.
Position belt tension tool on timing belt. Meter reading
should be between 40-50 SEEM units. If meter reading is
not within limits, timing belt must be retensioned. Remove
belt tensioning tool, then locking pins. Install lower cover.
Lock flywheel in position with Peugeot Lock Tool (J-36358)
or equivalent. Install crankshaft pulley.
just drive belts to proper tension.
Removal (SOHC):
Disconnect negative battery cable. Remove right mud
shield. Remove A/C compressor and alternator drive belts.
Remove upper timing belt cover. Rotate crankshaft using
pulley bolt, aligning holes in camshaft sprocket and crank-
shaft pulley for pin installation. Insert Peugeot Locking Pin
Tool (No. 0-0163) or equivalent, through camshaft sprocket
and crankshaft pulley locking pin holes. See Figs. 2 and 4.
Remove locking pins. Remove lower flywheel cover. Using
Flywheel Stop Tool (No. 91-86) or equivalent, lock flywheel in
position. Remove crankshaft pulley retaining bolt and crank-
shaft pulley. Remove stop tool that was used to lock flywheel
in position.
Remove upper portion of timing belt lower cover. Remove
lower portion of timing belt lower cover. Loosen three tim-
ing belt tensioner nuts. Do not remove timing belt tensioner
nuts. Push timing belt tensioner away from timing belt to
relieve tension. Tighten tensioner retaining bolt next to pul-
ley to hold tensioner in position.
Remove timing belt from sprockets.
Installation (SOHC):
Position crankshaft pulley and key to crankshaft, then loosely
install crankshaft pulley retaining bolt. Insert Peugeot Lock-
ing Pin Tool (No. 0-0163) or equivalent, through camshaft
sprocket and crankshaft pulley locking pin holes. See Figs.
2 and 4.
Remove crankshaft retaining bolt and pulley. Install timing
belt over camshaft sprocket, crankshaft sprocket and water
pump sprocket, then position timing belt on tensioner pul-
ley. Ensure timing belt is properly seated on sprockets.
Loosen tensioner nut, then turn tensioner square to re-
lease spring.
Remove locking pins, then tighten tensioner retaining nuts.
Rotate crankshaft 2 turns in direction of engine rotation
and bring No. 1 cylinder to TDC of compression stroke.
Loosen timing belt tensioner retaining nuts to tension tim-
ing belt. After timing belt has tensioned, tighten tensioner
retaining bolts. Position crankshaft pulley and key to crank-
shaft then loosely install crankshaft pulley retaining bolt.
Insert Peugeot Locking Pin Tool (No. 0-0163) or equiva-
lent, through camshaft sprocket and crankshaft pulley lock-
ing pin holes. See Figs. 2 and 4. If pins are not aligned with
holes, timing belt must be removed and reinstalled. Re-
move crankshaft retaining bolt and pulley.
Install lower and upper portions of timing belt lower cover.
Position crankshaft pulley and key to crankshaft, then loosely
install crankshaft pulley retaining bolt. Using Peugeot Flywheel
Stop Tool (No. 91-86) or equivalent, lock flywheel in position,
then tighten crankshaft pulley retaining bolt. To complete in-
461
PEUGEOT
Fig. 1: Installing Camshaft & Crankshaft Sprocket
Locking Pins (DOHC)
Fig. 3: Installing Timing Belt & Tensioning Tool (DOHC)
Fig. 2: Installing Camshaft Sprocket Timing Pin (SOHC)
Fig. 4: Installing Crankshaft Sprocket Timing Pin (SOHC)
Crankshaft Pulley Bolts
DOHC ....................................................................... 18 (25)
SOHC ...................................................................... 81 (111)
Timing Belt Tensioner Nut/Bolt
DOHC (4 Bolts) ........................................................ 18 (26)
SOHC ....................................................................... 12 (16)
Upper Engine Mount
DOHC ....................................................................... 33 (45)
462
PEUGEOT
2.2L 4-Cylinder
2.2L 4-Cyl.
505
1986-91................. 2.7 Hours .................. 250140
TIMING BELT
Removal:
Disconnect battery. Drain cooling system including cylin-
der block. Remove radiator and fan shroud. Remove ther-
mostat housing and auxiliary air device.
Align timing marks for crankshaft, camshaft and intermedi-
ate shaft. See Fig. 1. Remove crankshaft pulley bolt and
pulley. Ensure that crankshaft does not rotate. Remove tim-
ing belt cover. Loosen timing belt tensioner bolts and posi-
tion tensioner out of way. Remove camshaft pulley and tim-
ing belt.
Installation:
Ensure timing marks remain in alignment. See Fig. 1. Re-
move distributor cap and check rotor position. Distributor
rotor must be at a 90 degree angle to the crankshaft. If not,
turn intermediate shaft once or twice.
Install timing belt, centered on pulleys and tensioner.
Loosen belt tensioner mounting bolts and allow spring to
adjust timing belt. Tighten belt tensioner bolts.
To complete installation, reverse removal procedures.
Crankshaft pulley bolt must be reinstalled using Loctite.
tension ranges.
Crankshaft Pulley Bolts ............................................ 98 (133)
Timing Belt Tensioner Nut/Bolt ................................... 18 (26)
Fig. 1: Locating 2.2L Timing Marks
463
PORSCHE
*2.0L 4-Cylinder
Belt
2.0L 4-Cyl.
924
1977-82.......... 1.0 Hrs. ...... 2520170........ 250017
kits.
The manufacturer recommends that under normal operating
conditions, check tension at 2,000 miles, then every 15,000
miles. Replace belt every 45,000 miles.
TIMING BELT
Removal:
belts and any components as necessary to access cam-
shaft sprocket cover. Remove camshaft sprocket cover. Align
mark on camshaft sprocket with indicator on cylinder head
cover. The TDC mark on flywheel and housing must align
with each other. Loosen timing belt tensioner. Remove
timing belt.
Installation:
To install components, reverse removal procedure. Belt
must be tightened until belt can be turned 90 degrees with
thumb and index finger at a point midway between crank-
shaft and camshaft. Adjust drive belts to proper tension.
Crankshaft Pulley ................................................... 180 (245)
Tensioner Pulley ......................................................... 29 (39)
INCH Lbs. (N.m)
Camshaft Sprocket Cover ........................................... 84 (10)
464
PORSCHE
*2.5L, *2.7L & *3.0L 4-Cylinder
1
Belt Part No.
2.5 L 4-Cyl.
924
1987-88
Balance Shaft ... 1.5 Hours .................. 250293
Camshaft ............. 1.5 Hours .................. 250107
944
1983-89
Camshaft ............. 4.0 Hours .................. 250107
944S
1987-88
Camshaft ............. 2.4 Hours .................. 250152
2.7L 4-Cyl.
944
1989
Camshaft ............. 3.5 Hours .................. 250107
3.0L 4-Cyl.
944
1989-91
Camshaft ............. 3.5 Hours .................. 250152
968
1992-95
Camshaft ............. 3.4 Hours .................. 250152
1
45,000 miles.
NOTE: When using belt tension gauge, always zero telltale gauge
needle after lock pin is engaged (turned counterclockwise). Adjust
drive belt tension only on a cold engine. Ensure gauge does not
turn on belt and slides remain flat on belt surface.
TIMING BELT
CAUTION: On models equipped with supplemental restraint system
(air bags), wait 20 minutes after disconnecting battery before
starting repairs. Failure to wait the suggested time may result
in air bag deployment and possible personal injury.
Removal:
Disconnect negative battery cable. Remove splash shield.
Remove air cleaner assembly with air flow sensor. Discon-
nect vent hose and position to one side. Remove timing
belt cover assembly. Remove distributor cap and position
to one side. Raise and support vehicle. Ensure pressure
rod bolts are are slightly loose prior to loosening lock nuts.
See Fig. 1. Remove accessory drive belts.
Turn crankshaft clockwise to align camshaft sprocket TDC
mark with mark in distributor cap console. See Fig. 2. En-
sure mark on upper and lower balance shaft sprockets
align with mark on rear timing belt cover. See Fig. 3.
The flywheel mark for No. 1 cylinder must also align with
cast boss on clutch housing. On 1986 and earlier models,
release belt tension. On 1987 and later models, mechani-
cal belt tensioner must be removed. See Fig. 5. Remove
balance shaft drive belt. Loosen camshaft belt tensioning
sprocket lock nut and then sprocket by turning it clockwise.
Remove camshaft timing belt.
Installation (Camshaft Belt):
Ensure No. 1 cylinder is at TDC and marks on flywheel and
cast clutch housing are aligned. Align mark on camshaft
sprocket with mark on rear drive belt cover. Install camshaft
timing belt by placing belt on crankshaft sprocket, tensioner
sprocket, water pump pulley and camshaft sprocket. See
Fig. 4. Adjust drive belts to proper tension. See page A-60
for belt tension ranges. After drive belt tension is adjusted,
install balance belt. To complete installation, reverse re-
moval procedure.
Tension Adjustment:
Rotate crankshaft clockwise until TDC mark on camshaft
sprocket aligns with cast mark in distributor cap mount.
Ensure TDC marks on flywheel and cast clutch housing
are aligned. Loosen tensioner adjustment bolts. See Fig.
5. Using thumb pressure, press downward on camshaft
belt between water pump pulley and camshaft sprocket.
Force camshaft belt against belt cover.
NOTE: On 944-S models, intake camshaft is chain driven from
the exhaust camshaft.
Repeat procedure twice to ensure free movement of belt
idler pivot. Allow idler spring tension to apply tension against
belt. Tighten adjustment bolts to 15 ft. lbs. (20 N.m).
CAUTION: DO NOT remove balance shaft sprocket mounting
bolts to replace drive belt. Handle metal insert drive belts carefully.
Mark belt direction of rotation prior to removal if belt is to be
reused.
Installation (Balance Belt):
Ensure No. 1 cylinder is at TDC and marks on flywheel and
cast clutch housing are aligned. Align mark on camshaft
sprocket with mark on rear drive belt cover. Install balance
belt with color coded tooth facing out. Adjust drive belts to
proper tension. To complete installation, reverse removal
procedure.
Fig. 1: Loosening Pressure Rod
465
Adjustment:
For upper shaft, align grove 0 with Woodruff key. For lower
shaft, align unmarked grove with Woodruff key. See Fig. 3.
Pull out lock pin on tension gauge and push out gauge pin
opposite lock pin. Zero telltale needle.
Slide tension gauge onto belt. Push in gauge needle until
lock pin is heard engaging. Read value from dial gauge.
On engine with slotted guide roller, tension should be 2.4-
3.0 for both new and used belts.
If adjustment is necessary, turn tensioner clockwise to
tighten and counterclockwise to loosen. Tighten tensioner
nut. After adjusting drive belt tension, adjust idler pulley
position.
Use Adjusting Gauge (9207) or a .020" (.50 mm) feeler
gauge to ensure a .020" (.50 mm) clearance exists be-
tween drive belt (at lower balance shaft sprocket) and idler
pulley is maintained when upper portion of drive belt is
preloaded at .04-.08" (1.0-2.0 mm).
Tighten idler pulley. See Fig. 3. If correct gap cannot be
reached, rotate idler pulley 180 degrees and repeat adjust-
ment. Tighten mounting nut. Install and adjust poly-rib belt.
Balance Shaft Bearing Cover ...............................................
1
Step 1:
2 Bolts @ Bearing (8 mm) ..................................... 11 (15)
Step 2
6 mm ....................................................................... 7 (10)
8 mm ..................................................................... 15 (20)
Step 3:
2 Bolts @ Bearing (8 mm) ..................................... 24 (33)
Balance Shaft Sprocket Mounting Bolt ........................ 33 (45)
Belt Tensioner Mounting Bolt ...................................... 33 (45)
Camshaft Housing Mounting Bolt .............................. 15 (20)
Camshaft Plug (Aluminum) ........................................ 30 (41)
Camshaft Sprocket
Hex Mounting Bolt ..................................................... 33 (45)
Polygon Mounting Bolt .................................... 47-51 (64-69)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt ......................................... 96 (8)
Transport Clamp-to-Camshaft Housing ...................... 96 (8)
1
- Check movement of balance shaft between each tighten-
ing step.
PORSCHE
*2.5L, *2.7L & *3.0L 4-Cylinder (Cont.)
Fig. 3: Aligning Upper Balance Shaft Timing Mark
Fig. 4: Drive Belt Positioning
Fig. 2: Aligning Camshaft Sprocket Timing Mark
466
PORSCHE
*2.5L, *2.7L & *3.0L 4-Cylinder (Cont.)
Fig. 6: Balance Shaft Drive Belt Positioning
Fig. 5: Mechanical Belt Tensioner
467
PORSCHE
*4.5L, 4.7L, 5.0L & 5.4L V8
4.5L V8
928
1978-82................. 4.6 Hours .................. 250196
4.7L V8
928
1983-84................. 4.6 Hours ................. 250196
5.0L V8
928
1985-91................. 6.5 Hours .................. 250196
5.4L V8
928
1992-95................. 6.5 Hours .................. 250196
60,000 miles.
TIMING BELT
NOTE: On 1983 4.5L V8 models, the tooth shape of the timing
belt was changed to high torque drive (HTD). See Fig. 1. New HTD
belts can be used on older engines if sprockets with new tooth
shape are installed. NEVER mix sprockets with different tooth
shapes.
NOTE: When replacing drive belt, ensure proper type is used
and new belt teeth match used sprockets. Early design belt uses
square-shouldered teeth with belt thickness of .18" (4.5 mm). Late
design belt uses round teeth (high torque drive type) with a belt
thickness of .22" (5.6 mm). All sprockets must match belt tooth
design.
Removal:
Disconnect negative battery cable. Remove air cleaner in-
take hoses. Remove accessory drive belts. Disconnect
cables for throttle, cruise control and automatic transaxle.
Remove retainers and clamp on console and position cable
aside. Remove clutch slave cylinder.
CAUTION: NEVER operate clutch pedal when slave cylinder is
removed.
On 4.5L V8, align TDC mark on vibration damper with red
indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for
45 degrees BTDC on vibration damper with Red needle.
Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate
crankshaft clockwise until timing marks (notches) on cam-
shaft sprockets align with marks cast on camshaft bearing
caps.
On 4.7L, 5.0L & 5.4L V8, lock crankshaft by installing
Porsche Tool (9161/1) or equivalent. Secure tool with slave
cylinder mounting bolts.
Remove crankshaft pulley mounting bolt, both pulleys, vi-
bration damper and collar. Remove oil dipstick tube. Re-
move alternator. Remove left upper and center timing belt
covers. Loosen timing belt tensioner. Loosen tensioning
roller. Remove timing belt.
Installation:
On 4.5L V8, align TDC mark on vibration damper with Red
indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for
45 degrees BTDC on vibration damper with Red needle.
Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate
crankshaft clockwise until timing marks (notches) on cam-
shaft sprockets align with marks cast on camshaft bearing
caps.
Fig. 1: Camshaft Sprocket & Timing Belt Types
468
NOTE: Manufacturer indicates sufficient clearance exists so
pistons and valves will not collide when crankshaft is turned
with camshaft timing belt removed.
Preload belt by hand and install belt on sprockets in order
of crankshaft, oil pump, left camshaft, water pump, right
camshaft and tension roller. See Fig. 2. Ensure belt and
camshaft sprocket teeth match. If necessary, rotate cam-
shaft counterclockwise until teeth match. Tighten timing
belt to specification. Rotate engine 2 revolutions and align
cylinder No. 1 at TDC of compression stroke.
Check camshaft timing marks for proper alignment and
retighten camshaft drive belt. Ensure tester is not turned or
pushed during tension measurement. Recheck belt ad-
justment at least once. Adjust drive belts to proper tension.
Adjustment:
With both upper drive belt guards removed, rotate crank-
shaft (in direction of rotation) and position cylinder No. 1 at
TDC of compression stroke. Mark on vibration damper
should be in alignment with Red indicator on cover.
Ensure each camshaft sprocket timing mark is in align-
ment with mark cast on camshaft bearing cap. Turn engine
over 2 more times until TDC is reached again.
Check timing belt for damage and wear. Pull out lock pin,
then completely push out gauge pin (opposite lock pin) on
Timing Belt Tension Tester (9201) or equivalent. Move tell-
tale to 0 position on gauge. See Fig. 3.
Slide tension tester onto belt section between tension roller
and lower camshaft sprocket. Ensure measuring pin is
resting in belt grove. Push tester down on side closer to
tensioner, until gauge needle, resting on air pump bracket,
engages.
Read measured valve while keeping tester horizontal to
belt and free of tension. Tester must not touch plastic cover.
Move telltale to 0 position on gauge.
Pull out lock pin to disengage gauge needle again. Re-
move tester from timing belt and read measured value.
Correct belt tension if necessary. Adjustment screw is lo-
cated on bottom of engine, at right front side. To adjust,
loosen adjustment screw lock nut and turn adjustment
screw until tension is correct. Tighten lock nut and turn
engine 2 revolutions. Recheck tension adjustment.
TIMING BELT TENSION
Application Scale Value
New or used ..................................................................... 4.5
PORSCHE
*4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)
TIMING BELT TENSIONER
NOTE: The timing belt tensioning mechanism uses hydraulic
dampening and a temperature compensation mechanism to reduce
belt load and dampen oscillation. See Fig. 4. The tensioner roller
and carrier is supported against the pull of toothed belt by a
push rod and piston on a 7 packet (5 each) bi-metallic diaphragm
spring set. Tensioner is filled with engine oil (which is added
only after installation on block). Replacement tensioners are
not oil filled so oil must be added and unit bled for proper operation.
Pockets between tensioner roller housing and engine block are
used as oil reservoirs to aid in heat transfer between engine block
and tension roller housing and activate bimetallic diaphragm
springs.
When installing tensioner, ensure sealing surface on block
is in good condition. Apply Locktite (No. 574) to sealing
surface before installation. When filling tensioner, damp-
ing chamber may be bled by pumping tension roller carrier.
Ensure belt is loose and oil filler bolt and bleeder are open.
To fill, remove the larger oil filler and open Allen head bleeder
screws on tensioner housing. Using an oil can, slowly pour
oil into filler hole until air-free oil flows from bleeder hole.
Install and tighten filler and bleeder screws. Check fluid
level after 1000 miles and at 15,000 mile intervals thereaf-
ter. To check, remove filler bolt. If oil can be seen, level is
okay. If not, add oil as necessary.
Camshaft Housing Mounting Bolt .............................. 14 (20)
Camshaft Pulley Mounting Bolt ................................... 33 (45)
Front Pulley Mounting Nut ......................... 181-188 (250-260)
Fig. 2: View Of Camshaft Drive Belt Installation
469
PORSCHE
*4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)
Fig. 3: Drive Belt Tension Tester
470
RENAULT
*1.7L 4-Cylinder
Align timing belt marks with timing mark on camshaft
sprocket and crankshaft sprocket. See Fig. 2. Remove TDC
tool from crankcase, then rotate crankshaft clockwise, 2
complete revolutions. Reinstall TDC tool through crank-
case into crankshaft. Ensure that the camshaft sprocket
timing mark is aligned with mark on rear cover plate. See
Fig. 1.
NOTE: The intermediate shaft sprocket does not have a timing
mark.
There should be 66 timing belt teeth (cogs) between cam-
shaft sprocket timing mark and crankshaft sprocket timing
mark. See Fig. 2. Remove TDC tool and install plug into
cylinder block. Check timing belt deflection between interme-
diate shaft sprocket and idler pulley. With belt cold, deflection
should be .295 (7.49 mm). With belt hot, deflection should be
.216 (5.48 mm).
If deflection is excessive, loosen tensioner pulley lock nut,
then turn tensioner pulley nut counterclockwise to increase
tension or counterclockwise to decrease tension. While
holding tensioner pulley lock nut with a suitable wrench,
tighen tensioner pulley lock nut to specification. To com-
plete installation, reverse removal procedures. Adjust drive
ranges.
Tensioner Pulley Lock Nut .......................................... 30 (41)
Fig. 1: Camshaft Sprocket Alignment Marks
1.7L 4-Cyl.
Alliance & Encore
1985-87 .................... 2.3 Hours .................. 250119
TIMING BELT
Removal:
belts. Remove timing belt cover. Rotate crankshaft until No.
1 cylinder is at TDC of compression stroke. Ensure that
camshaft is positioned as shown. See Fig. 1. Insert Renault
TDC Lock Pin (Mot. 861) or equivalent through opening in
side of block. Ensure that tool engages slot in crankshaft.
Loosen timing belt tensioner, then remove timing belt.
NOTE: If there is no reference mark on camshaft sprocket rear
cover plate, scribe a matching mark in line with timing mark
on sprocket.
NOTE: DO NOT rotate crankshaft or camshaft with timing belt
removed.
Installation:
Ensure that Renault TDC Tool (Mot. 861) is properly seated
and align camshaft sprocket timing mark with mark on rear
cover plate. See Fig. 1. Position timing belt first over crank-
shaft sprocket, then intermediate shaft sprocket, and then
camshaft sprocket. See Fig. 2.
Position timing belt arrow, indicating direction of rotation
between intermediate shaft sprocket and idler pulley. See
Fig. 2. Loosen tensioner pulley lock nut, then turn tensioner
pulley nut counterclockwise until timing belt is taut. Hold
tensioner pulley nut from turning and tighten lock nut.
471
RENAULT
472
RENAULT
2.2L 4-Cylinder
2.2L 4-Cyl.
Fuego
1984-85................ 2.2 Hours ................. 250140
Sportwagon
1984-86................ 2.0 Hours ................. 250140
scheduled maintenance interval, manufacturers suggest the
belt be replaced at 60,000 mile intervals.
TIMING BELT
Removal:
Remove radiator upper support. Remove upper and lower
hoses from radiator. Disconnect wiring harness connec-
tors from cooling fan and thermo switch. Remove radiator
and A/C condenser as an assembly.
Release tension and remove serpentine drive belt. Re-
move timing belt cover. Remove hose from water pump.
Remove water pump pulley bolt and pulley. Remove water
pump.
Remove timing belt tension spring and plunger from water
pump and install them in replacement water pump. Clean
gasket mating surfaces. Loosen timing belt tensioner idler
bolts. Remove timing belt.
Installation & Adjustment:
Position camshaft sprocket timing index in line with static
timing mark. Position crankshaft so No. 1 piston is at TDC
of compression stroke. Remove plug in cylinder block and
insert TDC Rod (Mot. 861) or equivalent, into TDC hole in
crankshaft. Install timing belt. See Fig. 1.
Position timing belt cover over sprockets and check cam-
shaft timing mark with index on cover. Remove TDC rod
and install plug in cylinder block. Rotate crankshaft clock-
wise 2 complete revolutions. DO NOT rotate counterclock-
wise. Remove timing belt cover and loosen timing belt
tensioner bolts a maximum of 1/4 turn.
Spring loaded timing belt tensioner will automatically ad-
just to correct position. Ensure clearance between timing
belt tensioner and intermediate shaft cover is .004" (.10
mm). See Fig. 2. Tighten bottom timing belt tensioner bolt.
Tighten top bolt. Test belt tension with Tension Gauge (Ele.
343) or equivalent. Deflection should be .216-.276" (5.5-
7.0 mm). Install timing belt cover. To complete installation,
Fig. 2: Adjusting Intermediate Shaft Cover Clearance
473
Fig. 3: Timing Belt Cover TDC Marks
Fig. 5: Aligning Camshaft & Crankshaft Sprockets
RENAULT
474
SAAB
*2.5L & 3.0L V6
2.5L V6
900
1994-97................. 2.3 Hours ................. 250285
3.0L V6
9000
1995-97................. 2.3 Hours ................. 250285
60,000 miles.
TIMING BELT
Removal:
Move power steering reservoir out of the way, and remove
right side engine-to-frame torque arm. Remove the power
steering line clamp from the torque arm engine mount.
Remove torque arm engine mount.
Relieve tension on serpentine belt and remove serpentine
belt. Remove the water pump pulley. Remove upper part of
alternator air intake. Remove the serpentine belt tensioner.
Remove the power steering pump with lines attached, and
move out of way. Remove the timing belt cover. Remove the
6 outer bolts from the crankshaft pulley, NOT the center
bolt.
Turn crankshaft so No. 1 cylinder is at TDC of compression
stroke. Ensure marks on camshaft sprockets and timing
cover align. See Fig. 1. Install Belt Holder (KM-800-1 and
KM-800-2) to hold camshaft sprockets in place. See Fig. 2.
If belt is to be reused, mark belt with direction of rotation.
Remove timing belt from engine.
NOTE: Use the marks on each side of the direction of rotation
arrows to line up the left (drivers side) camshaft sprockets. For
this design (idler pulley located above crankshaft) engine, use
the remaining 3 White marks on the NAPA timing belt. Correct
belt marks MUST be used.
Installation:
Ensure crankshaft and camshaft timing marks are still
aligned. Install timing belt. Adjust lower roller counterclock-
wise to belt tension of 205-221 ft. lbs. (275-300 N.m). Ad-
just tensioning pulley with a hex head wrench until 2 marks
are aligned. Tighten bolt.
Remove locking tool for camshaft sprockets 1 and 2. Adjust
upper adjusting roller counterclockwise until No. 2 sprocket
moves .03-.07 (1-2 mm) clockwise. Remove camshaft lock-
ing tools.
Fig. 2: Camshaft Belt Holders
Courtesy of Saab-Scania of America, Inc.
Turn engine 2 revolutions in normal direction of rotation.
Recheck camshaft and crankshaft timing mark alignment.
Valve Cover Nuts ........................................................ 86 (10)
Courtesy of Saab-Scania of America, Inc.
475
STERLING
*2.5L & *2.7L V6
2.5L V6
825
1987-88.................. 4.0 Hours ................ 250129
2.7L V6
827
1989-91.................. 4.0 Hours ................ 250129
TIMING BELT
Removal:
Remove negative battery cable. Turn crankshaft clockwise
to bring No. 1 cylinder to TDC of compression stroke. Re-
move pulley cover from upper timing belt cover. Remove
engine wiring harness clamp from right side of engine com-
partment. Support front of engine. On right side of engine
compartment, remove engine-to-body mount (on front of
engine). Remove lower engine splash shield. Remove A/
C, power steering, and all other drive belts.
Remove alternator. Leaving hoses connected, remove
power steering pump and secure out of way. Remove up-
per timing belt pulley covers. Remove crankshaft pulley.
Remove timing belt lower cover. Loosen timing belt
tensioner to relieve tension on timing belt. If reusing timing
belt, mark direction of belt rotation before removing. Slide
belt off pulleys. Check belt for damage, missing teeth, or
cracks.
Installation:
Remove spark plugs. Turn crankshaft clockwise to bring
No. 1 cylinder to TDC of compression stroke. Advance crank-
shaft an additional 15 degrees from TDC position. Rotate
camshaft pulleys to compression stroke (TDC position) of
No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 de-
grees to TDC position.
Push timing belt tensioner to full release position and snug
adjuster bolt. Install timing belt over crankshaft pulley, front
camshaft pulley, water pump pulley, tensioner and then
over rear camshaft pulley. See Fig. 1. Note position of
timing belt pulley guides on both sides of crankshaft. In-
stall pulley guides so guides form a V groove for belt to
ride in. Loosen timing belt tensioner bolt. To complete in-
proper tension.
NOTE: Always adjust timing belt tension with engine cold.
Set No. 1 piston to TDC on compression stroke. Rotate
crankshaft clockwise 9 teeth on rear camshaft pulley. Blue
mark on crankshaft pulley should match pointer on lower
cover. Loosen timing belt tensioner bolt. See Fig. 1.
Ensure timing belt is seated properly on pulleys. Tighten ad-
juster bolt. Reverse removal procedure to complete installa-
tion.
NOTE: After timing belt installation, rotate engine clockwise
several times to ensure valves DO NOT contact pistons.
A/C Compressor Bolts ............................................... 16 (22)
Alternator Bracket Bolts .............................................. 33 (45)
Alternator Mount Bolts ................................................ 16 (22)
INCH Lbs. (N.m)
Valve Cover Bolts ...................................................... 106 (12)
Water Pump Bolts .................................................... 106 (12)
476
STERLING
*2.5L & *2.7L V6 (Cont.)
477
SUBARU
1.2L 3-Cylinder
1
Belt Part No.
1.2L 3-Cyl.
Justy
1987-95................. 1.4 Hours .................. 250135
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator drive
belt. Using Pulley Holder (499205500) or equivalent, loosen
crankshaft pulley bolts. Rotate engine until No. 3 cylinder is
at TDC. Remove crankshaft pulley retaining bolts using
access hole in fenderwell housing.
Remove outer timing belt cover. Loosen tensioner retain-
ing bolts. Move tensioner toward outside of engine. Tighten
bolts to hold tensioner. See Fig. 2. Mark timing belt for di-
rection of rotation. Remove crankshaft belt drive sprocket
plate and timing belt.
NOTE: Before removing timing belt, mark it indicating direction
of rotation. Timing belt must be installed in original direction
of rotation.
Inspection:
Inspect belt for signs of oil contamination. Replace belt if it
is damaged or contaminated. Inspect all drive sprockets
for wear in drive belt area. Inspect tensioner for noise and
grease leakage. Replace tensioner as necessary.
Installation:
Using Pulley Holder (499205500) or equivalent, rotate cam-
shaft to align camshaft sprocket alignment mark with align-
ment mark on timing belt cover. See Fig. 1. Install crank-
shaft belt drive sprocket (if removed) with flanged side fac-
ing inward. Rotate crankshaft so crankshaft belt drive
sprocket aligns with crankcase alignment mark. Remove
valve cover (if it was not previously removed). Loosen valve
adjusting screws to gain rocker arm free play.
Loosen tensioner retaining bolts. Apply tension to timing
belt. Tighten inner and then outer tensioner retaining bolts.
Ensure all timing marks are aligned. Install crankshaft belt
drive sprocket plate. Reverse removal procedure for re-
maining components. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS. Adjust valve clearance. Adjust
ranges.
Application
Ft. Lbs. (N.m)
INCH Lbs. (N.m)
Camshaft Sprocket Bolt ............................ 97-106 (11.0-12.0)
Tensioner Bolt ................................................ 50-53 (5.7-6.0)
Valve Cover Bolt .............................................. 53-71 (6.0-8.0)
Water Pump Impeller Bolt ............................ 80-89 (9.0-10.0)
478
Belt
Application Time
1
Kit No. No.
1.8L 4-Cyl.
DL, GL & RX (Coupe, Sedan & Station Wagon)
1985-89
Left Side ..... 2.7 Hrs ...... 2522990......... 250299
Right Side ... 2.7 Hrs. ..... 2522990......... 250300
Loyale
1990-94
Left Side ..... 2.7 Hrs. ..... 2522990......... 250299
Right Side ... 2.7 Hrs. ..... 2522990......... 250300
XT
1985-91
Left Side ..... 2.7 Hrs. ..... 2522990......... 250299
Right Side ... 2.7 Hrs. ..... 2522990......... 250300
1
- Both Belts.
kits.
52,500 miles.
TIMING BELT
Removal:
belt. Remove water pump pulley. Remove dipstick and tube.
Remove crankshaft pulley. If engine is removed from ve-
hicle, crankshaft can be held using Flywheel Stopper
(498277000) or equivalent, for M/T models or Drive Plate
Stopper (498497000) or equivalent, for A/T models.
CAUTION: If reusing timing belt, mark belt to indicate normal
Remove center, left and right timing belt covers. To remove
right side timing belt, loosen tensioner bolts on No. 1 cylin-
der 1/2 turn, rotate tensioner to release belt tension, and
retighten bolts. See Fig. 1. If reusing timing belt, mark belt
to indicate normal direction of rotation. Remove timing belt.
Loosen left side timing belt tensioner bolts on No. 2 cylin-
der 1/2 turn. See Fig. 1. Using tensioner wrench, rotate
tensioner until belt is slack. Tighten tensioner bolts. If re-
using timing belt, mark belt to indicate normal direction of
rotation. Remove outer crankshaft sprocket. Remove tim-
ing belt.
Inspection:
Inspect timing belt for wear and rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace
belt if it is damaged or contaminated. Inspect idler pulleys
and tensioners for smooth rotation. Check belt tensioner
roller for squareness. See Fig. 2. Replace tensioner if out-
of-square exceeds .02" (.5 mm).
Installation:
Install belt tensioners and belt idler. Position belt tensioners
to allow belt installation. Install inner (sprocket without dowel
pin) and outer crankshaft sprockets on crankshaft. Tempo-
rarily install crankshaft pulley.
Align center mark on flywheel with mark on flywheel hous-
ing. See Fig. 3. Align timing mark on left camshaft sprocket
(sprocket for timing belt closest to engine) with notch in
belt cover. See Fig. 4. Install left timing belt first on inner
crankshaft sprocket and then around oil pump sprocket.
Install left timing belt on idler and then camshaft sprocket.
If reusing belt, install it in original direction of rotation.
Loosen left tensioner retaining bolt to apply tension to tim-
ing belt. Push timing belt by hand to ensure smooth opera-
tion and movement of tensioner. Using Belt Tensioner
Wrench (499437000) or equivalent, apply 17-19 ft. lbs. (23-
26 N.m) of torque to camshaft sprocket in a counterclock-
wise direction.
While applying torque, tighten tensioner bolts. Ensure all
timing marks are aligned. See Figs. 3 and 4.
NOTE: After installing left side timing belt, crankshaft is rotated
1 full turn (360 degrees). This will be the position for installing
the right side camshaft belt. The camshaft timing mark for the
left side timing belt will now be pointing straight down (6 oclock
position). See Fig. 5.
To install right (outer) timing belt, rotate crankshaft clock-
wise 360 degrees and align center line on flywheel with
timing mark on flywheel housing. Align camshaft sprocket
timing mark with notch in housing. See Fig. 4.
Install right timing belt over crankshaft and camshaft sprock-
ets, keeping slack out of side opposite tensioner. Ensure
reused belt is installed in original direction of rotation.
Loosen inner tensioner bolt and allow tensioner to apply
belt tension. While turning camshaft sprocket counterclock-
wise, apply 17-19 ft. lbs. (23-26 N.m) of torque using Belt
Tension Wrench (499437000) or equivalent.
NOTE: When timing belts are properly installed, left side camshaft
sprocket timing mark will be pointing DOWN and right side camshaft
sprocket timing mark will be pointing UP. Engine timing marks
for both camshafts are located on TOP side of rear timing belt
covers. See Figs. 4 and 5.
SUBARU
1.8L 4-Cylinder Except Impreza & Legacy
Fig. 1: Identifying Timing Belts & Engine Components
479
SUBARU
1.8L 4-Cylinder Except Impreza & Legacy (Cont.)
Fig. 4: Camshaft Positions For Installing Timing Belts
Fig. 2: Measuring Tensioner Squareness
Fig. 5: Final Installed Position Of Left Timing Belt
Sprocket
Courtesy of Subaru of America, Inc.
While applying torque, tighten inner and then outer tensioner
retaining bolts. Ensure all timing marks are aligned. To
install remaining components, reverse removal procedure.
tension ranges.
Belt Idler Bolt .................................................... 29-35 (39-47)
Belt Tensioner Bolt ........................................... 13-15 (18-20)
Camshaft Case Bolt ......................................... 13-15 (18-20)
1
.................................. 66-79 (90-107)
Oil Pump Pulley Nut ......................................... 13-15 (18-20)
INCH Lbs. (N.m)
Camshaft Sprocket Bolt ...................................... 80-89 (9-10)
Camshaft Support Bolt ......................................... 53-62 (6-7)
Valve Cover Bolt .................................................... 35-44 (4-5)
1
- Coat bolt threads with oil before installation.
480
SUBARU
1.8L & 2.2L 4-Cylinder Impreza & Legacy
Belt
1.8L 4-Cyl.
Impreza
1993...............
1
2.2 Hrs. .... 2521720........ 250172
1994-97..........
1
2.2 Hrs. ........................... 250254
2.2L 4-Cyl.
Impreza
1995-98..........
1
2.2 Hrs. ........................... 250254
Legacy
1990-93..........
1
2.2 Hrs. .... 2521720........ 250172
1994-98..........
1
2.2 Hrs. ........................... 250254
1
kits.
For 1990-94 model years, the manufacturer recommends belt
the manufacturer recommends belt be replaced at 60,000
miles on Federal vehicles, and 105,000 miles on California
vehicles.
TIMING BELT
Removal:
belt. Remove crankshaft pulley bolt. Remove crankshaft
pulley. If engine is removed from vehicle, crankshaft can be
held using Flywheel Stopper (498277000) or equivalent for
M/T models or Drive Plate Stopper (498497000) or equiva-
lent for A/T models.
Remove front, left and right timing belt covers. If timing belt
is to be reused, mark belt to indicate original direction of
rotati on before removal . Use Crankshaft Socket
(499987500) to turn crankshaft pulley.
Align crankshaft and camshaft timing notches with corre-
sponding notches on timing cover and engine block. See
Fig. 1. Use White paint to mark timing belt in relation to
sprocket timing marks. Loosen tensioner adjuster mount-
ing bolts. Remove belt idler. Remove belt idler No. 2. Re-
move timing belt.
Inspection:
is damaged or contaminated. Inspect belt tension adjuster
oil seals for leaks. Inspect rod ends for abnormal wear and
scratches. Timing belt bend diameter must be greater than
2.36" (60.0 mm).
Slight trace of oil at rod oil seal does not indicate a prob-
lem. While holding tensioner using both hands, push rod
section against floor or wall using a force of 33-110 lbs.
(15-50 kg) to ensure rod section does not move.
If rod section moves, replace tension adjuster. Measure
extension of rod beyond body. Rod extension should be
.606-.646" (15.40-16.40 mm). Replace belt tension adjuster
if extension of rod is not as specified. Inspect belt tensioner
and belt adjuster rod mating surface. Check spacer and
tensioner bushing.
CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992
kg). DO NOT release pressure until stopper pin is completely installed.
Installation:
Ensure timing marks are aligned. Using a press, align
holes in belt tension adjuster rod and adjuster body, and
push rod into body. DO NOT allow press pressure to ex-
ceed 2205 lbs. (992 kg). Install a stopper pin with a diam-
eter of .059" (1.5 mm) through holes in adjuster body and
rod. See Fig. 2.
Temporarily tighten mount bolts while tension adjuster is
pushed completely right. Install belt tensioner. Ensure belt
direction of rotation is correct.
Install timing belt, being careful not to move sprockets. In-
stall belt idler No. 2 and belt idler. Loosen tension adjuster
mount bolts and push tension adjuster completely left.
Tighten adjuster mount bolts.
Fig. 1: Removing & Installing Timing Belt
Fig. 2: Installing Tension Adjuster Rod Stopper Pin
481
SUBARU
1.8L & 2.2L 4-Cylinder Impreza & Legacy (Cont.)
Ensure the marks on timing belt and sprockets align. See
Fig. 1. Remove stopper from tension adjuster. Remove
rocker covers and ensure valve lash adjuster does not con-
tain air. To complete installation, reverse removal proce-
Camshaft Support Bolt ............................................... 12 (16)
Timing Belt Idler Bolt ........................................ 26-32 (35-43)
Timing Belt Tension Adjuster Bolt ..................... 17-20 (23-27)
Timing Belt Tensioner Bracket Bolt .................. 17-20 (23-27)
INCH Lbs. (N.m)
Rocker Cover Bolt ...................................................... 44 (5.0)
Rocker Shaft Support Bolt
Long .................................................................... 108 (12.2)
Short ........................................................................ 44 (5.0)
Timing Belt Cover Bolt ............................................... 44 (5.0)
Water Pump Bolt ...................................... 89-124 (10.0-14.0)
482
SUBARU
2.2L & 2.5L 4-Cylinder SOHC
2.2L 4-Cyl.
Impreza
1999-01................
1
2.2 Hours ................. 250304
Legacy
1999.....................
1
2.5 Hours ................. 250304
Outback
2000-01................
1
2.5 Hours ................. 250304
2.5L 4-Cyl.
Forester
1999-01................
1
2.2 Hours ................. 250304
Impreza & Outback Sport
1999-01................
1
2.2 Hours ................. 250304
Legacy & Outback
2000-01................
1
2.5 Hours ................. 250307
1
105,000 miles on all 1999-01 vehicles.
TIMING BELT
Removal:
hicle. Remove engine under cover.
Lower vehicle. Remove radiator coolant reservoir and set
aside. Remove electric cooling fan and radiator shroud.
On Impreza and Forester, remove accessory drive belt cover.
On all models, remove accessory drive belts.
Hold crankshaft pulley stationary, remove crankshaft pulley
center bolt. Remove crankshaft pulley. Remove timing belt
covers.
Turn crankshaft to align crankshaft and camshaft timing
notches with marks on rear timing cover and engine block.
See Figs. 1 and 2. On manual transmission models, re-
move timing belt guide from top of crankshaft pulley.
On all models, if reusing old belt, use White paint to mark
timing belt in relation to sprocket timing marks. Count num-
ber of teeth between crankshaft sprocket and camshaft
sprockets so that belt will be installed in same position.
See Fig. 3.
Remove No. 2 timing belt idler pulley. See Fig. 4. Remove
timing belt. Remove timing belt automatic tensioner with
rod facing up.
Inspection:
is damaged or contaminated.
Inspect belt automatic tensioner oil seals for leaks. Slight
trace of oil at rod oil seal does not indicate a problem.
Inspect rod ends for abnormal wear and scratches.
Fig. 1: Timing Belt Routing & Timing Marks
Fig. 3: Marking Timing Belt For Reinstallation
Z
1
= 44 Teeth
Z
2
= 40.5 Teeth
483
SUBARU
2.2L & 2.5L 4-Cylinder SOHC (Cont.)
Fig. 5: Checking Automatic Tensioner Rod Extension
Measure extension of rod beyond tensioner body. Holding
tensioner with rod facing up, rod extension should be .224
plus or minus .020 (5.7 mm plus or minus 0.5 mm). See
Fig. 5. Replace automatic tensioner if rod extension is not
as specified.
CAUTION: Always use a vertical type pressing tool to compress
automatic tensioner rod. DO NOT use a bench vise to compress
rod. It may take more than 3 minutes to compress the automatic
tensioner rod.
Place automatic tensioner in a press with tensioner rod
facing up. Apply 66 lbs. (294 N) of pressure on rod. If rod
moves down easily, replace automatic tensioner.
Inspect automatic tensioner and idler pulleys for worn bear-
ings or lubricant leaks. Replace as necessary.
CAUTION: To prevent damage, DO NOT apply more than 2205 lbs.
(9807 N) to automatic adjuster rod. Do NOT press automatic tensioner
rod past the top surface of the housing. DO NOT allow press pressure
to exceed 2205 lbs. (1000 kg).
Installation:
aligned. Place automatic adjuster in a press with rod fac-
ing up. Apply 66 lbs. (294 N) pressure to end of rod. SLOWLY
(taking more than 3 minutes) compress rod into housing
until rod and housing holes are aligned. Insert locking pin
through holes. See Fig. 6.
Install automatic tensioner on engine with locking pin in
place. Install idler pulleys (if removed).
aligned. Install timing belt. If reusing old belt, ensure belt
direction of rotation is correct and mating marks are
aligned.
Install No. 2 idler pulley on engine. Remove automatic
tensioner locking pin. On manual transmission models,
install timing belt guide over crankshaft pulley. Adjust clear-
ance between belt guide and belt to .039 (1.0 mm), plus or
minus .019 (.5 mm).
On all models, install timing belt covers. Clean crankshaft
pulley bolt and bolt hole. Install crankshaft pulley. Coat crank-
shaft pulley bolt threads with engine oil. Install bolt, While
holding crankshaft pulley stationary, tighten bolt to specifi-
cation. See TORQUE SPECIFICATIONS.
CAUTION: If tightening angle of crankshaft pulley bolt is less
than 45 degrees, bolt is damaged. Bolt must be replaced.
Install accessory drive belts. Install radiator fan assembly.
tension ranges.
Fig. 4: Removing No. 2 Timing Belt Idler Pulley
Fig. 6: Compressing Automatic Tensioner Rod
2.2L ........................................................................ 94 (127)
2.5L ...................................................................... 130 (177)
Idler Pulley Bolt ............................................................. 29 (39)
Timing Belt Automatic Tensioner Bolt ............................ 29 (39)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ..................................................... 44 (5)
Timing Belt Guide Bolt (M/T) ....................................... 89 (10)
Valve Cover Bolt ................................................................ 44 (5)
Water Pump Bolt ...................................... 89-124 (10.0-14.0)
Fig. 7: Checking Timing Belt Guide Clearance
484
SUBARU
2.5L 4-Cyl. DOHC
Forester
1998.....................
1
2.5 Hours ................. 250277
Impreza
1996-99................
1
2.5 Hours ................. 250277
Legacy & Outback
1996-99................
1
2.5 Hours ................. 250277
1
60,000 miles on 1996-97 Federal vehicles. Replace belt at
105,000 miles on all 1998-99 vehicles.
TIMING BELT
Removal:
Remove drive belt cover. See Fig. 1. Remove drive belt.
Remove A/C compressor belt tensioner assembly (if
equipped). Holding crankshaft stationary, remove crank-
shaft pulley bolt. See Fig. 2. Remove crankshaft pulley.
Remove left and right timing belt covers. Remove front belt
cover. See Fig. 6. Rotate crankshaft and align crankshaft
and camshaft timing notches. See Fig. 5.
On manual transmission models, remove timing belt guide
from top of crankshaft pulley. On all vehicles, if reusing
timing belt, mark belt with arrow to indicate original direc-
tion of rotation. Also, place mating marks on timing belt and
crankshaft and camshaft sprockets.
Remove lower timing belt idler pulley. Remove timing belt.
Remove timing belt automatic tensioner.
CAUTION: To prevent intake and exhaust valves from contacting
each other, DO NOT rotate crankshaft or camshafts with timing
belt removed.
Inspection:
is damaged or contaminated.
Inspect belt automatic tensioner oil seals for leaks. Slight
trace of oil at rod oil seal does not indicate a problem.
Inspect rod ends for abnormal wear and scratches.
Measure extension of rod beyond tensioner body. Holding
tensioner with rod facing up, rod extension should be .224
plus or minus .020 (5.7 mm plus or minus 0.5 mm). See
Fig. 3. Replace automatic tensioner if rod extension is not
as specified.
Place automatic tensioner in a press with tensioner rod
facing up. Apply 66 lbs. (29.9 kg) of pressure on rod. If rod
moves down easily, replace automatic tensioner.
Inspect automatic tensioner and idler pulleys for worn bear-
ings or lubricant leaks. Replace as necessary.
CAUTION: To prevent damage to automatic tensioner, DO NOT
apply more than 2205 lbs. (1000 kg) to automatic adjuster rod. Compress
tensioner rod with using vertical press. DO NOT use bench vise.
DO NOT press automatic tensioner rod past the top surface of the
housing.
96I14512 Courtesy of Subaru of America, Inc.
Fig. 1: Removing Drive Belt Cover
96A14514 Courtesy of Subaru of America, Inc.
Fig. 2: Removing Crankshaft Pulley Bolt
Fig. 3: Measuring Automatic Tensioner Rod Extension
Installation:
aligned. Place automatic adjuster in a press with rod fac-
ing up. Apply 66 lbs. (29.9 kg) pressure to end of rod.
SLOWLY (taking more than 3 minutes) compress rod into
housing until rod and housing holes are aligned. Insert
locking pin through holes.
Install automatic tensioner on engine with locking pin in
place. Install idler pulleys (if removed). Install timing belt in
correct routing order. Ensure camshaft double marks are
aligned. If reusing old belt, ensure belt direction of rotation
is correct and mating marks are aligned.
485
96J14513 Courtesy of Subaru of America, Inc.
Fig. 5: Aligning Timing Marks & Sprocket Alignment Marks
SUBARU
486
Fig. 6: Removing & Installing Front Belt Cover
Count number of teeth between crankshaft and camshaft
pulleys to ensure belt is correctly installed. See Fig. 5. When
belt is correctly installed, remove automatic tensioner lock-
ing pin.
On manual transmission models, install timing belt guide
over crankshaft pulley. Clearance between belt guide and
belt should be .039 (1.0 mm).
Install timing belt covers. Install crankshaft pulley, Holding
crankshaft stationary, tighten bolt to specification. To com-
ranges.
Application Ft. Lbs.. (N.m)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................. 44 (5.0)
Timing Belt Guide Bolt .................................................. 89 (10)
Water Pump Bolt ...................................... 89-124 (10.0-14.0)
SUBARU
487
1
Belt Part No.
2.7L 6-Cyl.
XT6
1988-91
Left Side ............ 2.9 Hours ................. 250151
Right side .......... 2.9 Hours ................. 250150
1
- Both Belts.
60,000 miles.
TIMING BELT
Removal:
Loosen water pump pulley and alternator mounting bolts.
Loosen serpentine belt tensioner pulley lock nut and re-
lease belt tension. Ensure adjuster bolt is turned fully coun-
terclockwise and remove serpentine belt.
Remove water pump pulley. Remove crankshaft pulley.
Crankshaft can be held using Flywheel Stopper (498277000)
or equivalent, for M/T models or using Drive Plate Stopper
(498497000) or equivalent, for A/T models.
Unplug oil pressure switch connector. Remove oil level
gauge guide from front of engine. See Fig. 1. Remove cen-
ter, left and right timing belt covers.
Loosen right (passenger side) hand timing belt tensioner
bolts 1/2 turn. Rotate tensioner to release belt tension and
retighten bolts. See Fig. 2. If right (passenger side) timing
belt is to be reused, place arrow on belt to indicate direc-
tion of belt rotation. Remove timing belt.
Remove crankshaft outer sprocket. To remove left (driver
side) timing belt, remove idler pulley. See Fig. 3. Remove
rubber plug and retaining bolt located below belt tension
adjuster in rear timing cover. See Fig. 5.
Remove Phillips screw from bottom of belt tension adjuster.
See Fig. 6. Insert slot screwdriver in bottom of belt tension
adjuster and rotate screw clockwise to release belt ten-
sion. Install Belt Adjuster Stopper (13082AA000) or equiva-
lent, on tension adjuster. See Fig. 7.
Remove left hand timing belt tensioner. If timing belt is to
be reused, place arrow on belt to indicate direction of belt
rotation. Remove timing belt. Remove belt tension adjuster.
Inspection:
damaged or contaminated. Inspect idler pulleys and
tensioners for smooth rotation. Check belt tensioner roller
for squareness. See Fig. 8. Replace tensioner in out-of-
square exceeds .020" (.51 mm).
Installation:
If not already done, remove Phillips screw from bottom of
belt tension adjuster. Insert a standard slot screwdriver
into hole in bottom of belt tension adjuster. Turn screw
clockwise to compress rubber boot. Install belt adjuster
stopper on top of belt tension adjuster.
SUBARU
2.7L 6-Cylinder
Fig. 1: Removing Oil Level Gauge & Guide
Using syringe, add engine oil through vent hole on top of
rubber boot. Add oil until it overflows. Install Phillips screw
and new gasket.
Install belt tension adjuster on engine. Keep belt adjuster
stopper in place. Tighten bolts to specification. See
Install rubber plug and retaining bolt on engine Install left
timing belt idler pulley. Tighten bolt to specification. See
Install crankshaft sprocket (if removed). Align center line of
the 3 lines on flywheel or drive plate with mark on housing.
Align left camshaft sprocket timing mark with notch in rear
Fig. 2: Loosening Right Hand Timing Belt Tension
Fig. 3: Removing Left Timing Belt Idler Pulley
488
SUBARU
G00019666
489
SUBARU
Fig. 8: Checking Belt Tensioner Roller Squareness
Fig. 5: Removing Rubber Plug & Retaining Bolt
Fig. 6: Removing Phillips Screw From Belt Tension
Adjuster
Fig. 7: Installing Belt Adjuster Stopper
Install left (driver side) timing belt starting from the crank-
shaft sprocket. If installing used belt, ensure belt is in-
stalled in original direction of rotation. Install belt tension
adjuster. See Fig. 7. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Remove belt adjuster stop-
per from belt tension adjuster. Ensure tensioner moves
smoothly after it is installed.
CAUTION: Ensure end of tensioner arm contacts top of belt tension
adjuster and all timing marks align.
NOTE: After installing left (drivers side) timing belt, crankshaft
is rotated 1 full turn (360 degrees). This will be the position for
installing the right (passenger side) camshaft belt. The cam-
shaft timing mark for the left side timing belt will now be pointing
straight down (6 oclock position). See Fig. 10.
To install right (passenger side) timing belt, rotate crank-
shaft clockwise 360 degrees. Align flywheel or drive plate
timing marks with mark on housing. Align camshaft sprocket
timing mark with notch in rear timing belt cover. See Fig. 9.
Install right hand timing belt tensioner. Rotate tensioner
assembly down and temporarily tighten retaining bolts.
Install outer crankshaft sprocket. Install right timing belt
starting from crankshaft. If reusing old timing belt, ensure
belt is installed in original direction of rotation.
Loosen right hand tensioner bolts, and allow tensioner to
apply belt tension. Install Belt Tension Wrench (499437100)
on right camshaft sprocket.
Using torque wrench and belt tension wrench, apply 17-18
ft. lbs. (24-25 N.m) or torque in a counterclockwise direc-
tion to right camshaft sprocket. While applying torque, tem-
porarily tighten tensioner bolt closest to the tensioner pul-
ley, and then the tensioner pivot bolt.
490
SUBARU
Fig. 10: Final Installed Position Of Left (Driver Side)
Camshaft Sprocket
Check belt tension. Belt tension should be 33-55 lbs. (15-
25 kg). If belt tension is correct, tighten tensioner bolt clos-
est to the tensioner pulley, and then the tensioner pivot bolt
to specification. See TORQUE SPECIFICATIONS. Ensure
NOTE: When timing belts are properly installed, left camshaft
sprocket timing mark will be pointing DOWN and right camshaft
sprocket timing mark will be pointing UP. Engine timing mark
notches for both camshafts are located on TOP side of rear timing
belt covers. See Figs. 9 and 10.
Install rubber plug and retaining bolt below belt tension
adjuster. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt threads. Holding
crankshaft pulley stationary, install and tighten center bolt
to specification.
dure. Tighten alternator belt so belt tension is 143-165 lbs.
(65-75 kg) on new belt or 99-143 lbs. (45-65 kg) on used
belts. Adjust drive belts to proper tension. See page A-60
CAUTION: Readjust new alternator belt after 5 minutes of operation.
Belt Tension Adjuster Bolt ................................. 17-20 (23-27)
1
....................... 66-79 (90-107)
Left Hand Tensioner ....................................... 29-35 (39-47)
Right Hand Tensioner .................................... 17-20 (23-27)
INCH Lbs. (N.m)
Oil Level Guide Bolt .............................................. 40-48 (4-5)
1
491
SUBARU
3.3L 6-Cylinder
1
Belt Part No.
3.3L 6-Cyl.
SVX
1992-97................. 2.6 Hours .................. 250209
1
For 1992-94 model years, the manufacturer recommends belt
the manufacturer recommends belt be replaced at 60,000
miles on Federal vehicles, and 105,000 miles on California
vehicles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove undercover. Dis-
connect power steering cooler hoses from body. Discon-
nect cooling fan connectors. Remove drive belt cover. Re-
move upper radiator brackets. Remove radiator fan and
sub-fan assemblies. Remove charcoal canister and
bracket. Remove alternator/power steering drive belts and
A/C drive belt. Remove alternator and drive belt cover
bracket.
Remove A/C idler pulley. Remove power steering pump
and bracket. Remove crankshaft pulley and front timing
belt covers. To hold crankshaft, use Crankshaft Pulley
Wrench (49997-7000) or equivalent. If rotation indicating marks
on timing belt have rubbed off, remark timing belt before re-
moving.
Turn crankshaft to align marks on crankshaft sprocket and cam-
shaft sprockets with marks on cylinder block and timing belt cover.
See Fig. 1. Using White paint, put alignment marks and/or arrows
on timing belt in relation to sprockets. Loosen tensioner adjuster
bolts. Remove timing belt idlers. See Fig. 1. Remove timing belt.
Inspection:
is damaged or contaminated. Inspect tension adjuster for
leaking oil seals and worn rod ends. Slight traces of oil at
rod oil seal do not indicate problem or component failure.
Ensure tension adjuster rod does not move with less than
33-110 lbs. (15-50 kg) of force applied.
Replace tension adjuster if rod moves. Measure tension
adjuster rods extension beyond adjuster body. Distance
should be .606-.646" (15.40-16.40 mm). Replace tension ad-
juster if distance is not correct. Inspect idler pulleys and tensioners
for smooth rotation. Replace components if noise or excessive
play is noted.
Installation:
If tension adjuster was removed or replaced, use a press
to push adjuster rod down far enough to install a stopper
pin. See Fig. 2. Turn sprockets to align timing marks with
marks on rear timing belt covers and oil pump. See Fig. 1.
While aligning marks on timing belt with marks on sprock-
ets, position timing belt properly. Ensure belt rotating direc-
tion is correct. Install idler pulleys. Loosen tension adjuster
attaching bolts and move adjuster fully left.
CAUTION: Readjust new alternator belt after 5 minutes of operation.
Tighten adjuster bolts. Once all timing marks are aligned,
remove stopper pin from tension adjuster. Install front tim-
ing belt covers. To complete installation, reverse removal
procedure. Tighten all nuts and bolts to specification. See
Belt Idler Bolt .................................................... 26-32 (35-43)
Belt Tension Adjuster Bolt ................................. 17-20 (23-27)
Camshaft Sprocket Bolt ............................... 80-94 (108-127)
1
............................ 108-123 (147-167)
Tensioner Bolt .................................................. 26-32 (35-43)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................... 35-44 (4.0-5.0)
Valve Cover Bolt ................................................ 5-44 (4.0-5.0)
Water Pump Pulley Bolt ............................ 84-120 (10.0-14.0)
1
Fig. 1: View Of Timing Belt Components
Fig. 2: Setting Tension Adjuster
492
SUZUKI
1.3L 4-Cyl. DOHC
Swift
1989-94 ..............
1
2.6 Hours ................. 252171
1
not recommend a specific scheduled maintenance interval,
belt manufacturers suggest the belt be replaced at 60,000
mile intervals. For 1993-94 model years, the manufacturer
recommends the belt be replaced at 60,000 mile intervals.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner and
airflow meter assembly. Raise vehicle and remove right
fender apron extension by pushing center pin into clip. DO
NOT push in too far, as pin may fall into fender. Remove
water pump pulley and belt.
Remove crankshaft pulley 5 mm hexagon bolts. If engine is
in vehicle, remove crankshaft pulley center bolt. Remove
crankshaft pulley. Loosen right engine mount bolt, and push
air cleaner bracket aside. Remove timing belt covers.
Align all sprocket timing marks with timing marks on en-
gine. See Fig. 1. Move timing belt tensioner up and secure.
Mark timing belt for direction of rotation if it is to be reused.
Remove timing belt from sprockets.
Installation:
Align timing marks. Bolts with flanged nuts may be wedged
between cam sprocket teeth to hold camshaft on timing
mark during belt installation (if necessary). See Fig. 2.
CAUTION: While aligning timing marks, DO NOT turn camshaft
sprockets more than 20 degrees in either direction from aligned
position. DO NOT turn crankshaft more than 90 degrees in either
direction from aligned position.
Install timing belt so no slack exists on drive side of belt.
Adjust tensioner to remove timing belt slack from other
side of belt, and hand tighten tensioner bolt and nut. Turn
crankshaft 2 revolutions to seat timing belt, and readjust
tensioner.
Tighten tensioner bolt and nut. Ensure drive side of belt is
free of slack. Ensure timing marks are aligned. Install tim-
ing belt outer covers and tighten to specification. See
TORQUE SPECIFICATIONS. To complete installation, re-
verse removal procedure. Tighten bolts to specification.
tension ranges.
Alternator Mount & Adjusting Bolts .................... 13-21 (18-28)
Alternator Pulley Bolts
1992-94 ........................................................ 70-96 (95-130)
INCH Lbs. (N.m)
Alternator Pulley Bolt
1989-91 ........................................................ 90-108 (10-13)
Timing Belt Outer Cover Bolt ............................ 80-106 (9-12)
Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12)
Water Pump Mounting Bolt ............................... 80-106 (9-12)
493
SUZUKI
Fig. 3: Identifying Sprocket Movement Limits
Fig. 2: Securing Intake & Exhaust Camshaft Sprockets For
Timing Belt Installation
494
SUZUKI
Belt
1.3L 4-Cyl. SOHC
Samurai
1985-93..........
1
3.0 Hrs. ........................... 250095
1994...............
1
3.0 Hrs. .........................
2
250095
1994...............
1
3.0 Hrs. .........................
3
250243
1995...............
1
3.0 Hrs. ........................... 250243
Sidekick
1989...............
1
3.0 Hrs. ........................... 250095
Swift
1989-93..........
1
2.6 Hrs. ........................... 250095
1994...............
1
2.6 Hrs. ........................... 250243
1995-97..........
1
2.6 Hrs ............................ 250272
1998-01..........
1
2.6 Hrs. .... 2521941........ 250194
1
2
For VIN R4100375 and earlier.
3
For VIN R4100376 and later.
kits.
TIMING BELT
Removal (Samurai & Sidekick):
Disconnect negative battery cable. Remove cooling fan and
fan shroud. Discharge A/C system using approved refriger-
ant recovery/recycling equipment and disconnect compres-
sor flexible suction hose from suction pipe (if equipped).
Remove A/C compressor belt (if equipped).
Loosen alternator, and remove water pump pulley and belt.
Remove crankshaft pulley. Remove timing belt cover. Loosen
timing belt tensioner bolt and move away from timing belt.
Secure timing belt tensioner.
Mark belt with an arrow indicating direction of rotation for
installation reference. Remove timing belt from camshaft
CAUTION: With timing belt removed, DO NOT turn camshaft
sprocket more than 20 degrees in either direction from aligned
direction from aligned position. Doing so could damage piston(s)
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Installation (Samurai & Sidekick):
Loosen all valve adjusting screws fully before installing
timing belt. Allow camshaft to rotate freely during belt ten-
sion adjustment. Align timing mark on camshaft sprocket
with V mark on timing belt inner cover. See Fig. 2.
Turn crankshaft clockwise until punch mark on crankshaft
sprocket is aligned with arrow mark on oil pump housing.
With timing marks aligned, install timing belt. Ensure di-
rection arrow mark on timing belt is pointed in direction of
crankshaft rotation. Ensure drive side of belt is free of slack.
Move tensioner plate up with finger pressure, and loosely
secure tensioner bolt. Turn crankshaft 2 revolutions clock-
wise to remove all slack from belt. Tighten tensioner nut
and then tensioner bolt. See TORQUE SPECIFICATIONS.
Ensure timing marks are aligned. Install timing belt outer
cover and tighten to specification. See TORQUE SPECIFI-
CATIONS. Reverse removal procedure to complete instal-
lation. Adjust valve clearance. See VALVE CLEARANCE
Removal (Swift):
hicle. Remove right side fender apron extension by push-
ing center pin into clip. DO NOT push in too far as pin may
fall into fender. Lower vehicle.
Remove air cleaner assembly. Support engine with floor
jack. Remove engine mount from timing belt end of engine.
Loosen water pump pulley bolts. Remove accessory drive
belts. Remove water pump pulley.
Remove crankshaft pulley-to-crankshaft bolts. Remove
crankshaft pulley. It is NOT necessary to remove crank-
shaft center bolt.
Remove resonator and timing belt cover. Rotate crankshaft
clockwise to align camshaft and crankshaft timing marks.
See Fig. 2. Camshaft sprocket mark should align with V
mark on rear cover. Punch mark on crankshaft sprocket
should align with mark on oil pump case.
If reusing timing belt, mark belt with an arrow indicating
direction of rotation for installation reference.
Courtesy of Suzuki of America Corp.
495
SUZUKI
Fig. 2: Aligning Timing Belt & Tensioner
Fig. 3: Releasing Timing Belt Tensioner
Loosen timing belt tensioner eccentric bolt and stud nut.
Move tensioner away from belt and snug bolt and nut. Re-
move timing belt.
sprocket more than 20 degrees in either direction from aligned
direction from aligned position. Doing so could damage piston(s)
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Inspection:
Installation (Swift):
If the tensioner was removed, install tensioner plate on
of tensioner. Install tensioner spring. Tighten tensioner bolt
NOTE: It is NOT necessary to loosen valve adjusting screws on
1995 models.
On 1989-94 models with 8-valve engine, remove valve cover.
Loosen all valve adjusting screws before installing timing
belt. Camshaft must be free to rotate during tension ad-
justment.
On all models, ensure all timing marks align. See Fig. 2. If
timing marks are not aligned, rotate camshaft or crank-
shaft to align timing marks. DO NOT rotate camshaft or
crankshaft so timing mark moves more than 90 degrees or
engine damage may occur.
Fig. 4: Adjusting Valve Clearance
Install timing belt. If reusing old belt, ensure belt is installed
in original direction of rotation. Ensure there is no slack in
belt.
Move timing belt tensioner plate up with finger pressure,
and loosely secure tensioner bolt. See Fig. 3. Turn crank-
shaft 2 revolutions clockwise to remove all slack from belt.
Ensure timing marks are aligned. Tighten tensioner stud
nut and then tensioner bolt. See TORQUE SPECIFICA-
TIONS.
Install timing belt outer cover and resonator. Make sure
there are rubber seals installed between water pump and
oil pump case, and another between water pump and cyl-
inder head. Install crankshaft pulley.
496
SUZUKI
On 1989-94 Swift with 8-valve engine, adjust valves. See
VALVE CLEARANCE SPECIFICATIONS. Install valve cover.
tension ranges.
VALVE CLEARANCE SPECIFICATIONS
Cold Hot
Valve In. (mm) In. (mm)
Intake ................. .005-.007 (.13-.18) ........... .009-.011 (.23-.28)
Exhaust ............. .006-.008 (.15-.20) ........ .010-.011 (.25-.28)
Crankshaft Pulley-To-Crankshaft Bolt ................ 7-10 (10-13)
Except 2000-01 Swift ...................................... 77-85 (105-115)
2000-01 Swift ............................................................. 94 (130)
Engine Mount Bolt (Swift) ............................................... 40 (55)
Timing Belt Tensioner Pulley Bolt ..................... 18-22 (24-30)
INCH Lbs. (N.m)
Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12)
497
SUZUKI
1.6L 4-Cylinder
1.6L 4-Cyl. SOHC
Esteem
1995-00................
1
2.3 Hours ................. 250212
Esteem (Canadian)
2001.....................
1
2.3 Hours ................. 250212
Sidekick
1989-91................
1
3.6 Hours ................

250164
1992-95
Convertible.......
1
3.6 Hours ................. 250164
Hardtop .............
1
3.6 Hours ................. 250212
1996-98................
1
3.6 Hours ................. 250212
Vitara
1999-01................
1
4.0 Hours ................. 250212
X-90
1996-98................
1
4.0 Hours ................. 250212
1
- With Air Cond. add .4 hours, except Esteem.
For Esteem, add .2 hours.
TIMING BELT
Removal (Esteem):
Disconnect negative battery cable. Remove right side en-
gine under cover. Remove power steering and A/C com-
pressor drive belts.
Remove A/C compressor and power steering pump with
hoses attached, and secure out of way. Support engine
from above or with floor jack under oil pan. Remove air
cleaner case with air cleaner outlet hose.
From timing belt end of engine, remove engine mount and
mounting bracket. Loosen water pump pulley bolts. Re-
move water pump drive belt and pulley.
Remove 5 crankshaft pulley-to-crankshaft bolts. Remove
pulley. It is NOT necessary to remove crankshaft center
bolt. Remove timing belt cover. See Fig. 1.
Rotate crankshaft clockwise to align timing marks. See
Figs. 2 and 3. Stamped E on camshaft sprocket must
point straight up. Loosen timing belt tensioner bolt and
stud nut. Move tensioner away from belt, and hand tighten
and nut. See Fig. 4.
If reusing old belt, mark belt with an arrow indicating direc-
tion of rotation for installation reference. Remove timing
belt.
or crankshaft sprocket more than 90 degrees in either direction
from aligned position. Doing so could damage pistons and valves.
Removal (Sidekick, Vitara & X-90):
belts.Remove radiator cooling fan, water pump pulley, and
fan shroud. It may be necessary to drain cooling system
and remove upper radiator hose to remove fan shroud.
Remove 5 crankshaft pulley-to-crankshaft bolts. Remove
pulley. It is NOT necessary to remove crankshaft center
bolt. Remove timing belt cover. See Fig. 1.
Rotate crankshaft clockwise to align timing marks. See
Figs. 2 and 3. Stamped E or punch mark on camshaft
sprocket must straight up. Loosen timing belt tensioner
bolt and stud nut. Move tensioner away from belt, and hand
tighten bolt and nut. See Fig. 4. If reusing old belt, mark belt
with an arrow indicating direction of rotation for installation
reference. Remove timing belt.
more than 20 degrees in either direction from aligned position.
To prevent piston and valve damage, DO NOT turn crankshaft
more than 90 degrees in either direction from aligned position.
If the tensioner was removed, install tensioner plate on
of tensioner. Install tensioner spring. Tighten tensioner bolt
On 1989-94 Sidekick with 8-valve engine, remove valve cover.
Loosen all valve adjusting screws. On all models, ensure
timing marks are still aligned. Install timing belt. If reusing
old belt, ensure direction arrow mark on timing belt is
pointed in direction of crankshaft rotation. Ensure drive side
of belt is free of slack.
Loosen tensioner bolt and stud nut to place tension on
timing belt. Turn crankshaft 2 revolutions clockwise to re-
move all slack from belt. Tighten tensioner stud nut and
then tensioner bolt. See TORQUE SPECIFICATIONS.
Ensure timing marks are aligned. Install timing belt cover
and tighten bolts to specification. Reverse removal proce-
dure to complete installation. If coolant was drained, fill
and bleed air from system. Adjust drive belts to proper ten-
sion. See page A-60 for belt tension ranges. Adjust valve
498
SUZUKI
lash on 1989-94 Sidekick with 8-valve engine. See VALVE
CLEARANCE SPECIFICATIONS.
A/C Compressor Mounting Bolt (Esteem) .................... 17 (23)
Crankshaft Sprocket Center Bolt ............................... 80 (110)
Engine Mount Bolt/Nut (Esteem) ................................... 40 (55)
Power Steering Pump Bolt (Esteem) ............................. 25 (35)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft Bolt ........................ 106 (12)
Timing Belt Tensioner Stud Nut .................................... 97 (11)
Water Pump Pulley Bolt .................................................. 97 (11)
Fig. 4: Releasing Timing Belt Tensioner
VALVE CLEARANCE SPECIFICATIONS
Cold Hot
Valve In. (mm) In. (mm)
Intake ................. .005-.007 (.13-.18) ........... .009-.011 (.23-.28)
Exhaust ............. .006-.008 (.15-.20) ........ .010-.011 (.25-.28)
499
Belt
1.5L 4-Cyl.
Corolla Tercel
1980-82
A/T ............... 2.8 Hrs. ...... 2520700....... 250070
M/T .............. 2.8 Hrs. ...... 2520700....... 250070
Tercel
1983-86..........
1
2.7 Hrs. .... 2520700....... 250070
1987-88
Wagon
3A-C...........
1
2.7 Hrs. .... 2520700....... 250070
1
With Air Cond., add .3 hours.
kits.
recommends the belt be replaced every 60,000 miles under
severe service operating conditions.
TIMING BELT
NOTE: Do not bend or twist timing belt. Keep belt free of oil,
water or dust.
Removal:
Drain engine coolant. Remove radiator. Remove air cleaner
assembly. Remove accessory drive belts. Remove water
pump pulley.
If equipped with A/C, remove A/C drive belt idler pulley with
bracket. Remove PCV valve from valve cover. Remove valve
cover.
pression stroke. Timing notch on crankshaft pulley must
align with 0 timing mark on timing belt cover.
TOYOTA
1.5L 4-Cylinder 1A-C & 3A-C
Fig. 1: Exploded View of Timing Belt & Components
Courtesy of Toyota Motors Sales, U.S.A., Inc.
500
TOYOTA
1.5L 4-Cylinder 1A-C & 3A-C (Cont.)
Fig. 3: Measuring Tensioner Spring Free Length
Ensure cylinder No. 1 rocker arms are loose and cylinder
No. 4 rocker arms are tight. If conditions are not as de-
scribed, rotate crankshaft one complete revolution.
center bolt. Remove crankshaft pulley.
Remove timing belt covers and gaskets. See Fig. 1. Re-
move timing belt guide. See Fig. 1. If reusing old timing
belt, mark belt with arrow indicating direction of rotation.
Also place mating marks on timing belt and camshaft tim-
ing pulley. Place mating marks on timing belt and crank-
shaft timing pulley.
Loosen idler pulley retaining bolt. Move idler pulley away
from timing belt and tighten retaining bolt. Remove timing
belt.
Courtesy of Toyota Motors Sales, U.S.A., Inc.
Inspection:
tamination. Ensure idler pulley rotates freely. Inspect all
sprockets for damage. Replace damaged components.
Measure free length of tension spring. Free length should be
1.512" (38.40 mm) for models up to 1986, and 1.705 (43.3
mm) for 1987-88 models. See Fig. 3. Replace tension spring
if free length is not as specified.
Measure tension of spring at installed length. Tension should
be 8 lbs. at 1.976 (3.83 kg at 50.2 mm) up to 1986 models.
For 1987-88 models, tension should be 15.4 lbs. at 1.976 (7
kg at 50.2 mm). Replace tension spring if necessary.
Installation:
Ensure crankshaft and camshaft timing pulley timing marks
are correctly aligned. See Fig. 2.
Install idler pulley and tension spring (if removed). Secure
idler pulley as far to the left as possible and retighten bolt.
Install timing belt on engine. If reusing old belt, align mat-
ing marks made on disassembly. Ensure belt is installed
in original direction of rotation. See Fig. 5.
Loosen idler pulley retaining bolt, allowing tension spring
to move pulley against timing belt. Use crankshaft retain-
ing bolt to rotate crankshaft clockwise 2 full rotations from
TDC to TDC. Ensure camshaft and crankshaft timing marks
are still aligned. If they are not aligned, remove and rein-
stall timing belt.
Tighten idler pulley mounting bolt. Measure timing belt ten-
sion by applying 4.4 lbs. (2 kg) pressure to belt. See Fig. 4.
Timing belt deflection should be .236-.276 (6-7 mm). If not,
readjust timing belt tension.
Install timing belt guide on crankshaft. Install timing belt
covers. Install crankshaft pulley. Install and tighten crank-
shaft pulley center bolt to specification. See TORQUE
SPECIFICATIONS.
Install water pump pulley. Install A/C idler pulley (if equipped).
Install valve cover and air cleaner assembly. Install radia-
tor. Fill and bleed cooling system.
Idler Pulley Retaining Bolt ......................................... 27 (37 )
Fig. 5: Installing Used Timing Belt
501
TOYOTA
*1.5L 4-Cylinder 3E
Belt
Application Time
1
Kit No. No.
1.5L 4-Cyl. 3E
Tercel Sedan
1987............... 2.3 Hrs. ............................. 250136
Tercel
1988-94.......... 2.3 Hrs. ...... 2522330........ 250233
1
kits.
60,000 miles under severe service operating conditions.
TIMING BELT
CAUTION: On models equipped with air bag, DO NOT start work
until after 90 seconds from time ignition switch is turned to LOCK
position and negative battery cable is disconnected.
Removal:
hicle. Remove right side engine under cover (splash) shield.
Lower vehicle. Remove accessory drive belts.
Disconnect accelerator cable. On A/T models, disconnect
throttle cable. On all models, disconnect PCV hoses. On
1987-91 models, remove air cleaner assembly.
On all models, remove bolt, ground strap and vacuum trans-
mitting valves with bracket on right engine mount. This is
mount on timing belt end of engine.
Using floor jack, support weight of engine from below. Re-
move right engine mount from timing belt end of engine.
Remove valve cover. Remove spark plugs.
Set No. 1 cylinder at TDC on compression stroke. Turn
crankshaft pulley and align groove on crankshaft with 0
mark on timing belt cover. Ensure rocker arms on No. 1
cylinder are loose. If not, turn crankshaft pulley one com-
plete revolution.
Fig. 1: Exploded View Of Timing Belt & Components (1991-94 Shown; 1987-90 Use One-Piece Crankshaft Pulley)
Courtesy of Toytota Motor Sales, U.S.A., Inc.
502
TOYOTA
*1.5L 4-Cylinder 3E (Cont.)
Fig. 2: Routing Timing Belt
On 1991-94 models with A/C and/or power steering, re-
move accessory drive pulley from crankshaft pulley. See
Fig. 1.
Using Holder (09213-14010) or equivalent, hold crankshaft
pulley. Loosen crankshaft pulley center bolt. Remove holder.
Remove crankshaft pulley bolt. Use gear puller, remove
crankshaft pulley.
Remove timing belt cover. Noting installed position for re-
assembly reference, remove timing belt guide. See Fig. 1.
If reusing old timing belt, place arrow on belt to indicate
direction of rotation. Place mating marks on belt and crank-
shaft sprocket, and on camshaft sprocket.
Remove timing belt tension spring. See Fig. 1. Loosen No.
1 idler pulley bolt and push pulley to left as far as it will go.
See Fig. 1. Tighten bolt. Remove timing belt.
Inspection:
tamination. Ensure No. 1 and No. 2 idler pulleys rotate
freely. Inspect all sprockets for damage. Replace damaged
components.
Measure free length of tension spring. See Fig. 4. Tension
spring free length should be 1.528 (38.8 mm) on 1987-89
engines. On 1990-94 engines, free length should be 1.512
(38.4 mm). Replace tension spring if free length is not as
specified.
Measure tension spring at specified installed length. For
1987-89 engines, spring tension should be 18.3 lbs. at
2.157 (8.3 kg at 54.8 mm). For 1990-94 engines, spring
tension should be 11.3 lbs. at 2.028 (5.11 kg at 51.5 mm).
Replace spring if tension is not as specified.
NOTE: Before installing timing belt, remove any oil or water
from camshaft sprocket, crankshaft sprocket and idler pulleys.
Installation:
If camshaft sprocket was removed, align knock pin with No.
1 camshaft bearing cap mark. See Fig. 5. Install camshaft
sprocket with 3E mark facing up. See Fig. 3. Tighten cam-
shaft sprocket bolt to specification. See TORQUE SPECIFI-
CATIONS.
Align crankshaft sprocket timing mark with mark on oil pump
housing. See Fig. 3. If removed, install No. 1 idler pulley.
Move No. 1 idler pulley as far left as it will go, and tempo-
rarily tighten bolt.
Install No. 2 idler pulley (if removed). Install timing belt on
engine. If reusing old belt, ensure all mating marks are
aligned and belt is installed in original direction of rotation.
Loosen No. 1 idler pulley bolt and install pulley tension
spring. Temporarily install crankshaft pulley bolt. Turn crank-
shaft CLOCKWISE 2 revolutions from TDC to TDC. Realign
camshaft and crankshaft sprocket timing marks. If timing
marks do not align, remove and reinstall timing belt.
If timing marks do align, tighten No. 1 idler pulley bolt to
specification. See TORQUE SPECIFICATIONS. Install tim-
ing belt guide. Install timing belt covers.
Fig. 4: Measuring Tension Spring Free Length
503
TOYOTA
*1.5L 4-Cylinder 3E (Cont.)
Fig. 5: Aligning Camshaft Knock Pin With Bearing Cap
Install crankshaft pulley. Holding crankshaft pulley station-
ary, tighten crankshaft pulley bolt to specification. On 1991-
94 models, install accessory drive pulley.
On all models, install spark plugs. Install valve cover. In-
stall right engine mount to engine and body. Install vacuum
switching valves and engine ground strap to engine mount
(if equipped).
Connect negative battery cable. To complete installation,
Accessory Drive Belt Pulley Bolt ................................. 14 (19)
A/C Compressor Bolt ................................................. 18 (24)
A/C Compressor Mounting Bracket Bolt ..................... 20 (27)
Alternator Bracket Bolt .................................................. 13 (18)
Engine Mount
Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64)
Through-Bolt
1987-90...................................................................... 47 (64)
1991-94...................................................................... 54 (73)
Idler Pulley Bracket Bolt
12 mm ...................................................................... 20 (27)
14 mm ...................................................................... 27 (37)
No. 1 Idler Pulley Bolt .................................................. 13 (18)
Power Steering Bracket Bolt ....................................... 32 (43)
Spark Plugs .................................................................... 13 (18)
Timing Belt Idler Mount Bolt ........................................ 27 (37)
INCH Lbs. (N.m)
Valve Cover Nut ......................................................... 61 (6.5)
504
TOYOTA
1.5L 4-Cylinder 5E-FE
1.5L 4-Cyl.
Paseo
1992-95................. 2.5 Hours .................. 250208
1996-99................. 3.5 Hours .................. 250208
Tercel
1995-99................. 2.8 Hours .................. 250208
1
With Air Cond. & Pwr. Strng. add .4 hours.
belt be replaced every 60,000 miles under severe service op-
erating conditions.
be replaced every 90,000 miles for severe service operating
conditions. For 1999 model year, the manufacturer recom-
mends the belt be replaced every 90,000 miles or 72 months.
TIMING BELT
Removal:
hicle. Remove right engine undercover. Remove accessory
drive belts. Remove charcoal canister for access to timing
belt covers.
Slightly raise engine to remove weight from right (timing
belt side) engine mount. Remove the through-bolt and right
engine mount insulator. Remove No. 2 timing belt cover
and gasket. See Fig. 1.
Rotate crankshaft clockwise (viewed from timing belt end
of engine) so cylinder No. 1 is at TDC on compression
stroke. Cylinder No. 1 is front cylinder at timing belt end of
engine. Ensure timing mark on crankshaft pulley aligns
with 0 mark on timing belt cover. Remove No. 2 timing belt
cover.
With cylinder No. 1 at TDC on compression stroke, ensure
hole (5E timing mark) on camshaft sprocket aligns with
timing mark on camshaft bearing cap. See Fig. 3. If timing
mark is not aligned, rotate crankshaft clockwise one revo-
lution (360 degrees).
Remove bolt and accessory drive belt pulley from front of
crankshaft pulley. Using Pulley Holder (SST 09213-14010)
or equivalent, and Handle (SST 09330-00021) or equiva-
lent, hold crankshaft pulley, and remove crankshaft pulley
bolt. Using puller, remove crankshaft pulley.
Remove No. 3 and No. 1 timing belt cover and gasket. See
Fig. 1. Note direction of timing belt guide installation for
installation reference. See Fig. 3. Remove timing belt guide.
CAUTION: If reusing timing belt, mark direction of timing belt
rotation and place reference mark on timing belt at all sprockets
Remove tension spring from No. 1 idler pulley. See Fig. 1.
Loosen No. 1 idler pulley bolt. Move No. 1 idler away from
timing belt as far as possible and tighten bolt. Remove
timing belt, idler pulley bolt and No. 2 idler pulley (if neces-
sary).
If removing crankshaft sprocket, use soft-faced hammer to
lightly tap sprocket from crankshaft. DO NOT pry on outer
edges of sprocket. Also, note position of outer timing belt
guide on crankshaft sprocket. Concave surface should face
away from engine.
Inspection:
tamination. Ensure idler pulleys rotate freely. Inspect all
Measure free length of tension spring. Replace tension
spring if free length is not 1.512" (38.40 mm).
Measure tension required to extend tension spring to 1.866"
(47.40 mm). Replace tension spring if tension is not 7.3
lbs. (3.3 kg).
Installation:
If removed, install crankshaft sprocket with flange toward
engine. Install tension spring and No. 1 idler pulley with
bolt loosely installed. DO NOT tighten bolt at this time. Move
No. 1 idler pulley away from timing belt area as far as pos-
sible. Temporarily tighten No. 1 idler pulley bolt. Ensure all
sprockets and idler pulleys are clean. Temporarily install
crankshaft pulley bolt, and rotate crankshaft so timing mark
body. See Fig. 3 or Fig. 4.
belt align with those placed on all sprockets and timing belt
is installed in original direction of rotation.
Remove crankshaft pulley bolt. Install timing belt on crank-
shaft sprocket, oil pump drive sprocket, No. 1 idler pulley
and then No. 2 idler pulley in sequence. Ensure belt is
tensioned between crankshaft sprocket and camshaft
sprocket.
Loosen No. 1 idler pulley bolt, allowing tension spring to
move pulley against timing belt. Rotate crankshaft clock-
wise 2 full turns from TDC to TDC. Ensure camshaft timing
marks are still aligned. If all timing marks are aligned, tighten
No. 1 idler pulley bolt to specification. See TORQUE SPECI-
FICATIONS.
505
shaft sprocket and flat side toward timing belt. Install No. 1
and No. 3 timing belt covers and gasket. Align crankshaft
pulley key groove with key in crankshaft. Install crankshaft
pulley. Install and tighten crankshaft pulley bolt to specifi-
cation.
Install accessory drive belt pulley on front of crankshaft and
TIONS. Install gasket and No. 2 timing belt cover.
dure. If valve cover was removed, apply sealant at ends of
camshafts. See Fig. 2. To ensure proper mount alignment,
install all right (timing belt side) engine mount bolts/nuts
before tightening to specification. See TORQUE SPECIFI-
CATIONS. Adjust drive belts to proper tension. See page A-
Accessory Drive Belt Pulley Bolts ............................... 14 (19)
A/C Compressor Mounting Bracket Bolt ..................... 20 (27)
A/C Idler Pulley Bolt
12 mm Bolt ............................................................... 20 (27)
14 mm Bolt ............................................................... 27 (37)
Engine Mount
Right (Timing Belt Side)
Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64)
Through-Bolt ............................................................. 54 (73)
Idler Pulley Bolt
No. 1 Idler Pulley ....................................................... 13 (18)
No. 2 Idler Pulley ....................................................... 20 (27)
Oil Pump Drive Sprocket Nut ...................................... 27 (37)
Power Steering Pump
Adjusting Bracket Bolt .............................................. 15 (20)
Lower Bolt ................................................................ 29 (39)
Upper Bolt ................................................................ 32 (43)
Spark Plugs ................................................................ 13 (18)
INCH Lbs. (N.m)
Valve Cover Nut ......................................................... 61 (6.9)
TOYOTA
1.5L 4-Cylinder 5E-FE (Cont.)
Fig. 2: Cylinder Head Sealant Application Areas
506
TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE
1.6L 4-Cyl. DOHC
Corolla FX-16, GTS & Sport (4A-GE)
1985-88.........................
1
......................... 250112
Corolla GTS (4A-GE, 4A-GELC)
1989-91................... 1.6 Hrs. .................... 250176
MR2
1985-88..................
2
2.7 Hrs. ................... 250112
1989.......................
2
2.7 Hrs. ................... 250176
1
- 2.6 hours with FWD.
1.6 hours with RWD.
2
For 1985 model year, although the manufacturer does not
recommend a specific scheduled maintenance interval, belt
intervals. For 1986-91 model years, the manufacturer recom-
mends the belt be replaced at 60,000 mile intervals for severe
service operating conditions.
TIMING BELT
Removal (1985-87 RWD Corolla):
Remove air cleaner intake duct above radiator. If equipped
with power steering, remove power steering belt. Remove
the power steering pump with hoses attached and set
aside.
Loosen water pump pulley bolts. Remove cooling fan belt.
Remove cooling fan assembly. Remove spark plugs.
pression stroke. Crankshaft pulley notch must align with
0 timing mark on lower timing belt cover. With valve cover
oil filler cap removed, cavity in camshaft should be visible.
If not, turn crankshaft one complete revolution.
Remove crankshaft pulley using gear puller. Remove tim-
ing bel covers and gaskets. Noting installed position for
reassembly reference, remove timing belt guide from crank-
shaft.
If reusing timing belt, place mating marks on timing belt
and camshaft sprockets, and timing belt and crankshaft
sprocket. Also place arrow on belt indicating original direc-
tion of rotation.
Loosen idler pulley (tensioner) bolt. See Fig. 1. Move
tensioner pulley as far left as possible and temporarily
tighten bolt. Remove timing belt.
Inspection (1985-87 RWD Corolla):
Check timing belt teeth for cracks or damage. If tooth dam-
age is found, ensure camshaft and crankshaft sprockets
are okay. If wear or cracks on flat side of belt face are found,
check for nicks on idler pulleys. If wear or damage to only
one side of belt is found, check belt guide and alignment of
each pulley and sprocket.
If noticeable wear is found on belt teeth, check timing cover
gasket for damage or improper installation. Ensure sprocket
teeth are free of foreign material.
Check free length of idler pulley tension spring. See Fig. 2.
Replace spring if free length is not 1.713" (43.5 mm). In-
spect spring tension at installed length. Installed tension
is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if
not to specification.
Installation (1985-87 RWD Corolla):
If removed, install timing belt idler pulley (tensioner) and
spring. Secure pulley as far to the left as possible and
temporarily tighten bolt.
Install timing belt. If reusing old belt, ensure mating marks
made on disassembly match crankshaft and camshaft
marks. Ensure arrow points in direction of rotation.
Loosen tensioner pulley bolt allowing tensioner to apply
tension to belt. Temporarily install crankshaft pulley. Turn
crankshaft CLOCKWISE 2 revolutions. Align camshaft and
crankshaft timing marks. See Fig. 1. If timing marks align,
tighten tensioner pulley bolt to specification. See TORQUE
SPECIFICATIONS. Remove crankshaft pulley.
Measure timing belt deflection midway between camshaft
sprockets. See Fig. 3. If deflection is not correct, readjust
covers. Install crankshaft pulley. Install and tighten center
Install water pump pulley and fan assembly. Install gen-
erator drive belt. Install power steering pump pulley and
drive belt. Adjust drive belt to proper tension. See page A-
Removal (1985-88 FWD Corolla):
move engine under cover. Drain engine coolant.
If equipped with cruise control, disconnect accelerator cable
and cruise control cable from actuator. Disconnect cruise
507
control electrical connector. Remove cruise control actua-
tor. Remove windshield washer tank and set aside.
On FX-16 models, remove ignition coil with wires attached
and secure out of way. On all models, remove the upper
radiator hose.
Loosen water pump pulley bolts. Remove all accessory
drive belts. Rotate crankshaft so that No. 1 cylinder is at
TDC of compression stroke. Notch on crankshaft pulley
must align with 0 timing mark on timing belt cover. Re-
move oil filler cap from valve cover. Cavity in camshaft should
be visible in hole. If not, turn crankshaft one complete revo-
lution.
shaft.
tion of rotation.
Support weight of engine with floor jack. Remove engine
mount from timing belt end of engine.
Inspection (1985-88 FWD Corolla):
Installation (1985-88 FWD Corolla):
TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE (Cont.)
Fig. 3: Timing Belt Deflection
Install engine mount to timing belt end of engine. Tighten
Install water pump pulley. Install accessory drive belts. Ad-
tension ranges. Install right front wheel and engine under
cover.
Install upper radiator hose. Install windshield washer tank.
On FX-16, install ignition coil. On all models, install cruise
control actuator (if equipped). Fill radiator with coolant and
bleed air from system.
Removal (MR2):
move engine under cover.
drive belts. Rotate crankshaft so that No. 1 cylinder is at
TDC of compression stroke. Notch on crankshaft pulley
must align with timing mark on timing belt cover. Remove
oil filler cap from valve cover. Cavity in camshaft should be
visible in hole. If not, turn crankshaft one complete revolu-
tion.
Support weight of engine with floor jack. Remove engine
mount through bolt from timing belt end of engine.
shaft.
tion of rotation.
Inspection (MR2):
Installation (MR2):
508
TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE (Cont.)
Install engine mount to timing belt end of engine. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. In-
stall right front wheel and engine under cover.
tension ranges.
Corolla (FWD) .......................................................... 101 (137)
Corolla (RWD) .......................................................... 105 (142)
Engine Mounts (Corolla FWD)
FX-16
Through Bolt .......................................................... 58 (78)
Except FX-16
Mount-To-Engine Bracket Nut ................................ 34 (52)
Through Bolt .......................................................... 64 (87)
Engine Mount (MR2)
Through Bolt ............................................................. 43 (58)
Power Steering Pump-To-Bracket Bolts ..................... 29 (39)
Power Steering Pump Pulley Bolt
Corolla (RWD) .............................................................. 33 (44)
Spark Plug .................................................................. 13 (18)
Water Pump Bolts ...................................................... 11 (15)
Wheel Lug Nut ............................................................. 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ....................................................... 69 (7.8)
509
TOYOTA
Belt
1.6L 4-Cyl. SOHC
Corolla, FWD
1984-88..........
1
3.1 Hrs. .... 2520700........ 250070
Corolla RWD
1983...............
2
2.5 Hrs. .... 2520700........ 250070
1984-87.......... 1.6 Hrs. ...... 2520700........ 250070
Corolla FX
1987-88.......... 2.7 Hrs. ...... 2520700........ 250070
Corolla SR5
1985-87.......... 1.6 Hrs. ...... 2520700........ 250070
1988 (FWD) ... 3.1 Hrs. ...... 2520700........ 250070
1
- With Air Cond. and Pwr. Strng. add .4 hours.
2
- With Air. Cond. add .2 hours; with Pwr. Strng.
add .1 hours.
kits.
recommends the belt be replaced at 60,000 mile intervals for
TIMING BELT
Removal (RWD Models):
Remove power steering and A/C compressor drive belts (if
equipped). On models with power steering, remove power
steering pump with hoses attached and set aside.
Remove air cleaner assembly. Loosen water pump pulley
bolts. Remove cooling fan drive belt. Remove cooling fan.
Disconnect PCV hose and remove valve cover.
Hold crankshaft stationary and remove crankshaft pulley
center bolt. Remove crankshaft pulley using a gear puller.
Remove timing belt covers and gaskets. Noting installed
position for reassembly reference, remove timing belt guide
from crankshaft.
Rotate crankshaft so that No. 1 cylinder is at TDC on com-
pression stroke. Align crankshaft and camshaft timing
If reusing timing belt, place mating marks on belt and
sprockets for reassembly reference. See Fig. 3. Place ar-
row on belt to indicate original direction of rotation.
Loosen idler pulley bolt. Push idler pulley as far left as
possible and temporarily tighten center bolt. Remove tim-
ing belt.
Inspection (RWD Models):
Fig. 1: Aligning Timing Marks For Timing Belt Installation
Fig. 2: Aligning TDC Marks On Crankshaft Sprocket & Oil
Pump Body
1.705 (43.3 mm). See Fig. 4. Replace tension spring if free
length is not as specified.
be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension
spring if necessary.
Installation (RWD Models):
Align camshaft sprocket timing hole with camshaft bearing
cap mark. See Figs. 1 and 2. Align timing marks on oil
pump body and crankshaft timing sprocket.
510
TOYOTA
Install idler pulley (tensioner) and spring (if removed). Pry
idler pulley toward left and temporarily tighten. Install tim-
ing belt. If installing used belt, ensure mating marks are
aligned to camshaft sprocket and crankshaft sprocket. See
Fig. 3. Ensure arrow on belt points in original direction of
rotation.
Loosen timing belt idler pulley bolt so that pulley applies
tension to belt. Rotate crankshaft 2 revolutions from TDC to
TDC. Recheck alignment of sprockets and timing belt.
Tighten idler pulley (tensioner) bolt to specification. See
Check timing belt deflection. See Fig. 5. If timing belt de-
flection is not correct, readjust timing belt tension.
covers. Install crankshaft pulley and tighten bolt to specifi-
cation. Install valve cover. Install air cleaner assembly.
Tighten bolts and nuts to specification. See TORQUE SPECI-
FICATIONS. Apply sealant to cylinder head when installing
valve cover. Adjust drive belts to proper tension. See page
Removal (FWD Models:
move right undercover from wheelwell. Drain engine cool-
ant. Disconnect upper radiator hose.
drive belts. Remove generator with wires attached and set
aside. Remove A/C compressor from mount with hoses
attached, and set aside. Remove water pump pulley.
Remove upper and center timing belt covers. Turn crank-
shaft until No. 1 cylinder is at TDC of compression stroke.
Crankshaft pulley notch must align with 0 timing mark on
lower timing belt cover. Remove valve cover. Camshaft
sprocket timing mark must align with mark on bearing cap.
See Fig. 1.
Hold crankshaft stationary and remove crankshaft pulley
center bolt. Remove crankshaft pulley using a gear puller.
Remove lower timing belt cover.
Noting installed position for reassembly reference, remove
timing belt guide from crankshaft.
If reusing timing belt, place mating marks on belt and
sprockets for reassembly reference. See Fig. 3. Place ar-
row on belt to indicate original direction of rotation.
Loosen idler pulley bolt. Push idler pulley as far left as
possible and temporarily tighten center bolt.
Support weight of engine from below with a floor jack. Work-
ing from below the vehicle, remove the 4 lower engine
mount bolts from the engine crossmember. Remove en-
gine mount through-bolt from mount at timing belt end of
engine. Raise engine slightly and remove timing belt.
Inspection (FWD Models):
1.705 (43.3 mm). See Fig. 4. Replace tension spring if free
length is not as specified.
be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension
spring if necessary.
Installation (FWD Models):
Insert timing belt between engine mount and body. Lower
engine and install engine mount through-bolt through body
and mount insulator. Tighten bolt to specification. See
Align camshaft sprocket timing hole with camshaft bearing
cap mark. See Figs. 1 and 2. Align timing marks on oil
pump body and crankshaft timing sprocket.
Install idler pulley (tensioner) and spring (if removed). Pry
idler pulley toward left and temporarily tighten. Install tim-
ing belt. If installing used belt, ensure mating marks are
aligned to camshaft sprocket and crankshaft sprocket. See
Fig. 3. Ensure arrow on belt points in original direction of
rotation.
511
Loosen timing belt idler pulley bolt so that pulley applies
tension to belt. Rotate crankshaft 2 revolutions from TDC to
TDC. Recheck alignment of sprockets and timing belt.
Tighten idler pulley (tensioner) bolt to specification. See
Check timing belt deflection. See Fig. 5. If timing belt de-
flection is not correct, readjust timing belt tension.
covers. Install crankshaft pulley and tighten bolt to specifi-
cation.
Install water pump pulley. Install valve cover. Install air
cleaner assembly. Install A/C compressor to engine mount.
Install generator. Install valve cover. Apply sealant to cylin-
der head when installing valve cover.
Install upper radiator hose. Refill cooling system.
TOYOTA
Install right under cover. Install right front wheel. Adjust drive
ranges.
A/C Compressor-To-Block Bolts (4) ........................... 18 (25)
Engine Mount Through-Bolt (FWD Models) 58 (78)
Engine Mount-To-Crossmember Bolt ............................ 29 (39)
Wheel Lug Nut ............................................................. 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ....................................................... 69 (7.8)
512
TOYOTA
1.6L & 1.8L 4-Cylinder DOHC
Belt
Application Time Kit No. No. No.
1.6L 4-Cyl. DOHC
Celica
1990-92.......... 3.1 Hrs. ...... 2520360........ 250036
1993............... 3.1 Hrs. ............................. 250239
Corolla (4A-FE)
1988-92.......... 2.6 Hrs. ...... 2520360........ 250036
1993-97.......... 2.6 Hrs. ...... 2522360........ 250236
1.8L 4-Cyl. DOHC
Celica
1994-97.......... 2.8 Hrs. ............................. 250235
Corolla
1993-97.......... 2.6 Hrs. ............................. 250235
1
- 2.6 hours with FWD.
1.6 hours with RWD.
2
kits.
belt be replaced at 60,000 mile intervals for severe service
operating conditions.
TIMING BELT
Removal (Celica):
engine undercover. Lower vehicle. Remove cruise control
actuator from engine mount at timing belt end of engine (if
equipped).
Support weight of engine with a floor jack. Remove engine
Loosen water pump pulley bolts, then remove all acces-
sory drive belts.
On 1.8L (7AF engine), remove A/C compressor front en-
gine mount with hoses attached. Remove A/C compressor
mount from engine.
On 1.6L and 1.8L engine, remove upper and center timing
belt covers.
pression stroke. Notch in crankshaft pulley must align with
0 timing mark on timing belt cover. Hole in camshaft tim-
ing pulley must align with mark on bearing cap. See Fig. 3.
Remove water pump pulley. Remove crankshaft pulley bolt.
Using gear puller, remove crankshaft pulley. Remove lower
timing belt cover. See Fig. 6. Remove timing belt guide
(large washer) from crankshaft sprocket.
If reusing timing belt, mark direction of rotation on timing
belt. Match mark timing belt with marks on both sprockets
for installation reference. See Fig. 1. Place arrow on belt to
indicate original direction of rotation.
Loosen idler pulley (tensioner) bolt. Push idler pulley as far
to the left as possible, and snug tighten bolt. Remove tim-
ing belt.
Inspection (Celica):
Replace spring if free length is not 1.51" (38.4 mm) for 1.6L
(4AF engine), or 1.252 (31.8 mm) for 1.8L (4AF engine).
Check tension at installed length. Tension should be 8.8
lbs. at 1.976 (4 kg at 50.2 mm) for 1.6L (4AF engine), or
11.7 lbs. at 1.480 (5.3 kg at 37.6 mm) for 1.8L (7AF en-
gine). If tension is not as specified, replace spring.
Installation (Celica):
Ensure No. 1 cylinder is at TDC on compression stroke.
Crankshaft Woodruff key will be at 12 oclock position. On
1.6L engine, timing mark notch on crankshaft sprocket will
align with timing mark on oil pump housing. See Fig. 3.
Crankshaft sprocket on 1.8L engine does not have notch.
On 1.6L and 1.8L, hole in camshaft sprocket must align
with mark on bearing cap.
Ensure idler pulley (tensioner) is pushed as far to the left
as possible and pulley bolt is snug tight. If reusing old
timing belt, install belt and align match marks made during
removal. Install new timing belt.
Loosen idler pulley (tensioner) bolt and allow pulley to move
against belt. Install timing belt guide on crankshaft (dished
side facing away from belt).
Fig. 1: Placing Mating Marks On Timing Belt & Sprockets
513
Fig. 3: Aligning Timing Marks (1.6L; 1.8L Uses Same
Camshaft Sprocket Timing Mark)
Fig. 5: Identifying Cylinder Head Sealant Application Areas
(1993-97 1.6L & 1.8L)
Install lower timing belt cover. Install crankshaft pulley. In-
stall crankshaft pulley center bolt. Rotate crankshaft
CLOCKWISE 2 revolutions from TDC to TDC.
Ensure crankshaft pulley notch aligns with 0 timing mark
on lower timing belt cover. Ensure camshaft sprocket tim-
ing marks align. If timing marks are not aligned, remove
and reinstall timing belt. If timing marks are aligned, final
tighten crankshaft pulley center bolt. See TORQUE SPECI-
FICATIONS.
With idler pulley bolt still loose, measure timing belt deflec-
tion at midway point of belt longest run. See Fig. 4. Deflec-
tion should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at
2.0 kg) applied. See Fig. 4. If deflection is not as specified,
readjust tension on belt by moving idler pulley (tensioner).
Tighten idler pulley bolt to specification. See TORQUE
SPECIFICATIONS.
Install upper and center timing belt covers. When installing
valve cover, ensure sealant is apply in correct position. See
Fig. 5.
Install water pump pulley. On 1.8L engine, install A/C com-
pressor mount to engine. Install A/C compressor.
On 1.6L and 1.8L engines, install all accessory drive belts.
Adjust belts to proper tension. See page A-60 for belt ten-
sion ranges. Final tighten water pump pulley bolts.
Install engine mount to timing belt end of engine. Install
front wheel and engine under cover. Install cruise control
actuator (if equipped).
Removal (1988-92 Corolla):
engine undercover. Remove washer tank. Loosen water
pump pulley bolts, then remove all accessory drive belts.
Remove valve cover.
Disconnect engine wiring harness from upper timing belt
cover. Rotate crankshaft so that No. 1 cylinder is at TDC of
compression stroke. Notch in crankshaft pulley must align
with 0 timing mark on timing belt cover.
Remove water pump pulley. Remove crankshaft pulley bolt.
Using gear puller, remove crankshaft pulley. Remove tim-
ing belt covers. Remove timing belt guide (large washer)
from crankshaft sprocket.
TOYOTA
1.6L & 1.8L 4-Cylinder DOHC (Cont.)
Fig. 4: Timing Belt Deflection
Measure Deflection
Here
514
TOYOTA
ing belt.
Inspection (1988-92 Corolla):
Replace spring if free length is not 1.51" (38.4 mm). Check
tension at installed length. Tension should be 8.8 lbs. at
1.976 (4 kg at 50.2 mm).
Installation (1988-92 Corolla):
Crankshaft key will be at 12 oclock position, and timing
mark notch on crankshaft sprocket will align with timing
mark on oil pump housing. See Fig. 3. Hole in camshaft
sprocket must align with mark on bearing cap.
against belt. Rotate crankshaft CLOCKWISE 2 revolutions
from TDC to TDC.
Recheck timing mark alignment. If timing marks are not
aligned, remove and reinstall timing belt.
SPECIFICATIONS. Install timing belt guide to crankshaft
sprocket.
center bolt to specification. See TORQUE SPECIFICA-
TIONS. When installing valve cover, ensure sealant is ap-
ply in correct position. See Fig. 5.
tension ranges. Final tighten water pump pulley bolts.
Install front wheel and engine under cover.
Removal (1993-97 Corolla):
engine undercover. Lower vehicle.
Remove windshield washer tank. Remove cruise control
actuator from right side of engine compartment. Loosen
water pump pulley bolts, then remove all accessory drive
belts. Remove water pump pulley. Remove valve cover.
On models with A/C, remove A/C compressor from mount
bracket with hoses attached, and set aside. Remove A/C
compressor mount bracket from engine.
Disconnect engine wiring harness from upper timing belt
cover. Rotate crankshaft so that No. 1 cylinder is at TDC of
compression stroke. Notch in crankshaft pulley must align
with 0 timing mark on timing belt cover.
Remove upper timing belt cover. With No. 1 cylinder at TDC,
hole in camshaft sprocket must align with mark on bearing
cap. See Fig. 3.
Remove crankshaft pulley bolt. Using gear puller, remove
crankshaft pulley. Remove center and lower timing belt cov-
ers. Remove timing belt guide (large washer) from crank-
shaft sprocket.
ing belt.
Inspection (1993-97 Corolla):
See TENSION SPRING FREE LENGTH (1993-97 CO-
ROLLA). Replace spring if free length is not to specifica-
tion.
Check tension at installed length. See TENSION SPRING
INSTALLED TENSION (1993-97 COROLLA). Replace
spring if tension is not to specification.
TENSION SPRING FREE LENGTH (1993-97 COROLLA)
Free Length
Application In (mm)
1993-94 1.6L (4AF) ................................................ 1.453 (36.9)
1995-97 1.6L (4AF) ................................................ 1.717 (43.6)
1993-97 1.8L (7AF) ................................................ 1.252 (31.8)
TENSION SPRING INSTALLED TENSION (1993-97
COROLLA)
Tension At Installed Length
Application Lbs. At In. (Kg At mm)
1993-94 1.6L (4AF) .............................. 13 at 1.988 (5.9 at 50.5)
1993-94 1.8L (7AF) ......................... 26.5 at 1.988 (12.4 at 50.5)
1995-97 1.6L (4AF) ............................. 8.6 at 1.717 (3.9 at 43.6)
1995-97 1.8L (7AF) ........................... 11.7 at 1.480 (5.3 at 37.6)
Installation (1993-97 Corolla):
Crankshaft woodruff key will be at 12 oclock position. On
1.6L engine, timing mark notch on crankshaft sprocket will
align with timing mark on oil pump housing. See Fig. 3.
Crankshaft sprocket on 1.8L engine does not have notch.
On 1.6L and 1.8L, hole in camshaft sprocket must align
with mark on bearing cap.
against belt. Install timing belt guide on crankshaft (dished
side facing away from belt).
515
TOYOTA
Install lower timing belt cover. Install crankshaft pulley. In-
stall crankshaft pulley center bolt. Rotate crankshaft
CLOCKWISE 2 revolutions from TDC to TDC.
Ensure crankshaft pulley notch aligns with 0 timing mark
on lower timing belt cover. Ensure camshaft sprocket tim-
ing marks align. If timing marks are not aligned, remove
and reinstall timing belt. If timing marks are aligned, final
tighten crankshaft pulley center bolt. See TORQUE SPECI-
FICATIONS.
SPECIFICATIONS.
Install upper and center timing belt covers. When installing
valve cover, ensure sealant is apply in correct position. See
Fig. 5.
Install water pump pulley. Install A/C compressor mount to
engine. Install A/C compressor.
Install all accessory drive belts. Adjust belts to proper ten-
sion. See page A-60 for belt tension ranges. Final tighten
water pump pulley bolts.
Install engine mount to timing belt end of engine. On 1995-
97 models, ensure engine ground strap is connected to
ground wire on passenger side shock tower. Install front
wheel and engine under cover. Install cruise control actua-
tor (if equipped).
A/C Compressor Mount Bracket-To-Engine
Celica (1.8L) ................................................................. 35 (47)
A/C Compressor-To-Mount Bolts
Celica (1.8L) ............................................................. 18 (25)
Crankshaft Pulley Bolt .................................................. 87 (118)
Engine Mounts
Celica (1993)
Mount Bolt .............................................................. 47 (64)
Mount Nut .............................................................. 38 (52)
Celica (1994-97) & Corolla (1988-92)
Mount-To-Engine Bracket Bolt ............................... 47 (64)
Through-Bolt .......................................................... 64 (87)
Corolla (1993-97)
Mount-To-Body Bolt ................................................ 19 (25)
Mount-To-Engine Bracket Bolt ............................... 47 (64)
Power Steering Pump-To-Bracket Bolts ..................... 29 (39)
Spark Plug .................................................................. 13 (18)
Wheel Lug Nut ............................................................. 76 (103)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ............................................... 65 (7.4)
Valve Cover Cap Nuts
1988-92 1.6L ............................................................... 69 (7.8)
1993-97 1.6L & 1.8L ................................................... 52 (5.9)
Water Pump Pulley Bolt ................................................. 82 (9.3)
516
TOYOTA
1.8L 4-Cylinder Diesel
1.8L 4-Cyl. Diesel
Camry
1984-85................ 5.0 Hours ................. 250098
Corolla
1984-85................ 2.7 Hours ................. 250098
60,000 miles.
TIMING BELT
Removal (1984):
Disconnect negative battery cable. Remove air cleaner.
Drain engine coolant and remove radiator hoses, cooling
fan shroud and radiator from vehicle. Remove drive belts,
cooling fan and pulley.
If equipped with A/C, remove compressor pulley from crank-
shaft pulley. Using Pulley Holder and Socket (09213-14010
& 09330-00020) or equivalent, remove crankshaft pulley
set bolt and washer.
Using a puller, remove crankshaft pulley. If equipped with A/
C, remove idler pulley. Remove timing belt cover mount
bolts. Remove timing belt cover and belt guide.
Disconnect glow plugs by removing 4 screw grommets
and glow plug connecting nuts. Disconnect current sensor
by removing nut, plate washer, insulator and current con-
nector. Remove glow plug connector and glow plugs.
Using crankshaft set bolt, rotate engine and align TDC mark
on camshaft timing pulley with top surface of cylinder head
on intake manifold side. Using pliers, remove tensioner
spring. Loosen tensioner set bolts and remove timing belt.
Removal (1985):
Disconnect negative battery cable. Remove air cleaner.
Drain engine coolant and remove radiator hoses, washer,
and radiator reservoir tanks. Remove drive belts, cooling
fan and pulley.
Remove cruise control actuator (if equipped). Disconnect
the accelerator and cruise control cables. Disconnect the
actuator vacuum hose. Remove the actuator cover, and the
actuator. Disconnect the wiring connector.
Remove power steering pump with bracket (if equipped).
Remove drive belt and pulley. Remove 3 mounting bolts
and PS pump with bracket. Place pump aside and sus-
pend it. Remove alternator with bracket.
Remove No. 2 timing belt cover. Set No. 1 cylinder to TDC
on compression stroke. Align mark of camshaft pulley with
top end of cylinder head. Using Special Service Socket
(09213-14010 and 09330-00020) or equivalent, remove
crankshaft pulley.
Remove No. 1 timing belt cover and belt guide. Jack up
engine slightly. Remove RH engine mounting insulator and
bracket. Using a screwdriver, remove tension spring.
Loosen the No. 1 idler pulley mount bolt. Remove timing
belt. If reusing timing belt, scribe a mark on belt, indicating
direction of engine rotation. Place match marks on pulleys
and timing belt at each position.
Check timing belt for wear, cracks or missing teeth. If de-
fective, check if injection pump camshaft is locked or there
are nicks on belt side of idler pulley lock. Replace belt and
components as needed.
Inspect belt for excessive wear on one side only. If dam-
aged, check the belt guide and the alignment of each
sprocket. Before installing new belt, remove idler pulleys
and spring. Check idler pulley bearings for noise or rough-
ness.
Inspect spring for proper free length and tension. Standard
free length is 2.045" (51.93 mm). Replace idler pulley and/
or spring as necessary.
Check camshaft, injection pump and crankshaft timing
sprockets for wear or damage. If belt teeth are worn, check
timing belt cover gasket for damage and proper installa-
tion. Replace components as necessary.
Install timing belt tensioner, with larger bolt behind water
pump, and loosely fasten mounting bolts. Swing tensioner
toward the left. Check alignment of timing marks on each
pulley. See Fig. 2
NOTE: When tightening idler pulley and timing sprocket mount
bolts, do not move idler pulley bracket or apply tension to timing
belt.
Install timing belt onto camshaft timing pulley. Ensure tim-
ing belt is securely meshed and not loose. Align marks of
injector pump drive pulley and install timing belt onto pul-
ley. Install timing belt over lower idler pulley and under crank-
shaft timing belt pulley. Ensure timing belt is not twisted or
too tight.
Install tensioner spring and loosen bolts until tensioner
moves by spring tension. Using crankshaft pulley set bolt,
turn crankshaft 2 complete revolutions clockwise from TDC
to TDC. Always turn crankshaft clockwise. Check that each
pulley aligns with marks. If marks DO NOT align, remove
timing belt and repeat procedure in previous step.
Ensure that each pulley aligns with timing mark. See Fig. 2.
After ensuring proper alignment of pulley marks, tighten
tensioner pulley set bolts. Reverse remaining removal pro-
cedures to complete installation. Adjust drive belts to proper
Crankshaft Pulley Washer/Bolt
1984 ..................................................................... 102 (137)
1985 ......................................................................... 72 (98)
Injection Pump Drive Pulley Bolts
1984 ............................................................... 43-47 (58-64)
1985 ............................................................... 10-15 (20-28)
Nozzle Holder Mount Bolt
1984 ............................................................... 20-22 (27-29)
1985 ............................................................... 51-65 (69-88)
Tensioner Pulley Bolts
1984 ......................................................................... 14 (19)
1985 ......................................................................... 27 (37)
INCH Lbs. (N.m)
Glow Plugs ............................................................... 108 (13)
517
TOYOTA
1.8L 4-Cylinder Diesel (Cont.)
Fig. 1: Exploded View Of Timing Belt Cover & Gears
Fig. 2: Aligning Camshaft, Crankshaft & Injection Pump
Sprocket Timing Marks
518
TOYOTA
2.0L 4-Cylinder Except RAV4
Belt
Application Time
1
Kit No. No.
2.0L 4-Cyl.
Camry
1983-86.......... 3.6 Hrs. ...... 2520870........ 250087
1987-91.......... 3.0 Hrs. ...... 2521990........ 250199
Celica
1986
GTS ............. 3.0 Hrs. ............................. 250125
Exc. GTS..... 2.8 Hrs. ...... 2520870........ 250087
1987-88
GTS ............. 3.0 Hrs. ............................. 250125
Exc. GTS..... 2.8 Hrs. ...... 2521990........ 250199
1989............... 3.0 Hrs. ...... 2521990........ 250199
1990-93.......... 4.3 Hrs. ............................. 250125
MR2
1991-95.......... 4.0 Hrs. ............................. 250125
1
kits.
TIMING BELT
Removal (1983-86 Camry):
hicle. Remove right front wheel. Remove fender apron seal.
Remove alternator drive belt. Remove cruise control actua-
tor and bracket. Remove power steering oil reservoir tank
and drive belt.
Raise engine slightly and remove right side engine mount
insulator and bracket. Remove No. 2 timing belt cover and
gasket assembly. Remove spark plugs. Align oil seal re-
tainer mark with center of small hole on camshaft timing
sprocket by turning crankshaft pulley clockwise. See Fig. 1.
This will position No. 1 cylinder at 90 BTDC of compres-
sion stroke.
Loosen No.1 idler pulley retaining bolt and move pulley
toward left as far as possible, then temporarily tighten re-
taining bolt. Remove timing belt from camshaft timing
sprocket
Using Toyota tool (09278-54011) or equivalent, hold timing
sprocket in place, then remove sprocket retaining bolt and
sprocket. Remove No. 1 idler pulley and tension spring.
Using Toyota tools (09213-54010 and 09330-00020) or
equivalents, remove crankshaft pulley retaining bolt, then
pulley.
Remove No. 1 timing belt cover and gasket assembly. Re-
move timing belt and belt guide. Remove No. 2 idler pulley
and crankshaft timing sprocket.
Installation (1983-86 Camry):
Install crankshaft timing sprocket over crankshaft key. See
Fig. 2. Install No. 2 idler pulley. Tighten idler pulley retain-
ing bolt. Temporarily install timing belt onto sprockets. In-
stall timing belt guide. Install No. 1 timing belt cover and
gasket assembly.
Install crankshaft pulley. Pull timing belt upward and align
preset mark on No. 1 timing belt cover with crankshaft pul-
ley groove. See Fig. 4. Align camshaft oil seal retainer pre-
set mark with center of small hole on camshaft timing pul-
ley. Install timing belt. Loosen No. 1 idler pulley retaining
bolt 1/2 turn and release spring tension on timing belt. To
ranges.
Removal (Celica w/3S-GE Engine):
hicle. Remove right front wheel and engine undercover.
Remove radiator reservoir tank. Remove cruise control ac-
tuator and bracket.
Remove the power steering oil reservoir bolts and position
reservoir aside. Remove accessory drive belts. Remove
alternator and bracket. Raise the engine slightly with suit-
able jack with wooden block between jack and engine.
Remove the right engine mount through bolt, then mount.
Remove the valve cover. Remove spark plugs. Remove No. 2
timing belt cover with gasket. Set the cylinder No. 1 to TDC by
rotating crankshaft pulley until groove is aligned with 0 tim-
ing mark. See Fig. 8. Ensure alignment marks of camshaft
pulleys and No. 3 timing belt cover are aligned. See Fig. 9.
Loosen the spring loaded idler pulley attaching bolt. Pry
pulley as far left as possible and temporarily tighten bolt.
Remove the timing belt from the camshaft timing pulleys.
Hold the camshaft flats with a suitable wrench and remove
the camshaft sprocket attaching bolts, sprockets and pins.
Mark the intake and exhaust camshaft sprockets for instal-
lation reference before removing.
Remove the crankshaft pulley attaching bolt, then using
suitable puller, remove the crankshaft pulley. Remove No.
1 timing cover, then the timing belt guide from crankshaft
sprocket. Remove the timing belt, spring loaded idler pul-
ley, tension spring and fixed idler pulley from engine.
Installation (Celica w/ 3S-GE Engine):
Install fixed idler pulley. Pry the idler pulley as far to the left
as possible, then temporarily tighten attaching bolt. Tem-
porarily install the timing belt on crankshaft sprocket, oil
pump sprocket, fixed idler pulley and water pump pulleys.
Install the timing belt guide on crankshaft sprocket and
timing cover No. 1. Install the crankshaft pulley. Ensure
crankshaft pulley groove is still aligned with 0 timing mark.
This indicates No.1 cylinder is at TDC of compression
stroke. See Fig. 8.
519
On models equipped with 2-hole camshaft flanges, use
suitable wrench to align camshaft knock pins and cam
lobes as shown. See Fig. 10. On models equipped with 5-
hole camshaft flanges, use suitable wrench to align cam-
shaft alignment marks as shown. See Fig. 11.
Hang the timing belt on camshaft sprocket pulleys with
sprocket S markings facing outward. Align the camshaft
sprocket alignment marks with No. 3 timing cover match
mark and install sprockets. See Fig. 9. On models equipped
with 2-hole camshaft flange, ensure camshaft knock pin is
aligned with sprocket hole.
On models equipped with 5-hole camshaft flange, insert
knock pin into any holes in alignment. On 5-hole flange
type cams, if knock pin alignment is not exact, camshafts
can be rotated slightly to compensate. While holding the
camshafts with suitable wrench, install and tighten cam-
shaft sprocket attaching bolts.
Loosen the spring loaded idler pulley attaching bolt just
enough to allow pulley to move by itself under spring ten-
sion. Allow the pulley to take up belt tension. Rotate the
crankshaft clockwise 2 complete revolutions. Tighten pul-
ley bolt. Ensure that the timing belt has tension between
crankshaft sprocket and intake camshaft sprocket. See Fig.
12. To complete installation, reverse removal procedure.
tension ranges.
Removal (1987-91 Camry & 1988-89 Celica w/3S-FE En-
gine):
Disconnect negative battery cable. Raise and support
vehicle. Remove right front wheel. Remove undercover.
Remove cruise control actuator and bracket (if equipped).
Remove accessory drive belts. Remove alternator and
bracket.
Use a jack to raise engine slightly. Remove right side en-
gine mount through-bolt, and mount.
NOTE: Position a wooden block between jack and engine to
prevent damage.
Remove spark plugs. Remove upper timing belt cover and
gasket. Rotate crankshaft pulley until pulley groove is
aligned with 0 indication on timing marks, then ensure
camshaft sprocket hole is aligned bearing cap No. 1 align-
ment mark. See Fig. 14.
Loosen spring loaded idler pulley attaching bolt, then pry
pulley as far to left as possible. Temporarily tighten attach-
ing bolt. Remove timing belt from camshaft sprocket.
Remove crankshaft pulley attaching bolt, then using suit-
able puller, remove crankshaft pulley. Remove lower timing
belt cover and gasket. Remove belt and belt guide.
Installation (1987-91 Camry & 1988-89 Celica w/ 3S-FE
Engine):
Temporarily install timing belt on crankshaft sprocket, oil
pump sprocket, fi xed i dl er pul l ey and water pump
sprocket. Install camshaft sprocket, washer and attach-
ing bolts. Rotate camshaft by turning sprocket attaching
bolt to align bearing cap mark and camshaft sprocket.
See Fig. 14.
Install timing belt on camshaft sprocket. Ensure that belt
has tension between crankshaft sprocket, water pump
sprocket and camshaft sprocket. Loosen spring loaded
idler pulley attaching bolt just enough to allow pulley to
move under spring tension. Allow pulley to take up belt
tension.
Rotate crankshaft clockwise two complete revolutions, from
TDC compression stroke to TDC compression stroke, then
tighten spring loaded idler pulley. Ensure that timing belt
has tension between water pump sprocket and camshaft
sprocket. Install upper timing belt cover. To complete in-
Removal (1990-93 Celica & 1991-95 MR2 With 3S-GTE En-
gine):
Raise and support vehicle, then remove right front wheel
(Celica) or right rear wheel (MR2). Remove right engine
undercover. Remove radiator reservoir tank. Remove charge
air cooler. Remove strut tower-to-firewall braces.
NOTE: Air bag system must be disarmed before working on vehicle.
Turn ignition to LOCK. Disconnect negative battery cable. Wait
at least 20 seconds before working on vehicle.
Loosen power steering oil reservoir tank. Remove acces-
sory drive belts. Remove alternator and alternator brack-
ets. Use a suitable jack to raise engine slightly and remove
weight from engine mounting on right side. Remove right
engine mount insulator and bracket.
Remove control cables, electrical connectors, vacuum
hoses and coolant hoses from throttle body. Remove throttle
body assembly. Remove No. 2 timing belt cover. Remove
spark plugs. Place No.1 cylinder at TDC of compression
stroke by turning crankshaft pulley to align groove with No.1
timing belt cover 0 mark.
Ensure alignment marks on camshaft sprockets and No. 3
timing belt cover are aligned as shown in Fig. 15. If not, turn
crankshaft one complete revolution (360) to align marks.
Remove timing belt from camshaft timing sprockets.
Loosen No.1 idler pulley attaching bolt and shift to left as
far as possible. Temporarily tighten pulley attaching bolt,
then relieve tension from timing belt. Remove timing belt
from camshaft sprocket.
Support timing belt so meshing of crankshaft sprocket and
timing belt does not shift. Remove sprockets, No. 1 timing
belt covers, timing belt guide and timing belt. Install crank-
shaft sprocket and No. 2 idler pulley.
Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE
Engine):
Temporarily install No. 1 idler pulley and tension spring.
Install pulley attaching bolt. Do not tighten bolt. Install ten-
sion spring, then pry toward left as far as it will go and
tighten. Temporarily install timing belt onto crankshaft
sprocket, oil pump, No. 2 idler pulley and water pump pul-
ley.
TOYOTA
2.0L 4-Cylinder Except RAV4 (Cont.)
Fig. 1: Aligning Oil Seal Retainer Mark With Camshaft
Sprocket Hole
520
Fig. 2: Installing Crankshaft Sprocket
Fig. 3: Installing No. 2 Idler Pulley
Fig. 4: Aligning Mark On No. 1 Timing Belt Cover With
Groove In Crankshaft Pulley
Fig. 5: Installing Tension Spring & Idler Pulley
Fig. 6: Crankshaft Pulley Angle
Fig. 7: Positioning Sprocket To BTDC Or ATDC
TOYOTA
521
Fig. 8: Positioning Crankshaft pulley At TDC (3S-GE)
Fig. 9: Aligning Camshaft Sprocket Marks With Marks On
No. 3 Timing Belt Cover (3S-GE)
Fig. 10: Aligning Camshaft Sprocket With 2-Hole Camshaft
Flange (3S-GE)
Fig. 11: Aligning Marks On 5-Hole Camshaft Flange With
Marks On Camshaft Bearing Caps
TOYOTA
Install timing belt guide. Install No. 1 timing belt cover and
gasket. Make sure camshaft groove is aligned with drilled
out mark of No.1 camshaft bearing cap.
Place No.1 cylinder at TDC of compression stroke by turn-
ing crankshaft pulley and aligning its groove with 0 mark
on No. 1 timing belt cover. Turn camshaft and align marks
on camshaft sprockets and cylinder head cover.
Install timing belt. Ensure that tension between crankshaft
and intake camshaft timing sprockets exists. To complete
Camshaft Timing Sprocket Bolt ........................ 40-43 (54-59)
Engine Mount
Bolt ........................................................................... 65 (88)
Nut ............................................................................ 38 (52)
Through-Bolt ............................................................. 64 (87)
Idler Pulley Bolt
No. 1 ......................................................................... 31 (42)
No. 2 ......................................................................... 31 (42)
Oil Pump Pulley .......................................................... 31 (42)
Valve Cover Nut .......................................................... 17 (23)
INCH Lbs. (N.m)
Timing Cover Attaching Bolts ........................................ 78 (9)
522
Fig. 13: Installing Cylinder Head Packing (3S-GE)
Fig. 14: Camshaft Sprocket Alignment (3S-FE)
Fig. 15: Aligning Camshaft Sprocket Timing Marks (3S-GTE)
TOYOTA
Fig. 12: Timing Belt Installation (3S-GE)
523
TOYOTA
2.0L 4-Cylinder RAV4
2.0L 4-Cyl.
RAV4
1996-00
With ABS ...........
1
5.3 Hours ................. 250199
Without ABS ......
1
3.3 Hours ................. 250199
1
belt be replaced every 60,000 miles for severe service operat-
ing conditions. For 1998 model year, the manufacturer recom-
mends the belt be replaced every 90,000 miles for severe
service operating conditions. For 1999-00 models years, the
manufacturer recommends the belt be replaced every 90,000
miles or 72 months.
TIMING BELT
Removal:
Disconnect negative battery cable. Disconnect power steer-
ing reservoir and remove reservoir bracket. Disconnect wire
harness bracket for Data Link Connector No. 1. Remove
generator and generator bracket.
Remove ABS actuator. Raise and support vehicle. Remove
right front wheel. Remove right engine undercover. Remove
power steering drive belt. Slightly jack up engine and re-
move right engine mounting insulator.
NOTE: Always turn crankshaft clockwise.
Remove spark plugs, remove crankshaft pulley. Remove
right engine mounting bracket. Remove No. 2 timing belt
cover. See Fig. 2. Temporarily install crankshaft pulley with
pulley bolt. Set No. 1 cylinder to TDC on compression stroke.
See Fig. 3.
Loosen mounting bolt of No. 1 idler pulley and shift pulley
toward left as far as it will go to relieve belt tension. See Fig.
4. Temporarily tighten idler pulley. Remove crankshaft pul-
ley and No. 1 timing belt cover.
If reusing timing belt, mark direction of rotation on belt. Also
place match marks on belt and camshaft pulley. See Fig. 6.
Remove timing belt from engine.
Inspection:
Inspect idler pulleys for smoothness. Ensure free length of
tension spring is 1.653" (42.0 mm). See Fig. 6. Spring ten-
sion should be 8.5 lbs. (3.85 kg) at length of 1.988. If not
as specified, replace spring. Inspect timing belt cover gas-
kets. Replace if gaskets are cracked or peeling.
Installation:
Ensure that No. 1 cylinder is set to TDC on compression
stroke by temporarily installing No. 1 timing belt cover and
crankshaft pulley. Align groove with timing mark 0 on No.
1 timing belt cover. Ensure that camshaft and timing belt
match marks are aligned. Remove crankshaft pulley and
timing belt cover. Install timing belt. If reusing old belt, en-
sure rotation direction and mating marks are in correct po-
sition.
Install timing belt guide on crankshaft with cup side facing
out. Install No. 1 timing belt cover, crankshaft pulley, and
crankshaft pulley bolt. Loosen No. 1 idler pulley 1/2 turn to
tension timing belt. Slowly turn crankshaft pulley 2 revolu-
tions from TDC to TDC.
Check that each pulley aligns with timing marks as shown.
See Fig. 3. Slowly turn crankshaft pulley 1-7/8 revolutions
and align groove with mark at 45 degrees BTDC (for No. 1
cylinder) of No. 1 timing belt cover. See Fig. 5. Tighten No. 1
idler pulley mounting bolt to specification.
Place right engine mounting bracket in position but do not
install bolts. Install No. 2 timing belt cover. Disconnect en-
gine wire protector between cylinder head cover and No. 3
timing belt cover. Install No. 2 timing belt cover. Install en-
gine wire to No. 2 timing belt cover. Install engine wire pro-
tector to mounting bolts of No. 2 timing belt cover.
Remove crankshaft pulley. Install engine mounting bracket-
to-engine bolts and tighten to specification. Install crank-
shaft pulley, and tighten pulley bolt to specification. To com-
ranges.
Camshaft Timing Pulley Bolt ........................................ 40 (54)
Crankshaft Pulley Bolt .................................................. 80 (108)
Generator Bracket Bolts ............................................. 31 (42)
Engine Mount Insulator-To-Body Bolts ........................ 38 (52)
Engine Mount Insulator-To-Bracket Nut ...................... 27 (37)
No. 1 Idler Pulley Mounting Bolt ...................................... 31 (42)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Water Pump Bolts ......................................................... 78 (8.8)
96B14507 Courtesy of Toyota Motor Sales, U.S.A., Inc.
524
TOYOTA
2.0L 4-Cylinder RAV4 (Cont.)
Fig. 2: Removing No. 2 Timing Belt Cover
Fig. 3: Setting No. 1 Cylinder To TDC
Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt
Fig. 5: Locating 45 Degrees BTDC Mark
96H14511 Courtesy of Toyota Motor Sales, U.S.A., Inc.
Fig. 6: Aligning Match Marks Of Timing Belt & Camshaft
Pul l ey
525
TOYOTA
2.2L 4-Cylinder
Belt
2.2L 4-Cyl.
Camry
1992-01..........
1
3.0 hrs. .... 2521990........ 250199
Camry Solara
1999-01..........
1
3.0 hrs. .... 2521990........ 250199
Celica
1990-91..........
1
3.1 hrs. ..... 2521990........ 250199
1992-99..........
1
2.4 hrs. ..... 2521990........ 250199
Celica GT & GTS
1990-91..........
1 2
3.1 hrs. ... 2521990........ 250199
1992-93..........
1 2
3.1 hrs. ... 2521990........ 250199
MR2
1991-95..........
1
3.5 hrs. ..... 2521990........ 250199
1
- With Air Cond. add .2 hours. On MR2 with turbo
and Air Cond., time is 4.5 hours.
2
On all-wheel drive Celica, add 1.2 hours.
kits.
belt be replaced every 60,000 miles under severe service driv-
ing conditions. For 1998-01 model years, the manufacturer
recommends the belt be replaced every 90,000 miles.
TIMING BELT
Removal:
hicle. Remove lower engine cover. On Celica and Camry,
remove right front wheel. On all models, lower vehicle.
On MR2, remove right hood side panel and cruise control
actuator. Remove right rear wheel. On Celica and Camry,
remove alternator from engine and secure out of way. On
Camry, remove coolant reservoir tank if it interferes with
timing belt removal. Remove engine control (torque) rod
from front of engine.
On all models, remove accessory drive belts. Using floor
jack, slightly raise engine to remove weight from right (tim-
ing belt side) engine mount at timing belt cover.
Remove right (timing belt side) engine mount and bracket
from front of engine. Remove spark plugs. Remove No. 2
timing belt cover and gaskets. See Fig. 1.
compression stroke. Cylinder No. 1 is front cylinder at tim-
ing belt end of engine.
Ensure timing mark on crankshaft pulley aligns with 0"
mark on No. 1 timing belt cover. Ensure hole in camshaft
sprocket aligns with alignment mark on camshaft bearing
cap. See Fig. 2. If hole in camshaft sprocket is not aligned
with alignment mark, rotate crankshaft clockwise one full
revolution.
CAUTION: If reusing timing belt, mark direction of timing belt
rotation on belt. Place mating marks on timing belt at camshaft
sprocket and at crankshaft sprocket for reassembly reference.
Also place reference mark on timing belt at upper edge of No.
1 timing belt cover. See Fig. 2.
Loosen No. 1 idler pulley bolt. See Fig. 1. Move No. 1 idler
pulley outward, away from timing belt as far as possible.
Temporarily retighten No. 1 idler pulley bolt. Remove tim-
ing belt from camshaft sprocket.
Using Pulley Holder (SST 09213-54015) or equivalent, hold
crankshaft pulley. Remove crankshaft pulley bolt.
Using gear puller, remove crankshaft pulley. Remove No. 1
timing belt cover and gasket. Note direction of timing belt
guide installation. See Fig. 1. Remove timing belt guide.
Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing
belt from crankshaft sprocket. Remove idler pulleys (if nec-
essary).
526
Inspection:
tamination. Ensure idler pulleys rotate freely. Replace com-
ponents if damaged or worn.
Ensure free length of tension spring is within specification.
See TENSION SPRING SPECIFICATIONS table. Measure
free length between from inside edges of hooked portion of
spring. Do not measure spring coils. See Fig. 3.
Measure tension needed to extend tension spring to speci-
fied installed length. Replace spring if tension is not within
specification.
TENSION SPRING SPECIFICATIONS
Application Specification
Free Length
Except 2000-99 Camry ........................... 1.811" (46.00 mm)
2000-99 Camry ...................................... 1.654" (42.00 mm)
Tension At Spring Installed Length
1
Camry (1992-95)
Green Spring ............................. 7.2-8.3 lbs (3.25-3.75 kg)
Silver Spring .......................... 10.5-11.6 lbs. (4.75-5.25 kg)
Camry (1996-01) .......................... 7.2-8.3 lbs (3.25-3.75 kg)
Camry Solara ............................... 7.2-8.3 lbs (3.25-3.75 kg)
Celica & MR2 ............................... 7.2-8.3 lbs. (3.25-3.75 kg)
1
- At 1.988" (50.50 mm)
Revised Timing Belt Tension Spring:
For 1992-96 Camry models, the timing belt tension spring
was revised. When replacing the timing belt on 1992-96
Camry with 2.2L, tension spring MUST be replaced. The
revised tension spring 0(part no. 905-7-17003) is a 13-coil
design which replaces the original 10-coil design.
This information is from Toyota technical service bulletin
EG001-99; January 29, 1999.
Installation:
Install No. 2 idler pulley (if removed). Install and tighten bolt
to specification. See TORQUE SPECIFICATIONS. Ensure
idler pulley is clean and rotates smoothly.
Install No. 1 idler pulley and tension spring (if removed).
Pry No. 1 idler pulley away from timing belt area as far as
possible. Temporarily tighten No. 1 idler pulley bolt. En-
sure idler pulley is clean and rotates smoothly.
Using crankshaft pulley bolt, rotate crankshaft so timing
mark on crankshaft sprocket aligns with timing mark on oil
pump housing. See Fig. 4. This will position keyway in crank-
shaft sprocket at 12 oclock position.
belt align with reference marks placed on crankshaft and camshaft
sprockets. Ensure timing belt is installed in original direction
of rotation.
Ensure all sprockets and idler pulleys are clean. Install
timing belt on crankshaft sprocket, oil pump sprocket, No.
1 idler pulley and then No. 2 idler pulley in sequence.
shaft sprocket and flat side toward timing belt. Install No. 1
timing belt cover and new gasket.
Align crankshaft pulley key groove with key in crankshaft.
ley bolt to specification.
pulley aligns with 0 mark on No. 1 timing belt cover. If
reusing timing belt, ensure reference mark on timing belt
aligns with upper edge of No. 1 timing belt cover.
Rotate camshaft and align hole in camshaft sprocket with
alignment mark on camshaft bearing cap. See Fig. 2. In-
stall timing belt on camshaft sprocket. If reusing timing
belt, ensure reference mark on timing belt aligns with ref-
erence mark on camshaft sprocket. Ensure tension exists
on timing belt between crankshaft and camshaft sprock-
ets.
CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed
from timing belt end of engine.
Loosen No. 1 idler pulley bolt turn. Rotate crankshaft
pulley 2 full revolutions clockwise from TDC to TDC.
Ensure timing mark on crankshaft pulley aligns with 0"
mark on No. 1 timing belt cover and hole in camshaft
sprocket aligns with alignment mark on camshaft bearing
cap. See Fig. 2. If timing marks are not aligned, remove
timing belt and reinstall.
Rotate crankshaft clockwise 1 and 7/8 revolutions and align
crankshaft pulley 0 mark with 45-degree Before Top Dead
Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5.
Tighten No. 1 idler pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install No. 2 timing belt cover and gas-
kets. Install and tighten spark plugs to specification.
dure. Install all bolts/nuts on right (timing belt side) engine
mount before tightening to specification.
On Camry, when installing control rod and bracket on strut
tower and right (timing belt side engine mount, tighten bolts
to specification in sequence. See Fig. 6. On MR2, tighten
engine mount bolts in correct locations. See Fig. 7. Adjust
ranges.
TOYOTA
527
TOYOTA
Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC
M a r k
Fig. 6: Control Rod & Bracket Bolt Installation Sequence
( Camry)
TORQUE SPECIFICATIONS (CAMRY)
Coolant Outlet Bolt ...................................................... 11 (15)
Engine Mounts & Brackets
Bracket-To-Cylinder Block Bolt ............................... 38 (52)
Oil Pump Sprocket Nut ............................................... 21 (29)
Power Steering Pump-To-Bracket Bolt ....................... 32 (43)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Coolant By-Pass
Pipe-To-Water Pump Nut ........................................ 78 (8.8)
No 3 Timing Belt Cover Bolt ...................................... 69 (7.8)
Oil Pan Bolt/Nut ......................................................... 48 (5.4)
Oil Pump Body Cover Bolt .......................................... 78(8.8)
Oil Pump Pick-Up Tube Bolt/Nut ................................ 48 (5.4)
Oil Pump-To-Cylinder Block Bolt ................................ 82 (9.3)
Water Pump-To-Water Pump Cover Bolt ................... 82 (9.3)
TORQUE SPECIFICATIONS (CELICA)
Bracket-To-Cylinder Block Bolt .................................. 38 (52)
To-Bracket
Bolt ........................................................................ 27 (37)
Nut ......................................................................... 38 (52)
Power Steering Pump-To-Bracket Bolt
Adjusting Bolt ........................................................... 29 (39)
All Others .................................................................. 32 (43)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
528
Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts
( MR2 )
Fig. 8: Water Pump Bolt Removal & Installation Sequence
(Celica & MR2)
TOYOTA
TORQUE SPECIFICATIONS (MR2)
Left (Flywheel Side) Engine Mount
Through-Bolt ............................................................. 58 (79)
Bracket Bolt ..........................................................................
1
Support Bracket Bolt/Nut .......................................... 54 (73)
Bracket-To-Cylinder Block Bolt .................................. 45 (61)
Mounting Bracket Nut ............................................... 38 (52)
Through-Bolt ............................................................. 58 (79)
Idler Pulley Bracket-To-Cylinder Block Bolt
12-mm Head ............................................................ 20 (27)
14-mm Head ............................................................ 27 (37)
Fuel Pulsation Damper .............................................. 25 (34)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Water Pump-To-Cylinder Block Bolt .......................................
2
1
- Tighten bolts to specification. See Fig. 7
2
- Tighten Bolts to 78 (8.8) INCH lbs. in sequence. See
Fig. 7. On models without A/C, tighten large bracket
bolt to 20 ft. Lbs. (27 N.m).
529
TOYOTA
1
Belt Part No.
2.2L 4-Cyl. Diesel
Pickup
1981........................ 2.2 Hours ................ 250079
1982
Up To 5/31 ............ 2.2 Hours ................ 250079
From 6/1 ............... 2.2 Hours ................ 250084
1983........................ 2.2 Hours ................ 250084
1
100,000 miles.
TIMING BELT
NOTE: Late model 1982 engines with extra idler pulley use a different
design timing belt. ALL timing pulleys and camshaft pulleys are
also different from early 1982 engines. Timing pulleys and camshaft
pulleys are not interchangeable between engines.
Removal:
Using starter, turn engine over until No. 1 piston is at TDC
on compression stroke. Disconnect negative battery cable.
Remove fan belts, fan and pulley. Remove damper attach-
ing bolt and using puller, remove damper.
Remove air cleaner assembly. Drain cooling system. Re-
move radiator hoses, shroud and radiator as necessary.
Identify and remove any wiring, hoses and lines interfering
with timing belt cover removal. Remove crankshaft damper
bolt. Do not apply tension to timing belt during damper bolt
removal.
Remove crankshaft damper pulley using pulley removal
tool (SST09213-60016) or equivalent. Detach timing belt
cover mount bolts and remove belt cover and belt guide.
Discard gasket. See Fig. 1. Loosen idler pulley bolt, and
remove timing belt.
CAUTION: Before removing bolts securing crankshaft pulley,
camshaft pulley, and injection pump pulley, release tension on
timing belt. Do not bend or twist belt, and keep belt free from
oil, water or steam.
On late model 1982 engines, an extra idler pulley is used
between the crankshaft and oil pump timing pulleys. Re-
move center retaining bolt to remove pulley.
Inspection:
Check timing belt for wear, cracks, or missing teeth. Re-
place belt if defective. Before installing a new belt, remove
idler pulley and spring. Check idler pulley bearing for
smooth operation.
Check the free length of idler pulley spring. Length of spring
should be 1.563" (39.70 mm). Under 8.8 lbs. (4 kg) ten-
sion, spring should measure 2.05" (52.0 mm) in length.
Check camshaft timing pulley, injection pump pulley and
crankshaft pulley for wear or damage.
Installation:
Before installing timing belt, engine should be cold. Always
turn crankshaft clockwise. Install idler pulley loose enough
so it may be moved side to side by hand. Check alignment
of timing marks on each pulley. See Fig. 2. Injection pump
timing is normally retarded.
Install timing belt and idler spring. Turn the crankshaft 2
revolutions clockwise from TDC to TDC. While turning crank-
shaft make sure idler pulley bracket is moving. Ensure that
each pulley aligns with marks. See Fig. 3. Tighten timing
belt idler pulley bolt. Reverse removal procedure to com-
plete installation. Adjust drive belts to proper tension. See
Camshaft-To-Timing Pulley ............................ 69-75 (94-102)
Fig. 1: Exploded View Of Cylinder Head & Timing Belt
Components
530
TOYOTA
Fig. 3: Realigning Timing Marks Fig. 2: Aligning Timing Marks
531
TOYOTA
2.4L 4-Cyl. Diesel
Pickup
1984-87................ 2.2 Hours ................. 250084
100,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Drain engine coolant
and radiator hoses, fan shroud, and radiator from vehicle.
Remove water pump pulley, drive belts, cooling fan and
pulley. See Fig. 1.
If equipped with A/C, remove compressor pulley from crank-
shaft pulley. Using Special Service Tools (09213-54012 and
09330-00020) or equivalent, remove crankshaft pulley set
bolt and washer.
Using Puller (09213-60017) or equivalent, remove crank-
shaft pulley. If equipped with A/C , remove idler pulley. On
2L, remove timing belt cover mount bolts, timing belt cover,
and belt guide. On 2L-T, remove No. 1 turbocharger water
pipe, air cleaner pipe, No. 1 air cleaner hose, and timing
cover. Disconnect glow plugs by removing 4 screw grom-
mets and glow plug connecting nuts. Disconnect current
sensor by removing nut, plate washer, insulator and cur-
rent connector. Remove glow plug connector and glow
plugs.
Using crankshaft set bolt, rotate engine and align TDC mark
on camshaft timing pulley with top surface of cylinder head.
See Fig. 2. Using pliers, remove tensioner spring. Loosen
tensioner set bolts and remove timing belt. Using Pulley
Holder (09278-54011), and a wrench, remove camshaft
pulley set bolt. Using Puller (09950-20015), remove cam-
shaft pulley. Using Pulley Holder (09278-54011), and a
wrench on injection pump drive pulley, remove set bolt on
pulley.
Fig 1: Exploded View Of Timing Belt Components
532
TOYOTA
Fig 2: Aligning Timing Marks
Fig. 3: Realigning Timing Marks
Using Puller (09213-60017), remove injection pump drive
pulley. Remove lower timing belt idler pulley. Using Puller
(09213-60017), remove crankshaft timing belt pulley.
Inspection:
Check timing belt for wear, cracks or missing teeth. If de-
fective, check if injection pump camshaft is locked or if there
are nicks on belt side of idler pulley lock. Replace belt and
components as needed. Inspect belt for excessive wear on
one side only. If damaged, check belt guide and alignment
of each pulley. Before installing new belt, remove idler pul-
leys and spring. Check idler pulley bearings for noise or
roughness.
Inspect spring for proper free length and tension. Standard
free length is 1.563" (39.70 mm). See Fig. 4. Installed ten-
sion is 8.8 lbs. at 2.05" (4.0 kg at 52 mm). Replace idler
pulley and/or spring as necessary.
Check camshaft, injection pump and crankshaft timing
sprockets for wear or damage. If there is noticeable wear
on belt teeth, check timing belt cover gasket for damage
and proper installation. Replace components as neces-
sary.
Installation:
Install lower idler pulley. Install timing belt tensioner, with
large bolt behind water pump, and loosely fasten mounting
bolts. Swing tensioner toward the left. Set No. 1 cylinder to
TDC of compression stroke and check alignment of timing
marks on each pulley. See Fig. 2. If using a new timing belt,
note that injection pump timing is normally in the retarded
position.
NOTE: When tightening idler pulley and timing sprocket mount
bolts, DO NOT move idler pulley bracket or apply tension to timing
belt.
Install timing belt onto camshaft timing pulley. Ensure tim-
ing belt is securely meshed and not loose. Align marks of
injector pump drive pulley and install timing belt onto pul-
ley. Install timing belt over lower idler pulley and under crank-
shaft timing belt pulley. Ensure timing belt is not twisted or
too tight.
Install tensioner spring and loosen bolts until tensioner
moves by spring tension. Using crankshaft pulley set bolt,
turn crankshaft 2 complete revolutions clockwise from TDC
to TDC. Check that each pulley aligns with marks. If marks
DO NOT align, remove timing belt and follow repeat the
procedure in this step.
Ensure that each pulley aligns with timing mark. See Fig. 3.
Tighten tensioner pulley set bolts to 14 ft. lbs. (19 N.m).
Install glow plugs and tighten to 9 ft. lbs. (13 N.m). Install
current sensor, insulator, plate washer and nut. Install 4
glow plug connecting nuts and 4 screw grommets.
Align set key on crankshaft with key groove of timing belt
guide, and install guide with curved side facing out. Using
a new gasket, install belt cover. On 2L-T, install air cleaner
pipe and No. 1 air cleaner hose. Connect accelerator cable
and PCV hose. Install timing belt cover and No. 1 water
pipe. Connect turbocharger water hoses.
If equipped with A/C, install idler pulley. Install crankshaft
pulley using Driver (09214-60010). Install washer and bolt
and tighten bolt to 101 ft. lbs. (137 N.m). Install drive pulley
onto crankshaft drive pulley. Install water pump pulley and
cooling fan. Install radiator, hoses and fan shroud. Fill en-
gine cooling system and connect negative battery cable.
Install drive belts. Adjust drive belts to proper tension. See
page A-60 for belt tension ranges. Start engine and check
for leaks.
Glow Plugs ................................................................... 9 (13)
Injector Pump Drive Pulley Bolt ................................... 47 (64)
Timing Belt Tensioner Pulley Bolts ............................. 14 (19)
533
2.8L 6-Cyl.
Celica Supra
1982-83
A/T ..................... 3.5 Hours ................. 250074
M/T .................... 3.3 Hours ................. 250074
1984-86
A/T ..................... 3.5 Hours ................. 250101
M/T .................... 3.3 Hours ................. 250101
Cressida
1983 ................... 3.1 Hours ................. 250074
1984-88 .............. 3.1 Hours ................. 250101
TIMING BELT
Removal:
Remove air cleaner, upper radiator hose, fan shroud and
air intake connector. Remove all drive belts. Position No. 1
cylinder at TDC of compression stroke. See Fig. 3. Remove
camshaft covers and No. 3 timing cover.
To relieve timing belt tension, loosen idler pulley set bolt.
Rotate idler pulley toward alternator side of engine. Using
gear puller, remove crankshaft pulley. Remove No. 1 timing
cover. If timing belt is to be reused, place arrow on belt to
indicate belt rotation. Remove timing belt.
Inspection:
Inspect drive belt for wear, cracks or damage to teeth. Check
pulleys for wear or damage. If defective, service or repair
as necessary. Check idler pulley bearing for smooth op-
eration. Idler pulley tension spring free length must be 2.72"
(69.0 mm) or less. See Fig. 6. Replace spring if not within
specification.
Installation:
Install oil pump drive pulley (if removed). Tighten bolt to
specification. Install idler pulley and tension spring. Posi-
tion idler pulley to alternator side of engine as far as pos-
sible. Using Pulley Installer (SST 09214-60010), install
crankshaft timing pulley. Install timing belt on crankshaft
pulley. If used belt is installed, ensure belt is installed in
proper direction of rotation. Install No. 1 timing cover and
gasket. See Fig. 1.
Install crankshaft pulley and tighten bolt to specification.
Ensure No. 1 cylinder is on TDC of compression stroke.
Install timing belt on crankshaft pulley.
Rotate engine 2 complete revolutions in direction of rota-
tion and position No. 1 cylinder at TDC of compression
stroke. Recheck alignment of match marks.
Install timing belt cover and crankshaft pulley. To complete
CAUTION: Ensure camshaft timing pulleys are installed in original
location. Guide on exhaust side must be toward No. 2 timing cover
and intake side guide facing away from No. 2 timing cover. See
Fig. 1.
Camshaft Housing Bolt ............................................
1
16 (22)
Camshaft Timing Pulley Bolt ...................................... 51 (69)
Oil Pump Drive Pulley Bolt .......................................... 16 (22)
Rear Timing Cover Bolt .............................................. 36 (49)
Timing Belt Case Bolt
8 mm ........................................................................ 13 (18)
10 mm ...................................................................... 27 (37)
INCH Lbs. (N.m)
No. 2 Timing Belt Cover ............................................ 108 (12)
1
- Tighten in 3 steps in proper sequence. See Fig. 5.
TOYOTA
2.8L 6-Cylinder
Fig. 2: Aligning Camshaft Match Hole
534
TOYOTA
Fig. 3: Camshaft Pulley Match Marks
Fig. 4: Aligning Camshaft & Pulley
Fig. 5: Camshaft Housing Bolt Tightening Sequence
Fig. 6: Measuring Belt Tensioner Spring Free Length
535
TOYOTA
3.0L 6-Cylinder 7M-GE
3.0L 6-Cyl.
Cressida
1989-91................. 3.1 Hours .................. 250126
1992...................... 3.1 Hours .................. 250237
Supra
1986-90................. 3.3 Hours .................. 250126
1991-92................. 3.3 Hours .................. 250237
60,000 miles for severe service operating conditions.
TIMING BELT
Removal:
Remove radiator. Remove all accessory drive belts. Re-
move power steering pump with hoses attached and se-
cure aside (if equipped). Remove spark plugs. Disconnect
hoses from air pipe.
Remove coolant outlet and fan. Remove spark plug wire
clamps across front of No. 2 timing belt cover. Remove
retaining bolts, No. 3 timing belt cover and gaskets. See
Fig. 1.
Rotate crankshaft so cylinder No. 1 is at TDC of compres-
with 0 mark on timing belt cover.
ing marks on No. 4 timing belt cover. See Fig. 2. If timing
marks are not aligned, rotate crankshaft 360 degrees and
recheck alignment.
Remove power steering belt pulley. Using Pulley Holder
(SST 09213-58011) or equivalent, and Handle (SST 09330-
00021) or equivalent, hold crankshaft pulley and remove
retaining bolt.
Using puller, remove crankshaft pulley. Remove fan bracket,
No. 1 timing belt cover and gasket. See Fig. 1.
Note direction of timing belt guide installation. Mark direc-
tion of timing belt rotation. Remove timing belt guide and
tension spring. See Fig. 1. Loosen No. 1 idler pulley retain-
ing bolt.
Position No. 1 Idler pulley as far to the left as possible
(away from timing belt), and temporarily tighten retaining
bolt. Remove timing belt.
Inspection:
nated. Inspect idler pulleys and fan for smooth rotation.
Replace component if defective.
Inspect tension spring for damage, and measure spring
free length. Replace tension spring if damaged or free
length is not 2.216" (56.274 mm).
Installation:
Install No. 1 idler pulley as far to the left as possible (away
from timing belt), and temporarily tighten retaining bolt. Align
timing marks on camshaft sprockets with timing mark on No.
4 timing belt cover. See Fig. 2. Install timing belt.
Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pul-
ley as far to the right as possible (toward timing belt), and
temporarily tighten retaining bolt. Install tension spring.
Loosen No. 1 idler pulley retaining bolt until idler pulley
moves with spring force of tension spring.
Temporarily install crankshaft pulley retaining bolt. Using
crankshaft pulley retaining bolt, rotate crankshaft clockwise
(viewed from front of engine) 2 full revolutions.
Ensure all timing marks are properly aligned. See Fig. 2.
Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37
N.m). Check timing belt deflection.
To remove slack in timing belt, rotate intake and exhaust
camshaft timing pulleys inward by applying a turning torque
of 14 ft. lbs. (19 N.m). See Fig. 4.
Remove crankshaft pulley retaining bolt. Install timing belt
guide with cupped side toward front of engine.
CAUTION: Ensure timing belt guide is installed with cupped side
toward front of engine and flat side against crankshaft sprocket.
dure. Apply sealant to coolant outlet before installing. Tighten
bolts/nuts to specification. See TORQUE SPECIFICATIONS.
tension ranges.
Coolant By-Pass Outlet Bolt ....................................... 13 (18)
Coolant Inlet Nut ......................................................... 14 (19)
Fan Bracket Bolt ......................................................... 30 (41)
Idler Pulley Bolt
No. 1 Pulley .............................................................. 27 (37)
No. 2 Pulley .............................................................. 13 (18)
Spark Plug .................................................................. 13 (18)
Tension Spring Bracket Bolt ....................................... 13 (18)
INCH Lbs. (N.m)
Fan Retaining Nut ........................................................ 48 (5)
No. 1 & 2 Covers ........................................................ 48 (5)
No. 3 & 4 Covers ........................................................ 74 (8)
536
TOYOTA
3.0L 6-Cylinder 7M-GE (Cont.)
Fig. 3: Aligning Camshaft Pin Holes & Timing Marks
537
TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97
1
Belt Part No.
3.0L 6-Cyl. 2JZ
Supra
1993-97................. 2.7 Hours .................. 250215
1
- With Turbo add .9 hours.
60,000 miles or 96 months for severe operating conditions.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove battery, and
drain cooling system. Place reference mark on fan clutch
and water pump for reassembly reference. Remove drive
belt, cooling fan, fan clutch and water pump pulley.
Remove radiator and lower engine cover. Remove oil filler
cap, No. 2 and No. 3 timing belt covers, gasket and drive
belt tensioner. See Fig. 1.
cover.
ing marks on No. 4 timing belt cover. See Fig. 2. If condi-
tions are not as described, rotate crankshaft clockwise one
complete revolution
timing belt tensioner and dust boot. See Fig. 1. Remove
0921370010) or equivalent, hold crankshaft pulley and re-
move crankshaft pulley bolt. Using puller, remove crank-
shaft pulley.
ence. See Fig. 1. Remove timing belt guide.
Inspection:
fective. Inspect timing belt tensioner for signs of oil leak-
Installation:
242 on threads of idler pulley bolt. Install and tighten bolt to
pulley is clean and rotates smoothly, and idler pulley bracket
moves freely.
sing crankshaft pulley bolt, rotate crankshaft and align tim-
ing mark on crankshaft sprocket with timing mark on oil
sprocket.
kets and No. 1 timing belt cover. Align crankshaft pulley key
groove with crankshaft key. Install crankshaft pulley and
tighten pulley bolt to specification. See TORQUE SPECIFI-
CATIONS.
der) is at TDC on Compression stroke. Ensure timing mark
cover.
Using sprocket holder, rotate camshaft sprockets so tim-
on No. 4 timing belt cover. See Fig. 2. Install timing belt on
camshaft sprockets. Ensure tension exists on timing belt
between camshaft sprockets.
belt and reinstall.
avoid dropping bolts into timing belt cover.
CATIONS. Adjust fluid levels and check ignition timing. Ad-
tension ranges.
A/C Compressor Bolt/Nut ........................................... 38 (52)
Fan Clutch-To-Water Pump Nut ................................. 12 (16)
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Bolt/Nut .................................................. 73 (8.3)
538
TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97 (Cont.)
539
TOYOTA
3.0L 6-Cylinder 2JZ, 1998
3.0L 6-Cyl. 2JZ-GE & 2JZ-GTE
Supra
1998.....................
1
2.7 Hours ................. 250215
1
- With Turbo add .9 hours.
90,000 miles or 72 months for severe operating conditions.
TIMING BELT
Removal (Turbo):
Disconnect the negative battery cable. Remove battery and
battery tray. Raise and support vehicle. Remove lower en-
gine cover. Drain cooling system.
Remove No. 2 air tube located below radiator. Remove air
intake hose to air intake chamber for access to timing belt
covers. Remove air cleaner duct located above radiator.
Remove lower fan shroud and radiator assembly.
On manual transmission models, remove drive belt
tensioner damper, located between drive belt tensioner and
stud on front of engine. See Fig. 1. Rotate drive belt tensioner
clockwise. Remove drive belt.
Place reference mating marks on fan clutch, water pump
pulley, and water pump stud for reassembly reference. Re-
Remove front bracket for power steering pump for access
to timing belt covers. It may be necessary to remove pump
pulley. Remove oil filler cap and No. 3 timing belt cover. See
Fig. 1. Remove No. 2 timing belt cover and gasket. Remove
drive belt tensioner.
CAUTION: DO NOT rotate crankshaft counterclockwise. Rotate
crankshaft clockwise (as viewed from front of engine).
cover.
ing marks on No. 4 timing belt cover. See Fig. 2. If not, rotate
grees).
timing belt from camshaft sprockets. On automatic trans-
mission models, remove clamps securing oil cooler lines
near crankshaft pulley.
On all models, use Handle (SST 09330-00021) and Pulley
Holder (SST 09213-70010) or equivalent to hold crankshaft
pulley. Remove crankshaft pulley bolt. Using gear puller,
ence (flat side toward timing belt). See Fig. 1. Remove
timing belt guide. If reusing timing belt, place mating refer-
ence marks on timing belt and crankshaft sprocket. Re-
move timing belt.
Fig. 1: Exploded View Of Typical Timing Belt & Components
Fig. 2: Aligning Camshaft Timing Marks (Turbo)
540
TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)
Fig. 4: Aligning Camshaft & Crankshaft Tlming Marks
Inspection (Turbo):
Compress and extend drive belt tensioner damper. Make
sure there is no abnormal resistance or unusual operation
sounds. Replace if defective.
CAUTION: Before discarding drive belt tensioner damper, gas
must be released from damper. Fully extend damper. Drill small
hole in damper, just above lower mounting stud hole. Use care
as gas will force metal chips to fly out while drilling hole.
Installation (Turbo):
242 or equivalent on threads of idler pulley bolt. Install and
sprocket.
belt and crankshaft sprocket align, and timing belt is installed
groove with crankshaft key. Install crankshaft pulley and
tighten pulley bolt to specification while holding crankshaft.
On automatic transmission models, reinstall clamps for
oil cooler lines near crankshaft pulley.
cover.
Using spanner wrench, rotate camshaft sprockets so tim-
on No. 4 timing belt cover. See Fig. 2. Clean oil or water off
of crankshaft sprocket and install timing belt on camshaft
sprockets. Ensure tension exists on timing belt between
camshaft sprockets.
541
belt and reinstall.
avoid dropping bolts into timing belt cover.
Ensure water pump and fan clutch reference marks are
aligned. Tighten fasteners to specification. See TORQUE
Removal (Non-Turbo):
Remove battery and battery tray. Raise and support vehicle.
Drain cooling system.
Remove air cleaner duct located above radiator. Remove
lower fan shroud and radiator assembly. Rotate drive belt
tensioner clockwise. Remove drive belt.
Place reference mating marks on fan clutch, water pump
pulley, and water pump stud for reassembly reference. Re-
hang out of way. Remove power steering pump front
bracket. Remove No. 2 and No. 3 timing belt covers and
gaskets. Remove drive belt tensioner.
cover.
ing marks on No. 4 timing belt cover. See Fig. 6. If not, rotate
grees).
CAUTION: Crankshaft must be correctly positioned by aligning
sub-timing mark with 0 mark on timing belt cover to prevent
valves from contacting pistons.
TOYOTA
Fig. 6: Aligning Camshaft Timing Marks (Non-Turbo)
Fig. 7: Aligning Sub-Timing Marks (Non-Turbo)
542
Rotate crankshaft pulley 60 degrees counterclockwise. Align
sub-timing mark with 0 mark on timing belt cover. Per-
form STEP 1. See Fig. 7. Ensure dot marks of camshaft
sprockets are aligned with timing marks of No. 4 timing
belt cover. See Fig. 7, STEP 2.
09213-70010) or equivalent to hold crankshaft pulley, re-
move crankshaft pulley bolt. DO NOT allow the crankshaft
pulley to rotate.
Remove crankshaft pulley using gear puller. Remove No. 1
timing belt cover and gaskets. Note direction of timing belt
guide installation for reassembly reference (flat side to-
ward timing belt). See Fig. 1. Remove timing belt guide. If
reusing timing belt, place mating reference marks on tim-
ing belt and crankshaft sprocket. Remove timing belt.
Inspection (Non-Turbo):
Installation (Non-Turbo):
242 or equivalent on threads of idler pulley bolt. Install and
pump body. See Fig. 7, STEP 3. Clean oil or water off of
crankshaft sprocket and install timing belt on crankshaft
sprocket and around idler pulley.
belt and crankshaft sprocket align, and timing belt is installed
groove with crankshaft key. Install crankshaft pulley.
Ensure sub-timing mark (60 degrees BTDC) of crankshaft
pulley is aligned with 0 timing mark of No. 1 timing belt
cover. See Fig. 7, STEP 4. Temporarily install crankshaft
pulley bolt.
TOYOTA
If necessary, use spanner wrench to rotate camshaft sprock-
ets so timing marks on camshaft sprockets align with tim-
ing marks on No. 4 timing belt cover. See Fig. 6. Install
timing belt on camshaft sprockets. Ensure tension exists
on timing belt between camshaft sprockets.
TDC.
If timing marks are not aligned, remove timing belt and
reinstall.
Tighten crankshaft pulley bolt to specification. Install No. 2
and No. 3 timing belt covers. To install remaining compo-
nents, reverse removal procedure. Use care when install-
ing drive belt tensioner bolts to avoid dropping bolts into
timing belt cover.
Ensure water pump and fan clutch reference marks are
aligned. Tighten fasteners to specification. See TORQUE
Drive Belt Tensioner Damper Bolt .................................. 15 (21)
Fan Clutch-To-Water Pump Nut ................................. 12 (16)
Idler Pulley Bolt ...........................................................
1
26 (35)
Power Steering Pump Pulley Bolt
Turbo ............................................................................ 32 (43)
Power Steering Pump-To-Front Bracket (Non-Turbo)
Right Side Bolt ...........................................................
2
29 (39)
Left Side Bolt ..............................................................
2
42 (58)
Water Pump Bolt ........................................................ 15 (21)
INCH Lbs. (N.m)
Fan-To-Fan Clutch Nuts ................................................ 65 (7.5)
No. 1 & No. 2 Timing Belt Cover Bolt ................................ 71 (8)
1
2
- Right and left side as viewed from rear of engine.
543
2.5L V6
Camry
1988-91................. 3.8 Hours .................. 250157
3.0L V6
Avalon
1995-97................. 3.0 Hours .................. 250257
Camry
1992-93................. 3.9 Hours .................. 250200
1994-97................. 3.0 Hours .................. 250257
conditions.
TIMING BELT
Removal (2.5L & 1992-93 3.0L V6):
Disconnect negative battery cable. Remove cruise control
actuator and vacuum pump. Remove power steering res-
ervoir with hoses attached, and secure them aside. Raise
right lower engine cover. Remove all drive belts.
Remove top braces on right engine mount at timing belt
cover. Slightly raise engine to remove weight from right
engine mount. Remove retaining bolts/nuts and right en-
gine mount assembly. Remove spark plugs. Remove re-
taining bolts, No. 2 timing belt cover, gasket and right en-
gine mount bracket. See Fig. 1. Note bolt length and loca-
tion of No. 2 timing belt cover bolts for reassembly refer-
ence.
belt rotation and location on camshaft sprockets for reassembly
reference. Also place reference mark on timing belt at upper
edge of No. 1 timing belt cover.
TOYOTA
2.5L & 3.0L V6 1988-97
544
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of
pulley aligns with 0 mark on No. 1 timing belt cover. En-
sure timing marks on camshaft sprockets are aligned with
timing marks on No. 3 timing belt cover. See Fig. 2. Re-
move retaining bolts and timing belt tensioner.
tension on timing belt between camshaft sprockets. Re-
move timing belt from camshaft sprockets.
Handle (SST 0933000021), hold crankshaft pulley, and re-
move retaining bolt. If timing belt is to be reused, ensure
reference mark placed on timing belt aligns with upper
edge of No. 1 timing belt cover when timing mark on crank-
shaft pulley is aligned with 0 mark on No.1 timing belt
cover.
Using puller, remove crankshaft pulley. DO NOT allow crank-
shaft to rotate. Remove No. 1 timing belt cover and gasket.
If timing belt is to be reused, mark direction of belt rotation,
and place reference marks on timing belt and crankshaft
sprocket for reassembly reference. Note direction of timing
belt guide installation for reassembly reference. See Fig.
1. Remove timing belt guide and timing belt. Remove idler
pulleys (if necessary).
Removal (1994-97 3.0L V6):
voir. Raise and support vehicle. Remove right side front
wheel. Remove right lower engine cover. Remove acces-
sory drive belts.
cover. Remove the alternator bracket for access to timing
belt covers. Remove No. 2 timing belt cover. See Fig. 1.
Use Pulley Holder (SST 09213-54015) or equivalent, and
Handle (SST 0933000021) or equivalent, to hold crank-
shaft pulley. Remove crankshaft pulley bolt. Using puller,
remove crankshaft pulley. Remove No. 1 timing belt cover.
See Fig. 1.
Remove engine mounting bracket. Note direction of timing
belt guide installation for reassembly reference. Remove
timing belt guide.
on oil pump body. See Fig. 3. Ensure timing marks on cam-
shaft sprockets are aligned with timing mark on No. 3 tim-
ing belt cover. See Fig. 3. If timing marks are not aligned,
rotate crankshaft clockwise one full revolution (360 de-
grees).
Remove retaining bolts, timing belt tensioner and dust boot.
Remove crankshaft pulley bolt from crankshaft. Install cam-
shaft sprocket holder (SST 09278-54012) or equivalent, in
holes on front of right camshaft sprocket. Slightly rotate
right camshaft sprocket clockwise to release tension on
timing belt between camshaft sprockets. Remove timing
belt from camshaft sprockets.
Inspection (2.5L & 3.0L V6):
tamination. Ensure idler pulleys rotate freely. Replace dam-
aged components. Inspect timing belt tensioner for signs
of oil leakage. Replace timing belt tensioner if oil leakage
exists. Hold timing belt tensioner body. Press rod against
solid surface. Replace timing belt tensioner if rod moves.
rod to edge of timing belt tensioner housing. See Fig. 5. On
2.5L engines, replace timing belt tensioner if distance is
not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace
10.49 mm).
Installation (2.5L & 1992-93 3.0L V6):
Install No. 1 idler pulley (if removed). Apply Loctite 242 on
threads of No. 1 idler pulley retaining bolt. Install and tighten
retaining bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure idler pulley is clean, and pulley rotates
smoothly.
Install timing belt on crankshaft sprocket with installation
mark on timing belt aligned with timing mark on crankshaft
sprocket. See Fig. 2. Install timing belt guide with cupped
side away from crankshaft sprocket. Install No. 1 timing
belt cover and gasket. Align crankshaft key with key groove
of crankshaft pulley and install crankshaft pulley. Tighten
retaining bolt to specification.
CAUTION: If reusing timing belt, ensure timing mark on crankshaft
sprocket is aligned with reference mark placed on timing belt,
and timing belt is installed in original direction of rotation.
Install No. 2 idler pulley. Tighten retaining bolt to specifica-
tion. Ensure idler pulley rotates smoothly. Rotate crank-
shaft pulley so timing mark on crankshaft pulley aligns with
0 mark on No. 1 timing belt cover. Rotate left camshaft so
Rotate right camshaft so knock pin hole in camshaft aligns
reusing timing belt, ensure reference mark placed on tim-
ing belt aligns with upper edge of No. 1 timing belt cover
TOYOTA
2.5L & 3.0L V6 1988-97 (Cont.)
Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
545
when timing mark on crankshaft pulley is aligned with 0
shaft sprocket clockwise, and install timing belt on cam-
with timing mark on camshaft sprocket.
shaft sprocket, and align timing mark on camshaft sprocket
with timing mark on No. 3 timing belt cover. Ensure tension
exists on timing belt between crankshaft sprocket and left
camshaft reference mark on timing belt with timing mark
on right camshaft sprocket. Install right camshaft sprocket
on camshaft with flange side toward cylinder head. Ensure
timing mark on right camshaft sprocket aligns with timing
mark on No. 3 timing belt cover. See Fig. 2.
TOYOTA
2.5L & 3.0L V6 1988-97 (Cont.)
Using camshaft sprocket holder, slightly rotate right cam-
shaft sprocket so knock pin hole in camshaft sprocket aligns
with knock pin hole in camshaft. Install knock pin in right
camshaft. Install right camshaft sprocket retaining bolt, and
tighten it to specification. See TORQUE SPECIFICATIONS.
Place washer on bottom side of timing belt tensioner. Us-
ing press, apply pressure on rod of timing belt tension until
rod is retracted, and holes in rod and housing are aligned.
to hold rod in retracted position. See Fig. 6. Release press,
and install dust boot on timing belt tensioner. Install timing
belt tensioner. Tighten retaining bolts to specification. See
with those on No. 3 timing belt cover. See Fig. 2.
CAUTION: Crankshaft must always be rotated clockwise. DO
NOT rotate crankshaft counterclockwise.
Installation (1994-97 3.0L V6):
Install timing belt plate. Install and tighten bolt to specifica-
tion. Install No. 1 and No. 2 idler pulleys (if removed). Install
and tighten bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure idler pulleys are clean and rotate
smoothly.
Using camshaft sprocket holder, rotate each camshaft
sprocket so timing mark on camshaft sprocket aligns with
timing mark on No. 3 timing belt cover. See Fig. 3. Align
reference marks on timing belt with dot on crankshaft
sprocket and timing marks on camshaft sprocket. Ensure
front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing
mark on camshaft sprockets and dot on crankshaft sprocket
when installing timing belt. Front mark must face toward timing
belt end of engine.
ley, left camshaft sprocket, No. 2 idler pulley, right camshaft
sprocket, and then on No. 1 idler pulley. Using press, apply
pressure on rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. Install hexagon
wrench through holes in housing and rod to hold rod in
retracted position. See Fig. 6. Release press and install
dust boot on timing belt tensioner. Install timing belt
tensioner. Install and alternately tighten bolts to specifica-
tate crankshaft clockwise until timing mark on crankshaft
sprocket aligns with timing mark on oil pump body. See
Fig. 3. Ensure timing mark on each camshaft sprocket is
aligned with timing mark on No. 3 timing belt cover. See
Fig. 3. If all timing marks are not aligned, remove timing
belt and reinstall. Remove crankshaft pulley bolt.
Fig. 3: Aligning Timing Marks (1994-97 3.0L)
Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L)
546
TOYOTA
2.5L & 3.0L V6 1988-97 (Cont.)
Engine Crossmember-To-Body Bolt .......................... 29 (39)
Engine Mount Through-Bolt ........................................ 64 (87)
Crossmember Bolt .................................................. 54 (73)
Idler Pulley Bolt
No. 1 Idler Pulley ....................................................... 25 (34)
No. 2 Idler Pulley ....................................................... 29 (39)
Idler Pulley Support Bolt ............................................. 13 (18)
Bolt ........................................................................... 47 (64)
Nut
Bracket Side .......................................................... 38 (52)
Body Side .............................................................. 65 (88)
Water Pump Bolt ........................................................ 14 (19)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
No. 3 Timing Belt Cover Bolt ......................................... 65 (7)
Valve Cover Nut ............................................................ 52 (6)
Front Engine Mount-To-Crossmember Bolt
Toyota Motor Corporation Bolt .................................. 59 (80)
Toyota Motor Manufacturing Bolt ............................... 49 (66)
Front Engine Mount-To-Cylinder
Block Bolt .................................................................. 47 (64)
Stabilizer Bar Link-To
Lower Control Arm Nut ............................................. 29 (39)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolt ......................................................... 71 (8.0)
Water Pump Bolt/Nut ................................................. 71 (8.0)
tighten bolts to specification.
covers. Install and tighten bolts to specification. See
ley bolt to specification. To install remaining components,
547
3.0L V6 1MZFE
Avalon
1998-01................. 3.0 Hours .................. 250257
Camry & Camry Solara
1998-01................. 3.0 Hours .................. 250257
Highlander
2001...................... 3.8 Hours .................. 250257
Sienna
1998-01................. 3.8 Hours .................. 250257
TIMING BELT
Removal (Avalon, Camry & Camry Solara):
belts. Lower vehicle.
let. Disconnect ground strap connectors. On Camry Solara,
remove shock tower suspension brace.
On all models, remove engine stabilizer rod, engine mount-
ing bracket. Remove right engine mount brace, located near
timing belt cover. Remove generator-to-engine bracket for
access to timing belt covers.
pulley. Remove crankshaft pulley bolt. Using gear puller,
remove crankshaft pulley. Remove No. 1 and 2 timing belt
covers and gaskets. See Fig. 1. Remove engine mounting
bracket from front (timing belt end) of engine. Note direc-
ence. Remove timing belt guide.
on oil pump body. See Figs. 2 and 3.
with timing the mark on No. 3 timing belt cover. See Figs. 2
and 3. If timing marks are not aligned, rotate crankshaft
clockwise one full revolution (360 degrees).
TOYOTA
3.0L V6 1998-01
548
belt tensioner body with pushrod facing upward. Press rod
rod moves.
.425" (10.01-10.8 mm).
Installation (Avalon, Camry & Camry Solara):
Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler
pulley bolt, coat threads with Loctite 242 or equivalent. In-
stall and tighten bolts to specification. See TORQUE SPECI-
FICATIONS. Ensure idler pulleys are clean and rotate
smoothly.
with timing mark on oil pump body. See Figs. 2 and 3.
on No. 3 timing belt cover. See Figs. 2 and 3.
CAUTION: Clean timing belt sprockets before installing timing
belt. Wipe off any oil or water with rag, DO NOT use any cleaning
solvents.
TOYOTA
3.0L V6 1998-01 (Cont.)
Fig. 2: Aligning Timing Marks (1998)
Fig. 4: Identifying Timing Belt Reference Marks & Front Mark
and dust boot. Do NOT hold tensioner with push rod facing
Inspection (Avalon, Camry & Camry Solara):
leaking oil. Replace damaged components. Check water
CAUTION: Never hold timing belt tensioner with pushrod facing
downward.
549
TOYOTA
3.0L V6 1998-01 (Cont.)
ley, left (front of vehicle side) camshaft sprocket, No. 2 idler
pulley, right (firewall side) camshaft sprocket, and then on
direction.
Using press, SLOWLY apply about 200-2200 lbs. (100-
1000 Kg) of pressure on push rod of timing belt tensioner
aligned. See Fig. 6. Align holes in housing and push rod.
Install hex wrench through housing and push rod hole to
secure push rod. Release press and install dust boot on
timing belt tensioner.
Remove hex wrench from timing belt tensioner. Slowly ro-
tate crankshaft clockwise 2 revolutions until timing mark
body.
TIONS.
Using new gaskets, install No. 1 and 2 timing belt covers.
Ensure there are no gaps in gasket. Cut off any excess
gasket. Install and tighten bolts to specification.
dure. Tighten fasteners to specification. Connect engine
ground strap. Adjust drive belts to proper tension. See page
Removal (Highlander):
belts. Lower vehicle.
Remove control (torque) rod from timing belt end of en-
gine. Remove engine mount from timing belt end of en-
gine. Remove generator mounting bracket from engine for
access to timing belt covers.
pulley. Remove crankshaft pulley bolt.
Fig. 6: Retracting Tlming Belt Tensloner Rod
Using gear puller, remove crankshaft pulley. Remove No. 1
and 2 timing belt covers and gaskets. See Fig. 1. Remove
engine mounting bracket from front of engine. Note direc-
ence. Remove timing belt guide.
Inspection (Highlander):
downward.
rod moves.
Installation (Highlander):
Install No. 1 and 2 idler pulleys (if removed). Install and
TIONS table. Ensure idler pulleys are clean and rotate
smoothly.
solvents.
direction.
1000 Kg) of pressure on push rod of timing belt tension
Install hexagon wrench through housing and push rod hole
to secure push rod. Release press and install dust boot on
550
tate crankshaft CLOCKWISE 2 revolutions until timing mark
body.
TIONS.
Ensure there are no gaps in gasket. Cut off excess gasket.
Install and tighten bolts to specification.
Install generator bracket. Install crankshaft pulley. Install
and tighten crankshaft pulley bolt. See TORQUE SPECIFI-
CATIONS.
Install engine mount and control (torque) rod to engine and
body. Connect engine ground strap.
tension. See page A-60 for belt tension ranges. Install right
fender apron shield. Install right front wheel.
Removal (Sienna):
Remove the outer cowl top panel along with the ventilation
louvers and windshield wiper arm assembly. See Figs. 7
and 8. Raise and support vehicle.
Remove right side front wheel. Remove right fender apron
seal. Remove accessory drive belts. Lower vehicle. Dis-
connect Data Link Connector 1 (DLC1) from right side en-
gine mounting bracket.
let. Disconnect ground strap connectors.
Remove engine stabilizer rod and engine mounting bracket,
located near timing belt cover. Remove generator-to-en-
gine bracket for access to timing belt covers.
crankshaft pulley. Remove No. 1 and 2 timing belt covers
and gaskets. See Fig. 1. Remove engine mounting bracket
from front of engine. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt
guide.
on oil pump body. See Figs. 2 and 3.
with timing mark on No. 3 timing belt cover. See Figs. 2 and
3. If timing marks are not aligned, rotate crankshaft clock-
wise one full revolution (360 degrees).
TOYOTA
3.0L V6 1998-01 (Cont.)
Fig. 7: Exploded View Of Outer Cowl Top Panel
(1998-00 Sienna)
Fig. 8: Exploded View Of Outer Cowl Top Panel
(2001 Sienna)
551
TOYOTA
3.0L V6 1998-01 (Cont.)
Inspection (Sienna):
downward.
rod moves.
.425" (10.01-10.8 mm).
Installation (Sienna):
Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler
pulley bolt, coat threads with Loctite 242 or equivalent. In-
stall and tighten bolts to specification. See TORQUE SPECI-
FICATIONS table. Ensure idler pulleys are clean and rotate
smoothly.
with timing mark on oil pump body. See Figs. 2 and 3.
on No. 3 timing belt cover. See Figs. 2 and 3.
solvents.
direction.
1000 kg) of pressure on push rod of timing belt tension
Install hexagon wrench through housing and push rod hole
to secure push rod. Release press and install dust boot on
tate crankshaft clockwise 2 revolutions until timing mark
body.
with timing mark on No. 3 timing belt cover. See Figs. 2 and
3. If all timing marks are not aligned, remove timing belt
and reinstall. Remove crankshaft pulley bolt.
TIONS.
Ensure there are no gaps in gasket. Cut off excess gasket.
Install and tighten bolts to specification.
Install generator bracket. Install engine stabilizer rod and
engine mounting bracket, located near timing belt cover.
Connect engine ground strap.
dure. Tighten fasteners to specification. Adjust drive belts
Camshaft Sprocket Bolt (Except Highlander)
Left Hand (Front End of Vehicle Side) ......................... 92 (125)
Right Hand (Firewall Side of Vehicle) ........................... 65 (88)
Camshaft Sprocket Bolt (Highlander) ....................... 92 (125)
Engine Mount Bracket-to-Engine Bolt ............................. 21 (28)
Engine Control (Torque) Rod Bolt .................................. 47 (64)
Generator Adjusting Lock Bolt ........................................ 13 (18)
Generator Pivot Bolt
Except Avalon ............................................................... 38 (52)
Avalon........................................................................... 41 (56)
Shock Tower Brace-to-Shock Tower Nuts
Camry Solara .............................................................. 59 (80)
No. 1 Idler Pulley Bolt ..............................................
1
25 (34)
Wheel Lug Nut .......................................................... 76 (103)
Wiper Arm Nuts
Sienna ......................................................................... 15 (20)
INCH Lbs. (N.m)
Water Pump Bolt/Nut
Except Sienna ............................................................. 71 (8.0)
Sienna ........................................................................ 69 (7.8)
1
552
TOYOTA
3.0L V6 3V-ZE
3.0L V6
Pickup
1988-92................. 4.1 Hours .................. 250154
1993-95................. 4.1 Hours .................. 250240
T100
1993-94................. 4.1 Hours .................. 250240
4Runner
1988-92................. 4.1 Hours .................. 250154
1993-95 ............... 4.1 Hours .................. 250240
60,000 miles for severe operating conditions.
TIMING BELT
Removal:
Remove lower engine covers. Remove radiator. Remove
all accessory drive belts.
Remove power steering pump with hoses attached and
secure aside (if equipped). Remove spark plugs. Discon-
nect hoses from air pipe.
NOTE If separating fluid coupling from fan bracket, place reference
mark on fluid coupling and fan bracket for reassembly reference.
Remove coolant outlet. See Fig. 1. Remove fan. Remove
spark plug wire clamps across front of No. 2 timing belt
cover. Remove studs for coolant outlet from No. 2 idler pul-
ley. Remove bolts, No. 2 timing belt cover and gaskets. See
Fig. 1.
553
TOYOTA
3.0L V6 3V-ZE (Cont.)
CAUTION: If reusing timing belt, mark direction of timing belt rotation
and ensure reference marks are on timing belt. See Fig. 2. If reference
marks are not apparent, place reference mark on timing belt and
all sprockets for reassembly reference. Also place reference mark
on timing belt at upper edge of No. 1 timing belt cover with cylinder
No. 1 at TDC on compression stroke. See Fig. 2.
compression stroke. Cylinder No. 1 is front cylinder on right
cover.
marks are not aligned, rotate crankshaft clockwise one
complete revolution and recheck alignment.
Remove bolts and timing belt tensioner with dust boot.
Remove bolts/nuts, fan bracket and gasket. See Fig. 1.
tension on timing belt between camshaft sprockets.
Remove timing belt from camshaft sprockets. Remove
power steering belt pulley. Using Pulley Holder (SST 09213-
58012) and Handle (SST 09330-00021) or equivalent, hold
crankshaft pulley. Remove crankshaft pulley bolt.
NOTE: If reusing timing belt, ensure reference mark placed on
timing belt aligns with upper edge of No. 1 timing belt cover
when timing mark on crankshaft pulley aligns with 0 mark
on No. 1 timing belt cover.
Using puller, remove crankshaft pulley. Remove bolts, No.
1 timing belt cover and gasket. Note direction of timing belt
guide installation for reassembly reference. See Fig. 1. Re-
move timing belt guide.
If reusing timing belt, mark direction of timing belt rotation.
Ensure reference mark exists on timing belt at reference
mark (dot) on crankshaft sprocket. See Fig. 2.
If reference mark does not exist, install reference mark on
timing belt in alignment with timing mark (dot) on crank-
shaft sprocket for reassembly reference. See Fig. 2.
Remove timing belt. Remove bolt, No. 1 idler pulley and
plate washer (if necessary). See Fig. 1.
Inspection:
nated.
Inspect timing belt tensioner for oil leakage. Replace tim-
ing belt tensioner if oil leakage exists. Hold timing belt
tensioner housing and press rod against solid surface.
Replace timing belt tensioner if rod moves.
rod to edge of housing on timing belt tensioner. See Fig. 4.
Replace timing belt tensioner if distance is not .394-.413"
(10.00-10.50 mm).
Inspect No. 1 and No. 2 idler pulleys and fan for smooth
rotation. Replace component if defective.
Installation:
Install plate washer and No. 1 idler pulley (if removed).
Install and tighten bolt to specification. See TORQUE SPECI-
FICATIONS. Ensure No. 1 idler pulley is clean and rotates
smoothly.
Install crankshaft pulley bolt in end of crankshaft. Rotate
crankshaft and align timing mark on crankshaft sprocket
Install timing belt on crankshaft sprocket with reference
mark on timing belt aligned with reference mark (dot) on
crankshaft sprocket. See Fig. 2. Install timing belt on water
pump.
in original direction of rotation and reference mark on timing
belt aligns with reference mark (dot) on crankshaft sprocket.
shaft sprocket and flat side against timing belt. Install No. 1
timing belt cover and gasket. Align groove of crankshaft
pulley with crankshaft key. Install crankshaft pulley. Install
and tighten crankshaft pulley bolt to specification. See
TORQUE SPECIFICATIONS. Install power steering belt
pulley on crankshaft pulley.
Rotate crankshaft so cylinder No. 1 is at TDC on compres-
with 0 mark on timing belt cover.
Rotate left camshaft so timing mark on camshaft sprocket
aligns with timing mark on No. 3 timing belt cover. See Fig.
3. Rotate right camshaft so pin hole in camshaft aligns with
timing mark on No. 3 timing belt cover.
Pull timing belt outward (toward outside of cylinder block)
at area near sprocket on water pump. Ensure reference
mark on timing belt aligns with upper edge of No. 1 timing
belt cover when crankshaft pulley timing mark is aligned
with 0 mark on No. 1 timing belt cover. See Fig. 2.
shaft sprocket clockwise. Install timing belt on left cam-
with timing mark on camshaft sprocket. See Fig. 2.
shaft sprocket and align timing mark on camshaft sprocket
with timing mark on No. 3 timing belt cover. See Fig. 3.
Ensure tension exists on timing belt between crankshaft
sprocket and left camshaft sprocket.
Fig. 2: Identifying Timing Belt Reference Marks
554
TOYOTA
3.0L V6 3V-ZE (Cont.)
Align reference mark on timing belt with timing mark on
right camshaft sprocket. See Fig. 2. Ensure timing mark on
right camshaft sprocket aligns with timing mark on No. 3
Using new gasket, install fan bracket. Install and tighten
bolt/nuts to specification. See TORQUE SPECIFICATIONS.
Using press, apply pressure on rod of timing belt tension
Install dust boot on end of timing belt tensioner. Install tim-
ing belt tensioner. Install and alternately tighten bolts. See
CAUTION: Crankshaft must always be rotated clockwise. DO NOT
rotate crankshaft counterclockwise.
tate crankshaft 2 full revolutions clockwise from TDC to
TDC. Ensure crankshaft pulley timing mark aligns with 0
marks are not aligned, remove timing belt and reinstall
using proper procedure.
Install No. 2 idler pulley gasket. See Fig. 1. Install No. 2
timing belt cover and gaskets. Install crankshaft pulley.
dure. Apply sealant on coolant outlet before installing.
Tighten all bolts/nuts to specification. See TORQUE SPECI-
FICATIONS. Fill and bleed cooling system. Adjust drive belts
Alternator Bracket-To-Cylinder Head Bolt ................... 27 (37)
Crankshaft Pulley Bolt ........................................ 181 (245)
Spark Plug .................................................................. 13 (18)
INCH Lbs. (N.m)
Camshaft Housing Rear Cover Bolt .......................... 43 (4.9)
Fan Retaining Nut ..................................................... 48 (5.4)
Valve Cover Bolt ......................................................... 48 (5.4)
555
TOYOTA
3.4L V6
3.4L V6
Tacoma
1995-01................
1
2.4 Hours ................. 250271
T100
1995-98................
1
2.4 Hours ................. 250271
Tundra
2000-01................
1
2.8 Hours ................. 250271
4Runner
1996-01................
1
2.4 Hours ................. 250271
1
1990-97 model years, the manufacturer recommends the belt
be replaced every 60,000 miles under severe driving condi-
tions. For 1998-01 model years, the manufacturer recom-
TIMING BELT
Removal:
Remove lower engine cover (if equipped). Drain cooling
system. Disconnect upper radiator hose. Remove acces-
sory drive belts. Disconnect 2 power steering hoses from
the air intake chamber and resonator. Remove power steer-
ing pump driver belt. Remove power steering pump with
hoses attached and hang out of way. Remove A/C com-
pressor with hoses attached and hang out of way.
Loosen cooling fan with fluid coupling and fan pulleys. Re-
move lower fan shroud. Remove fan and fan pulleys.
Remove A/C compressor bracket from engine. Remove
engine oil dipstick and tube. Disconnect electrical connec-
tors and clamps from upper timing belt cover. Remove up-
per timing belt cover. See Fig. 2. Remove power steering
pump adjusting strut. Remove fan bracket.
NOTE: Always turn crankshaft clockwise as viewed from timing
belt end of engine.
Ensure No. 1 cylinder is set at TDC of compression stroke
(crankshaft pulley groove aligned with zero mark on lower
timing belt cover). Use Pulley Holder (SST 09213-54015)
or equivalent to hold crankshaft pulley. Remove crankshaft
pulley bolt. Use gear puller to remove crankshaft pulley.
Remove lower timing belt cover. Noting installed position
for reassembly reference, remove timing belt guide.
Check that the crankshaft sprocket timing mark is aligned
with mark on oil pump body. Check that camshaft sprocket
timing marks are aligned with timing marks on back cover.
See Fig. 1.
If marks are not aligned, temporarily install crankshaft pul-
ley. Turn crankshaft one revolution in direction of rotation
(clockwise). Recheck alignment of timing marks.
If reusing timing belt, check that there are 3 installation
marks and a front mark on belt. See Fig. 3. If marks are
missing, place 3 new marks on belt to match position of
belt on camshaft and crankshaft pulleys. Also place front
facing arrow on belt.
Remove timing belt tensioner. DO NOT hold tensioner with
push rod facing downward. Remove timing belt.
Inspection:
Inspect idler pulley for oil leakage. Inspect idle pulley bear-
ing for smoothness. Replace if defective.
NOTE: DO NOT hold tensioner with push rod facing downward.
Inspect timing belt tensioner for oil leakage. Hold tensioner
(push rod facing upward) with both hands and pushing
push rod against a hard surface. If push rod moves, re-
place tensioner. Measure protrusion of push rod. If protru-
sion is not .394-.425" (10.0-10.8 mm), replace tensioner.
See Fig. 4.
NOTE: Only wipe timing belt pulleys and sprockets clean. Do
NOT use any cleaning agents or solvents.
Installation:
Ensure No. 1 cylinder is at TDC of compression stroke by
aligning crankshaft sprocket with mark on oil pump body.
See Fig. 5. Ensure camshaft sprockets are still aligned at
TDC positions. See Fig. 6.
NOTE: Install timing belt when engine is cold.
Install timing belt on left (drivers side) camshaft pulley, No.
2 idler pulley, right (passengers side) camshaft pulley, wa-
ter pump pulley, crankshaft pulley and No. 1 idler pulley. If
reusing old belt, ensure all reference marks are aligned.
Using a press, SLOWLY press in tensioner push rod with
pressure of 200-2205 lbs. (100-1000 N.m). Align holes of
push rod and housing and insert a 1.27 mm hexagon
wrench. Release pressure on push rod. See Fig. 7.
Install dust boot on tensioner. Install tensioner and alter-
nately tighten 2 bolts to specification. See TORQUE SPECI-
FICATIONS table. Remove hexagon wrench from tensioner.
Ensure timing marks of crankshaft timing pulley and oil
pump body are aligned and check camshaft timing marks.
See Fig. 1.
Install timing belt guide with cup facing outward. Install
lower timing belt guide with new gaskets. Install crank-
shaft pulley. Install crankshaft pulley bolt and tighten to
specification.
Turn crankshaft clockwise 2 revolutions, from TDC to TDC.
Ensure V notch (TDC mark) on crankshaft pulley aligns
with 0 mark on lower timing belt cover. Ensure camshaft
timing marks are still aligned with marks on rear cover.
Install fan bracket. Install power steering adjusting strut.
Install upper timing belt cover with new gasket. Install gen-
erator drive belt. Install oil dipstick tube. Install A/C com-
556
TOYOTA
3.4L V6 (Cont.)
557
TOYOTA
3.4L V6 (Cont.)
Fig. 3: Timing Belt Installation Marks
Fig. 4: Measuring Tensioner Push Rod Protrusion
Fig. 7: Retracting Timing Belt Tensioner Push Rod
pressor bracket and A/C compressor. Install power steer-
ing pump. Connect 2 power steering air hoses to air intake
chamber and resonator. Install fan and lower fan shroud.
Install accessory drive belts. Install engine under cover.
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS table. Fill cooling system and bleed air
from system. Adjust drive belts to proper tension. See page
A/C Compressor-to-Bracket ......................................... 18 (25)
A/C Compressor Bracket-to-Engine ........................... 35 (47)
T100, 1995-98 Tacoma & 4Runner .......................... 184 (250)
1999-01 Tacoma & 4Runner .................................... 217 (295)
Tundra...................................................................... 217 (295)
No. 1 Idler Pulley Bolt ..................................................... 25 (35)
No. 2 Idler Pulley Bolt ..................................................... 30 (40)
Power Steering Pump Bolt/Nut ..................................... 31 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt ............................................................ 14 (20)
INCH Lbs. (N.m)
Fan Retaining Nut ..................................................... 48 (5.4)
Oil Dipstick Tube ............................................................ 71 (8)
558
VOLKSWAGEN
1.5L, 1.6L & 1.7L 4-Cylinder
Belt
1.5L 4-Cyl.
Dasher
1974-75.......... 1.8 Hrs. ...... 2520170........ 250017
Rabbit
1975-79.......... 1.8 Hrs. ...... 2520170........ 250017
Scirocco
1978............... 1.8 Hrs. ...... 2520170........ 250017
1.6L 4-Cyl.
Dasher
1976-80.......... 1.8 Hrs. ...... 2520170........ 250017
Jetta
1980............... 1.8 Hrs. ...... 2520170........ 250017
Pickup
1980............... 1.8 Hrs. ...... 2520170........ 250017
Rabbit
1980............... 1.8 Hrs. ...... 2520170........ 250017
Scirocco
1976-80.......... 1.8 Hrs. ...... 2520170........ 250017
1.7L 4-Cyl.
Jetta
1981-84.......... 1.8 Hrs. ...... 2520170........ 250017
Quantum
1982-83.......... 1.8 Hrs. ...... 2520170........ 250017
Rabbit
1981-84.......... 1.8 Hrs. ...... 2520170........ 250017
Rabbit Pickup
1981-83.......... 1.8 Hrs. ...... 2520170........ 250017
Scirocco
1981-83.......... 1.8 Hrs. ...... 2520170........ 250017
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator belt,
water pump pulley, and upper and lower drive belt covers. If
equipped, remove air conditioning compressor drive belt.
Remove timing belt guide, if equipped. Loosen belt
tensioner, and work belt off sprockets toward front of en-
gine.
Installation:
Rotate camshaft sprocket until index punch mark on cam-
shaft sprocket is lined up with top surface of valve cover
mounting flange on spark plug side of head. Rotate crank-
shaft and intermediate shaft until index punch mark on in-
termediate shaft sprocket aligns with V notch on crank-
shaft pulley. See Figs. 1 and 2.
Use care not to move any sprocket. Fit belt on bottom first
and then at top. There should be no slack between sprock-
ets. Tighten tensioner so belt can just be twisted 90 de-
grees halfway between camshaft and intermediate sprock-
ets. Tighten adjuster lock nut.
Reverse removal procedure for remaining components.
tension ranges.
Crankshaft Sprocket Bolt ............................................ 59 (80)
Intermediate Sprocket Bolt
1
....................................... 59 (80)
Timing Belt Tensioner Lock Nut ................................. 33 (45)
Water Pump Bolts ...................................................... 15 (20)
Water Pump Pulley Bolts ............................................ 15 (20)
1
- Use Loctite.
Fig. 1: Aligning Crankshaft & Intermediate Sprockets
Fig. 2: Aligning Camshaft With Cylinder Head Flange
559
VOLKSWAGEN
*1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel
1.5L 4-Cyl. Diesel
Dasher
1979-80..................... 1.5 Hours .............. 250043
Rabbit
1977-80..................... 2.8 Hours .............. 250043
Rabbit Pickup
1980.......................... 2.8 Hours .............. 250043
1.6L 4-Cyl. Diesel & Turbo Diesel
Dasher
1981.......................... 1.5 Hours ............. 250043
Golf
1985-87..................... 2.8 Hours .............. 250043
1988-92 (Canadian) .. 2.2 Hours .............. 250043
Jetta
1981-86..................... 2.8 Hours .............. 250043
1986 (Canadian) ....... 2.8 Hours .............. 250043
1989-92..................... 2.2 Hours .............. 250043
1988-92 (Canadian) .. 2.2 Hours .............. 250043
Quantum
1982-86..................... 2.0 Hours .............. 250043
Rabbit
1981-84..................... 1.5 Hours .............. 250043
Rabbit Pickup
1981-83..................... 2.8 Hours .............. 250043
Vanagon
1982.......................... 2.8 Hours .............. 250043
TIMING BELT
NOTE: Sprockets do not have to be removed to replace drive
belt.
Removal:
Disconnect negative battery cable. Loosen alternator and
remove drive belt. Remove crankshaft drive belt pulley. Re-
move air cleaner and ducting. Remove timing belt and cyl-
inder head cover. Remove timing plug on top of bell hous-
ing. Rotate engine to bring No. 1 cylinder to TDC. Check
that TDC mark on flywheel is aligned with reference.
Using Setting Bar (2065A for Vanagon, 2065 for other mod-
els) or equivalent, lock camshaft in position. See Fig. 1.
Align tool by turning camshaft until one end of tool touches
cylinder head. Measure gap at other end with feeler gauge.
Insert feeler gauges of 1/2 thickness measured between
tool and cylinder head at each end of tool.
Lock injection pump sprocket at TDC with Special Pin (2064)
or equivalent. Loosen belt tensioner and remove timing
belt from sprockets.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt
removed.
Installation:
Ensure that flywheel is still aligned with TDC mark. With
camshaft and injection pump locked in place, loosen cam-
shaft sprocket bolt 1/2 turn. Lightly tap camshaft gear loose
from camshaft. Install drive belt so there is no slack be-
tween camshaft sprocket and injection pump and injection
pump and crankshaft sprocket.
Tighten tension adjuster to keep belt firmly in place. Remove
injection pump locking pin. Adjust belt tension by turning
tensioner until scale reads 12-13 on Tension Gauge (210) or
equivalent. See Fig. 2. Tighten camshaft sprocket bolt and
tensioner adjuster lock nut. Remove lock from camshaft.
Turn crankshaft 2 revolutions in direction of engine rota-
tion. Using a rubber hammer, strike belt once between cam-
shaft sprocket and injection pump sprocket. Recheck belt
tension and install remaining components in reverse or-
der of removal. Check injection pump timing. Adjust drive
ranges.
Except Vanagon ...................................................... 81 (110)
Vanagon .............................................................. 110 (150)
Intermediate Sprocket Bolt .......................................... 33 (45)
Timing Belt Tensioner Lock Nut ................................. 33 (45)
560
Fig. 2: Installing Timing Belt Tension Gauge
Fig. 1: Installing Camshaft Setting Bar
VOLKSWAGEN
*1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel
(Cont.)
561
VOLKSWAGEN
*1.8L 4-Cylinder Beetle, 1999-01
Beetle (APH & AWV Engines)
1999-01................. 2.7 Hours .................. 250306
The manufacturer suggests the timing belt AND tensioner be
TIMING BELT
Removal:
Remove engine cover. Remove noise insulation pan from
under engine compartment.
Remove air duct pipe between turbocharger and charge air
cooler.
Mark rotation direction of serpentine drive belt. Move ser-
pentine drive belt tensioner as shown to release tension
on belt. See Fig. 1. Secure tensioner using a drift, about
.18 (4.5 mm) x 2.2 (55 mm). See Fig. 2. Remove serpen-
tine drive belt. Remove serpentine drive belt tensioner.
NOTE: On vehicles without headlight cleaning system, Connecting
Rod Support (3090) can also be used to secure tensioner.
pression stroke. Ensure that TDC marks on flywheel and
bellhousing are aligned. See Figs. 3 and 4.
Remove coolant expansion tank and set aside. Label all
vacuum hoses for reassembly reference, and disconnect
vacuum hoses from fuel evaporative canister. Disconnect
vacuum hoses at throttle body.
Remove upper timing belt cover. See Fig. 7.
Attach Engine Support Bridge (10-222A) with Bracket
(10222) and engage retainer in right lifting eye bolt located
at cylinder head. Lift engine slightly to remove weight from
engine mounts. Engine may also be support from below
with a floor jack.
Fig. 1: Releasing Serpentine Drive Belt Tension
Courtesy of Volkswagen United States, Inc.
Fig. 2: Releasing Serpentine Drive Belt Tension
CAUTION: Engine mount assembly is secured by torque-to-yield
bold. Crankshaft pulley CENTER bolt is also torque to yield bolt.
These bolts MUST be replaced if they are loosened or removed.
Remove bolts from engine mount assembly at timing belt
end of engine. Remove engine mount.
Remove crankshaft pulley outer bolts. Remove crankshaft
pulley. It is NOT necessary to remove crankshaft pulley center
bolt.
Remove lower and middle timing belt covers. Remove en-
gine bracket from engine block. See Fig. 6. If reusing old
timing belt, mark timing belt with arrow to indicate original
Fig. 3: Setting Crankshaft To TDC (Manual Transmission)
Fig. 4: Setting Crankshaft To TDC (Auto. Transmission)
562
VOLKSWAGEN
*1.8L 4-Cylinder Beetle, 1999-01 (Cont.)
Fig. 6: Installing Timing Belt Tensioner Locking Pin
Screw Tensioning Bolt (T10092) or M5 x 55x 1 stud into
timing belt tensioner bracket. See Fig. 6. Install hex nut and
washer onto stud.
SLOWLY turn hex nut on stud to compress timing belt
tensioner. Compress tensioner just enough so that Lock-
ing Pin (T40011) or drill bit can be inserted through the
tensioner body, locking the tensioner in place.
Remove timing belt. Turn crankshaft back just slightly to
ensure that crankshaft is not at TDC for any cylinder.
NOTE: When turning camshaft, crankshaft must not be at TDC
or there is a potential for valves to contact pistons. Install timing
belt when engine is cold or lukewarm.
Installation:
Ensure crankshaft is still at TDC of compression stroke for
No. 1 cylinder. Align timing marks on camshaft sprocket
with mark on cylinder head cover. See Fig. 5.
Install timing belt around crankshaft sprocket. If installing
used belt, ensure it is installed in original direction of rota-
tion. Install lower timing belt guard. Install crankshaft pul-
ley and tighten bolts to specification. See TORQUE SPECI-
FICATIONS.
Place timing belt on water pump, tensioner pulley and cam-
shaft sprocket.
Remove Locking Pin (T40011) or drill bit. Unscrew
Tensioning Bolt (T10092). See Fig. 6.
Turn crankshaft 2 revolutions and check that camshaft and
crankshaft marks align properly. See Fig. 5.
Install middle and upper timing belt covers. Tighten bolts
Install engine mount bracket to block. Install engine mount
to engine bracket and body using NEW bolts. Adjust engine
mount clearance. See Fig. 9.
Remove engine support bridge or floor jack. Install ser-
pentine drive belt tensioner. Install serpentine drive belt.
Install the A/C compressor drive belt (if equipped). Ensure
used belts are installed in original direction of rotation.
FICATIONS.
Fig. 8: Locating Engine Bracket-To-Block Bolts
563
VOLKSWAGEN
*1.8L 4-Cylinder Beetle, 1999-01 (Cont.)
Fig. 9: Adjusting Engine Mount Clearance
Crankshaft Pulley Bolt ................................................... 18 (25)
1
Step 1 ........................................................................... 66 (90)
Step 2 ........................................... Plus 1/4 Turn (90 Degrees)
Engine Mount Bracket-To-Engine ................................... 33 (45)
1
Step 1 ........................................................................... 30 (40)
Engine Mount-To-Engine Bracket
1
Step 1 ........................................................................... 44 (60)
Timing Belt Tensioner Mount Bolt ................................... 11 (15)
Water Pump Bolt ............................................................ 11 (15)
1
Replace bolts if loosened or removed.
564
VOLKSWAGEN
*1.8L 4-Cylinder Passat, 1998-2000
NOTE: Engine code is stamped on machined pad on left side (viewed
from flywheel end of engine) of engine block. Engine code is
also on vehicle data plate.
1.8L 4-Cylinder DOHC (AEB & ATW Engines)
Passat
1998-00
152 Tooth Belt ... 3.1 Hours .................. 250291
153 Tooth Belt ... 3.1 Hours .................. 250317
be replaced at 90,000 mile intervals. For 2000 model year, the
manufacturer suggests the belt AND tensioner be replaced at
TIMING BELT
NOTE: Front lock carrier (radiator support) must be moved forward
to remove timing belt.
Removal:
Raise and support vehicle. Remove front, lower engine
cover. Lower vehicle. Separate release lever from hood lock.
Remove front bumper cover. See Fig. 5. Remove bumper
carrier from impact damper.
Unbolt air duct between lock carrier and air cleaner on lock
carrier. Remove support bolt on passenger side of lock
carrier and insert one Lock Carrier Guide (3369) into hole.
See Fig. 6.
Remove lock carrier front support bolts. Remove lock car-
rier-to-side panel bolts. Insert Lock Carrier Guide (3369)
into hole on drivers side of vehicle. Slide lock carrier for-
ward on lock carrier guides.
On vehicles with A/C, mark direction of rotation on belt, and
remove A/C drive belt. On all vehicles, rotate accessory drive
belt tensioner clockwise to remove tension from belt. Mark
belt with rotation direction and remove accessory drive belt.
See Fig. 1.
Remove accessory drive belt tensioner pulley and lever.
Turn crankshaft to TDC of compression stroke on No. 1
cylinder. See Fig. 2.
Remove crankshaft pulley. It is NOT necessary to remove
center crankshaft pulley center bolt. Remove upper and
lower timing belt covers. Loosen timing belt tensioner lever
bolt.
If reusing timing belt, mark belt with arrow to indicate direc-
tion of rotation. Remove timing belt.
Fig. 1: Removing Timing Belt
Installation:
Align timing marks on camshaft sprocket with mark on cyl-
inder head cover. See Fig. 2. Ensure crankshaft is still at
TDC position. Install timing belt around crankshaft sprocket.
Temporarily install crankshaft pulley to ensure crankshaft
is still at TDC of compression stroke for No. 1 cylinder.
Place timing belt on intermediate shaft sprocket, tensioner
pulley and camshaft sprocket. To tension timing belt, use
spanner wrench to rotate tensioner pulley clockwise until
tensioner piston No. 1 is fully extended, and tensioner pis-
ton No. 2 lifts about .040 (1 mm). See Fig. 3.
Tighten tensioner pulley bolt to specification. See TORQUE
SPECIFICATIONS. Rotate crankshaft 2 revolutions. Make
sure camshaft and crankshaft timing marks are aligned.
565
VOLKSWAGEN
*1.8L 4-Cylinder Passat, 1998-2000 (Cont.)
Fig. 5: Exploded View Of Bumper Assembly
Fig. 6: Exploded View Of Lock Carrier Assembly
Belt tension is correct if edge of tensioner lever aligns with
piston upper edge (Area A), or piston No. 1 is extended
0.98-1.14 (25-29 mm) (dimension D). See Fig. 4. Check
for wear in Areas B and C is dimension is not correct.
Remove crankshaft pulley. Install lower and upper timing
belt covers. Install crankshaft pulley. Tighten bolts to speci-
fication. See TORQUE SPECIFICATIONS. Install accessory
drive belt tensioner. Install accessory drive belt. Install the
A/C compressor drive belt (if equipped). Ensure used belts
are installed in original direction of rotation.
Install lock carrier in original location. Install bumper and
bumper cover.
Accessory Drive Belt Tensioner Bolt .............................. 18 (25)
A/C Drive Belt Tensioner Bolt ......................................... 22 (30)
Bumper Carrier-To-Impact Damper
Vertical Bolt ................................................................... 15 (20)
Crankshaft Pulley Bolt ................................................... 18 (25)
Impact Damper-To-Lock Carrier Bolt ............................. 68 (50)
Lock Carrier
Front Support Bolt ......................................................... 37 (50)
INCH Lbs. (N.m)
Bumper Guide-To-Side Panel Bolt ................................... 18 (2)
Lock Carrier-To-Side Panel Bolt ....................................... 71 (8)
566
VOLKSWAGEN
*1.8L 4-Cylinder Passat, 2000-01
1.8L 4-Cylinder DOHC (AUG & AWM Engines)
Passat
2000-01
152 Tooth Belt ... 3.1 Hours .................. 250291
153 Tooth Belt ... 3.1 Hours .................. 250317
For 2000-01 model year, the manufacturer suggests the tim-
ing belt AND tensioner be replaced at 105,000 mile intervals.
TIMING BELT
NOTE: Front lock carrier (radiator support) must be moved forward
to remove timing belt.
Removal:
For vehicles manufacturered from up to September, 2000,
disconnect front turn signal light assembly wiring har-
nesses. Separate hood release lever from bumper cover.
beam. Remove air intake duct from air cleaner housing.
Remove support bolts from lock carrier assembly. See Fig.
3. Install Support Tool (3369) through lock carrier to body.
Remove oil cooler from lock carrier assembly. Move lock
carrier forward on support tools.
For vehicles manufacturered from October, 2000, remove
bumper cover from bumper carrier. See Fig. 2. Remove
noise insulation panel from under engine compartment.
Remove air intake duct at lock carrier. Remove bolts from
front of bumper carrier. See Fig. 4. Install guide rods on
right and left sides. Pull lock carrier forward about 4 (10
cm) on guide rods into service position.
CAUTION: DO NOT hang condenser or oil cooler from their lines.
On all vehicles, loosen bolts for air conditioning drive belt
and remove belt. Remove serpentine drive belt. Remove
serpentine drive belt tensioner.
Remove upper timing belt cover. See Fig. 6. Mark rotation
direction of timing belt with arrow. Rotate crankshaft to TDC
No. 1 cylinder. See Fig. 5.
CAUTION: Vibration damper outer bolts and center bolt are torque-
to-yield type. If loosened or removed, bolts must be replaced.
Remove vibration damper. It is NOT necessary to remove
center bolt from vibration damper. Remove lower and middle
timing belt covers. See Fig. 6.
NOTE: If necessary, align pressure piston using needle nose pliers
or a thin wire (hole in piston and hole in housing must align.
Align holes in timing belt tensioner piston rod and hous-
ing. Insert Tensioning Bolt (T10092) into timing belt
tensioner bracket. See Fig. 7. Turn tensioning bolt just
enough so that holes in tensioner piston rod and housing
align. Insert Locking Pin (T40011) into holes to secure
tensioner in place.
Remove timing belt. Turn crankshaft back just slightly to
ensure that crankshaft is not at TDC for any cylinder.
Fig. 2: Removing Front Bumper Cover (From October, 2000)
Fig. 1: Removing Front Bumper Cover (Up To Sept. 2000)
567
VOLKSWAGEN
*1.8L 4-Cylinder Passat, 2000-01 (Cont.)
(Up To September, 2000)
(From October, 2000)
Installation:
Align timing marks on camshaft sprocket with mark on cyl-
inder head cover. Ensure crankshaft sprocket is still aligned
with timing mark. See Fig. 5.
Install timing belt around crankshaft sprocket. Install lower
timing belt cover. Install vibration and tighten bolts to speci-
Set crankshaft pulley to TDC No. 1 cylinder. Place timing
belt on water pump, tensioner pulley and camshaft
sprocket.
NOTE: Engine must not be hotter than lukewarm when tensioning
timing belt.
Remove Locking Pin (T40011) and unscrew Tensioning
Bolt (T10092). See Fig. 7.
tion. Check that camshaft and crankshaft timing marks align
properly. See Fig. 5.
Install middle and upper timing belt covers. Tighten bolts
to specification. See TORQUE SPECIFICATIONS. Install
serpentine drive belt tensioner. Install serpentine drive belt.
Install the A/C compressor drive belt (if equipped). Ensure
used belts are installed in original direction of rotation.
Install lock carrier in original location. Install bumper and
bumper cover.
Bumper Carrier-To-Impact Absorber
Vertical Bolt ................................................................... 15 (20)
1
Step 1 ........................................................................... 66 (90)
Impact Damper-To-Lock
Carrier Bolt (From Oct. 2000) ......................................... 68 (50)
Lock Carrier
Front Support Bolt ......................................................... 37 (50)
Water Pump Bolt ............................................................ 11 (15)
INCH Lbs. (N.m)
Bumper Guide-To-Side Panel Bolt ................................... 18 (2)
Lock Carrier-To-Side Panel Bolt ....................................... 71 (8)
1
..................................................................................... 89 (10)
Vibration Damper Bolt
1
Step 1 ........................................................................... 89 (10)
1
Replace bolt if loosened or removed.
568
Fig. 7: Installing Timing Belt Tensioner Locking Pin
VOLKSWAGEN
1.8L 4-Cylinder Passat, 2000-01 (Cont.)
569
VOLKSWAGEN
1.8L 4-Cylinder SOHC, 1983-93
Belt
1.8L 4-Cyl. SOHC
Cabriolet
1985-93.......... 1.8 Hrs. ...... 2520170........ 250017
Corrado
1990-92.......... 1.8 Hrs. ...... 2520170........ 250017
Fox
1987-93.......... 1.8 Hrs. ...... 2520170........ 250017
Golf
1985-92.......... 1.8 Hrs. ...... 2520170........ 250017
Golf (Canadian)
1993-95.......... 1.8 Hrs. ...... 2520170........ 250017
GTI
1985-92.......... 1.8 Hrs. ...... 2520170........ 250017
Jetta
1984-92.......... 1.8 Hrs. ...... 2520170........ 250017
Jetta (Canadian)
1993-95.......... 1.8 Hrs. ...... 2520170........ 250017
Passat (Canadian)
1992-94.......... 1.8 Hrs. ...... 2520170........ 250017
Quantum
1985............... 1.8 Hrs. ...... 2520170........ 250017
Rabbit
1983-84.......... 1.8 Hrs. ...... 2520170........ 250017
Scirocco
1983-89.......... 1.8 Hrs. ...... 2520170........ 250017
kits.
TIMING BELT
Removal:
Disconnect negative battery cable. Match mark all compo-
nents to ensure reassembly in original position. See Fig.
1. DO NOT turn crankshaft with belt removed. Valve dam-
age may result. Remove upper drive belt cover, drive belt,
and pulley. Remove timing belt guide, if equipped. Loosen
belt tensioner. Remove vibration damper. Remove lower
belt cover. Remove timing belt.
Installation:
Align flywheel/flexplate 0 mark with pointer. This is TDC.
Remove distributor cap and check position of ignition rotor.
Rotate intermediate shaft and position ignition rotor at No.
1 cylinder mark on housing. See Fig. 2.
With intermediate shaft/ignition rotor positioned, rotate crank-
shaft and align mark on crankshaft pulley with mark on
intermediate shaft sprocket. Position camshaft sprocket
mark even with valve cover surface. See Fig. 3. Install tim-
ing belt.
Rotate tensioner clockwise to tighten belt and install lock
nut. Proper deflection is achieved when longest span of
belt between sprockets can be twisted 90 degrees. See
Fig. 4.
By hand, rotate crankshaft 2 turns and check timing mark
alignment. To complete installation, reverse removal pro-
A/C Bracket-To-Engine Bolt ........................................ 22 (30)
Crankshaft Timing Sprocket Bolt ................................ 66 (90)
Lower Pulley Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Retaining Nut .......................................... 89 (10)
Water Pump-To-Housing ........................................... 89 (10)
570
VOLKSWAGEN
1.8L 4-Cylinder SOHC, 1983-93 (Cont.)
Fig. 4: Checking 1.8L Timing Belt Tension (8-Valve)
Fig. 3: Aligning 1.8L Timing Marks (8-Valve)
571
1.8L 4-Cyl. - DOHC
Cabriolet
1985-89................. 1.8 Hours .................. 250292
Golf & GTI
1985-89................. 1.8 Hours .................. 250292
Jetta
1985-89................. 1.8 Hours .................. 250292
Scirocco (Canadian)
1988-89................. 1.8 Hours .................. 250292
Scirocco
1985-88................. 1.8 Hours .................. 250292
2.0L 4-Cyl. - DOHC
GTI
1990-92................. 1.8 Hours .................. 250292
Jetta
1990-92................. 1.8 Hours .................. 250292
Passat
1990-92................. 1.8 Hours .................. 250292
TIMING BELT
Removal:
Disconnect negative battery cable. Match mark all compo-
nents to ensure reassembly to original position. Remove
accessory drive belts.
pression stroke. Remove fan belt and water pump pulleys.
See Fig. 1. Remove timing belt covers. Remove tensioner
pulley. Remove timing belt.
Installation:
Install timing belt around crankshaft and intermediate shaft
sprockets. Install lower timing belt cover. Install vibration
damper, noting offset holes. If valve cover is installed, mark
on front of camshaft sprocket must align with mark on valve
cover. If valve cover is removed, place camshaft sprocket
mark even with valve cover surface. See Fig. 3.
Align crankshaft sprocket mark with mark on lower timing
belt cover. See Fig. 3. Install timing belt around camshaft
sprocket. Rotate tensioner clockwise until Timing Belt Ten-
sion Scale (VW 210) or equivalent, reads 13-14.
Rotate crankshaft 2 revolutions and check timing mark align-
ment. To complete installation, reverse removal procedure.
tension ranges.
VOLKSWAGEN
572
Fig. 4: Proper Timing Belt Tension
VOLKSWAGEN
Crankshaft Pulley Nut ................................................. 15 (20)
16-Valve ................................................................ 148 (200)
Intermediate Shaft Sprocket Bolt
16-Valve .................................................................... 48 (65)
Water Pump Pulley ..................................................... 15 (20)
INCH Lbs. (N.m)
Upper & Lower Timing Belt Cover Bolt ......................... 53 (6)
Water Pump-To-Housing ........................................... 84 (10)
573
VOLKSWAGEN
*1.9L 4-Cylinder Turbo Diesel, 1993-98
1.9L 4-Cylinder Turbo Diesel
Golf (Engine Code AAZ, AHU & 1Z)
1
1993-95................. 2.8 Hours .................. 250242
1996-97................. 2.2 Hours .................. 250242
Jetta (Engine Code AAZ, AHU & 1Z)
1
1993-95................. 2.8 Hours .................. 250242
1996-98................. 2.2 Hours .................. 250242
Passat (Engine Code AAZ, AHH & 1Z)
1
1994-99................. 2.2 Hours .................. 250242
1
- Code is stamped on pad on engine block
between diesel injection pump and exhaust
manifold. Engine code is also included on
vehicle data plate and timing belt cover.
The manufacturer recommends the belt AND tensioner be
TIMING BELT
Removal (Golf, Jetta & Passat w/AAZ Engine, Up To Sept.,
1994):
On models with tensioner, install Tensioner Tool (3299)
and rotate clockwise. Mark serpentine belt with arrow to
indicate rotation direction, and remove belt. See Fig. 1. Re-
move tensioner pulley. On models without serpentine belts,
remove accessory drive belts.
On all models, remove upper timing belt cover. See Fig. 3.
Remove valve cover.
pression stroke. Flywheel TDC mark must be aligned to
mark on transmission mating flange. See Fig. 2.
Lock camshaft in place with Setting Bar (2065A) installed
on rear of camshaft. See Fig. 4. Center setting bar by turn-
ing camshaft so one side of setting bar contacts cylinder
head. Using feeler gauge, measure distance between other
end of setting bar and cylinder head.
Divide this feeler gauge dimension in half. Place a feeler
gauge corresponding to half the bar-to-cylinder head di-
Fig. 2: Locating TDC Mark On Flywheel/Flexplate
mension between setting bar and one side of cylinder
head.
Turn camshaft until setting bar contacts feeler gauge. Place
second feeler gauge of same dimension between other
end of bar and cylinder head.
Lock injection pump in place using Lock Pin (2064). See
Fig. 5. Loosen timing belt tensioner. Remove crankshaft
vibration damper. Remove the lower timing belt cover. See
Fig. 3.
If reusing old timing belt, mark belt with arrow to indication
original direction of rotation. Move timing belt tensioner,
Installation (Golf & Jetta w/AAZ Engine, Up To Sept., 1994):
Ensure TDC mark on flywheel and transmission mating
flange are still aligned. See Fig. 2.
NOTE: Use spanner wrench to hold camshaft sprocket while loosening
center bolt. Do not use camshaft setting bar to hold camshaft
sprocket.
Loosen camshaft sprocket bolt about 1/2 turn. Insert pin
punch through hole in rear of timing belt cover until it con-
tacts rear of camshaft sprocket. LIGHTLY tap pin punch
with hammer to loosen camshaft sprocket on camshaft
taper.
With Camshaft Setting Bar (2065A) in place on rear of cam-
shaft and crankshaft at TDC, install timing belt on engine. If
reusing old belt, ensure belt is installed in original direc-
tion of rotation. Remove Lock Pin (2064) from injection pump
sprocket.
Fig. 1: Removing Serpentine Belt
Tensioner Tool (3299)
95B59106
574
On models without semiautomatic timing belt tensioner,
apply tension to timing belt using Tension Pin Wrench
(Matra V159). See Fig. 6. Turn tensioner clockwise to ten-
sion belt. Install Tension Tool (VW210) set to 12 to 13. Mea-
sure tension midway between camshaft sprocket and in-
jection pump sprocket. Tighten lock nut on timing belt
tensioner to 33 ft. lbs. (45 N.m).
On models with semiautomatic timing belt tensioner, in-
stall idler pulley and tighten center nut to 15 ft. lbs. (20
N.m). Using Tension Pin Wrench (Matra V159), turn
tensioner clockwise until notch aligns with raised portion
of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft.
lbs. (20 N.m).
On all models, tighten camshaft sprocket bolt. See TORQUE
SPECIFICATIONS. Remove setting bar from camshaft.
tion. Recheck timing belt tension.
VOLKSWAGEN
*1.9L 4-Cylinder Turbo Diesel, 1993-98 (Cont.)
Fig. 4: Locking Camshaft With Setting Bar (2065A)
Fig. 5: Locking Diesel Fuel Injection Pump Sprocket
(AHU & 1Z Engines; AAZ Engines Up To Sept. 1994)
On models with semiautomatic tensioner, apply thumb
pressure to timing belt. Notched and raised portions of
timing belt tensioner must move apart. Release thumb pres-
sure on belt. Tensioner must back to its original position
(raised and notched portions aligned). If not, replace
tensioner.
On all models, install timing belt covers. Install vibration
damper and belt pulleys (if removed). Install accessory drive
belts. To prevent damage to serpentine belt, install in origi-
nal direction of rotation.
(2065A)
575
VOLKSWAGEN
(AHH Engine & AAZ Engines From Oct. 1994)
(Semi-Automatic Timing Belt Tensioner)
Fig. 6: TensioningTiming Belt (AAZ Engines Up To Oct.
1994, Without Semi-Automatic Tensioner)
Install valve cover. On engine code AAZ, check fuel injection
delivery. Consult service information for procedure.
CAUTION: Timing belt replacement for Passat (1Z engine) requires
using factory scan tool VAG 1551/1552 to check injection pump
start of delivery after timing belt is installed.
Removal (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ
Engine, From Oct., 1994):
On models with tensioner, install Tensioner Tool (3299)
and rotate clockwise. Mark serpentine belt with arrow to
indicate rotation direction, and remove belt. See Fig. 1. Re-
move tensioner pulley. On models without serpentine belts,
remove accessory drive belts.
On all models, remove upper timing belt cover. See Fig. 3.
Remove valve cover.
pression stroke. Flywheel TDC mark must be aligned to
mark on transmission mating flange.
head.
Lock injection pump in place using lock pin. See Figs. 5
and 8. Loosen injection pump sprocket mounting bolt(s).
Loosen timing belt tensioner. On Passat with 1Z engine,
remove water pump pulley and power steering pump pul-
ley.
On all models, remove crankshaft vibration damper. Re-
move the lower timing belt cover. See Fig. 3.
Installation (Golf, Jetta & Passat w/AHU & 1Z Engines;
w/AAZ Engine, From Oct., 1994):
sprocket.
Loosen camshaft sprocket bolt about 1/2 turn. Insert pin
punch through hole in rear of timing belt cover until it con-
tacts rear of camshaft sprocket. LIGHTLY tap pin punch
with hammer to loosen camshaft sprocket on camshaft
taper.
tion of rotation.
Install idler pulley and tighten center nut to 15 ft. lbs. (20
lbs. (20 N.m).
Tighten camshaft sprocket bolt. See TORQUE SPECIFICA-
TIONS. Tighten injection pump sprocket mounting bolt(s).
Remove setting bar from camshaft. Remove lock pin from
injection pump.
tion. Set No. 1 cylinder to TDC of compression stroke.
On models with semiautomatic tensioner, apply thumb
pressure to timing belt. Notched and raised portions of
timing belt tensioner must move apart. Release thumb pres-
sure on belt. Tensioner must back to its original position
(raised and notched portions aligned). If not, replace
tensioner.
576
VOLKSWAGEN
On engine codes AHU and 1Z, ensure injection pump
sprocket can be locked using Lock Pin (2064). See Fig. 5.
On engine code AAZ, ensure injection pump sprocket can
be locked using Lock Pin (3359). See Fig. 8. If injection
pump cannot be locked using correct lock pin, loosen in-
jection pump sprocket mounting bolt(s), and turn sprocket
until lock pin can be inserted in place. Tighten mounting
bolt(s).
Install timing belt covers. Install vibration damper and belt
pulleys (if removed). Install valve cover. Install accessory
drive belts. To prevent damage to serpentine belt, install in
For Passat with 1Z engine, check injection pump start of
delivery. Consult service information for procedure using
VAG 1551/1552 factory scan tool.
CAUTION: Timing belt replacement for 1998 Passat (AHH engine)
requires using factory scan tool VAG 1551/1552 to check injection
pump start of delivery after timing belt is installed.
Removal (1998 Passat, w/AHH Engine):
Disconnect front turn signal light assembly wiring har-
nesses. Separate hood release lever from bumper cover.
beam.
Remove air intake duct from air cleaner housing. Remove
support bolts from lock carrier assembly. See Fig. 10. In-
stall Support Tool (3369) through lock carrier to body. Re-
move oil cooler from lock carrier assembly. Move lock car-
rier forward on support tools.
Mark serpentine drive belt with arrow to indicate direction of
rotation. Rotate tensioner counterclockwise, and remove
serpentine drive belt. Remove upper timing belt cover. See
Fig. 2.
head.
Remove timing belt tensioner. Lock injection pump in place
using lock pin. See Fig. 8. Loosen injection pump sprocket
mounting bolts.
Remove crankshaft vibration damper. Remove lower tim-
ing belt cover. See Fig. 3.
Installation (1998 Passat w/AHH Engine):
sprocket.
Holding camshaft stationary, loosen camshaft sprocket bolt
1/2 turn. Place drift punch through rear timing belt cover
and LIGHTLY tap camshaft sprocket loose from tapered
end of camshaft.
Fig. 9: Exploded View Of Bumper Assembly (1998 Passat)
tion of rotation.
Install idler pulley and tighten center nut to 15 ft. lbs. (20
lbs. (20 N.m).
Tighten camshaft sprocket bolt. See TORQUE SPECIFICA-
TIONS. Tighten injection pump sprocket mounting bolts.
Remove setting bar from camshaft. Remove lock pin from
injection pump.
tion. Set No. 1 cylinder to TDC of compression stroke.
Apply thumb pressure to timing belt. Notched and raised
portions of timing belt tensioner must move apart. Release
thumb pressure on belt. Tensioner must back to its origi-
nal position (raised and notched portions aligned). If not,
replace tensioner.
Ensure injection pump sprocket can be locked using Lock
Pin (3359). See Fig. 8. If injection pump cannot be locked
using correct lock pin, loosen injection pump sprocket
mounting bolt(s), and turn sprocket until lock pin can be
inserted in place. Tighten mounting bolts.
Install timing belt covers. Install vibration damper. Install
valve cover. To prevent damage to serpentine belt, install in
577
Fig. 10: Exploded View Of Lock Carrier Assembly
(1998 Passat)
VOLKSWAGEN
Place lock carrier in original position on body. Install front
bumper assembly.
Check injection pump start of delivery. Consult service in-
formation for procedure using VAG 1551/1552 factory scan
tool.
Fig. 11: Injection Pump Mounting Bracket
(1994-97 Golf, Jetta & Passat w/AAZ & 1Z Engines)
TORQUE SPECIFICATIONS (GOLF & JETTA)
1
Step 1 ........................................................................... 66 (90)
Injection Pump Sprocket Mounting Bolt
Center Mounting Bolt .................................................... 33 (45)
Three Mounting Bolts ................................................... 18 (25)
Intermediate Shaft Sprocket Bolt ................................... 33 (45)
Timing Belt Tensioner Pulley Lock Nut
With Semi-Automatic Tensioner ................................... 15 (20)
Without Semi-Automatic Tensioner .............................. 33 (45)
INCH. Lbs. (N.m)
Lower Timing Belt Cover Bolt ......................................... 89 (10)
Valve Cover Nut .............................................................. 89 (10)
1
ALWAYS replace if loosened or removed.
TORQUE SPECIFICATIONS (PASSAT)
Bumper Beam-To-Impact
Absorber Bolt (1998) .................................................... 15 (20)
1
Step 1 ........................................................................... 66 (90)
Injection Pump Sprocket

Mounting Bolts
1
Step 1 .......................................................................... 15 (20 )
Intermediate Shaft Sprocket Bolt ................................... 33 (45)
Timing Belt Tensioner Pulley Lock Nut ....................... 18 (25)
INCH. Lbs. (N.m)
Bumper Cover Bolt (1998) ................................................ 18 (2)
Lower Timing Belt Cover Bolt ......................................... 89 (10)
Valve Cover Nut .............................................................. 89 (10)
1
ALWAYS replace with new bolts if loosened or removed.
TIMING BELT RUNS TOWARD OUTSIDE,
WEARS OUT, JUMPS OFF SPROCKET OR
CRACKS
1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines):
If this condition exists, replace timing belt and semiauto-
matic tensioner (part No. 028 109 243F).
BEFORE installing new timing belt, clean all timing belt
sprockets. Install new belt. Before installing vibration
damper, start and run engine at idle for a few seconds.
Turn off engine
Belt must not protrude past edge of crankshaft sprocket. If
it does, remove diesel injection pump. Loosen 3 injection
pump bracket mount bolts. Tighten bolts to 18 ft. lbs. (25
N.m) while pressing mount down at A and lifting mount at
B. See Fig. 11.
Start and run engine at idle for a few seconds. Turn off
engine. Belt must not protrude past edge of crankshaft
sprocket.
NOTE: This information is from Volkswagen technical service
bulletin Group 15, No. 97-01; June 4, 1997.
578
VOLKSWAGEN
*1.9L 4-Cylinder Turbo Diesel, 1998-01
1.8L 4-Cylinder Turbo Diesel
Beetle (Engine Code ALH)
1
1998-01................. 4.0 Hours .................. 250301
Golf (Engine Code ALH)
1
1999-01................. 2.7 Hours .................. 250301
Jetta (Engine Code ALH)
1
1999-01................. 2.7 Hours .................. 250301
1
- Code is stamped on pad on engine block
between diesel injection pump and exhaust
manifold. Engine code is also included on
vehicle data plate and timing belt cover.
The manufacturer suggests the belt AND tensioner be replaced
at 40,000 mile intervals for automatic transmission model,
and 60,000 mile intervals on manual transmission models.
TIMING BELT REMOVAL
NOTE: Timing belt installation procedure requires using a factory
scan tester (VAG 1551/1552) to adjust injection pump timing.
Beetle:
Remove tube between charge air cooler and air intake pipe.
Disconnect and plug fuel supply and return lines at fuel
filter. Remove fuel filter from bracket.
Remove upper timing belt cover. Remove valve cover. Re-
move brake booster vacuum pump. Remove pipe between
charge air cooler and turbocharger.
Remove right side insulation tray. Rotate tensioner clock-
wise, and remove serpentine drive belt. If reusing serpen-
tine drive belt, mark belt with direction of rotation.
pression stroke. TDC mark can be viewed through access
hole in engine-to-transmission mating flange. See Fig. 1.
Lock camshaft in place with Camshaft Setting Bar (3418)
installed on rear of camshaft. See Fig. 2. Center setting bar
by turning camshaft so one side of setting bar contacts
cylinder head. Using feeler gauge, measure distance be-
tween other end of setting bar and cylinder head.
Divide this dimension in half. Place a feeler gauge corre-
sponding to half the bar-to-cylinder head dimension be-
tween setting bar and cylinder head. Turn camshaft until
setting bar contacts feeler gauge. Place second feeler
gauge of same dimension between other end of bar and
cylinder head.
Lock the injection pump in place using Lock Pin (3359).
See Fig. 3.
CAUTION: DO NOT loosen diesel injection pump center hub nut.
This will alter injection pump basic setting.
Fig. 1: Locating TDC Mark On Flywheel/Flexplate
NOTE: The 3 diesel injection pump bolts are torque-to-yield type.
Manufacturer recommends replacing bolts during final assembly.
Loosen, but do not remove, the 3 diesel injection pump
sprocket mounting bolts. Manufacturer recommends re-
placing these torque-to-yield bolts during final assembly.
Support engine weight from above or below with floor jack.
NOTE: On Beetle models, engine mount bolts are torque-to-yield
type. Manufacturer recommends replacing bolts if they are loosened
or removed.
Remove engine mount from timing belt end of engine. Re-
move 4 crankshaft pulley bolts and remove crankshaft pul-
ley (it is not necessary to remove center bolt). Remove tim-
ing belt covers.
original direction of rotation. Loosen, but do not remove,
timing belt tensioner nut, and remove timing belt.
removed.
scan tester (VAG 1551/1552) to adjust injection pump timing
Golf & Jetta:
Remove upper engine cover. Remove right sound damper
cover. Rotate serpentine belt tensioner clockwise to relieve
belt tension, and remove serpentine belt. Remove serpen-
tine belt tensioner.
579
Fig. 4: Adjusting Timing Belt Tension (Beetle, Golf & Jetta
With Manual Transaxle)
VOLKSWAGEN
Fig. 2: Locking Camshaft With Setting Bar
Remove brake booster vacuum pump. Remove upper tim-
ing belt cover. Remove engine valve cover. Remove tube
between charge air cooler and intake manifold.
pression stroke. TDC mark can be viewed through access
hole in engine-to-transmission mating flange. See Fig. 1.
Lock camshaft in place with Camshaft Setting Bar (3418)
installed on rear of camshaft. See Fig. 2. Center setting bar
by turning camshaft so one side of setting bar contacts
cylinder head. Using feeler gauge, measure distance be-
tween other end of setting bar and cylinder head.
Divide this dimension in half. Place a feeler gauge corre-
sponding to half the bar-to-cylinder head dimension be-
tween setting bar and cylinder head. Turn camshaft until
setting bar contacts feeler gauge. Place second feeler
gauge of same dimension between other end of bar and
cylinder head.
Lock injection pump in place using Lock Pin (3359). See
Fig. 3.
CAUTION: DO NOT loosen diesel injection pump center hub nut.
This will alter injection pump basic setting.
Loosen, but do not remove, the 3 diesel injection pump
sprocket mounting bolts. Support engine weight from above
or below with floor jack. Remove coolant reservoir bottle
and power steering reservoir (both with hoses attached)
and set aside.
Remove engine mount from timing belt end of engine. Re-
move 4 crankshaft pulley bolts and remove crankshaft pul-
ley (it is not necessary to remove center bolt). Remove
middle and lower timing belt covers. If reusing old timing
belt, mark belt with arrow to indicate original direction of
rotation. Move timing belt tensioner, and remove timing belt.
removed.
Beetle, Golf & Jetta:
Ensure cylinder No. 1 is at TDC. Check reference mark on
flywheel and bellhousing.
center bolt. DO NOT use camshaft setting bar to hold camshaft
sprocket.
Holding camshaft stationary, loosen camshaft sprocket bolt
1/2 turn. Place drift punch through rear timing belt cover
and LIGHTLY tap camshaft sprocket loose from tapered
end of camshaft. Gear puller may also be used to remove
sprocket. Remove camshaft sprocket.
Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta
With Automatic Transaxle)
580
Install timing belt onto crankshaft sprocket, idler pulley, water
pump, injection pump sprocket, and tensioner pulley. If in-
stalling old belt, note direction of rotation mark.
Install camshaft sprocket together with timing belt. Install
camshaft sprocket bolt finger tight. Camshaft sprocket
should still be free to turn.
On Golf and Jetta with manual transaxle and Beetle, install
Tension Pin Wrench (MATRA V159) on timing belt tensioner
pulley. See Fig. 4. Turn wrench clockwise until notch and
raised mark are aligned. Tighten tensioner pulley center
nut.
On Golf and Jetta with automatic transaxle, turn timing belt
tensioner clockwise until notch and pointer align. See Fig.
5. If tensioner is turned too far and correct tension is ex-
ceeded, tension must be fully released, and then read-
justed. Tighten center lock nut on tensioner pulley.
On all models, ensure tensioner is correctly installed in
rear timing belt cover. See Fig. 6. Ensure TDC marks on
flywheel are still aligned. Tighten camshaft sprocket center
scan tester (VAG 1551/1552) to adjust injection pump timing.
Install NEW torque-to-yield mounting bolts in diesel injec-
tion pump sprocket. Tighten injection pump bolts to 15 ft.
lbs. (20 N.m). Before final tightening injection pump mount-
ing bolts, perform start of injection procedure (dynamic tim-
ing) using factory scan tester (VAG 1551/1552). Final tighten
injection pump sprocket mounting bolts about 90 degrees.
If not already done, remove camshaft setting bar from rear
of camshaft. Remove lock pin from injection pump.
Rotate crankshaft 2 complete revolutions. Place crankshaft
at TDC and ensure belt timing is correct. Ensure timing
belt tensioner pulley marks are still aligned.
Install engine mount bracket to engine block. Install timing
belt covers. Install crankshaft pulley.
Tighten nuts and bolts to specification. See TORQUE
SPECIFICATIONS. Check fuel lines for leaks. Adjust drive
belts to proper tension. On Beetle models, check injection
pump start of delivery with scan tool.
VOLKSWAGEN
TORQUE SPECIFICATIONS (BEETLE)
Diesel Injection Pump Sprocket
1
Bolts .................................................... 15 (20 ) + 90 Degrees
Engine Mount Bracket-to-Engine
Bolt ......................................................
1
30 (40) + 90 Degrees
Engine Mount-To-Bracket
Bolt ......................................................
1
44 (60) + 90 Degrees
Water Pump Bolts ...................................................... 11 (15)
INCH. Lbs. (N.m)
Valve Cover Nut .............................................................. 89 (10)
1
Replace with new torque-to-yield bolts on installation.
TORQUE SPECIFICATIONS (GOLF & JETTA)
Diesel Injection Pump Sprocket
1
Bolts .................................................... 15 (20 ) + 90 Degrees
Engine Mount Bracket-to-Engine Bolt ............................ 33 (45)
Idler Pulley Bolt ............................................................ 15 (20)
Serpentine Drive Belt Tensioner .................................... 18 (25)
Vacuum Pump Bolt ....................................................... 15 (20)
Water Pump Bolts ........................................................ 16 (22)
INCH. Lbs. (N.m)
Valve Cover Nut .............................................................. 89 (10)
1
Replace with new torque-to-yield bolts on installation.
581
VOLKSWAGEN
*2.0L 4-Cylinder ABA Engine
NOTE: Engine code (ABA) is stamped into machined pad on front
of cylinder block above crankcase breather, near cylinder head
mating surface.
2.0L 4-Cyl., ABA Engine
Cabrio
1995-01................. 1.9 Hours .................. 250262
Golf (Canadian)
1995...................... 1.9 Hours .................. 250262
Golf
1993-99................. 1.9 Hours .................. 250262
GTI (Canadian)
1993-95................. 1.9 Hours .................. 250262
GTI
1996-99................. 1.9 Hours .................. 250262
Jetta
1993-99................. 1.9 Hours .................. 250262
Passat
1993-96................. 1.9 Hours .................. 250262
TIMING BELT
Removal:
Remove accessory drive belts. Remove accessory drive
belt tensioner bracket. See Fig. 1.
Remove crankshaft pulley bolts and pulley (it is NOT nec-
essary to remove center bolt).
Remove water pump pulley. Remove upper and lower tim-
ing belt covers.
NOTE: DO NOT turn crankshaft with belt removed. Valve damage
may result.
nal direction of rotation.
CAUTION: To prevent valves from contacting piston, DO NOT
rotate camshaft or crankshaft with timing belt removed.
Place crankshaft at TDC by aligning flywheel (M/T) or drive
plate (A/T) TDC marks. See Fig. 2. Ensure camshaft timing
mark is aligned with mark on belt guard. See Fig. 3. Loosen
belt tensioner. Remove timing belt.
Installation:
Ensure crankshaft is still at TDC position. See Fig. 2. Re-
move distributor cap. Rotate intermediate shaft counter-
clockwise until rotor is pointed at No. 1 cylinder mark. See
Fig. 2. Ensure camshaft timing mark is still aligned with
mark on belt guard. See Fig. 3.
Install timing belt around crankshaft, intermediate shaft,
tensioner, and camshaft sprockets.
Loosen timing belt tensioner center nut. Using spanner
wrench, rotate tensioner pulley clockwise to tension belt.
Belt tension is correct when it is possible to rotate belt 90
degrees with thumb and forefinger, half-way between cam-
shaft and intermediate shaft sprockets. See Fig. 4.
Fig. 2: Aligning Crankshaft & Distributor Timing Marks
582
VOLKSWAGEN
*2.0L 4-Cylinder ABA Engine (Cont.)
While holding tensioner pulley stationary, tighten tensioner
pulley center nut to specification. Rotate crankshaft 2 revo-
lutions and recheck check belt tension. Adjust tension as
necessary. Recheck all timing marks again.
Install timing belt covers. Install drive belt tensioner bracket.
tension ranges.
Camshaft Sprocket Bolt ..............................................

59 (80)
Crankshaft Pulley Bolt .................................................

18 (25)
Crankshaft Sprocket
Center Bolt ..........................................
1
66 (90) + 90 Degrees
Drive Belt Tensioner Bracket Bolt .................................. 15 (20)
INCH Lbs. (N.m)
1
- Replace torque-to-yield bolt on installation.
583
VOLKSWAGEN
*2.0L 4-Cylinder AEG Engine
NOTE: Engine code (AEG) is stamped into machined pad on front
of cylinder block above crankcase breather, near cylinder head
mating surface.
2.0L 4-Cyl., AEG Engine
Beetle
1998-01................. 2.7 Hours .................. 250296
Cabrio
1999.....................
1
1.9 Hours ................. 250296
Golf
1999.....................
1
1.9 Hours ................. 250296
1999-00................
2
3.1 Hours ................. 250296
GTI
1999.....................
1
1.9 Hours ................. 250296
Jetta
1999 ...................
1
1.9 Hours ................. 250296
1999-00................
2
3.1 Hours ................. 250296
1
Early 1999 model. 8th character of VIN is H.
2
Late 1999 model. 8th character of VIN is M
for Cabrio and Jetta; 8th character of VIN
is J for Golf.
mile intervals.
TIMING BELT
Removal:
Remove right hand insulation tray from engine compart-
ment. Remove engine cover. Rotate serpentine belt
tensioner clockwise to relieve belt tension. Remove ser-
pentine belt.
Remove serpentine belt tensioner assembly. See Fig. 1.
Turn crankshaft to TDC position. See Fig. 2. On Golf and
Jetta, align TDC marks visible in bellhousing access hole.
See Fig. 3. On all models, remove upper timing belt cover.
Ensure camshaft sprocket timing mark aligns with mark
on rear cover. See Fig. 2.
Support engine from above or below with floor jack to take
engine weight off of mounts. Remove coolant reservoir and
set aside. On Golf and Jetta, remove power steering reser-
voir (hoses attached), and set aside. On Beetle, pull off
EVAP hoses at EVAP canister and throttle valve housing.
On all models, remove engine mount from timing belt end
of engine. Remove crankshaft pulley from crankshaft
sprocket. It is NOT necessary to remove center bolt (center
bolt is torque-to-yield type that must be replaced if removed).
Remove timing belt covers. Remove engine support from
front of engine. See Fig. 1.
CAUTION: To prevent valves from contacting piston, DO NOT
rotate camshaft or crankshaft with timing belt removed.
If reusing old belt, mark belt with arrow to indicate original
direction of rotation. Rotate timing belt tensioner away from
belt and remove timing belt.
Installation:
aligned. See Figs. 2 and 3.
Install timing belt around crankshaft and water pump
sprockets. Install engine support on front of engine block.
Tighten mounting bolts to specification. See TORQUE
SPECIFICATIONS.
Install timing belt lower and center covers. Install crank-
shaft pulley and tighten bolts to specification. Install en-
gine mount-to-body and engine support. Remove floor jack
or engine support bar from engine.
Install timing belt on camshaft sprocket and timing belt
tensioner. Make sure there is no slack in timing belt.
To tension timing belt, engine must be at most warm to the
touch. Rotate tensioner pulley counterclockwise until
tensioner arrow is aligned with cut-out on cylinder head.
See Fig. 4.
584
VOLKSWAGEN
*2.0L 4-Cylinder AEG Engine (Cont.)
Fig. 3: Locating TDC Mark On Transaxle (Golf & Jetta)
Tighten tensioner pulley center nut to specification. Rotate
crankshaft 2 revolutions in normal direction of rotation, and
recheck check belt tension. Adjust tension as necessary.
Recheck all timing marks again.
Install upper timing belt cover. Install serpentine belt
tensioner. Install engine mount. To complete installation,
reverse removal procedure.
Camshaft Sprocket Bolt ............................................

74 (100)
Beetle ........................................................................... 18 (25)
Golf & Jetta .................................................................. 30 (40)
Crankshaft Sprocket
Center Bolt ..........................................
1
66 (90) + 90 Degrees
Engine Support-To-Engine Block .................................. 33 (45)
Serpentine Belt Tensioner Bolt .................................... 15 (20)
Water Pump Bolt ........................................................ 11 (15)
INCH Lbs. (N.m)
1
- Replace torque-to-yield bolt on installation.
585
VOLKSWAGEN
*2.8L V6
2.8L V6, 30-Valve
Passat
1998-01................. 3.1 Hours .................. 250297
mile intervals for 1998 models, and 75,000 mile intervals for
1999 models.
On 2000-01 models, replace timing belt and belt tensioner at
105,000 miles.
TIMING BELT
NOTE: Obtain radio anti-theft code before disconnecting battery.
Removal:
Disconnect negative battery cable. Remove engine top cover.
Remove noise insulation panel from under front of vehicle.
Hold cooling fan pulley with spanner wrench. Unscrew and
remove viscous cooling fan clutch from pulley. Viscous cool-
ing fan is LEFT-HAND threaded.
Use a 17 mm box wrench to turn serpentine belt tensioner
counterclockwise. Relieve belt tension and remove ser-
pentine belt. If reusing belt, mark belt rotation direction with
arrow for reassembly reference.
Unclip timing belt guard on front of both camshafts and
remove. Turn crankshaft in normal direction of rotation until
TDC marks on crankshaft pulley and timing belt cover are
Note securing plate on front end of each camshaft sprocket.
If large hole in each plate does not face inward, toward
center of engine, rotate crankshaft one revolution. See Fig.
2. Ensure crankshaft timing marks are still aligned.
Remove sealing plug from left side of engine block. TDC
mark on crankshaft must be visible or be felt through seal-
ing hole. Install Crankshaft Holding Tool (Audi 3242) into
sealing plug hole. See Fig. 3.
Remove serpentine belt tensioner. Remove center and left
timing belt covers.
Using an 8 mm hex wrench, SLOWLY turn timing belt
tensi oner pul l ey cl ockwi se to compress ti mi ng bel t
tensioner. See Fig. 4. Compress timing belt tensioner just
enough so a 2 mm pin can be inserted through the holes in
top of tensioner body and push rod. This will hold the
tensioner in the compressed position.
CAUTION: If reusing old timing belt, mark an arrow indicating
direction of rotation on accessory drive belt or timing belt. Damage
Remove crankshaft vibration damper from crankshaft. It is
NOT necessary to remove center bolt. If center bolt is re-
moved, manufacturer recommends using NEW bolt on re-
assembly. Remove serpentine belt idler pulley.
Remove lower timing belt guard (if equipped). Remove tim-
ing belt.
Fig. 2: Locating Camshaft Sprocket Holes
586
Fig. 3: Installing Crankshaft Holding Tool
VOLKSWAGEN
*2.8L V6 (Cont.)
Installation:
Install Camshaft Locator Bar (3391) into locking plates of
camshafts. See Fig. 5. Loosen camshaft sprocket bolts
about 5 turns. Remove locator bar.
Leaving camshaft sprocket bolts in place, use gear puller
to loosen camshaft sprockets on camshaft taper.
NOTE: Camshaft sprockets must be loose enough to ro-
tate on camshaft, but not loose enough to tilt.
Ensure all timing marks are still aligned. Install timing belt
on engine. Ensure belt routing is correct and there is no
slack in belt. See Fig. 6. Install Camshaft Locator Bar (3391)
into locking plates of camshafts.
Using an 8 mm hex wrench, SLOWLY compress timing
belt tensioner so that 2 mm pin can be removed from
tensioner.
Using 8 mm hex socket, place torque wrench on timing belt
tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in
direction of tension (clockwise). This will pre-load belt ten-
sion.
Tighten camshaft sprocket bolts to specification. Remove
camshaft locator bar. Remove crankshaft holder. Install
sealing plug.
Install timing belt cover. Install crankshaft pulley. Install ser-
pentine drive belt
installing crankshaft pulley, ensure notches in pulley are
aligned with locating lugs in crankshaft.
Crankshaft Pulley
Center Bolt ...................................
1
148 (200) + 180 Degrees
Crankshaft Pulley-To-Crankshaft Hex Bolt .................... 18 (25)
Lock Carrier-To-Body Bolts ........................................... 37 (50)
INCH Lbs. (N.m)
Timing Belt Tensioner Bolt/Nut ................................... 89 (10)
Water Pump Bolt ......................................................... 89 (10)
1
If removed, manufacturer recommends using NEW bolt.
587
VOLVO
*1.9L 4-Cylinder Turbo
1.9L 4-Cyl. Turbo
S40 & V40
2000-01
Up To Engine VIN
1219110............
1
2.4 Hours ................. 250252
From Engine VIN
1219111 ............
1
2.4 Hours ................. 250311
1
timing belt and belt tensioner be replaced every 105,000 miles.
TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while belt is
removed.
Removal:
Remove right engine compartment cover and cover above
right headlight unit. Release serpentine drive belt by turn-
ing tensioner clockwise. Remove serpentine drive belt. See
Fig. 1.
Remove two screws securing upper timing belt covers.
Remove upper cover by releasing the two clips then re-
move the screw and the cover. See Fig. 2.
Use an appropriate engine lifting tool to support the weight
of the engine at timing belt end of engine.
Remove engine mount bolts and nuts on timing end of
engine. Remove engine mount. See Figs. 3 and 7.
Fig. 4: Removing Lower Timing Gear Cover
Fig. 1: Removing Accessory Drive Belt
Courtesy of Volvo Cars of North America
Fig. 2: Removing Timing Gear Covers
Fig. 3: Locating Engine Mount (2000)
588
Fig. 5: Locating Engine Bracket Bolts
Fig. 6: Locating Upper Rear Timing Belt Cover
Fig. 7: Locating Engine Mount (2001)
VOLVO
*1.9L 4-Cylinder Turbo (Cont.)
589
Fig. 8: Locating Snow Cap & Bolts
Fig. 9: Installing New Tensioner
Fig. 10: Installing New Timing Belt
VOLVO
Remove lower timing gear cover by releasing the bottom
cover and moving it backwards. See Fig. 4. On 2000 mod-
els, engine bracket may have to be removed for clearance
to remove belt. See Fig. 5.
On all models, remove right front wheel. Turn crankshaft
clockwise until camshaft sprocket timing marks align with,
inner timing gear cover, and crankshaft sprocket aligns with
the oil pump housing. See Fig. 6.
Loosen timing belt tensioner pulley bolt. See Fig. 11. Hold-
ing tensioner pulley bolt stationary, rotate pulley eccentric
clockwise with a 6 mm Allen wrench. Remove timing belt
from tensioner pulley, camshaft sprockets and water pump.
Remove splashguards from under engine compartment.
Remove bolts and snow cap. See Fig. 8. Remove timing
belt with a turning motion. Remove timing belt tensioner.
Inspection:
Spin tensioner and idler pulleys and listen for bearing noise.
Ensure pulley surfaces in contact with belt are clean and
smooth.
Installation:
Place timing belt between vibration damper and engine
block, and route belt upwards. Reinstall the lower snow
cap and replace the bolts. Install splashguards under en-
gine compartment.
aligned. Position new timing belt tensioner, and finger
tighten bolt A. See Fig. 9. Turn eccentric from tensioner in
lowest position.
Install timing belt in correct sequence. See Fig. 10. Install
upper rear timing cover on engine (do not tighten).
NOTE: Timing belt tension MUST be adjusted when the engine
is cold. Around 68F (20C) is the best temperature.
590
VOLVO
With timing belt installed, turn crankshaft clockwise until
timing belt is tensioned. Belt must be tensioned between
intake camshaft sprocket, idler pulley and crankshaft.
Holding tensioner bolt stationary, use a 6 mm hex wrench
to turn tensioner counterclockwise until tensioner indicator
passes marked position. See Fig. 11.
Turn tensioner eccentric back so that indicators position is
in center of window. See Fig. 11. Holding eccentric in this
position, tighten bolt B to 15 ft. lbs (20 N.m) without mov-
ing tensioner. See Fig. 11.
Recheck adjustment by pressing pin A clockwise and coun-
terclockwise to check. Rotate crankshaft two complete revo-
lutions and check that markings on crankshaft pulley and
timing gears align with marks on timing gear cover. Ensure
indicator pin A is in middle. Readjust if necessary. See
Fig. 12. After readjustment, always turn crankshaft 2 com-
plete revolutions to check if tensioner indicator returns to
correct position.
NOTE: Timing belt tensioner indicator will be in different positions
depending on engine temperature. At very low or high temperatures,
tensioner indicator will be to the left or right of center. See Fig.
13.
591
VOLVO
Install engine bracket (if removed), timing belt covers, and
snow cap.
NOTE: Close lid in side cover and move wheels straight.
Install serpentine drive belt. Reinstall engine mount and
body support. Install power steering hose. Install right front
wheel. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS.
Engine Bracket-To-Engine Block Bolt
Step 1 ........................................................................... 26 (35)
Step 2 ..................................................... Plus 75 Degree Turn
Engine Mount (2000)
To-Body Through-Bolt .................................................. 72 (98)
To-Engine Bolt ............................................................. 50 (67)
Engine Mount (2001)
To-Body Nut ................................................................. 37 (50)
To-Engine Bolt ............................................................. 50 (67)
Water Pump Bolt ............................................................ 13 (17)
Wheel Lug Nut ............................................................. 81 (110)
INCH. Lbs. (N.m)
Power Steering Hose Bolt .............................................. 89 (10)
Snow Cap Bolt ............................................................ 89 (10)
Timing Belt Cover
Front ........................................................................... 106 (12)
Upper ........................................................................... 89 (10)
Fig. 13: Timing Belt Tension Positions
592
VOLVO
*2.1L & *2.3L 4-Cylinder B21 & B23
Belt
Application Time
1
Kit No. No.
2.1L 4-Cyl. B21
242, 244 & 245
1976-79.......... 1.3 Hrs. ...... 2520320........ 250032
DL, GL, GLT
1980-83.......... 1.3 Hrs. ...... 2520320........ 250032
DL (Canadian)
1983............... 1.3 Hrs. ...... 2520320........ 250032
GLT
1981-83.......... 1.3 Hrs. ...... 2520320........ 250032
Turbo
1984-85.......... 1.3 Hrs. ...... 2520320........ 250032
2.3L 4-Cyl. B23
DL & GL
1982-85.......... 2.0 Hrs. ...... 2520320........ 250032
GLE (Canadian)
1984............... 2.0 Hrs. ...... 2520320........ 250032
GLT (Canadian)
1983............... 2.0 Hrs. ...... 2520320........ 250032
760 GLE
1984............... 2.2 Hrs. ...... 2520320........ 250032
1
kits.
On 1976-85 engines, the manufacturer recommends the belt
On 1986-88 engines, the manufacturer recommends the belt
Fig. 1: Timing Marks For Crankshaft, Intermediate Shaft &
Camshaft
TIMING BELT REMOVAL
Removal:
Disconnect negative battery cable. Remove fan shroud and
accessory drive belts. Remove timing belt cover. Rotate crank-
shaft until timing marks are aligned. See Fig. 1. Loosen belt
tensioner and pull belt outward until tensioner spring is com-
pressed. Tighten tensioner nut. Remove timing belt.
Installation:
Ensure that timing marks are still aligned. See Fig. 1. In-
stall belt around crankshaft and intermediate shaft so that
lines on belt are aligned with timing mark on crankshaft.
Install belt over camshaft pulley and tensioner roller. Loosen
tensioner nut to release spring tension. Tighten tensioner
nut.
tension ranges.
Camshaft Sprocket ..................................................... 37 (50)
Crankshaft Sprocket ................................................. 22 (166)
Drive Belt Tensioner Nut ............................................. 37 (50)
Fan Bolt ...................................................................... 33 (45)
Intermediate Shaft Sprocket ....................................... 37 (50)
593
VOLVO
*2.3L 4-Cylinder B230, B230F, B230FT
Belt
Application Time
1
Kit No. No.
2.3L 4-Cyl. SOHC
Coupe
1991............... 2.0 Hrs. ...... 2520320........ 250032
240 Series
1986-92.......... 2.0 Hrs. ...... 2520320........ 250032
1993............... 2.0 Hrs. ............................. 250234
740 Series
1986-92.......... 2.2 Hrs. ...... 2520320........ 250032
760 Series
1985-90.......... 2.2 Hrs. ...... 2520320........ 250032
780 Series
1989-90.......... 2.2 Hrs. ...... 2520320........ 250032
940 Series
1991-92.......... 2.2 Hrs. ...... 2520320........ 250032
1993-95.......... 2.2 Hrs. ............................. 250234
1
kits.
50,000 miles, except for 1994 and later B230FT engines with
EGR. On these engines, the manufacturer recommends the
timing belt be replaced at 100,000 mile intervals.
* NOTE: This application is an interference en-
gine. See page A-59 for interference engine cau-
tions.
TIMING BELT REMOVAL
CAUTION: Ensure timing marks align before removing timing
belt. DO NOT rotate crankshaft or camshaft with timing belt removed,
or valves may contact pistons.
Removal:
Disconnect negative battery cable. Loosen adjusters and
remove all drive belts and water pump pulley. Remove fan,
preheater hose (below fan shroud) and fan shroud.
Using center bolt on crankshaft, rotate crankshaft so mark
on camshaft pulley aligns with timing mark on inner timing
belt cover, and crankshaft pulley mark aligns with TDC mark
on timing belt cover.
Remove nut and washer from belt tensioner. Install Crank-
shaft Holder (5284) or equivalent, on crankshaft pulley and
belt tensioner stud. Install nut on stud. Remove crankshaft
center bolt, crankshaft pulley and lower timing belt cover.
Ensure timing marks are aligned. See Fig. 1.
NOTE: If reusing timing belt, mark direction of rotation for installation
reference.
Place mark on timing belt to indicate direction of belt rota-
tion. Loosen belt tensioner nut one turn. Pull on timing belt
to compress belt tensioner spring. Tighten belt tensioner
nut.
Install a 3 mm drill bit through hole of belt tensioner bolt to
lock belt tensioner spring in place. Remove timing belt from
camshaft sprocket.
Inspection:
Check belt teeth for cracks, damage or oil contamination.
roughness in rotation. Replace components if damaged.
Installation:
Install belt tensioner if previously removed. Ensure all tim-
ing marks align. See Fig. 1.
Outer side of timing belt has 2 lines, which should fit to-
ward crankshaft marks. Install belt over crankshaft sprocket
first, then over intermediate shaft. Stretch belt on tension
side and fit over camshaft sprocket. Slide back of belt onto
belt tensioner.
Loosen bolt on belt tensioner to apply spring tension
against drive belt. Tighten belt tensioner nut. Ensure tim-
ing marks align. To install remaining components, reverse
removal procedure.
CAUTION: Readjust timing belt when engine reaches normal operating
temperature.
Warm engine to normal operating temperature. Remove
plug from front timing belt cover. Loosen belt tensioner bolt
one turn and allow for belt tensioner spring to apply pres-
sure on timing belt. This readjusts timing belt to allow for
belt stretch. Tighten belt tensioner nut. Install rubber plug.
tension ranges.
1
Step 1 ....................................................................... 44 (60)
Step 2 ............................................... Additional 60 degrees
1
- Apply light coat of oil to bolts before installation.
594
VOLVO
*2.3L 4-Cylinder B234
1
Belt Part No.
2.3L 4-Cyl. B234
740 Series (Canadian)
1986-88
Balance Shaft ...........
2
......................... 250174
Camshaft ............ 2.5 Hours .................. 250173
1989 (With Automatic Tensioner)
2
......................... 250174
Camshaft ............ 2.5 Hours .................. 250198
1989 (With Manual Tensioner)
2
......................... 250174
Camshaft ............ 2.5 Hours .................. 250173
1990
2
......................... 250174
Camshaft ............ 2.5 Hours .................. 250173
940 Series (Canadian)
1991-92
2
......................... 250174
Camshaft ............ 2.5 Hours .................. 250198
1
2
Balance shaft labor included in camshaft.
50,000 miles.
TIMING BELT
CAUTION: Ensure timing marks align before removing timing
belt. DO NOT rotate crankshaft or camshaft with timing belt removed,
as it is possible valves may contact pistons.
Removal:
Disconnect negative battery cable. Remove radiator fan and
pulley. Remove fan shroud and servo pump. Remove A/C
compressor drive belts, if equipped. Remove timing cover
attaching bolts, then all three covers starting with top cover.
Rotate crankshaft until No. 1 cylinder is at TDC position.
Check that marks on camshaft pulleys align with those on
transmission mounting plate. Marking on belt guide plate
on crankshaft should be opposite TDC marking on cylinder
block. See Fig. 1.
Loosen tensioner lock nut, then compress tensioner spring.
Tighten tensioner lock nut and remove camshaft timing
belt.
Do not turn crankshaft and camshafts while timing belt is
removed. Remove balance shaft belt idler pulley. Loosen
locknut and remove balance shaft belt. See Fig. 2.
Installation:
Check that balance shaft marking aligns with markings on
transmission mounting plate. See Fig. 3. Ensure that crank-
shaft marking is opposite TDC marking on cylinder head.
Install balance shaft belt under crankshaft pulley assem-
bly. Ensure that blue dot (marking B) is opposite bottom
TDC marking on belt guide plate at bottom of crankshaft.
See Fig. 4.
Install balance shaft belt around left (upper) balance shaft
with marking C opposite marking on pulley. See Fig. 4.
Install balance shaft belt on right (lower) balance shaft with
marking A opposite marking on pulley. Install balance shaft
belt around tensioner. Ensure that markings are still
aligned.
Tighten balance shaft belt tensioner, using an Allen key
inserted in adjusting hole in tensioner. See Fig. 5. Carefully
rotate crankshaft a few degrees on either side of TDC posi-
tion to ensure that balance shaft belt engages properly in
pulleys. Return crankshaft to TDC position.
Ensure that adjusting hole in balance shaft belt tensioner
is below 3 oclock position when tightening locking bolt.
Torque locking bolt to 29.5 ft. Ibs. (40.5 N.m), using an Allen
key inserted in adjusting hole as counter hold. See Fig. 5.
Check balance shaft belt tension using Volvo Gauge Tool
(No. 998 8500) or equivalent.
Position gauge above idler. See Fig. 7. Balance shaft belt
tension should be within 1 to 4 unit range. Align double line
marking on camshaft timing belt with top marking on belt
guide plate. See Fig. 6. Ensure that single line markings
align with pulley markings.
Place camshaft timing belt around oil pump drive pulley,
then install belt onto left hand idler. Ensure that timing marks
are aligned properly and No. 1 cylinder is at TDC position.
Rotate crankshaft clockwise until pulley markings align with
those on transmission mounting plate. See Fig. 8.
Rotate crankshaft clockwise until pulley markings are 1 1/2
teeth past markings on housing. Tighten camshaft timing
belt tensioner lock nut. Start engine and allow to reach nor-
mal operating temperature, then shut engine off.
To check balance timing belt tension, start engine and al-
low to reach normal operating temperatures. Turn engine
off. Position gauge above location of dismantled idler. Belt
tension should be within 4.7 to 5.1 unit range.
If belt tension is low, rotate tensioner slightly clockwise,
then rotate crankshaft clockwise one revolution. Belt ten-
sion should be within 4.7 to 5.1 unit range. If belt tension is
high, repeat procedure. Install idler pulley and timing cov-
ers.
To check timing belt tension, rotate crankshaft until No.1
cylinder is at TDC position, then position Volvo Belt Gauge
Tool (No. 998 8500) or equivalent, between exhaust cam-
shaft pulley and idler. Belt tension should be within 5.3 to
5.7 unit range. See Fig. 9. Torque tensioner lock nut to 37 ft.
Ibs. (51 N.m). Replace protective cap in measuring zone.
See Fig. 10.
Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Replace
protective cap. If belt tension reading is outside above range,
remove protective cap, then loosen tensioner locknut. Po-
sition Volvo Gauge (998 8500) or equivalent in measuring
zone. See Fig. 10. If belt tension is low, move roller to adjust
belt tension to 5.8 to 6.2 units.
If belt tension is high, adjust to obtain a reading of 4.8 to 5.2
units. Torque tensioner lock nut to 37 ft. Ibs. (51 N.m), and
rotate crankshaft clockwise. Measure belt tension. Belt ten-
sion should be 5.3 to 5.7 unit range.
Torque tensioner lock nut to 37 ft. Ibs. (51 N.m). Remove
protective cap, then loosen tensioner. To complete instal-
lation, reverse procedure. Adjust drive belts to proper ten-
Tensioner Locking Bolt ............................................ 29.5 (40)
Tensioner Lock Nut ................................................. 37.0 (49)
595
VOLVO
*2.3L 4-Cylinder B234 (Cont.)
Fig. 1: Aligning Camshaft & Crankshaft Markings
Fig. 2: Removing Balance Shaft Belt
Fig. 3: Aligning Balance Shaft & Crankshaft Markings
Fig. 4: Installing Balance Shaft Belt
596
VOLVO
Fig. 5: Adjusting Tensioner
Fig. 7: Checking Balance Shaft Belt Tension
Fig. 8: Rotating Crankshaft
597
VOLVO
Fig. 9: Checking Belt Tension
Fig. 10: Adjusting Belt Tension
598
VOLVO
TIMING BELT
removed.
Removal:
Remove key from ignition switch. On S60 models, remove
the cross brace between the front shock towers.
On all models, remove upper timing belt cover. Remove
power steering pump reservoir with hoses attached and
set aside. Remove coolant reservoir and set aside. Re-
move accessory drive belt.
Remove front timing belt cover. Raise and support vehicle.
Remove right front wheel. Remove nut from fender liner
cover. Remove upper timing belt cover.
Turn crankshaft clockwise (as viewed from timing belt end
of engine) to align the timing marks on the crankshaft pul-
ley and camshaft sprockets. See Fig. 1. Turn crankshaft an
additional 1/4 turn clockwise, and then back again until the
timing marks align.
Loosen timing belt tensioner pulley center bolt. Holding
center bolt, turn the tensioner eccentric clockwise with a 6
mm Allen wrench. Turn eccentric until the hole for the Allen
wrench is at the 10 oclock position.
CAUTION: Vibration damper pulley bolts are torque-to-yield
type. If vibration damper pulley bolts are removed so that Counterhold
(999 5433) or equivalent can be installed, pulley bolts MUST be
replaced.
Raise and support vehicle. Holding vibration damper sta-
tionary with Counterhold (999 5433) or equivalent, remove
vibration damper center bolt. Remove vibration damper.
Lower vehicle. Remove timing belt.
Inspection:
Ensure pulley surfaces in contact with belt are clean and
smooth.
Installation:
If timing belt tensioner was remove, ensure tensioner fork
is installed with fork centered over rib on engine block.
2.3L 5-Cyl. Turbo
C70, S70 & V70
1998-01, Up To Engine VIN
1266127 .............
1
2.4 Hours ................. 250252
1998-01, From Engine VIN
1266128 .............
1
2.4 Hours ................. 250311
S60
2001, Up To Engine VIN
1266127 .............
1
2.0 Hours ................. 250252
2001, From Engine VIN
1266128 .............
1
2.0 Hours ................. 250311
2.4L 5-Cyl.
C70, S70 & V70
1998-01, Up To Engine VIN
1266127 .............
1
2.4 Hours ................. 250252
1266128 .............
1
2.4 Hours ................. 250311
S60
2001, Up To Engine VIN
1266127 .............
1
2.0 Hours ................. 250252
1266128 .............
1
2.0 Hours ................. 250311
1
the manufacturer recommends the belt be replaced every
105,000 miles. In addition, manufacturer recommends replac-
ing timing belt tensioner on 2001 C70.
599
VOLVO
Place timing belt around crankshaft pulley. Install vibration
damper. Install vibration damper center bolt. Hold vibration
damper stationary with Counterhold (999 5433) or equiva-
lent, and tighten center bolt to specification. See TORQUE
SPECIFICATIONS. Install NEW vibration damper pulley bolts
(if removed).
Place timing belt around idler pulley, intake camshaft pul-
ley, exhaust camshaft pulley, water pump and timing belt
tensioner.
NOTE: Timing belt tension MUST be adjusted when the engine
is cold. Around 68F (20C) is the best temperature.
Slowly turn crankshaft clockwise (as viewed from timing
belt end of engine) until the timing belt is tensioned. The
belt should be tight between the intake camshaft sprocket,
idler pulley and crankshaft sprocket.
Hold timing belt tensioner pulley bolt secure and turn
tensioner eccentric counterclockwise until the tensioner
needle passes to the right of center position. See Fig. 3.
Turn tensioner eccentric back until the needle reaches the
marked position corresponding to engine temperature. At
68F (20C), the needle must be centered in the window.
Holding the timing belt tensioner eccentric steady, tighten
the center bolt to 15 ft. lbs. (20 N.m). Ensure tensioner
needle is still in correct position. Press timing belt to see if
the indicator on the tensioner moves easily.
Turn crankshaft clockwise 2 turns. Align camshaft and crank-
shaft timing marks. Ensure the timing belt tensioner indi-
cator is within the correct area.
tion. Ensure camshaft and crankshaft sprocket timing
marks are still aligned. Ensure timing belt tensioner indi-
cator is in the correct position for engine temperature.
Install front and upper timing belt covers. Install accessory
drive belt. Install power steering reservoir. Check power
steering fluid level. Refill, if necessary.
Install coolant reservoir. Install fender liner cover. Install
front wheel. On S60 models, install shock tower brace.
Shock Tower Brace (S60)
Engine Bracket Bolt .................................................... 37 (50)
Shock Tower Bolt ....................................................... 59 (80)
Timing Belt Idler Pulley Bolt ............................. 17-18 (24-25)
Vibration Damper Center Bolt .................................... 133 (180)
Vibration Damper Pulley Bolts
1
Step 1 ........................................................................... 18 (25)
Step 2 ........................................................... Plus 30 Degrees
Water Pump Bolt ............................................................ 13 (17)
Wheel Lug Nut ........................................................... 100 (130)
INCH Lbs. (N.m)
Front Timing Belt Cover Bolt ..................................... 106 (12)
Upper Timing Belt Cover Bolt ........................................... 71 (8)
1
Always replace bolts if loosened or removed.
600
VOLVO
*2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder
Remove right front wheel and release wheel arch liner to
gain access to vibration damper. Remove vibration damper
guard. Turn crankshaft clockwise until all timing marks are
Remove tensi oner upper mounti ng bol t and l oosen
tensioner lower bolt. Twist tensioner to free pulley. Remove
lower bolt, tensioner, upper timing belt cover. If reusing old
timing belt, mark belt with arrow to indicate rotation direc-
tion. Remove timing belt.
Removal (6-Cylinder):
Remove auxiliary drive belt, front transmission cover splash
guard under engine, vibration damper guard, and ignition
coil cover.
Turn crankshaft clockwise until timing marks on camshaft
pulleys/transmission plate and crankshaft pulley/oil pump
housing are aligned. See Fig. 1. Remove upper transmis-
sion cover.
Remove tensioner upper mounting bolt and loosen lower
mounting bolt. Twist tensioner to free plunger/pulley. If re-
using old timing belt, mark belt with arrow to indicate rota-
tion direction. Remove lower bolt, tensioner, and timing
belt.
removed.
Inspection:
See Fig. 2. Ensure pulley surfaces in contact with belt are
clean and smooth. Check tensioner pulley arm and idler
pulley mountings, and tighten bolts as necessary. See
TORQUE SPECIFICATIONS. Check tensioner for signs of
leakage, no resistance when depressed, or a plunger that
cannot be depressed.
2.3L 5-Cyl. Turbo
850
1994.....................
1
2.4 Hours ...............
2
250217
1994.....................
1
2.4 Hours ...............
3
250252
1995-97................
1
2.4 Hours ................

250252
850 (Canadian)
1996.....................
1
2.4 Hours ................. 250252
2.4L 5-Cyl.
850
1993.....................
1
2.4 Hours ...............
2
250217
1993 ...................
1
2.4 Hours ...............
3
250252
1994-97................
1
2.4 Hours ................. 250252
850 (Canadian)
1995.....................
1
2.4 Hours ...............
2
250217
1995.....................
1
2.4 Hours ...............
3
250269
2.9L 6-Cyl.
S90 & V90
1997-98................
1
2.2 Hours ................. 250270
960
1992-93................
1
2.2 Hours ................. 250217
1994 ...................
1
2.2 Hours ................. 250252
1995-97................
1
2.2 Hours ................. 250270
1
- With Air Cond. add .5 hours. With shimmed Air
Cond. belt add .5 hours.
2
Through engine number 131034.
3
From engine number 131035.
On 1992 960 models, the manufacturer recommends the belt
be replaced every 30,000 mile intervals, starting at the first
40,000 mile service.
be replaced at 30,000 mile intervals, starting at the first 30,000
mile service.
to be replaced every 50,000 miles.
On 1993 850 models, with engine number 131034 and ear-
lier, the manufacturer suggests the belt be replaced every
50,000 miles. On 1994 850 models, and 1993 850 models
from engine number 131035, the manufacturer recommends
On ALL 1995-98 models, the manufacturer recommends the
belt be replaced every 70,000 miles.
TIMING BELT
Removal (5-Cylinder):
Disconnect negative battery cable. Remove spark plug cover
and 2 fuel line clips. Lift out expansion tank and place on
top of engine. Remove front timing belt cover. Remove aux-
iliary drive belt.
601
Fig 2: Checking Tensioner & Idler Pulleys
VOLVO
*2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder (Cont.)
Installation:
Compress tensioner and tighten center nut. Wait until com-
pression has taken place and insert a 2 mm locking pin in
plunger. Install tensioner and tighten mounting bolts to
specification.
Place timing belt around crankshaft pulley and right idler.
Place belt over camshaft pulleys. Position belt around wa-
ter pump and press over tensioner pulley.
Remove tensioner locking pin. To complete installation,
reverse removal procedure. Turn crankshaft 2 revolutions
to ensure timing marks on crankshaft and camshaft pul-
leys are aligned. See Fig. 1. Adjust drive belts to proper
Camshaft Cover Bolt .................................................. 13 (17)
Spark Plug .................................................................. 18 (25)
Timing Belt Pulley Bolt ................................................ 30 (40)
Vibration Damper Center Nut
5-Cylinder ................................................................. 133 (180)
6-Cylinder ................................................................. 221 (300)
Vibration Damper-To-Crankshaft Bolt
5-Cylinder
Step 1 ........................................................................ 18 (25)
Step 2 .................................................. Plus 30 Degree Turn
6-Cylinder
Step 1 ........................................................................ 26 (35)
Step 2 .................................................. Plus 50 Degree Turn
Water Pump Bolt ........................................................ 13 (17)
Wheel Lug Nut ............................................................. 81 (110)
602
VOLVO
2.4L 6-Cyl. Diesel
DL
1982
Camshaft ............
1
3.6 Hours ................. 250083
GL
1982-84
Camshaft ............
1
3.6 Hours ................. 250083
740 Series
1985-86
Camshaft ............
1
3.6 Hours ................. 250083
760 GLE
1983-84
Camshaft ............
1
3.6 Hours ................. 250083
760 Series
1985
Camshaft ............
1
3.6 Hours ................. 250083
1
75,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove splash guard,
cooling fan, spacer, and pulley. Remove fan and power
steering pump belts, power steering pump and expansion
tank cap. Drain and remove radiator. Disconnect battery
ground cable.
Remove valve cover and front and rear timing belt covers.
Using a 1 1/16" (27 mm) socket on damper pulley bolt, set
No. 1 cylinder at TDC (timing mark on flywheel at 0). Loosen
water pump and idler pulley bolts to remove timing belt
from camshaft gear. See Fig. 1.
Using Damper Pulley Wrench (5187) or equivalent, and
Damper Pulley Bolt Tool (5188) or equivalent, remove
damper pulley bolt. Using a (6 mm) socket, remove 4 screws
from damper pulley and pulley (it may be necessary to tap
pulley from shaft). Remove lower belt shield and timing
gear belt.
Remove center bolt from idler pulley. Using Idler Pulley
Removal Tool (5202) or equivalent, remove idler pulley. Re-
place and tap new idler pulley into position. Using Spanner
Wrench Tool (5199) or equivalent, hold front camshaft drive
gear in place and remove center retaining bolt. See Fig. 2.
NOTE: Idler pulley must be replaced when replacing timing gear
belt. Use Puller (5202) to remove pulley.
NOTE: Camshaft MUST NOT rotate or damage to valves and
pistons may result.
Tap gear loose from camshaft tapered end. Remove injec-
tion pump drive belt by loosening retaining bracket bolts.
Tighten one screw to hold pump in upper position. Use
Spanner Wrench Tool (5199) or equivalent to hold rear cam-
shaft sprocket and Wrench (5201) or equivalent to remove
center retaining bolt. Tap gear loose from camshaft. See
Fig. 2.
Installation:
Check that No. 1 cylinder is at TDC, timing mark on fly-
wheel is at 0 and camshaft lobes for No. 1 cylinder are
facing up with equally large angles in comparison with cyl-
inder head. See Fig. 1. Place Camshaft Lock Gauge Tool
(5190) or equivalent in camshaft groove at rear of cylinder
head.
Place a .008" (.2 mm) feeler gauge under left side of Cam-
shaft Locking Gauge Tool (5190) or equivalent. See Fig. 3.
Install timing gear belt and damper pulley. Replace 4
damper pulley bolts and torque to 15 ft. lbs. (20 N.m).
NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool
(5190) or equivalent is to compensate for timing gear clearance.
Using Damper Pulley Wrench Tools (5187 and 5188) or
equivalent, install and torque center bolt (use sealing agent
on center bolt threads) of damper pulley to 255 ft. lbs. (350
N.m). Install front timing gear belt and camshaft timing gear
(ensuring camshaft does not turn). Torque to 33 ft. lbs. (45
N.m) after setting timing marks.
Remove Camshaft Gauge Locking Tool (5190) and feeler
gauge from rear of camshaft. Install rear camshaft gear
and injection pump belt. Set injection pump timing. See
Fig. 4.
Position Belt Tension Gauge Tool (5197) or equivalent on
timing and injection pump belt, set gauge to .50" (12.5 mm).
Place tension on belt until mark on plunger is flush with
gauge sleeve and tighten bolts.
Using coolant pump to adjust timing gear belt tension, place
tension on belt until mark on plunger is flush with gauge
sleeve. Install valve cover and new gaskets. Install front
and rear timing gear covers. Install lower belt shield. Re-
ranges.
Camshaft Gear Bolt
Front ......................................................................... 33 (45)
Rear ....................................................................... 74 (100)
Crankshaft Pulley Nut ............................................. 258 (350)
Injector Pump Gear .................................................... 33 (45)
603
VOLVO
Fig. 1: Camshaft Timing & Injection Timing At TDC
Fig. 2: Using Camshaft Gear Retaining Wrench
Fig. 3: Setting Timing Using Camshaft Locking Gauge
Fig. 4: Injection Pump Alignment Marks
604
YUGO
1.1L 4-Cyl.
GV Series
1986-89................. 2.5 Hours .................. 250018
1.3L 4-Cyl.
GV Series
1987...................... 2.5 Hours .................. 250018
The manufacturer recommends inspection of the timing belt
every 15,000 miles. Although the manufacturer does not rec-
ommend a specific scheduled replacement interval, belt manu-
vals.
TIMING BELT
Removal:
Disconnect negative battery cable. Position No. 1 cylinder
at TDC of compression stroke. Disconnect positive battery
cable. Remove accessory drive belt. Remove cooling fan
and shroud. Remove crankshaft pulley. Remove timing belt
covers.
Align camshaft sprocket with timing mark. See Fig. 1.
Loosen tensioner lock nut and move tensioner pulley to-
ward engine mount. Tighten nut to secure tensioner in slack
position. Remove and discard timing belt.
CAUTION: Timing belts cannot be reused. DO NOT readjust belt
tension following initial installation of a new belt.
Installation:
Align camshaft sprocket with timing mark. Align crankshaft
sprocket with reference index. See Fig. 2. Position timing
belt tensioner to its !imit of travel toward engine mount and
partially tighten lock nut. Install a new timing belt with slack
on tensioner side. Loosen tensioner lock nut to apply ten-
sion. Tighten tensioner lock nut to 33 ft. Ibs. (45 N.m).
To apply equal tension to each side of timing belt, turn
crankshaft 2 revolutions in direction of travel. Tighten
tensioner lock bolt. Check for proper alignment of timing
marks. Reverse removal procedure to complete installa-
tion. Adjust drive belts to proper tension. See page A-60 for
Camshaft Housing Bolts ............................................ 14 (19)
Crankshaft Pulley Nut ............................................. 101 (137)
Tensioner Pulley Support Nut ..................................... 33 (45)
Fig. 1: Camshaft-To-Crankshaft Alignment

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