Table of Contents

Introduction & Technical Information . . . . . . . . . . A1

Alphabetical Model Listing . . . . . . . . . . . . . . . . A15
Replacement Instructions . . . . . . . . . . . . . . . . . . . 1
Changeover Listing . . . . . . . . . . . . . . . . . . . . . 786
Manufacturers Part Numbers . . . . . . . . . . . . . . 800

WARNING
Be Safe! Do not use Gates belts, pulleys or
sprockets on any aircraft propeller or rotor drive
systems or in-flight accessory drives. Those
Gates products are not designed or intended for
aircraft use.
CAUTION
Use Gates products only on applications specified
in Gates literature. Install and maintain products
according to the vehicle manufacturers recommended procedures and with the recommended
tools. Failure to follow these instructions could
result in injury or property damage. Gates
Corporation disclaims all liability due to failure to
follow these instructions.

Gates PowerGrip
Timing Component Kits
and
Individual Timing Components
Now you can have it either way!

PowerGripTiming
Component Kits

PowerGrip
Timing Components!

PowerGrip Timing Component Kits give you the best

and most complete repair solution for your customers.
Save time and money by preventing costly comebacks
and warranties. Ideal for the consumer because the job
is done right the first time; saving them from returning
when other components fail and accrue additional
labor costs.

Gates is the largest producer of automotive timing

belts in the world. Because we are the leader, we are
the experts in the timing system. Our expertise is used
globally to help OEMs design the most durable and
efficient timing systems available.

A broken belt can cause severe and expensive engine

damage. A failing or failed tensioner or idler pulley
bearing often causes timing belt failure. Thats why
each kit comes with the right components, plus detailed
installation instructions specific to each application.
With PowerGrip kits, its not necessary to multi-source
components, look up several different manufacturers,
or present your customer with several cartons containing different parts. Deliver in one carton with all the
components required to do a thorough job.
(Kits can contain multiple belts, tensioners, idler and tensioner pulleys, depending on the application. Kits do not
contain hydraulic tensioning cylinders or tensioning springs.)

Now Gates brings this expertise to you with

PowerGrip Timing tensioners and idlers!
Although Gates recommends a PowerGrip Timing
Component Kit whenever changing a timing belt,
there are those who will only want to replace a single
part. PowerGrip Timing Components provide the
solution. The broad Gates line covers passenger car
and light truck applications and includes automatic
timing tensioners that, until now, were only available
through an OEM dealership.
So, whether its the complete job or just what's necessary, Gates PowerGrip Timing Component System
products are the solution!
Note: Beware of low cost timing belts with little or no warranty. For Gates warranty information, see inside front cover.
A1

Gates Timing Component Oil Seals

Order these high quality cam and crank oil seals with our popular
Timing Component Kits to create the ultimate timing repair solution.
Gates TCK Oil Seals offer:
Improved belt life with Gates Timing Component Kit installation
Convenience through single source ordering
These quality seals are engineered to work in conjunction with our popular Timing Component Kit. They are designed to
keep oil away from the timing belt assembly, ensuring maximum belt life.
Gates suggests that installers replace oil seals when they install our Timing Component Kits, to ensure the best possible repair.

Timing System Operation

The crankshaft drives the
camshaft(s) and actuates the
valves via a belt or a chain.
The timing belt is widely used
by car manufacturers because
of its advantages over a chain,
namely reduced space, as well
as lighter and quieter running.

Important:
In order to achieve safe and thorough servicing of the engine, we recommend the belt, belt tensioner pulley, and idler pulleys of the timing system or the auxiliary drive, all be changed at the same time. It is highly probable that the source of damage to the belt
(too much or too little tension, vibration, high temperature, belt misalignment, etc.) will also have affected the other rotating components of the
system including the belt tensioner and idler pulley. If they are not changed together with the belt, early breakdown may be encountered, resulting in serious damage to the engine. It is highly recommended that belt tension be measured using a timing belt tension tester (Gates part
#91000.) See page A12 for more details.

A2

Technical Support
Several factors can cause timing belt tensioner or idler failure.
Bearing life is limited by wear, temperature, misalignment, and loss of lubricant. Most of these problems cannot be
readily identified by an inspection, so it is always best to replace the tensioner and/or idlers as part of the timing
belt replacement.
Top reasons to Replace Belt Tensioner and Idler when Replacing the Timing Belt
OE recommends as part of normal preventative maintenance
Preventative maintenance should address all forms of failure
After 60,000 miles tensioners are more likely to fail (especially after installation and adjustment of new belt)
Reduce labor claims and comebacks
A worn or loose pulley can cause belt problems
Normal tensions cannot be maintained to assure proper life of replacement belt
Internal bearing wear is not noticeable

Todays Timing Belts are Highly Sophisticated

The days of generic timing belts of standard materials and tooth profiles are gone.
Improved new generation belts are providing the extended durability and smoother performance characteristics
required by todays engines.
Gates leads the world in timing belt technology, assuring customers a replacement belt to match the capabilities of
the original belts.
HNBR Elastomeric Compound

High-Strength Tensile Cord

Formulated for better heat resistance and durability

Designed for high-tension applications

Improved Tooth Jacket

Engineered for improved wear resistance

Tooth Profiles Arent Interchangeable

The earliest timing belts had a trapezoidal tooth profile. Competition and more demanding applications led to the development of a curvilinear
profile. This in turn, evolved into a modified-curvilinear profile. Belts with different tooth profiles are not interchangeable.
Gates has the most complete timing belt line available, with more than 250 part numbers. The line includes both neoprene and HSN constructions,
and all three tooth profiles:
Trapezoidal

Curvilinear

Modified Curvilinear

Positioning Marks for Easy Installation

Gates timing belts have positioning marks to make installation fast and easy. You wont find
that with many competitive belts, which require you to count individual teeth for correct
belt installation.

A3

Timing System Component Identification

Hydraulic Damper Pivot Arm
Several engine manufacturers use a pivot arm in correlation with a hydraulic
damper to tension the belt. This damper uses a piston that pushes a pivot
arm with a pulley, providing the required tension. When re-using the
hydraulic damper the piston will need to be driven back into its cylinder
and locked in place. A vice can be used to
retract the piston. Simply remove the
damper from the engine, place it
between vice jaws and slowly
compress the piston. Once compressed, line up the holes in the
piston with the holes in the
cylinder and insert a pin to hold
the piston in place. The Gates
91010 pin set is a great tool, and
the only tool, created just for
this purpose.
See page A12 for details.

Automatic Spring Loaded Tensioner

Also known as frictional tensioner. Manufacturers are increasing their usage
each year because this type of tensioner provides a more consistent belt
tension that can react and adjust to todays high reving engines.
Gates carries several of these tensioners, many of which were only
available through the OE until now.
Proper installation of these tensioners is critical and
installation instructions must be followed. Once installed,
belt installation is generally very simple. In most cases a hexhead wrench is used to rotate the tensioner into a position
that permits the belt to slip into place. Once the belt is in
place the tensioner is allowed to return to its relaxed position,
applying the necessary tension.
When replacing any timing component always refer to the vehicles
Service Manual or this Gates Timing Belt Replacement Manual for
the most complete timing belt replacement instructions.

A5

What Makes Up a PowerGrip

Automatic Timing Belt Tensioner?
A Great Deal of Technology goes into a PowerGrip Automatic Tensioner:
Installation Shaft Assures proper positioning on the engine
when tensioner is installed.
Front Plate Retains the complete tensioner assembly axially.

Thrust Washer A self-lubricating surface that provides the

alignment for the tensioner.
Pulley Produced in either a highly engineered polymer or
metallic surface.
Bearing Precision ball bearings constructed for high heat and
premium seals for a maintenance free long life.
Pivot Bushing Assures proper tensioner arm alignment while
providing damping through this self-lubricating, exceptionally
wear resistant polymer component.
Arm Torque from the spring is transmitted to the pulley
through this precision aluminum component, providing a constant
belt tension. Includes operation range stops that impede kickback.
Spring Designed with a specific torque for each application,
this essential component provides the critical belt tension.
Spring Support This highly wear resistant, engineered polymer
provides secondary damping for an efficient timing belt system.
Pivot Shaft Sustains alignment between the tensioner arm and
pulley.
Base Plate Assures proper positioning on the engine while providing the secondary anti-kickback element.

NOTE: PowerGrip Automatic Tensioners are not serviceable and should never be disassembled.
These components are under a spring load and attempting to disassemble can cause injury.
A6

Timing Belt System Troubleshooting

One out of every three passenger cars and light trucks use a timing belt to transmit power from the crankshaft to the camshaft(s).
Most 4-cylinder and V-6 engines, as well as a few V-8s, use a timing belt. The timing belt is critical to the engine because it sets
the engines fuel/air and exhaust valves in motion.
There are two basic types of engines using timing belts, conventional and interference. If a timing belt on a conventional type
fails there is generally no additional engine damage, the engine simply can no longer function. However, many engines utilize the
interference design. This design allows for better power and fuel efficiency, but the valve to piston timing is extremely vital.
If the timing belt fails the pistons will collide with valves. This type of failure is one of the most costly repairs to a vehicle.
Whether your customers vehicle utilizes a conventional or interference engine, these failures can be avoided by adhering to the
OEM recommended replacement intervals and preventative maintenance. Typically an automaker recommends a timing belt
replacement at about 60,000 miles, but certain make/models require replacement at an earlier or later interval. See replacement
intervals noted in this manual. Also, severe conditions such as towing, aggressive driving and maintenance history need to
be considered.
The most common type of timing belt failure is through a failed bearing within the timing belt system pulley. Below are some
pulley failure modes to help you recognize a failing pulley:
Misalignment: Misalignment can be determined by rotating the pulley. Does it
wobble or is there roughness felt when spinning the pulley? Is the pulley bracket
worn or broken? Has the pulley been installed correctly and all foreign material
(grease, grime) removed from behind the mount? And finally, are all the bolts tightened
to specification?
Locked Pulley: A worn bearing commonly causes a locked or seized pulley. It could
also be a result of improper installation or the pulley coming into contact with
another object. Pulley surface discoloration is a direct result of a locked pulley.

Damaged Pulley Surface: A pitted, cracked, uneven, discolored or chipped pulley

should always be replaced. Foreign material build-up on the pulley surface is also an
issue and should be removed or replace the pulley.

Noise: Noise is a result of a failing bearing or improper belt tension. Replace the
pulley if the bearing is failing. In the case of improper tension, the use of a tension
meter is always recommended. Gates Timing Belt Tensioning Tester, part number
91000, is an excellent and simple tool for this task. See page A12 for details.
Damaged Pulley Bearing Seal: Grease leaking from the front or back of a pulley is
an indicator of the bearing seal being damaged and the bearing will soon fail.

Many times you can diagnose a timing belt system problem by looking at the belts appearance.
The chart on page A8 lists several of the conditions you may find.

A7

Timing Belt Troubleshooting Guide

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 handling
since this could seriously damage the tensile members and
lead to premature failure.

Installation Tips
IMPORTANT: Avoid crimping the belt when installing it on
pulleys no tools should be used on the belt.
Replace and properly refit timing 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. If engine is being repaired and belt is near
OEM recommended replacement interval, its a good time to
replace the belt.

A8

Timing Belt Troubleshooting Guide

Symptom

Probable Cause

Concern/Corrective Action
1. Excessive RPMs; Modified engine.
2. Follow proper storage and handling procedures.

Tensile Failure

1. Excessive shock load.

2. Improper belt handling and storage prior
to installation.
3. Debris or foreign object in drive.
4. Extreme pulley/sprocket run-out.
5. Extreme Over-tension.
1. Seized Drive Component

1. Replace Component (Tensioner/Idler pulley, W.P.,

camshaft, Oil pump).
2. Excessive RPMs; Modified engine.
3. Check camshaft/crankshaft journals.
4. Replace sprocket.
5. Worn sprocket bearing, replace sprocket; Bent bracket;
Improper sprocket installation.
6. Adjust tension to recommended value.

Tooth Shear

2. Excessive shock loads.

3. Extreme sprocket run-out.
4. Worn sprocket.
5. Misaligned drive.
6. Belt under tensioned.

3. Remove objects; Replace pulleys.

4. Replace pulley/sprocket.
5. Adjust tension to recommended value.

4. Worn sprocket.

1. Adjust tension to recommended value.

2. Correct alignment.
3. Worn sprocket bearing, replace sprocket; Bent bracket;
Improper sprocket installation.
4. Replace sprocket.

Backside Cracks

1. Extreme high temperature

2. Extreme low temperature at start-up.
3. Cocked sprocket.
4. Excessive tension

1. Overheated engine; Seized or partially seized pulley

2. Install engine heater
3. Replace Sprocket.
4. Adjust tension to recommended value.

Land Wear
(wear between teeth)

1. Excessive tension
2. Worn Sprocket

1. Adjust tension to recommended value.

2. Replace Sprocket

1. Oil, fuel, coolant leak.

1. Replace faulty seals and/or gaskets; Check timing cover

for improper installation, replace if cracked or worn.

1. Damage due to handling.

2. Flange damage.
3. Belt tension too low.
4. Rough belt pulley flange.
5. Improper tracking.
6. Belt contacting engine, timing cover or
other engine component.

1. Follow proper handling instructions.

2. Replace sprocket.
3. Adjust tension to recommended value.
4. Replace sprocket.
5. Correct alignment.
6. Remove obstruction or correct alignment.

1. High tension.
2. Low tension.
3. Misalignment.

1. Adjust tension to recommended value.

2. Adjust tension to recommended value.
3. Worn sprocket bearing, replace sprocket; Bent bracket;
Improper sprocket installation.
4. Replace pulley(s).

Tooth Wear

Contamination

Edge Wear

Unusual Noise

1. Too low or high belt tension.

2. Belt running partly off unflanged sprocket.
3. Misaligned drive.

4. Damaged pulley flange.

A9

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 heads, and 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

Interference

No Valve/Piston
Interference

Valve/Piston
Interference

NOTE: For your convenience, interference engines have been footnoted with a star in the application listings of
this publication and are noted in the index. 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 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 and pulleys checked. If either/or both need replacing, do
it now, along with the other repairs and save time and money.

A10

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 who may not know the engine type they have, but may
be able to identify it through these illustrations.

A11

Timing System Tools

Gates professional tools help you quickly and easily
install and maintain timing system components.
Multi-Lock Tool
Part No. 91009
Many engines risk expensive damage from interference piston-to-valve or
valve-to-valve contact. Multi-Lock tool locks twin camshafts in place during timing belt replacement or engine overhaul. Fits onto sprockets and
extends to hold sprocket teeth. Incorporates variable pitch adjustable
arms to fit various diameters and tooth pitches. Unique design is fully
adjustable to fit numerous applications including diesel injector pump
sprockets and sprockets that are positioned closely together like those on
Mitsubishi or GM EcoTec engines. Ratchet locking handle provides compact,
strong lever action for secure positioning. Includes extension bar for wider
spaced cams ($25 value).

Timing Belt Tension Tester

Part No. 91000
Provides a precise method of testing timing belt tension on a variety of automotive applications. Traditionally, technicians needed to purchase several
specialized tools for each type of vehicle being serviced. Gates tension tester
will test any timing belt up to 30mm wide, thus replacing several expensive
tools. Comes with adapters for varying belt thicknesses. Uses force deflection
method to measure tension. Compact design works in tight engine compartments. Scale can be read in any position. Includes coupon for free timing
belt manual on CD.

Hydraulic Tensioner Pin Set

Part No. 91010
A Gates exclusive thats a must have for every technician. Timing belt
tensioners need to be compressed during service. Many technicians use a
drill bit or allen wrench to hold tensioners in their compressed state,
which can be dangerous and may bend or damage tools. Pin set is made
of hardened spring steel to hold the strongest tensioners. Comes conveniently mounted on key chain with six different sizes to service a variety
of applications. Can also be used to hold certain serpentine belt tensioners in place during service.

A12

Timing System Tools - Continued

Master Timing Kit
Part No. 91007
Kit includes one Gates Timing Belt Tension Tester (#91000), one Cam Gear
Sprocket Tool (#91008) and two Gates Multi-Lock Tools (#91009).

Cam Gear Sprocket Tool

Part No. 91008
Many engine-timing procedures require camshaft to be held in position
while gear or belt is removed from shaft to re-align cam timing position
properly. Gear holding tool provides safe, effective means for holding gear
while removing and reinstalling belt or sprockets without damaging gears,
cams or valves. Tool can also be used to turn gears during timing alignment. Essential tool for many timing belt, pump adjustment and engine
timing applications.

Gates offers several timing belt sales aids:

Timing Belt Counter Card (428-1437)

and Brochures (428-1438)

PowerGrip Timing Systems

Product Catalog (428-1448)

Timing Belt Replacement

Mileage Wall Chart (428-0408)

A13

Belt Tensioning
V- Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the Gates 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.
Suggested
Tension (lbs.)
Ranges

Installation
Tension (lbs.)
Used Belts

Installation
Tension (lbs.)
New Belts

1/4"

45-65

60.0

80.0

5/16"

60-85

75.0

100.0

190-255

205.0

270.0

3/8"

85-115

100.0

130.0

1"

215-295

230.0

310.0

1/2"

105-145

120.0

160.0

1-1/16"

225-310

240.0

325.0

Belt Top
Width

Belt Top
Width
13/16"
7/8"

Suggested
Tension (lbs.)
Ranges

Installation
Tension (lbs.)
Used Belts

Installation
Tension (lbs.)
New Belts

175-240

190.0

255.0

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

3/4"

160-220

175.0

235.0

NOTE:

A belt is considered "used" once it has been "run-in".

Micro-V Belt Tension Ranges for Manual Tensioners

Always use a belt tension gauge that indicates static tension, such as the Gates Krikit Tension Gauge, to
determine proper tension from the Installation Chart. Many Micro-V 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.

A14

Number
of Ribs

Suggested
Tension (lbs.)
Ranges

Installation
Tension (lbs.)
Used Belts

Installation
Tension (lbs.)
New Belts

Number
of Ribs

45-60

67.5

90.0

60-80

90.0

120.0

10

75-100

112.5

150.0

11

90-125

135.0

187.5

12

105-145

157.5

217.5

14

120-160

180.0

240.0

NOTE:

A belt is considered "used" once it has been "run-in".

Suggested
Tension (lbs.)
Ranges

Installation
Tension (lbs.)
Used Belts

Installation
Tension (lbs.)
New Belts

135-180

202.5

270.0

150-200

225.0

300.0

165-220

247.5

333.0

180-240

270.0

360.0

210-280

292.5

420.0

ALPHABETICAL MODEL LISTING

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

ACURA
Passenger Cars
EL (Canadian)
1997-00
1.6L 4-Cyl. *#
Integra
1986-89
1.6L 4-Cyl. *#
1992-93
1.7L 4-Cyl. *#
1990-94
1.8L 4-Cyl. (Exc. VTEC) *#
1995-96
1.8L 4-Cyl. (Exc. VTEC) *#
1997-01
1994
1995-96
1997-01
Legend
1986-87
1987-89
1990
1991-94
1995
MDX
2001-04
NSX
1991-96

T224

4
5
6
6
6
6
6
6
6
6

T41018
T41016
T41016
T41016

Not Applicable
Not Applicable
Not Applicable
Not Applicable

1.8L 4-Cyl. (Exc. VTEC) *#

1.8L 4-Cyl. (VTEC) *#
1.8L 4-Cyl. (VTEC) *#

T184
T247
T247

TCK184
TCK247
TCK247

T41016
T41016
T41016

Not Applicable
Not Applicable
Not Applicable

1.8L 4-Cyl. (VTEC) *#

T247

TCK247

T41016

Not Applicable

2.5L V6 *#
2.7L V6 *#
2.7L V6 *#
3.2L V6 (C32A1) *#
3.2L V6 (C32A1) *#

T129
T129
T129
T193
T193

TCK129
TCK129
TCK129
TCK193
TCK193

T41015
T41015
T41015
T41021
T41021

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
90,000
90,000
90,000 Normal
60,000 Severe

12
12
12
26
26
26

3.5L V6 (J35A3) *#

T286

TCK286

Not Available

Not Available

105,000 3

23

Inspect at 90,000,
replace if needed
105,000 3
105,000 3

14
14
14
14

Inspect at 90,000,
replace if needed
105,000 3
105,000 3

14
14
14
14

1997-04
1997-04
NSX-T
1995-96

3.0L V6
3.2L V6

3.0L V6

1997-03
1997-03
Vigor
1992-94
2.2CL
1997

3.0L V6
3.2L V6

1997-98
3.0CL
1997-99
3.2CL
2001-03

60,000 1
90,000
90,000
90,000 Normal
60,000 Severe
105,000 3
90,000
90,000 Normal
60,000 Severe
105,000 3

TCK130
TCK227
TCK184
TCK184

2.5TL
1995-96

T130
T227
T184
T184

3.0L V6

2.3CL
1998-99

105,000 3

2.5L 5-Cyl. *#

T211

T41020

Not Applicable

90,000

10

2.2L 4-Cyl. *#
Balance Shaft

T186

TCK244

T41013

Not Applicable

T244

TCK244

T41014

Not Applicable

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

8
8
8
8

Camshaft
2.3L 4-Cyl. *#
Balance Shaft
Camshaft

T186
T244

TCK244
TCK244

T41013
T41014

Not Applicable
Not Applicable

105,000 3
105,000 3

8
8

2.5L 5-Cyl. *#

T211

T41020

Not Applicable

2.5L 5-Cyl. *#

T211

T41020

Not Applicable

90,000 Normal
60,000 Severe
105,000 3

10
10
10

3.0L V6 (J30A1) *#

T286

TCK286

Not Available

Not Available

105,000 3

20

3.2L V6 (J32A1/A2) *#

T286

TCK286

Not Available

Not Available

105,000 3

23

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A15

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

3.2L V6 (C32A6) *#

T193

TCK193

T41021

Not Applicable

3.2L V6 (C32A6) *#
3.2L V6 (J32A1/A2) *#
3.2L V6 (J32A1/A2) *#
3.2L V6 (J32A1/A2) *#
3.2L V6 (J32A3) *#

T193
T286
T286
T286
T329

TCK193
TCK286**
TCK286**

T41021
T41090**
T41090**

Not Applicable
T42038
T42038

3.5L V6 (C35A1) *#
Balance Shaft
Camshaft

T280
T279

3.2L V6 (SOHC) #
3.5L V6 (DOHC) #

T221
T303

2.5L V6
3.0L V6

Engine

Recommended
Replacement
Interval (Miles)

Page

ACURA (Cont.)
3.2TL
1996
1997-98
1999
2000
2001-03
2004
3.5RL
1996-04
Light Trucks
SLX
1996-97
1999-98

90,000 Normal
60,000 Severe
105,000 3
105,000 3
105,000 3
105,000 3
105,000 3

26
26
26
20
23
23
23

105,000 3
105,000 3

29
29

60,000
75,000

35
33

T120

50,000

37

T120

50,000

39

1.7L 4-Cyl. *

T119

60,000 1

609

2.0L 4-Cyl. *

T017

60,000 1

41

1.7L 4-Cyl. *

T119

60,000 1

41

2.0L 4-Cyl. *

T017

TCK017

T41079

Not Applicable

60,000 1

41

2.0L 4-Cyl. *

T017

TCK017

T41079

Not Applicable

60,000 1

41

60,000

292

60,000 1
60,000

298
300

TCK221**

T41028**

T42002

ALFA ROMEO
GTV Coupe
1982-86
164L, LS & S
1991-93

AMERICAN MOTORS
Alliance
1985-87
Concord
1978-79
Encore
1985-86
Gremlin
1977-78
Spirit
1979

TCK017

T41079

Not Applicable

ASUNA
Passenger Cars
Sunfire (Canadian)
1993
1.8L 4-Cyl. (DOHC) #
Light Trucks
Sunrunner (Canadian)
1989-95
1.6L 4-Cyl. (SOHC, VIN U)
1994-02
1.6L 4-Cyl. (SOHC, VIN 6)

T205

T164
T212

TCK164
TCK212

T41064
T41065

Not Applicable
Not Applicable

AUDI
Allroad
2001-04
A4
1997-98

2.7L V6 Twin Turbo (APB) *#

T297

105,000

72

1.8L 4-Cyl. Turbo (AEB) *

152 Tooth Belt 5

T291

153 Tooth Belt

T317

105,000 Normal
52,500 Severe
105,000 Normal
52,500 Severe

47
47
47
47

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
5
- ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).
A16

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

105,000 Normal
52,500 Severe
105,000 Normal
52,500 Severe
120,000
90,000
60,000 1
90,000
90,000
75,000
105,000

47
47
47
47
59
59
80
80
82
82
82

105,000 Normal
52,500 Severe
105,000 Normal
52,500 Severe

49
49
86
86

105,000 Normal
52,500 Severe
105,000 Normal
52,500 Severe

49
49
86
86

105,000 Normal
52,500 Severe
105,000 Normal

47
47
47

105,000 Normal
52,500 Severe
105,000 Normal
52,500 Severe
120,000
90,000
60,000 1
90,000
90,000
75,000

47
47
47
47
59
59
80
80
82
82

AUDI (Cont.)
A4 (Cont.)
1999-00

1.8L 4-Cyl. Turbo

(AEB & ATW) *
152 Tooth Belt 5

T291

153 Tooth Belt

T317

2000-01
1.8L 4-Cyl. Turbo (AWM) *
2002-04
1.8L 4-Cyl. Turbo (AWM) *
1996
2.8L V6, 12-Valve *#
1997
2.8L V6, 12-Valve *#
1998
2.8L V6, 30-Valve *#
1999
2.8L V6, 30-Valve *#
2000-01
2.8L V6, 30-Valve *#
A4 Avant & Sedan
2002-04
1.8L 4-Cyl. Turbo (AMB) *#

T306
T306
T218
T218
T297
T297
T297
T306

2002-04

3.0L V6, 30-Valve (AVK) *#

T330

A4 Cabriolet
2003-04

1.8L 4-Cyl. Turbo (AMB) *#

T306

2002-04

3.0L V6, 30-Valve (AVK) *#

T330

1.8L 4-Cyl. Turbo (AEB) *

152 Tooth Belt

T291

A4 Quattro
1997-98

1999-00

2000-01
2002-04
1996
1997
1998
1999

153 Tooth Belt

1.8L 4-Cyl. Turbo
(AEB & ATW) *
152 Tooth Belt 5

T317
T291

153 Tooth Belt

T317

1.8L 4-Cyl. Turbo (AWM) *

1.8L 4-Cyl. Turbo (AWM) *
2.8L V6, 12-Valve *#
2.8L V6, 12-Valve *#
2.8L V6, 30-Valve *#
2.8L V6, 30-Valve *#

T306
T306
T218
T218
T297
T297

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
5
- ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).
A17

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Recommended
Replacement
Interval (Miles)

Page

T218
T218
T297
T297
T297
T297
T330

60,000 1
90,000
90,000
90,000
75,000
105,000
105,000 Normal
52,500 Severe

80
80
80
82
82
82
86
86

T297
T218
T218
T297
T297
T297
T297
T297

105,000
60,000 1
90,000
90,000
90,000
75,000
105,000
105,000 Normal
52,500 Severe

72
80
80
80
82
82
82
111
111

3.7L V8 (AEW) *#
3.7L V8 (AEW) *#
4.2L V8 *#

T207
T207
T297

90,000
75,000
105,000

104
104
108

4.2L V8 (ABZ Engine) *#

4.2L V8 (ABZ Engine) *#
4.2L V8 (ABZ Engine) *#

T207
T207
T297

90,000
75,000
105,000

104
104
108

2.8L V6, 12-Valve *#

2.8L V6, 12-Valve *#

T218
T218

60,000 1
90,000

80
80

2.2L 5-Cyl. #
2.2L 5-Cyl. #
113 Tooth Belt
120 Tooth Belt

T065

60,000 1

118

T065
T127

60,000 1
60,000 1

118
118

2.2L 5-Cyl. #

T127

60,000 1

118

2.3L 5-Cyl. #

T197

60,000 1

68

1.6L 4-Cyl. #

T017

60,000 1

43

2.2L 5-Cyl. #
2.2L 5-Cyl. #
113 Tooth Belt
120 Tooth Belt

T065

60,000 1

118

T065
T127

60,000 1
60,000 1

118
118

2.2L 5-Cyl. Turbo

T225

60,000 1

66

2.7L V6 Twin Turbo *#

T297

105,000

76

2.2L 5-Cyl. Turbo #

T225

60,000 1

66

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

AUDI (Cont.)
A6
1995-96
1997
1998
1998
1999
2000
2002-04

2.8L V6, 12-Valve *#

2.8L V6, 12-Valve *#
2.8L V6, 12-Valve *#
2.8L V6, 30-Valve *#
2.8L V6, 30-Valve *#
2.8L V6, 30-Valve *#
3.0L V6, 30-Valve (AVK) *#

A6 Quattro & Quattro Turbo

2000-04
2.7L V6, Twin Turbo *#
1995-96
2.8L V6, 12-Valve *#
1997
2.8L V6, 12-Valve *#
1998
2.8L V6, 12-Valve *#
1998
2.8L V6, 30-Valve *#
1999
2.8L V6, 30-Valve *#
2000-01
2.8L V6, 30-Valve *#
2000-04
4.2L V8 *#
A8
1997-98
1999
2000-03
A8 Quattro
1997-98
1999
2000
Cabriolet
1994-96
1997-98
Coupe
1981-83
1984-85
Coupe GT
1986-87
Coupe Quattro
1990-91
Fox
1973-79
Quattro
1983
1984-85
S4
1992-94
S4 Quattro
2000-02
S4 Sedan
1992-94

TCK017

T41079

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A18

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

AUDI (Cont.)
S6
1995
2.2L 5-Cyl. Turbo #
S6 Avant Quattro
2002-03
4.2L V8 #
S6 Quattro
1995
2.2L 5-Cyl. Turbo #
S8
2001-03
4.2L V8 *#
TT Coupe & Roadster
2000-04
1.8L 4-Cyl. Turbo *#
V8 Quattro
1990-91
3.6L V8 (PT Engine) *#
1992-94
4.2L V8 (ABH Engine) *#
80
1988-90
2.0L 4-Cyl. *
1991-92
2.3L 5-Cyl. #
80 Quattro
1988
2.3L 5-Cyl. #
1989
2.3L 5-Cyl. #
Up To Chas. 89J394742
From Chas. 89J394743
1990-92
2.3L 5-Cyl. #
90
1988
2.0L 4-Cyl. *
1988
2.3L 5-Cyl. #
1989
2.3L 5-Cyl. #
Up To Chas. 89J396702
From Chas. 89J396703
1990-91
2.3L 5-Cyl. #
1993-95
2.8L V6, 12-Valve *#
90 Quattro
1988
2.3L 5-Cyl. #
1989
2.3L 5-Cyl. #
Up To Chas. 89J394742
From Chas. 89J394743
1990-92
2.3L 5-Cyl. #
1993-95
2.8L V6, 12-Valve *#
100
1989-91
2.3L 5-Cyl. #
Up To Chas. 063969
From Chas. 063970
1990-91
2.3L 5-Cyl. #
1992-94
2.8L V6, 12-Valve *#
100 Quattro
1989-91
2.3L 5-Cyl. #
Up To Chas. 063969
From Chas. 063970
1990-91
2.3L 5-Cyl. #
1992-94
2.8L V6, 12-Valve *#

T225

60,000 1

66

T297

105,000 Normal
52,500 Severe

111
111

T225

60,000 1

66

T297

105,000

108

T306

120,000

56

T207
T207

60,000
90,000

98
98

60,000 1
60,000 1

63
70

T127

60,000 1

70

T127
T170
T170

60,000 1
60,000 1
60,000 1

70
70
70

60,000 1
60,000 1

63
70

T127
T170
T170
T218

60,000 1
60,000 1
60,000 1
60,000 1

70
70
70
80

T127

60,000 1

70

T127
T170
T170
T218

60,000 1
60,000 1
60,000 1
60,000 1

70
70
70
80

T127
T170
T170
T218

60,000 1
60,000 1
60,000 1
60,000 1

70
70
70
80

T127
T170
T170
T218

60,000 1
60,000 1
60,000 1
60,000 1

70
70
70
80

T017
T170

T017
T127

TCK017

TCK017

T41079

T41079

Not Applicable

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A19

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

AUDI (Cont.)
200
1989
1990-91
200 Quattro
1989

2.2L 5-Cyl. #
Up To Chas. 44K400000
From Chas. 44K400001
2.2L 5-Cyl. #

T127
T170
T170

60,000 1
60,000 1
60,000 1

118
118
118

2.2L 5-Cyl. #
Up To Chas. 44K004457
From Chas. 44K004458
2.2L 5-Cyl. #

T127
T170
T170

60,000 1
60,000 1
60,000 1

118
118
118

60,000 1
60,000 1
60,000 1

42
43
118

T127

60,000 1

118

T127

60,000 1

118

60,000 1

45

60,000 1
60,000 1
60,000 1

118
118
118

1990-91
4000
1982-83
1.6L 4-Cyl. Diesel
1980-83
1.7L 4-Cyl. *#
1980-81
2.2L 5-Cyl. #
4000CS
1986-87
2.2L 5-Cyl. #
4000CS Quattro
1987
2.2L 5-Cyl. #
4000S
1984-87
1.8L 4-Cyl. *
4000S Quattro
1984-85
2.2L 5-Cyl. #
113 Tooth Belt
120 Tooth Belt
1986
2.2L 5-Cyl. #
5000
1979-83
2.0L 5-Cyl. Diesel *#
Camshaft
Injection Pump
1979-83
2.0L 5-Cyl.Turbo Diesel *#
Camshaft
Injection Pump
1978-83
2.2L 5-Cyl. Turbo #
5000 Quattro
1988
2.3L 5-Cyl. #
5000CS Quattro
1987-88
2.2L 5-Cyl. #
5000S
1987-88
2.3L 5-Cyl. #
1984-85
2.2L 5-Cyl. #
113 Tooth Belt
120 Tooth Belt
1986-87
2.2L 5-Cyl. #
5000S Quattro
1988
2.3L 5-Cyl. #

T043
T017
T065

T017
T065
T127
T127

TCK017

TCK017

T41079

T41079

Not Applicable

Not Applicable

1, 2

65
65

T083
T082

60,000
60,000

T083
T082
T065

60,000 1, 2
60,000 1, 2
60,000 1

65
65
118

T127

60,000 1

118

T127

60,000 1

118

T127

60,000 1

70

T065
T127
T127

60,000 1
60,000 1
60,000 1

118
118
118

T127

60,000 1

70

T131
T106

60,000 3
60,000 3

120
120

1, 2

BMW
325 Series
1987

2.5L 6-Cyl. *
127 Tooth Belt
128 Tooth Belt

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A20

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T131
T106
T131

TCK131

T41083

Not Applicable

TCK131

T41083

Not Applicable

Recommended
Replacement
Interval (Miles)

Page

60,000 3
60,000 3
60,000 3

120
120
120

60,000 3
60,000 3

120
120

BMW (Cont.)
325 Series (Cont.)
1988
2.5L 6-Cyl. *
127 Tooth Belt
128 Tooth Belt
1989-91
2.5L 6-Cyl. *
1984-87
2.7L 6-Cyl. *
127 Tooth Belt
128 Tooth Belt
1988
2.7L 6-Cyl. *
127 Tooth Belt
128 Tooth Belt
525i
1989-93
2.5L 6-Cyl. *
1994-95
2.5L 6-Cyl. *
528e
1982-88
2.7L 6-Cyl. *
127 Tooth Belt
128 Tooth Belt

T131
T106
T131
T106

TCK131

T41083
T41083

Not Applicable

60,000 3
60,000 3

120
120

T131
T131

TCK131

T41083

Not Applicable

60,000 3
60,000 3

120
120

60,000 3
60,000 3

120
120

T131
T106

BUICK
Skyhawk
1982-86
1987-88

1.8L 4-Cyl. #
2.0L 4-Cyl. #

T081
T081

TCK081
TCK081A

Not Applicable Not Applicable

Not Applicable Not Applicable

60,000 1
60,000 1

271
272

3.0L V6 (DOHC) *#
3.0L V6 (DOHC) *#

T285
T285

TCK285
TCK285A

Not Available
Not Available

100,000
100,000

274
274

3.2L V6 *

T285

100,000

278

T310

60,000

266

T037
T039
T037
T039
T061
T076

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

265
265
265
265
265
270

CADILLAC
Catera
1997-98
1999-01
CTS
2003-04

Not Available
Not Available

CHEVROLET
Passenger Cars
Aveo
2004
1.6L 4-Cyl. #
Chevette
1976
1.4L 4-Cyl.
1977
1.4L 4-Cyl.
1976
1.6L 4-Cyl.
1977-78
1.6L 4-Cyl.
1979-87
1.6L 4-Cyl.
1981-86
1.8L 4-Cyl. Diesel *
Lumina (Exc. Van)
1991-95
3.4L V6 #
1996-97
3.4L V6 *#
Metro
1998-00
1.0L 3-Cyl.
1998-01
Monte Carlo
1995
1996-97
Nova
1988
1985-88

T192
T273

TCK192
TCK273

Not Available
Not Available

Not Available
Not Available

60,000
60,000

284
284

T194

TCK194A

T41010

Not Applicable

Inspect at 60,000;
replace at 100,000
100,000

294
296

1.3L 4-Cyl.

T194

3.4L V6 #
3.4L V6 *#

T192
T273

TCK192
TCK273

Not Available
Not Available

Not Available
Not Available

60,000
60,000

284
284

1.6L 4-Cyl. (DOHC)

1.6L 4-Cyl. (SOHC)

T112
T070

TCK070

T41066

Not Applicable

60,000 1
60,000 1

269
269

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A21

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T118
T162
T162

TCK118
TCK118

Not Available
Not Available

Not Applicable
Not Applicable

60,000
60,000
60,000

293
293
293

T41009

Not Applicable

60,000
60,000

294
294

T075

60,000

405

T075

60,000

405

60,000

300

100,000 Federal
105,000 Calif.
105,000
105,000
100,000 Federal
105,000 California
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

131
131
150
150
150
150
162
162
162
162
182
182
182
182
182
182
182
182
182
182
182
182

CHEVROLET (Cont.)
Spectrum
1985-87

1.5L 4-Cyl. *#
Up To 4/30/87
From 5/1/87
1988
1.5L 4-Cyl. *#
Sprint (Includes Canadian)
1985-88
1.0L 3-Cyl.
1989-91
1.0L 3-Cyl.

T095
T166

CHEVROLET/G.M.C.
Light Trucks
LUV
1981-82
2.2L 4-Cyl. Diesel *
S10 & S15 Pickups
1983-85
2.2L 4-Cyl. Diesel *
Tracker
1998-02
1.6L 4-Cyl. (SOHC, VIN 6)

T212

TCK212

T41065

Not Applicable

CHRYSLER
Passenger Cars
Cirrus
2000
2.0L 4-Cyl. (SOHC, VIN C) *#

T245

1995-96
1997
2000

2.4L 4-Cyl. (DOHC, VIN X) #

2.4L 4-Cyl. (DOHC, VIN X) #
2.4L 4-Cyl. (DOHC, VIN X) #

T265
T265
T265

1995-00

2.5L V6 *#

T259

Concorde (Includes Canadian)

1998-99
3.2L V6 *#
2000
3.2L V6 *#

T43005
T43005

Not Available
Not Available

TCK259**

T41039**

T42018

T295
T295

TCK295**
TCK295**

T41084**
T41084**

Not Applicable
Not Applicable

2001

3.2L V6 *#

T295

TCK295**

T41084**

Not Applicable

1993-94
1995-97
2000-01

3.5L V6 *#
3.5L V6 *#
3.5L V6 *#

T219
T255
T295

TCK219**
TCK255**
TCK295**

T41084**
T41084**

Not Applicable
T41002**
Not Applicable

2002

3.5L V6 *#

T295

TCK295**

T41084**

Not Applicable

T295

TCK295**

T41084**

Not Applicable

105,000
100,000 Federal
105,000 California
100,000 Federal
105,000 California
105,000
105,000
100,000 Federal
105,000 California
100,000 Federal
105,000 California
102,000

T071

TCK071

T41000

Not Applicable

60,000 1

143

T071

TCK071

T41000

Not Applicable

60,000 1

143

T295
T295

TCK295**
TCK295**

T41084**
T41084**

Not Applicable
Not Applicable

T295

TCK295**

T41084**

Not Applicable

105,000
100,000 Federal
105,000 California
100,000 Federal
105,000 California

182
182
182
182
182

2003-04
3.5L V6 *#
E Class
1983-84
2.2L 4-Cyl. (SOHC)
Executive Limo (Includes Canadian)
1986
2.2L 4-Cyl. (SOHC)
Intrepid (Includes Canadian)
1998-99
3.2L V6 *#
2000
3.2L V6 *#
2001

3.2L V6 *#

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A22

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T219
T255
T295

TCK219**
TCK255**
TCK295**

T41084**
T41002**
T41084**

Not Applicable
T41002
Not Applicable
Not Applicable

105,000
105,000
100,000 Federal
105,000 California
102,000

182
182
182
182
182

T295

TCK295**

T41084**

T168
T167
T071
T114

TCK167**
TCK167**
TCK071
TCK114

T41047
T41046**
T41000

Not Applicable
T42017
Not Applicable
Not Applicable

60,000 2
60,000 2
60,000 1
60,000 1

175
175
143
143

T071
T153
T114
T132
T153
T139
T139

TCK071
TCK153
TCK114
TCK132
TCK153
TCK139
TCK139

T41000
T41001
Not Available
Not Available
T41001
T41048
T41048

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 3
60,000 3 Federal
100,000 California

143
143
143
143
143
164
164
164

3.5L V6 *#
3.5L V6 *#
3.5L V6 *#
3.5L V6 *#

T219
T255
T295
T295

TCK219**
TCK255**
TCK295**
TCK295**

T41084**
T41002**
T41084**
T41084**

Not Applicable
T41002
Not Applicable
Not Applicable

105,000
105,000
105,000
100,000 Federal
105,000 California

182
182
182
182
182

2.2L 4-Cyl. (SOHC)

2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #
3.5L V6 *#
3.5L V6 *#

T071
T114
T132
T139
T219
T255

TCK071
TCK114

T41000
Not Available

Not Applicable
Not Applicable

TCK139
TCK219**
TCK255**

T41048
T41084**
T41002**

Not Applicable
Not Applicable
T41002

60,000 1
60,000 1
60,000 1
60,000 3
105,000
105,000

143
143
143
164
182
182

2.4L 4-Cyl. (DOHC, VIN B) *#

2.4L 4-Cyl. (DOHC, VIN B) *#
2.4L 4-Cyl. (DOHC, VIN B) *#

T265
T265
T265

T43005
T43005
T43008

Not Available
Not Available

120,000
90,000
102,000 Non-Turbo
105,000 Turbo
90,000 Severe

152
152
152
152
152

Sebring Convertible
1996
2.4L 4-Cyl. (DOHC, VIN X) #
1997-98
2.4L 4-Cyl. (DOHC, VIN X) #
2002-04
2.4L 4-Cyl. (DOHC, VIN X) #
1996-00
2.5L V6 *#

T265
T265
T265
T259

TCK259**

T43005
T43005
T41039**

Not Available
Not Available
T42018

105,000
105,000
90,000
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

150
150
156
162
162
162
162

Sebring Coupe
1995-99
2.0L 4-Cyl. (DOHC, VIN Y) *#

T246

TCK246**

T41002**

T41002

60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

200
200
200
200

Engine

CHRYSLER (Cont.)
Intrepid (Includes Canadian - Cont.)
1993-94
3.5L V6 *#
1995-97
3.5L V6 *#
2000-02
3.5L V6 *#
2003-04
Laser
1990-94
1984-86
1986
LeBaron &
1982-88
1989-90
1986-87
1988
1989-94
1990-93
1994-95

3.5L V6 *#
2.0L 4-Cyl. (DOHC, 4G6) *#
Balance Shaft
Camshaft
2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
LeBaron GTS
2.2L 4-Cyl. (SOHC)
2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #
3.0L V6 (SOHC) #

LHS
1994
1995-97
1999
2000-01
New Yorker
1983-88
1986-87
1988
1988-89
1994
1995-96
PT Cruiser
2001
2002
2003-04

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A23

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA , CT & MA)
100,000 3
(CA , CT & MA)

159
159
159
159

60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

159
159
159
159
162
162
162
162
168
168
168
168
168
168
168
168

90,000

156

CHRYSLER (Cont.)
Sebring Coupe (Cont.)
2001-02
2.4L 4-Cyl. (SOHC, VIN G) *#
Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *#

Balance Shaft

T168

Camshaft

T232

1995-00

2.5L V6 *#

T259

TCK259**

T41039**

T42018

2001-02

3.0L V6 (SOHC) *#

T259

TCK259**

T41039**

T42018

2003-04

3.0L V6 (SOHC) *#

T259

2.4L 4-Cyl. (DOHC, VIN X) #

T265

2.2L 4-Cyl. (DOHC, VIN R)

3.0L V6 (SOHC) #

T153
T139

TCK153
TCK139

T41001
T41048

Not Applicable
Not Applicable

60,000 1
60,000 1

141
164

3.5L V6 *#
3.5L V6 *#

T295
T295

TCK295**
TCK295**

T41084**
T41084**

Not Applicable
Not Applicable

3.5L V6 *#

T295

105,000
100,000 Federal
105,000 California
102,000

182
182
182
182

3.5L V6, 24-Valve *#

T295

N/A

170

2.2L 4-Cyl. (SOHC)

2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)

T071
T114
T132

2.4L 4-Cyl. (DOHC, VIN B) *#

2.4L 4-Cyl. (DOHC, VIN B) *#

T265
T265

Lanos
1999-02

1.6L 4-Cyl. (DOHC) *#

Leganza
1999-02
Nubira
1999-02

2003-04

Sebring Sedan
2001-04
TC (Maserati)
1990
1990-91
300M
1999
2000-02
2003-04
Light Trucks
Pacifica
2004
Town & Country
1982-88
1986-87
1988
Voyager
2001-02
2003

T41000

Not Applicable

60,000 1
60,000 1
60,000 1

143
143
143

T43005
Not Available

Not Available
Not Available

120,000
120,000

156
156

T310

60,000 Federal
102,000 Federal 3

205
205

2.2L 4-Cyl. (DOHC) *#

T305

72,000 Federal
102,000 Federal 3

210
210

2.0L 4-Cyl. (DOHC) *#

T309

72,000 Federal
102,000 Federal 3

208
208

TCK071

DAEWOO

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A24

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

DAIHATSU
Passenger Cars
Charade
1988-92
1.0L 3-Cyl. *#
1989-92
1.3L 4-Cyl. *#
Light Trucks
Rocky
1990-92
1.6L 4-Cyl. *#

T178
T181

T41003
T41004

60,000
60,000

212
214

T182

T41004

60,000

214

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

143
143
143
143
143

60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

200
200
200
200
162
162
162
162

DATSUN (SEE NISSAN)

DODGE
Passenger Cars
Aries
1981-88
2.2L 4-Cyl. (SOHC)
1989
2.2L 4-Cyl. (SOHC)
1986-87
2.5L 4-Cyl. (SOHC)
1988
2.5L 4-Cyl. (SOHC)
1989
2.5L 4-Cyl. (SOHC)
Avenger
1995-99
2.0L 4-Cyl. (DOHC, VIN Y) *#

1995-00

Challenger
1978-79
1978-79
Charger
1983
1983-87
Colt
1979
1980-84
1985-86
1987-90
1991
1992-94
1978-79
1979-82
1983-89
1977-80
1989-90

2.5L V6 *#

T071
T153
T114
T132
T153

TCK071
TCK153
TCK114

T41000
T41001

Not Applicable
Not Applicable
Not Applicable

TCK153

T41001

Not Applicable

T246

TCK246**

T41002**

T41002

T259

TCK259**

T41039**

T42018

1.6L 4-Cyl. (SOHC)

w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T064

60,000

126

T062
T013

60,000 2
60,000 2

124
124

1.7L 4-Cyl. *
2.2L 4-Cyl. (SOHC)

T017
T071

TCK017
TCK071

1.4L 4-Cyl. *
1.4L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.6L 4-Cyl. (SOHC, RWD)
w/o Balance Shaft
1.6L 4-Cyl. (SOHC, FWD)
w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1.6L 4-Cyl. (DOHC) *

T073
T073
T073
T128
T191
T191

TCK073
TCK073
TCK128
TCK191
TCK191

T41079
T41000

Not Applicable
Not Applicable

60,000 1
60,000 1

128
143

T41042
T41042
T41051

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000
60,000
60,000
60,000

122
122
173
173
173
173

T064

60,000

126

T064

60,000

126

T093

60,000

126

T062
T013
T165

60,000 2
60,000 2
60,000

124
124
192

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A25

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

60,000
60,000

130
198

60,000
60,000
60,000
60,000

173
173
173
173

T201

60,000

198

T090
T089

60,000 2
60,000 2

180
180

Timing
Tensioners

Timing
Pulleys

DODGE (Cont.)
Colt (Cont.)
1989-90
1.8L 4-Cyl. (VIN T)
1992-94
1.8L 4-Cyl. (VINs C & D) #
Colt (Canadian)
1985-86
1.5L 4-Cyl. *
1989-90
1.5L 4-Cyl. *
1991
1.5L 4-Cyl. *
1992 & 1995 1.5L 4-Cyl. *
Colt Vista (Includes Canadian)
1992-94
1.8L 4-Cyl. (VINs C & D) #
1984-86
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1987-89
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1990-91
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1992
2.4L 4-Cyl.
Balance Shaft
Camshaft
1993
2.4L 4-Cyl.
Balance Shaft
Camshaft
1994
2.4L 4-Cyl.
Balance Shaft
Camshaft
Colt Wagon (Includes Canadian)
1989-90
1.8L 4-Cyl. (VIN T)
1992
2.4L 4-Cyl.
Balance Shaft
Camshaft
1993
2.4L 4-Cyl.
Balance Shaft
Camshaft
1994
2.4L 4-Cyl.
Balance Shaft
Camshaft
Colt 100 (Canadian)
1989-90
1.6L 4-Cyl. (DOHC) *
Colt 200 (Canadian)
1989-90
1.6L 4-Cyl. (DOHC) *
Daytona & Daytona Shelby
(Includes Canadian)
1984-88
2.2L 4-Cyl. (SOHC)
1989-90
2.2L 4-Cyl. (SOHC)
1992-93
2.2L 4-Cyl. (DOHC, VIN A)
1986-87
2.5L 4-Cyl. (SOHC)
1988
2.5L 4-Cyl. (SOHC)
1989-93
2.5L 4-Cyl. (SOHC)
1990-93
3.0L V6 (SOHC) #

T093
T201
T073
T128
T128
T191

TCK128
TCK128
TCK191

T41042
T41042
T41051

Not Applicable
Not Applicable
Not Applicable

T159
T158

TCK158A
TCK158A

T41045
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

T159
T158

TCK158A
TCK158A

T41045
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

T159
T204

60,000 2
60,000 2

203
203

T159
T230

60,000 2
60,000 2

203
203

T168
T230

60,000 2
60,000 2

203
203

T093

60,000

130

T159
T204

60,000 2
60,000 2

203
203

T159
T230

60,000 2
60,000 2

203
203

T168
T230

60,000 2
60,000 2

203
203

T165

60,000

192

T165

60,000

192

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 3

143
143
139
143
143
143
164

T071
T153
T206
T114
T132
T153
T139

TCK071
TCK153

T41000
T41001

Not Applicable
Not Applicable

TCK114

Not Available

Not Applicable

TCK153
TCK139

T41001
T41048

Not Applicable
Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A26

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T132
T153
T139

TCK153
TCK139

T41001
T41048

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 3

143
143
164

T071
T153

TCK071
TCK153

T41000
T41001

Not Applicable
Not Applicable

60,000 1
60,000 1

143
143

T295
T295

TCK295
TCK295**

T41084**
T41084**

Not Applicable
Not Applicable

TCK219**
TCK255**
TCK295**

T41084**
T41002**
T41084**

Not Applicable
Not Applicable
Not Applicable

105,000
100,000 Federal
105,000 California
100,000 Federal
105,000 California
105,000
105,000
100,000 Federal
105,000 California
102,000

182
182
182
182
182
182
182
182
182
182

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

143
143
143
143
143

105,000
105,000
105,000

200
131
131

105,000

134

105,000
105,000 Normal
90,000 Severe

134
152
152

DODGE (Cont.)
Dynasty (Includes Canadian)
1988
2.5L 4-Cyl. (SOHC)
1989-93
2.5L 4-Cyl. (SOHC)
1988-93
3.0L V6 (SOHC) #
Expo (Canadian)
1987-88
2.2L 4-Cyl.
1989
2.2L 4-Cyl.
Intrepid (Includes Canadian)
1998-99
3.2L V6 *#
2000
3.2L V6 *#
2001

3.2L V6 *#

T295

1993-94
1995-97
2000-02

3.5L V6 *#
3.5L V6 *#
3.5L V6 *#

T219
T255
T295

2003-04
Lancer
1985-88
1989
1986-87
1988
1989
Neon
1995-99
1995-97
1998-99
2000-02

3.5L V6 *#

T295

2.2L 4-Cyl. (SOHC)

2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)

T071
T153
T114
T132
T153

TCK071
TCK153

T41000
T41001

Not Applicable
Not Applicable

TCK153

T41001

Not Applicable

2.0L 4-Cyl. (DOHC, VIN Y) *#

2.0L 4-Cyl. (SOHC, VIN C) *#
2.0L 4-Cyl. (SOHC, VIN C) *#
2.0L 4-Cyl. *#
(SOHC, VINs C & F)
2.0L 4-Cyl. *#
(SOHC, VINs C & F)
2.4L 4-Cyl. (DOHC, VIN S) *#

T246
T245
T245

TCK246**
TCK245**

T41002**
T41002**

T41002
Not Applicable

1.7L 4-Cyl. *
2.2L 4-Cyl. (SOHC)
2.2L 4-Cyl. (SOHC)

T017
T071
T153

TCK017
TCK071
TCK153

T41079
T41000
T41001

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

128
143
143

60,000 1

143

2003-04
2003-04

T245

T43001

T245
T265

Omni
1978-83
1981-88
1989-90
Rampage
1982-84
Shadow
1987-88
1989-94
1988
1989-94
1992-93
1994

2.2L 4-Cyl. (SOHC)

T071

TCK071

T41000

Not Applicable

2.2L 4-Cyl. (SOHC)

2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #
3.0L V6 (SOHC) #

T071
T153
T132
T153
T139
T139

TCK071
TCK153

T41000
T41001

Not Applicable
Not Applicable

TCK153
TCK139
TCK139

T41001
T41048
T41048

Spirit
1991-92
1989-95
1989-93

2.2L 4-Cyl. (DOHC, VIN A)

2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #

T206
T153
T139

TCK153
TCK139

T41001
T41048

60,000 1
60,000 1
60,000 1
Not Applicable
60,000 1
Not Applicable
60,000 3
Not Applicable
60,000 3 Federal
100,000 3 California
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 3

143
143
143
143
164
164
164
139
143
164

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A27

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

3.0L V6 (SOHC) #

T139

TCK139

T41048

T195

TCK195

T41039

T195
T195

TCK195

T41039

1994-96

3.0L V6 *#
(DOHC Non-Turbo)
3.0L V6 (DOHC Turbo) *#
3.0L V6 *#
(DOHC Non-Turbo)
3.0L V6 (DOHC Turbo) *#

1991-93
1994-96

3.0L V6 (SOHC) #
3.0L V6 (SOHC) #

T139
T139

TCK139
TCK139

T41048
T41048

2.0L 4-Cyl. (SOHC, VIN C) *#

T245

TCK245**

2000

2.0L 4-Cyl. (SOHC, VIN C) *#

T245

1995-96
1997-99
2000

2.4L 4-Cyl. (DOHC, VIN X) #

2.4L 4-Cyl. (DOHC, VIN X) #
2.4L 4-Cyl. (DOHC, VIN X) #

T265
T265
T265

2001-02
2003-04
2001-04

2.4L 4-Cyl. (DOHC, VIN X) #

2.4L 4-Cyl. (DOHC, VIN X) #
2.4L 4-Cyl. (SOHC, VIN G) #
Balance Shaft
Camshaft

T265
T265
T168
T232

2.5L V6 *#

T259

TCK259**

T41039**

T42018

3.0L V6 (SOHC) *#

T259

TCK259**

T41039**

T017
T071

TCK017
TCK071

T071

Engine

Recommended
Replacement
Interval (Miles)

Page

Not Applicable

60,000 3 Federal
100,000 3 California

164
164

T42018

60,000 3

189

DODGE (Cont.)
Spirit (Cont.)
1994-95
Stealth
1991-93
1991-93
1994-96

Stratus
1995-99

1995-00
Stratus Coupe
2001-04

024
1981-82
1.7L 4-Cyl. *
1981-82
2.2L 4-Cyl. (SOHC)
400
1982-83
2.2L 4-Cyl. (SOHC)
600
1983-88
2.2L 4-Cyl. (SOHC)
1986-87
2.5L 4-Cyl. (SOHC)
1988
2.5L 4-Cyl. (SOHC)
2000 GTX (Canadian)
1989-90
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1991-92
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

60,000 3
60,000 3 Federal
100,000 3 California
60,000 3 Federal
100,000 3 California
Not Applicable
60,000 3
Not Applicable
60,000 3 Federal
100,000 3 California

189
189
189
189
189
164
164
164

T41002**

Not Applicable

T43005
T43005

Not Available
Not Available

T43005

Not Available

100,000 Federal
105,000 California
100,000 Federal
105,000 California
105,000
105,000
100,000 Federal
105,000 California
90,000
90,000

131
131
131
131
150
150
150
150
156
156

60,000 2, 3
(Exc. CA & Select)
100,000 2, 3
(CA & Select)
60,000 3

159
159
159
159
162

T42018

60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

168
168
168
168

T41079
T41000

Not Applicable
Not Applicable

60,000 1
60,000 1

128
143

TCK071

T41000

Not Applicable

60,000 1

143

T071
T114
T132

TCK071
TCK114

T41000
Not Available

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

143
143
143

T159
T155

TCK155
TCK155

T41053
T41043

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

60,000 2
60,000 2

180
180

T195

T159
T155

T42018

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A28

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T41000
T41000
T41000
Not Available
T43005
T43005

Not Applicable
Not Applicable
Not Applicable
Not Available
Not Available
Not Available

Recommended
Replacement
Interval (Miles)

Page

143
143
143
148
148
156
156
143
143
143
143
164
164
164
164

DODGE/PLYMOUTH
Light Trucks
Caravan
1982-83
1984-87
1988
1996
1997-00
2001-02
2003-04
1986
1987
1988
1989-95
1987-93
1994-96
1997-00
Dakota
1987-88
1989-95
Mini Ram Van
1984-87
1987
1988
1987-93
Raider
1989
Ram 50
1983-86
1987-89
1983-85
1990-92
1993
1990-91
Scamp Pickup
1983
Voyager
1984-87
1996
1997-00
1987
1988
1989-95

2.2L 4-Cyl. (SOHC)

2.2L 4-Cyl. (SOHC)
2.2L 4-Cyl. (SOHC)
2.4L 4-Cyl. (DOHC, VIN B) #
2.4L 4-Cyl. (DOHC, VIN B) #
2.4L 4-Cyl. (DOHC, VIN B) *#
2.4L 4-Cyl. (DOHC, VIN B) *#
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #

T071
T071
T071
T265
T265
T265
T265
T114
T114
T132
T153
T139

TCK114
TCK132
TCK153
TCK139

Not Available
T41001
T41001
T41048

Not Applicable
Not Applicable
Not Applicable
Not Applicable

3.0L V6 (SOHC) #
3.0L V6 (SOHC) #

T139
T139

TCK139
TCK139

T41048
T41048

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
120,000
120,000
120,000
120,000
60,000 1
60,000 1
60,000 1
60,000 1
60,000 3 Federal
100,000 3 California
60,000 3
60,000 3

2.2L 4-Cyl. (SOHC)

2.5L 4-Cyl. (SOHC)

T071
T153

TCK071
TCK153

T41000
T41001

Not Applicable
Not Applicable

60,000 1
60,000 1

143
143

2.2L 4-Cyl. (SOHC)

2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #

T071
T114
T132
T139

TCK071

T41000

Not Applicable

TCK132
TCK139

Not Available
T41048

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 3

143
143
143
164

3.0L V6 (SOHC) #

T139

TCK139

T41048

Not Applicable

60,000 3

164

60,000 2
60,000 2

180
180

60,000 2
60,000 2

180
180

50,000 2
50,000 2

185
185

Not Applicable
Not Applicable

60,000 2
60,000 2

187
187
187
187
164

2.0L 4-Cyl. (SOHC)

Balance Shaft
Camshaft
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
2.3L 4-Cyl. Turbo Diesel *#
Balance Shaft
Camshaft
2.4L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
2.4L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
3.0L V6 (SOHC) #

TCK071

T090
T089
T159
T158

TCK158A
TCK158A

T092
T091
T159
T124

T41045
T41044

Not Applicable
Not Applicable

T41049
T41050
TCK124
TCK124

T41053
T41044

T168
T229
T139

TCK139

T41048

Not Applicable

60,000 2
60,000 2
60,000 3

2.2L 4-Cyl.

T071

TCK071

T41000

Not Applicable

60,000 1

143

2.2L 4-Cyl.
2.4L 4-Cyl. (DOHC, VIN B) #
2.4L 4-Cyl. (DOHC, VIN B) #
2.5L 4-Cyl.
2.5L 4-Cyl.
2.5L 4-Cyl.

T071
T265
T265
T114
T132
T153

TCK071

T41000
Not Available
T43005
Not Available
Not Available
T41001

Not Applicable
Not Available
Not Available
Not Applicable
Not Applicable
Not Applicable

60,000 1
120,000
120,000
60,000 1
60,000 1
60,000 1

143
148
148
143
143
143

TCK114
TCK132
TCK153

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A29

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T139
T139

TCK139
TCK139

T41048
T41048

Not Applicable
Not Applicable

3.0L V6 (SOHC) #

T139

TCK139

T41048

Not Applicable

2.2L 4-Cyl.

T140

1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.6L 4-Cyl. (DOHC) *
1.8L 4-Cyl. (VINs C & D) #
2.4L 4-Cyl.
Balance Shaft
Camshaft
2.4L 4-Cyl.
Balance Shaft
Camshaft

T128
T191
T165
T201

Engine

Recommended
Replacement
Interval (Miles)

Page

60,000 3
60,000 3 Federal
100,000 3 California
60,0003

164
164
164
164

60,000 1

216

60,000
60,000
60,000
60,000

173
173
192
198

T159
T204

60,000 2, 3
60,000 2, 3

203
203

T168
T230

60,000 2, 3
60,000 2, 3

203
203

T201

60,000

198

DODGE/PLYMOUTH (Cont.)
Voyager (Cont.)
1987-93
3.0L V6 (SOHC) #
1994-96
3.0L V6 (SOHC) #
1997-00

EAGLE
Medallion
1989
Summit
1989-90
1991-96
1989-90
1992-96
1992
1993-96

Summit Wagon
1992-96
1.8L 4-Cyl. (VINs C & D) #
Talon
1993-94
1.8L 4-Cyl.
Balance Shaft
Camshaft
1990-94
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
1995-97
2.0L 4-Cyl. *#
(DOHC, VIN Y, Non-Turbo)
1998

1995-96

1997-98

TCK128
TCK191

T41042
T41051

Not Applicable
Not Applicable

T159
T158

TCK158
TCK158

T41057
T41056

Not Applicable
Not Applicable

60,000 2
60,000 2

195
195

T168
T167

TCK167**
TCK167**

T41047
T41046**

Not Applicable
T42017

60,000 2
60,000 2

175
175

T246

TCK246**

T41002**

T41002

60,000 2, 3 Federal
100,0002, 3 California

200
200

2.0L 4-Cyl. *#
(DOHC, VIN Y, Non-Turbo)

T246

TCK246**

T41002**

T41002

60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)

200
200
200
200

2.0L 4-Cyl. (DOHC Turbo) *

Balance Shaft
Camshaft

T168
T167

60,000 2, 3 Federal
100,000 2, 3 California

175
175

2.0L 4-Cyl. (DOHC Turbo) *

Balance Shaft

T168

Camshaft

T167

60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)

175
175
175
175

Vision
1993-94
3.5L V6 *#
1995-97
3.5L V6 *#
Vista (Canadian)
1989-91
1.5L 4-Cyl. *
1992
1.5L 4-Cyl. *
1989-90
1.6L 4-Cyl. (DOHC) *

T219
T255

TCK219**
TCK255**

T41084**
T41002**

Not Applicable
Not Applicable

105,000
105,000

182
182

T128
T191
T165

TCK128
TCK191

T41042
T41051

Not Applicable
Not Applicable

60,000
60,000
60,000

173
173
192

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A30

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000

126

EAGLE (Cont.)
Vista (Canadian - Cont.)
1989
1.6L 4-Cyl. (SOHC)
w/o Balance Shaft
1989-91
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
2000 GTX (Canadian)
1989-93
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
1989-92
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T093
T159
T158

TCK158A
TCK158A

T41045
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

T168
T167

TCK167
TCK167

T41047
T41046

Not Applicable
T42017

60,000 2
60,000 2

175
175

T159
T155

60,000 2
60,000 2

180
180

1.8L 4-Cyl. *
2.0L 4-Cyl. *

T020
T068

25,000
30,000

218
220

2.0L 4-Cyl. *

T068

30,000

220

1.5L 4-Cyl. *

T069

30,000

217

1.3L 4-Cyl. *
1.5L 4-Cyl. *

T018
T069

36,000
30,000

217
217

1.6L 4-Cyl. *
1.8L 4-Cyl. *

T020
T020

25,000
25,000

218
218

1.3L 4-Cyl. *

T018

36,000

217

1.8L 4-Cyl. *

T020

25,000

218

FIAT
Brava
1974-78
1979-81
Spider 2000
1979-82
Strada
1979-82
X1/9
1974-78
1979-83
124 Series
1971-74
1974-78
128 Series
1973-79
131 Series
1975-78

FORD
Passenger Cars
Aspire
1994-97
1.3L 4-Cyl.

T185

TCK185

T41030

Not Applicable

60,000 Federal
105,000 California

221
221

Contour
1995-97

2.0L 4-Cyl. (DOHC, VIN 3)

T258

TCK285

T41008

60,000 1

234

1998

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294

T43003

T42032 (LH)
T42033 (RH)
T42035 (Upr)
T42034 (Lwr)

Inspect at 120,000;
replace if needed

236
236

1999

2.0L 4-Cyl. (DOHC, VIN 3)

Up To 3/28/1999

T294

TCK294

T43003

From 3/29/1999

T294

TCK294A

T43003

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294A

T43003

T42035
T42034
T42036
T42034
T42036
T42034

Inspect at 120,000;
replace if needed
Inspect at 120,000;
replace if needed
Inspect at 120,000;
replace if needed

236
236
236
236
236
236

1.6L 4-Cyl. (SOHC) *#

1.8L 4-Cyl. (DOHC)
1.9L 4-Cyl. (SOHC) *#

T067
T179
T067

TCK067
TCK179
TCK067

T41006
T41031
T41006

60,000
60,000
60,000

224
227
224

2000
Escort
1981-85
1991-96
1985-90

(Upr)
(Lwr)
(Upr)
(Lwr)
(Upr)
(Lwr)

Not Applicable
T42005
Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A31

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T067
T194
T194

TCK067
TCK194
TCK194

T41006
T41007
T41007

Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000

224
224
224

100,000 2
100,000 2
Inspect at 120,000;
replace if needed
120,000

229
229
250
250
250

Inspect at 120,000;
replace if needed
120,000

240
240
240

FORD (Cont.)
Escort (Cont.)
1991
1992-96
1984-87

1.9L 4-Cyl. (SOHC) *#

Up To 3/25/1991
From 3/26/1991
1.9L 4-Cyl. (SOHC) #
2.0L 4-Cyl. Diesel *#
Camshaft
Injection Pump
2.0L 4-Cyl. (SOHC, VIN P)

T103
T102
T283

TCK283

T43004

Not Applicable

2001-02
2.0L 4-Cyl. (SOHC, VIN P)
Escort Coupe & ZX2
1998-2/9/99 2.0L 4-Cyl. (DOHC, VIN 3)

T283

TCK283

T43004

Not Applicable

T294

TCK294

T43003

2/10/99-2003 2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294A

T43003

T42035
T42034
T42036
T42034

1.6L 4-Cyl. (SOHC) *#

1.9L 4-Cyl. *#

T067
T067

TCK067
TCK067

T41006
T41006

Not Applicable
Not Applicable

60,000
60,000

224
224

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

1.3L 4-Cyl.
1.3L 4-Cyl.

T141
T185

TCK141
TCK185

T41030
T41030

Not Applicable
Not Applicable

60,000
60,000

221
221

2.0L 4-Cyl. (DOHC, VIN 3) *

T294

TCK294A

T43003

120,000

242

2002-04

2.0L 4-Cyl. (DOHC, VIN 5) *

T294

TCK294A

T43003

120,000

246

2000

2.0L 4-Cyl. (SOHC, VIN P)

T283

TCK283

T43004

T42036 (Upr)
T42034 (Lwr)
T42036 (Upr)
T42034 (Lwr)
Not Applicable

2.0L 4-Cyl. (SOHC, VIN P)

T283

TCK283

T43004

Not Applicable

Inspect at 120,000;
replace if needed
120,000

250
250
250

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.3L 4-Cyl.
2.3L 4-Cyl.
2.3L 4-Cyl.
Round Tooth Sprocket
Square Tooth Sprocket
2.3L 4-Cyl.

T014
T014

TCK014
TCK014

T41005

Not Applicable
Not Applicable

60,000 1
60,000 1

254
254

T210
T014
T210

TCK014

T41005
T41005

Not Applicable

60,000 1
60,000 1
60,000 1

254
254
254

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.0L 4-Cyl.
2.3L 4-Cyl.

T013
T014

TCK014

T41005

Not Applicable

60,000 1
60,000 1

226
254

2.0L 4-Cyl. *

T228

TCK228

T41091

T42008

2.2L 4-Cyl. *

T134

TCK134

T41029

T42003

60,000 Federal
105,000 California
60,000

252
252
252

1997-00

EXP
1982-85
1986-88
Fairmont
1978-83
Festiva
1988-89
1990-93
Focus
2000-04

2001-04
Granada
1981-82
LTD
1983-86
Mustang
1974-79
1980-91
1992
1993
Mustang II
1974-78
Pinto
1971-74
1974-80
Probe
1993-97
1989-92

(Upr)
(Lwr)
(Upr)
(Lwr)

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A32

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

2.5L V6 *#

T214

TCK214**

T41034**

T42010 (Upr)
T42009 (Lwr)

60,000 Federal
105,000 California

260
260

3.0L V6
3.2L V6

T248
T248

100,000
100,000

263
263

2.0L 4-Cyl. Diesel *#

Camshaft
Injection Pump

T103
T102

100,000 2
100,000 2

229
229

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.0L 4-Cyl. (DOHC, VIN B) *

T294

TCK294A

T41085

T42036 (Upr)
T42034 (Lwr)

120,000

231

2.0L 4-Cyl.
2.3L 4-Cyl.
2.3L 4-Cyl.
Round Tooth Sprocket
Square Tooth Sprocket
2.3L 4-Cyl.
2.3L 4-Cyl.
2.3L 4-Cyl. Diesel *
Balance Shaft
Camshaft
2.5L 4-Cyl.

T014
T014

TCK014

T41005

Not Applicable

60,000 1
60,000 1

254
254

T210
T014
T210
T276

TCK210
TCK014
TCK210
TCK276

T41005
T41005
T41005
T41005

Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000

254
254
254
258
256
256
259
259
259

Engine

FORD (Cont.)
Probe (Cont.)
1993-97
Taurus SHO
1989-95
1993-95
Tempo
1984-86
Thunderbird
1983-88
Light Trucks
Aerostar
1987
Courier
1977-82
Escape
2001-04
Ranger
1983-88
1983-91
1992
1993-94
1995-97
1985-87
1998-00
2001

2.5L 4-Cyl.
G.M.C. (SEE CHEVROLET/G.M.C.)

T092
T091
T276

TCK276

T41005

Not Applicable

T276

TCK276

T41005

Not Applicable

60,000 1
60,000 1
Inspect at 120,000;
replace if needed
120,000

T166

TCK166

T41009

Not Applicable

60,000

294

T166
T241
T241
T194
T194

TCK166
TCK241
TCK241
TCK194A
TCK194A

T41009

Not Applicable

T41010
T41010

Not Applicable
Not Applicable

TCK272

T41065

Not Applicable

60,000
60,000
60,000
60,000
Inspect at 60,000;
replace at 100,000
60,000
60,000
60,000
Inspect at 60,000;
replace at 100,000

294
294
294
294
294
294
296
296
296
296
296

GEO
Passenger Cars
Metro
1989-92
1.0L 3-Cyl.
1993
1.0L 3-Cyl.
4-Bolt Sprocket
5-Bolt Sprocket
1994-95
1.0L 3-Cyl.
1996-97
1.0L 3-Cyl.
1998-00
1.0L 3-Cyl.
1992-93
1994
1995-97
1998-01

1.3L 4-Cyl.
1.3L 4-Cyl.
1.3L 4-Cyl.
1.3L 4-Cyl.

T095
T243
T272
T194

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A33

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000
60,000

296
296

Inspect at 30,000 3,
replace at 60,000
Inspect at 30,000 3,
replace at 60,000
Inspect at 30,000 3,
replace at 60,000

290
290
290
290
290
290

GEO (Cont.)
Metro (Canadian)
1992-93
1.3L 4-Cyl.
1994
1.3L 4-Cyl.
Prizm
1989-92
1.6L 4-Cyl. (DOHC, VIN 6) *

T095
T243
T036

TCK036

T41066

Not Applicable

1993-97

1.6L 4-Cyl. (DOHC, VIN 6) *

T236

TCK236

T41072

Not Applicable

1993-97

1.8L 4-Cyl. (DOHC, VIN 8) *

T235

TCK235

T41072

Not Applicable

1.6L 4-Cyl. (DOHC, VIN 5)

T176

60,000

287

1.5L 4-Cyl. *#

T162

60,000

293

1.6L 4-Cyl. (DOHC) #

1.6L 4-Cyl. (SOHC) *#
1.8L 4-Cyl. (DOHC) #

T169
T177
T205

TCK177

T41027
Not Available

T42001
Not Applicable

60,000
30,000
60,000

292
288
292

1.6L 4-Cyl. (SOHC, VIN U)

1.6L 4-Cyl. (SOHC, VIN 6)

T164
T212

TCK164
TCK212

T41064
T41065

Not Applicable
Not Applicable

60,000 1
60,000

298
300

T041
T041
T041
T094
T160

TCK041

Not Available

Not Applicable

TCK160
TCK160

T41012
T41012

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

314
314
324
324
329

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

90,000 2
90,000 2

338
338

T186
T244

TCK244
TCK244

T41013
T41014

Not Applicable
Not Applicable

90,000 2
90,000 2

338
338

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

90,000 2
90,000 2

338
338

T186

TCK244

T41013

Not Applicable

T244

TCK244

T41014

Not Applicable

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

338
338
338
338

T186

TCK186

T41013

Not Applicable

T187

TCK186

T41014

Not Applicable

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

338
338
338
338

Prizm GSI
1990-92
Spectrum
1989
Storm
1990-91
1990-93
1992-93
Light Trucks
Tracker
1989-95
1994-02

HONDA
Passenger Cars
Accord (Includes Canadian)
1976-78
1.6L 4-Cyl. (SOHC) *
1979-83
1.6L 4-Cyl. (SOHC) *
1979-83
1.8L 4-Cyl. *
1984-85
1.8L 4-Cyl. *
1986-89
2.0L 4-Cyl. *
1990-93
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1994 (EX)
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1994 (Exc. EX) 2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1995 (EX)
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1995 (Exc. EX) 2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A34

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T41013

Not Applicable

Recommended
Replacement
Interval (Miles)

Page

HONDA (Cont.)
Accord (Includes Canadian - Cont.)
1996
2.2L 4-Cyl. (SOHC) *#
Balance Shaft

T186

Camshaft (w/o VTEC)

T187

TCK186

T41014

Not Applicable

Camshaft (w/ VTEC)

T244

TCK244

T41014

Not Applicable

T186
T187
T244

TCK186
TCK244

T41013
T41014
T41014

Not Applicable
Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3
105,000 2, 3

338
338
338

TCK244

T41013
T41014

Not Applicable
Not Applicable

TCK286

T41090

T42038

105,000 2, 3
105,000 2, 3
90,000 Normal
60,000 Severe
105,000 3
105,000 3
105,000 3
105,000 3

342
342
347
347
347
348
348
348

1997

1998-02
1996
1997
1998-00
2001-02
2003-04
Civic
1973-79
1980-83
1984-85
1986-87
1980-83
1984-85
1986-87
1988-89
1990-94
1995

90,000 2
60,000 2
90,000 2
60,000 2
90,000 2
60,000 2

Normal
Severe
Normal
Severe
Normal
Severe

338
338
338
338
338
338

2.2L 4-Cyl. (SOHC) *#

Balance Shaft
Camshaft (w/o VTEC)
Camshaft (w/ VTEC)
2.3L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
2.7L V6 *#

T186
T244
T263

2.7L V6 *#
3.0L V6 (J30A1) *#
3.0L V6 (J30A1) *#
3.0L V6 (J30A1) *#

T263
T286
T286
T329

1.2L 4-Cyl. *
1.3L 4-Cyl. *#
Canada
USA
1.3L 4-Cyl. *#
1.3L 4-Cyl. *#
1.5L 4-Cyl. *#
1.5L 4-Cyl. *#
1.5L 4-Cyl. *#
1.5L 4-Cyl. *#
1.5L 4-Cyl. *#
1.5L 4-Cyl. *#

T028

60,000 1

302

T028
T073
T099
T161
T041
T099
T161
T143
T143
T143

TCK161
TCK161

T41017
T41017

Not Applicable
Not Applicable

TCK161
TCK161
TCK143
TCK143
TCK143

T41017
T41017
T41011
T41011
T41011

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
90,000
90,000 Normal
60,000 Severe
105,000 3
60,000 1
90,000

303
303
303
303
306
306
306
306
306
306
306
312
314
314

90,000
90,000
90,000
90,000 Normal
60,000 Severe
90,000 Normal
60,000 Severe
105,000 3
110,000 3

314
314
314
314
314
318
318
318
321

60,000 1

303

60,000 1
60,000 1

306
306

1999-00
1988-89
1991
1992
Except Si
Si
1993-94
1995

1.6L 4-Cyl. (DOHC) *#

1.6L 4-Cyl. (SOHC) *#
1.6L 4-Cyl. (SOHC) *#

T227
T145
T145

TCK227
TCK145
TCK145

T41016
T41011
T41011

Not Applicable
Not Applicable
Not Applicable

1.6L 4-Cyl. (SOHC) *#

1.6L 4-Cyl. (SOHC) *#
1.6L 4-Cyl. (SOHC) *#
1.6L 4-Cyl. (SOHC) *#

T145
T224
T224
T224

TCK145
TCK244
TCK244
TCK244

T41011
T41023
T41023
T41023

Not Applicable
Not Applicable
Not Applicable
Not Applicable

1996

1.6L 4-Cyl. (SOHC) *#

T224

TCK224

T41023

Not Applicable

1997-00
1.6L 4-Cyl. (SOHC) *#
2001-04
1.7L 4-Cyl. (SOHC) *#
Civic (Canadian)
1980-83
1.3L 4-Cyl. *
Civic CVCC
1975
1.5L 4-Cyl. *
1976-79
1.5L 4-Cyl. *

T224
T312

TCK224

T41023

Not Applicable

T028
T036
T041

TCK041

Not Available

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A35

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T099
T099
T161
T145
T145

TCK161
TCK161
TCK161

T41017
T41017
T41017

Not Applicable
Not Applicable
Not Applicable

TCK145

T41011

Not Applicable

T143
T143

TCK143
TCK143

T41011
T41011

Not Applicable
Not Applicable

Recommended
Replacement
Interval (Miles)

Page

60,000 1
60,000 1
60,000 1
60,000 1
90,000

303
306
306
314
314

90,000
90,000 Normal
60,000 Severe
90,000
90,000 Normal
60,000 Severe
90,000 Normal
60,000 Severe
105,000 3
90,000
90,000 Normal
60,000 Severe
105,000 3

306
306
306
314
314
314
318
318
318
312
312
312
312

HONDA (Cont.)
Civic CRX
1984
1.3L 4-Cyl. *#
1984-85
1.5L 4-Cyl. *#
1986-87
1.5L 4-Cyl. *#
1988-89
1.6L 4-Cyl. (SOHC) *#
1990-91
1.6L 4-Cyl. (SOHC) *#
Civic del Sol (Except VX)
1993-94
1.5L 4-Cyl. *#
1995
1.5L 4-Cyl. *#
1993-94
1995

1.6L 4-Cyl. (SOHC) *#

1.6L 4-Cyl. (SOHC) *#

T224
T224

TCK224
TCK224

T41023
T41023

Not Applicable
Not Applicable

1996

1.6L 4-Cyl. (SOHC) *#

T224

TCK224

T41023

Not Applicable

1997
1994
1995-96

1.6L 4-Cyl. (SOHC) *#

1.6L 4-Cyl. (DOHC) *#
1.6L 4-Cyl. (DOHC) *#

T224
T227
T227

TCK224
TCK227
TCK227

T41023
T41016
T41016

Not Applicable
Not Applicable
Not Applicable

1997
1.6L 4-Cyl. (DOHC) *#
Civic del Sol VX
1993-94
1.5L 4-Cyl. *#
1995
1.5L 4-Cyl. *#

T227

TCK227

T41016

Not Applicable

T223
T223

90,000
90,000 Normal
60,000 Severe

306
306
306

Civic VX
1992-94
1995

1.5L 4-Cyl. *#
1.5L 4-Cyl. *#

T223
T223

90,000
90,000 Normal
60,000 Severe

306
306
306

1.6L 4-Cyl. (SOHC) *

1.8L 4-Cyl. *
1.8L 4-Cyl. *#
1.8L 4-Cyl. *#
1.8L 4-Cyl. *#
2.0L 4-Cyl. (SOHC) *
2.0L 4-Cyl. (SOHC) *
2.0L 4-Cyl. (SOHC) *#
2.0L 4-Cyl. (SOHC) *#
2.0L 4-Cyl. (DOHC) *#
2.0L 4-Cyl. (DOHC) *#
2.1L 4-Cyl. (DOHC) *#
2.2L 4-Cyl. (DOHC) *#
Balance Shaft
Camshaft
2.2L 4-Cyl. (DOHC) *#
Balance Shaft

T041
T041
T094
T094
T160
T094
T160
T144
T144
T142
T142
T142

314
324
324
324
324
329
329
329
329
331
331
331

Prelude
1980-82
1979-82
1983
1984-85
1986-87
1985
1986-87
1988-89
1990
1988-89
1990-91
1990-91
1993-94
1995-96

1997-01

Not Applicable
Not Applicable
Not Applicable
Not Applicable

TCK142
TCK142
TCK142

T41012
T41012
T41012
T41012
T41019
T41019
T41019
T41019
T41019

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
90,000
60,000 1
90,000
90,000

T186
T226

TCK186
TCK186

T41022
T41024

Not Applicable
Not Applicable

90,000 2
90,000 2

333
333

T186

TCK186

T41022

Not Applicable

Camshaft

T226

TCK186

T41024

Not Applicable

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

333
333
333
333

2.2L 4-Cyl. (DOHC) *#

Balance Shaft
Camshaft

T186
T226

TCK186
TCK186

T41022
T41024

Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3

333
333

TCK160
TCK160
TCK160
TCK160

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A36

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

90,000 2
90,000 2

338
338

T186

TCK186

T41013

Not Applicable

T187

TCK186

T41014

Not Applicable

T186
T216

TCK216
TCK216

T41013
T41014

Not Applicable
Not Applicable

T186

TCK216

T41013

Not Applicable

T216

TCK216

T41014

Not Applicable

T184

TCK184

T41016

Not Applicable

105,000 3

327

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

90,000 2
90,000 2

336
336

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3

336
336

T186
T244
T286

TCK244
TCK244

T41013
T41014

Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3
105,000 3

342
342
348

2.6L 4-Cyl. *
3.2L V6 (SOHC) #
3.2L V6 (DOHC) #
3.2L V6 (DOHC) #

T147
T221
T303
T303

TCK147
TCK221

T41026
T41028

Not Applicable
T42002

60,000
60,000
75,000
105,000 3

345
35
351
351

3.5L V6 (J35A1 & J35A4) *#

T286

348

1.5L 4-Cyl. (DOHC) *

1.5L 4-Cyl. (DOHC) *
1.5L 4-Cyl. (SOHC) *
1.5L 4-Cyl. (SOHC) *
1.5L 4-Cyl. (SOHC) *
1.6L 4-Cyl. (DOHC) *

T282
T282
T191
T191
T324
T282

1.6L 4-Cyl. (DOHC) *

Balance Shaft
Camshaft

T168
T165

Engine

HONDA (Cont.)
Prelude (Cont.)
1992-94
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1995-96
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
1992-94
1995-96

2.3L 4-Cyl. (DOHC) *#

Balance Shaft
Camshaft
2.3L 4-Cyl. (DOHC) *#
Balance Shaft
Camshaft

Light Trucks
CR-V
1997-01
Odyssey
1995-96
1997
1998
1999-04
Passport
1994-96
1994-97
1998-99
2000-02
Pilot
2003-04

2.0L 4-Cyl. *#
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
2.2L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
2.3L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft
3.5L V6 (J35A1 & J35A4) *#

90,000 2
60,000 2
90,000 2
60,000 2

Normal
Severe
Normal
Severe

90,000 2
90,000 2
90,000 2
60,000 2
90,000 2
60,000 2

Normal
Severe
Normal
Severe

105,000

338
338
338
338
338
338
338
338
338
338

HYUNDAI
Accent
1996
1997
1995-96
1997-99
2000-02
2001-04
Elantra
1992-95

TCK191
TCK191

T41037
T41037
T41051
T41051
T41037
T41037

T42016
T42016
Not Applicable
Not Applicable
Not Applicable
Not Available

60,000
60,000 3
60,000
60,000 3
60,000 3
60,000 3

353
353
354
354
354
356

TCK165
TCK165

T41047
T41046

Not Applicable
T42017

60,000
60,000

357
357

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A37

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T168
T167
T278
T284
T284
T284

TCK167**
TCK167**
TCK278
TCK284

T41047
T41046**
T41041
T41041

Not Applicable
T42017
T42015
T42015

60,000 2
60,000 2
60,000 3
60,000 3
60,000 3
60,000 3

357
357
361
361
361
362

T073
T128

TCK073
TCK128

Not Available
T41042

Not Applicable
Not Applicable

60,000
60,000

354
354

T42014

Not Available

60,000
60,000
60,000

60,000
60,000

HYUNDAI (Cont.)
Elantra (Cont.)
1993-95
1.8L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
1996-98
1.8L 4-Cyl. *
1999-01
2.0L 4-Cyl. (DOHC) *
2002-03
2.0L 4-Cyl. (DOHC) *
2004
2.0L 4-Cyl. (DOHC) *
Excel
1986-89
1.5L 4-Cyl. (SOHC) *
1990-94
1.5L 4-Cyl. (SOHC) *
Santa Fe
2001-04
2.4L 4-Cyl. (DOHC) *#
Balance Shaft
Camshaft
2001-04
2.7L V6 (DOHC) *#
Scoupe
1991-93
1.5L 4-Cyl. (SOHC) *
1994-95
1.5L 4-Cyl. (SOHC) *
Sonata
1992-98
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
1989-91
2.4L 4-Cyl. (SOHC) *
Balance Shaft
Camshaft
1999-2003
2.4L 4-Cyl. (DOHC) *#
Balance Shaft
Camshaft
1999-01
2.5L V6 (DOHC) *#
2002-04
2.7L V6 (DOHC) *#
1990-98
3.0L V6 *#
Tiburon
1997
1.8L 4-Cyl. *
1997
2.0L 4-Cyl. *
1998-01
2.0L 4-Cyl. *
2003-04
2.0L 4-Cyl. *
2003-04
2.7L 4-Cyl. *#
XG300
2001
3.0L V6 (DOHC) *#
XG350
2002-03
3.5L V6 (DOHC) *#
2004
3.5L V6 (DOHC) *#

T314
T313
T315
T128
T128

TCK128
TCK191

T41042
T41051

Not Applicable
Not Applicable

T168
T167

TCK167
TCK167

T41047
T41046

Not Applicable
T42017

T159
T124

TCK124
TCK124

T41053
T41044

Not Applicable
Not Applicable

T314
T313
T315
T315
T139
T278
T284
T284
T284
T315

TCK139

T41048

T42014
T42014
Not Applicable

TCK278

T41041
T41041
T41041

T42015
T42015
T42015

TCK284

T42014

T322
T323
T323

T41040
T41040

T42014
T42014

60,000
60,000
60,000
60,000

2
2
3

2, 3
2, 3

2
2

371
371
383
354
354
368
368
374
374

60,000 2, 3
60,000 2, 3
60,000 3
60,000 3
60,000 3

371
371
381
383
376

60,000 3
60,000 3
60,000 3
60,000 3
60,000 3

361
361
361
361
383

60,000 3

385

60,000 3
60,000 3

385
378

60,000
60,000

388
388

60,000

391

INFINITI
Passenger Cars
J30
1993
3.0L V6 *
1994-97
3.0L V6 *
M30
1990-92
3.0L V6 *

T180
T251
T104

TCK104

T41059

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A38

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T249

TCK249

T41059

Not Applicable

105,000

393

T118
T162
T162
T169
T076

TCK118
TCK118
TCK118

Not Available
Not Available
Not Available
T41027

Not Applicable
Not Applicable
Not Applicable
T42001

60,000
60,000
60,000
60,000
60,000

293
293
293
397
400

T41027
T41027
T41027

T42001
T42001
T42001

TCK122

T41025

Not Applicable

60,000
60,000
60,000
60,000
60,000

397
397
397
402
402

TCK177
TCK177

T41027
Not Available
Not Available
T41027

T42001
Not Applicable
Not Applicable
T42001

60,000
60,000
60,000
60,000

397
397
397
397

Not Applicable
Not Applicable

75,000
100,000 Normal
75,000 Severe
60,000
60,000
75,000
100,000 Normal
75,000 Severe

407
407
407
402
402
416
416
416

100,000 Normal
75,000 Severe

416
416

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

409
409
409
409

INFINITI (Cont.)
Light Trucks
QX4
1997-00

3.3L V6 (SOHC) *

ISUZU
Passenger Cars
I-Mark (Includes Canadian)
1985-87
1.5L 4-Cyl. *#
Up To 6/30/86
From 7/1/86
1988-90
1.5L 4-Cyl. *#
1989
1.6L 4-Cyl. (DOHC) #
1981-84
1.8L 4-Cyl. Diesel *
Impulse
1990-92
1.6L 4-Cyl. Non-Turbo #
1991-92
1.6L 4-Cyl. Turbo #
1992
1.8L 4-Cyl. #
1985-89
2.0L 4-Cyl. Turbo *
1988-89
2.3L 4-Cyl. *
Stylus
1991
1.6L 4-Cyl. (DOHC) #
1991
1.6L 4-Cyl. (SOHC) *#
1992-93
1.6L 4-Cyl. (SOHC) *#
1992-93
1.8L 4-Cyl. (SOHC) #
Light Trucks
Amigo
1998
2.2L 4-Cyl. (DOHC) *#
1999-00
2.2L 4-Cyl. (DOHC) *#
1989-93
1989-94
1998
1999-00
Axiom
2002-04
Oasis
1996

1997
1998-99

T169
T169
T205
T121
T122
T169
T177
T177
T205
T305
T305

2.3L 4-Cyl. *
2.6L 4-Cyl. *
3.2L V6 (DOHC) #
3.2L V6 (DOHC) #

T122
T147
T303
T303

3.5L V6 (DOHC) *#

T303

2.2L 4-Cyl. (SOHC) *#

Balance Shaft

T186

TCK186

T41013

Not Applicable

Camshaft

T187

TCK186

T41014

Not Applicable

T186
T187

TCK186
TCK186

T41013
T41014

Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3

409
409

T186
T244

TCK244
TCK244

T41013
T41014

Not Applicable
Not Applicable

105,000 2, 3
105,000 2, 3

411
411

T075
T122
T147

TCK122
TCK147

T41025
T41026

Not Applicable
Not Applicable

60,000
60,000
60,000

405
402
402

2.2L 4-Cyl. (SOHC) *#

Balance Shaft
Camshaft
2.3L 4-Cyl. (SOHC) *#
Balance Shaft
Camshaft

Pickup & PUP

1981-87
2.2L 4-Cyl. Diesel *
1986-95
2.3L 4-Cyl. *
1988-95
2.6L 4-Cyl. *

TCK122
TCK147

T41025
T41026

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A39

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

75,000
100,000 Normal
75,000 Severe
75,000 Normal
60,000 Severe
60,000
60,000
75,000
100,000 Normal
75,000 Severe
100,000 Normal
75,000 Severe

407
407
407
407
407
402
414
416
416
416
416
416

75,000 Normal
60,000 Severe
100,000 Normal
75,000 Severe

407
407
416
416

60,000
60,000
60,000
75,000
100,000 Normal
75,000 Severe

402
414
414
416
416
416

60,000
60,000
60,000

405
402
402

100,000 Normal
75,000 Severe

416
416

120,000 Normal
90,000 Severe
120,000 Normal
90,000 Severe

145
145
145
145

120,000 Normal
90,000 Severe

145
145

60,000 3

385

105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)

428
428
428
428

ISUZU (Cont.)
Rodeo
1998
1999-00

2.2L 4-Cyl. (DOHC) *#

2.2L 4-Cyl. (DOHC) *#

T305
T305

2001-03

2.2L 4-Cyl. (DOHC) *#

T305

1991-97
1993-97
1998
1999-04

2.6L 4-Cyl. *
3.2L V6 (SOHC) #
3.2L V6 (DOHC) #
3.2L V6 (DOHC) #

T147
T221
T303
T303

2004

3.5L V6 (DOHC) #

T303

2.2L 4-Cyl. (DOHC) *#

T305

3.2L V6 (DOHC) *#

T303

2.6L 4-Cyl. *
3.2L V6 (DOHC) #
3.2L V6 (SOHC) #
3.5L V6 (DOHC) #
3.5L V6 (DOHC) #

T147
T220
T221
T303
T303

2.2L 4-Cyl. Diesel *

2.3L 4-Cyl. *
2.6L 4-Cyl. *

T075
T122
T147

3.5L V6 (DOHC) #

T303

2.4L 4-Cyl. (DOHC, VIN 1) *#

T265

T43005

Not Available

2003-04

2.4L 4-Cyl. (DOHC, VIN 1) *#

T265

T43008

Not Available

Wrangler
2003-04

2.4L 4-Cyl. (DOHC, VIN 1) *#

T265

T43008

Not Available

Rodeo Sport
2001-03
2001-03
Trooper
1990-91
1992-95
1992-97
1998
1999-02
Trooper II
1984-87
1986-87
1988-89
VehiCROSS
1999-01

TCK147
TCK221**

TCK147

T41026
T41028**

Not Applicable
T42002

TCK221**

T41026
T41028
T41028**

Not Applicable
T42002
T42002

TCK122
TCK147

T41025
T41026

Not Applicable
Not Applicable

JEEP
Liberty
2002

KIA
Passenger Cars
Amanti
2004
3.5L V6 (DOHC) *#
Optima
2001-04
2.4L V6 (DOHC) *
Balance Shaft
Camshaft

T323
T314

T41038

Not Applicable

T313

T41087**

T42017

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A40

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)

381
381
383
383

105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)

418
418
418
418

105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)

421
421
420
420
420
420
423
423
421
421

Not Available

105,000 (CA) 3
60,000 (Exc. CA)

423
423

T41039**

T42018

60,000 3

385

T41039**

T42018

60,000 3 Normal
40,000 Severe
60,000 3 Normal
40,000 Severe

385
385
385
385

T41029

T42004

T41029

T42003

105,000 (CA) 3
60,000 (Exc. CA)
105,000 (CA) 3
60,000 (Exc. CA)

425
425
427
427

T020

25,000

430

2.5L KV6 (DOHC) *#

Front
Rear

T327
T326

72,000 3
72,000 3

431
431

2.5L V6 (2VZ-FE) #

T157

TCK157**

T41057**

T42030

60,000 1, 3

442

3.0L V6 (3VZ-FE) #
3.0L V6 (1MZ-FE) #
3.0L V6 (1MZ-FE) #

T200
T257
T257

TCK200**

T41057**

T42030

60,000 1, 3
60,000 1, 3
90,000

442
442
451

Timing
Tensioners

Timing
Pulleys

T315

T41040**

T42014

2.7L V6 (DOHC) *#

T315

T41040**

T42014

Rio
2001-02

1.5L 4-Cyl. (DOHC) *

T318

2003-04

1.6L 4-Cyl. (DOHC) *

T318

Sephia
1994-95

1.6L 4-Cyl. (SOHC) *

T185

TCK185

T41030

Not Applicable

1996-97

1.6L 4-Cyl. (DOHC) *

T179

TCK179

T41031

T42005

1995-97

1.8L 4-Cyl. (DOHC) *

T179

TCK179

T41031

T42005

1998-01

1.8L 4-Cyl. (DOHC) *

T302

T41032

T42005

1996-97

1.8L 4-Cyl. (SOHC) *

T185

Spectra
2000-04

1.8L 4-Cyl. (DOHC) *

T302

T41032

3.5L V6 (DOHC) *#

T323

3.5L V6 (DOHC) *#

T323

3.5L V6 (DOHC) *#

T323

2.0L 4-Cyl. (DOHC) *

T281

2.0L 4-Cyl. (SOHC) *

T264

1.8L 4-Cyl. *

Engine

KIA (Cont.)
Optima (Cont.)
2001
2.5L V6 (DOHC) *#
2002-04

Light Trucks
Sedona
2002-04
Sorento
2003
2004
Sportage
1995-02
1995

TCK281

LANCIA
Beta
1976-78

LAND ROVER
Freelander
2002-04

LEXUS
ES 250
1990-91
ES 300
1992-93
1994-98
1999-01

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A41

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

LEXUS (Cont.)
ES 300 (Cont.)
2002-03
ES 330
2004
GS 300
1993-97
1998-04
GS 400
1998-99
2000
GS 430
2001-04
IS 300
2001-04
LS 400
1990-94
1995-97

3.0L V6 (1MZ-FE) #

T257

90,000

451

3.3L V6 (3MZ-FE) *#

T257

90,000

472

3.0L 6-Cyl. (2JZ-GE)

3.0L 6-Cyl. (2JZ-GE) *

T215
T215

60,000 1, 3
90,000

446
448

4.0L V8 (1UZ-FE) *#
4.0L V8 (1UZ-FE) *#

T298
T298

Not Available

T42031

90,000
90,000

458
458

4.3L V8 (3UZ-FE) *

T298

Not Available

T42031

90,000

462

3.0L 6-Cyl. (2JZ-GE) *

T215

90,000

448

4.0L V8 (1UZ-FE) #
4.0L V8 (1UZ-FE) #

T190
T190

1998-00
LS 430
2001-04
SC 300
1993-97
1998-00
SC 400
1992-94
1995-97

4.0L V8 (1UZFE) *#

T298

60,000 1, 3
90,000 Normal
60,000 Severe
90,000

454
454
454
458

4.3L V8 (3UZ-FE) *

T298

90,000

462

3.0L 6-Cyl. (2JZ-GE) *

3.0L 6-Cyl. (2JZ-GE)

T215
T215

60,000 1, 3
90,000

446
448

4.0L V8 (1UZ-FE) #
4.0L V8 (1UZ-FE) #

T190
T190

1998-00
SC 430
2002-04
Light Trucks
GX 470
2003-04
LX 470
1998-04
RX 300
1999-01
2002-03
RX 330
2004

4.0L V8 (1UZ-FE) #

T298

60,000 1, 3
90,000 Normal
60,000 Severe
90,000

454
454
454
458

4.3L V8 (3UZ-FE) *

T298

90,000

467

4.7L V8 (2UZ-FE) *#

T298

90,000

482

4.7L V8 (2UZ-FE) *#

T298

90,000

477

3.0L V6 (1MZ-FE) *#
3.0L V6 (1MZ-FE) *#

T257
T257

90,000
90,000

451
451

3.3L V6 (3MZ-FE) *#

T257

90,000

472

60,000
60,000 Federal
105,000 California
60,000 Federal
105,000 California
60,000
(Exc. CA & MA)
105,000 (CA & MA)

489
489
489
492
492
492
492
492

Not Available

Not Available

TCK257**

T41075**

T42031

T42031

T42030

MAZDA
Passenger Cars
Miata & MX-5 Miata
1990-92
1.6L 4-Cyl. (DOHC)
1993
1.6L 4-Cyl. (DOHC)

T179
T179

TCK179
TCK179

T41031
T41031

T42005
T42005

1994-96

1.8L 4-Cyl. (DOHC)

T179

TCK179

T41031

T42005

1997

1.8L 4-Cyl. (DOHC)

T179

TCK179

T41031

T42005

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A42

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T179

TCK179

T41031

T42005

TCK179

T41031

T42005

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
60,000

492
492
492
492
492

MAZDA (Cont.)
Miata & MX-5 Miata (Cont.)
1999-00
1.8L 4-Cyl. (DOHC)

2001-04
Millenia
1995-96

1.8L 4-Cyl. (DOHC)

T179

2.3L V6

T267

1997-98

2.3L V6

T267

1999-00

2.3L V6

T267

2001-02
1995-96

2.3L V6
2.5L V6

T267
T214

TCK214**

T41034**

1997-98

2.5L V6

T214

TCK214**

T41034**

1999-00

2.5L V6

T214

TCK214**

T41034**

2001-02

2.5L V6

T214

TCK214**

T41034**

1.6L 4-Cyl. (DOHC)

T179

TCK179

T41031

T42005

1992
1993

1.6L 4-Cyl. (SOHC)

1.6L 4-Cyl. (SOHC)

T185
T185

TCK185
TCK185

T41030
T41030

Not Applicable
Not Applicable

1992

1.8L V6

T214

TCK214**

T41034**

1993

1.8L V6

T214

TCK214**

T41034**

MX-3 (Canadian)
1995
1.8L V6

T214

TCK214**

MX-6
1993
1994-96

2.0L 4-Cyl. (DOHC)

2.0L 4-Cyl. (DOHC)

T228
T228

1997

2.0L 4-Cyl. (DOHC)

1988-92
1993
1994-96

MX-3
1994-95

60,000 Federal
105,000 California
60,000 3
(Exc, CA & MA)
105,000 3 (CA & MA)
60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
60,000
60,000 Federal
T42010 (Upr)
T42009 (Lwr) 105,000 California
60,000 3
T42010 (Upr)
T42009 (Lwr)
(Exc. CA & MA)
105,000 3 (CA & MA)
T42010 (Upr)
60,000 3
T42009 (Lwr)
(Exc. CA & Select)
105,000 3
(CA & Select)
105,000 3
T42010 (Upr)
T42009 (Lwr)

514
514
514
514
514
514
514
514
514
514
518
518
518
518
518
518
518
518
518
518

(Upr)
(Lwr)
(Upr)
(Lwr)

60,000 Federal
105,000 California
60,000
60,000 Federal
105,000 California
60,000

489
489
489
489
489
499

60,000 Federal
105,000 California

499
499

T41034**

T42010 (Upr)
T42009 (Lwr)

60,000 Federal
105,000 California

499
499

TCK228
TCK228

T41091
T41091

T42008
T42008

T228

TCK228

T41091

2.2L 4-Cyl. *
2.5L V6

T134
T214

TCK134
TCK214**

T41029
T41034**

2.5L V6

T214

TCK214**

T41034**

T42010
T42009
T42010
T42009

60,000
60,000 Federal
105,000 Calif.
T42008
60,000 3
(Exc. CA & MA)
105,000 3 (CA & MA)
T42003
60,000
T42010 (Upr)
60,000
T42009 (Lwr)
60,000 Federal
T42010 (Upr)
T42009 (Lwr) 105,000 California

504
504
504
504
504
504
571
578
578
578

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A43

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T42010 (Upr)
T42009 (Lwr)

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)

578
578
578
578

MAZDA (Cont.)
MX-6 (Cont.)
1997

2.5L V6

T214

TCK214**

T41034**

Protege
1995-97

1.5L 4-Cyl.

T266

TCK266

Not Available

Not Available 60,000 (Ex. CA & MA) 486

105,000 (CA & MA) 3 486

1.5L 4-Cyl.
Up To Eng. No. 19472

T266

TCK266

Not Available

From Eng. No. 19473

T308

TCK266

Not Available

1999-00

1.6L 4-Cyl. (DOHC)

T308

2001
1990-92
1993-94

1.6L 4-Cyl. (DOHC)

1.8L 4-Cyl. (DOHC)
1.8L 4-Cyl. (DOHC)

T308
T179
T179

TCK179
TCK179

T41031
T41031

1995-96

1.8L 4-Cyl. (DOHC)

T179

TCK179

T41031

1997-98

1.8L 4-Cyl. (DOHC)

T179

TCK179

T41031

1999-00

1.8L 4-Cyl. (DOHC)

T316

1990-92
1993-94

1.8L 4-Cyl. (SOHC)

1.8L 4-Cyl. (SOHC)

T185
T185

TCK185
TCK185

T41030
T41030

T228

TCK228

T41091

Not Available 60,000 (Ex. CA & MA)

105,000 (CA & MA) 3
Not Available 60,000 (Ex. CA & MA)
105,000 (CA & MA) 3
60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
105,000 3
T42005
60,000
T42005
60,000 Federal
105,000 California
T42005
60,000 Federal
105,000 California
T42005
60,000 3
(Exc. CA & MA)
105,000 3 (CA & MA)
60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
Not Applicable
60,000
Not Applicable
60,000 Federal
105,000 California
T42008
105,000 3

T228

TCK228

T41091

1998

2001-03
2.0L 4-Cyl. (DOHC) *
Protege5
2002-03
2.0L 4-Cyl. (DOHC) *
Serenia (Canadian)
1992-95
3.0L V6 (DOHC) *
323
1988-89
1986
1987-89
1990-92
1993-94
626
1984-85
1983

105,000 3

504

T183

60,000 Federal
105,000 California

521
521

1.6L 4-Cyl. (DOHC)

1.6L 4-Cyl. (SOHC)
1.6L 4-Cyl. (SOHC)
1.6L 4-Cyl. (SOHC)
1.6L 4-Cyl. (SOHC)

T149
T123
T141
T185
T185

60,000
60,000
60,000
60,000
60,000 Federal
105,000 California

489
489
489
489
489
489

2.0L 4-Cyl. Diesel *

Camshaft
Injection Pump
2.0L 4-Cyl. (SOHC) *

T103
T102
T088

100,000
100,000
60,000

502
502
511

TCK141
TCK185
TCK185

T41030
T41030
T41030

T42008

Not Applicable
Not Applicable
Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A44

486
486
486
486
487
487
487
487
487
489
489
489
492
492
492
492
492
497
497
497
497
489
489
489
504

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000
60,000
60,000
60,000
60,000 Federal
105,000 California
60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
105,000 3
60,000
60,000

511
511
511
504
504
504
504
504
504
504
504
511
518

60,000 Federal
105,000 California
60,000 3
(Exc. CA & Select)
105,000 3
(CA & Select)
105,000 3

518
518
518
518
518
518
518

60,000 Federal
105,000 California
60,000 Federal
105,000 California
60,000

521
521
521
521
523

511
511
511

MAZDA (Cont.)
626 (Cont.)
1984-85
1986-87
1993
1994-96

2.0L 4-Cyl. (SOHC) *

Round Tooth Sprocket
Square Tooth Sprocket
2.0L 4-Cyl. (SOHC) *#
2.0L 4-Cyl. (DOHC)
2.0L 4-Cyl. (DOHC)

T113
T088
T117
T228
T228

TCK117
TCK228
TCK228

T41035
T41091
T41091

Not Applicable
T42008
T42008

1997-00

2.0L 4-Cyl. (DOHC)

T228

TCK228

T41091

T42008

2001-02
1988-92
1993

2.0L 4-Cyl. (DOHC)

2.2L 4-Cyl. *
2.5L V6

T228
T134
T214

TCK228
TCK134
TCK214**

T41091
T41029
T41034**

1994-96

2.5L V6

T214

TCK214**

T41034**

1997-00

2.5L V6

T214

TCK214**

T41034**

T42008
T42003
T42010 (Upr)
T42009 (Lwr)
T42010 (Upr)
T42009 (Lwr)
T42010 (Upr)
T42009 (Lwr)

2001-02

2.5L V6

T214

TCK214**

T41034**

T42010 (Upr)
T42009 (Lwr)

929
1990-91

3.0L V6 (DOHC) *

T183

TCK183A**

T41036**

1992-95

3.0L V6 (DOHC) *

T183

TCK183**

T41036**

1988-91

3.0L V6 (SOHC) *

T146

TCK146**

T41033**

T42007
T42006
T42013
T42012
T42011
T42001

2.0L 4-Cyl. (SOHC) *

Up To Chas. 568707
From Chas. 568708
2.0L 4-Cyl. (SOHC) *

T113
T117
T117

TCK117

T41035

Not Applicable

60,000
60,000
60,000

2.2L 4-Cyl. *

T134

TCK134

T41029

T42003

60,000

511

2.3L 4-Cyl.
2.3L 4-Cyl.

T210
T276

TCK210
TCK276

T41005
T41005

Not Applicable
Not Applicable

60,000
60,000

513
513

2.5L 4-Cyl.

T276

TCK276

T41005

Not Applicable

120,000

517

3.0L V6 (SOHC) *

T146

TCK146**

T41033**

60,000

523

1994-96

3.0L V6 (SOHC) *

T146

TCK146**

T41033**

1997-98

3.0L V6 (SOHC) *

T146

TCK146**

T41033**

T42011
T42001
T42011
T42001
T42011
T42001

60,000 Federal
105,000 California
60,000 3
(Exc. CA & MA)
105,000 3 (CA & MA)

523
523
523
523
523

Light Trucks
B2000
1986
1987
B2200
1987-93
B2300
1994
1995-97
B2500
1998-00
MPV
1989-93

(Upr)
(Lwr)
(Upr)
(Lwr)
(Upr)
(Lwr)

(Upr)
(Lwr)
(Upr)
(Lwr)
(Upr)
(Lwr)

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A45

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T294

TCK294A

T43003

T42036 (Upr)
T42034 (Lwr)

Recommended
Replacement
Interval (Miles)

Page

90,000

508

60,000 1
60,000 1

226
254

60,000 1
60,000
60,000 1
60,000 1

226
222
226
254

MAZDA (Cont.)
Tribute
2001-04

2.0L 4-Cyl. (DOHC)

MERCURY
Passenger Cars
Bobcat
1974
2.0L 4-Cyl.
1975-80
2.3L 4-Cyl.
Capri
1972
1.6L 4-Cyl.
1991-94
1.6L 4-Cyl. (DOHC)
1971-74
2.0L 4-Cyl.
1976-86
2.3L 4-Cyl.
Cougar
1999
2.0L 4-Cyl. (DOHC, VIN 3)
Up To 3/28/1999

T013
T014

TCK014

T41005

Not Applicable

TCK179

T41031

T42005

TCK014

T41005

Not Applicable

T294

TCK294

T43003

From 3/29/1999

T294

TCK294A

T43003

2000

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294A

T43003

2001-02

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294A

T43003

Inspect at 120,000,
replace if needed
Inspect at 120,000,
replace if needed
Inspect at 120,000,
replace if needed
120,000

236
236
236
236
236
236
236

2.3L 4-Cyl.
2.3L 4-Cyl.

T014
T014

TCK014
TCK014

T41005
T41005

T42035 (Upr)
T42034 (Lwr)
T42036 (Upr)
T42034 (Lwr)
T42036 (Upr)
T42034 (Lwr)
T42036 (Upr)
T42034 (Lwr)
Not Applicable
Not Applicable

60,000 1
60,000 1

254
254

1.6L 4-Cyl. (SOHC) *#

T067

TCK067

T41006

Not Applicable

60,000

224

1.6L 4-Cyl. (SOHC) *#

1.9L 4-Cyl. (SOHC) *#
2.0L 4-Cyl. Diesel *#
Camshaft
Injection Pump

T067
T067

TCK067
TCK067

T41006
T41006

Not Applicable
Not Applicable

60,000
60,000

224
224

T103
T102

100,000 2
100,000 2

229
229

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

2.0L 4-Cyl. (DOHC, VIN 3)

T258

TCK258

T41008

60,000 1

234

1998

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294

T43003

T42032 (LH)
T42033 (RH)
T42035 (Upr)
T42034 (Lwr)

Inspect at 120,000,
replace if needed

236
236

1999

2.0L 4-Cyl. (DOHC, VIN 3)

Up To 3/28/1999

T294

TCK294

T43003

From 3/29/1999

T294

TCK294A

T43003

2.0L 4-Cyl. (DOHC, VIN 3)

T294

TCK294A

T43003

T42035
T42034
T42036
T42034
T42036
T42034

Inspect at 120,000,
replace if needed
Inspect at 120,000,
replace if needed
Inspect at 120,000,
replace if needed

236
236
236
236
236
236

2.0L 4-Cyl. Diesel *#

Camshaft
Injection Pump

T103
T102

100,000 2
100,000 2

229
229

1981
1984-86
LN7
1982-83
Lynx
1981-85
1985-87
1984-87
Marquis
1983-86
Mystique
1995-97

2000
Topaz
1984-86

T013
T179
T013
T014

(Upr)
(Lwr)
(Upr)
(Lwr)
(Upr)
(Lwr)

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A46

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

1.6L 4-Cyl. (SOHC) *#

1.8L 4-Cyl. (DOHC)
1.9L 4-Cyl. (SOHC) *#
Up To 3/25/1991
From 3/26/1991
1.9L 4-Cyl. (SOHC) #
2.0L 4-Cyl. (SOHC, VIN P)

T141
T179

TCK141
TCK179

T41030
T41031

Not Applicable
T42005

60,000
60,000

224
227

T067
T194
T194
T283

TCK067
TCK194
TCK194

T41006
T41007
T41007

Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000
Inspect at 120,000,
replace if needed

224
224
224
250
250

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

3.0L V6 (SOHC)
3.0L V6 (SOHC)
3.3L V6 (SOHC) *

T104
T249
T249

TCK104
TCK249

T41059
T41059

Not Applicable
Not Applicable

105,000
105,000
105,000

262
262
393

2.3L 4-Cyl.

T014

TCK014

T41005

Not Applicable

60,000 1

254

T090
T089

60,000 2
60,000 2

530
530

T159
T089

60,000 2
60,000 2

530
530

60,000 2
60,000 2

530
530

T090
T089

60,000 2
60,000 2

530
530

T159
T089

60,000 2
60,000 2

530
530

T159
T158

60,000 2
60,000 2

530
530

60,000
60,000 3 Federal
100,000 California
60,000
60,000 Federal
100,000 California
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

189
189
189
563
563
563
575
575
575
575

Engine

MERCURY (Cont.)
Tracer
1987-90
1991-96
1991
1992-96
1997-99
Zephyr
1978-83
Light Trucks
Villager
1993
1994-98
1999-02

MERKUR
XR4Ti
1985-89

MITSUBISHI
Passenger Cars
Cordia & Tredia
1983-84
1.8L 4-Cyl.
Balance Shaft
Camshaft
1985-86
1.8L 4-Cyl.
Balance Shaft
Camshaft
1987-88
1.8L 4-Cy
Balance Shaft
Camshaft
1984
2.0L 4-Cyl.
Balance Shaft
Camshaft
1985-86
2.0L 4-Cyl.
Balance Shaft
Camshaft
1987-88
2.0L 4-Cyl.
Balance Shaft
Camshaft
Diamante
1992-93
3.0L V6 (DOHC) *#
1994-95
3.0L V6 (DOHC) *#

T159
T158

TCK158
TCK158

T41057
T41056

Not Applicable
Not Applicable

T195
T195

TCK195**
TCK195**

T41039**
T41039**

T42018
T42018

1992-93
1994-96

3.0L V6 (SOHC, 12-Valve) #

3.0L V6 (SOHC, 12-Valve) #

T139
T139

TCK139
TCK139

T41048
T41048

Not Applicable
Not Applicable

1997-02

3.5L V6 (SOHC) *#

T287

TCK287

Not Available

Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A47

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

575
575
575
575

MITSUBISHI (Cont.)
Diamante (Cont.)
2003-04
3.5L V6 (SOHC) *#

Eclipse
1990-94
1990-94
1995-97
1998-99

1995-97

1998-99

1996

1997-99

1.8L 4-Cyl.
Balance Shaft
Camshaft
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
2.0L 4-Cyl. Non-Turbo *#
(DOHC, VIN Y)

T287

T159
T158

TCK158
TCK158

T41057
T41058

Not Applicable
Not Applicable

60,000 2
60,000 2

195
195

T168
T167

TCK167**
TCK167**

T41047
T41046

Not Applicable
T42017

60,000 2
60,000 2

537
537

T246

TCK246**

T41002**

T41002

60,000 3 Federal
100,000 3 California

200
200

2.0L 4-Cyl. Non-Turbo *#

(DOHC, VIN Y)

T246

TCK246**

T41002**

T41002

60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

200
200
200
200

2.0L 4-Cyl. (DOHC) Turbo *

Balance Shaft

T168

Camshaft

T167

60,000 2, 3 Federal
100,000 2, 3 California
60,000 2, 3 Federal
100,000 2, 3 California

537
537
537
537

2.0L 4-Cyl. (DOHC) Turbo *

Balance Shaft

T168

Camshaft

T167

60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)
60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)

537
537
537
537
537
537
537
537

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T230

60,000 2 Federal
100,000 2 California
60,000 2 Federal
100,000 2 California

558
558
558
558

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T230

60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)
60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)

558
558
558
558
558
558
558
558

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A48

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)
60,000 2, 3
(Exc. CA, CT & MA)
100,000 2, 3
(CA, CT & MA)

558
558
558
558
558
558
558
558

60,000 2, 3 Federal
100,000 2, 3 California
60,000 2, 3 Federal
100,000 2, 3 California

558
558
558
558

60,000 2, 3
(Exc. CA & Select)
100,000 2, 3
(CA & Select)
60,000 2, 3
(Exc. CA & Select)
100,000 2, 3
(CA & Select)

558
558
558
558
558
558
558
558

60,000 2, 3
(Exc. CA & Select)
100,000 2, 3
(CA & Select)
60,000 2, 3
(Exc. CA & Select)
100,000 2, 3
(CA & Select)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 Federal
100,000 California
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

558
558
558
558
558
558
558
558
568
568
568
568
568
568
568
568
568
568

60,000
60,000 3 Federal
100,000 3 California

198
198
198

T159
T204

60,000 2, 3
60,000 2, 3

203
203

T168
T230

60,000 2, 3
60,000 2, 3

203
203

Timing
Tensioners

Timing
Pulleys

MITSUBISHI (Cont.)
Eclipse (Cont.)
2000
2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T332

2000

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

2001

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

2002-04

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

T201
T201

TCK201
TCK201

T41052
T41052

Not Applicable
Not Applicable

2001

2002-03

2004

Expo & Expo LRV

1992-93
1.8L 4-Cyl. (VINs C & D) #
1994
1.8L 4-Cyl. (VINs C & D) #
1992
1993-95

2.4L 4-Cyl.
Balance Shaft
Camshaft
2.4L 4-Cyl.
Balance Shaft
Camshaft

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A49

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T159
T155

TCK155
TCK155

T41053
T41043

Not Applicable
Not Applicable

60,000 2
60,000 2

530
530

T168
T232

TCK232
TCK232

T41047
T41054

Not Applicable
Not Applicable

60,000 2
60,000 2

530
530

T168
T167

TCK167**
TCK167**

T41047**
T41046**

Not Applicable
T42017

60,000 2
60,000 2

537
537

T168
T232

TCK232
TCK232

T41047
T41054

Not Applicable
Not Applicable

60,000 2
60,000 2

537
537

60,000 2 Federal
100,000 California

544
544

MITSUBISHI (Cont.)
Galant
1989-92
1993
1989-92
1993
1994

2.0L 4-Cyl. (SOHC)

Balance Shaft
Camshaft
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
2.4L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
Up To May, 1994

1985-87
1994-96

1997-98

1999-00

2001

2.4L 4-Cyl. (SOHC)

Balance Shaft
Camshaft
2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft

T168

T41038

T256

TCK256**

T41054**

T42017

60,000 2 Federal
100,000 California

544
544

T159
T124

TCK124
TCK124

T41053
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

555
555

60,000 2, 3 Federal
100,000 2, 3 California
60,000 2, 3 Federal
100,000 2, 3 California

558
558
558
558

60,000 2 , 3
(Exc. CA , CT & MA)
100,000 2 , 3
(CA , CT & MA)
60,000 2 , 3
(Exc. CA , CT & MA)
100,000 2 , 3
(CA , CT & MA)

558
558
558
558
558
558
558
558

60,000 2 , 3
(Exc. CA , CT & MA)
100,000 2 , 3
(CA , CT & MA)
60,000 2 , 3
(Exc. CA , CT & MA)
100,000 2 , 3
(CA , CT & MA)

558
558
558
558
558
558
558
558

60,000 2 , 3 Federal
100,000 California
60,000 2 , 3 Federal
100,000 California

558
558
558
558

T168

Camshaft

T230

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T230

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T232

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A50

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000 2 , 3
(Exc. CA & Select)
100,000 2 , 3
(CA & Select)
60,000 2 , 3
(Exc. CA & Select)
100,000 2 , 3
(CA & Select)

558
558
558
558
558
558
558
558

60,000 2 , 3
(Exc. CA & Select)
100,000 2 , 3
(CA & Select)
60,000 2 , 3
(Exc. CA & Select)
100,000 2 , 3
(CA & Select)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 3 Federal
100,000 California
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Exc. CA, MA & VT)
100,000 3
(CA , MA & VT)

558
558
558
558
558
558
558
558
568
568
568
568
568
568
568
568
568
568
582
582
582
582

60,000

563

60,000 3
(Exc. CA , MA & VT)
100,000 3
(CA , MA & VT)
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

542
542
542
542
547
547
547
547

60,000 3
(Exc. CA , MA & VT)
100,000 3
(CA , MA & VT)

532
532
532
532

60,000
60,000

525
525

MITSUBISHI (Cont.)
Galant (Cont.)
2002-03

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T232

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T332

1999-00

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

2001

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

2002-03

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

T42018

2004

3.8L V6 (SOHC)

TCK139

T41048

Not Applicable

2004

Galant Sigma
1988
Lancer
2002-04

2004

3.0L V6 (SOHC, 12-Valve) #

T139

2.0L 4-Cyl. (SOHC) *#

T201

2.4L 4-Cyl. (SOHC) *

T332

Lancer Evolution Turbo

2003-04
2.0L 4-Cyl. (DOHC) *#
Balance Shaft
Camshaft
Mirage
1985-86

1.5L 4-Cyl. *
Up To 5/31/1986
From 6/1/1986

T168
T167

T073
T073

TCK073

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A51

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *

T128
T191
T191
T191

TCK128
TCK191
TCK191
TCK191

T41042
T41051
T41042
T41051

Not Applicable
Not Applicable
Not Applicable
Not Applicable

1997-99

1.5L 4-Cyl. *

T289

TCK289

Not Available

2000-02

1.5L 4-Cyl. *

T289

1985-86
1987-88
1989
1991-92
1993
1994-96

1.6L 4-Cyl. (SOHC) *

1.6L 4-Cyl. (SOHC) *
1.6L 4-Cyl. (DOHC) *
1.6L 4-Cyl. (DOHC) *
1.8L 4-Cyl. (VINs C & D) #
1.8L 4-Cyl. (VINs C & D) #

T093
T093
T165
T165
T201
T201

1997-02

1.8L 4-Cyl. (VINs C & D) #

T288

1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *

Engine

Recommended
Replacement
Interval (Miles)

Page

MITSUBISHI (Cont.)
Mirage (Cont.)
1987-90
1991
1992-93
1994-96

Precis
1987-89
1990-93
1994

Sigma
1989-90
3.0L V6 (SOHC, 12-Valve) #
Tredia (See Cordia)
3000GT
1991-93
3.0L V6 (DOHC) *#
1994-95
3.0L V6 (DOHC) *#

T41055
T41056

60,000
60,000
60,000
60,000 Federal
100,000 3 California
Not Applicable
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)
Not Applicable
60,000
Not Applicable
60,000
60,000
60,000
Not Applicable
60,000
Not Applicable
60,000 Federal
100,000 3 California
60,000 3
(Exc. CA, CT & MA)
100,000 3
(CA, CT & MA)

525
525
525
525
525
525
525
525
525
525
525
525
525
528
528
192
192
198
198
198
198
198
198
198

TCK201
TCK201

T41052
T41052

T073
T128
T128

TCK073
TCK128
TCK128

Not Available
T41042
T41042

Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000 Federal
100,000 California

525
525
525
525

T139

TCK139

T41048

Not Applicable

60,000

563

T195
T195

TCK195**
TCK195**

T41039**
T41039**

T42018
T42018

60,000
60,000 3 Federal
100,000 California
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Ex. CA & MA)
100,000 (CA & MA)
60,000 3
(Ex. CA, CT & MA)
100,000
(CA, CT & MA)

189
189
189
189
189
189
189
189
189
189
563
563
563
563

1996-98

3.0L V6 (DOHC) *#

T195

TCK195**

T41039**

T42018

1999

3.0L V6 (DOHC) *#

T195

TCK195**

T41039**

T42018

1997-99

3.0L V6 (SOHC, 12-Valve) #

T139

TCK139

T41048

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A52

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA, MA & VT)
100,000 3
(CA, MA & VT)

582
582
582
582

60,000
60,000 3 Federal
100,000 California
60,000 3 Federal
100,000 California
60,000 3 Federal
100,000 California
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Exc. CA , MA & VT)
100,000 3
(CA , MA & VT)

563
563
563
568
568
572
572
575
575
575
575
575
575
575
575
586
586
586
586

60,000 2, 3
(Exc. CA , CT & MA)
100,000 2, 3
(CA , CT & MA)
60,000 2 , 3
(Exc. CA , CT & MA)
100,000 2, 3
(CA , CT & MA)

558
558
558
558
558
558
558
558

60,000 2 , 3
60,000 2 , 3
60,000 3
(Exc. CA , CT & MA)
100,000 2, 3
(CA , CT & MA)
60,000 3
(Exc. CA , CT & MA)
100,000 2, 3
(CA , CT & MA)
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

558
558
568
568
568
568
568
568
568
568
575
575
575
575

MITSUBISHI (Cont.)
Light Trucks
Endeavor
2004

3.8L V6 (SOHC) *#

Montero
1989-93
1994

3.0L V6 (SOHC, 12-Valve) #

3.0L V6 (SOHC, 12-Valve) #

T139
T139

TCK139
TCK139

T41048
T41048

Not Applicable
Not Applicable

1995-96

3.0L V6 (SOHC, 24-Valve) *#

T259

TCK259**

T41039**

Not Applicable

1994-96

3.5L V6 (DOHC) *#

T253

1997-00

3.5L V6 (SOHC) *#

T287

TCK287

Not Available

Not Available

2001-02

3.5L V6 (SOHC) *#

T320

2003-04

3.8L V6 (SOHC) *#

T320

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft

T168

Camshaft

T230

1997-02

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft
Camshaft
3.0L V6 (SOHC, 24-Valve) *#

T168
T232
T259

2003

3.0L V6 (SOHC, 24-Valve) *#

T259

1999-00

3.5L V6 (SOHC) *#

T287

Montero Sport
1997-98

1999

TCK259**

T41039**

T42018

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A53

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

T287

TCK287

Not Available

Not Available

Recommended
Replacement
Interval (Miles)

Page

60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)
60,000 3
(Exc. CA & Select)
100,000 3
(CA & Select)

575
575
575
575
575
575
575
575

MITSUBISHI (Cont.)
Montero Sport (Cont.)
2001-02
3.5L V6 (SOHC) *#

2003-04

Outlander
2003-04

Pickup
1983-86
1987-89
1983-85
1990-92
1993-96
1990-93
1994
Van
1987-90

3.5L V6 (SOHC) *#

T287

2.4L 4-Cyl. (SOHC, VIN G) *

Balance Shaft
Camshaft (2003)
Camshaft (2004)

T168
T232
T332

60,000 3
(Ex. CA & Select)
100,000
(CA & Select)

547
547
547
547

T090
T089

60,000 2
60,000 2

530
530

60,000 2
60,000 2

530
530

50,000 2
50,000 2

185
185

60,000 2
60,000 2

187
187

60,000 2
60,000 2
60,000
60,000 Federal
100,000 California

187
187
563
563
563

2.0L 4-Cyl.
Balance Shaft
Camshaft
2.0L 4-Cyl.
Balance Shaft
Camshaft
2.3L 4-Cyl. Turbo Diesel *
Balance Shaft
Camshaft
2.4L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
2.4L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
3.0L V6 (SOHC, 12-Valve) #
3.0L V6 (SOHC, 12-Valve) #
2.4L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T159
T158

TCK158A
TCK158A

T092
T091
T159
T124

T41045
T41044

Not Applicable
Not Applicable

T41049
T41050
TCK124
TCK124

T41053
T41044

Not Applicable
Not Applicable

T168
T229
T139
T139

TCK139
TCK139

T41048
T41048

Not Applicable
Not Applicable

T159
T124

TCK124
TCK124

T41053
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

555
555

T104
T104

TCK104
TCK104

T41059
T41059

Not Applicable
Not Applicable

60,000 1
60,000

596
596

T249
T104

TCK249
TCK104

T41059
T41059

Not Applicable
Not Applicable

60,000
60,000

596
596

T077
T077
T077
T137
T137

TCK077
TCK077
TCK077

T41058
T41058
T41058
T41058

Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000
60,000
60,000

589
589
589
590
590

NISSAN
Passenger Cars
Maxima
1985
3.0L V6 (SOHC) *
1986-91
3.0L V6 (SOHC) *
1992-94
3.0L V6 (SOHC) *
Round Tooth Sprocket
Square Tooth Sprocket
Pulsar & Pulsar NX (Includes Canadian)
1983-84
1.5L 4-Cyl. (SOHC) *
1983-85
1.6L 4-Cyl. (SOHC) *
1986-88
1.6L 4-Cyl. (SOHC) *
1987
1.6L 4-Cyl. (DOHC) *
1988-89
1.8L 4-Cyl. (DOHC) *

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A54

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T077
T077
T077

TCK077
TCK077
TCK077

T41058
T41058
T41058

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000

589
589
589

T096
T097

60,000 1
60,000 1

592
592

T096
T097

60,000
60,000

592
592

NISSAN (Cont.)
Sentra (Includes Canadian)
1982-83
1.5L 4-Cyl. (SOHC) *
1983-85
1.6L 4-Cyl. (SOHC) *
1986-88
1.6L 4-Cyl. (SOHC) *
1983-85
1.7L 4-Cyl. Diesel *
Camshaft
Injection Pump
1986-87
1.7L 4-Cyl. Diesel *
Camshaft
Injection Pump
Stanza
1982-85
2.0L 4-Cyl. *
1986-89
2.0L 4-Cyl. *
Stanza Wagon
1982-85
2.0L 4-Cyl. *
1986-89
2.0L 4-Cyl. *
200SX (Includes Canadian)
1984-85
1.8L 4-Cyl. Turbo
1986-87
1.8L 4-Cyl. Turbo
1984-85
2.0L 4-Cyl. *
1986-87
2.0L 4-Cyl. *
1988
2.0L 4-Cyl. *
1987-88
3.0L V6 (SOHC) *
300ZX
1984-85
3.0L V6 (SOHC) *
1986-89
3.0L V6 (SOHC) *
1990-92
3.0L V6 (DOHC) *

T078
T078

TCK078
TCK078

T41088
T41088

Not Applicable
Not Applicable

60,000 1
60,000

593
593

T078
T078

TCK078
TCK078

T41088
T41088

Not Applicable
Not Applicable

60,000 1
60,000

593
593

Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000
60,000 1
60,000
60,000
60,000

593
593
593
593
593
596

T100
T100
T078
T078
T078
T104
T104
T104
T180

TCK078A
TCK078A
TCK078
TCK104

T41089
T41089
T41088
T41059

TCK104
TCK104

T41059
T41059
T41085**

60,000 1
Not Applicable
Not Applicable
60,000
T42021 (Upr)
60,000
T42020 (Lwr)
T42021 (Upr) 60,000 (Convertible)
T42020 (Lwr)
105,000
(Non-Convertible)
T42021 (Upr)
60,000
T42020 (Lwr)

596
596
594

1993

3.0L V6 (DOHC) *

T180

T41085**

1994-96

3.0L V6 (DOHC) Turbo *

T251

T41085**

1994-96

3.0L V6 *
(DOHC) Non-Turbo

T251

T41085**

T42021 (Upr)
T42020 (Lwr)

105,000

594

1.5L 4-Cyl. *

T077

TCK077

T41058

Not Applicable

60,000 1

589

3.3L V6 (SOHC) *
3.3L V6 (SOHC) *

T249
T249

TCK249
TCK249

T41059

Not Applicable

105,000
105,000

393
393

3.0L V6 (SOHC) *
3.0L V6 (SOHC) *
Round Tooth Sprocket
Square Tooth Sprocket
3.0L V6 (SOHC) *
3.3L V6 (SOHC) *

T104

TCK104

T41059

Not Applicable

60,000

596

T249
T104
T249
T249

TCK249
TCK104
TCK249
TCK249

T41059
T41059
T41059
T41059

Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000
105,000

596
596
596
393

3.0L V6 (SOHC) *

T104

TCK104

T41059

Not Applicable

60,000

596

310
1982
Light Trucks
Frontier
1999-03
2004
Pathfinder
1986-92
1993-94
1995-96
1996-00
Pickup
1986-92

594
594
594
594

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A55

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

3.0L V6 (SOHC) *
Round Tooth Sprocket
Square Tooth Sprocket
3.0L V6 (SOHC) *

T249
T104
T249

TCK249
TCK104
TCK249

T41059
T41059
T41059

Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000

596
596
596

3.0L V6 (SOHC) *
Round Tooth Sprocket
Square Tooth Sprocket
3.0L V6 (SOHC) *
3.3L V6 (SOHC) *

T249
T104
T249
T249

TCK249
TCK104
TCK249
TCK249

T41059
T41059
T41059
T41059

Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000
105,000

596
596
596
393

3.3L V6 (SOHC) *
3.3L V6 (SOHC) *

T249
T249

TCK249
TCK249

T41059
T41059

Not Applicable
Not Applicable

105,000
105,000

393
393

T192
T273

TCK192
TCK273

Not Available
Not Available

Not Available
Not Available

60,000
60,000

284
284

T081
T081

TCK081

Not Applicable Not Applicable

60,000 1
60,000 1

271
272

60,000 1
60,000 1
60,000 1

599
599
599

Engine

NISSAN (Cont.)
Pickup (Cont.)
1993-94
1995
Quest
1993-94
1995-98
1999-02
Xterra
2000-02
2003-04

OLDSMOBILE
Cutlass Supreme
1991-95
3.4L V6 #
1996
3.4L V6 *#
Firenza
1982-86
1.8L 4-Cyl. #
1987-88
2.0L 4-Cyl. #

OPTIMA
Optima (Canadian)
1988-92
1.6L 4-Cyl. #
1988-89
2.0L 4-Cyl. #
1990-91
2.0L 4-Cyl. #

T148
T081
T163

TCK163

T43002

Not Applicable

PEUGEOT
405
1989-91
1989-91
505
1986-91

1.9L 4-Cyl. (DOHC)

1.9L 4-Cyl. (SOHC)

T188
T189

60,000 1
60,000 1

600
600

2.2L 4-Cyl. (Exc. Turbo)

T140

60,000 1

602

60,000 1
60,000
60,000 3 Federal
100,000 California

143
164
164
164

PLYMOUTH
Passenger Cars
Acclaim
1989-95
2.5L 4-Cyl. (SOHC)
1989-93
3.0L V6 (SOHC) #
1994-95
3.0L V6 (SOHC) #
Arrow
1978-80

T153
T139
T139

TCK153
TCK139
TCK139

T41001
T41048
T41048

Not Applicable
Not Applicable
Not Applicable

1.6L 4-Cyl. (SOHC)

w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T064

60,000

126

T062
T013

60,000 2
60,000 2

124
124

2.0L 4-Cyl. (SOHC, VIN C) *#

T245

2000

2.0L 4-Cyl. (SOHC, VIN C) *#

T245

1997-99

2.4L 4-Cyl. (DOHC, VIN X) #

T265

100,000 Federal
105,000 California
100,000 Federal
105,000 California
105,000

131
131
131
131
150

1977-80
Breeze
1996-99

TCK245**

T41002**

Not Applicable

T43005

Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A56

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

Not Available

100,000 Federal
105,000 California

150
150

Timing
Tensioners

Timing
Pulleys

T43005

PLYMOUTH (Cont.)
Breeze (Cont.)
2000
Caravelle
1983-88
1986-87
1988
Champ
1979
1980-82
1979-82
1979-80
Colt
1979-82
1983-84
1985-86
1987-90
1991-94
1978-79
1979-82
1983-89
1977-80

2.4L 4-Cyl. (DOHC, VIN X) #

T265

2.2L 4-Cyl. (SOHC)

2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)

T071
T114
T132

TCK071
TCK114
TCK132

T41000

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

143
143
143

1.4L 4-Cyl. *
1.4L 4-Cyl. *
1.6L 4-Cyl. (SOHC)
w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T073
T073

TCK073

Not Available

Not Applicable

60,000
60,000

122
122

T064

60,000

126

T062
T013

60,000 2
60,000 2

124
124

60,000
60,000
60,000
60,000
60,000

122
122
173
173
173

T064

60,000

126

T064

60,000

126

T093

60,000

126

T062
T013
T165
T093
T201

60,000 2
60,000 2
60,000
60,000
60,000

124
124
192
130
198

60,000
60,000

173
173

T201

60,000

198

T090
T089

60,000 2
60,000 2

180
180

1.4L 4-Cyl. *
1.4L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.5L 4-Cyl. *
1.6L 4-Cyl. (RWD)
w/o Balance Shaft
1.6L 4-Cyl. (FWD)
w/o Balance Shaft
1.6L 4-Cyl. w/o Bal. Shaft
w/o Balance Shaft
1.6L 4-Cyl.
Balance Shaft
Camshaft
1.6L 4-Cyl. (DOHC) *
1.8L 4-Cyl. (VIN T)
1.8L 4-Cyl. (VINs C & D) #

1989-90
1989-90
1992-94
Colt (Canadian)
1989-92
1.5L 4-Cyl. *
1995
1.5L 4-Cyl. *
Colt Vista (Includes Canadian)
1992-94
1.8L 4-Cyl. (VINs C & D) #
1984-86
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1987-89
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1990-91
2.0L 4-Cyl. (SOHC)
Balance Shaft
Camshaft
1992
2.4L 4-Cyl.
Balance Shaft
Camshaft
1993
2.4L 4-Cyl.
Balance Shaft
Camshaft

T073
T073
T073
T128
T191

T128
T191

TCK073
TCK073
TCK128
TCK191

TCK128
TCK191

Not Available
Not Available
T41042
T41051

T41042
T41051

Not Applicable
Not Applicable
Not Applicable
Not Applicable

Not Applicable
Not Applicable

T159
T158

TCK158A
TCK158A

T41045
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

T159
T158

TCK158A
TCK158A

T41045
T41044

Not Applicable
Not Applicable

60,000 2
60,000 2

180
180

T159
T204

60,000 2
60,000 2

203
203

T159
T230

60,000 2
60,000 2

203
203

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A57

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

T168
T230

60,000 2
60,000 2

203
203

T165

60,000

192

Timing
Tensioners

Timing
Pulleys

PLYMOUTH (Cont.)
Colt Vista (Includes Canadian - Cont.)
1994
2.4L 4-Cyl.
Balance Shaft
Camshaft
Colt 100 & 200 (Canadian)
1989-90
1.6L 4-Cyl. (DOHC) *
Horizon
1978-83
1.7L 4-Cyl. *
1981-88
2.2L 4-Cyl. (SOHC)
1989-90
2.2L 4-Cyl. (SOHC)
Laser
1990-94
1.8L 4-Cyl.
Balance Shaft
Camshaft
1990-94
2.0L 4-Cyl. (DOHC) *
Balance Shaft
Camshaft
Neon
1995-99
2.0L 4-Cyl. (DOHC, VIN Y) *#
1995-97
2.0L 4-Cyl. (SOHC, VIN C) *#
1998-99
2.0L 4-Cyl. (SOHC, VIN C) *#
2000-04
2.0L 4-Cyl. *#
(SOHC, VINs C & F)
Prowler
1999
3.5L V6 *#
2000-02
3.5L V6 *#
Reliant
1981-88
1989
1986-87
1988
1989
Sapporo
1978-80
1977-80
Scamp Pickup
1983
Sundance
1987-88
1989-94
1988
1989-94
1992-93
1994
TC3
1981-82
1981-82

2.2L 4-Cyl. (SOHC)

2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)

T017
T071
T153

TCK017
TCK071
TCK153

T41079
T41000
T41001

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

128
143
143

T159
T158

TCK158
TCK158

T41057
T41056

Not Applicable
Not Applicable

60,000 2
60,000 2

195
195

T168
T167

TCK167**
TCK167**

T41047
T41046**

Not Applicable
T42017

60,000 2
60,000 2

175
175

T246
T245
T245

TCK246**
TCK245**
TCK245**

T41002**
T41002**
T41002**

T41002
Not Applicable
Not Applicable

105,000
105,000
105,000

200
131
131

T245

105,000

134

T295
T295

105,000
100,000 Federal
105,000 California

182
182
182

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

143
143
143
143
143

T071
T153
T114
T132
T153

TCK071
TCK071
TCK114

T41000
T41001
Not Available

Not Applicable
Not Applicable
Not Applicable

TCK153

T41001

Not Applicable

1.6L 4-Cyl. (SOHC)

w/o Balance Shaft
1.6L 4-Cyl. (SOHC)
Balance Shaft
Camshaft

T064

60,000

126

T062
T013

60,000 2
60,000 2

124
124

2.2L 4-Cyl. (SOHC)

T071

TCK071

T41000

Not Applicable

60,000 1

143

2.2L 4-Cyl. (SOHC)

2.2L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
2.5L 4-Cyl. (SOHC)
3.0L V6 (SOHC) #
3.0L V6 (SOHC) #

T071
T153
T132
T153
T139
T139

TCK071
TCK153
TCK132
TCK153
TCK139
TCK139

T41000
T41001
T41001
T41001
T41048
T41048

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 3

143
143
143
143
164
164

1.7L 4-Cyl. *
2.2L 4-Cyl. (SOHC)

T017
T071

TCK017
TCK071

T41079
T41000

Not Applicable
Not Applicable

60,000 1
60,000 1

128
143

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A58

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T017
T071

TCK017
TCK071

T41079
T41000

Not Applicable
Not Applicable

60,000 1
60,000 1

128
143

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

265
265
265
265
265
270

PLYMOUTH (Cont.)
Turismo
1983
1.7L 4-Cyl. *
1983-87
2.2L 4-Cyl. (SOHC)
Light Trucks
(See DODGE/PLYMOUTH Light Trucks)

PONTIAC
Passenger Cars
Acadian (Canadian)
1976
1.4L 4-Cyl.
1977
1.4L 4-Cyl.
1976
1.6L 4-Cyl.
1977-78
1.6L 4-Cyl.
1979-87
1.6L 4-Cyl.
1981-85
1.8L 4-Cyl. Diesel *
Firefly (Canadian)
1985-88
1.0L 3-Cyl.
1989-91
1.0L 3-Cyl.
1994-95
1.0L 3-Cyl.
1996-97
1.0L 3-Cyl.
1998-00
1.0L 3-Cyl.
1995-97
1.3L 4-Cyl.
1998-00
1.3L 4-Cyl.
Grand Am
1987-88
2.0L 4-Cyl. #
1989
2.0L 4-Cyl. #
Grand Prix
1991-95
3.4L V6 #
1996
3.4L V6 *#
J2000
1982
1.8L 4-Cyl. #
LeMans
1988-89
1.6L 4-Cyl. #
1990
1.6L 4-Cyl. *#
With Tensioner
Without Tensioner
1991-93
1.6L 4-Cyl. *#
1989
2.0L 4-Cyl. #
First Design
Second Design
1990
2.0L 4-Cyl. #
Sunbird
1985-86
1.8L 4-Cyl. #
1987-88
2.0L 4-Cyl. #
1989-94
2.0L 4-Cyl. #
Sunburst (Canadian)
1985-88
1.5L 4-Cyl. *#
T1000
1981-82
1.6L 4-Cyl.
1000
1983-87
1.6L 4-Cyl.
2000
1983
1.8L 4-Cyl. #

T037
T039
T037
T039
T061
T076
T095
T166
T241
T194
T194
T272
T194

TCK166
TCK241
TCK194A
TCK194A
TCK272

Not Available
Not Available
T41010
T41010
T41065

Not Available
Not Available
Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000
60,000
100,000
60,000
100,000

294
294
294
294
294
296
296

T081
T163

TCK081A
TCK163

Not Applicable Not Applicable

T43002
Not Applicable

60,000 1
60,000 1

272
272

T192
T273

TCK192
TCK273

Not Available
Not Available

60,000
60,000

285
285

T081

TCK081

Not Applicable Not Applicable

60,000 1

271

T148

TCK148

Not Applicable Not Applicable

60,000 1

268

T203
T148
T203

TCK148

Not Applicable Not Applicable

60,000 1
60,000 1
60,000 1

268
268
268

T081
T163
T163

TCK081A
TCK163
TCK163

Not Applicable Not Applicable

T43002
Not Applicable
T43002
Not Applicable

60,000 1
60,000 1
60,000 1

272
272
272

T081
T081
T163

TCK081
TCK081A
TCK163

Not Applicable Not Applicable

Not Applicable Not Applicable
T43002
Not Applicable

60,000 1
60,000 1
60,000 1

271
272
272

T118

TCK118

Not Available

60,000

293

T061

60,000 1

265

T061

60,000 1

265

60,000 1

271

T081

TCK081

Not Available
Not Available

Not Applicable

Not Applicable Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A59

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

T081

TCK081

T164
T212

TCK164
TCK212

T41064
T41065

T017

TCK017

T41079

Timing
Tensioners

Recommended
Replacement
Interval (Miles)

Page

60,000 1

271

Not Applicable
Not Applicable

60,000 1
60,000

298
300

Not Applicable

45,000 3

603

Timing
Pulleys

PONTIAC (Cont.)
2000 Sunbird
1984
1.8L 4-Cyl. #
Light Trucks
Sunrunner (Canadian)
1989-95
1.6L 4-Cyl. (SOHC, VIN U)
1994-02
1.6L 4-Cyl. (SOHC, VIN 6)

Not Applicable Not Applicable

PORSCHE
924
1977-82
1987-88
928
1978-82
1983-84
1985-91
1992-95
944
1983-89

2.0L 4-Cyl. *
2.5L 4-Cyl. *#
Balance Shaft
Camshaft

T293
T107

45,000
45,000

604
604

4.5L V8 *#
4.7L V8 *#
5.0L V8 *#
5.4L V8 *#

T196
T196
T196
T196

60,000
60,000
60,000
60,000

607
607
607
607

T293
T107

45,000
45,000

604
604

T293
T107

45,000
45,000

604
604

T293
T152

45,000
45,000

604
604

T293
T152

45,000
45,000

604
604

T293
T152

45,000
45,000

604
604

T119

60,000 1

609

T140

60,000 1

610

T140

60,000 1

610

2.5L V6 *

T285

60,000

612

3.0L V6 *

T285

60,000

612

3.0L V6 (DOHC)

T285

90,000

613

2.5L 4-Cyl. *#
Balance Shaft
Camshaft
1989
2.7L 4-Cyl. *#
Balance Shaft
Camshaft
1989-91
3.0L 4-Cyl. *#
Balance Shaft
Camshaft
944S & 944 Turbo
1987-88
2.5L 4-Cyl. *#
Balance Shaft
Camshaft
968
1992-95
3.0L 4-Cyl. *#
Balance Shaft
Camshaft

RENAULT
Alliance & Encore
1985-87
1.7L 4-Cyl. *
Fuego
1984-85
2.2L 4-Cyl.
Sportwagon
1984-86
2.2L 4-Cyl.

SAAB
900
1994-97
9000
1995-97
9-5
1999-03

TCK285

Not Available

Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A60

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Recommended
Replacement
Interval (Miles)

Page

T285

100,000

619

T285

100,000

619

T285
T285

100,000
100,000

619
616

T285
T329

100,000
100,000

616
622

Timing
Tensioners

Timing
Pulleys

SATURN
LS2 & LW2
2000
3.0L V6 (DOHC, VIN R) *#
L300 & LW300
2001
3.0L V6 (DOHC, VIN R) *#
2002-04
3.0L V6 (DOHC, VIN R) *#
Up To S/N 578511
From S/N 578512
Vue
2002-03
3.0L V6 (DOHC, VIN B) *#
2004
3.5L V6 (SOHC) *#

STERLING
825
1987-88
827
1989-91

2.5L V6 *#

T129

TCK129

T41015

Not Applicable

60,000 1

624

2.7L V6 *#

T129

TCK129

T41015

Not Applicable

60,000 1

624

T299
T300

TCK299
TCK299

T41061
T41062

T42022
Not Applicable

52,000 2
52,000 2

628
628

105,000
105,000

637
635

SUBARU
Passenger Cars
Coupe
1985-89
1.8L 4-Cyl.
Left Hand Belt
Right Hand Belt
Forester
1998
2.5L 4-Cyl. (DOHC) #
1999-04
2.5L 4-Cyl. (SOHC) *
Impreza & Outback Sport
1993
1.8L 4-Cyl.

T277
T304
T172

TCK172**

T41063**

1994

1.8L 4-Cyl.

T254

TCK254**

T41063**

1995-97

1.8L 4-Cyl.

T254

TCK254**

T41063**

2002-04
1995-96

2.0L 4-Cyl. (DOHC) Turbo *

2.2L 4-Cyl. (SOHC)

T328
T254

TCK254**

T41063**

1997-98

2.2L 4-Cyl. (SOHC)

T254

1999-01
1998

2.2L 4-Cyl. (SOHC) *

2.5L 4-Cyl. (DOHC) #

T304
T277

1999-04
2.5L 4-Cyl. (SOHC) *#
Justy
1987-95
1.2L 3-Cyl.
Legacy & Outback
1990-93
2.2L 4-Cyl.

TCK277**

T41092**

T304
T135
T172

T42023 (Upr-L)
60,000
T42023 (Lwr-L)
T42024 (Lwr-R)
T42023 (Upr-L)
60,000
T42023 (Lwr-L)
T42024 (Lwr-R)
T42023 (Upr-L)
60,000 Federal
T42023 (Lwr-L) 105,000 California
T42024 (Lwr-R)
105,000
T42023 (Upr-L)
60,000 Federal
T42023 (Lwr-L) 105,000 California
T42024 (Lwr-R)
60,000 Federal
105,000 California
105,000
T42023 (Upr-L)
105,000
T42023 (Lwr-L)
T42024 (Lwr-R)
105,000

T41060
TCK172**

T41063**

T42023 (Upr-L)
T42023 (Lwr-L)
T42024 (Lwr-R)

627
627
627
627
630
627
627
627
627
635
637
635

60,000

626

60,000

627

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A61

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

T254
T254

TCK254**
TCK254**

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

SUBARU (Cont.)
Legacy & Outback (Cont.)
1994
2.2L 4-Cyl.
1995-96
2.2L 4-Cyl.

Not Applicable
Not Applicable

1997-98

2.2L 4-Cyl.

T254

1999
1996-97

2.2L 4-Cyl. (SOHC) *

2.5L 4-Cyl. (DOHC) #

T304
T277

TCK277**

T41092**

1998-99

2.5L 4-Cyl. (DOHC) #

T277

TCK277**

T41092**

2000-03
Loyale
1990-94

2.5L 4-Cyl. (SOHC) *

T307

1.8L 4-Cyl.
Left Hand
Right Hand

T299
T300

TCK299
TCK299

T41061
T41062

T299
T300

TCK299
TCK299

T41061
T41062

T299
T300

TCK299
TCK299

60,000
60,000 Federal
105,000 California
60,000 Federal
105,000 California
105,000
T42023 (Upr-L)
60,000
T42023 (Lwr-L)
T42024 (Lwr-R)
T42023 (Upr-L)
105,000
T42023 (Lwr-L)
T42024 (Lwr-R)

627
627
627
627
627
635
637
637

105,000

635

T42022
Not Applicable

52,000 2
52,000 2

628
628

T42022
Not Applicable

52,000 2
52,000 2

628
628

Not Applicable
Not Applicable

52,000 2
52,000 2

628
628

60,000
60,000 Federal
105,000 Calif.

644
644
644

52,000 2
52,000 2

628
628

RX
1985-89

1.8L 4-Cyl.
Left Hand
Right Hand
Sedan & Station Wagon
1985-89
1.8L 4-Cyl.
Left Hand
Right Hand
SVX
1992-94
3.3L 6-Cyl.
1995-97
3.3L 6-Cyl.
XT
1985-91
XT6
1988-91
Light Trucks
Baja
2003-04

T209
T209

1.8L 4-Cyl.
Left Hand
Right Hand

T299
T300

2.7L 6-Cyl.
Left Hand
Right Hand

T151
T150

60,000 2
60,000 2

641
641

2.5L 4-Cyl. (SOHC) *

T307

105,000

635

TCK299
TCK299

T41061
T41062

T42022
Not Applicable

SUZUKI
Passenger Cars
Esteem
1995-00
1.6L 4-Cyl. (SOHC)
Esteem (Canadian)
2001-02
1.6L 4-Cyl. (SOHC)
Forenza
2004
2.0L 4-Cyl.

T212

TCK212

T41065

Not Applicable

60,000

649

T212

TCK212

T41065

Not Applicable

60,000

649

Inspect at 30,000
Replace at 60,000

651
651

T309

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A62

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

645
645
647
647
647
647
647

SUZUKI (Cont.)
Swift
1989-92
1993-94
1989-92
1993
1994
1995-97
1998-01
Light Trucks
Samurai
1985
1986-92
1993
1994
1995
Sidekick
1989
1989-91
1992

1.3L 4-Cyl. (DOHC) *

1.3L 4-Cyl. (DOHC) *
1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)

T171
T171
T095
T095
T243
T272
T194

TCK095
TCK095

T41064
T41064

Not Applicable
Not Applicable

TCK272
TCK194A

T41065

Not Applicable
Not Applicable

60,000 1
60,000
60,000 1
60,000
60,000
60,000
60,000

1.3L 4-Cyl. (SOHC)

1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)
1.3L 4-Cyl. (SOHC)
Up To VIN R4100375
From VIN R4100376
1.3L 4-Cyl. (SOHC)

T095
T095
T095

TCK095
TCK095

T41064

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000

647
647
647

T095
T243
T243

TCK095

T41064

Not Applicable

60,000
60,000
60,000

647
647
647

T095
T164

TCK095
TCK164

T41064
T41064

Not Applicable
Not Applicable

60,000 1
60,000 1

647
649

T164
T212

TCK164
TCK212

T41064
T41065

Not Applicable
Not Applicable

60,000 1
60,000 1

649
649

T164
T212
T212

TCK164
TCK212
TCK212

T41064
T41065
T41065

Not Applicable
Not Applicable
Not Applicable

60,000
60,000
60,000

649
649
649

T212

TCK212

T41065

Not Applicable

60,000

649

T212

TCK212

T41065

Not Applicable

60,000

649

T257
T257

TCK257**
TCK257**

T41075**
T41075**

T42030
T42030

60,000 Severe
90,000

683
697

T098
T087
T087

TCK087
TCK087

T41077
T41070
T41070

T42027
T42025
T42025

60,000
60,000 1
60,000 Severe

667
669
669

TCK199
TCK199
TCK199
TCK199
TCK157**
TCK200**
TCK257**
TCK257**

T41067
T41067
T41067
T41067
T41067
T41075**
T41075**
T41075**
T41075**

T42025
T42025
T42025
T42025
T42025
T42030
T42030
T42030
T42030

60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
90,000
60,000 Severe
60,000 Severe
60,000 Severe
90,000
90,000
90,000

669
669
669
678
678
683
683
683
697
697
472

1.3L 4-Cyl. (SOHC)

1.6L 4-Cyl.
1.6L 4-Cyl.
Convertible
Hardtop
1993-95
1.6L 4-Cyl.
Convertible
Hardtop
1996-98
1.6L 4-Cyl.
Vitara (Includes Canadian)
1999-01
1.6L 4-Cyl.
X-90
1996-98
1.6L 4-Cyl.

TOYOTA
Passenger Cars
Avalon
1995-97
3.0L V6 #
1998-04
3.0L V6 (1MZ-FE) *#
Camry
1984-86
1.8L 4-Cyl. Diesel
1983-85
2.0L 4-Cyl. #
1986
2.0L 4-Cyl. #
1987
2.0L 4-Cyl. #
GT-S
Exc. GT-S
1988-91
2.0L 4-Cyl. #
1992-97
2.2L 4-Cyl. #
1998-01
2.2L 4-Cyl.
1988-91
2.5L V6 #
1992-93
3.0L V6 #
1994-97
3.0L V6 #
1998-02
3.0L V6 (1MZ-FE) *#
2003-04
3.0L V6 (1MZ-FE) *#
2004
3.3L V6 (3MZ-FE) *#

T125
T138
T138
T199
T199
T157
T200
T257
T257
T257
T257

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A63

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T199
T199
T257
T257

TCK199
TCK199
TCK257**

T41067
T41067
T41075**

T42025
T42025
T42030

90,000
90,000
90,000
90,000

678
678
697
472

T036
T239
T235
T087
T138
T125
T125
T138
T199
T199

TCK036

T41066

Not Applicable

TCK235
TCK087
TCK199

T41072
T41070
T41067
T41067

Not Applicable
T42025
T42025
T42025

TCK199
TCK199
TCK199

T41067
T41067
T41067

T42025
T42025
T42025

60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
90,000

664
664
664
669
669
669
669
678
678
678

T41070

T42025

60,000
60,000
60,000
60,000

Severe
Severe
Severe
Severe

669
669
678
678

TOYOTA (Cont.)
Camry Solara
1999-00
2.2L 4-Cyl.
2001
2.2L 4-Cyl.
1999-03
3.0L V6 (1MZ-FE) *#
2004
3.3L V6 (3MZ-FE) *#
Celica, Celica GT & ST
1990-92
1.6L 4-Cyl. (DOHC)
1993
1.6L 4-Cyl. (DOHC)
1994-97
1.8L 4-Cyl. (DOHC)
1986
2.0L 4-Cyl. #
1987-89
2.0L 4-Cyl. #
1990
2.0L 4-Cyl. #
1991-93
2.0L 4-Cyl. #
1990-91
2.2L 4-Cyl.
1992-97
2.2L 4-Cyl.
1998-99
2.2L 4-Cyl.
Celica GTS
1986
2.0L 4-Cyl. #
1987-88
2.0L 4-Cyl. #
1990-91
2.2L 4-Cyl.
1992-93
2.2L 4-Cyl.
Celica Supra
1982-83
2.8L 6-Cyl.
1984-85
2.8L 6-Cyl.
Corolla
1983-85
1.6L 4-Cyl. (SOHC)
1986-87
1.6L 4-Cyl. (SOHC)
1988
1.6L 4-Cyl. (SOHC)
1988-92
1.6L 4-Cyl. (DOHC, 4A-FE)
1993-97
1.6L 4-Cyl. (DOHC, 4A-FE)
1984-85
1.8L 4-Cyl. Diesel
1993-97
1.8L 4-Cyl. (7A-FE)
Corolla FX & FX-16
1987-88
1.6L 4-Cyl. (SOHC)
1985
1.6L 4-Cyl. (DOHC, 4A-GE)
1986-88
1.6L 4-Cyl. (DOHC, 4A-GE)
Corolla GTS
1985
1.6L 4-Cyl. (DOHC, 4A-GE)
1986-88
1.6L 4-Cyl. (DOHC, 4A-GE)
1989
1.6L 4-Cyl. (4A-GE/GELC)
1990-91
1.6L 4-Cyl. (4A-GE/GELC)
Corolla SR5
1985
1.6L 4-Cyl.
1986-87
1.6L 4-Cyl.
1988
1.6L 4-Cyl.
Corolla Sport
1985
1.6L 4-Cyl. (4A-GE)
1986-87
1.6L 4-Cyl. (4A-GE)
Corolla Tercel
1980-82
1.5L 4-Cyl.
Cressida
1983
2.8L 6-Cyl.
1984-85
2.8L 6-Cyl.

T125
T125
T138
T199

TCK199
TCK199

T41067
T41067

T42025
T42025

T074
T101

TCK101

T41069

Not Applicable

60,000 1
60,000 Severe

687
687

TCK070
TCK070
TCK036
TCK036
TCK236

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
T42027
Not Applicable

60,000 1
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000
60,000 Severe

662
662
662
664
664
667
664

T070
T070
T036
T036
T236
T098
T235

TCK235

T41066
T41066
T41066
T41066
T41072
T41077
T41072

T070
T112
T112

TCK070
TCK176
TCK176

T41066
T41074
T41074

Not Applicable
Not Applicable
Not Applicable

60,000 Severe
60,000 1
60,000 Severe

662
660
660

T112
T112
T176
T176

TCK176
TCK176
TCK176

T41074
T41074
T41074

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 Severe
60,000 Severe
60,000 Severe

660
660
660
660

T070
T070
T036

TCK070
TCK070
TCK036

T41066
T41066
T41066

Not Applicable
Not Applicable
Not Applicable

60,000 1
60,000 Severe
60,000 Severe

662
662
662

T112
T112

TCK176
TCK176

T41074
T41074

Not Applicable
Not Applicable

60,000 1
60,000 Severe

660
660

T070

TCK070

T41066

Not Applicable

60,000 1

653

T074
T101

TCK101

T41069

Not Applicable

60,000 1
60,000 1

687
687

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A64

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T101
T126
T237

TCK101

T41069

Not Applicable

60,000 Severe
60,000 Severe
60,000 Severe

687
695
695

T112
T112
T176
T125
T138
T199

TCK176
TCK176
TCK176

T41074
T41074
T41074

Not Applicable
Not Applicable
Not Applicable

TCK199
TCK199

T41067
T41067

T42025
T42025

60,000 1
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe

660
660
660
669
678
678

T208
T208
T208

TCK208
TCK208
TCK208

T41071
T41071
T41071

T42029
T42029
T42029

60,000 Severe
90,000 Severe
90,000

658
658
658

T101
T126
T237

TCK101

T41069

Not Applicable

60,000 Severe
60,000 Severe
60,000 Severe

687
695
695

T215

60,000 Severe

689

T215

90,000 Severe

691

TOYOTA (Cont.)
Cressida (Cont.)
1986-88
2.8L 6-Cyl.
1989-91
3.0L 6-Cyl. (7M-GE)
1992
3.0L 6-Cyl. (7M-GE)
MR2
1985
1.6L 4-Cyl. (4A-GE)
1986-88
1.6L 4-Cyl. (4A-GE)
1989
1.6L 4-Cyl. (4A-GE)
1991-95
2.0L 4-Cyl. #
1991
2.2L 4-Cyl. #
1992-95
2.2L 4-Cyl. #
Paseo (Includes Canadian)
1992-97
1.5L 4-Cyl. (5E-FE)
1998
1.5L 4-Cyl. (5E-FE)
1999
1.5L 4-Cyl. (5E-FE)
Supra
1986
2.8L 6-Cyl.
1986-90
3.0L 6-Cyl. (7M-GE & GTE)
1991-92
3.0L 6-Cyl. (7M-GE & GTE)
1993-97
3.0L 6-Cyl.
(2JZ-GE & 2JZ-GTE)
1998
3.0L 6-Cyl.
(2JZ-GE & 2JZ-GTE)
Tercel
1983-86
1.5L 4-Cyl. (3A-C)
1988-94
1.5L 4-Cyl. (3E) *#
1995-97
1.5L 4-Cyl. (5E-FE)
1998
1.5L 4-Cyl. (5E-FE)
Tercel (Canadian)
1999
1.5L 4-Cyl. (5E-FE)
Tercel Sedan
1987
1.5L 4-Cyl. (3E) *
Tercel Wagon
1987-88
1.5L 4-Cyl. (3A-C)
Light Trucks
Highlander
2001-03
3.0L V6 (1MZ-FE) *#
2004
3.3L V6 (3MZ-FE) *#
Land Cruiser
1998-01
4.7L V8 (2UZ-FE) *#
2002-04
4.7L V8 (2UZ-FE) *#
Pickup
1981
2.2L 4-Cyl. Diesel *
1982
2.2L 4-Cyl. Diesel *
Up To 5/31/1982
From 6/1/1982
1983
2.2L 4-Cyl. Diesel *
1984-87
2.4L 4-Cyl. Diesel *
1988-91
3.0L V6 (3V-ZE) #
1992
3.0L V6 (3V-ZE) #
Up To 8/92
From 9/92
1993-95
3.0L V6 (3V-ZE) #

T070
T233
T208
T208

TCK070
TCK233
TCK208
TCK208

T41066
T41076
T41071
T41071

Not Applicable
T42028
T42029
T42029

60,000 1
60,000 Severe
60,000 Severe
90,000 Severe

653
655
658
658

T208

TCK208

T41071

T42029

90,000

658

60,000 Severe

655

T136
T070

TCK070

T41066

Not Applicable

60,000 Severe

653

T257
T257

TCK257**

T41075**

T42030

90,000
90,000

697
472

T298
T298

T41078
T41078

T42031
T42031

90,000
90,000

477
477

T079

T41068

T42026

100,000

676

T079
T084
T084
T084
T154

T41068
T41068
T41068

T42026
T42026
T42026

TCK240**

T41073**

T42037

100,000
100,000
100,000
100,000
60,000 Severe

676
676
676
681
702

T154
T240
T240

TCK240**
TCK240A**
TCK240A**

T41073**
Not Available
Not Available

T42037
T42037
T42037

60,000 Severe
60,000 Severe
60,000 Severe

702
702
702

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A65

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

2.0L 4-Cyl. #
2.0L 4-Cyl. #
2.0L 4-Cyl. #

T199
T199
T199

TCK199
TCK199
TCK199

T41067
T41067
T41067

T42025
T42025
T42025

60,000 Severe
90,000 Severe
90,000

674
674
674

4.7L V8 (2UZ-FE) *#

T298

90,000

477

3.0L V6 (1MZ-FE) *#
3.3L V6 (3MZ-FE) *#

T257
T257

TCK257**

T41075**

T42030

90,000
90,000

697
472

3.4L V6 (5VZ-FE) *#
3.4L V6 (5VZ-FE) *#

T271
T271

TCK271
TCK271

Not Available
Not Available

Not Available
Not Available

60,000 Severe
90,000

705
705

3.4L V6 (5VZ-FE) *#
4.7L V8 (2UZ-FE) *#
4.7L V8 (2UZ-FE) *#

T271
T298
T298

TCK271

Not Available
T41078**

Not Available
T42031

90,000
90,000
90,000

705
477
477

3.0L V6 (3V-ZE) #
3.4L V6 (5VZ-FE) *#
3.4L V6 (5VZ-FE) *#

T240
T271
T271

TCK240A**
TCK271
TCK271

Not Available
Not Available
Not Available

T42037
Not Available
Not Available

60,000 Severe
60,000 Severe
90,000

702
705
705

3.0L V6 (3V-ZE) #
3.0L V6 (3V-ZE) #
Up To 8/92
From 9/92
3.0L V6 (3V-ZE) #
3.4L V6 (5VZ-FE) *#
3.4L V6 (5VZ-FE) *#
4.7L V8 (2UZ-FE) *#

T154

TCK240**

T41073**

T42037

60,000, Severe

702

T154
T240
T240
T271
T271
T298

TCK240**
TCK240A**
TCK240A**
TCK271
TCK271

T41073**
Not Available
Not Available
Not Available
Not Available

T42037
T42037
T42037
Not Available
Not Available

60,000 Severe
60,000 Severe
60,000 Severe
60,000 Severe
90,000
90,000

702
702
702
705
705
482

105,000

715

Engine

TOYOTA (Cont.)
RAV4
1996-97
1998
1999-00
Sequoia
2001-03
Sienna
1998-03
2004
Tacoma
1995-97
1998-04
Tundra
2000-04
2000-01
2002-03
T100
1993-94
1995-97
1998
4Runner
1988-91
1992
1993-95
1996-97
1998-02
2003-04

VOLKSWAGEN
Passenger Cars
Beetle (New Beetle)
1999-04
1.8L 4-Cyl. *#
(APH, AWP, & AWV)
1998
1.9L 4-Cyl. Diesel (ALH) *#
1999
1.9L 4-Cyl. Diesel (ALH) *#
2000
2001

2002
2003-04
2004
1998-00
2001-03
2004
Cabrio
1995-02

T306
T301
T301 or
T321
T301

T43007
T43007

Not Available
Not Available

60,000
60,000

733
733

T43007

Not Available

40,000

733

T301

T43007

Not Available

From Eng. No. 500,001

T321

T43007

Not Available

1.9L 4-Cyl. Diesel (ALH) *#

1.9L 4-Cyl. Diesel (ALH) *#
1.9L 4-Cyl. Diesel (BEW) *#
2.0L 4-Cyl. (Exc. ABA) *#
2.0L 4-Cyl. (Exc. ABA) *#
2.0L 4-Cyl. (Exc. ABA) *#

T321
T321
T321
T296
T296
T296

T43007
T43007

Not Available
Not Available

TCK296
TCK296
TCK296

T43010
T43010
T43010

Not Available
Not Available
Not Available

40,000 (A/T)
60,000 (M/T)
40,000 (A/T)
60,000 (M/T)
80,000
100,000
90,000
60,000 1
105,000
N/A

733
733
733
733
733
733
736
743
743
743

2.0L 4-Cyl. (ABA) *

T262

TCK262

T41079

Not Applicable

60,000 1

740

1.9L 4-Cyl. Diesel (ALH) *#

1.9L 4-Cyl. Diesel (ALH) *#
Up To Eng. No. 500,000

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A66

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

1.8L 4-Cyl. (SOHC) *

T017

TCK017

T41079

Not Applicable

60,000 1

724

1.8L 4-Cyl. (SOHC) *

T017

TCK017

T41079

Not Applicable

60,000 1

724

1.5L 4-Cyl. *
1.5L 4-Cyl. Diesel *
1.6L 4-Cyl. *
1.6L 4-Cyl. Diesel *

T017
T043
T017
T043

TCK017

T41079
T41080
T41079
T41080

Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1

711
710
711
710

1.8L 4-Cyl. (SOHC) *

T017

TCK017

T41079

Not Applicable

60,000 1

724

1.6L 4-Cyl. Diesel *

1.8L 4-Cyl. (SOHC) *
1.8L 4-Cyl. Turbo *#
1.9L 4-Cyl. Diesel *
(AAZ, AHU & 1Z)
1.9L 4-Cyl. Diesel (ALH) *#

T043
T017
T306

TCK017

T41080
T41079

Not Applicable

60,000 1
60,000 1
120,000

710
724
712

T242
T301 or
T321
T301

T43006
T43007

Not Available
Not Available

60,000
60,000

728
733

T43007

Not Available

40,000

733

T301

T43007

Not Available

T321

T43007

Not Available

T321
T321
T321
T262
T296
T296
T296
T296

T43007
T43007

Not Available
Not Available

TCK262
TCK296
TCK296
TCK296
TCK296

T41079
T43010
T43010
T43010
T43010

Not Applicable
Not Available
Not Available
Not Available
Not Available

40,000 (A/T)
60,000 (M/T)
40,000 (A/T)
60,000 (M/T)
80,000
100,000
90,000
60,000 1
60,000 1
60,000 1
N/A
N/A

733
733
733
733
733
733
736
740
743
743
743
746

T043
T017
T262

TCK017
TCK262

T41079
T41079

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

710
724
740

60,000 3

728
726
724
712
726
740
743

Engine

VOLKSWAGEN (Cont.)
Cabriolet
1985-93
Corrado
1990-92
Dasher
1974-75
1979-80
1976-80
1981
Fox
1987-93
Golf
1985-87
1985-92
2000-01
1993-97
1999
2000
2001

1.9L 4-Cyl. Diesel (ALH) *#

1.9L 4-Cyl. Diesel (ALH) *#
Eng. No. 500,000 & Before
Eng. No. 500,001 & After

2002
1.9L 4-Cyl. Diesel (ALH) *#
2003-04
1.9L 4-Cyl. Diesel (ALH) *#
2004
1.9L 4-Cyl. Diesel (BEW) *#
1993-99
2.0L 4-Cyl. (ABA) *
1999-00
2.0L 4-Cyl. (Exc. ABA) *#
2001-03
2.0L 4-Cyl. (Exc. BBW) *#
2004
2.0L 4-Cyl. (Exc. BBW) *#
2004
2.0L 4-Cyl. (BBW) *#
Golf (Canadian)
1988-92
1.6L 4-Cyl. Diesel *
1993-95
1.8L 4-Cyl. (SOHC) *
1995
2.0L 4-Cyl. (ABA) *
Golf III
1993-95
1.9 4-Cyl. Turbo Diesel *
GTI
1987-89
1.8L 4-Cyl. (DOHC) *
1985-92
1.8L 4-Cyl. (SOHC) *
2000-04
1.8L 4-Cyl. Turbo *#
1990-92
2.0L 4-Cyl. (DOHC) *
1996-99
2.0L 4-Cyl. (ABA) *
1999-00
2.0L 4-Cyl. (Exc. ABA) *#
GTI (Canadian)
1993-95
2.0L 4-Cyl. (ABA) *
Jetta
1980
1.6L 4-Cyl. *
1981-86
1.6L 4-Cyl. Diesel *
1989-92
1.6L 4-Cyl. Diesel *
1981-84
1.7L 4-Cyl. *

TCK017

Not Applicable

T242
TCK017

T41079

Not Applicable

TCK262
TCK296

T41079
T43010

Not Applicable
Not Applicable

60,000 1
60,000 1
120,000
60,000 1
60,000 1
60,000 1

T262

TCK262

T41079

Not Applicable

60,000 1

740

T017
T043
T043
T017

TCK017

T41079
T41080

Not Applicable

TCK017

T41079

Not Applicable

60,000 1
60,000 1
60,000 1
60,000 1

711
710
710
711

T292
T017
T306
T292
T262
T296

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A67

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

T292
T017
T306

TCK017

T41079

Not Applicable

60,000 1
60,000 1
120,000

726
724
712

T242
T301 or
T321
T301

T43006
T43007

Not Available
Not Available

60,000
60,000

728
733

T43007

Not Available

40,000

733

T301

T43007

Not Available

T321

T43007

Not Available

T321
T321
T321
T292
T262
T296
T296
T296
T296

T43007
T43007

Not Available
Not Available

T41079
T43010
T43010
T43010
T43010

Not Applicable
Not Available
Not Available
Not Available
Not Available

40,000 (A/T)
60,000 (M/T)
40,000 (A/T)
60,000 (M/T)
80,000
100,000
90,000
60,000 1
60,000 1
60,000 1
60,000 1
N/A
N/A

733
733
733
733
733
733
736
726
740
743
743
743
746

Not Applicable

60,000 1
60,000 1
60,000 1

710
710
724

60,000 3

728

60,000 3

728

T291
T317

90,000
90,000

718
718

T291
T317
T306
T292
T262
T297
T297
T297

105,000 3
105,000 3
105,000 3
60,000 1
60,000 1
90,000
75,000
105,000

718
718
720
726
740
755
755
755

60,000 1
60,000 3
60,000 3
60,000 3

724
728
728
728

VOLKSWAGEN (Cont.)
Jetta (Cont.)
1987-89
1984-92
2000-04
1993-98
1999
2000
2001

1.8L 4-Cyl. (DOHC) *

1.8L 4-Cyl. (SOHC) *
1.8L 4-Cyl. Turbo *#
1.9L 4-Cyl. Diesel *
(AAZ, AHU & 1Z)
1.9L 4-Cyl. Diesel (ALH) *#
1.9L 4-Cyl. Diesel (ALH) *#
1.9L 4-Cyl. Diesel (ALH) *#
Up To Eng. No. 500,000
From Eng. No. 500,001

2002
1.9L 4-Cyl. Diesel (ALH) *#
2003-04
1.9L 4-Cyl. Diesel (ALH) *#
2004
1.9L 4-Cyl. Diesel (BEW) *#
1990-92
2.0L 4-Cyl. (DOHC) *
1993-99
2.0L 4-Cyl. (ABA) *
1999-00
2.0L 4-Cyl. (Exc. ABA) *#
2001-03
2.0L 4-Cyl. (Exc. BBW) *#
2004
2.0L 4-Cyl. (Exc. BBW) *#
2004
2.0L 4-Cyl. (BBW) *#
Jetta (Canadian)
1986
1.6L 4-Cyl. Diesel *
1988-92
1.6L 4-Cyl. Diesel *
1993-95
1.8L 4-Cyl. (SOHC) *
Jetta III
1993-95
1.9L 4-Cyl. Turbo Diesel *
Passat
1996-97
1.9L 4-Cyl. Turbo Diesel *
1998-99
1.8L 4-Cyl. (AEB) *#
152 Tooth Belt 5
153 Tooth Belt
2000
1.8L 4-Cyl. (AEB & ATW) *#
152 Tooth Belt 5
153 Tooth Belt
2000-04
1.8L 4-Cyl. (AUG & AWM) *#
1990-92
2.0L 4-Cyl. (DOHC) *
1993-96
2.0L 4-Cyl. (ABA) *
1998
2.8L V6 *#
1999
2.8L V6 *#
2000-04
2.8L V6 *#
Passat (Canadian)
1992-94
1.8L 4-Cyl. (SOHC) *
1993-94
1.9L 4-Cyl. Turbo Diesel *
1995-97
1.9L 4-Cyl. Turbo Diesel *
1998
1.9L 4-Cyl. Turbo Diesel *

T043
T043
T017

TCK262
TCK296
TCK296
TCK296
TCK296

T41080
TCK017

T41079

T242
T242

T017
T242
T242
T242

T43006

Not Available

TCK262

T41079

Not Applicable

TCK017

T41079

Not Applicable

T43006

Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
5
- ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).
A68

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

TCK017
TCK017

T41080
T41079
T41079

Not Applicable
Not Applicable

60,000 1
60,000 1
60,000 1

710
711
724
118
118

VOLKSWAGEN (Cont.)
Quantum
1982-85
1982-83
1985
1984-85
1983-86

1.6L 4-Cyl. Diesel *

1.7L 4-Cyl. *
1.8L 4-Cyl. (SOHC) *
2.1L 5-Cyl. #
.70 Belt Width
.75 Belt Width
2.2L 5-Cyl. #
.70 Belt Width
.75 Belt Width
2.2L 5-Cyl. #

1987-88
Rabbit
1975-79
1.5L 4-Cyl. *
1977-78
1.5L 4-Cyl. Diesel *
1979-80
1.5L 4-Cyl. Diesel *
1980
1.6L 4-Cyl. *
1981-84
1.6L 4-Cyl. Diesel *
1981-84
1.7L 4-Cyl. *
1983-84
1.8L 4-Cyl. (SOHC) *
Scirocco (Includes Canadian)
1978
1.5L 4-Cyl. *
1976-80
1.6L 4-Cyl. *
1981-83
1.7L 4-Cyl. *
1985-89
1.8L 4-Cyl. (DOHC) *
1983-89
1.8L 4-Cyl. (SOHC) *
Light Trucks
Eurovan
1992-96
2.5L 5-Cyl. *
Pickup & Rabbit Pickup
1980
1.5L 4-Cyl. Diesel *
1980
1.6L 4-Cyl. *
1981-83
1.6L 4-Cyl. Diesel *
1981-83
1.7L 4-Cyl. *
Transporter (Canadian)
1992-96
2.5L 5-Cyl. *
Vanagon
1982
1.6L 4-Cyl. Diesel *

T043
T017
T017
T127
T065

60,000
60,000

T127
T065
T127

60,000
60,000
60,000

1
1

118
118
118

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

711
710
710
711
710
711
724

60,000 1
60,000 1
60,000 1
60,000 1
60,000 1

711
711
711
726
724

60,000 1

750

60,000 1
60,000 1
60,000 1
60,000 1

710
711
710
711

60,000 1

750

60,000 1

710

T252
T311

70,000
70,000

766
766

T252
T311
T252

105,000 3
105,000 3
105,000

766
766
775

T017
T043
T043
T017
T043
T017
T017

TCK017

T017
T017
T017
T292
T017

T41079

Not Applicable

TCK017
TCK017

T41080
T41079
T41080
T41079
T41079

Not Applicable
Not Applicable

TCK017
TCK017
TCK017

T41079
T41079
T41079

Not Applicable
Not Applicable
Not Applicable

TCK017

T41079

Not Applicable

TCK017

Not Applicable

T043
T017
T043
T017

TCK017
TCK017

T41080
T41079
T41080
T41079

T043

T41080

Not Applicable
Not Applicable

VOLVO
C70
1998
1999-01
2002-04

2.3L 5-Cyl. Turbo *#

To Eng. VIN 1266127
From Eng. VIN 1266128
2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.3L 5-Cyl. Turbo *#

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
5
- ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).
A69

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

VOLVO (Cont.)
C70 (Cont.)
1998
1999-01
2002-04
Coupe
1991
DL & GL
1980-83
1982
1983-85
1980-84

2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.4L 5-Cyl. Turbo *#

T252
T311

70,000
70,000

766
766

T252
T311
T331

105,000 3
105,000 3
105,000

766
766
775

2.3L 4-Cyl. (B230, F & FT) *

T032

TCK032

T41081

Not Applicable

50,000

770

2.1L 4-Cyl. (B21) *

2.3L 4-Cyl. (B23) *
2.3L 4-Cyl. (B23) *
2.4L 6-Cyl. Diesel *
Camshaft
Injection Pump

T032
T032
T032

TCK032
TCK032
TCK032

T41081
T41081
T41081

Not Applicable
Not Applicable
Not Applicable

40,000
40,000
40,000

765
765
765

75,000 2
75,000 2

780
780

DL (Canadian)
1983
2.1L 4-Cyl. (B21) *
GLE (Canadian)
1984
2.3L 4-Cyl. (B23) *
GLT
1981-83
2.1L 4-Cyl. (B21) *
GLT (Canadian)
1983
2.3L 4-Cyl. (B23) *
GT Turbo
1984-85
2.1L 4-Cyl. (B21) *
S40
2000-01
1.9L 4-Cyl. Turbo *#
To Eng. VIN 1219110
From Eng. VIN 1219111
2002-04
1.9L 4-Cyl. Turbo *#
2004 1/2
2.4L 5-Cyl. Turbo *#
2004 1/2
2.5L 5-Cyl. Turbo *#
S60
2001
2.3L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2002-04
2.3L 5-Cyl. Turbo *#
2001
2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2002-04
2.4L 5-Cyl. Non-Turbo *#
2002-04
2.4L 5-Cyl. Turbo *#
S70
1998
2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127
From Eng. VIN 1266128
1999-00
2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127
From Eng. VIN 1266128

T083
T082
T032

TCK032

T41081

Not Applicable

40,000

765

T032

TCK032

T41081

Not Applicable

40,000

765

T032

TCK032

T41081

Not Applicable

40,000

765

T032

TCK032

T41081

Not Applicable

40,000

765

T032

TCK032

T41081

Not Applicable

40,000

765

T252
T311
T311
T331
T331

105,000 3
105,000 3
105,000 3
120,000
120,000

758
758
762
777
777

T252
T311
T252

105,000 3
105,000 3
105,000

766
766
775

T252
T311
T252
T331

105,000 3
105,000 3
105,000
105,000

766
766
775
775

T252
T311

70,000
70,000

766
766

T252
T311

105,000 3
105,000 3

766
766

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A70

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

VOLVO (Cont.)
S70 (Cont.)
1998
1999-00
S80
1999
2000-01
2002-03
1999
2000-03
S90
1997-98
V40
2000-01
2002-04
V70
1998
1999-01
2002-04
1998
1999-01
2002-04
2002-04
V90
1997-98
XC90
2003
2004
2003-04
240
1986-92
1993
242, 244 & 245
1976-79
740 Series
1986-92
1985-86

2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128

T252
T311

70,000
70,000

766
766

T252
T311

105,000 3
105,000 3

766
766

2.8L 6-Cyl. Turbo *

2.8L 6-Cyl. Turbo *
2.9L 6-Cyl. Turbo *
2.9L 6-Cyl. Non-Turbo *
2.9L 6-Cyl. Non-Turbo *

T270
T319
T319
T270
T319

105,000 3
105,000 3
105,000 3
105,000 3
105,000 3

782
782
782
782
782

2.9L 6-Cyl. Turbo *#

T270

70,000

768

1.9L 4-Cyl. Turbo *#

To Eng. VIN 1219110
From Eng. VIN 1219111
1.9L 4-Cyl. Turbo *#

T252
T311
T311

105,000 3
105,000 3
105,000 3

758
758
762

T252
T311

70,000
70,000

766
766

T252
T311
T252

105,000 3
105,000 3
105,000

766
766
775

2.3L 5-Cyl. Turbo *#

To Eng. VIN 1266127
From Eng. VIN 1266128
2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.3L 5-Cyl. Turbo *#
2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.4L 5-Cyl. *#
To Eng. VIN 1266127
From Eng. VIN 1266128
2.4L 5-Cyl. Non-Turbo *#
2.4L 5-Cyl. Turbo *#

T252
T311

70,000
70,000

766
766

T252
T311
T252
T331

105,000 3
105,000 3
105,000
105,000

766
766
775
775

2.9L 6-Cyl. Turbo *#

T270

70,000

768

2.5L 5-Cyl. Turbo *#

2.5L 5-Cyl. Turbo *#

T331
T331

2.9L 6-Cyl. Turbo *

T319

120,000
120,000 (AWD)
105,000 (FWD)
120,000 3

775
775
775
782

2.3L 4-Cyl. (B230, F & FT) *

2.3L 4-Cyl. (B230, F & FT) *

T032
T234

TCK032
TCK234

T41081
Not Available

Not Applicable
Not Applicable

50,000
50,000

770
770

2.1L 4-Cyl. (B21) *

T032

TCK032

T41081

Not Applicable

40,000

765

2.3L 4-Cyl. (B230, F & FT) *

2.4L 6-Cyl. Diesel *
Camshaft
Injection Pump

T032

TCK032

T41081

Not Applicable

50,000

770

75,000 2
75,000 2

780
780

T083
T082

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A71

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

VOLVO (Cont.)
740 Series (Canadian)
1986-88
2.3L 4-Cyl. (B234, DOHC) *#
Balance Shaft
Camshaft
1989
2.3L 4-Cyl. (B234, DOHC) *#
Automatic Tensioner
Balance Shaft
Camshaft
Manual Tensioner
Balance Shaft
Camshaft
1990
2.3L 4-Cyl. (B234, DOHC) *#
Balance Shaft
Camshaft
760 Series
1985-90
2.3L 4-Cyl. (B230, F & FT) *
1985
2.4L 6-Cyl. Diesel *
Camshaft
Injection Pump
760 GLE
1984
2.3L 4-Cyl. (B23) *
1983-84
2.4L 6-Cyl. Diesel *
Camshaft
Injection Pump
780 Series
1989-90
2.3L 4-Cyl. (B230, F & FT) *
850
1994
2.3L 5-Cyl. Turbo *#
Up To Eng. No. 131034
From Eng. No. 131035
1995-97
2.3L 5-Cyl. Turbo *#
1993
2.4L 5-Cyl. Turbo *#
Up To Eng. No. 131034
From Eng. No. 131035
1994-97
2.4L 5-Cyl. Turbo *#
850 (Canadian)
1996
2.3L 5-Cyl. Turbo *#
1995
2.4L 5-Cyl. Turbo *#
Up To Eng. No. 131034
From Eng. No. 131035
940 Series
1991-92
2.3L 4-Cyl. (B230, F & FT) *
1993
2.3L 4-Cyl. (B230, F & FT) *
1994-95
2.3L 4-Cyl. (B230, F & FT) *
940 (Canadian)
1991
2.3L 4-Cyl. (B234, DOHC) *#
Balance Shaft
Camshaft
1992
2.3L 4-Cyl. (B234, DOHC) *#
Balance Shaft
Camshaft

T174
T173

50,000 2
50,000 2

771
771

T174
T198

50,000 2
50,000 2

771
771

T174
T173

50,000 2
50,000 2

771
771

T174
T173

50,000 2
50,000 2

771
771

50,000

770

75,000 2
75,000 2

780
780

40,000

765

75,000 2
75,000 2

780
780

50,000

770

T217
T252
T252

70,000
70,000
70,000

768
768
768

T217
T252
T252

50,000
70,000
70,000

768
768
768

T252

70,000

768

T217
T269

70,000
70,000

768
768

50,000
50,000
50,000 w/o EGR
100,000 w/ EGR

770
770
770
770

50,000 2
50,000 2

771
771

50,000 2
50,000 2

771
771

T032

TCK032

T41081

Not Applicable

T083
T082
T032

TCK032

T41081

Not Applicable

T083
T082
T032

T032
T234
T234

TCK032

TCK032
TCK234
TCK234

T41081

T41081
Not Available
Not Available

Not Applicable

Not Applicable
Not Applicable
Not Applicable

T174
T198
T174
T198

TCK032
TCK032

T41081
T41081

Not Applicable
Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A72

ALPHABETICAL MODEL LISTING (Cont.)

Make
Model/
Year

Engine

Timing
Belt
Part No.

Timing
Component
Kit Part No.

Timing
Tensioners

Timing
Pulleys

Recommended
Replacement
Interval (Miles)

Page

VOLVO (Cont.)
960
1992-93
1994
1995-97

2.9L 6-Cyl. *#
2.9L 6-Cyl. *#
2.9L 6-Cyl. *#

T217
T252
T270

30,000 3
50,000
70,000

768
768
768

1.1L 4-Cyl. *
1.3L 4-Cyl. *

T018
T018

60,000 1
60,000 1

785
785

YUGO
GV Series
1986-89
1987

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for
interference engine cautions.
# - Uses a timing belt driven water pump.
** - Does not include camshaft tensioner hydraulic assembly.
1
- 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.
4
- While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience.
A73

ACURA

1.6L 4-Cylinder EL
TIMING BELT APPLICATION
Application
1.6L 4-Cyl. SOHC
EL (Canadian)
1997-00 ....................................................
1

Labor Time

Belt
Part No.

2.0 Hours .. ..... T224

With Air Conditioning, add .4 hours.

With Cruise Control, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.
Removal 1) Disconnect battery negative cable. Remove engine lower
splash shield. Remove power steering, alternator, and A/C compressor
drive belts. Rotate crankshaft counterclockwise to TDC of compression
stroke. See Fig. 3.
2) 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.
3) Use jack to support engine. Working from front of engine, remove
engine mount bracket nuts. Remove crankshaft pulley. Remove lower
cover and dipstick tube.
4) 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 1) 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.

2) Set camshaft pulley to TDC. TDC marks should align with top surface
of cylinder head. See Fig. 3.
3) 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 direction. Ensure crankshaft and camshaft pulley timing
mark are aligned with TDC marks.
4) Loosen and retighten adjusting bolt to tension timing belt. Install lower
cover. Install crankshaft pulley. Tighten pulley bolt to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.
5) 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. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary,
retorque crankshaft pulley bolt.
6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If
not, timing belt will need to be removed and repositioned. To complete
installation, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
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 Clockwise
Engine Mount Bracket Nuts ...................................................................................... 54 (74)
Power Steering Pump Bracket Bolt
Power Steering Pump Lock Bolt .............................................................................. 17 (24)
Timing Belt Tensioner Adjusting Bolt ........................................................................ 33 (45)
INCH Lbs. (N.m)
CKF Sensor Bolt ..................................................................................................... 106
Engine Lower Splash Shield .................................................................................... 89
Timing Belt Cover Bolt .............................................................................................. 89
Water Pump Bolt ..................................................................................................... 106
1

Lubricate bolt threads and bolt head shoulder.

(12)
(10)
(10)
(12)

ACURA

1.6L 4-Cylinder EL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark

ACURA

1.6L 4-Cylinder EL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Timing Belt Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Bolt

ACURA

1.6L 4-Cylinder Integra

TIMING BELT APPLICATION
Application
1.6L 4-Cyl.
Integra
1986-89 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.8 Hours .. .. TCK130 .. ..... T130

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Courtesy of American Honda Motor Co., Inc.

TIMING BELT
Removal 1) Disconnect negative battery cable. Turn crankshaft
counterclockwise 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 the way without disconnecting hoses. Remove crankshaft pulley. See Fig. 1.
2) 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.
3) Slide belt off sprockets. Remove bolts, washers, camshaft sprockets,
and Woodruff key (if necessary).
Installation 1) Ensure No. 1 piston is still at TDC. Install Woodruff
keys, camshaft sprockets, washer, and retaining bolts (if removed).
Position UP mark on sprockets at top. Align grooves on sprockets. See
Fig. 2.
2) Install timing belt on sprockets. Use care not to excessively bend or
twist belt.
3) Rotate crankshaft counterclockwise 3 teeth on camshaft sprockets to
create tension on belt. Tighten tensioner adjustment bolt. To complete
installation, reverse removal procedure. Adjust the drive belts to proper
tension.

Fig. 1: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS

Fig. 2: Locating Camshaft Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor/Bracket Bolts ................................................................................. 33 (45)
Alternator Belt Adjustment Bolt ................................................................................. 17 (23)
Alternator Mount Bolt ................................................................................................ 33 (45)
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)

Courtesy of American Honda Motor Co., Inc.

ACURA

1.7L 4-Cylinder
TIMING BELT APPLICATION
Application
1.7L 4-Cyl.
Integra
1992-93 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.8 Hours .. .. TCK227 .. ..... T277

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 90,000 miles
or 72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove left front wheel. Remove left front wheelwell splash
shield. Remove drive belts. Remove power steering pump with hoses
attached, and set it aside.
2) 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.
3) Remove left engine mount. Remove cylinder head cover. Remove
crankshaft pulley. Loosen timing belt tension adjuster bolt 180 degrees.
See Fig. 3. Push tensioner to relieve tension on timing belt. Retighten
adjuster bolt. Remove timing belt.
Installation 1) Ensure No. 1 piston is at TDC of compression stroke.
Install timing belt onto sprockets. DO NOT bend or twist belt excessively.
Adjust timing belt tension.
2) To complete installation, reverse removal procedure. Lubricate
threads only of crankshaft pulley bolt, leaving underside of bolt head dry.
On 1993 models, tighten crankshaft pulley bolt to 147 ft. lbs. (200 N.m),
loosen, then retighten to 133 ft. lbs. (180 N.m). Adjust drive belts to
proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts .......................................................................................... 27 (37)
Crankshaft Pulley Bolt
1992 ....................................................................................................................... 87 (118)
1993 ................................................................................................................... 1 133 (180)
Power Steering Mount Bolt ....................................................................................... 17 (23)
Timing Belt Tension Adjuster Bolt .............................................................................. 40 (54
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, then retighten to 133 ft. lbs. (180 N.m).
Courtesy of American Honda Motor Co., Inc.

Fig. 3: Locating Timing Belt Adjuster Bolt

ACURA

1.8L 4-Cylinder
TIMING BELT APPLICATION
Application
1.8L 4-Cyl.
Integra
1990-01
1.8L 4-Cyl.
Integra
1994-01
1

Labor Time

Component
Belt
Kit No.
Part No.

(Exc. VTEC)
............................... 2.8 Hours ... .. TCK184 .. ..... T184
(VTEC)
............................... 2.8 Hours ... .. TCK247 .. ..... T247

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-94 models, manufacturer recommends the belt be replaced
every 90,000 miles. For 1995-96 models, the manufacturer recommends the belt be replaced 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
temperatures (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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove left front wheel. Remove left front wheelwell splash
shield. Remove all drive belts. Remove power steering pump with hoses
attached. Set power steering pump aside.
2) 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 sprockets at top. See Fig. 2. Align
grooves on sprockets. Remove crankshaft pulley.
3) 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. See Fig. 4. Install timing
belt onto sprockets. DO NOT bend or twist belt excessively. Adjust
timing belt tension. To complete installation, reverse removal procedure.
On 1993-01 models, tighten crankshaft pulley bolt to 147 ft. lbs. (200
N.m), loosen, then retorque to 133 ft. lbs. (180 N.m). On all models,
adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor/Bracket Bolts ................................................................................. 17 (23)
Alternator Belt Adjustment Bolt ................................................................................. 17 (23)
Alternator Mount Bolt ................................................................................................ 33 (45)
Camshaft Sprocket Bolts .......................................................................................... 27 (37)
Crankshaft Pulley Bolt
1990-92 .................................................................................................................. 87 (118)
1993-01 .............................................................................................................. 1 133 (180)
Engine Block-To Transaxle Bolt ................................................................................ 47 (64)
Engine Mount Bolts ....................................................................... ..................................... 2
Power Steering Bolt .................................................................................................. 17 (23)
Timing Belt Tension Adjuster Bolt ............................................................................. 40 (54)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
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).
See Fig. 3.

ACURA

1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Positioning Camshaft

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Engine/Transaxle Mount Location & Tightening Sequence

ACURA

2.2L & 2.3L 4-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl.
2.2CL
1997
Balance Shaft ............... .......... 1 .......... ..
Camshaft .......................... 3.1 Hours ... ..
2.3L 4-Cyl.
2.3CL
1998-99
Balance Shaft ............... .......... 1 .......... ..
Camshaft .......................... 3.1 Hours ... ..
1

TCK244 .. ..... T186

TCK244 .. ..... T244

TCK244 .. ..... T186

TCK244 .. ..... T244

With balance shaft belt, add .2 hour.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

5) Push tensioner to remove tension from balance shaft belt adjuster,

then retighten nut.
6) 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.
7) Align groove on balance shaft pulley with pointer on oil pump housing.
See Fig. 6. Install balance shaft belt. Loosen adjuster nut about one turn
to tension balance shaft belt.
8) Remove 6x100 mm bolt from balance shaft. Install sealing bolt in side
of engine block. Install crankshaft pulley and bolt. Rotate crankshaft
about one turn counterclockwise, then tighten adjuster nut. Remove
6x1.0 mm bolt from timing belt adjuster arm.
9) Remove crankshaft pulley. Install lower cover. Install rubber seal
around adjuster nut. DO NOT loosen adjuster nut. Install crankshaft
pulley. To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 degrees F).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Identifying TDC Mark On Crankshaft Drive Pulley

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft
counterclockwise 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. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a
jack, with cushion between oil pan and jack, to support engine. Remove
side engine mount.
2) Remove oil dipstick and pipe. Remove valve cover. Remove 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 1) 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.
2) Install timing belt in sequence shown. See Fig. 3. Loosen and
retighten the timing belt adjusting nut about one turn. Install balance
shaft drive pulley and lower cover. Install crankshaft pulley and center
bolt.
3) Rotate crankshaft about 5-6 times counterclockwise. Set No. 1 piston
at TDC. Loosen timing belt adjusting nut about one turn. Rotate
crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten timing
belt adjusting nut. Make sure crankshaft and camshaft pulleys are at
TDC.
4) Remove crankshaft pulley and lower cover. Ensure crankshaft 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 one turn, and
make sure balance shaft belt adjuster moves freely.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

ACURA

2.2L & 2.3L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning & Locking Balance Shaft

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Timing Belt Adjuster Nut

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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 (45)
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)
Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Balance Shaft Pulley

ACURA

10

2.5L 5-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.5L 5-Cylinder
Vigor
1992-94 ..................................................... 3.1 Hours ......... T211
2.5TL
1995-98 ..................................................... 3.1 Hours ......... T211
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For Vigor, normal replacement interval is 90,000 miles. For 1995-96
2.5TL, replacement interval is 90,000 miles for normal service and
60,000 for severe service. For 1997-98 2.5TL, 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: Before disconnecting negative battery cable, obtain radio
anti-theft code from vehicle owner.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory
drive belts. Remove cylinder head cover and upper timing belt cover.
See Fig. 1. Rotate crankshaft counterclockwise to bring No. 1 piston to
TDC of compression stroke. Remove crankshaft pulley. Remove lower
timing belt cover.
2) Loosen timing belt tension adjuster bolt 180 degrees. See Fig. 2.
Push tensioner to relieve tension on timing belt. Retighten adjuster bolt.
If reusing timing belt, mark direction of belt rotation before removing.
Remove timing belt.
Installation 1) Ensure No. 1 piston is at TDC. See Fig. 3. Position
timing marks on camshaft pulley. See Figs. 4 and 5. Install timing belt (in
sequence) onto crankshaft pulley, tension adjuster pulley, water pump
pulley and camshaft pulley. See Fig. 6. DO NOT bend or twist belt
excessively. Ensure arrow on used belt points in original rotation
direction.
2) Loosen and retighten adjusting bolt to tension timing belt. Install
upper and lower covers. Install crankshaft pulley, and tighten bolt to
specification. See TORQUE SPECIFICATIONS. Rotate crankshaft
counterclockwise about 5-6 turns.
3) 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 positioned at TDC, remove and reposition timing belt.
4) To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View of Timing Belt Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Locating Timing Belt Adjuster Bolt

ACURA

11

2.5L 5-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Positioning Camshaft

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Camshaft Timing Marks

Fig. 6: Identifying Timing Belt Installation Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Belt Idler Pulley Bolt .......................................................................................... 32 (44)
A/C Compressor Bracket Bolts ................................................................................. 36 (49)
A/C Compressor Mount Bolts ................................................................................... 16 (22)
Alternator Mounting Bolts .......................................................................................... 33 (45)
Camshaft Pulley Bolts ............................................................................................... 52 (70)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Power Steering Pump Mount .................................................................................... 33 (45)
Timing Belt Tension Adjuster Bolt ............................................................................. 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Cylinder Head Cover Nuts ...................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

ACURA

12

2.5L & 2.7L V6

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.5L V6
Legend
1986-87 ............................... 4.0 Hours ... .. TCK129 .. ..... T129
2.7L V6
Legend
1987-90 ............................... 4.0 Hours ... .. TCK129 .. ..... T129
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1986-89 models, although the manufacturer does not recommend 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) 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.
3) Remove alternator. Leaving hoses connected, remove power steering
pump and secure out of way. Remove upper timing belt pulley covers.
Remove crankshaft pulley. Remove timing belt lower cover.
4) Loosen timing belt tensioner to relieve tension on timing belt. See
Figs. 1 and 2. Check belt for damage, missing teeth or cracks.
Installation 1) Remove spark plugs. Turn crankshaft clockwise to
bring No. 1 piston to TDC of compression stroke. Advance crankshaft an
additional 15 degrees from TDC position.
2) Rotate camshaft pulleys to compression stroke (TDC position) of
No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC
position.
3) 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.
4) 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.
5) 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.
6) Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt.
Reverse removal procedure to complete installation. Adjust drive belts to
proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Adjusting Timing Belt

NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolts .............................................................................................. 16 (22)
A/C Compressor Bracket Bolts ................................................................................. 33 (45)
Alternator Bracket Bolts ............................................................................................ 33 (45)
Alternator Mount Bolts .............................................................................................. 16 (22)
Camshaft Pulley Bolts ............................................................................................... 23 (31)
Crankshaft Pulley Bolt ........................................................................................... 123 (170)
Engine Mount Bolts ................................................................................................... 40 (54)
Power Steering Pump Mount Bolt ............................................................................ 33 (45)
Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ............................................................................................ 86 (10)
Valve Cover Bolts .................................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

ACURA

13

2.5L & 2.7L V6 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

ACURA

14

3.0L & 3.2L NSX & NSX-T

TIMING BELT APPLICATION
Application
3.0L V6
NSX
1991-04
NSX-T
1995-03
3.2L V6
NSX
1997-04
NSX-T
1997-03

Labor Time

Belt
Part No.

..................................................... 4.8 Hours ... ....... N/A

..................................................... 4.8 Hours ... ....... N/A

..................................................... 4.8 Hours ... ....... N/A

..................................................... 4.8 Hours ... ....... N/A
Courtesy of American Honda Motor Co., Inc.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Removing Intake Manifold Plate & Top Cover

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1991-96 models, inspect belt at 90,000 miles, and replace if
necessary. For 1997-04 models, 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
CAUTION: DO NOT rotate crankshaft counterclockwise. Timing
belt could jump a tooth on camshaft pulleys.

TIMING BELT
NOTE: Different ignition coils and ignition coil covers are used for
front side and rear side. Be sure to use correct ones for side being
serviced. Coils and covers for front side are marked FR. Coils
and covers for rear side are marked RR.
Removal 1) Mark timing belt direction of rotation BEFORE removal.
Remove spare tire and spare tire holder. Disconnect negative battery
cable. Disconnect positive battery cable.
2) Raise vehicle on hoist and remove right rear wheel. Remove engine
oil cooler base assembly mounting bolts. Wire oil cooler base assembly
out of way without disconnecting hoses. Lower vehicle. Remove engine
compartment strut brace, if equipped.
3) Remove intake manifold plate and top cover. See Fig. 1. Remove
ignition coil covers, fuel injector covers and wire harness covers.
Disconnect electrical connectors from ignition coils. Remove ignition
coils and spark plugs.
4) Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. See Fig. 2. Remove expansion tank, and set out of way
without removing coolant hoses.
5) Remove air cleaner assembly and breather hose. Disconnect electrical connectors from generator. Remove belt cover, mounting bolt,
adjusting bolt, and mounting nut from generator. Remove generator belt
and generator. See Fig. 3 or 4.
6) Remove cylinder head covers. Remove side engine mount bolts.
Push side engine mount bracket into body support bracket. Remove
transmission mount. See Fig. 5. Place wood brace under front of engine
and pad oil pan for protection. Using a floor jack, tilt front of engine 5.
See Fig. 6.
7) Remove generator bracket stiffener, dipstick and dipstick pipe. See
Fig. 7. Loosen A/C idler pulley center nut and adjusting nut. Remove A/C
compressor belt.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying Camshaft & Crankshaft Positions With No. 1

Cylinder At TDC

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15

3.0L & 3.2L NSX & NSX-T (Cont.)

8) Ensure No. 1 piston is at TDC of compression stroke. See Fig. 2.
Using Crankshaft Pulley Holder Handle (07JAB-001020A) and Holder
Attachment (07NAB-001040A for automatic transmission, or
07NAB-001030A for manual transmission), hold crankshaft pulley and
remove crankshaft pulley bolt. Remove crankshaft pulley.
9) Remove rubber seal from adjusting bolt, then remove timing belt front
middle cover, timing belt rear middle cover, and lower cover. See Fig. 8.
Loosen timing belt adjusting bolt 180. Push tensioner to release tension
from belt, then retighten adjusting bolt. See Fig. 9.
10) Remove timing belt from pulleys. DO NOT crimp or bend timing belt
more than 90 or less than 1 (25 mm) in diameter. DO NOT bend, twist
or turn timing belt inside out. DO NOT allow belt to contact coolant or oil.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Removing Side Engine Mount Bolts & Transmission

Mount Through-Bolt

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Removing Generator (1991-94)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Tilting Engine For Timing Belt Removal

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Removing Generator Bracket Stiffener

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing Generator (1995-04)

Inspection 1) Inspect timing belt for cracks or damaged teeth. Ensure
timing belt is not contaminated with oil or coolant. If one edge of belt is
damaged, check alignment of gears and tensioner. Replace as necessary.

2) Ensure water pump pulley turns freely (both directions on 1991-94

models; counterclockwise on 1995 and later models). Check for signs of
seal leakage. Small amount of weeping from bleed holes is normal.
See Figs. 10 and 11.
Installation 1) To install, reverse removal procedure. Clean middle
and lower timing belt covers, and timing belt drive pulley. Ensure No. 1
piston is at TDC of compression stroke. On 1991-94 models, set timing
belt drive pulley (crankshaft) keyway pointing upward. See Fig. 12.

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16

3.0L & 3.2L NSX & NSX-T (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 9: Releasing Timing Belt Tension

2) On 1995-04 models, set timing belt drive pulley (crankshaft) keyway
pointing upward and align mark on tooth side of pulley with pointer on oil
pump. See Fig. 12.
3) On all models, set front camshaft pulleys so piston No. 1 is at TDC.
Align TDC marks on front exhaust camshaft pulley and front intake
camshaft pulley to pointer on back cover. See Fig. 13. Set rear camshaft
pulleys so piston No. 1 is at TDC. Align TDC mark on rear intake
camshaft pulley to pointer on back cover. Align rear exhaust camshaft
pulley 1/2 tooth clockwise past TDC. See Fig. 14.
4) Install timing belt onto timing belt drive pulley (crankshaft), tension
adjusting pulley, front exhaust camshaft pulley, front intake camshaft
pulley, water pump pulley, rear intake camshaft pulley and rear exhaust
camshaft pulley, in that order. See Fig. 15. Ensure timing belt drive
pulley (crankshaft) and camshaft pulleys are still at TDC. See
Figs. 12-14.

Courtesy of American Honda Motor Co., Inc.

Fig. 10: Inspecting Water Pump (1991-96)

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17

3.0L & 3.2L NSX & NSX-T (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 13: Setting Front Camshaft Pulleys For

Timing Belt Installation

Courtesy of American Honda Motor Co., Inc.

Fig. 11: Inspecting Water Pump (1997-04)

Courtesy of American Honda Motor Co., Inc.

Fig. 14: Setting Rear Camshaft Pulleys For

Timing Belt Installation

Courtesy of American Honda Motor Co., Inc.

Fig. 12: Setting Crankshaft For Timing Belt Installation

5) Remove slack in timing belt between timing belt drive pulley (crankshaft) and front exhaust camshaft pulley, front exhaust camshaft and
front intake camshaft pulleys, front intake camshaft and water pump
pulleys, water pump and rear intake camshaft pulleys, and rear intake
camshaft and rear exhaust camshaft pulleys, in order, by turning each
camshaft pulley SLIGHTLY.

Courtesy of American Honda Motor Co., Inc.

Fig. 15: Installing Timing Belt

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18

3.0L & 3.2L NSX & NSX-T (Cont.)

NOTE: Do not rotate crankshaft when timing belt adjusting bolt is
loose, or timing belt will skid over the teeth of the rear intake
camshaft pulley.
6) Loosen timing belt adjusting bolt 180. Slack between rear exhaust
camshaft pulley and tension adjusting pulley should be eliminated.
Tighten timing belt adjusting bolt to specification. See TORQUE SPECIFICATIONS.
7) If No. 1 piston is at TDC, rotate crankshaft CLOCKWISE 9 teeth on
camshaft pulley. Blue mark on crankshaft pulley should be aligned with
pointer on lower cover, and TDC mark (White mark) on crankshaft pulley
should be at about 5 oclock position. See Fig. 16. Loosen adjusting bolt.
Retighten adjusting bolt to specification. See TORQUE SPECIFICATIONS.
8) Install timing belt lower cover, rear middle cover and front middle
cover. Install crankshaft pulley with No. 1 piston at TDC of compression
stroke. Hold crankshaft pulley and tighten crankshaft pulley bolt to
specification. See TORQUE SPECIFICATIONS.
9) Verify that No. 1 piston and camshaft pulleys are still at TDC. See
Fig. 17. When camshafts are at TDC, 5.0 mm pin punches can be
inserted through camshaft holder hole into camshaft hole to hold
camshafts at TDC. See Fig. 17. If crankshaft and camshafts are at TDC,
go to step 11). If a camshaft is not positioned at TDC, go to next step.

Courtesy of American Honda Motor Co., Inc.

Fig. 16: Final Step Of Adjusting Timing Belt Tension

10) If a camshaft is not positioned at TDC, remove timing belt lower
cover, rear middle cover, front middle cover and timing belt. Adjust
position of crankshaft and camshaft pulleys, and reinstall timing belt.
See Figs. 12-14. Align holes on camshaft holder with camshaft holes
and insert 5.0 mm pin punches to hold camshafts at TDC. Remove pin
punches after timing belt has been reinstalled. Go to next step.
11) Complete installation of components in reverse order of removal.
Always use NEW O ring at engine oil cooler base and NEW rubber
seals on intake side of ignition coil covers. Apply thin layer of liquid
gasket to cylinder head cover mating surface and rubber seals to hold
seals in place. After all nuts and bolts have been tightened to specification, adjust A/C compressor belt and generator belt tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 17: Checking Crankshaft & Camshaft Pulleys At TDC

ACURA
3.0L & 3.2L NSX & NSX-T (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Holder Bolts (8 mm) ................................................................................. 16 (22)
Camshaft Holder Bridge Bolts .................................................................................. 16 (22)
Camshaft Pulley Bolts ............................................................................................... 51 (69)
Crankshaft Pulley Bolt ......................................................................................... 1 181 (245)
Generator Bracket
8 mm Bolts .............................................................................................................. 16 (22)
10 mm Bolts ............................................................................................................ 33 (45)
Generator Bracket Stiffener
8 mm Bolts .............................................................................................................. 16 (22)
10 mm Bolts ............................................................................................................ 33 (45)
Generator Mounting Bolt & Nut ................................................................................ 33 (45)
Idler Pulley Assembly Bolts ...................................................................................... 16 (22)
Idler Pulley Center Nut ............................................................................................. 33 (45)
Side Engine Mount
Mounting Bolts ......................................................................................................... 53 (72)
Through-Bolt ............................................................................................................ 69 (94)
Timing Belt Adjusting Bolt ......................................................................................... 31 (42)
Water Pump Mounting Bolts (8 mm) ........................................................................ 16 (22)
INCH Lbs. (N.m)
Camshaft Holder Bolts (6 mm) ................................................................................. 88 (10)
Dipstick Pipe Bolt .................................................................................................... 106 (12)
Generator
Adjusting Bolt (1991-94) ........................................................................................... 71 (8)
Cover Bolts ............................................................................................................ 106 (12)
Ignition Coil Bolts .................................................................................................... 106 (12)
Ignition Coil Cover Bolts ........................................................................................... 88 (10)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Mounting Bolts (6 mm) ...................................................................... 106 (12)
1

For NEW bolt on 1991-94 models, tighten to 206 ft. lbs. (280 N.m), loosen completely
and then tighten to 181 ft. lbs. (250 N.m).

19

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20

3.0L & 3.2L V6 3.0CL & 1999 3.2TL

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

3.0L V6 (J30A1)
3.0CL
1997-99 ............................... 4.0 Hours ... .. TCK286 .. ..... T286
3.2L V6 (J32A1/A2)
3.2TL
1999 .................................... 4.0 Hours ... .. TCK286 .. ..... T286
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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).

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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 generator and power steering pump drive belts.
2) 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.
3) Remove upper and lower timing belt covers. See Fig. 1. If reusing
timing belt, mark direction of belt rotation for installation reference.
4) Remove one of the battery clamp bolts from battery tray. Grind
threaded end of bolt to a partial point (about 45-degree chamfer).
Thread battery bolt into rear cover to hold timing belt adjuster in installed
position. Hand tighten ONLY. See Fig. 2.
5) 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.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

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21

3.0L & 3.2L V6 3.0CL & 1999 3.2TL (Cont.)

Installation 1) Ensure that engine is at TDC. Align dimple on timing
belt drive pulley with pointer on oil pump. See Fig. 3. Align camshaft
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.
2) Remove battery clamp bolt from back cover. Remove the timing belt
auto-tensioner.
3) Hold auto-tensioner with maintenance bolt pointing up. Remove
maintenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed vise.
DO NOT grip auto-tensioner housing. Insert flat-bladed screwdriver into
maintenance hole. Place stopper on auto-tensioner while turning screwdriver clockwise to compress tensioner to bottom.
4) If any of the oil has spilled or leaked out of the auto-tensioner, refill it
with 5W-30 motor oil. The total capacity is 6.5 ml (0.22 fl oz). Reinstall
maintenance bolt with NEW gasket. Ensure no oil is leaking around
maintenance bolt, then reinstall auto-tensioner onto engine with stopper
in place.
5) Install timing belt in the following sequence: Crankshaft pulley, idler
pulley, front camshaft pulley, water pump pulley, rear camshaft pulley
and tension adjust pulley. See Fig. 5. Ensure crankshaft and camshaft
pulleys remained aligned with marks on back cover. Tighten idler pulley
bolt.
6) 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.
7) 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 rubber plugs from upper covers to check camshaft pulley
positions.
8) 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 tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Compressing Auto-Tensioner

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22

3.0L & 3.2L V6 3.0CL & 1999 3.2TL (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Center Bolt ................................................................................ 67 (90)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Side Mount Bracket-To-Mount Through-Bolt
3.0CL ....................................................................................................................... 47 (64)
3.2TL ........................................................................................................................ 40 (54)
Engine Side Mount-To-Engine Bolts ......................................................................... 33 (44)
Idler Pulley Bolt ......................................................................................................... 33 (44)
Power Steering Pump Lock Nut ............................................................................... 17 (24)
Power Steering Pump Mount Bolt ............................................................................ 17 (24)
INCH Lbs. (N.m)
Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Timing Belt

Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)

Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
Lower Engine Splash Shield Bolts ......................................................................... 106 (12)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

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23

3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL)

NOTE: For timing belt replacement information on 3.2L NSX and
NSX-T, see 3.0L & 3.2L NSX & NSX-T article. For timing belt
replacement information on 3.5L 3.5RL, see 3.5L V6 3.5RL article.

5) Using a battery hold-down bolt, grind threaded end to a slight bevel.

Hand tighten bolt into timing belt adjuster to hold position. See Fig. 3.
6) Remove engine mount bracket on end of front cylinder head. Loosen
idler pulley bolt about 5-6 turns, then remove timing belt.

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

3.2L V6 (J32A1/A2)
3.2CL
2001-03 ............................... 4.0 Hours ... .. TCK286 .. .....
3.2TL
2000 .................................... 4.0 Hours ... . 1 TCK286 . .....
2001-03 ............................... 4.0 Hours ... ...... ..... ...... .....
TL
2004 ................................. ........ N/A ........ ...... ..... ...... .....
3.5L V6 (J35A3)
MDX
2001-04 ............................... 4.0 Hours ... .. TCK286 .. .....
1

T286
T286
T286
T329

T286

Timing component kit does not include camshaft tensioner

hydraulic assembly.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing Side Engine Mount Bracket

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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: Radio and navigation system (if equipped) contain an antitheft protection circuit. Obtain anti-theft code numbers before
disconnecting battery. Note radio preset frequencies.

TIMING BELT
NOTE: To inspect belt to determine if replacement is needed,
disconnect negative battery cable. Remove ignition coil cover (if
necessary) and front upper timing belt cover. Inspect timing belt
for cracks or signs of oil or coolant leakage onto belt. Replace belt
if necessary.
Removal (Except 2003-04 MDX) 1) Set No. 1 piston to TDC by
turning crankshaft so White mark aligns with pointer. On MDX and
3.2CL, ensure marks on front camshaft pulley and front cover are
aligned. On 3.2TL, check through rear timing belt cover opening to
ensure camshaft pulley mark and rear cover mark are aligned.
2) Raise vehicle and remove front wheels. Remove splash shield. Using
lever tool, move auto-tensioner to relieve tension from generator belt.
Remove generator belt.
3) Loosen power steering pump adjusting nut, lock nut and mounting
bolt. Remove power steering pump belt. Support engine with jack and
wood block under oil pan. Remove side engine mount bracket. See
Fig. 1.
4) Remove dipstick and tube. Discard O ring. Hold crankshaft pulley,
and remove pulley bolt. Remove upper timing belt covers and lower
timing belt cover. See Fig. 2.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Removal (2003-04 MDX) 1) Set No. 1 piston to TDC by turning
crankshaft so White mark aligns with pointer. Ensure marks on front
camshaft pulley and front cover are aligned.
2) Raise vehicle and remove front wheels. Remove splash shield. Using
lever tool, move auto-tensioner to relieve tension from generator belt.
Remove generator belt.
3) Support engine with jack and wood block under oil pan. Remove side
engine mount bracket. See Fig. 1.

24

ACURA
3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL) (Cont.)
9) On 2003-04 MDX, perform Powertrain Control Module (PCM) reset
procedure and Crankshaft Position (CKP) pattern learn procedure. See
RESET PROCEDURES (2003-04 MDX).

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Hold-Down Bolt To Hold Timing Belt Adjuster In

Position
4) Hold crankshaft pulley, and remove pulley bolt. Remove upper timing
belt covers and lower timing belt cover. See Fig. 2.
5) Using a battery hold-down bolt, grind threaded end to a slight bevel.
Hand tighten bolt into timing belt adjuster to hold position. See Fig. 3.
6) Remove engine mount bracket on end of front cylinder head. Remove
idler pulley bolt, and idler pulley. Remove timing belt.
Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and roughness in rotation. Check sprockets
and pulleys for wear, cracks or damage. Replace components if
necessary.
Installation (New Belt All Models) 1) Clean timing belt pulleys, and
the upper and lower covers. Ensure timing belt pulley is still set to TDC
position. See Fig. 4. Clean camshaft pulleys. Set pulleys to TDC position
by aligning TDC marks on camshaft pulleys with pointers on back
covers. Remove battery hold-down bolt from back cover.
2) Remove auto-tensioner. Ensure maintenance bolt is always pointing
upward. Ensure no oil leaks or spills from auto-tensioner during handling.
CAUTION: Do NOT exceed 2200 lbs. of pressure when compressing auto-tensioner.
3) Align holes on rod and auto-tensioner housing. Mount auto-tensioner
in press, and slowly compress until a holding pin can be placed through
housing and rod. See Fig. 5.
4) Install auto-tensioner, making sure the pin stays in place. On 2003-04
MDX, apply liquid thread lock to idler pulley bolt, and loosely install idler
pulley. On all models, install timing belt, working in counterclockwise
direction, until belt is around all pulleys in the following order: crankshaft
sprocket, idler pulley, front camshaft pulley, water pump pulley, rear
camshaft pulley and tensioner adjusting pulley. See Fig. 6.
5) Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Pull out set pin of auto-tensioner. Install engine mount bracket.
If timing belt guide plate was removed, install with concave side facing
outward. Install upper and lower timing belt covers.
6) Clean crankshaft pulley and bolt. Lubricate pulley bolt and washer.
Install crankshaft pulley, and tighten bolt to specification while holding
pulley. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley
about 5-6 turns clockwise so timing belt properly sets on all pulleys.
7) Turn crankshaft pulley to align TDC mark. Check TDC mark alignment
of camshaft pulleys. If camshaft pulley marks are at TDC, go to next
step. If camshaft pulley marks are not at TDC, repeat installation
procedure.
8) On all models except 2003-04 MDX, install dipstick and tube with
NEW O ring. Install and adjust tension of power steering belt. On all
models, install generator belt. Install side engine mount bracket, and
tighten bolts to specification (tighten shorter vertical mounting bolts first,
then horizontal mounting bolt). See TORQUE SPECIFICATIONS.
Reconnect negative battery cable. Reset radio and navigation system (if
equipped) anti-theft code. Reset preset radio frequencies.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Compressing Auto-Tensioner

ACURA

25

3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL) (Cont.)
RESET PROCEDURES (2003-04 MDX)
Powertrain Control Module (PCM) Reset Procedure/Clearing Diagnostic Trouble Codes To clear codes using the Honda PGM Tester or
the HDS, use the CLEAR COMMAND. The PCM stores data and
DTCs to correct the system even when there is no electrical power (such
as the No. 10 BACK UP fuse removed or battery negative cable
disconnected).

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt

Installation (Used Belt All Models) 1) Clean timing belt pulleys,
and the upper and lower covers. Ensure timing belt pulley is still set to
TDC position. See Fig. 4. Clean camshaft pulleys. Set pulleys to TDC
position by aligning TDC marks on camshaft pulleys with pointers on
back covers.
2) On 2003-04 MDX, apply liquid thread lock to idler pulley bolt, and
loosely install idler pulley. If auto-tensioner has extended and timing belt
cannot be installed, perform new belt installation procedure. See
INSTALLATION (NEW BELT ALL MODELS). On all other models, if
auto-tensioner has extended and timing belt cannot be installed, remove
and compress auto-tensioner. Install auto-tensioner.
3) Install timing belt, working in counterclockwise direction, until belt is
around all pulleys in the following order: crankshaft sprocket, idler pulley,
front camshaft pulley, water pump pulley, rear camshaft pulley and
tensioner adjusting pulley. See Fig. 6.
4) Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Remove battery hold-down bolt from back cover. Install engine
mount bracket. If timing belt guide plate was removed, install with
concave side facing outward. Install upper and lower timing belt covers.
5) Clean crankshaft pulley and bolt. Lubricate pulley bolt and washer.
Install crankshaft pulley, and tighten bolt to specification while holding
pulley. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley
about 5-6 turns clockwise so timing belt properly sets on all pulleys.
6) Turn crankshaft pulley to align TDC mark. Check TDC mark alignment
of camshaft pulleys. If camshaft pulley marks are at TDC, go to next
step. If camshaft pulley marks are not at TDC, repeat installation
procedure.
7) On all models except 2003-04 MDX, install dipstick and tube with
NEW O ring. Install and adjust tension of power steering belt. On all
models, install generator belt. Install side engine mount bracket, and
tighten bolts to specification (tighten shorter vertical mounting bolts first,
then horizontal mounting bolt). See TORQUE SPECIFICATIONS.
Reconnect negative battery cable. Reset radio and navigation system
anti-theft code. Reset preset radio frequencies.
8) On 2003-04 MDX, perform Powertrain Control Module (PCM) reset
procedure and Crankshaft Position (CKP) pattern learn procedure. See
RESET PROCEDURES (2003-04 MDX).

Honda PGM Tester and HDS has 3 kinds of clear commands to meet the
purpose:
DTC Clear This command erases all stored DTC codes and
Freeze Data.
PCM Clear This command erases all stored DTC codes, Freeze
Data and all specific data to correct the system except CKP pattern.
CKP Clear This command erases only CKP pattern data. This
command is for the repair of a misfire or CKP sensor. If CKP pattern
data is cleared from PCM, you must do the CKP pattern relearn
procedure by test drive. See CKP PATTERN LEARN PROCEDURE.
NOTE: Enable criteria: Engine coolant temperature must be 176F
(80C) or higher.
Crankshaft Position (CKP) Pattern Learn Procedure 1) Having
cleared the CKP pattern from PCM, leave Honda PGM Tester or the
HDS connected to DLC and turn ignition switch off. Turn ignition switch
on. Wait for 30 seconds.
2) Start vehicle and test drive on a level road. Decelerate (with throttle
fully closed) from engine speed of 2500 RPM to 1000 RPM with A/T in
2 or D3 position.
3) Stop vehicle. DO NOT turn the ignition switch off. Select the ALL
DATA list in DATA LIST menu using Honda PGM Tester or the HDS .
4) Check status of PULSER F/B LEARN. If it is set to NG, enable criteria
was probably not met. Repeat the procedure from beginning.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Center Bolt ................................................................................ 67 (90)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Mount Bracket
6 x 1.0 mm Bolt ..................................................................................................... 8.7 (12)
10 x 1.25 mm Bolt .................................................................................................. 33 (44)
Engine Side Mount Bracket
10 x 1.25 mm Bolt .................................................................................................. 33 (44)
12 x 1.25 mm Bolt .................................................................................................. 40 (54)
Idler Pulley Bolt ......................................................................................................... 33 (44)
Power Steering Pump Lock Nut ............................................................................... 17 (24)
Power Steering Pump Mount Bolt ............................................................................ 17 (24)
INCH Lbs. (N.m)
Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)
Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
Dipstick & Tube ....................................................................................................... 106 (12)
Lower Engine Splash Shield Bolts ......................................................................... 106 (12)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

ACURA

26

3.2L V6 Legend & 1996-98 3.2TL

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.2L V6
Legend (C32A1)
1991-95 ............................... 5.6 Hours ... .. TCK193 .. ..... T193
3.2TL (C32A6)
1996-98 ............................... 4.0 Hours ... .. TCK193 .. ..... T193
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: Some vehicles may be equipped with radio/cassette or
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) 1) Disconnect negative battery cable. Remove
injector harness covers. See Fig. 1. Remove engine wiring harness from
front of engine. Disconnect breather pipe. Remove vacuum pipe
bracket. Remove accessory drive belts.
2) Remove timing belt upper covers. See Fig. 2. Rotate crankshaft
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 engine oil dipstick tube.
3) Remove timing belt lower cover. If timing belt is to be reused, mark
belt with arrow indicating direction of rotation. Loosen timing belt
adjusting bolt 1/2 turn. Push tensioner to release belt tension, then
retighten adjusting bolt. 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) 1) Remove spark plugs. When installing timing
belt, turn crankshaft clockwise 15 degrees past No. 1 cylinder TDC. After
adjusting left and right camshaft pulleys to TDC, turn crankshaft pulley
counterclockwise back to TDC.
2) Install timing belt in this sequence: Crankshaft pulley, tensioner pulley,
left camshaft, water pump pulley, right camshaft. To ease installation,
advance right camshaft pulley about a half tooth from TDC position.
3) Loosen timing belt tension adjusting bolt, and retighten it after
tensioning the timing belt. Temporarily install lower timing 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.
4) Rotate crankshaft clockwise 9 teeth on camshaft pulley. Blue mark on
crankshaft pulley will should line up with pointer on lower cover. See
Fig. 3.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Intake Manifold (1991-93)

5) Loosen timing belt adjusting bolt 180 degrees. Tighten timing belt
adjusting bolt to 31 ft. lbs. (42 N.m). Verify crankshaft and camshaft
timing marks are still 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. 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.
Removal (1994-98) 1) Disconnect negative battery cable. Use jack to
support engine. Remove center bracket and mount from front, lower part
of engine. Remove the generator, A/C compressor, and power steering
belts.
2) If equipped, remove Traction Control System (TCS) valve assembly
brackets. Disconnect TCS throttle sensor and actuator connectors. See
Fig. 4. Remove TCS control valve assembly, leaving breather pipe
by-pass hose connected.
3) Remove engine front wiring harness cover with oil pressure switch
and engine ground cable connectors. Remove idler pulley bracket,
dipstick, and dipstick pipe. Remove crankshaft pulley.
4) Remove timing belt upper and lower covers. See Fig. 2. Rotate
crankshaft clockwise until No. 1 piston is at TDC of compression stroke.
Align timing marks. See Fig. 5. Loosen timing belt adjusting bolt 180
degrees to remove tension from belt. Retighten adjusting bolt.

ACURA

27

3.2L V6 Legend & 1996-98 3.2TL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

5) If timing belt is to be reused, mark direction of belt rotation before
removing. Remove timing belt.
Installation (1994-98) 1) Remove all spark plugs. Ensure No. 1 piston
is at TDC of compression stroke. Position crankshaft and camshaft
pulleys as shown. See Fig. 5.
2) 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 direction of original rotation.
3) Install timing belt in this sequence: Crankshaft pulley, tension adjuster
pulley, left camshaft pulley, water pump pulley, and right camshaft pulley.
Loosen and tighten tensioner adjuster bolt to remove slack in belt.
4) Install upper and lower covers and crankshaft pulley. Tighten pulley
bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise 5-6 revolutions to seat timing belt.
5) Adjust timing belt tension. Remove upper left camshaft cover.
Remove damper from center bracket. Rotate crankshaft clockwise until
No. 1 piston is at TDC of compression stroke. Rotate crankshaft 9 teeth
clockwise on camshaft pulley. Align Blue mark on crankshaft pulley with
pointer on lower cover. See Fig. 3. Loosen tensioner adjusting bolt 1/2
turn, then tighten bolt to 31 ft. lbs. (42 N.m).
6) 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.
NOTE: After installing timing belt, slowly rotate engine clockwise
several times to be sure valves do not contact pistons.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Timing Marks For Timing Belt Tension

ACURA

28

3.2L V6 Legend & 1996-98 3.2TL (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolts ............................................................................................... 23 (31)
Center Bracket Bolts ................................................................................................. 40 (54)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Power Steering Mount Lock Nut .............................................................................. 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)
Courtesy of American Honda Motor Co., Inc.

Fig. 4: Locating TCS Connectors & Control Valve

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (TDC)

ACURA

29

3.5L V6 3.5RL
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.5L V6 (C35A1)
3.5RL
1996-04
Balancer .............................................. .......... 1 .......... ..... T280
Camshaft ................................................ 4.6 Hours ... ..... T279
1

Balancer belt labor included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
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 & BALANCER BELTS

Removal 1) Turn crankshaft until No. 1 piston is at TDC of compression stroke. Remove engine cover, intake air duct, and air cleaner
assembly.
2) 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 brackets. Loosen adjusting bolt, lock nut and mounting
bolt, then remove power steering pump belt.
3) Disconnect TCS throttle sensor connector, TCS throttle actuator
connector and throttle position sensor connector. Remove TCS control
valve assembly. See Fig. 1. Disconnect vehicle speed sensor subharness connector, then remove wire harness holder.
4) Remove crankcase breather hose and vacuum hoses from front of
right upper cover. Remove Ignition Control Module (ICM) bracket from
right upper cover. Remove idler pulley bracket, dipstick, and dipstick
tube. Remove crankshaft pulley. See Fig. 2.
5) Remove upper and lower covers. If reusing balancer timing belt, mark
direction of belt rotation for installation reference. Loosen balancer
timing belt adjuster bolt 180 degrees. Push on tensioner to release belt
tension, then retighten adjusting bolt. Remove balancer timing belt.
6) If camshaft timing belt is to be reused, mark direction of rotation
before removing. Loosen camshaft timing belt adjuster bolt 180
degrees. Push on tensioner to release belt tension, then retighten
adjusting bolt. Remove camshaft 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 1) Remove spark plugs. Remove balancer belt drive
pulley. Noting installed position, remove timing belt guide plate from end

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Locating TCS Connectors & Control Valve

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. 3.
NOTE: For easier installation, turn right camshaft pulley clockwise
about half a tooth from TDC position. Ensure crankshaft pulley and
left camshaft pulley are at TDC.
2) Set camshaft pulleys so that No. 1 piston is at TDC. Align TDC marks
on camshaft pulleys to pointers on back covers. See Fig. 3. Install timing
belt (in sequence) on timing belt drive (crankshaft) pulley, adjusting
pulley, left camshaft pulley, water pump pulley, and right camshaft pulley.
See Fig. 4. Ensure camshaft and crankshaft pulleys remain at TDC.
Loosen and retighten timing belt adjusting bolt. Install lower cover and
crankshaft pulley.
3) Rotate crankshaft clockwise 5-6 turns to properly position timing belt
on pulleys. To set timing belt tension, set No. 1 piston at TDC of
compression stroke. White mark on crankshaft pulley must be aligned
with pointer on lower cover. See Fig. 5. 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. See TORQUE SPECIFICATIONS.
4) Remove crankshaft pulley and lower cover. Install timing belt guide
plate and balancer belt drive pulley on crankshaft. See Fig. 2. Ensure
guide plate is installed in correction direction.
5) Remove 12-mm sealing bolt from side of engine block. See Fig. 6.
Align maintenance hole and balancer shaft hole. Insert a 6-mm bolt into
sealing bolt hole. Ensure balancer belt pulley pointer aligns with pointer
on balancer gear case. See Fig. 7.
6) Set timing belt drive pulley so that No. 1 piston is at 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 a new washer.
7) 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. See TORQUE SPECIFICATIONS.
8) 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.
9) To complete installation, reverse removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
drive belts to proper tension.

ACURA

30

3.5L V6 3.5RL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

ACURA

31

3.5L V6 3.5RL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Routing

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning TDC Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (TDC)

ACURA

32

3.5L V6 3.5RL (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Balancer Belt Tension Adjusting Bolt ........................................................................ 33 (44)
Camshaft Pulley Bolt ................................................................................................. 23 (31)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Idler Pulley Bracket Bolt ........................................................................................... 16 (22)
Engine Sealing Bolt (12 mm) ................................................................................... 14 (20)
Traction Control System (TCS) Control Valve
Lower Bracket Bolts ................................................................................................ 16 (22)
Upper Bracket Bolts .................................................................... ..................................... 1
Timing Belt Tension Adjuster Bolt ............................................................................. 31 (42)
Water Pump Bolt (8 x 1.25 mm) .............................................................................. 16 (22)
INCH Lbs. (N.m)
Engine Cover Bolts/Nuts ........................................................................................... 89
Dipstick Tube Bolt ................................................................................................... 106
Ignition Control Module (ICM) Bracket Bolts ......................................................... 106
Timing Belt Cover Bolts .......................................................................................... 106
Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106
Wire Harness Holder Bolts ..................................................................................... 106
1

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Balancer Shaft Lock Bolt

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Balancer Shaft Marks

Tighten bolts to 106 INCH lbs. (12 N.m).

(10)
(12)
(12)
(12)
(12)
(12)

ACURA

33

3.5L V6 SLX
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.5L V6 DOHC
SLX
1998-99 ..................................................... 2.4 Hours ... ..... T303
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Normal replacement interval is at 75,000 miles for 1998-99 model years.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly. Remove upper fan shroud. Remove serpentine drive belt.
2) Remove cooling fan and drive pulley. Remove serpentine drive belt
idler pulley assembly. Remove serpentine drive belt tensioner assembly.
3) Remove power steering pump with hoses attached, and set aside.
Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent,
remove crankshaft pulley.
4) Remove timing belt covers. Rotate crankshaft to align timing marks.
See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be
at TDC.
5) If reusing timing belt, mark belt with arrow to indicate original rotation
direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove 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.

Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

water pump pulley and install on other left hand camshaft sprocket,
aligning the White alignment 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.
4) 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.
5) 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.
6) Install tensioner on engine with locking pin in place. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Remove locking pin from timing belt tensioner. Remove clips from
camshaft and crankshaft sprockets.
8) Rotate crankshaft 2 turns clockwise. Ensure timing marks are still
aligned.
9) Remove crankshaft pulley and install timing belt covers. Ensure
rubber sealing bushings are installed on timing belt cover bolts. See
Fig. 6.
10) Install crankshaft pulley. Tighten center bolt to specification. Install
cooling fan pulley. Install power steering pump. Install cooling fan. Install
serpentine drive belt idler pulley and tensioner assemblies. Install
radiator fan shroud. Connect battery.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks

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 1) 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.
2) Align timing mark on right hand (passengers side) camshaft sprocket
with alignment mark on valve cover. See Fig. 3. Install timing belt on
right hand camshaft sprocket, aligning 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
removal. Secure belt with spring clip.
3) Align timing mark on left hand (drivers side) camshaft sprocket with
alignment mark on valve cover. See Fig. 4. Route timing belt around

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

ACURA

34

3.5L V6 SLX (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 72 (98)
Cooling Fan Pulley Bolt ............................................................................................ 16 (22)
Crankshaft Pulley Bolt ........................................................................................... 123 (167)
Power Steering Pump Bolt
M8 Bolt .................................................................................................................... 16 (22)
M10 .......................................................................................................................... 34 (46)
Timing Belt Cover Bolt .............................................................................................. 14 (19)
Timing Belt Idler Arm Pulley Bolt ............................................................................. 38 (52)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42)
Water Pump Bolt ....................................................................................................... 18 (25)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt Cover Bushings

ACURA & HONDA

35

3.2L V6 1994-97
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.2L V6 SOHC
Passport
1994-97 .............................. 1 2.8 Hours .. .. TCK221 .. ..... T221
SLX
1996-97 ............................... 2.8 Hours ... .. TCK221 .. ..... T221
1

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly. Remove upper fan shroud. Remove cooling fan assembly.
Remove all accessory drive belts.
2) Remove fan pulley assembly. Remove crankshaft pulley bolt. Using
Puller (J-8614-01) or equivalent, remove crankshaft pulley. Remove oil
cooler hose from timing cover. Remove timing belt cover. Align all timing
marks prior to belt removal. See Figs. 1 and 2. Remove belt tensioner
pusher and timing belt.

Installation 1) Ensure all timing marks are aligned. Install belt over
one pulley at a time starting at crankshaft sprocket working counterclockwise. 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.
2) 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.
3) Loosen tensioner pulley bolt. Apply pressure on belt by rotating
tensioner. Tighten tensioner pulley bolt to specification. Remove pin
from timing belt tensioner pusher.
4) Remove pinch clips from timing belt, (if used). Install crankshaft
pulley, tightening center bolt finger tight. Rotate crankshaft 2 turns
clockwise. Ensure timing belt tensioner pusher rod protrudes proper
amount. See Fig. 4.
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 timing belt tensioning
procedure. Remove crankshaft pulley and install timing belt cover. To
complete installation, reverse removal procedure. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

Courtesy of Isuzu Motor Co.

Fig. 3: Installing Pinch Clips On Timing Belt

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks

Courtesy of Isuzu Motor Co.

Fig. 4: Adjusting Timing Belt Tensioner Pusher

Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

36

ACURA & HONDA

3.2L V6 1994-97 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ................................................................................................. 41 (56)
Camshaft Sprocket Bolt ............................................................................................ 41 (56)
Crankshaft Pulley Bolt ........................................................................................... 123 (167)
Fan Pulley Bolt .......................................................................................................... 16 (22)
Front Plate Bolt ......................................................................................................... 14 (19)
Idler Arm Retaining Bolt ............................................................................................ 33 (44)
Power Steering Pump Bolt ....................................................................................... 34 (46)
Timing Belt Cover Bolt .............................................................................................. 13 (18)
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)

Courtesy of Isuzu Motor Co.

Fig. 5: Exploded View Of Cylinder Head Components

ALFA ROMEO

37

2.5L V6 GTV
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.5L V6
GTV Coupe
1982-86 ..................................................... 3.9 Hours ... ..... T120
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 50,000 miles

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Unplug connector
from airflow sensor and release cable from bracket. Disconnect hose
from air intake duct and separate duct from throttle body.
2) Disconnect idle speed adjustment hose from air intake box. See
Fig. 2. Disconnect air hose and wiring to auxiliary air solenoid valve.
Remove auxiliary air solenoid valve from timing belt cover.
3) Disconnect distributor vacuum hose from throttle body. Disconnect oil
vapor hose from timing belt cover. Disconnect fuel vapor canister hose
from air intake box.
4) Disconnect pressure regulator hose. Remove air filter cover, air intake
duct, and oil vapor separator. Remove air filter. Disconnect spark plug
leads, coil lead, and remove distributor cap. Remove timing belt covers.
5) Remove all fan belts. Disconnect coolant hoses and wiring from
thermostat housing. Remove coolant temperature sending unit from
thermostat housing. Clean spark plug seats and remove spark plugs.
6) Remove bolt, screws, and timing belt cover. Engage 5th gear and
push vehicle forward until P (TDC notch) on crankshaft pulley aligns
with reference pin. See Fig. 1.
7) Ensure camshaft marks align with marks on camshaft caps. Ignition
rotor must point toward notch on distributor body. Make sure piston in
cylinder No. 1 is at TDC of compression stroke (both valves closed).
8) Lift arm of timing belt tensioner and insert Adjustment Pin (A.2.0363)
in block to keep tensioner arm up. Loosen nuts on tensioner arm, press
tensioner downward to end of travel, and then tighten top nut. Remove
timing belt from pulleys.
Installation 1) Check that engine is on TDC of compression stroke by
installing TDC Adapter (C.6.0183) and dial indicator into spark plug seat
of cylinder No. 1. Ensure P (TDC notch) on crankshaft pulley aligns
with reference pin and camshafts are aligned with marks on camshaft
caps. See Fig. 1.
2) Install timing belt over crankshaft pulley, left cylinder head, right
cylinder head, distributor drive gear, and over belt tensioner pulleys.
Loosen top nut on belt tensioner.
3) Engage 5th gear on transmission and push vehicle forward to rotate
crankshaft 2 complete revolutions. Stop vehicle when P (TDC notch)
on crankshaft pulley aligns with reference pin.
4) Recheck all alignment marks and ensure rotor points toward reference notch. Press belt tensioner against timing belt and tighten tensioner arm nuts. Lift tensioner arm slightly and remove adjustment pin.
Reverse removal procedure to complete installation. Adjust drive belts to
proper tension.

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 1: Replacing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Tensioner Pulley Bolt ......................................................................................... 15 (20)
Camshaft Hub Nut .................................................................................................. 85 (115)
Crankshaft Pulley Nut ........................................................................................... 174 (235)
INCH Lbs. (N.m)
Front Cover Bolts .......................................................................... ..................... 72-82 (8-9)
Valve Cover Bolts .............................................................................................. 82-96 (9-11)

38

ALFA ROMEO
2.5L V6 GTV (Cont.)

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 2: Disconnecting Engine Components

ALFA ROMEO

39

3.0L V6
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6
164
1991-93 ..................................................... 4.8 Hours ... ..... T120
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 50,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right front wheel. Remove right front inner fenders.
Disconnect throttle opening switch electrical connector. Remove throttle
body cover.
2) 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 connector. Disconnect oil vapor separator hoses.
3) Disconnect accelerator cable. On models equipped with automatic
transmission, disconnect kickdown cable. On S models, disconnect
engine throttle sensor electrical connector. On all models, disconnect
fuel vapor and cruise control hoses.
4) 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.
5) Disconnect spark plug wires for cylinders No. 1, 2 and 3. Remove
intake ducts and gaskets. Remove right valve cover and gasket.
Disconnect spark plug wires for cylinders No. 4, 5 and 6. Remove left
side valve cover and gasket.
6) 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.
7) 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.
8) 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 upper retaining nut. Remove timing belt.
Installation 1) 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.
2) 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 hydraulic tensioner upper retaining nut.
3) Turn crankshaft in normal direction of rotation 2-3 revolutions 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.

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 1: Identifying Flywheel Timing Marks

4) Position No. 1 cylinder at TDC compression stroke. Ensure 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.
5) 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.
6) Connect spark plug wires for cylinders No. 4, 5 and 6. Install right side
valve cover and gasket. Install intake ducts and gaskets. Connect spark
plug wires for cylinders No. 1, 2 and 3. Install air intake box. Connect
ground strap to air intake box. Connect fuel pressure regulator and
power brake unit vacuum hoses. Connect fuel vapor and cruise control
hoses.
7) On S models, connect engine throttle sensor electrical connector.
Connect accelerator cable. On models with automatic transmission,
connect kickdown cable. Install throttle body cover. Connect throttle
body switch electrical connector.
8) Connect oil vapor separator hoses. Connect constant idle speed
actuator electrical connector. Install crankshaft position sensor and
electrical connector. Install hydraulic drive belt tensioner. Install power
steering pump, A/C compressor, and water pump drive belts.
9) Install front right inner fenders. Install right front wheel and tire
assembly, then lower vehicle. Connect negative battery cable. Adjust
accessory drive belt tension.

ALFA ROMEO

40

3.0L V6 (Cont.)

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 3: Installing Timing Belt

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 2: Identifying Camshaft Timing Marks

AMERICAN MOTORS

41

2.0L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

2.0L 4-Cyl.
Concord & Gremlin
1977-78 ............................... 1.5 Hours ... .. TCK017 .. ..... T017
Concord & Spirit
1979 .................................... 1.5 Hours ... .. TCK017 .. ..... T017
1

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of American Motors/Renault Corp.

Fig. 1: Aligning Timing Marks

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
CAUTION: Rotate engine by turning crankshaft. Do not turn engine
by camshaft.
Removal 1) Disconnect negative battery cable. Rotate engine until
timing mark (notch) on crankshaft is pointing to zero. Camshaft sprocket
timing mark should now be adjacent to pointer on cylinder head cover.
See Fig. 1.
2) Loosen front pulley retaining screws. Remove alternator and power
steering drive belts. Remove cam drive belt shield.
3) Mark rotation of belt rotation before removal. Loosen tensioner
retaining screw and remove camshaft drive belt. See Fig. 2.

Courtesy of American Motors/Renault Corp.

Fig. 2: Exploded View Of Timing Belt & Components

CAUTION: Use hands to install belt. DO NOT pry with tool.
Installation 1) Mount belt onto crankshaft sprocket. Position belt in
tensioning pulley groove and install belt to camshaft sprocket. See
Fig. 2.
CAUTION: Excessive tension may cause pulley to fail.
2) 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.
3) Reverse removal procedure to complete installation. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

AUDI

42

1.6L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.6L 4-Cyl.
4000
Diesel
1982-83 ..................................................... 2.3 Hours ... ..... T043
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

Courtesy of Audi of America, Inc.

Fig. 1: Installing Camshaft Locking Tool

REMOVAL & INSTALLATION

TIMING BELT & SPROCKET
Removal 1) 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 compression stroke. Lobes
of camshaft on No. 1 cylinder must point upward.
2) Secure camshaft in place by installing Setting Bar (2065) at rear of
camshaft. Tool must be properly installed to prevent camshaft from
moving. See Fig. 1.
3) 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.
4) 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 bellhousing.
5) Loosen timing belt tensioner to relieve tension on timing belt. Remove
crankshaft pulley. Do not allow crankshaft to turn. Remove timing belt.
Installation 1) Check that TDC mark on flywheel is still aligned with
reference mark. Loosen camshaft sprocket bolt 1/2 turn. Loosen
sprocket from camshaft by tapping with a rubber mallet.
2) 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.
3) Using Tension Gauge (210), check timing belt tension midway
between camshaft and injection pump sprockets. Tension is correct if
gauge reads 12-13. See Fig. 2.
4) Turn crankshaft clockwise 2 turns. Strike timing belt with a rubber
mallet midway between camshaft sprocket and injection pump sprocket.
Using Tension Gauge (210), recheck timing belt tension.
5) If necessary, readjust timing belt tension. Check injection pump
timing. Install remaining components in reverse order of removal. Adjust
drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 2: Using Timing Belt Tension Gauge

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley/Damper
Standard .............................................................................................................. 108 (150)
Turbo .................................................................................................................... 145 (200)
Injection Pump Sprocket ........................................................................................... 33 (45)
Intermediate Shaft Pulley .......................................................................................... 33 (45)
Timing Belt Tensioner ................................................................................................ 33 (45)

AUDI

43

1.6L & 1.7L 4-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl.
Fox
1973-79 ............................... 1.1 Hours ... .. TCK017 .. ..... T017
1.7L 4-Cyl.
4000
1980-83 ............................... 1.1 Hours ... .. TCK017 .. ..... T017
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

Courtesy of Audi of America, Inc.

Fig. 2: Aligning Timing Marks (1.6L)

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
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. 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 removal procedure. Adjust drive belts to
proper tension.

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Camshaft Sprocket With Upper Edge Of Gasket

(1.7L)

Courtesy of Audi of America, Inc.

Fig. 4: Adjusting Timing Belt Tension (1.7L)

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components (1.7L)

AUDI

44

1.6L & 1.7L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

AUDI

45

1.8L 4-Cylinder 1984-87

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.8L 4-Cyl.
4000S
1984-87 ............................... 1.1 Hours ... .. TCK017 .. ..... T017
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Installation 1) Set crankshaft at point just before TDC compression

for No. 1 cylinder. Place timing belt on crankshaft and intermediate 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.
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.
3) 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 tension of timing belt at point midway
between camshaft sprocket and intermediate sprocket. See Fig. 4.
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 timing marks. To complete installation,
reverse removal procedure. Adjust drive belts to proper tension.

Although the manufacturer does not recommend a specified scheduled

maintenance, belt manufacturers suggest the belt be replaced at 60,000
mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: Never use camshaft sprocket attaching bolt to turn
engine, as timing belt could be stretched.

Courtesy of Audi of America, Inc.

Fig. 2: Aligning Intermediate Shaft & Crankshaft

Removal 1) Disconnect negative battery cable. Loosen alternator

adjusting bolts. Remove all drive belts. Remove water pump pulley,
crankshaft pulley, and vibration damper. See Fig. 1. Remove upper and
lower timing belt outer covers. On 16-valve engine, remove upper half of
intake manifold.
2) On all models, remove camshaft cover from cylinder head. Turn
crankshaft to position No. 1 piston at TDC of compression stroke. Make
sure distributor housing and flywheel timing marks are correctly aligned.
3) Loosen timing belt tensioner to relieve tension on timing belt. Slide
timing belt off intermediate shaft sprockets.

Courtesy of Audi of America, Inc.

Fig. 3: Setting Camshaft Timing Marks

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

(16-Valve Shown)

AUDI

46

1.8L 4-Cylinder 1984-87 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

Courtesy of Audi of America, Inc.

Fig. 4: Adjusting Timing Belt Tension

AUDI

47

1.8L 4-Cylinder Turbo AEB & ATW Engines 1997-00 A4

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder Turbo (AEB & ATW)

A4 & A4 Quattro
1997-00
152 Tooth Belt ........................................ 4.7 Hours ... ..... T291
153 Tooth Belt ........................................ 4.7 Hours ... ..... T317
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the belt be replaced at 105,000 mile
intervals under normal driving conditions, and 52,500 mile intervals
under severe driving conditions.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Courtesy of Audi of America, Inc.

NOTE: ATW engines use T317 (153 tooth belt). AEB engines are
originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).

Fig. 1: Exploded View Of Lock Carrier Assembly (A4)

TIMING BELT
Removal 1) Remove complete front bumper assembly. Remove
engine undercover. Remove air intake duct from air filter housing.
Disconnect all necessary electrical connectors from front of vehicle.
2) Install Lock Carrier Support Tool (3369) through lock carrier to
chassis. See Figs. 1 and 2. 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.
3) Remove serpentine drive belts. Remove serpentine drive belt tensioner. Remove viscous fan clutch and pulley assembly. 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.
4) Remove upper timing belt cover. Rotate crankshaft by hand to Top
Dead Center (TDC). See Fig. 3. Remove crankshaft vibration damper
pulley. It is NOT necessary to remove crankshaft center bolt. Remove
lower timing belt cover.
5) 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 1) Align mark on camshaft sprocket with mark on cylinder
head cover and/or timing belt guard. See Fig. 3. Install timing belt on
crankshaft sprocket. Install lower timing belt cover. Install vibration
damper pulley, and tighten bolts to specification. See TORQUE SPECIFICATIONS.
2) Ensure crankshaft vibration damper is correctly aligned to lower
timing belt cover. See Fig. 3.
3) 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. 4.

Courtesy of Audi of America, Inc.

Fig. 2: Positioning Lock Carrier Support Tool (3369)

4) Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions in normal direction of
rotation. Make sure camshaft and crankshaft timing marks are aligned.
5) 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. 5. Check for wear in Areas B and C.
6) Install upper timing belt cover. Install serpentine drive belt tensioner
and belt. To complete installation, reverse removal procedure. Ensure
lock carrier Torx bolts are installed in correct position. See Fig. 6.

AUDI

48

1.8L 4-Cylinder Turbo AEB & ATW Engines 1997-00 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 6: Positioning Lock Carrier Assembly Torx Bolts

Courtesy of Audi of America, Inc.

Fig. 3: Identifying Top Dead Center (TDC) Position

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 48 (65)
Crankshaft Sprocket Center Bolt 1
Step 1 ...................................................................................................................... 66 (90)
Step 2 ................................................................................................... Additional 1/4 Turn
Lock Carrier-To-Frame 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)

Courtesy of Audi of America, Inc.

Fig. 4: Tensioning Camshaft Belt

Lock Carrier-To-Fender Torx Bolts ............................................................................ 89 (10)

Timing Belt Tensioner Bottom Bolt ........................................................................... 89 (10)
Water Pump Bolt ....................................................................................................... 89 (10)
1
2

Courtesy of Audi of America, Inc.

Fig. 5: Identifying Tensioner Dimensions

REPLACE torque-to-yield bolt if loosened or removed.

Bolt strength grade is 10.9.

AUDI

49

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder Turbo (AMB)

A4 Avant & Sedan
2002-04 ..................................................... 4.4 Hours ... ..... T306
A4 Cabriolet
2003-04 ..................................................... 4.4 Hours ... ..... T306
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the belt be replaced at 105,000 mile
intervals under normal driving conditions, 52,500 mile intervals under
severe driving conditions.

REMOVAL & INSTALLATION

NOTE: Take special note of the installed position of the upper part
of the timing belt cover, particularly where it meets the center part
of the timing belt cover.
CAUTION: The engine must only be turned in the direction of
engine rotation (clockwise) at the crankshaft. To turn engine over,
use center bolt on the crankshaft.
14) Remove upper part of timing belt cover. Bring engine to TDC
cylinder 1. Mark on camshaft sprocket and mark on crankshaft must be
at TDC cylinder 1. See Fig. 14. Remove vibration damper. Remove
center and lower part of timing belt cover.
CAUTION: Timing belt tensioner is oil-damped and can only be
compressed slowly and with evenly applied force.
15) When compressing the tensioner, excessive force can damage the
tensioning pulley. Push pulley counter-clockwise in direction of arrow
with a socket head wrench using even but not excessive application of
force until tensioner piston can be locked with Locking Plate (T10008).
See Fig. 15.
CAUTION: The stop tab of the eccentric bolt must not be bent.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

NOTE: Mark direction of rotation of timing belt with chalk or felt tip
pen.

TIMING BELT

16) To release tension from timing belt, loosen nut on pulley and rotate
eccentric bolt clockwise in direction of arrow using special tool (3387).
See Fig. 16. Remove timing belt.

NOTE: Many service operations are made easier by moving lock

carrier into service position.
Removal (Sedan & Avant) 1) Raise and support vehicle. Remove
front tires. Remove bolts and quick release screws (1 and 2). See Fig. 1.
Rear noise insulation (3) remains installed.
2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of
parking/auxiliary heater at noise insulation. See Fig. 2.
3) Remove right cover in engine compartment. Unbolt air guide between
lock carrier and air filter on lock carrier. Remove left cover in engine
compartment. Pull off hood seal from lock carrier and fender edges.
4) Loosen left and right wheelhousing liners in front area. See Fig. 3. Pull
back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip
bumper rear edge from catch (B). See Fig. 4. Repeat procedure on
opposite side of the vehicle.
5) Release catches (1-4) using a screwdriver and remove air inlet grille
on left and right on bottom part of bumper. See Fig. 5. Remove left and
right retaining bolts until bumper is fully released. See Fig. 6.
6) If installed, disconnect hose (1) to headlight cleaning system.
Disconnect harness connectors (2) and remove bumper. See Fig. 7.
7) Inspect headlight and turn signal electrical connectors and wiring
harness (which may hang up when lock carrier is moved forward).
8) On right side, remove bolt (5) and install support tool (3369) in its
place. See Figs. 8 and 9.
9) On left side, install support tool (3369) in threaded hole in chassis.
See Fig. 10.
10) Remove on both sides, all bolts (2). See Fig. 8.
11) Remove on both sides, all bolts (3 and 4). See Fig. 8. Slide lock
carrier forward unit the rear bolt hole in lock carrier aligns with the
forward threaded fender bolt hole.
12) Secure lock carrier in this position, by placing fender bolts in holes.
See Fig. 11. To install, reverse placing in service position procedure.
NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior
to removal. Running a used belt in the opposite direction could
destroy it.
13) Remove engine cover by lifting up. Swivel tensioning element in
direction of arrow to slacken off ribbed belt. See Fig. 12. Lock tensioner
using a mandrel (T10060) and remove ribbed belt. See Fig. 13. Remove
ribbed belt tensioner.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Under-Car Noise Insulation (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts

(Sedan & Avant)

AUDI

50

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 6: Identifying Bumper Fasteners (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 3: Locating Wheelhousing Fasteners (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Washer Hoses & Harness Connectors

(Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Front Bumper-To-Fender Fasteners

(Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Lock Carrier Components (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 5: Removing Grilles (Sedan & Avant)

AUDI

51

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Support Tool (Part No. 3369)

Courtesy of Audi of America, Inc.

Fig. 13: Locking Ribbed Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis

(Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 14: Identifying Top Dead Center (TDC) Position

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position

Courtesy of Audi of America, Inc.

Fig. 15: Compressing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 12: Removing/Installing Ribbed Belt

AUDI

52

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

CAUTION: The stop tab of the eccentric bolt must not be bent.
NOTE: Mark direction of rotation of timing belt with chalk or felt tip
pen.
10) To release tension from timing belt, loosen nut on pulley and rotate
eccentric bolt clockwise in direction of arrow using special tool (3387).
See Fig. 16. Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 16: Releasing Timing Belt Tension

Removal (Cabriolet) 1) Loosen bolts or quick release fasteners (1
and 2). See Fig. 17. The rear noise insulation quick-release fasteners (3)
should remain installed. The quick-release fasteners remain in the
bumper cover (1).
2) Loosen the wheel housing liners on left and right at front. Pull the
wheel housing liner back. Remove the bolt (2) and nuts (1). See Fig. 18.
Unclip bumper extension from catch (B).
3) Remove bolts and tilt front grille slightly forward and pull it out in an
upward direction from bumper cover. Remove bolts (1-8) and pull side
extensions out of guide piece. See Fig. 19. Pull bumper cover forward
slightly.
4) If equipped, disconnect hose for headlight washer unit. Disconnect
connector(s) and remove bumper cover from vehicle.
5) Remove left and right engine compartment covers. Remove air duct
between lock carrier and air cleaner (air duct is bolted to lock carrier).
Install Lock Carrier Support Tool (3369) into thread on left and right side
near impact absorbers. See Figs. 9 and 20.
6) Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier
forward until rear hole in lock carrier aligns with front threaded hole in
fender flange. See Fig. 11.

Courtesy of Audi of America, Inc.

Fig. 17: Identifying Bumper Cover Fasteners (Cabriolet)

NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior
to removal. Running a used belt in the opposite direction could
destroy it.
7) Remove engine cover by lifting up. Swivel tensioning element in
direction of arrow to slacken off ribbed belt. See Fig. 12. Lock tensioner
using a mandrel (T10060) and remove ribbed belt. See Fig. 13. Remove
ribbed belt tensioner.
NOTE: Take special note of the installed position of the upper part
of the timing belt cover, particularly where it meets the center part
of the timing belt cover.
CAUTION: The engine must only be turned in the direction of
engine rotation (clockwise) at the crankshaft. To turn engine over,
use center bolt on the crankshaft.
8) Remove upper part of timing belt cover. Bring engine to TDC cylinder
1. Mark on camshaft sprocket and mark on crankshaft must be at TDC
cylinder 1. See Fig. 14. Remove vibration damper. Remove center and
lower part of timing belt cover.
CAUTION: Timing belt tensioner is oil-damped and can only be
compressed slowly and with evenly applied force.
9) When compressing the tensioner, excessive force can damage the
tensioning pulley. Push pulley counter-clockwise in direction of arrow
with a socket head wrench using even but not excessive application of
force until tensioner piston can be locked with Locking Plate (T10008).
See Fig. 15.

Courtesy of Audi of America, Inc.

Fig. 18: Identifying Bumper Cover Fasteners At Wheel Opening

(Cabriolet)
CAUTION: To prevent pistons from hitting valves, make sure
crankshaft is NOT at TDC for any piston before turning camshaft.
Installation (Sedan & Avant) 1) Place timing belt on crankshaft
sprocket (if reusing belt, observe direction of rotation). Install lower part
of timing belt cover. Install vibration dampener. The hole in the vibration
damper must be located over the raised part on the crankshaft timing
belt sprocket. Tighten vibration damper/pulley to specification. See
TORQUE SPECIFICATIONS.
2) If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks.
See Fig. 14. Install timing belt in this order: water pump, tensioning
pulley, camshaft sprocket.

AUDI

53

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

vehicle. Torque left and right retaining bolts to specification. See
TORQUE SPECIFICATIONS. Install left and right air inlet grille on
bumper. Remainder of installation is the reverse of removal.
Installation (Cabriolet) 1) Place timing belt on crankshaft sprocket (if
reusing belt, observe direction of rotation). Install lower part of timing
belt cover. Install vibration dampener. The hole in the vibration damper
must be located over the raised part on the crankshaft timing belt
sprocket. Tighten vibration damper/pulley to specification. See
TORQUE SPECIFICATIONS.
2) If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks.
See Fig. 14. Install timing belt in this order: water pump, tensioning
pulley, camshaft sprocket.

Courtesy of Audi of America, Inc.

Fig. 19: Removing Bumper Cover (Cabriolet)

NOTE: If the timing belt tensioner has not been restrained and is at
its travel limit, it must be pushed back in the installed position
together with the pulley. This procedure can take up to 5 minutes.
When compressing the tensioner, excessive force can damage the
tensioning pulley. Push pulley on counter-clockwise in direction of
arrow with a socket head wrench using even but not excessive
application of force until tensioner piston can be locked with
locking plate (T10008). See Fig. 15.
3) Turn eccentric bolt counter-clockwise in direction of arrow using
special tool (3387). See Fig. 21. Hold eccentric bolt in this position and
remove locking plate. Turn eccentric bolt clockwise to right in direction of
arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed
between tensioning lever and tensioner housing. See Fig. 22. Hold
eccentric bolt in this position and tighten pulley nut to specification. See
TORQUE SPECIFICATIONS.
4) Turn crankshaft two complete turns by hand in direction of engine
rotation until crankshaft is at TDC again. Mark on camshaft sprocket and
mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check
dimension between tensioning lever and tensioner housing with a
gauge. Dimension should be 6-10 mm. If dimension is not obtained,
tension timing belt again. Go to step 3).
5) Install center and upper timing belt cover and ribbed belt tensioner.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
When installing ribbed belt, make sure that direction of rotation is correct
and that belt is installed correctly to pulleys. On vehicles with A/C, install
ribbed belt to A/C compressor last.
6) To install lock carrier, reverse removal procedures outlined in
REMOVAL (SEDAN & AVANT). Torque all fasteners to specification. See
TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for
torque support with its own weight and tighten bolts to 21 ft. lbs. (28
N.m). See Fig. 23.
NOTE: Before installing bumper, check for the presence of
threaded pins at bumper rear edge as well as expanding clips and
sleeves in the fenders. Always replace bumper retaining bolts.
7) Slide bumper onto impact absorber and re-connect hose (1) of
headlight cleaning system and electrical harness connectors (2). See
Fig. 7. Move bumper into installation position. Make sure threaded pins
in bumper side edges engage into holes at the fenders. Install bumper
retaining bolts until bumper can stay in place without any assistance.
8) Do not tighten completely allowing for any necessary adjustments.
Pull back wheelhousing liner (A). See Fig. 3. Engage bumper rear edge
into catch (B). Torque nuts. Repeat procedure on opposite side of the

NOTE: If the timing belt tensioner has not been restrained and is at
its travel limit, it must be pushed back in the installed position
together with the pulley. This procedure can take up to 5 minutes.
When compressing the tensioner, excessive force can damage the
tensioning pulley. Push pulley on counter-clockwise in direction of
arrow with a socket head wrench using even but not excessive
application of force until tensioner piston can be locked with
locking plate (T10008). See Fig. 15.
3) Turn eccentric bolt counter-clockwise in direction of arrow using
special tool (3387). See Fig. 21. Hold eccentric bolt in this position and
remove locking plate. Turn eccentric bolt clockwise to right in direction of
arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed
between tensioning lever and tensioner housing. See Fig. 22. Hold
eccentric bolt in this position and tighten pulley nut to specification. See
TORQUE SPECIFICATIONS.
4) Turn crankshaft two complete turns by hand in direction of engine
rotation until crankshaft is at TDC again. Mark on camshaft sprocket and
mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check
dimension between tensioning lever and tensioner housing with a
gauge. Dimension should be 6-10 mm. If dimension is not obtained,
tension timing belt again. Go to step 3).
5) Install center and upper timing belt cover and ribbed belt tensioner.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
When installing ribbed belt, make sure that direction of rotation is correct
and that belt is installed correctly to pulleys. On vehicles with A/C, install
ribbed belt to A/C compressor last.
6) To install lock carrier, reverse removal procedures outlined in
REMOVAL (CABRIOLET). Torque all fasteners to specification. See
TORQUE SPECIFICATIONS.
NOTE: Prior to installation of the bumper cover check for presence
of threaded pins (2) at the bumper extensions as well as grommets
(3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m).
7) To install bumper cover, reverse removal procedures outlined in
REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and
connect the hose of headlight washer unit as necessary. Reconnect
connectors as necessary. Ensure that the threaded pins in the bumper
side extensions engage in the holes at the fender.
8) Clip in side extensions and fasten using the bolts (8). See Fig. 19.
Loosely screw in bolt (3). Tighten bolts (2 and 4) to 48 INCH lbs. (6 N.m),
and bolts (5, 6 and 7) to 24 INCH lbs. (3 N.m). Close hood and check
overlap or gap dimension of bumper cover with respect to the hood. If
OK, tighten all the bolts. If not, open hood and loosen bolts (2 or/and 4)
to correct upper bumper as required. Tighten bolt (3) to 48 INCH lbs. (6
N.m).
9) Verify fender gaps as follow: A = 2 mm +/ 0.5 mm, B = 0 mm +/ 0.5
mm and C = 0 mm +/ 0.5 mm. See Fig. 24. Gap dimensions can be
checked using Audi special tool (3371). Adjust gaps as necessary.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Remainder of installation is the reverse of removal.

AUDI

54

1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 20: Exploded View Of Lock Carrier Components (Cabriolet)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 23: Identifying Torque Support Bolts (Sedan & Avant)

Fig. 21: Releasing Locking Plate From Tensioner

Courtesy of Audi of America, Inc.

Fig. 24: Bumper Cover Gaps (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 22: Adjusting Timing Belt Tensioner

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Component
Ft. Lbs. (N.m)
Camshaft Gear Bolt .................................................................................................. 48 (65)
Crankshaft Gear Bolt .............................................................................................. 1 66 (90)
Impact Absorber-To-Bumper Bolts ............................................................................ 17 (23)
Impact Absorber-To-Frame Bolts .............................................................................. 33 (45)
Ribbed Belt Tensioner-To-Bracket Bolts ................................................................... 17 (23)
Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
Timing Belt Tensioner-To-Bracket Bolts
Smaller Bolt ............................................................................................................. 11 (15)
Larger Bolt ............................................................................................................... 18 (25)
Torque Reaction Support Bolts ................................................................................. 21 (28)
Wheel Bolt ............................................................................................................... 89 (120)
INCH Lbs. (N.m)
Timing Belt Guard Bolts 2 ......................................................................................... 89 (10)
Vibration Damper Bolts 3 ......................................................................................... 1 89 (10)
1
2
3

After achieving torque, tighten an additional quarter turn (90).

Install with locking fluid D 000 600 A2.
Replace bolts.

55

AUDI

56

1.8L 4-Cylinder Turbo

AMU, ATC, AWP & BEA Engines TT
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder Turbo (AMU, ATC & AWP)

TT Coupe & Roadster
2000-04 ..................................................... 3.4 Hours ... ..... T306
NOTE: Engine code is located on machined pad on bellhousing
flange, where engine connects to transaxle.

CAUTION: To prevent engine damage, DO NOT turn camshaft while

the crankshaft is at TDC.
11) SLOWLY turn hex nut on stud to compress timing belt tensioner.
Compress tensioner just enough so that a locking pin or drill bit can be
inserted through the tensioner body, locking the tensioner in place. Pull
out timing belt through space between engine support and cylinder
block.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the belt be replaced at 105,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) On ATC and AWP engines, disconnect charge air cooler
duct at bottom of right-hand crossmember. See Fig. 1. To identify
engine, check engine code located on a pad on engine block near
bellhousing of transmission. See Fig. 2. On all models, remove center
and right-hand noise insulation panels from under vehicle. See Fig. 3.
2) Rotate serpentine drive belt tensioner clockwise (as viewed from front
of engine) to relieve belt tension. Remove serpentine drive belt and
tensioner. See Fig. 4.
3) Remove cooling system expansion tank and power steering reservoir
bolts, leaving hoses attached, secure expansion tank and reservoir out
of way.
4) 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.
5) Remove weight of engine from engine mounts by installing Support
Bracket (10-222) or equivalent. Engine may be supported from below
using floor jack. Use care not to damage components.
6) 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. 6. Slightly lift engine.
NOTE: Crankshaft sprocket center bolt is a torque-to-yield type. If
removed, manufacturer recommends replacing the bolt.
7) 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 during removal of vibration dampener.
NOTE: Engine console and right-hand engine support bolts are
torque-to-yield type. Manufacturer recommends replacing the
bolts if they are removed.
8) Remove center and bottom timing belt covers. Remove bolts from
engine console and right-hand engine support arm. See Fig. 7. Remove
engine console and right-hand engine support arm.
9) Remove bolts for engine support, but do not remove engine support.
See Fig. 8. If reusing old timing belt, mark belt with arrow to indicate
original direction of rotation.
10) Screw a M5 x 55 stud into the timing belt tensioner bracket. See
Fig. 9. Install hex nut and washer onto stud.

Courtesy of Audi of America, Inc.

Fig. 1: Identifying Air Duct (ATC & AWP Engines)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Engine Code

Installation 1) 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.
2) Ensure camshaft and crankshaft timing marks are still aligned. See
Fig. 6. Install timing belt on water pump, tensioner pulley and camshaft
sprocket.
3) Remove locking pin or drill bit from timing belt tensioner. Remove M5
x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions
in normal direction of rotation. Align camshaft and crankshaft timing
marks.
4) 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 0.50 (13 mm). See Fig. 7.
5) 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.

AUDI

57

1.8L 4-Cylinder Turbo

AMU, ATC, AWP & BEA Engines TT (Cont.)
6) Install coolant expansion tank and power steering reservoir. Install
vacuum line between fuel evaporative canister and throttle body. To
install remaining components, reverse removal procedure.

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Components

Fig. 3: Identifying Noise Insulation Panels

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Timing Marks

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Serpentine Belt & Tensioner

AUDI

58

1.8L 4-Cylinder Turbo

AMU, ATC, AWP & BEA Engines TT (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Audi of America, Inc.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 48 (65)
Crankshaft Sprocket Center Bolt 1
Step 1 ...................................................................................................................... 66 (90)
Step 2 ................................................................................................... Additional 1/4 Turn
Engine Console-To-Body 1
Step 1 ...................................................................................................................... 30 (40)
Step 2 ................................................................................................... Additional 1/4 Turn
Engine Support Arm-To-Engine Bracket 1
Step 1 ...................................................................................................................... 44 (60)
Step 2 ................................................................................................... Additional 1/4 Turn
Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
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)

Fig. 7: Locating Right-Hand Engine Support Arm

INCH Lbs. (N.m)

Timing Belt Cover Bolt .............................................................................................. 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Right-Hand Engine Support

Courtesy of Audi of America, Inc.

Fig. 9: Compressing Timing Belt Tensioner

Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.

AUDI

59

1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder Turbo (AWM Engine)

A4 & A4 Quattro
2000 ........................................................... 4.7 Hours ... ..... T306
2001-04 ..................................................... 4.4 Hours ... ..... T306
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.
Courtesy of Audi of America, Inc.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Fig. 1: Identifying Lower Engine Shield (Noise Insulator)

Mounting Points

For 2000-01, the manufacturer suggests the belt be replaced at 120,000

mile intervals.For 2002-04, the manufacturer suggests the belt be
replaced at 90,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Raise and support vehicle. Remove front tires. Remove
lower front engine shield (noise insulator). See Fig. 1. With vehicle
raised, remove Torx screws at wheelhousing liner.
2) Remove air inlet grilles by using screwdriver to disengage clips. See
Fig. 2. Remove inner end of grille first. Remove bolt/washer assembly
(1). See Fig. 3.
3) Unclip bumper from bracket (9) and pull forward. Disconnect any
wiring harness attached to the front bumper and remove front bumper
cover.
4) Remove lower air duct hose-to-charge air cooler. See Fig. 4. Remove
air duct between lock carrier and air filter housing. Disconnect harness
retaining clips from left side of radiator shroud.
5) Remove bolt and install Lock Carrier Support Tool (3369) through lock
carrier to chassis. See Figs. 5, 6 and 7. Install Lock Carrier Support Tool
into bore on opposite side of vehicle. See Fig. 5. Remove lock carrier
support bolts securing lock carrier to vehicle. Slide lock carrier forward
onto support tool. Secure lock carrier to vehicle using holes in lock
carrier and fender. See Fig. 8. This will allow servicing of front engine
components.
6) Remove engine cover and loosen bolts securing ribbed belt tensioning roller for A/C compressor. Remove A/C compressor belt. Rotate
tensioner in direction of arrow to loosen ribbed belt. See Fig. 9. Remove
ribbed belt from generator and release tensioner.
NOTE: When lock carrier is in the service position, ribbed belt
tensioner can be secured to prevent from turning by inserting a
suitable pin or Allen key into holes. See Fig. 10.
7) Secure pulley for viscous fan with pin punch (1) and remove using
Allen key (2). See Fig. 11. Remove viscous fan from mounting.
NOTE: If serpentine belt is to be reused, mark direction of timing
belt rotation with chalk or felt pen before removing the belt. If belt
rotates in the wrong direction when it is refitted, belt breakage may
result.
8) Remove upper timing belt guard. Set crankshaft to markings for TDC
of No. 1 cylinder by turning central bolt on crankshaft sprocket in
direction of rotation. See Fig. 12.
9) Unbolt and remove vibration damper. Remove lower and center
sections of timing belt guard. Attach Socket Head Fastener (T10092 or
any M5 x 55 stud) into tensioner for timing belt. See Fig. 13. Only tension
pressure piston of tensioner until pressure piston can be secured with
pin (T40011). Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 2: Removing Inner End Of Air Inlet Grill (A4)

CAUTION: To prevent pistons from hitting valves, make sure
crankshaft is NOT at TDC for any piston before turning camshaft.
Installation 1) Align marking on camshaft sprocket with marking at
cylinder head cover. See Fig. 12. Place timing belt on crankshaft
sprocket (if reusing old belt, observe direction of rotation noted during
removal). Install lower timing belt guard. Secure vibration damper/belt
pulley with one bolt (note installation arrangement). Set crankshaft to
TDC for cylinder No. 1. Install timing belt onto coolant pump, then
tensioning roller, and finally camshaft sprocket.
2) Remove socket head fastener (T10092) and pull out pin (T40011)
from tensioner. See Fig. 10.
3) Turn crankshaft two full turns in direction of rotation (by turning central
bolt on crankshaft sprocket by hand) and check that camshaft and
crankshaft marks align with their reference points. Install remaining
vibration damper bolts and torque to specification. See TORQUE
SPECIFICATIONS.
4) Install timing belt guard (center and top sections). Install viscous fan.
Install tensioner for ribbed belt. Attach ribbed belt to pulleys from
crankshaft and vane pump and, if necessary, pull up with auxiliary tool.
Swivel tensioner for ribbed belt in direction of arrow. See Fig. 9. Install
ribbed belt over generator pulley last. Release tensioner and check that
ribbed belt is properly seated.
5) Fit ribbed belt for A/C compressor. Attach torque wrench at 7 oclock
position to hex on tensioner and pretension to 22 ft. lbs. (30 N.m). While
applying tension, tighten tensioner bolts to 17 ft. lbs. (23 N.m).
6) For installation of lock carrier, reverse removal procedures outlined in
REMOVAL. After installing lock carrier, ensure harness next to radiator
is routed correctly. Attach limit stop for torque reaction support to rest on
rubber buffer for reaction support under its own weight. See Fig. 14.
Torque bolts to specification. See TORQUE SPECIFICATIONS.
7) For installation of bumper, reverse removal procedures outlined in
REMOVAL. Bumper height is adjusted by shifting the threaded sleeve in
the impact absorber. See Fig. 15. Tighten combination bolt to 17 ft. lbs.
(23 N.m) when installing bumper. Bolt (4) is for securing impact absorber
to lock carrier for service position. Torque to 3 ft. lbs. (4 N.m).

AUDI

60

1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 3: Identifying Front Bumper Components (A4)

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Air Charge Cooler Hose (A4)

Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Lock Carrier Assembly (A4)

AUDI

61

1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Identifying Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 9: Removing/Installing Alternator Belt (A4)

Courtesy of Audi of America, Inc.

Fig. 7: Positioning Lock Carrier Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 10: Securing Tensioner

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 8: Positioning Lock Carrier Assembly Torx Bolts

Fig. 11: Removing Viscous Fan

AUDI

62

1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 12: Identifying Top Dead Center (TDC) position

Courtesy of Audi of America, Inc.

Fig. 15: Adjusting Front Bumper Height (A4)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Fig. 13: Compressing Timing Belt Tensioner

Component
Ft. Lbs. (N.m)
Camshaft Gear Bolt .................................................................................................. 48 (65)
Crankshaft Gear Bolt .............................................................................................. 1 66 (90)
Impact Absorber-To-Bumper Bolts ............................................................................ 17 (23)
Impact Absorber-To-Frame Bolts .............................................................................. 33 (45)
Ribbed Belt Tensioner-To-Bracket Bolts ................................................................... 17 (23)
Timing Belt Guard Bolts 2 ........................................................................................... 7 (10)
Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
Timing Belt Tensioner-To-Bracket Bolts
Smaller Bolt ............................................................................................................. 11 (15)
Larger Bolt ............................................................................................................... 18 (25)
Torque Reaction Support Bolts ................................................................................. 21 (28)
Vibration Damper Bolts 3 ........................................................................................... 1 7 (10)
1
2
3

Courtesy of Audi of America, Inc.

Fig. 14: Adjusting Stop For Torque Reaction Support

After achieving torque, tighten an additional quarter turn (90).

Install with locking fluid D 000 600 A2.
Replace bolts.

AUDI

63

2.0L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl.
80
1988-90 ............................... 1.8 Hours ... .. TCK017 .. ..... T017
90
1988 .................................... 1.8 Hours ... .. TCK017 .. ..... T017
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Installation 1) Align flywheel/flexplate 0 mark with pointer. Remove

distributor cap, and check position of ignition rotor. Rotate intermediate
shaft and position rotor at No. 1 cylinder mark on housing. See Fig. 2.
Install timing belt on crankshaft and intermediate shaft gears.
2) With intermediate shaft/ignition rotor positioned, rotate crankshaft 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 or 4. Install timing belt on camshaft sprocket.
3) Rotate tensioner clockwise to tighten belt and install lock nut. Proper
tension is achieved when belt can be twisted 90 degrees. See Fig. 5.
Rotate crankshaft 2 revolutions and check timing mark alignment. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

Courtesy of Audi of America, Inc.

Fig. 2: Aligning Ignition Rotor

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal 1) 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).
2) Remove upper timing belt cover. Remove water pump and crankshaft
pulleys. Remove lower timing belt cover. Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks (8-Valve)

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View of Timing Belt & Components

AUDI

64

2.0L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 58 (80)
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)

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Timing Marks (16-Valve)

Courtesy of Audi of America, Inc.

Fig. 5: Checking Proper Timing Belt Tension

AUDI

65

2.0L 5-Cylinder Diesel & Turbo Diesel

TIMING BELT APPLICATION
Application
2.0L 5-Cyl. Diesel
5000
1979-83
Camshaft ................................................
Inject. Pump ...........................................
2.0L 5-Cyl. Turbo Diesel
5000
1979-83
Camshaft ................................................
Inject. Pump ...........................................

Labor Time

Belt
Part No.

2.6 Hours ... ..... T083

1.1 Hours ... ..... T082

2.6 Hours ... ..... T083

1.1 Hours ... ..... T082

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT & INJECTION PUMP BELT

Removal 1) Disconnect negative battery cable. Remove accessory
drive 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. See
Fig. 1. Remove injection pump covers. Note position and number of
spacer washers on pulley.
2) Remove cam cover. Rotate crankshaft to position No. 1 cylinder at
TDC. Timing marks on flywheel and clutch housing must be aligned.
Also, timing marks on fuel injection pump sprocket and pump mounting
plate must be aligned.
3) 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 retaining bolt. Remove inner pulley half, pump
sprocket and injection pump drive belt.
4) Secure crankshaft from moving with Support Tool (2084). Loosen
crankshaft damper/pulley center bolt. Install Camshaft Holding Tool
(2065A) at rear of camshaft.
5) 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 1) Ensure crankshaft and injection pump timing marks are
aligned. Install crankshaft damper/pulley with sprocket and timing belt.
Using Support Tool (2084) to hold crankshaft, install and tighten center
bolt.
2) With camshaft still locked in place, loosen camshaft sprocket bolt one
full turn. Using a brass drift inserted through hole in rear timing belt
cover, tap camshaft sprocket loose from camshaft taper.
3) Attach timing belt to camshaft sprocket. To adjust timing belt tension,
turn water pump until pump sprocket provides tension against timing
belt.
4) Using tension tester (VW210), check timing belt tension midway
between camshaft and water pump sprockets. Tension is correct when
tester reads 12-13.
5) Check that crankshaft and injection pump timing marks are still
aligned. Tighten camshaft sprocket bolt and remove camshaft holding
tool.

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

6) Install injection pump sprocket, drive belt and inner pulley half. See
Fig. 2. Tighten injection pump drive sprocket retaining bolt until it is just
possible to turn sprocket on camshaft by hand.
7) Adjust fuel injection pump drive belt tension by loosening mounting
bolts and repositioning mounting plate and support on engine. Using
Tension Tester (VW 210), check belt tension midway between fuel
injection pump and drive sprockets.
8) Tighten fuel injection pump drive sprocket bolt and remove Pin Tool
(2064) from injection pump sprocket. Install remaining components in
reverse order of removal. Ensure valve timing and injection pump timing
are correct. Adjust drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 2: Replacing Injection Pump Drive Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket
Front ......................................................................................................................... 33 (45)
Rear ....................................................................................................................... 72 (100)
Crankshaft Damper/Pulley (Locktite) .................................................................... 258 (350)
Water Pump Bolts ..................................................................................................... 14 (20)

AUDI

66

2.2L 5-Cylinder Turbo, 1992-95

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 5-Cyl. Turbo

S4
1992-94 ..................................................... 1.8 Hours ... ..... T225
S6 & S6 Quattro
1995 ........................................................... 3.4 Hours ... ..... T225
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. 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.
2) Attach special Radiator Support Tool (3251) to right bumper mount
bracket, and swing radiator forward. Remove viscous fan, and unclip
wiring from fan frame. Relieve tension from accessory drive belt by
swinging tensioner in direction shown. See Fig. 1. Insert Pin (3204) into
holes. Remove belt. Remove tensioner. Remove upper timing belt
guard.

Courtesy of Audi of America, Inc.

Fig. 1: Relieving Tension On Accessory Drive Belt

NOTE: Turn engine by hand using hex flange on hydraulic pump.

Loosen tensioner bolts.
3) Turn crankshaft to TDC of No. 1 cylinder. See Fig. 2. Camshaft
sprocket mark must align with mark on cylinder cover. See Fig. 3.
Remove vibration damper. Remove lower timing belt cover. Remove
timing belt with vibration damper.
Installation 1) Ensure crankshaft and camshaft are at TDC of cylinder
No. 1. TDC marking must be positioned below edge in inspection hole.
See Fig. 2. Markings on camshaft sprocket and cylinder head cover
must align. See Fig. 3. 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
turning tensioner toward right with bolts loosened. See Fig. 4.
2) 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.

Courtesy of Audi of America, Inc.

Fig. 2: Locating No. 1 Cylinder TDC Inspection Hole

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Camshaft Sprocket Timing Marks

AUDI

67

2.2L 5-Cylinder Turbo, 1992-95 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20)
Timing Belt Tensioner ................................................................................................ 15 (20)
Vibration Damper Bolt ........................................................................................... 258 (350)
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)

Courtesy of Audi of America, Inc.

Fig. 4: Installing Timing Belt

AUDI

68

2.3L 5-Cylinder Coupe Quattro

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.3L 5-Cyl.
Coupe Quattro
1990-91 ..................................................... 1.8 Hours ... ..... T197
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT & COVER
Removal 1) 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. See Fig. 1.
2) 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.
3) 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.

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Installation 1) Ensure both camshaft lobes on No. 1 cylinder point
upward. Mark (notch or dot) on back of camshaft sprocket must be
aligned with top of valve cover gasket or rear timing belt cover.
Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must
be aligned with index point on transmission housing. See Fig. 3.
2) 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.
See Fig. 4.
3) Recheck valve timing. Complete installation in reverse order of
removal. Adjust drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 2: Aligning Timing Marks

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Ignition Rotor

AUDI

69

2.3L 5-Cylinder Coupe Quattro (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
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)

Courtesy of Audi of America, Inc.

Fig. 4: Checking Proper Timing Belt Tension

AUDI

70

2.3L 5-Cylinder Except Coupe Quattro

TIMING BELT APPLICATION
Application
2.3L 5-Cyl.
80
1991-92 .....................................................
80/90 Quattro
1988 ...........................................................
1989
Thru Chassis No. 89 J 394 742 ............
From Chassis No. 89 J 394 743 ...........
1990-92 .....................................................
90
1988 ...........................................................
1989
Thru Chassis No. 89 J 396 702 ............
From Chassis No. 89 J 396 703 ...........
1990-91 .....................................................
100/100 Quattro
1989-91
Thru Chassis No. 063 969 ....................
From Chassis No. 063 970 ...................
1990-91 .....................................................
5000S
1987-88 .....................................................
5000S Quattro
1988 ...........................................................

Labor Time

Belt
Part No.

1.8 Hours ... ..... T170

1.8 Hours ... ..... T127
1.8 Hours ... ..... T127
1.8 Hours ... ..... T170
1.8 Hours ... ..... T170
1.8 Hours ... ..... T127
1.8 Hours ... ..... T127
1.8 Hours ... ..... T170
1.8 Hours ... ..... T170

1.8 Hours ... ..... T127

1.8 Hours ... ..... T170
1.8 Hours ... ..... T170
Courtesy of Audi of America, Inc.

2.2 Hours ... ..... T127

2.2 Hours ... ..... T127

Fig. 1: Exploded View Of Timing Belt & Components

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1987-90) 1) 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. See Fig. 1.
2) 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.
3) 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.
Installation (1987-90) 1) Ensure both camshaft lobes on No. 1
cylinder point upward. Mark (notch or dot) on back of camshaft sprocket
must be aligned with top of valve cover gasket or rear timing belt cover.
Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must
be aligned with index point on transmission housing.
2) 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 order of removal.
Adjust drive belts to proper tension.
Removal (1991-92) 1) Disconnect negative battery cable. Remove
accessory drive belts. Remove upper front and lower front timing belt
covers. Rotate crankshaft until timing marks are aligned. See Fig. 3.
Mark an arrow on timing belt (if reusing) to indicate direction of rotation.
2) Slightly loosen 3 water pump bolts. Pivot water pump toward 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, remove vibration damper bolt. Remove vibration
damper/crankshaft sprocket. Remove timing belt.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Aligning Camshaft Sprocket

Installation (1991-92) 1) Ensure timing marks are aligned. See Fig. 3.
With crankshaft sprocket attached to vibration damper, loop timing belt
around crankshaft sprocket. Install vibration damper/crankshaft
sprocket with belt onto crankshaft end, ensuring belt is not jammed
between crankshaft sprocket and front cover.
2) Slightly loosen 3 water pump bolts. Pivot water pump toward 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.
3) 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 tension 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 tension.

AUDI

71

2.3L 5-Cylinder Except Coupe Quattro (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20)
Vibration Damper Bolt ........................................................................................... 258 (350)
Water Pump Bolt ....................................................................................................... 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 89 (10)
Timing Belt Cover ..................................................................................................... 89 (10)

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks

AUDI

72

2.7L V6 DOHC APB Engine A6 Quattro & Allroad

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.7L V6, Twin Turbo (APB Engine)

A6 Quattro
2000-04 ..................................................... 5.2 Hours ... ..... T297
Allroad
2001-04 ..................................................... 5.2 Hours ... ..... T297
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends belt and belt tensioner be replaced at
105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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
revolution more.
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
could result.
9) 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. Screw Crankshaft Holding Tool (Audi 3242) into
sealing plug and tighten.
NOTE: Center bolt does NOT have to be loosened to remove the
vibration damper.
10) Remove 8 socket-head bolts and remove vibration damper. See
Fig. 12.
11) Remove idler wheel for accessory drive belt. Remove timing belt
guard behind vibration damper. See Fig. 13.
12) Using a hex key, turn timing belt tensioner clockwise 8 mm in
direction of arrow. See Fig. 14. The toothed belt tensioning element is
oil-damped and can be compressed slowly by applying constant pressure. 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.

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of
rotation on accessory drive belt and/or timing belt. Damage may
result if belts are installed in opposite direction of rotation.
Removal 1) Disconnect negative battery cable. Working under
vehicle, remove noise insulator. See Fig. 1.
2) 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.
3) To move lock carrier into service position, perform following steps:
Remove intake air duct between lock carrier and air cleaner housing
at lock carrier.
Remove bolts from lock carrier.
On right side, remove bolt and install Support Tool (3369) into right
bore. See Fig. 3.
On left side, install Support 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.
4) Remove viscous fan using spanner wrench and Pin Wrench (3212) to
hold fan. See Fig. 6.
CAUTION: Mark the direction of the accessory drive belt rotation
with chalk or felt pen before removing. A used belt can break if it
rotates in the opposite direction when reinstalled.
5) Using a 17-mm wrench turn belt tensioner to the right until two holes
are aligned. Hold tensioner in position with Mandrel (3204). Remove
accessory drive belt. See Fig. 7.
6) Unscrew bolts and remove center engine cover panel. Remove
pressure hoses between charge air coolers and pressure pipes on left
and right sides. See Fig. 8. Remove turbocharger pressure pipes.
NOTE: Take note of position of the retaining strips.
7) Remove accessory drive belt tensioner (1). Remove left and right
timing belt guards (2) and center guard (3). See Fig. 9.
8) Rotate crankshaft by hand to TDC. Ensure notch A is aligned with
notch B. See Fig. 10. Check position of camshafts. Ensure that the

Courtesy of Audi of America, Inc.

Fig. 1: Removing Noise Insulation

Installation 1) Insert Camshaft Locator Bar (3391) into securing
plates of the two camshafts. See Fig. 15. Loosen both camshaft bolts
and unscrew approximately 5 turns.
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).
2) Remove Camshaft Locator Bar (3391). Loosen, but do not remove,
both camshaft sprockets with Gear Puller (T40001). See Fig. 16.
3) Reinstall both camshaft sprockets with securing plates and tighten
hand tight.
4) Position timing belt over camshaft sprockets. See Fig. 17. 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.
5) 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.
6) Remove camshaft locator bar. Remove crankshaft holding tool. Install
plug in engine block. Install timing belt guards.
7) Remaining installation is reverse of removal procedure. For accessory drive belt routing, see Fig. 18. Ensure lock carrier-to-fender Torx
bolts are installed correctly. See Fig. 5.

AUDI

73

2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

Courtesy of Audi of America, Inc.

Fig. 4: Positioning Lock Carrier Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 2: Removing Front Bumper

Courtesy of Audi of America, Inc.

Fig. 5: Securing Lock Carrier

Courtesy of Audi of America, Inc.

Fig. 3: Moving Lock Carrier To Service Position

Courtesy of Audi of America, Inc.

Fig. 6: Removing Viscous Fan

AUDI

74

2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

Courtesy of Audi of America, Inc.

Fig. 7: Loosening Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 10: Aligning Crankshaft Timing Marks

Courtesy of Audi of America, Inc.

Fig. 8: Removing Pressure Hoses

Courtesy of Audi of America, Inc.

Fig. 11: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 9: Removing Accessory Drive Belt Tensioner &

Timing Belt Covers

Courtesy of Audi of America, Inc.

Fig. 12: Removing Vibration Damper

AUDI

75

2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

Courtesy of Audi of America, Inc.

Fig. 13: Removing Timing Belt Guard

Courtesy of Audi of America, Inc.

Fig. 16: Removing Camshaft Sprockets With Gear Puller

Courtesy of Audi of America, Inc.

Fig. 17: Installing Timing Belt On Sprockets

Courtesy of Audi of America, Inc.

Fig. 14: Compressing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 18: Accessory Drive Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Audi of America, Inc.

Application
Ft. Lbs. (N.m)
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 (1/2 Turn)
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)

Fig. 15: Installing Camshaft Locking Bar

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.

AUDI

76

2.7L V6 DOHC APB Engine S4 Quattro

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

larger holes in the securing plates on the camshaft sprockets face one
another on the inside. See Fig. 14. If this is not the case, rotate
crankshaft one revolution more.

2.7L V6 Twin Turbo (APB Engine)

S4 Quattro
2000-02 ..................................................... 5.5 Hours ... ..... T297

WARNING: DO NOT turn engine while feeling for TDC mark. Injury
could result.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

11) 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.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 2000 model vehicles, manufacturer recommends belt be replaced at
105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

NOTE: The center bolt does not have to be loosened to remove the
vibration damper.
12) Screw Crankshaft Holding Tool (Audi 3242) into sealing plug and
tighten. See Fig. 10. Remove crankshaft vibration damper. See Fig. 11.
13) Remove idler wheel for accessory drive belt and timing belt guard
behind vibration damper. See Fig. 12.
14) Using a 8 mm hex key, turn timing belt tensioner clockwise 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.

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of
rotation on accessory drive belt or timing belt. Damage may result
if belts are installed in opposite direction of rotation.
Removal 1) Disconnect negative battery cable. Working under
vehicle, remove noise insulator. See Fig. 1.
2) 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.
3) On VIN 8DXA200001 and forward, remove bumper by removing 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 using 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.
4) Move lock carrier to service position. 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.
5) 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.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Noise Insulation

NOTE: Viscous fan has left-hand threads.

6) Remove viscous fan using Pin Wrench (3212) to hold fan. See Fig. 5.
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.
7) Loosen accessory drive belt by using a 17-mm wrench to turn belt
tensioner to the right until two holes are aligned. Hold tensioner in
position with Mandrel (3204). Remove accessory drive belt. See Fig. 6.
8) Unscrew bolts and remove center engine cover panel. Remove
pressure hoses between charge air coolers and pressure pipes on left
and right sides. See Fig. 7. Remove pressure pipes, noting installed
position of retaining strips.
9) Remove timing belt tensioner 1. Remove left and right timing belt
guards 2 and center guard 3. See Fig. 8.
10) Rotate crankshaft by hand to TDC. Ensure notch A is aligned with
notch B. See Fig. 9. Check position of camshafts. Ensure that the

Courtesy of Audi of America, Inc.

Fig. 2: Removing Front Bumper (Up to VIN 8DXA200000 Shown;

Later Models Are Similar)
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).
Installation 1) Insert Camshaft Locator Bar (3391) into securing
plates of the two camshafts. See Fig. 14. Loosen both camshaft bolts
and unscrew approximately 5 turns. Remove Camshaft Locator Bar
(3391). Loosen, but do not remove, both camshaft sprockets with Gear

AUDI

77

2.7L V6 DOHC APB Engine S4 Quattro (Cont.)

Puller (T40001). See Fig. 15. Reinstall both camshaft sprockets with
securing plates, and tighten hand tight.
2) Position timing belt over camshaft sprockets. See Fig. 16. With large
holes in camshaft securing plates facing inboard, install Camshaft
Locator Bar (3391) on camshafts.
3) Using hex key, turn timing belt tensioner clockwise 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.
4) 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.
5) Install accessory drive belt. See Fig. 17. Install lock carrier to body.
Ensure lock carrier aligns correctly with fender and install Torx bolts. See
Fig. 18. Install bumper. To complete installation, reverse removal
procedure. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS.

Courtesy of Audi of America, Inc.

Fig. 5: Removing Viscous Fan

Courtesy of Audi of America, Inc.

Fig. 3: Removing Inner End Of Air Inlet Grill

Courtesy of Audi of America, Inc.

Fig. 6: Loosening Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 7: Removing Pressure Hoses

Courtesy of Audi of America, Inc.

Fig. 4: Moving Lock Carrier To Service Position

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78

2.7L V6 DOHC APB Engine S4 Quattro (Cont.)

Courtesy of Audi of America, Inc.

Fig. 8: Removing Accessory Drive Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 9: Aligning Crankshaft Timing Marks

Courtesy of Audi of America, Inc.

Fig. 11: Removing Vibration Damper

Courtesy of Audi of America, Inc.

Fig. 12: Removing Timing Belt Guard

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 10: Using Crankshaft Holding Tool

Fig. 13: Compressing Timing Belt Tensioner

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2.7L V6 DOHC APB Engine S4 Quattro (Cont.)

Courtesy of Audi of America, Inc.

Fig. 17: Routing Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 14: Installing Camshaft Locking Bar

Courtesy of Audi of America, Inc.

Fig. 18: Positioning Lock Carrier Torx Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Audi of America, Inc.

Fig. 15: Removing Camshaft Sprockets With Gear Puller

Application
Ft. Lbs. (N.m)
Bumper Combination Bolts ....................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 40 (55)
Crankshaft Damper Center Bolt ......................................................................... 1 147 (200)
Crankshaft Pulley Bolt ............................................................................................... 15 (20)
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)
Timing Belt Tensioner Bolt ........................................................................................ 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 16: Installing Timing Belt On Sprockets

Plus 190 degrees. Always use new bolt.

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80

2.8L V6 12-Valve
TIMING BELT APPLICATION
Application
2.8L V6
A4
1996-97 .....................................................
A4 Quattro
1996-97 .....................................................
A6
1995-97 .....................................................
1998 ...........................................................
A6 Quattro
1995-97 .....................................................
1998 ...........................................................
Cabriolet
1994-98 .....................................................
90 & 90 Quattro
1993-95 .....................................................
100 & 100 Quattro
1992-94 .....................................................

Labor Time

Belt
Part No.

4.9 Hours ... ..... T218

4.9 Hours ... ..... T218
3.4 Hours ... ..... T218
4.9 Hours ... ..... T297
3.4 Hours ... ..... T218
4.9 Hours ... ..... T297
2.5 Hours ... ..... T218
2.5 Hours ... ..... T218
2.5 Hours ... ..... T218

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Audi of America, Inc.

Fig. 1: Aligning Crankshaft Timing Marks

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 the belt be replaced at 60,000
mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of
rotation on accessory drive belt or timing belt. Damage may result
if belts are installed in opposite direction of rotation.
Removal 1) Disconnect negative battery cable. Remove accessory
drive 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.
2) 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 center of engine, rotate crankshaft one revolution.
3) 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. 2. Lightly tighten
crankshaft holder.
4) Remove crankshaft vibration damper. Remove lower timing belt
guard. Install Camshaft Holding Tool (Audi 3243). See Fig. 3. Loosen
camshaft sprocket bolts about 3 turns. DO NOT remove bolts. Remove
camshaft holder. Using puller, loosen camshaft sprockets. Loosen and
remove timing belt. See Fig. 4.

Courtesy of Audi of America, Inc.

Fig. 2: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 3: Using Camshaft Holding Tool

NOTE: Camshaft sprockets must be loose enough to rotate on
camshaft, but not loose enough to tilt.

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2.8L V6 12-Valve (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Bearing Cap Nut ....................................................................................... 11 (15)
Camshaft Sprocket Bolt ............................................................................................ 52 (71)
Crankshaft Damper Bolt ........................................................................................ 295 (400)
Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
INCH Lbs. (N.m)
Crankshaft Position (CKP) Sensor ........................................................................... 96 (10)
Valve Cover Bolt ........................................................................... ................... 53-89 (6-10)

Courtesy of Audi of America, Inc.

Fig. 4: Exploded View Of Timing Belt & Components

CAUTION: Camshaft sprockets are not keyed nor do they have
alignment marks. Alignment of camshafts for proper valve timing is
accomplished through the camshaft locking plates located on end
of camshaft, between camshaft sprocket and retaining bolts. The
larger hole on both of the camshaft locking plates should point
toward the center of the engine when number one cylinder is at
TDC (compression stroke). To properly align the camshafts, the
camshaft holder (3243) must be used.
Installation 1) Position timing belt over camshaft sprockets. See
Fig. 4. Install camshaft holder. Position timing belt over all sprockets,
then position over tensioner. Lightly tighten tensioner bolt (ensure
tensioner can be rotated by hand).
2) Tighten belt by rotating tensioner on bolt. Tighten belt until it can be
twisted 90 degrees by hand at midway point between right camshaft
sprocket and water pump pulley. Tighten tensioner bolt to specification.
See TORQUE SPECIFICATIONS.
3) Tighten camshaft sprocket bolts to specification. Remove camshaft
holding tool. Remove crankshaft holding tool. Install Crankshaft Position
(CKP) sensor. To install accessory drive belt, install mandrel. Position
accessory drive belt over drive sprockets and idler roller, then over
tensioner roller. Remove mandrel. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension. Connect
negative battery cable.

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2.8L V6 30-Valve
10) Remove lower timing belt guard (if equipped). Remove timing belt.

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

2.8L V6, 30-Valve (AHA & ATQ Engines)

A4 & A4 Quattro
1998-01 ..................................................... 5.2 Hours ... ..... T297
A6 & A6 Quattro, Non-Turbo
1998-01 ..................................................... 4.9 Hours ... ..... T297
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the belt be replaced at 90,000 mile intervals
for 1998 models, 75,000 mile intervals for 1999 models, and 105,000
miles on 2000-01 models.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Courtesy of Audi of America, Inc.

NOTE: Obtain radio anti-theft code before disconnecting battery.

Fig. 1: Exploded View Of Bumper Assembly (A4)

TIMING BELT
CAUTION: If reusing old timing belt, mark an arrow indicating
direction of rotation on accessory drive belt or timing belt. Damage
may result if belts are installed in opposite direction of rotation.
Removal 1) Disconnect negative battery cable. Remove engine top
cover. Working under vehicle, remove noise insulation panel from under
front of vehicle.
2) Remove front bumper. See Fig. 1 or 2. Remove air intake 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.
3) Hold cooling fan pulley with spanner wrench. Unscrew and remove
viscous cooling fan clutch from pulley. Viscous cooling fan is LEFTHAND threaded.
4) Use a 17-mm box wrench to turn serpentine belt tensioner counterclockwise to relieve belt tension and remove serpentine belt. If reusing
belt, mark belt rotation direction with arrow for reassembly reference.
5) Unclip left and right timing belt guards and remove. Turn crankshaft in
normal direction of rotation until TDC marks on crankshaft pulley and
timing belt cover are aligned. See Figs. 6 and 7.
6) Note securing plate on front end of each camshaft sprocket. Large
holes of securing plates on camshaft sprockets must face toward inside
and align. If large hole in each plate does not face inward, toward center
of engine, rotate crankshaft one revolution. See Fig. 8. Ensure crankshaft timing marks are still aligned.
NOTE: DO NOT turn crankshaft while checking for TDC mark.
Personal injury may result.
7) Remove sealing plug from left side of engine block. TDC mark on
crankshaft must be visible or be felt through sealing plug hole. Install
Crankshaft Holding Tool (Audi 3242) into sealing plug hole. See Fig. 9.
8) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley
clockwise to compress timing belt tensioner. See Fig. 10. 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.
9) Remove crankshaft vibration damper from crankshaft. It is NOT
necessary to remove center bolt. If center bolt is removed, manufacturer
recommends using NEW bolt on reassembly. Remove serpentine belt
idler pulley.

Courtesy of Audi of America, Inc.

Fig. 2: Exploded View Of Bumper Assembly (A6)

NOTE: Camshaft sprockets must be loose enough to rotate on
camshaft, but not loose enough to tilt.
Installation 1) Install Camshaft Locator Bar (3391) into locking plates
of camshafts. See Fig. 12. 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.
2) 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. 13.
Install Camshaft Locator Bar (3391) into locking plates of camshafts.
3) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner
so that 2-mm pin can be removed from tensioner.
4) 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 tension.

AUDI

83

2.8L V6 30-Valve (Cont.)

5) Tighten camshaft sprocket bolts to specification. See TORQUE
SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft
holder. Install sealing plug. To complete installation, reverse removal
procedure. When installing crankshaft pulley, ensure notches in pulley
are aligned with locating lugs in crankshaft. On A4, A6 and Quattro
models, ensure lock carrier-to-body Torx bolts are correctly positioned.
See Fig. 14.

Courtesy of Audi of America, Inc.

Fig. 5: Positioning Lock Carrier Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 3: Exploded View Of Lock Carrier Assembly (A4)

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Crankshaft Timing Marks (1 Of 2)

Courtesy of Audi of America, Inc.

Fig. 4: Exploded View Of Lock Carrier Assembly (A6)

Courtesy of Audi of America, Inc.

Fig. 7: Aligning Crankshaft Timing Marks (2 Of 2)

AUDI

84

2.8L V6 30-Valve (Cont.)

Courtesy of Volkswagen United States, Inc.

Courtesy of Audi of America, Inc.

Fig. 11: Marking Timing Chain & Sprockets

Fig. 8: Locating Camshaft Sprocket Holes

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 12: Installing Camshaft Locator Bar

Fig. 9: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 13: Identifying Timing Belt Routing

Courtesy of Audi of America, Inc.

Fig. 10: Compressing Timing Belt Tensioner

AUDI

85

2.8L V6 30-Valve (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 40 (55)
Crankshaft Pulley-To-Crankshaft Hex Bolt ............................................................... 15 (20)
Crankshaft Pulley Center Bolt ............................................................... 1 148 (200) + 180
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)
Lock Carrier-To-Body Torx Bolts ............................................................................... 89 (10)
Timing Belt Tensioner Bolt/Nut ................................................................................. 89 (10)
Water Pump Bolt ....................................................................................................... 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 14: Positioning Lock Carrier Torx Bolts

If removed, manufacturer recommends using NEW bolt.

AUDI

86

3.0L V6 AVK Engine A4 & A6

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 (AVK Engine)

A4 Avant & Sedan
2002-04 ..................................................... 5.4 Hours ... ..... T330
A4 Cabriolet
2003-04 ..................................................... 5.4 Hours ... ..... T330
A6
2002-04 ..................................................... 5.8 Hours ... ..... T330
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends belt be replaced at 105,000 miles under
normal driving conditions, 52,500 miles under severe driving conditions.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools. This will
allow servicing of front engine components. Lock carrier can be
removed at technicians discretion.

CAUTION: Before removing ribbed belt, mark direction of rotation

with chalk or felt-tip marker. Reversing the direction of rotation of
a run-in belt can destroy the belt.
13) Remove front engine cover. See Fig. 12. Using Ribbed Belt
Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner
in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of
power steering pump.
14) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear
of power steering vane pump (arrows) using 3212 spanner wrench as
retainer. See Fig. 15.
NOTE: Thrust washer is only installed on timing belt gear with part
number 06C 105 063. Thrust washer is NOT installed for timing belt
gear with part number 06C 105 063 B.
15) Remove 8 bolts attaching harmonic balancer to crankshaft and
remove balancer. Remove thrust washer if equipped.
16) Without disconnecting coolant hoses, remove bolts (1, 2) attaching
front coolant pipe (3) and remove timing belt guards (4, 5, 6). See
Fig. 16.
17) Remove rear engine cover at rear of intake manifold. Remove screw
attaching expansion tank to vehicle. Disconnect Engine Coolant Level
(ECL) warning switch harness connector at bottom of expansion tank.
Without disconnecting coolant hoses, tie expansion tank off to side.
18) Disconnect Mass Air Flow (MAF) sensor harness connector (1). See
Fig. 17. Remove air guide hose (2) together with MAF sensor. Remove
air filter housing (arrows).
19) Remove bolts (1) and (3). See Fig. 18. Disconnect hose (4) from line
of secondary air injection. Pull out guide tube for oil dipstick (2) from the
oil pan (upper part) toward top and swing it forward for removal.
20) Remove ignition coils from right valve cover. Remove hose of
crankshaft housing ventilation located at rear of valve cover. Remove
bolts for right valve cover in the sequence 12-1 and remove valve cover.
See Fig. 19. Repeat procedure for left valve cover. See Fig. 20.

NOTE: To ease repair work, remove front noise insulation completely.

CAUTION: Turning of the engine must only occur in direction of

engine rotation (clockwise) at the crankshaft.

Removal (A4) 1) Raise vehicle, remove front tires. Remove bolts and
quick release screws (1 and 2). See Fig. 1. Rear noise insulation (3)
remains installed.
2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of
parking/auxiliary heater at noise insulation. See Fig. 2.
3) Remove right cover in engine compartment. Unbolt air guide between
lock carrier and air filter on lock carrier. Remove left cover in engine
compartment. Pull off hood seal from lock carrier and fender edges.
4) Loosen left and right wheelhousing liners in front area. See Fig. 3. Pull
back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip
bumper rear edge from catch (arrow B). See Fig. 4. Repeat procedure
on opposite side of the vehicle.
5) Release catches (1-4) using a screwdriver and remove air inlet grille
on left and right on bottom part of bumper. See Fig. 5. Remove left and
right retaining bolts until bumper is fully released. See Fig. 6.
6) If installed, disconnect hose (1) to headlight cleaning system.
Disconnect harness connectors (2) and remove bumper. See Fig. 7.
7) Inspect headlight and turn signal electrical connectors and wiring
harness (which may hang up when lock carrier is moved forward).
8) On right side, remove bolt (5) and install support tool (3369) in its
place. See Figs. 8 and 9.
9) On left side, install support tool (3369) in threaded hole in chassis.
See Fig. 10 .
10) Remove on both sides, all bolts (2). See Fig. 8.
11) Remove on both sides, all bolts (3 and 4). See Fig. 8. Slide lock
carrier forward unit the rear bolt hole in lock carrier aligns with the
forward threaded fender bolt hole.
12) Secure lock carrier in this position, by placing fender bolts in holes.
See Fig. 11. To install, reverse placing in service position procedure.

21) Turn engine at crankshaft central bolt. Turn engine until the cams
(arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder
bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster
Gauge (T40030) at camshafts of right cylinder head. See Fig. 22.
22) Slightly turn crankshaft back and forth so that the claw of camshaft
adjuster gauge can properly grab the camshafts. Spread and tighten
camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until
seated without axial play. Repeat procedure for left cylinder head.
23) If installed, disconnect after-run coolant pump harness connector.
Remove sealing plug of TDC mark at cylinder block. Install Locking Pin
(T40026) into the hole of the removed sealing plug and tighten. See
Fig. 23. Slightly turn crankshaft back and forth to allow locking pin to
bottom in crankshaft properly.
NOTE: During next step, catch escaping oil using a rag.
24) Pry off securing rings (1) for caps (2) at all camshaft gears. See
Fig. 24. Loosen but do not remove bolts for camshaft gears.
CAUTION: If reusing timing belt, mark rotational direction of belt.
Reversing the direction can ruin timing belt.
25) Using an 8 mm hex socket wrench, turn timing belt tensioner in
direction of arrow until tensioning lever pushes the tensioner together far
enough so pin (T40011) can be inserted into the bore of the piston and
housing of tensioner. See Fig. 25. The timing belt tensioner is oildampened. Compress it by slowly applying constant pressure. Loosen
bolt of eccentric pulley on opposite side of tensioner and remove timing
belt.
Removal (Cabriolet) 1) Loosen bolts or quick release fasteners (1
and 2). See Fig. 26. The rear noise insulation quick-release fasteners (3)
remain installed. The quick-release fasteners remain in bumper cover
(1).

AUDI

87

3.0L V6 AVK Engine A4 & A6 (Cont.)

2) Loosen the wheel housing liners on left and right at front. Pull the
wheel housing liner back. Remove the bolt (2) and nuts (1). See Fig. 27.
Unclip bumper extension from catch (B).
3) Remove bolts and tilt front grille slightly forward and pull it out in an
upward direction from bumper cover. Remove bolts (1-8) and pull side
extensions out of guide piece. See Fig. 28. Pull bumper cover forward
slightly.
4) If equipped, disconnect hose for headlight washer unit. Disconnect
connector(s) and remove bumper cover from vehicle.
5) Remove left and right engine compartment covers. Remove air duct
between lock carrier and air cleaner (air duct is bolted to lock carrier).
Install Lock Carrier Support Tool (3369) into thread on left and right side
near impact absorbers. See Figs. 9 and 29.
6) Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier
forward until rear hole in lock carrier aligns with front threaded hole in
fender flange. See Fig. 11.
CAUTION: Before removing ribbed belt, mark direction of rotation
with chalk or felt-tip marker. Reversing the direction of rotation of
a run-in belt can destroy the belt.
7) Remove front engine cover. See Fig. 12. Using Ribbed Belt Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner in
direction of arrow. See Fig. 13. Remove ribbed belt from pulley of power
steering pump.
8) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear
of power steering vane pump (arrows) using 3212 spanner wrench as
retainer. See Fig. 15. Remove 8 bolts attaching harmonic balancer to
crankshaft and remove balancer. Remove thrust washer if equipped.
NOTE: Thrust washer is only installed on timing belt gear with part
number 06C 105 063. Thrust washer is NOT installed for timing belt
gear with part number 06C 105 063 B.
9) Without disconnecting coolant hoses, remove bolts (1, 2) attaching
front coolant pipe (3) and remove timing belt guards (4, 5, 6). See
Fig. 16.
10) Remove rear engine cover at rear of intake manifold. Remove screw
attaching expansion tank to vehicle. Disconnect electrical wiring to
Engine Coolant Level (ECL) warning switch at bottom of expansion tank.
Without disconnecting coolant hoses, tie expansion tank off to side.
11) Disconnect electrical harness connector (1) at Mass Air Flow (MAF)
sensor. See Fig. 17. Remove air guide hose (2) together with Mass Air
Flow (MAF) sensor. Remove air filter housing (arrows).
12) Remove bolts (1) and (3). See Fig. 18. Disconnect hose (4) from line
of secondary air injection. Pull out guide tube for oil dipstick (2) from the
oil pan (upper part) toward top and swing it forward for removal.
13) Remove ignition coils from right valve cover. Remove hose of
crankshaft housing ventilation located at rear of valve cover. Remove
bolts for right valve cover in the sequence 12 to 1 and remove valve
cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20.
CAUTION: Turning of the engine must only occur in direction of
engine rotation (clockwise) at the crankshaft.
14) Turn engine at crankshaft central bolt. Turn engine until the cams
(arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder
bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster
Gauge (T40030) at camshafts of right cylinder head. See Fig. 22.
15) Slightly turn crankshaft back and forth so that the claw of camshaft
adjuster gauge can properly grab the camshafts. Spread and tighten
camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until
seated without axial play. Repeat procedure for left cylinder head.
16) If installed, disconnect electrical harness connector at after-run
coolant pump. Remove sealing plug of TDC mark at cylinder block.
Install Locking Pin (T40026) into the hole of the removed sealing plug
and tighten. See Fig. 23. Slightly turn crankshaft back and forth to allow
locking pin to bottom in crankshaft properly.

NOTE: During next step, catch escaping oil using a rag.

17) Pry off securing rings (1) for caps (2) at all camshaft gears. See
Fig. 24. Loosen but do not remove bolts for camshaft gears.
CAUTION: If reusing timing belt, mark rotational direction of belt.
Reversing the direction can ruin timing belt.
18) Using an 8 mm hex socket wrench, turn timing belt tensioner in
direction of arrow until tensioning lever pushes the tensioner together far
enough so pin (T40011) can be inserted into the bore of the piston and
housing of tensioner. See Fig. 25. The timing belt tensioner is oildampened. Compress it by slowly applying constant pressure. Loosen
bolt of eccentric pulley on opposite side of tensioner and remove timing
belt.
NOTE: It is not necessary to completely remove noise insulation
from beneath the engine. Only remove the quick release fasteners
that attach to the front bumper assembly.
Removal (A6) 1) Raise and support vehicle. Remove front tires.
Remove lower front engine shield (noise insulator). See Fig. 30. Loosen
front half of wheel housing splash shield (liner). See Fig. 31. Remove
flange nut (10) on both sides. See Fig. 32.
2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of
parking/auxiliary heater at noise insulation. See Fig. 2.
3) Remove right cover in engine compartment. Unbolt air guide between
lock carrier and air filter on lock carrier. Remove left cover in engine
compartment. Pull off hood seal from lock carrier and fender edges.
4) Release catches (1-4) using a screwdriver and remove air inlet grille
on left and right on bottom part of bumper. See Fig. 5. Remove left and
right retaining bolts until bumper is fully released. See Fig. 6.
5) Remove screw with washer assembly (6) from wheel housing liner
(5). See Fig. 32. Disconnect any wiring harness that attach to the front
bumper. Remove socket-head bolts (7) and remove bumper cover
together with impact absorber towards front. See Fig. 32.
6) Inspect headlight and turn signal harness connectors and wiring
harness (which may hang up when lock carrier is moved forward).
7) On right side, remove bolt (5) and install support tool (3369) in its
place. See Figs. 8 and 9.
8) On left side, install support tool (3369) in threaded hole in chassis.
See Fig. 10.
9) Remove on both sides, all (2, 3 and 4) bolts. See Fig. 8. Slide lock
carrier forward unit the rear bolt hole in lock carrier aligns with the
forward threaded fender bolt hole.
10) Secure lock carrier in this position, by placing fender bolts in holes.
See Fig. 11. To install, reverse placing in service position procedure.
CAUTION: Before removing ribbed belt, mark direction of rotation
with chalk or felt-tip marker. Reversing the direction of rotation of
a run-in belt can destroy the belt.
11) Remove front engine cover. See Fig. 12. Using Ribbed Belt
Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner
in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of
power steering pump.
NOTE: Thrust washer is only installed on timing belt gear with part
number 06C 105 063. Thrust washer is NOT installed for timing belt
gear with part number 06C 105 063 B.
12) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear
of power steering vane pump using 3212 spanner wrench as retainer.
See Fig. 15. Remove 8 bolts attaching harmonic balancer to crankshaft.
Remove thrust washer.
13) Without disconnecting coolant hoses, remove bolts (1 and 2)
attaching front coolant pipe (3) and remove timing belt guards (4, 5, and
6). See Fig. 16.
14) Remove rear engine cover at rear of intake manifold. Remove screw
attaching expansion tank to vehicle. Disconnect Engine Coolant Level
(ECL) warning switch harness connector at bottom of expansion tank.
Without disconnecting coolant hoses, tie expansion tank off to side.

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3.0L V6 AVK Engine A4 & A6 (Cont.)

15) Disconnect Evaporative Emission (EVAP) Canister Purge Regulator
Valve (1) at air filter housing. Disconnect Mass Air Flow (MAF) sensor
harness connector (2). See Fig. 35. Remove air guide hose (3) together
with MAF sensor. Remove air filter housing (arrows).
16) Remove bolts (1 and 3). See Fig. 18. Disconnect hose (4) from line
of secondary air injection. Pull out dipstick tube (2) from the oil pan
(upper part) toward top and swing it forward for removal.
17) Remove ignition coils from right valve cover. Remove hose of
crankshaft housing ventilation located at rear of valve cover. Remove
bolts for right valve cover in the sequence 12 to 1 and remove valve
cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20.
CAUTION: Turning of the engine must only occur in direction of
engine rotation (clockwise) at the crankshaft.
18) Turn engine at crankshaft central bolt. Turn engine until the cams
(arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder
bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster
Gauge (T40030) at camshafts of right cylinder head. See Fig. 22.
19) Slightly turn crankshaft back and forth so that the claw of camshaft
adjuster gauge can properly grab the camshafts. Spread and tighten
camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until it
is seated without axial play.
20) Repeat procedure for left cylinder head. If installed, disconnect
electrical harness connector at after-run coolant pump. Remove sealing
plug of TDC mark at cylinder block. Install Locking Pin (T40026) into the
hole of the removed sealing plug and tighten. See Fig. 23. Slightly turn
crankshaft back and forth to allow locking pin to bottom in crankshaft
properly.
NOTE: During next step, catch escaping oil using a rag.
21) Pry off securing rings (1) for caps (2) at all camshaft gears. See
Fig. 24. Loosen but do not remove bolts for camshaft gears.
CAUTION: Mark rotational direction of timing belt. Reversing the
direction in which it runs can ruin it.
22) Using an 8 mm hex socket wrench, turn timing belt tensioner in
direction of arrow until tensioning lever pushes the tensioner together far
enough so pin (T40011) can be inserted into the bore of the pistons and
housing. See Fig. 25. The timing belt tensioner is oil-dampened.
Compress it by slowly applying constant pressure. Loosen bolt of
eccentric pulley on opposite side of tensioner and remove timing belt.
CAUTION: Before installation, ensure camshafts are aligned,
crankshaft is locked in place and camshaft gear bolts are loose as
described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons
may be damaged.
Installation (A4) 1) Ensure bolts (1-4) attaching camshaft gears are in
far enough to allow camshaft gears to spin freely without wobbling. See
Fig. 36. Install timing belt. For exact valve timing adjustment, the timing
belt must make exact contact with front edge of all timing belt gears.
2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise
direction until the handle of the pin wrench is exactly above the center
axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this
position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench
horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45
N.m) in direction of arrow to pre-tension timing belt. See Fig. 38.
3) Using 8 mm socket head wrench, turn timing belt tensioning roller in
opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25.
Place torque wrench horizontally on socket-head of tensioning lever.
Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt.
See Fig. 38.
4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on
left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs.
(10 N.m) up to stop. See Fig. 39. Turn rotor of camshaft adjuster at right
cylinder bank clockwise to 7.5 ft. lbs. (10 N.m) up to stop. Torque bolts
for all four camshaft gears to 74 ft. lbs. (100 N.m).

5) Insert caps with new O rings at camshaft gears and secure with ring.
Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove
Alignment Bolt (T10026) and install sealing plug of TDC marking with
new O ring into cylinder block. See Fig. 23. Install valve covers and
tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See
Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to
specification. See TORQUE SPECIFICATIONS.
6) To install lock carrier, reverse removal procedures outlined in
REMOVAL (A4). Torque all fasteners to specification. See TORQUE
SPECIFICATIONS. Let support stop rest on rubber buffer for torque
support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See
Fig. 40.
NOTE: Before installing bumper, check for the presence of
threaded pins at bumper rear edge as well as expanding clips and
sleeves in the fenders. Always replace bumper retaining bolts.
7) Slide bumper onto impact absorber and re-connect hose (1) of
headlight cleaning system and electrical harness connectors (2). See
Fig. 7. Move bumper into installation position. Make sure threaded pins
in bumper side edges engage into holes at the fenders. Install bumper
retaining bolts until bumper can stay in place without any assistance.
8) Do not tighten completely allowing for any necessary adjustments.
Pull back wheelhousing liner (arrow A). See Fig. 3. Engage bumper rear
edge into catch (arrow B). Torque nuts. Repeat procedure on opposite
side of the vehicle. Torque left and right retaining bolts to specification.
See TORQUE SPECIFICATIONS. Install left and right air inlet grille on
bumper. Remainder of installation is the reverse of removal.
CAUTION: Before installation, ensure camshafts are aligned,
crankshaft is locked in place and camshaft gear bolts are loose as
described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons
may be damaged.
Installation (Cabriolet) 1) Ensure bolts (1-4) attaching camshaft
gears are in far enough to allow camshaft gears to spin freely without
wobbling. See Fig. 36. Install timing belt. For exact valve timing
adjustment, the timing belt must make exact contact with front edge of
all timing belt gears.
2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise
direction until the handle of the pin wrench is exactly above the center
axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this
position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench
horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45
N.m) in direction of arrow to pre-tension timing belt. See Fig. 38.
3) Using 8 mm socket head wrench, turn timing belt tensioning roller in
opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25.
Place torque wrench horizontally on socket-head of tensioning lever.
Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt.
See Fig. 38.
4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on
left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs.
(10 N.m) up to stop. See Fig. 39. Turn rotor of camshaft adjuster at right
cylinder bank clockwise to 7.5 ft. lbs. (10 N.m) up to stop. Torque bolts
for all four camshaft gears to 74 ft. lbs. (100 N.m).
5) Insert caps with new O rings at camshaft gears and secure with ring.
Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove
Alignment Bolt (T10026) and install sealing plug of TDC marking with
new O ring into cylinder block. See Fig. 23. Install valve covers and
tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See
Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to
specification. See TORQUE SPECIFICATIONS.
6) To install lock carrier, reverse removal procedures outlined in
REMOVAL (CABRIOLET). Torque all fasteners to specification. See
TORQUE SPECIFICATIONS.

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3.0L V6 AVK Engine A4 & A6 (Cont.)

NOTE: Prior to installation of the bumper cover check for presence
of threaded pins (2) at the bumper extensions as well as grommets
(3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m).
7) To install bumper cover, reverse removal procedures outlined in
REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and
connect the hose of headlight washer unit as necessary. Reconnect
connectors as necessary. Ensure that the threaded pins in the bumper
side extensions engage in the holes at the fender.
8) Clip in side extensions and fasten using the bolts (8). See Fig. 28.
Loosely screw in bolt (3). Tighten bolts (2 and 4) to 48 INCH lbs. (6 N.m),
and bolts (5, 6 and 7) to 24 INCH lbs. (3 N.m). Close hood and check
overlap or gap dimension of bumper cover with respect to the hood. If
OK, tighten all the bolts. If not, open hood and loosen bolts (2 or/and 4)
to correct upper bumper as required. Tighten bolt (3) to 48 INCH lbs. (6
N.m).
9) Verify fender gaps as follow: A = 2 mm 0.5 mm, B = 0 mm 0.5 mm
and C = 0 mm 0.5 mm. See Fig. 41. Gap dimensions can be checked
using Audi special tool (3371). Adjust gaps as necessary. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Remainder
of installation is the reverse of removal.
CAUTION: Before installation, ensure camshafts are aligned,
crankshaft is locked in place and camshaft gear bolts are loose as
described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons
may be damaged.
Installation (A6) 1) Ensure bolts (1-4) attaching camshaft gears are in
far enough to allow camshaft gears to spin freely without wobbling. See
Fig. 36. Install timing belt. For exact valve timing adjustment, the timing
belt must make exact contact with front edge of all timing belt gears.
2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise
direction until the handle of the pin wrench is exactly above the center
axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this
position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench
horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45
N.m) in direction of arrow to pre-tension timing belt. See Fig. 38.
3) Using 8 mm socket head wrench, turn timing belt tensioning roller in
opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25.
Place torque wrench horizontally on socket-head of tensioning lever.
Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt.
See Fig. 38.
4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on
left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs.
(10 N.m) up to stop. See Fig. 39. Repeat for right cylinder bank. Torque
bolts for all four camshaft gears to 74 ft. lbs. (100 N.m).
5) Insert caps with new O rings at camshaft gears and secure with ring.
Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove
Alignment Bolt (T10026) and install sealing plug of TDC marking with
new O ring into cylinder block. See Fig. 23. Install valve covers and
tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See
Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to
specification. See TORQUE SPECIFICATIONS.
6) To install lock carrier, reverse removal procedures outlined in
REMOVAL (A6). Torque all fasteners to specification. See TORQUE
SPECIFICATIONS. Let support stop rest on rubber buffer for torque
support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See
Fig. 40.
7) Before installing the bumper, ensure the expanding clips are pressed
into the fender. See Fig. 42. When installing the tabs, the bumper cover
must latch into clip (4). See Fig. 32.
8) Latch bumper cover (1) into guide (2). See Fig. 32. Torque flange nuts
(10) to 53 INCH lbs. (6 N.m).

NOTE: The impact absorber is installed vertical to the cross member and has height compensating elements. See Fig. 33.
9) Torque left and right retaining bolts to specification. See TORQUE
SPECIFICATIONS. Install left and right air inlet grille on bumper.
Remainder of installation is the reverse of removal.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Under-Car Noise Insulation (A4)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 3: Locating Wheelhousing Fasteners (A4)

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Front Bumper-To-Fender Fasteners (A4)

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Lock Carrier Components (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 5: Removing Grilles (A4 & A6)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Support Tool (Part No. 3369)

Courtesy of Audi of America, Inc.

Fig. 6: Identifying Bumper Fasteners (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Washer Hoses & Harness Connectors (A4)

AUDI

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position

Courtesy of Audi of America, Inc.

Fig. 14: Identified Ribbed Belt Tensioner Bolts

Courtesy of Audi of America, Inc.

Fig. 12: Identifying Front Engine Cover

Courtesy of Audi of America, Inc.

Fig. 15: Removing/Installing Power Steering Vane Pump Pulley

Courtesy of Audi of America, Inc.

Fig. 13: Removing/Installing Ribbed Belt

Courtesy of Audi of America, Inc.

Fig. 16: Identifying Timing Belt Guards

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 17: Air Filter Housing Components

Courtesy of Audi of America, Inc.

Fig. 20: Left Valve Cover Bolt Sequence

Courtesy of Audi of America, Inc.

Fig. 21: Lining Up Cylinder #3 Camshaft Lobes

(Right Cylinder Bank)

Courtesy of Audi of America, Inc.

Fig. 18: Identifying Secondary Air Injection Component

Courtesy of Audi of America, Inc.

Fig. 22: Installing Cam Adjuster Gauge On Cam Lobes

(Right Bank Shown; Left Bank Similar)

Courtesy of Audi of America, Inc.

Fig. 19: Right Valve Cover Bolt Sequence

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 23: Installing Locking Pin Into Cylinder Block

Courtesy of Audi of America, Inc.

Fig. 26: Identifying Bumper Cover Fasteners (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 24: Removing Securing Rings

Courtesy of Audi of America, Inc.

Fig. 27: Identifying Bumper Cover Fasteners At Wheel Opening

(Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 25: Compressing & Securing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 28: Removing Bumper Cover (Cabriolet)

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 29: Exploded View Of Lock Carrier Components (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 30: Identifying Lower Engine Shield (Noise Insulator)

Mounting Points (A6)

Courtesy of Audi of America, Inc.

Fig. 31: Identifying Wheel Housing Liner Components (A6)

AUDI

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 32: Identifying Front Bumper Components (A6)

Courtesy of Audi of America, Inc.

Fig. 34: Identifying Bumper Guide Components (A6)

Courtesy of Audi of America, Inc.

Fig. 33: Identifying Bumper Attaching Point To Impact Absorber (A6)

AUDI

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3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 35: Identifying EVAP & MAF Connectors (A6)

Courtesy of Audi of America, Inc.

Fig. 36: Timing Belt Routing (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 38: Adjusting Timing Belt Tension (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 39: Preloading Camshaft Adjuster (Left Shown;

Right Is Similar A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 40: Identifying Torque Support Bolts (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 37: Adjusting Eccentric Pulley (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 41: Bumper Cover Gaps (Cabriolet)

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3.0L V6 AVK Engine A4 & A6 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Pulley Power Steering Vane Pump Bolts ......................................................... 17 (23)
Bumper-To-Long Member Bolts ................................................................................ 37 (50)
Camshaft Gear-To-Camshaft Bolts ......................................................................... 74 (100)
Eccentric Pulley-To-Front Sealing Flange Bolt ......................................................... 33 (45)
Harmonic Balancer Bolts .......................................................................................... 17 (23)
Impact Absorber Bolts ............................................................................................... 37 (50)
Ribbed Belt Tensioner-To-Cylinder Block
M8 Bolts .................................................................................................................. 17 (23)
M10 Bolts ................................................................................................................ 30 (40)
Sealing Plug In Cylinder Block ................................................................................. 18 (25)
Torque Support Lock-To-Lock Carrier Bolts ............................................................. 21 (28)
Wheel Bolt ............................................................................................................... 89 (120)
INCH Lbs. (N.m)
Bumper-To-Fender Bolts ...........................................................................................
Front Coolant Pipe Bolts ...........................................................................................
Timing Belt Guard Bolts 1 .........................................................................................
Valve Cover Bolts ......................................................................................................
1

Courtesy of Audi of America, Inc.

Fig. 42: Identifying Bumper Cover Attaching Points For

Removal & Installation (A6)

Use NEW bolts.

89
89
89
89

(10)
(10)
(10)
(10)

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3.6L & 4.2L V8 1990-94

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.6L V8 (PT Engine)

V8 Quattro
1990-91 ..................................................... 4.3 Hours ... ..... T207
4.2L V8 (ABH Engine)
V8 Quattro
1992-94 ..................................................... 4.3 Hours ... ..... T207
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

REMOVAL & INSTALLATION

11) Noting positions for reassembly, disconnect ignition secondary wires

at ignition coils. Remove both ignition distributor caps.
12) Rotate crankshaft to TDC of compression stroke. Ensure TDC mark
on crankshaft pulley aligns with mark on timing belt cover. See Fig. 10.
13) Ensure distributor rotor points to mark on distributor housing. If not,
turn crankshaft one more revolution. See Fig. 11. Remove both distributors.
14) 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 engine block). See Fig. 13. Remove
timing belt damper top bolt. Remove timing belt tensioner pulley with
eccentric center.
15) Fit Locating Flange (3199) at end of each camshaft. Locating pin on
distributor flange should fit in slot in locating flange. See Fig. 14. Secure
locating flange with distributor mounting bolts.
16) Using spanner wrench, hold camshaft sprocket. Loosen camshaft
sprocket bolts about 2 turns. DO NOT use Locating Flange (3199) to
hold camshaft while loosening sprocket bolt.
17) Using a plastic hammer, LIGHTLY tap edge of camshaft sprockets
until camshaft sprockets are loose. Remove camshaft sprocket Woodruff keys.
18) Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket.
Remove crankshaft center bolt and remove crankshaft pulley. It is not
necessary to remove sprocket from crankshaft. Remove timing belt.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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.
Removal 1) Disconnect negative battery cable. Battery is under rear
seat. Remove noise insulation panel from under front of vehicle.
Remove coolant expansion tank cap. Drain coolant from radiator.
Remove alternator cooling air duct. See Fig. 1. Loosen clip and
disconnect coolant temperature sensor harness connector.
2) 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. 2 and 3.
Remove alternator and set aside.
3) 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.
4) 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.
5) 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.
6) Disconnect fan shrouds for viscous fan and electric fan.
7) Hold viscous cooling fan mount with a spanner wrench. Loosen
viscous cooling fan by turning clockwise. Viscous cooling fan is LEFTHAND threaded. See Fig. 5. Lift out fan and shroud.
8) Remove front engine support mount. Note number and position of
shims for reassembly. Remove lower radiator hose. Loosen center bolt
of crankshaft pulley one turn while using Crankshaft Pulley Holder
(3197). See Fig. 6.
9) Remove flanged nuts and left side timing belt cover. See Fig. 7.
Remove lower radiator hose support from front of engine.
10) Turn serpentine belt tensioner clockwise and insert Setting Tool
(3204) below mounting bolt. See Figs. 8 and 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.

Courtesy of Audi of America, Inc.

Fig. 1: Locating Coolant Temperature Sensor

Inspection Inspect tensioner and idler pulley for ease of rotation and
rough bearings. Replace as necessary.
Installation 1) 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.
2) Apply locking sealant (AMV 188 0012), or equivalent, to crankshaft
center bolt threads. Install crankshaft pulley center bolt and hand tighten
temporarily.
3) Loosen camshaft sprocket center bolts by about 1 turn. Camshaft
sprocket should still be loose on camshaft. Install 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.
4) Position timing belt in position over idler pulleys, water pump pulley
and camshaft sprockets. Install tensioner pulley with eccentric center.
Leave center nut loose so that eccentric can be turned. Fully tighten 4
crankshaft pulley bolts to specification. See TORQUE SPECIFICATIONS.
5) 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.
6) On 3.6L and 4.2L engines, set basic timing belt tension by turning
tensioner pulley with eccentric center in clockwise direction. Use span-

AUDI

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3.6L & 4.2L V8 1990-94 (Cont.)

ner wrench to turn eccentric. Turn eccentric until damper length is at
specified dimension. See Fig. 17. Tighten tensioner pulley center nut to
specification. See TORQUE SPECIFICATIONS.
7) 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.
8) Ensure timing belt damper length is still correct. Readjust, if necessary. On 3.6L engine, tighten stop plate mounting bolt to specification.
See TORQUE SPECIFICATIONS. Remove Adjusting Tool (3204).
9) On 3.6L and 4.2L engines, to complete installation, reverse removal
procedure. When refilling cooling system, manufacturer recommends
using Audi anti-freeze (Part No. G 001 1V8A). Use 50/50 mix of coolant
and water.
10) To bleed air from cooling system, turn on ignition with engine off. Set
A/C controls to high. Open radiator expansion tank. Fill with coolant
while squeezing upper hoses to allow trapped air to escape. Install
expansion tank cap.
11) 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 coolant level to MAX mark. Restart engine and repeat topping off
procedure. Adjust drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 2: Exploded View Of Serpentine Belt Assembly

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3.6L & 4.2L V8 1990-94 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 5: Removing Viscous Cooling Fan (Left-Hand Thread)

Courtesy of Audi of America, Inc.

Fig. 3: Removing Serpentine Belt

Courtesy of Audi of America, Inc.

Fig. 6: Loosening Crankshaft Pulley Center Bolt

Courtesy of Audi of America, Inc.

Fig. 4: Removing Electric Cooling Fan

Courtesy of Audi of America, Inc.

Fig. 7: Removing Left Side Timing Belt Cover

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3.6L & 4.2L V8 1990-94 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 8: Exploded View Of Timing Belt Assembly

Courtesy of Audi of America, Inc.

Fig. 10: Aligning Crankshaft Pulley Timing Marks

Courtesy of Audi of America, Inc.

Fig. 9: Positioning Serpentine Belt Tension

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3.6L & 4.2L V8 1990-94 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 11: Aligning Distributor Rotor To Housing

Courtesy of Audi of America, Inc.

Fig. 14: Positioning Camshafts With Locating Flange (3199)

Courtesy of Audi of America, Inc.

Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate

(3.6L Engine)
Courtesy of Audi of America, Inc.

Fig. 12: Identifying Timing Belt Routing

Courtesy of Audi of America, Inc.

Fig. 13: Timing Belt Tensioner With Eccentric Center

Courtesy of Audi of America, Inc.

Fig. 16: Rotating Tensioner Lever In Direction Of Arrow

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3.6L & 4.2L V8 1990-94 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Bottom Mount Bolt ................................................................................... 18 (25)
Alternator Top Mounting Bolt .................................................................................... 33 (45)
Camshaft Sprocket 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)
Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25)
Timing Belt Tensioner Nut ........................................................................................ 18 (25)
INCH Lbs. (N.m)

Courtesy of Audi of America, Inc.

Fig. 17: Setting Timing Belt Damper Length

Fan Shroud Bolts ......................................................................................................

Stop Plate Mounting Bolt (3.6L) ...............................................................................
Timing Belt Cover Flanged Nut ................................................................................
Water Pump Bolts .....................................................................................................
1

Install with thread locking sealant AMV 18800102.

89
89
89
89

(10)
(10)
(10)
(10)

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3.7L & 4.2L V8 1997-99

TIMING BELT APPLICATION
Application

TIMING BELT
Labor Time

Belt
Part No.

3.7L V8 (AEW Engine)

A8
1997-99 ..................................................... 4.9 Hours ... ..... T207
4.2L V8 (ABZ Engine)
A8 Quattro
1997-99 ..................................................... 4.9 Hours ... ..... T207
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1997 and 1998 model vehicles, manufacturer recommends belt be
replaced at 90,000 miles. For 1999 model year, the manufacturer
recommends the belt be replaced at 75,000 miles.

REMOVAL & INSTALLATION

CAUTION: If serpentine or timing belt are being reused, mark belt

with an arrow indicating direction of rotation. Damage may result if
belts are installed in opposite direction of rotation.
Removal 1) Disconnect negative battery cable. Remove noise insulation panel from under front of vehicle. Remove air intake grille from
front of bumper. Drain coolant from radiator.
2) Using box wrench, turn serpentine belt tensioner clockwise 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.
3) Remove air intake duct between air cleaner and throttle body.
Disconnect fan shrouds for viscous fan and electric fan.
4) Hold viscous cooling fan pulley with a spanner wrench. Remove
viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded.
See Fig. 2.
5) Remove right front engine mount. See Fig. 3. Remove coolant hoses
at front of engine. Rotate crankshaft to TDC of compression stroke.
Ensure TDC mark on crankshaft pulley aligns with mark on timing belt
cover. See Fig. 4.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Serpentine Belt Assembly

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3.7L & 4.2L V8 1997-99 (Cont.)

CAUTION: Manufacturer recommends that crankshaft pulley center bolt be REPLACED whenever the bolt is loosened or removed.
6) 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 revolution. Remove camshaft flange at rear of right side cylinder
head.
7) Disconnect harness connector from switch for intake manifold
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.
8) Holding camshaft sprocket with Sprocket Holder (3036), loosen
camshaft sprocket bolts. See Fig. 7. Remove camshaft 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 removing the
valve cover and using the hex machined into the front end of the
camshaft.

Courtesy of Audi of America, Inc.

Fig. 3: Removing Right Front Engine Mount

CAUTION: The Camshaft Locking Devices (3341) are NOT to be

used to hold camshafts in place when loosening or tightening the
camshaft sprocket bolts.
9) 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.
10) Remove timing belt from camshaft sprockets. LIGHTLY strike edge
of camshaft sprockets with plastic hammer to loosen sprocket from
tapered ends of camshafts.
11) Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket.
Remove crankshaft center bolt and remove crankshaft pulley. It is not
necessary to remove sprocket from crankshaft. Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Crankshaft Pulley TDC Marks

Courtesy of Audi of America, Inc.

Fig. 5: Loosening Crankshaft Pulley Center Bolt

Courtesy of Audi of America, Inc.

Fig. 2: Removing Viscous Cooling Fan (Left-Hand Thread)

Installation 1) 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.
CAUTION: Manufacturer recommends that crankshaft pulley center bolt be REPLACED whenever the bolt is loosened or removed.
2) 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.

3) 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.
4) Push timing belt over tensioner pulley. Tighten tensioner pulley center
nut hand tight. Eccentric insert should still be able to turn.
5) Tighten 4 crankshaft pulley-to-crankshaft sprocket mounting nuts.
See TORQUE SPECIFICATIONS.
6) To set basic timing belt tension, turn tensioner pulley eccentric 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 specified range. See Fig. 11.
7) Tighten timing belt tensioner center nut to specification. See
TORQUE SPECIFICATIONS. Holding camshaft sprockets in place,
tighten camshaft sprocket center bolts to specification.

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3.7L & 4.2L V8 1997-99 (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 6: Locating Camshaft Position Sensor & Housing

Courtesy of Audi of America, Inc.

Fig. 7: Loosening Camshaft Sprocket Bolts

8) Remove Camshaft Locking Device (3341) from rear of each camshaft. Install housing behind camshaft position sensor and tighten bolts
to specification. Camshaft position sensor plate MUST engage in
camshaft with catch.
9) 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 tension, if necessary.
10) 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.
11) 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 expansion tank.

Fig. 8: Installing Camshaft Locking Device (3341)

12) Disconnect 2-pin electrical connector from coolant pump unit.
Coolant pump unit is located in left rear corner of engine compartment,
near power brake booster.
13) 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.
14) 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.
15) 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 repeated. If there are no unusual noises from
coolant pump, turn off ignition. Refill radiator expansion tank.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Position Sensor Housing Bolt .................................................................. 15 (20)
Camshaft Sprocket Bolt ............................................................................................ 41 (55)
Crankshaft Pulley Center Bolt ............................................................................ 1 332 (450)
Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 18 (25)
Serpentine Belt Idler Pulley Bolt .............................................................................. 18 (25)
Timing Belt Adjustment Damper Bolts ...................................................................... 18 (25)
Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25)
Timing Belt Tensioner Nut ........................................................................................ 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.

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3.7L & 4.2L V8 1997-99 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 9: Exploded View Of Timing Belt & Components

Courtesy of Audi of America, Inc.

Fig. 10: Locating Timing Belt Tensioner Pulley

Courtesy of Audi of America, Inc.

Fig. 11: Adjusting Timing Belt Damper Length

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108

4.2L V8 AKB, AUX & AYS Engines A8 & S8

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

sprocket. Remove timing belt along with camshaft sprocket for cylinders
No. 1 through No. 4 (passenger side cylinder head).

4.2L V8 (AKB, AUX & AYS Engines)

A8
2000-03 ..................................................... 4.9 Hours ... ..... T297
S8
2001-03 ..................................................... 4.9 Hours ... ..... T297
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends belt be replaced at 105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

Courtesy of Audi of America, Inc.

Fig. 1: Removing Viscous Cooling Fan (Left-Hand Threads)

CAUTION: If serpentine or timing belt are being reused, mark belt

with an arrow indicating direction of rotation. Damage may result if
belts are installed in opposite direction of rotation.
Removal 1) Raise and support vehicle. Remove noise insulation
panel from under front of vehicle.
2) Remove trim cover at front of engine compartment. Remove air intake
duct for air cleaner. Remove engine top trim cover and cylinder head
trim covers.
3) Remove outer ring for viscous fan. Hold viscous cooling fan pulley
with pin wrench (3212). See Fig. 1. Remove viscous fan by turning
clockwise. Viscous fan is LEFT-HAND threaded.
4) Using box wrench, turn serpentine belt tensioner clockwise with 19
mm ring wrench until the two holes are aligned. Hold tensioner in
position with pin (3204). See Fig. 2. Remove serpentine belt.
5) Disengage spring clips at timing belt covers. Remove timing belt
covers.
6) Rotate crankshaft by hand to TDC of compression stroke. Ensure
TDC mark on vibration dampener aligns with mark on engine. See
Fig. 3.
7) Check position of camshafts. Larger hole in camshaft sprocket
securing plates must face inboard and align with each other. See Fig. 4.
8) 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. 5.

Courtesy of Audi of America, Inc.

Fig. 2: Removing & Installing Serpentine Belt

CAUTION: Manufacturer recommends REPLACING vibration

dampener center bolt if it has been loosened or removed.
9) Remove serpentine belt tensioner from front of engine block. Remove
vibration dampener retaining bolts. It is NOT necessary to remove
center bolt. Remove vibration dampener.
10) Remove bracket for viscous cooling fan. See Fig. 6.
11) Using 8-mm hex wrench, SLOWLY compress hydraulic timing belt
tensioner by turning tensioning lever counterclockwise. See Fig. 7.
Insert Spring Pin (T40011) through top of timing belt tensioner and
through hole in top of tensioner piston.
12) Install Camshaft Bar (T40005) onto securing plates of both camshafts. See Fig. 8.
13) 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.
14) Loosen center bolt of timing belt tensioner pulley with eccentric
center. Tensioner pulley is located above and to the right of crankshaft

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Crankshaft Pulley TDC Marks

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4.2L V8 AKB, AUX & AYS Engines A8 & S8 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Camshaft Sprocket Securing Plate Holes

Courtesy of Audi of America, Inc.

Fig. 7: Relieving Timing Belt Tension

Courtesy of Audi of America, Inc.

Fig. 5: Locating Crankshaft Clamping Bolt (3242)

Courtesy of Audi of America, Inc.

Fig. 8: Installing Camshaft Bar (T40005)

Courtesy of Audi of America, Inc.

Fig. 6: Locating Viscous Cooling Fan Mounting Bracket

Installation 1) Ensure crankshaft is still at TDC position. Place timing
belt over crankshaft sprocket, tensioner pulleys, camshaft sprocket for
cylinders No. 5 through No. 8, water pump pulley and dampener pulley.
Then take camshaft sprocket for cylinder bank 1-4, install toothed belt
and bolt sprocket onto camshaft.
2) Lightly secure both camshaft sprockets with securing plates by
tightening hand-tight. Camshaft sprockets must be tight enough on
camshaft tapers to be turned, but should not tilt back and forth.

3) Attach Camshaft Bar (T40005) to camshafts. Insert a 5-mm drill bit

between the tensioning lever and the tip of the hydraulic tensioner
piston.
4) 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.
5) Using 8-mm hex wrench, rotate timing belt tensioning lever counterclockwise until Spring Pin (T40011) can be removed from hydraulic
tensioner.
6) 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.
7) Remove Camshaft Bar (T40005) after camshaft sprocket bolts are
tightened. Remove 7-mm drill bit. Remove Crankshaft Clamping Bolt
(3242) from side of engine block. Install sealing plug in hole. Turn
crankshaft 2 revolutions in normal direction of rotation.
8) Measure distance between tensioning lever and top of hydraulic
tensioner body. Dimension should be .197 (5 mm). See Fig. 10. If
dimension is not correct, readjust timing belt tension until dimension is
.197 (5 mm).

AUDI

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4.2L V8 AKB, AUX & AYS Engines A8 & S8 (Cont.)

9) Measure clearance between bottom of right 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.
10) Measure clearance between bottom of left hand timing belt guard
and top of timing belt. See Fig. 12. If clearance is not correct, turn
crankshaft by hand until all rear timing belt cover bolts are exposed.
Loosen bolts and adjust clearance to .0393 (1 mm). Tighten rear timing
belt cover bolts.
11) Install vibration dampener. Align notch in vibration dampener with
locating lug on timing belt sprocket. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS. To complete installation, reverse removal
procedure. When installing serpentine belt, rotate tensioner clockwise
and remove pin.
Courtesy of Audi of America, Inc.

Fig. 11: Measuring Timing Belt-To-Guard Clearance

(Right-Side Cylinder Head)

Courtesy of Audi of America, Inc.

Fig. 9: Setting Initial Timing Belt Tension

Courtesy of Audi of America, Inc.

Fig. 12: Measuring Timing Belt-To-Guard Clearance

(Left-Side Cylinder Head)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 41 (55)
Vibration Dampener Center Bolt
Step 1 ................................................................................................................ 1 148 (200)
Step 2 .................................................................................................................. Plus 180
Vibration Dampener-To-Sprocket Bolts ..................................................................... 15 (20)
Timing Belt Tensioner Center Nut ............................................................................ 16 (22)
Viscous Cooling Fan-To-Pulley ................................................................................. 52 (70)
Water Pump Bolts ..................................................................................................... 10 (14)
INCH Lbs. (N.m)

Courtesy of Audi of America, Inc.

Fig. 10: Measuring Tensioning Lever-To-Piston Clearance

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.

AUDI

111

4.2L V8 ART, AWN & BBD Engines A6 & S6

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.2L V8 (ART, AWN & BBD Engines)

A6 Quattro
2000-04 ..................................................... 6.4 Hours ... ..... T297
S6 Avant Quattro
2002-03 ..................................................... 6.4 Hours ... ..... T297
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends belt be replaced at 105,000 miles under
normal driving conditions, and 52,500 miles under severe driving
conditions.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools to allow
servicing of front engine components. Lock carrier can be
removed at technicians discretion.

12) Using a 19-mm wrench, rotate drive belt tensioner clockwise to

loosen belt tensioner. Secure belt tensioner using Drift (3204). Remove
drive belt. Ensure belt has no splits, cracks or other damage. Replace
drive belt if necessary. See Fig. 13.
13) Remove upper cylinder head covers. Disengage clips and remove
timing belt cover. Remove noise insulation panel. Rotate crankshaft by
to Top Dead Center (TDC). See Fig. 14.
14) Check position of camshafts. Larger holes of camshaft securing
plates (located on front of camshaft sprockets) must be on inside and
must align. See Fig. 15. If camshafts are in correct position, go to next
step. If camshafts are not in correct position, rotate crankshaft one turn
further.
15) Remove sealing plug from alignment access hole in left side of
engine block. Ensure that hole in crankshaft is visible through alignment
access hole. Install Crankshaft Holder (3242) into alignment access hole
to prevent crankshaft from rotating. See Fig. 16.
16) Remove accessory drive belt tensioner. Loosen 8 Allen-headed
bolts and remove crankshaft vibration damper (center bolt does not
have to be removed). Remove engine torque support. See Fig. 17.
NOTE: Timing belt tensioner is oil-dampened. Compress it by
slowly applying constant pressure.
17) Using an 8-mm wrench, turn timing belt tensioning roller clockwise
until tensioning lever compresses tensioner so a pin (2 mm in diameter)
can be inserted into plunger. See Fig. 18. Insert pin and release tension.
18) Install Camshaft Locator Bar (3391) into camshaft locking plates.
Loosen camshaft bolts and back bolts out 5 turns. Remove camshaft
locator bar. Using Camshaft Sprocket Puller (T40001), remove camshaft
sprocket. See Fig. 19. Loosen timing belt tensioning roller. Remove
timing belt and left camshaft sprocket together.

NOTE: It is not necessary to completely remove noise insulation

from beneath the engine. Only remove the quick-release fasteners
that attach to the front bumper assembly.
Removal 1) Raise and support vehicle. Remove front tires. Remove
lower front engine shield (noise insulator). See Fig. 1. Loosen the front
half of the wheelhousing splash shield (liner). See Fig. 2. Remove flange
nut on both sides. See Figs. 3 and 4.
2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of
parking/auxiliary heater at noise insulation. See Fig. 5.
3) Remove right cover in engine compartment. Unbolt air guide between
lock carrier and air filter on lock carrier. Remove left cover in engine
compartment. Pull off hood seal from lock carrier and fender edges.
4) Release catches (1-4) using a screwdriver, and remove air inlet grille
on left and right sides of bottom part of bumper. See Fig. 6. Remove left
and right retaining bolts until bumper is fully released. See Fig. 7.
5) Remove screw with washer assembly (6) from wheelhousing liner (5).
See Fig. 3. Disconnect any wiring harness that attaches to the front
bumper. Remove socket-head bolts (7), and remove bumper cover
together with impact absorber towards front. See Fig. 3.
6) Inspect headlight and turn signal electrical connectors and wiring
harness (which may hang up when lock carrier is moved forward).
7) On passengers side, remove bolt (5) and install Support Tool (3369)
in its place. See Figs. 8 and 9.
8) On drivers side, install Support Tool (3369) in threaded hole in
chassis. See Fig. 10.
9) Remove bolts (2, 3 and 4) from both sides. See Fig. 8. Slide lock
carrier forward unit the rear bolt hole in lock carrier aligns with the
forward-threaded fender bolt hole.
10) Secure lock carrier in this position by placing fender bolts in holes.
See Fig. 11.
NOTE: Fan clutch is fitted with left-handed threads. Turn clockwise
to loosen.
11) Remove air intake hose to air cleaner. Remove engine cover. See
Fig. 12. Using Spanner Wrench (3212) to hold fan clutch pulley, use
Open-End Spanner (3312) or equivalent to loosen fan clutch. Remove
radiator fan and fan shroud from vehicle.

Courtesy of Audi of America, Inc.

Fig. 1: Identifying Lower Engine Shield (Noise Insulator)

Mounting Points
CAUTION: Before installation, ensure camshafts are aligned,
crankshaft is locked in place and camshaft gear bolts are loose as
described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons
may be damaged.
Installation 1) Install timing belt first to crankshaft, then to tensioner,
water pump, timing belt tensioning roller and right camshaft sprocket.
See Fig. 20. Install left camshaft sprocket to camshaft with timing belt,
and hand tighten camshaft sprocket bolts. Camshaft sprockets must be
able to move on tapered camshaft.
2) Install Camshaft Holding Bar. See Fig. 21. Insert a 5-mm drill bit
between timing belt tensioner and tensioner piston. See Fig. 22. Using
Spanner (T40009) and torque wrench, apply 35 INCH lbs. (4 N.m) to
timing belt tensioning roller. See Fig. 23. Remove drill bit.
3) Using an 8-mm Allen wrench, turn timing belt tensioner clockwise until
tensioning lever compresses and remove pin. See Fig. 18. Continue
turning timing belt tensioner clockwise until a 7-mm drill bit can be
inserted between timing belt tensioner and tensioner piston. Tighten
camshaft sprockets to 41 ft. lbs. (55 N.m).

AUDI

112

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

4) Remove Camshaft Holding Bar. Remove drill bit. Turn crankshaft by
hand 2 full revolutions. Measure distance between timing belt tensioner
and tensioner body. See Fig. 24. Dimension should be 5 mm. If
dimension is as specified, go to next step. If dimension is not as
specified, repeat belt tensioning procedure.
5) Using feeler gauge, check distance between timing belt and timing
belt guard at right camshaft. See Fig. 25. Dimension should be .040 (1
mm). If dimension is not as specified, go to next step. If dimension is as
specified, repeat procedure on left camshaft timing belt guard.
6) Rotate crankshaft until all bolts are exposed. Loosen bolts, and move
guard until dimension is .040 (1 mm). Tighten bolts to 89 INCH lbs. (10
N.m). To complete timing belt installation, reverse remaining removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
7) To install lock carrier, reverse removal procedures outlined in
REMOVAL. Torque all fasteners to specification. See TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for torque support
with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See Fig. 26.
8) Before installing the bumper, ensure the expanding clips are pressed
into the fender. See Fig. 27. When installing the tabs, the bumper cover
must latch into clip (4). See Figs. 3 and 4.
9) Latch bumper cover (1) into guide (2). See Fig. 3. Torque flange nuts
(10) to 53 INCH lbs. (6 N.m).
NOTE: The impact absorber is installed vertical to the cross member and has height compensating elements. See Fig. 28.
10) Torque left and right retaining bolts to specification. See TORQUE
SPECIFICATIONS. Install left and right air inlet grille on bumper. To
complete installation, reverse removal procedures.

Courtesy of Audi of America, Inc.

Fig. 3: Identifying Front Bumper Components (1 Of 2)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Wheelhousing Liner Components

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Front Bumper Components (2 Of 2)

AUDI

113

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Identifying Auxiliary Heater Exhaust Pipe Bolts

Fig. 9: Identifying Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 6: Removing Grilles

Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Bumper Fasteners

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position

Courtesy of Audi of America, Inc.

Fig. 12: Removing Engine Cover

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Lock Carrier Components

AUDI

114

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 13: Drive Belt Routing

Courtesy of Audi of America, Inc.

Fig. 16: Installing Crankshaft Holder

Courtesy of Audi of America, Inc.

Fig. 14: Aligning Timing Marks

Courtesy of Audi of America, Inc.

Fig. 17: Removing Engine Torque Support

Courtesy of Volkswagen United States, Inc.

Fig. 15: Aligning Camshaft Securing Plates

Courtesy of Volkswagen United States, Inc.

Fig. 18: Compressing Timing Belt Tensioner

AUDI

115

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 19: Installing Sprocket Puller

Courtesy of Audi of America, Inc.

Fig. 23: Tensioning Timing Belt Tensioning Roller

Courtesy of Volkswagen United States, Inc.

Fig. 20: Installing Timing Belt

Courtesy of Audi of America, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 21: Installing Camshaft Holding Bar

Courtesy of Audi of America, Inc.

Fig. 22: Setting Up Timing Belt Tensioner

Fig. 24: Checking Timing Belt Tensioner Adjustment

AUDI

116

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 27: Identifying Bumper Cover Attaching Points For

Removal & Installation
Courtesy of Audi of America, Inc.

Fig. 25: Checking Timing Belt Guard Adjustment

Courtesy of Audi of America, Inc.

Fig. 26: Identifying Torque Support Bolts

AUDI

117

4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 28: Identifying Bumper Attaching Point To Impact Absorber

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Bumper-To-Long Member Bolts ................................................................................ 37 (50)
Camshaft Gear-To-Camshaft Bolts ........................................................................... 41 (55)
Eccentric Pulley-To-Front Sealing Flange Bolt ......................................................... 16 (22)
Timing Belt Tensioning Pulley ................................................................................... 15 (20)
Timing Belt Idler Pulley ............................................................................................. 33 (45)
Vibration Dampener Bolts ......................................................................................... 15 (20)
Impact Absorber Bolts ............................................................................................... 37 (50)
Ribbed Belt Tensioner-To-Cylinder Block
M8 Bolts .................................................................................................................. 17 (23)
M10 Bolts ................................................................................................................ 30 (40)
Sealing Plug In Cylinder Block ................................................................................. 18 (25)
Torque Support Lock-To-Lock Carrier Bolts ............................................................. 21 (28)
Viscous Fan
Using Torque Wrench & Open End Wrench .......................................................... 27 (37)
Using Torque Wrench Without Open End Wrench ................................................ 52 (70)
INCH Lbs. (N.m)
Bumper-To-Fender Bolts ...........................................................................................
Timing Belt Guard Bolts 1 .........................................................................................
Timing Belt Tensioner ................................................................................................
Valve Cover Bolts ......................................................................................................
1

Use NEW bolts.

89
89
89
89

(10)
(10)
(10)
(10)

118

AUDI & VOLKSWAGEN

2.1L & 2.2L 5-Cylinder, 1978-91
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

2.1L 5-Cyl.
Quantum
1984-85
.70 Belt T.W. ......................................... 1 2.3 Hours .. .....
.75 Belt T.W. ......................................... 1 2.3 Hours .. .....
2.2L 5-Cyl.
Coupe
1981-83 ..................................................... 1.8 Hours ... .....
1984-85
113 Tooth Belt ........................................ 1.8 Hours ... .....
120 Tooth Belt ........................................ 1.8 Hours ... .....
1986-87 ..................................................... 1.8 Hours ... .....
Quantum
1983-85
.70 Belt T.W. ......................................... 1 2.3 Hours .. .....
.75 Belt T.W. ......................................... 1 2.3 Hours .. .....
1986
.70 Belt T.W. .......................................... 2.3 Hours ... .....
.75 Belt T.W. .......................................... 2.3 Hours ... .....
1987-88 ..................................................... 2.3 Hours ... .....
Quattro
1983 ........................................................... 1.8 Hours ... .....
1984-85
113 Tooth Belt ........................................ 1.8 Hours ... .....
120 Tooth Belt ........................................ 1.8 Hours ... .....
200
1989
Thru Chassis No. 44 K 400 000 ........... 2.5 Hours ... .....
From Chassis No. 44 K 400 001 .......... 2.5 Hours ... .....
1990-91 ..................................................... 2.5 Hours ... .....
200 Quattro
1989
Thru Chassis No. 44 K 004 457 ........... 2.5 Hours ... .....
From Chassis No. 44 K 004 458 .......... 2.5 Hours ... .....
1990-91 ..................................................... 2.5 Hours ... .....
4000
1980-81 ..................................................... 1.8 Hours ... .....
4000CS
1986-87 ..................................................... 1.8 Hours ... .....
4000CS Quattro
1987 ........................................................... 1.8 Hours ... .....
4000S Quattro
1984-85
113 Tooth Belt ........................................ 1.8 Hours ... .....
120 Tooth Belt ........................................ 1.8 Hours ... .....
1986 ........................................................... 1.8 Hours ... .....
5000
1978-83 ..................................................... 1.1 Hours ... .....
5000CS Quattro
1987-88 ..................................................... 2.2 Hours ... .....
5000S
1984-85
113 Tooth Belt ........................................ 2.2 Hours ... .....
120 Tooth Belt ........................................ 2.2 Hours ... .....
1986-87 ..................................................... 2.2 Hours ... .....
1

T127
T065

T065
T065
T127
T127

TIMING BELT
Removal 1) 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. See Fig. 1.
2) 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.
3) 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.

T127
T065
T127
T065
T127
T065
T065
T127

T127
T170
T170

T127
T170
T170
Courtesy of Audi of America, Inc.

T065

Fig. 1: Exploded View Of Timing Belt & Components

T127
T127

T065
T127
T127
T065
T127

T065
T127
T127

With Air Conditioning, Without Factory Air Conditioning,

With Radiator removal, labor time is 3.9 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Aligning Camshaft Sprocket

Installation 1) Ensure both camshaft lobes on No. 1 cylinder point
upward. Mark (notch or dot) on back of camshaft sprocket must be
aligned with top of valve cover gasket or rear timing belt cover.
Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must
be aligned with index point on transmission housing. See Fig. 3.
2) 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. Reverse installation order of removal. Adjust drive
belts.

AUDI & VOLKSWAGEN

119

2.1L & 2.2L 5-Cylinder, 1978-91 (Cont.)

NOTE: Turn engine by hand using hex flange on hydraulic pump.
Loosen tensioner bolts.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20)
Timing Belt Tensioner ................................................................................................ 15 (20)
Vibration Damper Bolt ........................................................................................... 258 (350)
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)

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks

BMW

120

2.5L & 2.7L 6-Cylinder

TIMING BELT APPLICATION
Application
2.5L 6-Cyl.
325 Series
1987-88
127 Tooth Belt .................
128 Tooth Belt .................
1989-91 ...............................
525i
1989-95 ...............................
2.7L 6-Cyl.
325 Series
1984-88
127 Tooth Belt .................
128 Tooth Belt .................
528e
1982-88
127 Tooth Belt .................
128 Tooth Belt .................

Labor Time

Component
Belt
Kit No.
Part No.

3.2 Hours ... ...... ..... ...... ..... T131

3.2 Hours ... ...... ..... ...... ..... T106
3.2 Hours ... .. TCK131 .. ..... T131

2) Using a puller, remove vibration damper hub from crankshaft.

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 tension bracket and move aside.
3) Remove front cover. Loosen timing belt tensioner mounting bolts, and
press in on tension roller. Tighten upper mounting bolt to hold tensioner
in place. Remove timing belt. See Fig. 2.

3.2 Hours ... ...... ..... ...... ..... T131

2.7 Hours ... ...... ..... ...... ..... T131

2.7 Hours ... ...... ..... ...... ..... T106

2.7 Hours ... ...... ..... ...... ..... T131

2.7 Hours ... ...... ..... ...... ..... T106

NOTE: Use 127 tooth belt with retrofit tensioner pulley. Use 128
tooth belt with OEM tensioner pulley. DO NOT use 128 tooth belt on
new style adjusting pulley.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
or whenever tensioner roller has been released.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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 electrical connector from radiator switches.
Remove radiator. Hold crankshaft in place and remove center bolt from
vibration damper hub.

Courtesy of BMW of North America, Inc.

Fig. 1: Aligning Timing Sprockets

Installation 1) Ensure arrow on camshaft sprocket is still aligned with
timing mark on cylinder head. Ensure timing mark on crankshaft
sprocket is aligned with notch in cover (about one oclock position). See
Fig. 1.
2) Install timing belt on sprockets. Loosen tensioner adjusting bolt to
allow spring tension on timing belt. Turn crankshaft in direction of normal
rotation until timing belt tightens. Tighten tensioner bolt.
3) Clean gasket mating surfaces. Coat oil pan-to-cover gasket with
gasket sealer. Install Centering Tool (11 2 211) on crankshaft and on
intermediate shaft to align front cover.
4) Using new gasket, install and tighten timing belt cover. When
installing crankshaft sprocket, lettering must face forward. Install
remaining components in reverse order of removal procedure. Adjust
drive belts to proper tension.

BMW

121

2.5L & 2.7L 6-Cylinder (Cont.)

Courtesy of BMW of North America, Inc.

Fig. 2: Exploded View Of Camshaft Drive Assembly

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ................. 47-50 (65-70)
Intermediate Shaft Sprocket ......................................................... ................. 40-47 (55-64)
Vibration Damper Hub ............................................................................ 283-311 (390-430)

CHRYSLER

122

1.4L 4-Cylinder
TIMING BELT APPLICATION
Application

1.4L 4-Cyl.
Colt
1979 ....................................
1980-84 ...............................
Champ
1979 ....................................
1980-82 ...............................
1

Labor Time Component

Belt
Kit No.
Part No.

1.1 Hours ... ...... ..... ...... ..... T073

1.1 Hours ... .. TCK073 .. ..... T073
1.1 Hours ... ...... ..... ...... ..... T073
1.1 Hours ... .. TCK073 .. ..... T073

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. On front wheel drive
models, remove air cleaner assembly, then disconnect accelerator 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, support engine using a suitable engine support bar.
2) 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 direction of rotation for installation reference, and remove
timing belt. See Fig. 1.
Installation 1) Align camshaft and crankshaft sprockets. Mount belt
tensioner, spring, spacer and temporarily tighten bolt. Position spring
against tensioner first, then against case and tighten bolt. See Fig. 2.
Position and secure tensioner toward water pump.
2) 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 direction. 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.
3) 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 counterclockwise direction. Loosen tensioner spring bolt first then slotted adjustment hole bolt. Tighten tensioner bolts by tightening slotted adjustment hole bolt first and tensioner
spring bolt last.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing & Installing Timing Belt

4) 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 mounting bolt head width (across flats)
away from bolt head center. See Fig. 3. Adjust drive belts to proper
tension.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt Tensioner

CHRYSLER

123

1.4L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ................. 47-54 (64-73)
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)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Checking Timing Belt Tension

CHRYSLER

124

1.6L 4-Cylinder With Balance Shaft

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. SOHC
Arrow & Sapporo
1977-80 ....................................................
1977-80 ....................................................
Challenger
1978-79 ....................................................
1978-79 ....................................................
Champ
1979-80 ....................................................
1979-80 ....................................................
Colt
1977-80 ....................................................
1977-80 ....................................................
1

2
3

Labor Time

1
1

1
1

1
1

1
1

Belt
Part No.

1.8 Hours .. ...

1.9 Hours .. ...

1.8 Hours .. ...

1.9 Hours .. ...

1.8 Hours .. ...

1.9 Hours .. ...

1.8 Hours .. ...

1.9 Hours .. ...

T013
T062
T013
T062
T013
T062
T013
T062

Counterbalance shaft belt included in labor time. With Air

Conditioning, add .2 hours. With Power Steering, add .2 hours.
Camshaft timing belt.
Counterbalance shaft belt.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Counterbalance & Timing Belt Routing

The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft so
that No. 1 cylinder is at TDC of compression stroke. Remove 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.
2) 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.
3) Remove outer crankshaft sprocket and flange. Loosen center bolt on
counterbalance belt tensioner pulley. Remove counterbalance shaft
belt.
Installation 1) 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.
2) Position counterbalance shaft tensioner so that the eccentric 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.
3) If camshaft timing belt tensioner was removed, install tensioner.
Ensure tension spring is seated in correct position on water pump body.
See Fig. 5. Secure tensioner away from timing belt.
4) 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.
5) 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.
6) 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, then bolt. If bolt is tightened first, the
tensioner may also turn more than necessary.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Holding Counterbalance (Silent) Shaft In

Stationary Position
7) 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.
8) 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.
9) 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.
10) Remove crankshaft pulley. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft sprocket center bolt and pulley bolts to
specification. See TORQUE SPECIFICATIONS. Install accessory drive
belts. Adjust drive belts to proper tension.

CHRYSLER

125

1.6L 4-Cylinder With Balance Shaft (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 6: Checking Camshaft Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS

Fig. 3: Aligning Counterbalance Shaft Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Positioning Counterbalance Pulley

Courtesy of DaimlerChrysler Corp.

Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring

CHRYSLER

126

1.6L 4-Cylinder Without Balance Shaft

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.6L 4-Cyl. SOHC, Without Balance Shaft

Arrow & Sapporo
1978-80 .................................................... 1 1.6 Hours .. .....
Challenger & Colt (RWD)
1978-79 .................................................... 1 1.6 Hours .. .....
Champ
1979-82 ..................................................... 2.8 Hours ... .....
Colt (FWD)
1979-82 .................................................... 1 2.8 Hours .. .....
1983-89 .................................................... 1 2.8 Hours .. .....
Vista (Canadian)
1989 .......................................................... 1 2.8 Hours .. .....
1

T064
T064
T064
T064
T093
T093

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

3) Ensure all timing marks are still aligned. Temporarily install crankshaft
pulley.
4) 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.
5) 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 specified
torque. See TORQUE SPECIFICATIONS. Tighten timing belt tensioner
bolt.
6) To check timing belt tension, grasp belt between thumb and forefinger
near timing belt tensioner. See Fig. 4. Tension 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.
7) 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.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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.
2) On all models, remove accessory drive belts. Remove crankshaft
pulley, upper and lower timing belt front covers. Turn crankshaft
clockwise to align camshaft and crankshaft timing marks. See Fig. 1.
3) Loosen belt tensioner mounting nut and bolt. Move tensioner away
from belt and temporarily tighten nut. Remove timing belt. See Fig. 1.
Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Timing Belt Routing & Alignment

Installation 1) 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.
2) Install timing belt on crankshaft sprocket, on oil pump sprocket and
camshaft sprocket, in that order. Keep slack out of belt during installation.

CHRYSLER

127

1.6L 4-Cylinder Without Balance Shaft (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Timing Belt Tensioner Nut/Bolt ..................................................... ................. 16-21 (22-29)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt ................................................................................... 90-102 (10-11)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Checking Timing Belt Tension

CHRYSLER

128

1.7L 4-Cylinder
TIMING BELT APPLICATION
Application
1.7L 4-Cyl.
Charger
1983 ...................................
Horizon
1978-83 ..............................
Omni
1978-83 ..............................
TC3
1981 ...................................
1982 ...................................
Turismo
1983 ...................................
024
1981-82 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

3.1 Hours .. .. TCK017 .. ..... T017

3.1 Hours .. .. TCK017 .. ..... T017

3.1 Hours .. .. TCK017 .. ..... T017

1
2

3.1 Hours .. .. TCK017 .. ..... T017

3.1 Hours .. .. TCK017 .. ..... T017

3.1 Hours .. .. TCK017 .. ..... T017

3.1 Hours .. .. TCK017 .. ..... T017

With Air Conditioning, add .2 hours. With Air Pump, add .2

hours. With Power Steering, add .2 hours.
With Air Conditioning, add .2 hours. With Air Pump, add .1
hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal 1) 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.
2) Raise vehicle and remove inner fender splash shield. On 1981-83
models, remove water pump. On all models, remove AIR pump belts (if
equipped). Remove idler pulley assembly. Remove crankshaft pulley
and power steering belt. Remove lower plastic timing belt cover. See
Fig. 1.
3) 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 1) Align timing marks on crankshaft and intermediate
sprockets. See Fig. 2. Turn camshaft sprocket until timing mark on
sprocket is lined up with camshaft cover sealing surface. See Fig. 3.
2) Install timing belt and Belt Tensioner Tool (L-4502 or equivalent)
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.
3) Turn engine clockwise from TDC 2 complete crankshaft revolutions to
TDC. Tighten tensioner lock nut while holding belt tensioner wrench in
position. Reverse removal procedure to complete installation. Adjust
drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Locating Crankshaft & Intermediate Sprocket

Timing Marks

CHRYSLER

129

1.7L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 58 (80)
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)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Locating Camshaft Timing Mark

Courtesy of DaimlerChrysler Corp.

Fig. 4: Tensioning Timing Belt

CHRYSLER

130

1.8L 4-Cylinder VIN T

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl.
Colt & Colt Wagon
1989-90 ....................................................
1

Belt
Part No.

2.4 Hours .. ..... T093

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of DaimlerChrysler Corp.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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 pulley. Remove A/C belt tensioner
(if equipped).
2) Remove crankshaft pulley assembly. Remove upper front and lower
timing belt covers. Note bolt lengths and locations. 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.
3) If reusing belt, mark timing belt position on camshaft sprocket and
indicate direction of belt rotation. Loosen timing belt tensioner bolt and
nut. Move timing belt tensioner toward water pump to release tension,
and tighten nut temporarily to maintain tensioner position. See Fig. 2.
Remove timing belt.

Fig. 2: Positioning Timing Belt Tensioner

shaft sprocket, in counterclockwise direction, to apply tension on tension
side of belt. Ensure all timing marks are aligned.
3) Loosen belt tensioner bolt, then loosen nut to place tension on 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 nut, then tighten bolt.
4) 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 procedure. Adjust accessory drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Timing Mark Alignment & Belt Arrangement

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 rotation. Replace components
if damaged.
Installation 1) Rotate tensioner toward water pump and temporarily
tighten retaining nut. See Fig. 2. Ensure camshaft and crankshaft timing
marks are aligned. See Fig. 1.
2) Apply pressure on tension side of belt, and install timing belt on oil
pump sprocket and then on crankshaft sprocket. Apply force on cam-

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
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)

CHRYSLER

131

2.0L 4-Cylinder VIN C 1995-00

TIMING BELT APPLICATION
Application
2.0L 4-Cyl. SOHC
Breeze
1996-00 .....................................................
Cirrus
2000 ...........................................................
Neon
1995-99 .....................................................
Stratus
1995-00 .....................................................

Labor Time

Belt
Part No.

2.6 Hours ... ..... T245

2.6 Hours ... ..... T245
2.4 Hours ... ..... T245
2.6 Hours ... ..... T245

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On Neon, the manufacturer recommends the belt be replaced at
105,000 mile intervals.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

On Breeze, Cirrus and Stratus, the manufacturer recommends the belt

be replaced at 100,000 mile intervals on vehicles with Federal emissions, and 105,000 mile intervals with California emissions.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Hydraulic Tensioner) 1) Remove No. 1 spark plug. Using
dial indicator, set number one cylinder to TDC of compression stroke.
Remove access plug from top of timing belt cover. See Fig. 1. Ensure
timing mark on camshaft aligns with mark on rear cover. See Fig. 2.
2) Disconnect negative battery cable. Remove accessory drive belts.
Raise vehicle and remove right inner splash shield. See Fig. 3. Remove
crankshaft damper bolt. Use gear puller to remove crankshaft damper.
3) Lower vehicle and place a jack under engine to support weight.
Remove right engine mount. On Breeze and Stratus, 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. On all models, remove right engine mount bracket from engine.
See Fig. 4.
4) Remove front timing belt cover. See Fig. 1. Rotate crankshaft so that
timing marks are aligned. See Fig. 2. Loosen timing belt tensioner bolts.
If reusing timing belt, mark arrow on belt to indicate direction of rotation.
Remove timing belt and tensioner. DO NOT loosen, tighten, or remove
tensioner pulley pivot bolt.
Courtesy of DaimlerChrysler Corp.

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.
CAUTION: 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 timing 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.

Fig. 2: Aligning Timing Marks & Adjusting Belt Tension

(Hydraulic Timing Belt Tensioner)
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) 1) Place tensioner in soft-jawed
vise and slowly compress plunger. See Fig. 5. When plunger is
compressed into tensioner body, install a 5/16 (1.9 mm) hex wrench or
locking pin through body and plunger to hold plunger in place until
tensioner is installed.
2) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil
pump housing, then back off to 3 notches before TDC.

CHRYSLER

132

2.0L 4-Cylinder VIN C 1995-00 (Cont.)

7) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle.
Install accessory drive belts. Adjust drive belts to proper tension.
8) On Neon, connect scan tool to Data Link Connector (DLC) under
lower left edge of instrument panel. Follow scan tool manufacturers
instructions to access the cam/crank relearn procedure. Perform cam/
crank relearn procedure.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Exploded View Of Splash Shield Components

Courtesy of DaimlerChrysler Corp.

Fig. 5: Compressing Hydraulic Timing Belt Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 4: Locating Right Engine Mount Bracket (Typical)

3) Set camshaft to TDC by aligning mark on sprocket with arrow on rear
of timing belt cover. See Fig. 2. Move crankshaft to 1/2 notch mark
before TDC for belt installation. See Fig. 6. Install timing belt by starting
at crankshaft, then around water pump sprocket and then camshaft
sprocket.
4) Move crankshaft sprocket to TDC to take up belt slack. Install
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.
5) 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 steering pump (Neon).
6) Install right engine mount. Remove jack from under engine. Install
crankshaft damper, and tighten bolt to specification. See TORQUE
SPECIFICATIONS.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Aligning Crankshaft Sprocket Timing Marks

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) 1) Remove No. 1 spark plug.
Using dial indicator, set number one cylinder to TDC of compression
stroke. Remove access plug from top of timing belt cover. See Fig. 1.
Ensure timing mark on camshaft aligns with mark on rear cover. See
Fig. 7.
2) Disconnect negative battery cable. Remove accessory drive belts.
Raise vehicle and remove right inner splash shield. See Fig. 3. Remove
crankshaft damper bolt. Use gear puller to remove crankshaft damper.
3) On Breeze and Stratus, lower vehicle and place a jack under engine
to support weight. Remove right engine mount from engine and body.
Remove generator (with wiring attached) and bracket, and secure out of
way. Remove engine mount bracket from engine. For 2000 Breeze and
Stratus, remove accessory drive belt idler pulley from generator bracket.
Remove generator bracket-to-engine bolts. Move bracket away from
engine for clearance to remove timing belt cover.

CHRYSLER

133

2.0L 4-Cylinder VIN C 1995-00 (Cont.)

4) On Neon, lower vehicle and place jack under engine to support
weight. Remove power steering pump with hoses attached, and secure
out of way. Remove right engine mount-to-engine mount bracket
through-bolt. Remove engine mount bracket from engine.
5) On all models, remove timing belt cover. Rotate the crankshaft so that
timing marks are aligned. See Fig. 7.
6) Install an 8-mm Allen wrench into timing belt tensioner. See Fig. 7.
Insert long end of a 3-mm Allen wrench into pin hole in the front of
tensioner. Slowly rotate tensioner counterclockwise with 8-mm Allen
wrench while pushing lightly on the 3-mm Allen wrench, until it slides into
the locking hole.
7) If reusing old timing belt, mark belt with arrow to indicate direction of
rotation. Remove timing belt.
CAUTION: To prevent pistons from hitting valves, do not rotate
camshaft or crankshaft after removing the timing belt.
CAUTION: 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 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 (Mechanical Tensioner) 1) Set crankshaft sprocket to
TDC by aligning sprocket with arrow on oil pump housing, then back off
to 3 notches before TDC.
2) Set camshaft to TDC by aligning mark on sprocket with arrow on rear
of timing belt cover. See Fig. 7. Move crankshaft to 1/2 mark before TDC
for belt installation. See Fig. 6. Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket.
See Fig. 7. Move crankshaft sprocket to TDC to take up belt slack.
3) Remove Allen wrench from timing belt tensioner pulley. Rotate
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.
4) Install front timing belt cover. Install engine mount bracket to engine.
Continue installation in reverse of removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
accessory drive belts to proper tension.
5) On 1998-99 Neon, connect scan tool to Data Link Connector (DLC)
under lower left edge of dash. Follow scan tool manufacturers instructions to access the cam/crank relearn procedure. Perform cam/crank
relearn procedure.

Courtesy of DaimlerChrysler Corp.

Fig. 7: Aligning Timing Marks & Adjusting Belt Tension

(Mechanical Timing Belt Tensioner)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 85 (115)
Crankshaft Damper Bolt ........................................................................................ 105 (142)
Engine Mount Bolt ..................................................................................................... 45 (61)
Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61)
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)

CHRYSLER

134

2.0L 4-Cylinder VINs C & F 2000-04

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cyl. SOHC

Neon
2000-04 ..................................................... 2.6 Hours ... ..... T245
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the timing belt be replaced at 105,000 mile
intervals or at 84 months.

ADJUSTMENTS
Courtesy of DaimlerChrysler Corp.

ENGINE TORQUE STRUT ADJUSTMENT

Fig. 2: Removing Upper & Lower Engine Torque Struts

NOTE: Whenever a torque strut bolt(s) is loosened, this procedure
must be performed. Upper and lower torque struts need to be
adjusted together to assure proper engine positioning and engine
mount loading.
NOTE: To prevent minimal upward lifting of engine, floor jack must
be positioned as shown. See Fig. 1.
1) Loosen upper and lower torque strut attaching bolt at suspension
crossmember and shock tower bracket. Engine position may now be
adjusted by positioning a suitable floor jack on the forward edge of
transmission bellhousing. See Fig. 1.
2) With engine supported, remove upper and lower torque struts
attachment bolt(s) at shock tower bracket and suspension crossmember. See Fig. 2. Verify that torque struts are free to move within shock
tower bracket and crossmember. Reinstall torque strut bolt(s), but DO
NOT tighten.
3) Carefully apply upward force, allowing upper engine to rotate
rearward until distance between center of rearmost attaching stud on
engine mount bracket (point A) and center of hole for washer hose clip
on shock tower bracket (point B) is 4.7 (119 mm). See Fig. 3.
4) With engine held at proper position, tighten both upper and lower
torque strut bolts to specification. See TORQUE SPECIFICATIONS.
Remove floor jack.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Measuring Engine Position (Top View)

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: For identification of timing belt with hydraulic tensioner and
related components, refer to illustration. See Fig. 4.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Positioning Floor Jack

Removal (With Hydraulic Tensioner) 1) Remove No. 1 spark plug.

Using dial indicator, set No. 1 cylinder to TDC of compression stroke.
Remove access plug from top of timing belt cover, and ensure timing
mark on camshaft aligns with mark on rear cover. See Fig. 5.
2) Disconnect negative cable from battery, and ground strap from engine
mount bracket. Remove upper torque strut from front of engine. See
Fig. 2. Remove accessory drive belts. Raise vehicle and remove right
inner splash shield. See Fig. 6. Remove crankshaft damper bolt, and
use gear puller to remove crankshaft damper. See Fig. 7. Remove lower
engine torque strut. See Fig. 2.
3) Lower vehicle and place a jack under engine. Raise jack enough to
support engine weight. Remove right engine mount-to-engine mount
bracket bolt. See Fig. 8. Lower engine enough with jack to remove lower
engine mount bracket bolt. See Fig. 9. Raise engine with jack to allow
engine-to-body clearance for engine bracket removal. Remove power

CHRYSLER

135

2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)

steering pump with hoses attached, and secure out of way. Remove two
remaining upper engine mount bracket bolts and remove engine mount
bracket. See Fig. 9. Remove front timing belt cover bolts and remove
front timing belt cover. See Fig. 4.
4) Rotate crankshaft so that timing marks are aligned. See Fig. 10.
Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow 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.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Removing Right Front Splash Shield

Courtesy of DaimlerChrysler Corp.

Fig. 4: Exploded View Of Timing Belt & Components

(With Hydraulic Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 5: Identifying Camshaft Sprocket & Rear Cover Timing Marks

CAUTION: 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 timing belt tensioner, do not loosen, tighten, or remove timing belt
tensioner pivot bolt. Pivot bolt is located on timing belt tensioner
assembly. See Fig. 10. 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.
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.

Courtesy of DaimlerChrysler Corp.

Fig. 8: Removing Right Engine Mount Bolt

136

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)
NOTE: When hydraulic tensioner is removed from engine, it is
necessary to compress plunger into tensioner body.

Courtesy of DaimlerChrysler Corp.

Fig. 9: Locating Engine Mount Bracket Upper & Lower Bolts

Installation (With Hydraulic Tensioner) 1) Place tensioner in

soft-jawed vise and slowly compress plunger. See Fig. 11. When
plunger is compressed into tensioner body, install a 5/64 (1.9 mm) hex
wrench or locking pin through body and plunger to hold plunger in place
until tensioner is installed.
2) Set crankshaft sprocket to TDC by aligning sprocket TDC mark with
TDC reference mark arrow on oil pump housing, then back off to 3
notches before TDC. See Fig. 12.
3) Set camshaft to TDC by aligning mark on sprocket with arrow on rear
of timing belt cover. See Fig. 10. Move crankshaft to 1/2 notch mark
before TDC for belt installation. See Fig. 12. Install timing belt starting at
crankshaft sprocket, then around water pump sprocket, and then
camshaft sprocket, and finally around timing belt tensioner pulley.
4) Move crankshaft sprocket to TDC to take up belt slack. Install
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. See Fig. 10. Final tighten tensioner
bolts to specification. See TORQUE SPECIFICATIONS.
5) Pull tensioner plunger locking pin. Pre-tension is correct when pin can
be removed and installed. Rotate crankshaft 2 revolutions. Check
alignment of the timing marks. See Fig. 10. Check belt tension by
installing pin into tensioner housing. If pin cannot be reinstalled, repeat
tensioning procedure.
6) Install front timing belt cover. Install engine mount bracket and power
steering pump. Install right engine mount, and remove jack from under
engine. Install and adjust upper and lower engine torque struts. See
ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS.
Install crankshaft damper, and tighten bolt to specification. See
TORQUE SPECIFICATIONS.
7) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle.
Install accessory drive belts. Adjust drive belts to proper tension.
8) Connect scan tool to Data Link Connector (DLC), located under lower
left edge of instrument panel. Turn ignition on. Perform cam/crank
relearn procedure by accessing ENGINE diagnostics. Select MISCELLANEOUS, then select RELEARN CAM CRANK and follow directions
on scan tool screen.

Courtesy of DaimlerChrysler Corp.

Fig. 10: Aligning Timing Marks & Adjusting Belt Tension

(Hydraulic Timing Belt Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 11: Compressing Hydraulic Timing Belt Tensioner

NOTE: For identification of timing belt with mechanical tensioner
related components, refer to illustration. See Fig. 14.

CHRYSLER

137

2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)

CAUTION: 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.

Courtesy of DaimlerChrysler Corp.

Fig. 12: Adjusting Crankshaft Sprocket For Timing Belt

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 (With Mechanical Tensioner) 1) Remove No. 1 spark plug.
Using dial indicator, set No. 1 cylinder to TDC of compression stroke.
Remove access plug from top of timing belt cover and ensure timing
mark on camshaft aligns with mark on rear cover. See Fig. 5.
2) Disconnect negative cable from battery, and ground strap from engine
mount bracket. Remove upper torque strut from front of engine. See
Fig. 2. Remove accessory drive belts. Raise vehicle and remove right
inner splash shield. See Fig. 6. Remove crankshaft damper bolt, and
use gear puller to remove crankshaft damper. See Fig. 7. Remove lower
engine torque strut. See Fig. 2.
3) Lower vehicle and place a jack under engine. Raise jack enough to
support engine weight. Remove right engine mount-to-engine mount
bracket bolt. See Fig. 8. Lower engine enough with jack to remove lower
engine mount bracket bolt. See Fig. 9. Raise engine with jack to allow
engine-to-body clearance for engine bracket removal. Remove power
steering pump with hoses attached, and secure out of way. Remove two
remaining upper engine mount bracket bolts and remove engine mount
bracket. See Fig. 9. Remove front timing belt cover bolts and remove
front timing belt cover. See Fig. 14.
4) Install a 6-mm Allen wrench into hexagon opening of top plate
tensioner pulley. Slowly rotate tensioner clockwise with 6-mm Allen
wrench until there is enough slack in timing belt to allow removal. If
reusing old timing belt, mark belt with arrow to indicate direction of
rotation. See Fig. 13. Remove timing belt.
CAUTION: To prevent pistons from hitting valves, do not rotate
camshaft or crankshaft after removing the timing belt.

Courtesy of DaimlerChrysler Corp.

Fig. 13: Identifying Mechanical Tensioner &

Adjusting Timing Belt

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 (With Mechanical Tensioner) 1) Set crankshaft sprocket
to TDC by aligning sprocket TDC mark with TDC reference mark arrow
on oil pump housing, then back off to 3 notches before TDC. See Fig. 12.
2) Set camshaft to TDC by aligning mark on sprocket with arrow on rear
of timing belt cover. See Fig. 15. Move crankshaft to 1/2 notch mark
before TDC for belt installation. See Fig. 12. Install timing belt starting at
crankshaft sprocket, then around water pump sprocket, and then
camshaft sprocket, and finally around timing belt tensioner pulley.
3) Move crankshaft sprocket to TDC to take up belt slack. Install a 6-mm
Allen wrench into hexagon opening of top plate tensioner pulley. Rotate
tensioner counterclockwise with 6-mm Allen wrench. See Fig. 13. The
tensioner pulley will move against timing belt and tensioner setting notch
will eventually start to move clockwise. Watching movement of notch,
continue rotating tensioner counterclockwise until the setting notch is
aligned with spring tang. See Fig. 13. Hold tensioner setting notch
aligned with spring tang, and tighten tensioner bolts to specification. See
TORQUE SPECIFICATIONS.
4) Remove Allen wrench from timing belt tensioner pulley. Rotate
crankshaft clockwise 2 revolutions. Check alignment of camshaft and
crankshaft timing marks. See Fig. 15. Also check if spring tang is within
tolerance window. See Fig. 16. If timing marks align and spring tang is
within specification, go to next step. If timing marks do not align or if
spring tang is not within specification, repeat step 3).
5) Install front timing belt cover. Install engine mount bracket and power
steering pump. Install right engine mount and remove jack from under
engine. Install and adjust upper and lower engine torque struts. See
ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS.
Install crankshaft damper, and tighten bolt to specification. See
TORQUE SPECIFICATIONS.
6) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle.
Install accessory drive belts. Adjust drive belts to proper tension.
7) Connect scan tool to Data Link Connector (DLC), located under lower
left edge of instrument panel. Turn ignition on. Perform cam/crank
relearn procedure by accessing ENGINE diagnostics. Select MISCELLANEOUS, then select RELEARN CAM CRANK and follow directions
on scan tool screen.

138

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 14: Exploded View Of Timing Belt & Components (With Mechanical Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 16: Timing Belt Tension Verification

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

Fig. 15: Aligning Camshaft & Crankshaft Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 85 (115)
Crankshaft Damper Bolt ........................................................................................ 100 (136)
Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61)
Engine Mount Through-Bolt .................................................................................... 87 (118)
Engine Torque Strut Bolts ....................................................................................... 87 (118)
Power Steering Pump Mounting Bolts ..................................................................... 40 (54)
Timing Belt Tensioner Bolt (Hydraulic Tensioner) .................................................... 23 (31)
Timing Belt Tensioner Bracket Bolt (Mechanical Tensioner) ................................... 23 (31)
Timing Belt Tensioner Lock Nut (Mechanical Tensioner) ........................................ 22 (30)
INCH Lbs. (N.m)
Timing Belt Cover Bolts (M6) ................................................................................. 106 (12)
Water Pump Mounting Bolts ................................................................................... 106 (12)

CHRYSLER

139

2.2L 4-Cylinder DOHC, VIN A

Belt
Part No.

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 SPECIFICATIONS.

2.6 Hours .. ..... T206

CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate

crankshaft using camshaft or intermediate shaft bolt.

2.6 Hours .. ..... T206

TIMING BELT APPLICATION

Application

Labor Time

2.2L 4-Cyl. DOHC, Turbo III

Daytona (Includes Canadian)
1992-93 ....................................................
Spirit
1991-92 ....................................................
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

5) Rotate crankshaft clockwise 2 revolutions. Check alignment of

camshaft and crankshaft timing marks.
6) Recheck timing belt tension. Readjust, if necessary. Tighten rocker
arm shafts to specification in specified sequence. See Fig. 1. See
TORQUE SPECIFICATIONS.
7) Install valve covers, spark plugs and ignition wire covers. Install fresh
air duct. To complete installation, reverse removal procedure. Adjust
drive belts to proper tension.

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Remove PCV hose. Remove upper timing belt cover.
Remove accessory drive belts. Rotate crankshaft so that cylinder No. 1
is at TDC of compression stroke.
2) Raise vehicle on hoist, and remove right wheel and inner splash
shield. Remove water pump pulley. Remove crankshaft pulley bolts and
remove pulley. It is NOT necessary to remove center bolt from the
crankshaft.
3) Remove lower accessory drive belt idler pulley and tensioner pulley.
Remove lower timing belt cover. Remove accessory drive belt idler
pulley bracket.
4) 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.
5) Remove air cleaner fresh air duct. Remove ignition secondary wire
cover from top of engine. Remove valve covers.
6) 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 timing belt.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Check
camshaft, crankshaft and intermediate shaft seals for leaks. Replace
damaged components.
Installation 1) 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.
2) Install a dial indicator in No. 1 spark plug hole. Rotate crankshaft until
No. 1 piston is at TDC. Mark engine block for TDC reference.
3) 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.
4) Install a belt tension gauge on the timing belt. Install tension 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

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Rocker Arm Loosening & Tightening Sequence

140

CHRYSLER
2.2L 4-Cylinder DOHC, VIN A (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Timing Belt Tensioner Bolt ........................................................................................ 45 (61)
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)

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt

CHRYSLER

141

2.2L 4-Cylinder DOHC, VIN R

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

9) To complete installation, reverse removal procedure. Adjust drive

belts to proper tension.

2.2L 4-Cyl. DOHC, Turbo

TC (Maserati)
1990 .................................... 2.9 Hours ... .. TCK153 .. ..... T153
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Rotate crankshaft so that cylinder No. 1 is at TDC of
compression stroke. Raise vehicle on hoist, and remove right inner
splash shield. Remove accessory drive belts.
2) 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.
3) Place floor jack under vehicle to support weight of engine and
transaxle assembly. Remove right engine mount (timing belt end of
engine). Remove valve cover.
4) Loosen center bolt of timing belt tensioner pulley. If reusing old timing
belt, mark belt with arrow to indicate original direction of rotation.
Remove timing belt.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Check
camshaft, crankshaft and intermediate shaft seals for leaks. Replace
damaged components.
Installation 1) Turn crankshaft and intermediate shaft until the
alignment marks on the sprockets are aligned. See Figs. 1 and 4. The
distributor rotor must be facing the No. 1 cylinder in the distributor cap.
2) Position pin punches in intake and exhaust camshaft alignment holes.
See Fig. 2. 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. 1. The 2 keyways not used must
be positioned at the top, outside of the vertical centerline of the
camshafts.
3) Turn crankshaft until the alignment mark on the sprocket is in line with
the crankshaft and intermediate shaft centerline.
4) 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.
5) 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 camshaft sprockets.
6) 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. 3.
7) Loosen tensioner pulley lock nut. Adjust tensioner tool index, if
necessary, to position the axis within 15 degrees of horizontal. See
Fig. 3.
CAUTION: Do NOT rotate crankshaft counterclockwise or attempt
to rotate the engine using the camshaft or intermediate shaft
mounting bolt.
8) Rotate crankshaft clockwise from TDC 2 full revolutions back to TDC.
Tighten the lock nut on the timing belt tensioner.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Camshaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Pin Punches In Camshafts

Courtesy of DaimlerChrysler Corp.

Fig. 3: Adjusting Timing Belt Tension

CHRYSLER

142

2.2L 4-Cylinder DOHC, VIN R (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Camshaft, Crankshaft & Intermediate Shafts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 60 (80)
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)
Timing Belt Tensioner Bolt ........................................................................................ 45 (61)
INCH Lbs. (N.m)
Water Pump Pulley Bolt .......................................................................................... 106 (12)

CHRYSLER

143

2.2L & 2.5L 4-Cylinder

TIMING BELT APPLICATION
Application

TIMING BELT APPLICATION (Cont.)

Labor Time

2.2L 4-Cyl. SOHC

Aries & Reliant
1981-88 ............................ ... 1 2.2 Hrs.
1989 ................................. ... 1 2.2 Hrs.
Caravan, Town & Country & Voyager
1982-88 ............................ ... 1 2.2 Hrs.
Caravelle, New Yorker & 600
1983-88 ............................ ... 1 2.2 Hrs.
Charger & Turismo
1983-87 ............................ ... 1 2.2 Hrs.
Dakota
1987-88 ............................ ... 2 1.1 Hrs.
Daytona
1984-88 ............................ ... 1 2.2 Hrs.
1989-93 ............................ ... 1 2.2 Hrs.
E Class
1983-84 ............................ ... 1 2.2 Hrs.
Executive Limo (Canadian)
1986 ................................. ... 1 2.2 Hrs.
Expo (Canadian)
1987-88 ............................ ... 1 2.2 Hrs.
1989 ................................. ... 1 2.2 Hrs.
Horizon & Omni
1981-88 ............................ ... 1 2.2 Hrs.
1989-90 ............................ ... 1 2.2 Hrs.
Lancer
1985-88 ............................ ... 1 2.2 Hrs.
1989 ................................. ... 1 2.2 Hrs.
Laser
1984-86 ............................ ... 1 2.2 Hrs.
LeBaron & LeBaron GTS
1982-88 ............................ ... 1 2.2 Hrs.
1989-90 ............................ ... 1 2.2 Hrs.
Mini Ram Van
1984-87 ............................ ... 1 2.2 Hrs.
New Yorker
1983-88 ............................ ... 1 2.2 Hrs.
Rampage
1982-84 ............................ ... 1 2.2 Hrs.
Scamp Pickup
1983 ................................. ... 1 2.2 Hrs.
Shadow & Sundance
1987-88 ............................ ... 1 2.2 Hrs.
1989-94 ............................ ... 1 2.2 Hrs.
TC3
1981-82 ............................ ... 1 2.2 Hrs.
Turismo
1983-87 ............................ ... 1 2.2 Hrs.
024
1981-82 ............................ ... 1 2.2 Hrs.
400
1982-83 ............................ ... 1 2.2 Hrs.
600
1983-88 ............................ ... 1 2.2 Hrs.
2.5L 4-Cyl. SOHC
Acclaim
1989-95 ............................ ... 1 2.2 Hrs.
Aries, Lancer & Reliant
1986-87 ............................ ... 1 2.2 Hrs.
1988 ................................. ... 1 2.2 Hrs.
1989 ................................. ... 1 2.2 Hrs.
Caravan, Town & Country & Voyager
1986 ................................. ... 1 2.2 Hrs.
1987 ................................. ... 1 2.2 Hrs.
1988 ................................. ... 1 2.2 Hrs.
1989-95 ............................ ... 1 2.2 Hrs.
Caravelle & 600
1986-87 ............................ ... 1 2.2 Hrs.
1988 ................................. ... 1 2.2 Hrs.

Component
Belt
Kit No.
Part No.

Application

Dakota
1989-95 ............................ ...
Daytona
1986-87 ............................ ...
1988 ................................. ...
1989-93 ............................ ...
Dynasty
1988 ................................. ...
1989-93 ............................ ...
Lancer
1986-87 ............................ ...
1988 ................................. ...
1989 ................................. ...
Laser
1986 ................................. ...
LeBaron & LeBaron GTS
1986-87 ............................ ...
1988 ................................. ...
1989-94 ............................ ...
Mini Ram Van
1987 ................................. ...
1988 ................................. ...
New Yorker
1986-87 ............................ ...
1988 ................................. ...
Shadow
1988 ................................. ...
1989-94 ............................ ...
Spirit
1989-95 ............................ ...
Sundance
1988 ................................. ...
1989-94 ............................ ...

... .. TCK071 .. ..... T071

... .. TCK153 .. ..... T153
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK153 .. ..... T153
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK153 .. ..... T153
... .. TCK071 .. ..... T071
... .. TCK153 .. ..... T153
... .. TCK071 .. ..... T071
... .. TCK153 .. ..... T153
... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071
... .. TCK153 .. ..... T153
1

... .. TCK071 .. ..... T071

2

... .. TCK071 .. ..... T071

... .. TCK071 .. ..... T071
... .. TCK071 .. ..... T071

Labor Time

Component
Belt
Kit No.
Part No.

1.1 Hrs. ... .. TCK153 .. ..... T153

2.2 Hrs. ... .. TCK114 ........ T114

2.2 Hrs. ... ...... ..... ...... ..... T132
2.2 Hrs. ... .. TCK153 .. ..... T153

1
1

1
1

1
1
1

2.2 Hrs. ... ...... ..... ...... ..... T132

2.2 Hrs. ... .. TCK153 .. ..... T153
2.2 Hrs. ... ...... ..... ............ T114
2.2 Hrs. ... ...... ..... ...... ..... T132
2.2 Hrs. ... .. TCK153 .. ..... T153

2.2 Hrs. ... .. TCK114 ........ T114

2.2 Hrs. ... .. TCK114 ........ T114

2.2 Hrs. ... .. TCK132 .. ..... T132
2.2 Hrs. ... .. TCK153 .. ..... T153

1
1

1
1

1
1

2.2 Hrs. ... ...... ..... ............ T114

2.2 Hrs. ... .. TCK132 .. ..... T132
2.2 Hrs. ... .. TCK114 ........ T114
2.2 Hrs. ... ...... ..... ...... ..... T132

2.2 Hrs. ... ...... ..... ...... ..... T132

2.2 Hrs. ... .. TCK153 .. ..... T153

2.2 Hrs. ... .. TCK153 .. ..... T153

2.2 Hrs. ... .. TCK132 .. ..... T132

2.2 Hrs. ... .. TCK153 .. ..... T153

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.
With Air Conditioning, add .5 hours.
With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

... .. TCK071 .. ..... T071

... .. TCK153 .. ..... T153

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

... .. TCK071 .. ..... T071

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

... .. TCK071 .. ..... T071

... .. TCK071 .. ..... T071

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

... .. TCK071 .. ..... T071

REMOVAL & INSTALLATION

... .. TCK071 .. ..... T071

TIMING BELT
... .. TCK153 .. ..... T153
... .. TCK114 ........ T114
... ...... ..... ...... ..... T132
... .. TCK153 .. ..... T153
... ...... ..... ............
... .. TCK114 ........
... .. TCK132 .. .....
... .. TCK153 .. .....

T114
T114
T132
T153

... .. TCK114 ........ T114

... .. TCK132 .. ..... T132

Removal 1) Disconnect negative battery cable. Remove all accessory

drive belts. If necessary, remove alternator, mounting brackets, and A/C
compressor (if equipped). DO NOT disconnect refrigerant lines.
Remove A/C belt idler pulley.
2) 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.
NOTE: If timing belt is to be reused, mark direction of rotation for
reassembly reference.
3) Remove right engine mount bolt, and raise engine slightly. Loosen the
timing belt tensioner, and remove timing belt. See Fig. 2.
Installation 1) Remove spark plugs. Place cylinder No. 1 on TDC.
Align timing marks on crankshaft and intermediate shaft sprockets. See

CHRYSLER

144

2.2L & 2.5L 4-Cylinder (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Crankshaft, Intermediate Shaft & Camshaft

Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Timing Belt Covers

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of DaimlerChrysler Corp.

Fig. 2: Adjusting Timing Belt Tension

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. 4.
2) 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.
3) Rotate crankshaft clockwise 2 complete revolutions to TDC. Tighten
tensioner retaining bolt to specification while holding belt tensioner
wrench in position. See TORQUE SPECIFICATIONS. Check all timing
marks for proper alignment. To complete installation, reverse removal
procedure. Adjust drive belts to proper tension.

Application
Ft. Lbs. (N.m)
Bracket-To-Block Bolt ................................................................................................ 70 (95)
Damper Weight .............................................................................. ................. 21-23 (28-30)
Intermediate Shaft Sprocket Bolt .............................................................................. 65 (88)
Timing Belt Tensioner Bolt ........................................................................................ 40 (54)
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)

CHRYSLER

145

2.4L 4-Cylinder DOHC, VIN 1

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. DOHC, VIN 1

Liberty
2002-04 ..................................................... 1.1 Hours ... ..... T265
Wrangler
2003-04 ..................................................... 1.0 Hours ... ..... T265
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the timing belt be replaced every 120,000
miles for normal service, or every 90,000 miles for severe service.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Crankshaft Vibration Damper

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove air cleaner upper cover, housing, and clean air
tube. Raise vehicle on hoist and remove accessory drive belts. Remove
bolt and crankshaft vibration damper. See Fig. 1. Remove A/C-generator
belt tensioner pulley assembly. See Fig. 2.
2) Remove lower timing belt cover bolts and remove cover. See Fig. 2.
Lower vehicle. Remove upper timing belt cover bolts and remove cover.
See Fig. 2.
CAUTION: When aligning crankshaft and camshaft timing marks,
always rotate engine from crankshaft. Camshaft should not be
rotated after timing belt is removed, or damage to valve components may occur.
3) Before removal of timing belt, rotate crankshaft until TDC mark on oil
pump housing aligns with the TDC mark on crankshaft sprocket (trailing
edge of sprocket tooth). See Fig. 3.
NOTE: Crankshaft sprocket TDC mark is located on the trailing
edge of sprocket tooth. See Fig. 3. Failure to align trailing edge of
sprocket tooth to TDC mark on oil pump housing will cause
camshaft timing marks to be misaligned.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Identifying Upper & Lower Timing Belt Covers &

Drive Belt Tensioner

4) Install a 6-mm Allen wrench into timing belt tensioner. Insert long end
of a 3-mm Allen wrench into pin hole in the front of tensioner. Slowly
rotate tensioner counterclockwise with 6-mm Allen wrench while pushing lightly on the 3-mm Allen wrench until it slides into the locking hole.
See Fig. 4. Remove timing belt. If necessary, remove crankshaft
sprocket from crankshaft using Special Tool (6793) and Insert
(C-4685-C2).
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.
CAUTION: Ensure that arrows on both camshaft sprockets are
facing up. See Fig. 5.
CAUTION: The crankshaft sprocket is set to a predetermined depth
from the factory for correct timing belt tracking. If removed, use of
Special Tool (6792) is required to set the sprocket to original
installation depth. An incorrectly installed sprocket will result in
timing belt and engine damage.
Installation 1) If necessary, install crankshaft sprocket to crankshaft
using Special Tool (6792). Set crankshaft sprocket to TDC by aligning

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

sprocket with arrow on oil pump housing. See Fig. 6. Also set camshaft
timing marks so that exhaust camshaft sprocket is a 1/2 notch below
intake camshaft sprocket. See Figs. 5 and 6.

CHRYSLER

146

2.4L 4-Cylinder DOHC, VIN 1 (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Camshaft Sprockets For Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 4: Locking Timing Belt Tensioner

2) Install timing belt. Starting at the crankshaft, go around water pump
sprocket, idler pulley, camshaft sprockets and then around tensioner.
See Fig. 6. Move exhaust camshaft sprocket counterclockwise to align
marks and take up belt slack. See Fig. 6. Insert a 6-mm Allen wrench
into hexagon opening located on top plate of belt tensioner pulley, and
rotate top plate counterclockwise. See Fig. 7.
3) Tensioner pulley will move against belt and tensioner setting notch will
eventually start to move clockwise. Watching movement of setting
notch, continue rotating top plate counterclockwise until setting notch is
aligned with spring tang. See Fig. 7. Using Allen wrench to prevent top
plate from moving, tighten tensioner lock nut to specification. See
TORQUE SPECIFICATIONS. Setting notch and spring tang should
remain aligned after lock nut is torqued. Remove Allen wrench and
torque wrench from timing belt tensioner pulley.
NOTE: Repositioning the crankshaft to the TDC position must be
done only during the clockwise rotation movement. If TDC is
missed, rotate crankshaft an additional 2 revolutions until TDC is
achieved. DO NOT rotate crankshaft counterclockwise.
4) Rotate crankshaft clockwise 2 revolutions, until crankshaft is repositioned to TDC. Check alignment of camshaft and crankshaft timing
marks. See Fig. 3. If timing marks do not align, remove timing belt and
realign timing marks.
5) Check if spring tang is within tolerance window. See Fig. 8. If spring
tang is within tolerance window, installation process is complete and
nothing further is required. If spring tang is not within tolerance window,
repeat installation procedure from beginning.
6) Install upper and lower timing belt covers. Install A/C-generator belt
tensioner pulley. See Fig. 2. Install crankshaft vibration damper. Install
accessory drive belts. Install air cleaner upper cover, housing, and clean
air tube. Connect negative battery cable.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Timing Belt

Courtesy of DaimlerChrysler Corp.

Fig. 7: Adjusting Timing Belt Tension

CHRYSLER

147

2.4L 4-Cylinder DOHC, VIN 1 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 74 (101)
Crankshaft Vibration Damper Bolt ........................................................................ 105 (142)
Drive Belt Tensioner Bracket Bolts ........................................................................... 30 (41)
Drive Belt Tensioner Pulley Bolt ............................................................................... 45 (61)
Timing Belt Idler Pulley Bolt ..................................................................................... 45 (61)
Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
Timing Belt Tensioner Lock Nut ............................................................................... 22 (30)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Verifying Timing Belt Tension

CHRYSLER

148

2.4L 4-Cylinder DOHC, VIN B

TIMING BELT APPLICATION
Application
2.4L 4-Cyl. DOHC, VIN B
Caravan & Voyager
1996-00 ....................................................
1

Labor Time

Belt
Part No.

2.0 Hours .. ..... T265

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 120,000
miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Raise vehicle on hoist and remove right front wheel.
Remove right inner splash panel. Remove accessory drive belts.
Remove crankshaft vibration damper.
2) Remove generator drive belt idler pulley. Remove lower timing belt
cover. Lower vehicle, and remove upper timing belt cover.
3) 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).
4) 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.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

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.
5) On 1996 models equipped with hydraulic tensioner, remove 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.
6) 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. 2.
7) On all models, if reusing old timing belt, mark belt with arrow to
indicate original direction of rotation. Remove timing belt.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components.
NOTE: If timing belt tensioner needs to be replaced, camshaft
sprockets and rear timing belt cover will need to be removed.
Installation 1) Ensure camshaft and crankshaft timing marks are still
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 sprocket. See Fig. 3.
2) Install timing belt starting at crankshaft, around water pump sprocket,
idler pulley, camshafts sprockets and then around tensioner pulley.
3) Move exhaust camshaft counterclockwise to take out belt slack and
align timing marks. See Fig. 1.
4) On 1996 models with hydraulic timing belt tensioner, install tensioner
on engine block, but do NOT final tighten bolts. See Fig. 4. Apply 21 ft.
lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See

Courtesy of DaimlerChrysler Corp.

Fig. 2: Adjusting Timing Belt Tension (Mechanical)

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.
5) On models with mechanical timing belt tensioners, pull locking Allen
wrench from timing belt tensioner.
6) On all models, rotate crankshaft 2 revolutions and check alignment of
timing marks. If timing marks are not correct, reposition timing belt.
7) Install right engine mount support and support bracket. Install upper
and lower timing belt covers. Install generator idler pulley. Install
crankshaft vibration damper.
8) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

CHRYSLER

149

2.4L 4-Cylinder DOHC, VIN B (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension (Hydraulic)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt Tensioner Assembly

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 75 (101)
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)

CHRYSLER

150

2.4L 4-Cylinder DOHC, VIN X

TIMING BELT APPLICATION
Application
2.4L 4-Cyl. DOHC, VIN X
Breeze
1996-00 ....................................................
Cirrus
1995-00 ....................................................
Sebring Convertible
1996-99 ....................................................
Stratus
1995-00 ....................................................
1

Labor Time

Belt
Part No.

3.6 Hours .. ..... T265

3.6 Hours .. ..... T265

3.6 Hours .. ..... T265

3.6 Hours .. ..... T265

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 replaced at 100,000 miles for Federal
vehicles and at 105,000 miles for California vehicles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Raise vehicle on hoist and remove right front wheel.
Remove right inner splash panel. Remove accessory drive belts.
Remove crankshaft vibration damper.
2) Remove generator drive belt idler pulley. Remove lower timing belt
cover.
3) Remove right engine support assembly vertical bolts from bottom of
frame rail (timing belt end of engine).
4) 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 assembly to engine bracket.
5) Move A/C drier aside. Remove coolant reservoir tank. Remove right
engine mount. Remove 3 bolts attaching engine mount bracket to
engine block.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

CAUTION: Align timing marks by rotating crankshaft only. Do not

rotate camshaft after timing belt is removed, or engine damage
may result.
6) Rotate crankshaft clockwise 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.

Fig. 2: Adjusting Timing Belt Tension (Mechanical)

7) On models equipped with hydraulic tensioner, remove hydraulic

tensioner bolts and remove tensioner. Place hydraulic 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.
8) 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. 2.
9) On all models, if reusing old timing belt, mark belt with arrow to
indicate original direction of rotation. Remove timing belt.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components.

Installation 1) Ensure camshaft and crankshaft timing marks are still

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 sprocket. See Fig. 3.
2) Install timing belt starting at crankshaft, around water pump sprocket,
idler pulley, camshafts sprockets and then around tensioner pulley.
3) On models with hydraulic timing belt tensioner, install tensioner on
engine block, but do NOT final tighten bolts. See Fig. 4. 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.

Courtesy of DaimlerChrysler Corp.

CHRYSLER

151

2.4L 4-Cylinder DOHC, VIN X (Cont.)

4) On models with mechanical timing belt tensioners, pull locking Allen
wrench from timing belt tensioner.
5) On all models, rotate crankshaft 2 revolutions and check alignment of
timing marks. If timing marks are not correct, reposition timing belt.
6) Install right engine mount and support bracket. Install upper and lower
timing belt covers. Install generator idler pulley. Install crankshaft
vibration damper.
7) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension (Hydraulic)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 75 (101)
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)
Timing Belt Cover Bolts
M6 (Outer-To-Inner) ................................................................................................ 40 (4.5)
M6 (Inner-To-Head) ............................................................................................... 105 (12)
Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt Tensioner Assembly

CHRYSLER

152

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. DOHC, VINs B & S

Neon
2003-04 ..................................................... 2.3 Hours ... ..... T265
PT Cruiser
2001-04 ..................................................... 3.6 Hours ... ..... T265
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 2001 PT Cruiser, normal replacement interval is at 120,000 miles or
96 months. For 2002 PT Cruiser, normal replacement interval is at
90,000 miles. For 2003-04 PT Cruiser, normal replacement interval is at
102,000 miles or 102 months (non-turbo) or 105,000 miles or 84 months
(turbo), with a severe service replacement recommendation of 90,000
miles. For Neon, normal replacement interval is at 105,000 miles or 84
months, with a severe service replacement recommendation of 90,000
miles.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Positioning Floor Jack

ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
NOTE: Whenever a torque strut bolt(s) is loosened, this procedure
must be performed. Upper and lower torque struts need to be
adjusted together to assure proper engine positioning and engine
mount loading.
NOTE: To prevent minimal upward lifting of engine, floor jack must
be positioned as shown. See Fig. 1.
1) Remove pencil strut. See Fig. 2. Loosen upper and lower torque strut
attaching bolt at suspension crossmember and shock tower bracket.
Engine position may now be adjusted by positioning a suitable floor jack
on the forward edge of transmission bellhousing. See Fig. 1.
2) With engine supported, remove upper and lower torque struts
attachment bolt(s) at shock tower bracket and suspension crossmember. See Fig. 3. Verify that torque struts are free to move within shock
tower bracket and crossmember. Reinstall torque strut bolt(s), but DO
NOT tighten.
3) Carefully apply upward force, allowing upper engine to rotate
rearward until distance between center of rearmost attaching stud on
engine mount bracket (point A) and center of hole for washer hose clip
on shock tower bracket (point B) is 4.7 (119 mm). See Fig. 4.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Pencil Strut

CAUTION: Engine must be held in position with jack until both

upper and lower torque strut bolts are tightened.
4) With engine held at proper position, tighten both upper and lower
torque strut bolts to specification. See TORQUE SPECIFICATIONS.
Install pencil strut, and tighten nuts to specification. Remove floor jack.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove upper engine
torque strut attaching bolts and remove engine torque strut. See Fig. 5.
Remove engine torque strut bracket from strut tower. On PT Cruiser
(Turbo), discharge and evacuate A/C system. Disconnect A/C lines at
junction block near upper timing belt cover.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Removing Upper & Lower Engine Torque Struts

2) On all models, remove upper timing belt cover bolts and remove
cover. See Fig. 6. Raise vehicle on hoist and remove right front wheel.
Remove splash shield. See Fig. 7. Remove accessory drive belts.
Remove crankshaft damper. See Fig. 8. Remove pencil strut. See Fig. 2.
Remove lower engine torque strut. See Fig. 5.

CHRYSLER

153

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Measuring Engine Position (Top View)

3) Disconnect exhaust system front pipe from manifold. Disconnect A/C
pressure switch at rear of compressor housing. Lower vehicle and
support engine with a jack. If not done previously, discharge and
evacuate A/C system. Disconnect A/C lines at junction block. Remove
screw attaching ground strap to strut bracket. Remove torque strut
bracket from strut tower. Remove upper radiator closure panel. Without
disconnecting lines from power steering pump, remove pump and
bracket and set pump aside.
4) With engine properly supported, remove right engine mount throughbolt. See Fig. 5. Raise engine with jack until engine support bracket bolts
are accessible, and remove engine support bracket. See Fig. 9. Remove
lower timing belt cover bolts and remove cover. See Fig. 6.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Locating Engine Mounting Components

CAUTION: When aligning crankshaft and camshaft timing marks,

always rotate engine from crankshaft. Camshaft should not be
rotated after timing belt is removed, or damage to valve components may occur.
5) Before removal of timing belt, rotate crankshaft until TDC mark on oil
pump housing aligns with the TDC mark on crankshaft sprocket (trailing
edge of sprocket tooth). See Fig. 10.
CAUTION: Crankshaft sprocket TDC mark is located on the trailing
edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth to TDC mark on oil pump housing will cause camshaft timing
marks to be misaligned.
6) Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench
into hexagon opening located on top plate of belt tensioner pulley. See
Fig. 11. Rotate top plate clockwise until there is enough slack in timing
belt to allow for removal. If reusing old timing belt, mark belt with arrow
to indicate original direction of rotation. Remove timing belt.
CAUTION: If timing belt was damaged due to incorrect rotating
tracking (alignment), belt tensioner pulley and bracket must be
replaced as an assembly.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components as necessary.
CAUTION: Ensure that arrows on both camshaft sprockets are
facing up.
Installation 1) Set crankshaft sprocket to TDC by aligning sprocket
with arrow on oil pump housing. Also set camshaft timing marks so that
exhaust camshaft sprocket is a 1/2 notch below intake camshaft
sprocket. See Fig. 12
.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Removing Front Timing Belt Covers

2) Install timing belt. Starting at the crankshaft, go around water pump
sprocket, idler pulley, camshaft sprockets, and then around tensioner.
See Fig. 10. Move exhaust camshaft sprocket counterclockwise to align
marks and take up belt slack. Insert a 6-mm Allen wrench into hexagon
opening located on top plate of belt tensioner pulley, and rotate top plate
counterclockwise. See Fig. 11.
3) Tensioner pulley will move against belt and tensioner setting notch will
eventually start to move clockwise. Watching movement of setting
notch, continue rotating top plate counterclockwise until setting notch is
aligned with spring tang. See Fig. 11. Using Allen wrench to prevent top
plate from moving, tighten tensioner lock bolt to specification. See
TORQUE SPECIFICATIONS. Setting notch and spring tang should
remain aligned after lock bolt is torqued. Remove Allen wrench and
torque wrench.

CHRYSLER

154

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Removing Right Front Splash Shield

Courtesy of DaimlerChrysler Corp.

Fig. 10: Identifying Camshaft & Crankshaft TDC & Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 8: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 11: Adjusting Timing Belt Tension

NOTE: Repositioning the crankshaft to the TDC position must be
done only during the clockwise rotation movement. If TDC is
missed, rotate a further 2 revolutions until TDC is achieved. DO
NOT rotate crankshaft counterclockwise.

Courtesy of DaimlerChrysler Corp.

Fig. 9: Removing Engine Support Bracket

4) Rotate crankshaft clockwise two complete revolutions manually for

seating of belt until crankshaft is repositioned at TDC position. Verify that
camshaft and crankshaft timing marks are in proper position. See
Fig. 10.
5) Check if spring tang is within tolerance window. See Fig. 13. If spring
tang is within tolerance window, installation process is complete and
nothing further is required. If spring tang is not within tolerance window,
repeat installation procedure from beginning.

CHRYSLER

155

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)

6) Install upper and lower timing belt covers, and tighten bolts to
specification. See TORQUE SPECIFICATIONS. Install engine support
bracket. Ensure power steering pump is properly located in mounting
location on bracket and tighten mount bracket bolts to specification. See
TORQUE SPECIFICATIONS.
7) Lower engine into mounting position and install right engine mount
through-bolt. See Fig. 5. Install power steering pump and bracket. Install
upper radiator closure panel. Install engine torque strut bracket to strut
tower. Connect ground strap to bracket. Tighten all bolts to specification.
See TORQUE SPECIFICATIONS. Install upper torque strut attaching
bolts. See Fig. 5.
8) Connect A/C lines, evacuate and recharge system. Raise vehicle and
connect exhaust system to manifold. Connect A/C pressure switch
connector. Install crankshaft damper and accessory drive belts. Install
lower torque strut. Perform torque strut adjustment. See ENGINE
TORQUE STRUT ADJUSTMENT under ADJUSTMENTS. Install pencil
strut. See Fig. 2. Install splash shield and install right front wheel.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
Connect negative cable to battery.

Courtesy of DaimlerChrysler Corp.

Fig. 12: Identifying Camshaft Sprocket Alignment For

Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 13: Verifying Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 85 (115)
Crankshaft Vibration Damper ................................................................................ 100 (136)
Engine Mount Through-Bolt (Right) .............................................. .......................... 87 (118)
Engine Support Bracket Bolts ................................................................................... 45 (61)
Engine Torque Strut Bolts ....................................................................................... 85 (115)
Pencil Strut Nut ......................................................................................................... 43 (58)
Power Steering Mounting Bracket ............................................................................ 40 (54)
Timing Belt Idler Pulley ............................................................................................. 45 (61)
Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
Wheel Mounting Nuts ............................................................................................ 100 (136)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .............................................................................................. 50 (6)
Timing Belt Tensioner Lock Bolt ............................................................................. 220 (25)

CHRYSLER

156

2.4L 4-Cylinder
DOHC, VINs B & X Except Neon & PT Cruiser
TIMING BELT APPLICATION
Application
2.4L 4-Cyl. DOHC, VINs B & X
Caravan
2001-04 ....................................................
Sebring Convertible & Sedan
2001-04 ....................................................
Stratus Sedan
2001-04 ....................................................
Voyager
2001-03 ....................................................
1

Labor Time

Belt
Part No.

2.0 Hours .. ..... T265

3.6 Hours .. ..... T265

3.6 Hours .. ..... T265

2.0 Hours .. ..... T265

CAUTION: If timing belt was damaged due to incorrect tracking

(alignment), belt tensioner pulley and bracket must be replaced as
an assembly.

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the timing belt be replaced every 90,000
miles for Sebring and Stratus models, and every 120,000 miles for
Caravan and Voyager (this maintenance is recommended by manufacturer, but is not required to maintain emission warranty).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Timing Cover & Engine Support Bracket

(Caravan & Voyager)

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove upper timing
belt cover bolts and remove cover. See Fig. 1 or 2. Raise vehicle on
hoist and remove right front wheel. Remove splash shield. Remove
accessory drive belts. Remove crankshaft damper. See Fig. 3.
2) Remove A/C-generator belt tensioner and pulley assembly. See
Fig. 4. Remove generator and bracket. Remove lower timing belt cover
bolts and remove cover. See Fig. 1 or 2. On Sebring and Stratus,
remove coolant recovery bottle.
3) With engine properly supported, remove right engine mount. Raise
engine with jack until engine support bracket bolts are accessible.
Remove engine support bracket bolts and then engine bracket. See
Fig. 1 or 2.
CAUTION: When aligning crankshaft and camshaft timing marks,
always rotate engine from crankshaft. Camshaft should not be
rotated after timing belt is removed, or damage to valve components may occur.
4) Before removal of timing belt, rotate crankshaft until TDC mark on oil
pump housing aligns with the TDC mark on crankshaft sprocket (trailing
edge of sprocket tooth). See Fig. 5.
CAUTION: Crankshaft sprocket TDC mark is located on the trailing
edge of sprocket tooth. See Fig. 5. Failure to align trailing edge of
sprocket tooth to TDC mark on oil pump housing will cause
camshaft timing marks to be misaligned.
5) Loosen timing belt tensioner lock bolt and insert a 6-mm Allen wrench
into hexagon opening located on top plate of belt tensioner pulley. See
Fig. 6. Rotate top plate clockwise until there is enough slack in timing
belt to allow for removal. If reusing old timing belt, mark belt with arrow
to indicate original direction of rotation. Remove timing belt.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Timing Belt Cover & Engine Support Bracket

(Sebring & Stratus)
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components as necessary.

CHRYSLER

157

2.4L 4-Cylinder
DOHC, VINs B & X Except Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 6: Adjusting Timing Belt Tension

CAUTION: Ensure that arrows on both camshaft sprockets are
facing up.

Courtesy of DaimlerChrysler Corp.

Fig. 4: Removing Drive Belt Tensioner

Installation 1) Set crankshaft sprocket to TDC by aligning sprocket

with arrow on oil pump housing. Also set camshaft timing marks so that
exhaust camshaft sprocket is a 1/2 notch below intake camshaft
sprocket. See Fig. 7.
2) Install timing belt. Starting at the crankshaft, go around water pump
sprocket, idler pulley, camshaft sprockets, and then around tensioner.
See Fig. 8. Move exhaust camshaft sprocket counterclockwise to align
marks and take up belt slack. Insert a 6-mm Allen wrench into hexagon
opening located on top plate of belt tensioner pulley, and rotate top plate
counterclockwise. See Fig. 6.
3) Tensioner pulley will move against belt and tensioner setting notch will
eventually start to move clockwise. Watching movement of setting
notch, continue rotating top plate counterclockwise until setting notch is
aligned with spring tang. See Fig. 6. Using Allen wrench to prevent top
plate from moving, tighten tensioner lock bolt to specification. See
TORQUE SPECIFICATIONS. Setting notch and spring tang should
remain aligned after lock bolt is torqued. Remove Allen wrench and
torque wrench.
NOTE: Repositioning the crankshaft to the TDC position must be
done only during the clockwise rotation movement. If TDC is
missed, rotate a further two revolutions until TDC is achieved. DO
NOT rotate crankshaft counterclockwise.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Identifying Crankshaft & Camshaft Timing Marks

4) Rotate crankshaft clockwise two complete revolutions manually for

seating of belt until crankshaft is repositioned at TDC position. Verify that
camshaft and crankshaft timing marks are in proper position. See Fig. 5.
5) Check if spring tang is within tolerance window. See Fig. 9. If spring
tang is within tolerance window, installation process is complete and
nothing further is required. If spring tang is not within tolerance window,
repeat installation procedure from beginning.
6) Install engine support bracket. Install upper and lower timing belt
covers. See Fig. 1 or 2. Install generator and bracket. Install
A/C-generator belt tensioner. See Fig. 4. Install crankshaft damper.
Install right engine mount. On Sebring and Stratus, install coolant
recovery bottle. On all models, install accessory drive belts. Install
splash shield and right front wheel. Connect negative battery cable.

CHRYSLER

158

2.4L 4-Cylinder
DOHC, VINs B & X Except Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Identifying Camshaft Sprocket Alignment For

Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 9: Timing Belt Tension Verification

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 85 (115)
Crankshaft Damper Bolt ........................................................................................ 100 (136)
Drive Belt Tensioner Bolt .......................................................................................... 40 (54)
Engine Mount Bracket Bolts ..................................................................................... 45 (61)
Right Engine Mount Bolt ........................................................................................... 45 (61)
Timing Belt Idler Pulley Bolt ..................................................................................... 45 (61)
Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .............................................................................................. 50 (6)
Timing Belt Tensioner Bolt ...................................................................................... 220 (25)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Identifying Camshaft & Crankshaft TDC & Timing Marks

CHRYSLER

159

2.4L 4-Cylinder SOHC, VIN G

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. SOHC

Sebring Coupe & Stratus Coupe
2001-04
Balance Shaft ...................................... .......... 1 .......... ..... T168
Camshaft ............................................... 1 2.4 Hours .. ..... T232
1

Balance shaft belt labor time included in

camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 2001-02 vehicles, manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts and Connecticut. In California, Massachusetts and Connecticut, 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 2003-2004 vehicles, manufacturer recommends the belt be
replaced every 60,000 miles except in California, Massachusetts, Maine
and Vermont. In California, Massachusetts, Maine and Vermont, 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Support weight of engine with floor jack. Move coolant
reservoir bottle out of way, and remove upper engine mount located
near timing belt cover.
2) Remove all accessory drive belts. Remove water pump pulley. See
Fig. 1.
3) Remove crankshaft pulley. Noting bolt lengths and locations, remove
upper and lower timing belt cover with gasket.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed
from timing belt end of engine). If timing belt is to be reused, mark
direction of rotation before removing.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Crankshaft Sprocket & Sensing Blade

2) Check timing belt and balance shaft belt tensioner pulleys for worn
bearings. Replace as necessary.
3) Check timing belt auto tensioner for leaks. Hold timing belt auto
tensioner upright. 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. See Fig. 3.

CAUTION: The crankshaft should always be turned in the forward

direction only.
4) Turn crankshaft in forward direction (to the right) to align camshaft
sprocket timing marks. Loosen tension pulley fixing bolt.
CAUTION: If timing belt is to be re-used, use chalk to mark (on flat
side) an arrow indicating the clockwise direction.
5) Move tension pulley to water pump side, and then remove timing belt.
6) Use crankshaft pulley mounting bolt to hold Special Tool (MB991367).
Loosen crankshaft sprocket mounting bolt, and remove sprocket. See
Fig. 2.
7) If reusing old balance shaft belt, mark belt with arrow to indicate
rotation direction. Loosen balance shaft tensioner pulley center bolt.
Remove balance shaft belt.
Inspection 1) 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, cracking and rubber
from canvas also indicates that belt warrants replacement. Cracks are
most evident at base of tooth.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Inspecting Timing Belt Auto Tensioner

Installation 1) Align crankshaft rear sprocket (sprocket B) and
balance shaft sprocket timing marks. See Fig. 5. Install balance shaft
belt. If reusing old belt, install in original direction of rotation. Ensure that
there is no slack in the belt.

160

CHRYSLER
2.4L 4-Cylinder SOHC, VIN G (Cont.)

2) To prevent the crankshaft bolt from loosening, degrease or clean

seating surfaces of crankshaft, crankshaft sprocket B, crankshaft sensing blade and crankshaft. See Fig. 2. Install crankshaft front sprocket.
Apply engine oil to threads and seat of crankshaft sprocket bolt. Install
and tighten bolt to specification while holding crankshaft stationary. See
TORQUE SPECIFICATIONS.
3) 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. 6. The tensioner pulley flange should face toward
the front of the engine.
NOTE: When tightening balance shaft tensioner pulley center bolt,
ensure tensioner pulley shaft does not rotate with bolt. Allowing it
to rotate with bolt can cause excessive tension of bolt.
4) Holding timing belt B tensioner up with your finger in direction of
arrow, apply pressure on timing belt so tension side of belt is taut. Now
tighten bolt to fix the tensioner. See TORQUE SPECIFICATIONS. To
ensure tension is correct, depress belt with a finger. Adjust belt tension
is not within specification, 0.2-0.3 (5-7 mm). See Fig. 6.
5) Apply 22-44 lbs. force to pushrod of auto-tensioner by pressing it
against a metal object (such as the engine block) and measure the
movement of the pushrod. See Fig. 3. If outside standard value, replace
auto-tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Front Timing Belt Marks

CAUTION: Never compress pushrod too fast, it may be damaged.

6) Use a press or vise to gently compress auto-tensioner pushrod until
pin hole A of pushrod and pin hole B of tensioner cylinder are aligned.
When holes are aligned, insert set pin.
7) Align timing marks on camshaft sprocket, crankshaft sprocket and oil
pump sprocket. See Fig. 4.
8) After aligning timing mark on oil pump sprocket, remove cylinder
block plug and insert a 3 (80 mm) Phillips head screwdriver. Check to
be sure that screwdriver goes in 2.4 (60 mm) or more. If screwdriver will
only go in 0.8-1.0 (20-25 mm) before striking the counterbalance shaft,
turn sprocket once, realign timing marks and check that screwdriver
goes in 2.4 (60 mm) or more. The screwdriver should not be taken out
until timing belt is installed. See Fig. 8.
9) After turning crankshaft 1/4 of a revolution in counterclockwise
direction, turn it in clockwise direction until the timing marks are aligned.
CAUTION: When tightening fixing bolt make sure that tension
pulley does not turn with bolt.
10) Loosen tension pulley fixing bolt, and then use Special Tool
(MD998767) and a torque wrench to tighten fixing bolt to specifications.
Tighten bolt to 32-40 ft. lbs. (42-54 N.m). Timing belt tension torque
should be 31 INCH lbs. (3.5 N.m). See Fig. 7.
11) Remove set pin that has been inserted into the auto-tensioner.
12) Turn crankshaft 2 revolutions clockwise so that the timing marks are
aligned. After leaving it for 15 minutes, measure amount of protrusion of
auto-tensioner. Standard value 0.15-0.18 (3.8-4.5 mm).
13) If amount of protrusion is outside the standard value, repeat
steps 9)-12).
14) Check again to be sure that timing marks of each sprocket are
aligned.
15) Install timing belt covers. To complete installation, reverse removal
procedures.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Balance Shaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 6: Adjusting Balance Shaft Timing Belt Tensioner

CHRYSLER

161

2.4L 4-Cylinder SOHC, VIN G (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Adjusting Timing Belt Tension

Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ....................................................................... ................. 14-20 (20-26)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Crankshaft Drive Belt Pulley Bolt ................................................. ................. 14-22 (20-29)
Crankshaft Sprocket Center Bolt .................................................. ........... 1 80-94 (109-127)
Drive Belt Tensioner Pulley Bracket Bolt ..................................... ................. 14-18 (20-25)
Engine Upper Mount
Mount-To-Body Through-Bolt ...................................................... ............... 2 51-69 (69-93)
Mount-To-Engine Bracket Nut/Bolt .............................................. ................. 56-72 (74-98)
Tensioner Pulley Center Bolt
Balance Shaft Belt Pulley ........................................................... ................. 12-16 (16-22)
Camshaft Belt Pulley ................................................................... ................. 32-40 (42-54)
INCH Lbs. (N.m)
Timing Belt Cover Bolt
Lower Cover Bolts ...................................................................................... 80-97 (9.04-11)
Upper Cover Bolts ....................................................................... ............. 104-130 (13-15)
Water Pump Pulley Bolt ................................................................ ................ 69-81 (8-9.15)
1
2

Courtesy of DaimlerChrysler Corp.

Fig. 8: Holding Balance Shaft In Stationary Position

Apply engine oil to bolt threads.

Final tighten bolt with weight of engine on mount.

CHRYSLER

162

2.5L V6
TIMING BELT APPLICATION
Application
2.5L V6
Avenger & Sebring Coupe
1995-00 ..............................
Cirrus & Stratus
1995-00 ..............................
Sebring Convertible
1996-00 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

4.8 Hours .. .. TCK259 .. ..... T259

4.8 Hours .. .. TCK259 .. ..... T259

4.8 Hours .. .. TCK259 .. ..... T259

With Air Conditioning add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Setting Crankshaft Sprocket

NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 60,000 mile
intervals, except in California, Connecticut, and Massachusetts. 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Camshaft Sprockets

TIMING BELT
Removal (Avenger & Sebring Coupe) 1) Disconnect negative
battery cable. Remove coolant reservoir bottle. On models with cruise
control, remove cruise control actuator and set aside.
2) On all models, raise and support vehicle. Remove right front wheel.
Remove side panel from right wheelwell.
3) Remove accessory drive belts. Remove generator and bracket from
engine block, and set aside. Remove crankshaft vibration damper.
4) Lower vehicle. Place floor jack under vehicle to support weight of
engine and transaxle assembly. Remove engine mount-to-frame
through-bolt. Remove engine mount-to-engine bracket nuts and bolt.
Remove engine mount.
5) Remove 3 bolts attaching engine support bracket to engine 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 identification.
6) Remove power steering pump (hoses attached) and bracket from
engine block, and set aside. Remove timing belt covers.
7) Rotate crankshaft to align camshaft and crankshaft timing marks. See
Figs. 1 and 2.
8) If reusing old timing belt, mark timing belt direction of rotation 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.
Removal (Cirrus, Sebring Convertible & Stratus) 1) Disconnect
negative battery cable from jumper terminal. Raise and support vehicle.
Remove right front wheel. Remove accessory drive belt splash shield
from right wheelwell.

2) Remove accessory drive belts. Remove right engine support assembly vertical bolts from bottom side of frame rail (timing belt end of
engine).
3) Lower vehicle. Place floor jack under vehicle to support weight of
engine and transaxle assembly. Remove 3 bolts attaching engine
support assembly to engine block bracket.
4) Move the A/C drier aside with hoses attached. Remove coolant
reservoir tank. Remove right engine support assembly. Remove 3 bolts
attaching engine support bracket to engine block, and remove bracket.
5) Remove crankshaft vibration damper. Remove power steering pump
(hoses attached) and bracket from engine block. Remove timing belt
covers.
6) Rotate crankshaft to align camshaft and crankshaft timing marks. See
Figs. 1 and 2.
7) If reusing old timing belt, mark timing belt direction of rotation 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.
Installation (All Models) 1) 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. 3.
2) Index tensioner in vise the same direction as installed. This will
ensure proper pin orientation when tensioner is installed in engine. See
Fig. 3.
3) Set crankshaft mark with timing mark on oil pump housing, then back
off 3 notches before TDC. See Fig. 1. Set camshaft sprockets by
aligning timing marks on sprockets with marks on rear timing belt cover.
See Fig. 2.

CHRYSLER

163

2.5L V6 (Cont.)
NOTE: If reusing old timing belt, install in original direction of
rotation.
4) 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.
5) Rotate crankshaft clockwise to TDC. Continue routing belt around
idler pulley, crankshaft sprocket, and tensioner pulley. Apply rotating
force to crankshaft sprocket in clockwise direction to tension belt.
Ensure all timing marks are still aligned.
6) Loosen tensioner pulley center bolt. Position tensioner pulley with pin
holes facing down. Install Adapter (MD998767) or equivalent, and
torque wrench, to tensioner pulley. See Fig. 4. Apply 39 INCH lbs. (4.4
N.m) in a counterclockwise direction to tensioner. Tighten tensioner bolt
to specification, without letting tensioner pulley rotate.
7) With torque being applied to tensioner pulley, install automatic
tensioner (with locking pin in place) to tensioner pulley bracket. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Pull tensioner
plunger locking pin.
8) Rotate crankshaft 2 revolutions clockwise, and check alignment of
timing marks. Install tensioner locking pin into automatic tensioner. Pin
should slide in and out with no resistance. 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 necessary.
9) Install timing belt covers. Install crankshaft vibration damper. Tighten
crankshaft damper bolt to specification. See TORQUE SPECIFICATIONS.
NOTE: Reamer bolt head will have a R marking for identification.
10) 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.
11) On all models, reverse removal procedure to complete installation.
Adjust drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Compressing Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 4: Tensioning Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
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 Coupe .......................................................... ................. 47-54 (64-74)
Cirrus, Sebring Convertible & Stratus .................................................................... 45 (61)
Engine Support Assembly-To-Frame Rail
Avenger & Sebring Coupe .......................................................... ................. 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 Idler Pulley Bolt ..................................................................................... 32 (44)
Timing Belt Tensioner Pivot Arm Bolt ....................................................................... 33 (45)
Timing Belt Tensioner Pulley Bolt ............................................................................. 35 (48)
Timing Belt Tensioner-To-Engine Bolt ...................................................................... 17 (23)
Water Pump Bolt ....................................................................................................... 18 (24)
Wheel Lug Nut
Avenger & Sebring Coupe .......................................................... ............... 65-80 (88-108)
Cirrus, Sebring Convertible & Stratus ................................................................ 100 (135)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................................ ............... 89-106 (10-12)

CHRYSLER

164

3.0L V6 SOHC 1987-00

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.0L V6
Acclaim & Spirit
1989-95 ............................... 3.5 Hours ... ..
Caravan, Mini Ram Van & Voyager
1987-00 .............................. 1 4.0 Hours .. ..
Daytona (Includes Canadian)
1990-93 ............................... 3.5 Hours ... ..
Dynasty (Includes Canadian)
1988-93 ............................... 3.5 Hours ... ..
LeBaron
1990-95 .............................. 1 3.5 Hours .. ..
New Yorker
1988-89 ............................... 3.5 Hours ... ..
Raider
1989 ................................... 2 3.5 Hours .. ..
Ram 50
1990-91 ............................... 3.5 Hours ... ..
Shadow & Sundance
1992-94 ............................... 3.5 Hours ... ..
Stealth
1991-96 ............................... 2.0 Hours ... ..
TC Maserati
1990-91 ............................... 3.5 Hours ... ..
1

TCK139 .. ..... T139

TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139
TCK139 .. ..... T139

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.
With Air Conditioning, add .7 hours.
With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Up to 1993 model year, the manufacturer recommends the 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
previously 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.

REMOVAL & INSTALLATION

TIMING BELT REMOVAL
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker,
Shadow, Spirit & Sundance (1987-89) 1) 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.
2) 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) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove A/C compressor and power steering pump with
hoses attached, and secure aside (if equipped). Remove A/C compressor mounting bracket and drive belt tensioner. Remove power steering/
alternator belt tensioner.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Locating Timing Belt & Sprockets

2) 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.
3) Slightly raise engine. Remove engine mount bracket. Remove timing
belt covers, noting bolt length for installation reference. Rotate engine
and align timing marks on camshaft sprockets and crankshaft sprocket.
See Fig. 1. If reusing timing belt, mark direction of timing belt rotation for
installation reference.
4) 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 crankshaft sprocket. Remove flange
and crankshaft sprocket from crankshaft (if necessary).
5) 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 1) Raise vehicle. Remove accessory drive belt
splash shield. Remove accessory drive belts. Remove crankshaft
pulleys and vibration damper.
2) Lower vehicle. Support engine weight with floor jack. Remove purge
duty solenoid and wiring harness from right engine mount bracket.
3) Remove 2 right engine mount insulator vertical bolts 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 engine mount.
4) Remove engine support bracket from front of engine. Remove 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.
5) 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 installation reference.
6) Loosen timing belt tensioner bolt. Move timing belt tensioner away
from timing belt, and temporarily tighten bolt. Remove timing belt.
Raider & Ram 50 1) Disconnect negative battery cable. Drain cooling
system. Disconnect upper radiator hose. Remove upper radiator
shroud. Remove cooling fan and fan clutch assembly. Remove cooling
fan pulley. Remove all accessory drive belts. Remove power steering
pump with pressure and return hoses connected, and set aside.
2) Remove power steering pump brackets. Remove A/C tensioner pulley
and mounting bracket. Remove A/C compressor (with hoses connected)
and mounting bracket. Remove cooling fan bracket assembly. Remove
timing belt No. 1 upper outer cover and gaskets. See Fig. 2.

CHRYSLER

165

3.0L V6 SOHC 1987-00 (Cont.)

CAUTION: V belt will be damaged by tool. DO NOT use engine
V belt to hold crankshaft pulley unless belt is to be replaced.
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, remove crankshaft pulley bolt. Remove
crankshaft pulley.
4) 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 tension.
5) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt and belt tensioner.
Courtesy of DaimlerChrysler Corp.

Fig. 3: Identifying Engine Support Bracket (Stealth)

TIMING BELT INSTALLATION

Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker,
Shadow, Spirit & Sundance (1987-89) 1) 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 temporarily to hold tensioner in position.
2) Install timing belt on crankshaft sprocket first while keeping belt tight
on tension side. See Fig. 1. Install belt on radiator side camshaft
sprocket. Then, install belt on water pump pulley, rear camshaft
sprocket, and finally on timing belt tensioner.
3) 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 tensioner from temporary position,
and allow it to apply tension to timing belt. Turn crankshaft 2 full turns in
a clockwise direction ONLY.
NOTE: Turn crankshaft smoothly and ONLY in a clockwise direction.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt & Components

(Raider & Ram 50)
Stealth 1) Remove lower splash shields. Remove cruise control
actuator (if equipped). Remove all drive belts. Unplug electrical connector at power steering pump. Remove A/C tensioner pulley and mounting
bracket.
2) 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.
3) Remove engine support bracket bolts in proper sequence. See Fig. 3.
Remove engine support bracket. Remove timing cover cap, timing belt
cover, and gaskets. Using Holder (MB990767) and Adapter Bolts
(MD998719), remove crankshaft pulley.
4) Remove lower timing belt cover, gaskets, and flange. Rotate crankshaft to align all timing marks. See Fig. 1. Loosen belt tensioner bolt.
Rotate belt tensioner counterclockwise to relieve belt tension.
5) 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.

4) Again line up all timing marks and tighten tensioner against belt.
Tighten tensioner locking bolt to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Adjust
drive belts to proper tension.
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) 1) Rotate timing belt tensioner counterclockwise and
temporarily tighten bolt. Ensure all timing marks are aligned. See Fig. 1.
Install timing belt on crankshaft sprocket while holding timing belt tight
on tension side. If reusing timing belt, ensure timing belt is installed in
original direction of rotation.
2) 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.
3) Apply rotating force on front (radiator side) camshaft sprocket in
opposite direction to apply pressure on tension side of timing belt.
Ensure all timing marks align. See Fig. 1.
4) 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, allowing spring tension to be applied on timing
belt tensioner and timing belt.
5) 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.
6) To install remaining components, reverse removal procedure. Ensure
timing belt cover bolts are installed in original location. See Fig. 4.
Tighten bolts to specification. Adjust drive belts to proper tension.
Caravan & Voyager 1) If timing belt tensioner spring was removed,
install spring on tensioner arm with end of hook facing out (away from
engine).

CHRYSLER

166

3.0L V6 SOHC 1987-00 (Cont.)

5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining
components, reverse removal procedure. Install proper length bolts in
timing belt covers. See Fig. 5. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Identifying Timing Belt Cover Bolt Lengths

(Raider & Ram 50)
Courtesy of DaimlerChrysler Corp.

Fig. 4: Identifying Timing Belt Cover Bolt Lengths

(Except Raider, Ram 50 & Stealth)
2) 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, ensure timing belt is installed in original
direction of rotation.
3) 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.
4) Install flange on front of crankshaft sprocket with flat side against
timing belt and offset side toward front of crankshaft. Loosen timing belt
tensioner bolt, allowing spring tension to be applied on timing belt
tensioner and timing belt.
5) 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.
6) Install timing belt covers. Ensure bolts are installed in original
locations. See Fig. 4. Install engine support bracket. Install right side
engine mount. Install crankshaft vibration damper.
7) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.
NOTE: Engine support bracket reamer bolt must be tightened
slowly while spraying lubricant on bolt.
Raider & Ram 50 1) 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.
2) 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.
3) Install timing belt on crankshaft sprocket and then left camshaft
sprocket with all slack removed from tension side of belt. Route timing
belt onto water pump pulley, right camshaft sprocket and tensioner.
Remove any slack from belt by rotating left and then right camshaft
sprockets counterclockwise. Ensure all timing marks are aligned. Install
flange on crankshaft. Loosen belt tensioner bolts slightly and allow
tensioner to apply belt tension.
4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions
clockwise. DO NOT rotate counterclockwise. Realign all timing marks.
Tighten belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway
between crankshaft sprocket and camshaft sprocket on side opposite
belt tensioner.

Stealth 1) 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. Temporarily tighten bolt. Align all timing
marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1.
2) 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 timing marks are aligned. Install flange onto
crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to
apply belt tension.
3) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign
all timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt
tension halfway between crankshaft sprocket and camshaft sprocket on
side opposite belt tensioner.
NOTE: Engine support bracket reamer bolt must be tightened
slowly. Apply lubricant onto bolt during installation.
4) Belt tension should be 44-66 lbs. (20-30 kg). To install remaining
components, reverse removal procedure. 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 tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Identifying Timing Belt Cover Bolt Lengths (Stealth)

CHRYSLER

167

3.0L V6 SOHC 1987-00 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 & STEALTH)

TORQUE SPECIFICATIONS (STEALTH)

Application
Ft. Lbs. (N.m)
A/C Compressor Drive Belt Idler Pulley Bolt ........................................................... 40 (54)
Camshaft Sprocket Bolt ............................................................................................ 70 (95)
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 Cover Bolt .............................................................................................. 10 (14)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 18-21 (25-28)
Water Pump Bolts ..................................................................................................... 20 (27)

Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .......................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Pulley Bolt
1991 ....................................................................................................... 108-116 (146-157)
1992-94 ................................................................................................................ 136 (185)
Engine Support Bracket Bolt
10 X 40 mm ................................................................................ ................. 47-54 (64-73)
10 X 40 mm .............................................................................................. 76-83 (103-113)
Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42)
Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49)
Water Pump Bolt ....................................................................................................... 17 (23)

TORQUE SPECIFICATIONS (RAIDER & RAM 50)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt
Pickup .......................................................................................... ......... 130-137 (176-186)
Raider .................................................................................................... 108-116 (146-157)
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 Bolt .................................................................. ................. 84-108 (9-12)
Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)

INCH Lbs. (N.m)

Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)

CHRYSLER

168

3.0L V6 SOHC, 2001-04

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 SOHC
Sebring Coupe & Stratus Coupe
2001-04 ..................................................... 2.6 Hours ... ..... T259
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 2001-02 vehicles, manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts and Connecticut. In California, Massachusetts and Connecticut, 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 2003-04 vehicles, manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts, Maine and
Vermont. In California, Massachusetts, Maine and Vermont, 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.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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 steering pump drive
belt and tensioner pulley.
2) Support weight of engine with jack. Remove engine mount from
timing belt end of engine. Remove engine mount bracket from engine
block.
3) Using End Yoke Holder (MB990767) and Crankshaft Pulley Holder
Pin (MD998715), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley.
4) Remove upper and lower timing belt covers. See Fig. 1. Remove
engine support bracket from front of engine.
Courtesy of Mitsubishi Motor Sales of America.

CAUTION: Do not turn crankshaft counterclockwise.

Fig. 2: Aligning Timing Marks
5) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Turn crankshaft clockwise to align camshaft and
crankshaft timing marks and to set No. 1 cylinder at TDC. See Fig. 2.
Loosen center bolt of timing belt tensioner pulley, and remove timing
belt. Remove timing belt auto tensioner from engine block.
Inspection 1) 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 pulley for smooth rotation.
Replace if defective.
2) Check timing belt auto tensioner for leaks. Hold timing belt auto
tensioner upright. See Fig. 3. Apply 22-44 lbs. (98-196 N) of force to end
of push rod. If auto tensioner push rod moves more than 0.039 (1 mm),
replace the auto tensioner. Check push rod for cracks.
Installation 1) Place auto tensioner in soft-jawed vise to SLOWLY
compress 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 the
vise jaw.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Inspecting Timing Belt Auto Tensioner

CHRYSLER

169

3.0L V6 SOHC, 2001-04 (Cont.)

CAUTION: Never compress the auto tensioner too fast, or the push
rod will be damaged.
2) 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. If replacing auto tensioner, pin will already be inserted
into pin holes of new part. Leaving locking pin inserted, install auto
tensioner on engine.
WARNING: Right bank camshaft can easily turn from applied
spring pressure. Be careful not to pinch fingers when installing
timing belt.
3) Ensure all timing marks are still aligned. See Fig. 2. Install 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 by turning right bank camshaft sprocket counterclockwise. Check all timing marks again.
4) Using Tensioner Wrench (MD998767), push tensioner pulley into
timing belt. Temporarily tighten center bolt.
5) Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn
counterclockwise. Then turn crankshaft clockwise until timing marks are
aligned.
6) Loosen tensioner pulley center bolt. Position tensioner pin holes at
top of tensioner. Install Tensioner Wrench (MD998767) on tensioner
pulley. See Fig. 4. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of
torque (clockwise direction) to tensioner pulley. Tighten tensioner center
bolt to specification while holding tensioner stationary. See TORQUE
SPECIFICATIONS.
7) Remove locking pin from auto tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
8) 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 arm of tensioner pulley bracket. Clearance
should be 0.15-0.20 (3.8-5.0 mm). See Fig. 5. If protrusion is not
correct, repeat tensioning procedure.
9) Install engine support bracket on engine block. Tighten top bolt first,
then working in a counterclockwise direction, tighten the remaining
bolts. See Fig. 6. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt, then tighten bolt to specification. See TORQUE SPECIFICATIONS.
10) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Measuring Auto Tensioner Push Rod Protrusion

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Engine Support Bracket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner-To-Engine Block Bolt ........................................... ................. 15-19 (20-26)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186)
Dipstick Tube Bolt ......................................................................... ................. 31-40 (42-54)
Engine Mount
To-Engine Support Bracket Bolt
10-mm ........................................................................................ ................. 55-72 (74-98)
12-mm ........................................................................................ ................. 51-69 (69-93)
To-Body Through-Bolt .................................................................. ............... 2 55-72 (74-98)
Engine Support Bracket-To-Engine Bolt ....................................... ................. 29-36 (39-49)
Generator Pivot Bolt ...................................................................... ................. 29-44 (39-59)
Generator Top Bolt ........................................................................ ................. 13-18 (17-25)
Power Steering Pump Belt Tensioner Bolt ................................... ................. 25-40 (34-54)
Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 25-40 (34-54)
Timing Belt Tensioner Center Bolt ................................................ ................. 31-40 (42-54)
INCH Lbs. (N.m)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Adjusting Timing Belt Tension

Timing Belt Lower Cover Bolt ....................................................... ............... 89-106

Timing Belt Rear Cover Bolt ....................................................................... 115-133
Timing Belt Upper Cover Bolt
6-mm ............................................................................................ ............... 89-106
8-mm .......................................................................................................... 115-133
1
2

Apply engine oil to bolt threads before installation.

Final tighten bolt with full weight of engine on mount.

(10-12)
(13-15)
(10-12)
(13-15)

CHRYSLER

170

3.5L V6 24 Valve
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.5L V6
Pacifica
2004 ........................................................... 2.7 Hours ... ..... T295
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Information is not available from manufacturer.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Crankshaft Damper

TIMING BELT
CAUTION: The 3.5L is NOT a freewheeling engine. Therefore,
loosen the valve train rocker assemblies before servicing the
timing device.
Removal 1) Relieve fuel system pressure and disconnect negative
battery cable.
2) Remove both cylinder head covers and loosen the rocker arm
assemblies.
3) Raise vehicle on hoist.
4) Remove accessory drive belt and tensioner.
5) Remove bolts for power steering pump and move pump aside.
6) Remove right front wheel and accessory drive belt splash shield.
7) Remove crankshaft damper bolt. Using Puller (1023) and Insert
(9020-R), remove crankshaft damper. See Fig. 1.
8) Remove the lower front timing belt cover fasteners.
9) Lower vehicle.
10) Support engine with a floor jack.
11) Remove the air cleaner housing.
12) Remove the front engine mount.
13) Disconnect the fuel supply line at the fuel rail. See Fig. 2.
14) Remove the upper timing belt cover bolts and remove front timing
belt cover.
15) If timing belt is to be reused, mark belt running direction.
16) Rotate engine clockwise until crankshaft mark aligns with the TDC
mark on the oil pump housing and the camshaft sprocket marks are
aligned with the marks on the rear cover. See Fig. 3.
17) Remove the timing belt tensioner and remove timing belt.
Inspection 1) Inspect both sides of the timing belt. Replace belt if any
of the following conditions exist. See Fig. 4:
Hardening of back rubber or back side is glossy without resilience
and leaves no indent when pressed with fingernail.
Cracks on rubber back.
Crack on peeling of canvas.
Cracks on rib root.
Cracks on belt sides.
Missing teeth.
Abnormal wear on belt sides. The sides are normal if they are sharp
as if cut by a knife.
Vehicle mileage or time at component maintenance requirement.
See MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE.
2) Inspect tensioner for fluid leakage around the plunger seal. Replace
tensioner if leaking.
3) Inspect the pivot and for free movement, bearing grease leakage, and
smooth rotation. If not rotating freely, replace arm and pulley assembly.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing & Installing Front Timing Belt Cover

CAUTION: If camshafts have moved from the timing marks, always
rotate camshaft toward the direction nearest the timing marks. DO
NOT turn camshafts a full revolution or damage to valves and/or
pistons could result.
CAUTION: Index tensioner in the vise the same way it is installed
on the engine. This ensures proper pin orientation when tensioner
is installed on the engine.
Installation 1) Place tensioner into a vise and slowly compress the
plunger. See Fig. 5. Total bleed down of tensioner should take about 5
minutes.
2) When plunger is compressed into the tensioner body, install a pin
through the body and plunger to retain plunger in place until tensioner is
installed.
3) Align the crankshaft sprocket with the TDC mark on oil pump cover.
See Fig. 3.

CHRYSLER

171

3.5L V6 24 Valve (Cont.)

Courtesy of DaimlerChrysler Corp.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Timing Marks

4) Align the camshaft sprockets timing reference mark with the mark on
the rear cover. See Fig. 3.
5) Install the timing belt starting at the crankshaft sprocket going in a
counterclockwise direction. Install the belt around the last sprocket.
Maintain tension on the belt as it is positioned around the tensioner
pulley.
6) Holding the tensioner pulley against the belt, install the tensioner into
the housing and tighten bolts. See TORQUE SPECIFICATIONS. Each
camshaft mark should remain aligned at the rear cover marks.

Fig. 4: Inspecting Timing Belt

16) Install crankshaft damper bolt. See TORQUE SPECIFICATIONS.
17) Install accessory drive belt tensioner. See TORQUE SPECIFICATIONS.
18) Install accessory drive belt.
19) Install the accessory drive belt splash shield and right front wheel.
20) Lower vehicle.
21) Tighten the rocker arm assemblies and install cylinder head covers.
See TORQUE SPECIFICATIONS.
22) Connect negative battery cable.

NOTE: If the camshaft gears have been removed, it is only necessary to have camshaft gear retaining bolts installed to a snug
torque at this time. See TORQUE SPECIFICATIONS.
7) When tensioner is in place, pull retaining pin to allow the tensioner to
extend to the pulley bracket.
8) Rotate camshaft sprocket 2 revolutions and check the timing marks
on the camshafts and crankshaft. The marks should line up within their
respective locations. See Fig. 3. If marks do not line up, repeat
procedure.
NOTE: If camshaft gears have been removed and timing is correct,
counter hold and tighten the camshaft gears to final torque
specification. See TORQUE SPECIFICATIONS.
9) Install front timing cover.
10) Install the upper engine mount. See TORQUE SPECIFICATIONS.
11) Connect fuel supply line at fuel rail. See Fig. 2.
12) Install air cleaner housing.
13) Remove floor jack and raise vehicle.
14) Install crankshaft damper using 5.9 Bolt With Nut (C-4685-C1) and
Thrust Bearing (6792), and Installer (6792-1). See Fig. 6.
15) Install power steering pump fasteners. See TORQUE SPECIFICATIONS.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Installing Timing Belt Tensioner

CHRYSLER

172

3.5L V6 24 Valve (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Accessory Drive Belt Tensioner Bolt ........................................................................ 21 (28)
Camshaft Sprocket Bolt
Right Side
Step 1 .................................................................................................................. 75 (102)
Step 2 .......................................................................................................... Plus 1/4 Turn
Left Side
Step 1 .................................................................................................................. 85 (115)
Step 2 .......................................................................................................... Plus 1/4 Turn
Crankshaft Damper Bolt ................................................................................ 70-85 (90-115)
Power Steering Pump Belt Tensioner Bolt ............................................................... 17 (23)
Timing Belt Cover Bolts
M6 Bolts ...................................................................................... ..................................... 1
M8 Bolts .................................................................................................................. 21 (28)
M10 Bolts ................................................................................................................ 40 (54)
Timing Belt Tensioner Bolts ...................................................................................... 21 (28)
Timing Belt Tensioner Pulley Assembly Bolt ............................................................ 45 (61)
Upper Engine Mount
Upper Engine Mount-To-Frame Rail Bolts ............................................................. 50 (68)
Upper Engine Mount-To-Timing Belt Cover ........................................................... 40 (54)
INCH Lbs. (N.m)
Cylinder Head Cover Bolts ..................................................................................... 105 (12)
1

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Crankshaft Damper

Tighten to 105 INCH Lbs. (12 N.m).

CHRYSLER & EAGLE

173

1.5L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application
1.5L 4-Cyl.
Colt
1985-86 ...............................
1987-88 ...............................
1989-90 ...............................
1991-94 ...............................
Colt (Canadian)
1985-86 ...............................
1989-91 ...............................
1992 & 1995 .......................
Summit
1989-90 ...............................
1991-96 ...............................
Vista (Canadian)
1989-91 ...............................
1992 ....................................
1

Labor Time

2.8
2.8
2.4
2.4

Hours
Hours
Hours
Hours

Component
Belt
Kit No.
Part No.

... .. TCK073 .. .....

... ...... ..... ...... .....
... .. TCK128 .. .....
... .. TCK191 .. .....

T073
T128
T128
T191

2.8 Hours ... .. TCK073 .. ..... T073

2.8 Hours ... .. TCK128 .. ..... T128
2.4 Hours ... .. TCK191 .. ..... T191
2.4 Hours ... .. TCK128 .. ..... T128
2.4 Hours ... .. TCK191 .. ..... T191
2.8 Hours ... .. TCK128 .. ..... T128
2.4 Hours ... .. TCK191 .. ..... T191

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.
Courtesy of DaimlerChrysler Corp.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

Fig. 1: Aligning Timing Marks

tensioner mounting bolts. See Fig. 3. 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.
2) Rotate crankshaft one full revolution clockwise, until crankshaft
sprocket timing mark aligns with TDC position. Recheck 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. 4. A
tension gauge can also be used to check belt tension.
3) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly, then disconnect accelerator cable and oxygen lead sensor.
Mark position of spark plug wires for installation, 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 pulleys.
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.
2) Remove timing belt covers and gaskets, noting bolt lengths and
locations as they are removed. Rotate engine clockwise to align timing
mark on camshaft sprocket with mark on cylinder head. Ensure all timing
marks are aligned. See Fig. 1.
3) 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. Remove 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 1) 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 crankshaft and camshaft
sprockets. Ensure tension side is tight and all timing marks are aligned
when camshaft sprocket is rotated. Install crankshaft pulley. Loosen

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Installing Timing Belt Tensioner

CHRYSLER & EAGLE

174

1.5L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
1985-91 ........................................................................................ ................. 47-54 (65-75)
1992-96 ........................................................................................ ............... 52-74 (70-100)
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)
Timing Belt Tensioner Bolt
1985-96 ........................................................................................ ................. 14-20 (19-27)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

Fig. 4: Checking Timing Belt Tension

INCH Lbs. (N.m)

Crankshaft Pulley Bolt
1985-90 ........................................................................................................ 90-102 (10-11)
1987-88 ........................................................................................ ............. 108-120 (12-14)
1991-96 ........................................................................................................ 90-102 (10-11)
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)

CHRYSLER & EAGLE

175

2.0L 4-Cylinder DOHC, Except VIN Y

TIMING BELT APPLICATION
Application
2.0L 4-Cyl. DOHC (4G6)
Laser
1990-94 ............................
1990-94 ............................
Talon (Non-Turbo & Turbo)
1990-94 ............................
1990-94 ............................
Talon (Turbo)
1995-98 ............................
1995-98 ............................
2000 GTX (Canadian)
1989-93 ............................
1989-93 ............................
1
2

3
4

Labor Time

1, 2
1, 2

1, 2
1, 2

1, 2
1, 2

1, 2
1, 2

Component
Belt
Kit No.
Part No.

3.6 Hours . .. TCK167 .. ...

3.6 Hours . ...... ..... ...... ...

3.6 Hours . .. TCK167 .. ...

3.6 Hours . ...... ..... ...... ...

4.5 Hours . .. TCK167 .. ...

4.5 Hours . ...... ..... ...... ...

3.6 Hours . .. TCK167 .. ...

3.6 Hours . ...... ..... ...... ...

T167
T168
T167
T168
T167
T168
T167
T168

Balance shaft labor time included in camshaft labor time.

With Air Conditioning, add .2 hours.
With Power Steering, add .2 hours.
Timing belt.
Balance shaft belt.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-94 vehicles, the manufacturer recommends the belt be
replaced every 60,000 miles.
For 1995-97 vehicles, the 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. 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 timing belt at 100,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT & BALANCE SHAFT BELT

Removal 1) Disconnect negative battery cable. Remove engine
undercover. Place wooden block between jack and oil pan, and raise
engine slightly. Remove engine mount assembly near timing belt cover.
2) 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 pulleys. 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.
3) 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.
4) Ensure camshaft, crankshaft and oil pump sprocket timing marks are
aligned. See Fig. 2 or 3. Loosen tensioner pulley center bolt. Move

tensioner to relieve timing belt tension. Remove timing belt. Remove

timing belt auto tensioner. See Fig. 1.
5) 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. 4. 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.
6) To remove timing belt B (balance shaft belt), hold crankshaft
sprocket stationary with a spanner wrench. Remove crankshaft sprocket
bolt. Using gear puller, remove outer crankshaft sprocket.
7) Remove crankshaft sensing blade (if equipped). See Fig. 5. Loosen
timing belt B tensioner bolt. If reusing timing belt B, mark direction of
belt rotation for reassembly reference. Remove timing belt B.
Inspection 1) Inspect timing belts for damaged teeth and cracking.
Ensure belts are not contaminated with oil. Check tensioners for free
rotation and grease leakage. Replace components if damaged or if
grease leakage exists.
2) 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 1) 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.
2) Align balance shaft and crankshaft timing marks with rear cover. See
Fig. 7 or 8. Install timing belt B on sprockets. If using old belt, install belt
in original direction of rotation. 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 timing belt.
3) Install timing belt B tensioner so center of tensioner pulley 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
deflection at designated area. Belt deflection should be .20-.28 (5.0-7.0
mm). Readjust timing belt if belt deflection is not within specification.
CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions, or timing belt may be damaged.
4) 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. Install idler pulley (if removed).
5) Ensure camshaft, crankshaft and oil pump timing marks are still
aligned. See Fig. 2 or 3. DO NOT remove screwdriver 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.
6) 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 Fig. 2 or 3.
7) 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.

176

CHRYSLER & EAGLE

2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belts & Components

8) 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) 1) 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.
2) Remove screwdriver from balance shaft hole in side of engine block.
Install plug.
3) 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.
4) 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. 12. With torque applied to eccentric,
tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m).
5) Insert Set Screw (MD998738) through inner timing belt cover until it
contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin
can be removed. Remove set screw from engine.
6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes
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. 14, Dimension A. If distance is not correct,
timing belt tension will have to be readjusted. If distance is correct, go to
FINAL ASSEMBLY.
Timing Belt Tension Adjustment (1993-98) 1) 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. 13. 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).
2) 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 timing marks align.

3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or

equivalent to tensioner eccentric. Install torque wrench on adapter. See
Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH
lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley.
4) Hold tensioner pulley at specified torque, and tighten tensioner center
bolt to specification. Do not let tensioner pulley turn with bolt. See
TORQUE SPECIFICATIONS.
5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are
aligned. Allow engine to stand for 15 minutes without turning crankshaft.
Distance between top of auto tensioner housing and tensioner arm
should be .15-.18 (3.8-4.5 mm). See Fig. 14, Dimension A. If distance
is incorrect, repeat tensioning procedure until distance is correct. Once
distance is correct, go to FINAL ASSEMBLY.
Final Assembly To install remaining components, reverse removal
procedure. Ensure proper length bolts are installed in timing belt covers.
See Fig. 16. See TIMING COVER BOLT LENGTH & TORQUE table.
Adjust drive belts to proper tension.
TIMING COVER BOLT LENGTH & TORQUE
Application
INCH Lbs. (N.m)
A 6 x 16 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
B 6 x 18 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
C 6 x 25 mm Loose Washer Bolt .............. .......................................................... 58 (6.5)
D 6 x 25 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
E 6 x 45 mm Flange Bolt ........................... ............................................... 89-106 (10-12)

CHRYSLER & EAGLE

177

2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Belt A Timing Marks (1990-93)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Holding Balance (Silent) Shaft Stationary

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Timing Belt A Timing Marks (1994-98)

178

CHRYSLER & EAGLE

2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 9: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 5: Locating Timing Belt B (Balance Shaft Belt)

Components

Courtesy of DaimlerChrysler Corp.

Fig. 10: Installing Crankshaft Sprocket & Crankshaft Sensing

Blade

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Inspecting Timing Belt Auto Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 11: Installing Timing Belt On Intake Sprockets

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Aligning Timing Belt B (1990-92)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Aligning Timing Belt B (1993-98)

CHRYSLER & EAGLE

179

2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 12: Adjusting Timing Belt Tension (1990-92)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 16: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Installing Set Screw On Tensioner Pulley

Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ................................................................................................... 17 (24)
Balance Shaft Sprocket Bolt ..................................................................................... 33 (46)
Camshaft Sprocket Bolt ............................................................................................ 65 (90)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (108-127)
Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26)
Engine Mount-To-Body Through-Bolt
1990-92 ........................................................................................ ................. 43-58 (60-80)
1993-98 ........................................................................................................ 72-87 (98-118)
Engine Mount-To-Engine Bolt/Nut
1990-92 ........................................................................................ ................. 36-47 (50-65)
1993-98 .................................................................................................................... 49 (67)
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)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion

Courtesy of DaimlerChrysler Corp.

Fig. 15: Adjusting Timing Belt Tension (1993-98)

180

CHRYSLER & EAGLE

2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. SOHC

Colt Vista
1984-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... .....
1987-91
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.8 Hours ... TCK158A . .....
Ram 50
1983-86
Balance Shaft .................. 2.8 Hours ... ...... ..... ...... .....
Camshaft ......................... 3 2.3 Hours .. ...... ..... ...... .....
1987-89
Balance Shaft .................. 2.8 Hours ... ...... ..... ...... .....
Camshaft ......................... 3 2.3 Hours ... TCK158A . .....
Vista (Canada)
1989-91
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.8 Hours ... TCK158A . .....
2000GTX (Canada)
1989-92
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... .....
1
2

T090
T089
T159
T158

T090
T089
T159
T158

T159
T158

T159
T155

Balance Shaft labor time included in camshaft labor time.

With Air Conditioning, add .2 hours.
With Power Steering, add .2 hours.
With Air Conditioning, add .7 hours.
With Power Steering, add .2 hours.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Timing Marks

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 60,000 mile
intervals.

REMOVAL & INSTALLATION

Courtesy of DaimlerChrysler Corp.

TIMING BELT

Fig. 2: Locking Balance Shaft In Place

Removal 1) 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.
2) On all models, position No. 1 cylinder at TDC of compression stroke.
Loosen pulley bolts. Remove drive belts. Remove crankshaft, water
pump and power steering pulleys. Remove upper and lower front timing
belt covers.
3) On 1989-91 models, remove tensioner pulley bracket.
4) On all models, relieve 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 camshaft timing belt.
5) 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).
6) 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.
7) 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, flaking, peeling, cracking and
separating rubber. Cracks are most evident at base of tooth.
Installation 1) 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. Ensure that the pulley is to left of
installation bolt and pulley flange faces front of engine. See Fig. 4.
2) 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.
3) Check belt tension by pressing center of tension side inward, using
index finger and measuring belt deflection. Deflection should be
.195-.265 (5.0-7.0 mm). Readjust if not within specification.
4) 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. Ensure tension side of belt has no slack. Loosen
tensioner mounting bolt and nut, and allow tensioner spring to tension
belt.

CHRYSLER & EAGLE

181

2.0L 4-Cylinder SOHC (Cont.)

5) 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.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Balance Shaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt
1983-85 .......................................................................................................... 11-15 (15-20)
1986-91 ........................................................................................ ................. 15-21 (20-29)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
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 Bracket Bolt ....................................................... ................. 17-20 (23-27)
Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
Timing Belt Cover Bolt
Except Left Lower Rear .............................................................. ..................................... 1
Left Lower Rear .......................................................................... ................. 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)
1

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Balance Shaft Tensioning Pulley

Tighten bolts to 84-108 INCH lbs. (9-12 N.m).

CHRYSLER & EAGLE

182

3.2L & 3.5L V6

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.2L V6
Concorde & Intrepid (Includes Canadian)
1998-01 .............................. 1 2.8 Hours .. .. TCK295 .. .....
3.5L V6
Concorde & Intrepid (Includes Canadian)
1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. .....
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. .....
2000-02 .............................. 1 2.7 Hours .. .. TCK295 .. .....
2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... .....
LHS & 300M
1994 ................................... 1 2.7 Hours .. .. TCK219 .. .....
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. .....
1999-02 .............................. 1 2.7 Hours .. .. TCK295 .. .....
2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... .....
New Yorker
1994 ................................... 1 2.7 Hours .. .. TCK219 .. .....
1995-96 .............................. 1 2.7 Hours .. .. TCK255 .. .....
Prowler
1999-02 ............................... 2.8 Hours ... ...... ..... ...... .....
Vision
1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. .....
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. .....
1

T295

T219
T255
T295
T295
T219
T255
T295
T295
T219
T255
T295
T219
T255

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 105,000
miles up to the 1999 model year. For 2000-02 model years, the
manufacturer recommends the timing belt be replaced at 100,000 miles
for Federal vehicles, and 105,000 miles for California vehicles. For
2003-04 model years, the manufacturer recommends the timing belt be
replaced at 102,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
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.
Removal 1) Disconnect negative battery cable from jumper terminal.
Remove upper radiator crossmember (may also be referred to as the
engine compartment support). Remove electric cooling fan module with
fans.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components (2000 & Up)

CHRYSLER & EAGLE

183

3.2L & 3.5L V6 (Cont.)

2) Remove accessory drive belts. Hold crankshaft damper stationary
while removing center bolt. See Fig. 1. Use gear puller to remove
crankshaft damper. Remove the A/C belt guide/lift bracket.
3) Remove lower timing belt cover. Remove stamped steel (right side)
timing belt cover. DO NOT remove the sealer on the stamped steel
cover, as it is reusable.
4) Remove cast (left side) timing belt cover. If reusing old timing 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.
CAUTION: When aligning timing marks, always rotate engine by
turning crankshaft. Failure to do so will result in valve and/or
piston damage.
5) Rotate crankshaft to align crankshaft sprocket timing mark with TDC
mark on oil pump housing. Align camshaft sprockets with marks on rear
covers. See Figs. 2 and 3.
CAUTION: When timing belt tensioner is removed from engine,
always store tensioner with plunger facing up.
6) Remove timing belt tensioner. See Fig. 1. Store with plunger facing
up. Remove timing belt.
Courtesy of DaimlerChrysler Corp.

Fig. 3: Installing Timing Belt

CAUTION: If camshafts have moved from the timing marks, always
rotate camshafts toward the direction nearest to the timing marks.
DO NOT turn the camshafts a full revolution or damage to valves
and/or pistons could result.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

CAUTION: This procedure can only be used when the camshaft
sprockets have NOT been loosened or removed from the camshafts.

Installation 1) 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.
2) SLOWLY compress plunger. See Fig. 4. Total bleed down of plunger
should take about 5 minutes. When pin holes are aligned, install locking
pin through tensioner and plunger.
3) Ensure camshaft and crankshaft sprocket timing marks are still
aligned. If camshaft timing marks are not aligned, always rotate camshafts toward nearest timing marks. DO NOT turn camshafts a full
revolution. This could cause valves to contact pistons.
4) 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.
5) Holding tensioner pulley against belt, install tensioner into housing
and tighten bolts to specification. See TORQUE SPECIFICATIONS.
Ensure camshaft timing marks are aligned. When tensioner is in place,
pull locking pin to allow tensioner to extend to pulley bracket.
6) 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 Figs. 2 and 3.
7) Install timing belt covers and crankshaft damper. See Fig. 1. Install
accessory drive belts. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
8) 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.

184

CHRYSLER & EAGLE

3.2L & 3.5L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt
1993-97 .................................................................................................................. 85 (115)
1999-04 .................................................................................................................... 70 (95)
Timing Belt Cover Bolts
M6 ................................................................................................ ..................................... 1
M8 ............................................................................................................................ 21 (28)
M10 .......................................................................................................................... 40 (54)
Timing Belt Tensioner ................................................................................................ 21 (28)
Timing Belt Tensioner Pulley Assembly ................................................................... 45 (61)
INCH Lbs. (N.m)
Water Pump Bolts ................................................................................................... 106 (12)
1

Courtesy of DaimlerChrysler Corp.

Fig. 4: Compressing Tensioner

Tighten bolts to 106 INCH lbs. (12 N.m).

CHRYSLER & MITSUBISHI

185

2.3L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

2.3L 4-Cyl. Turbo Diesel

Pickup
1983-85
Balance Shaft ........................................
Camshaft ...............................................
Ram 50
1983-85
Balance Shaft ........................................
Camshaft ...............................................
1

1
1

1
1

Belt
Part No.

1.8 Hours .. ..... T092

1.8 Hours .. ..... T091

1.8 Hours .. ..... T092

1.8 Hours .. ..... T091

With Air Conditioning, add .7 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 50,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT & SPROCKETS

Removal 1) 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.
2) 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.
3) Remove silent shaft sprockets by removing plug from right side of
block and cover from left side of block. Insert screwdriver and socket
extension into holes to hold silent shafts in place. See Fig. 2.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Timing Marks

Installation 1) 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.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Silent Shaft Sprockets

2) 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.
3) Install both silent shaft sprockets. Tighten nut and bolt to specification.
Keep silent shafts from turning by using method described in removal
procedure.
4) 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 reference mark if refitting old belt.
5) Install timing belt B, ensuring tension side has no slack. Check
alignment of timing marks. Loosen tensioner B mounting nut and bolt,
and allow tensioner spring pressure to adjust belt.
6) 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).
7) Position and secure camshaft timing belt tensioner fully toward water
pump. Align camshaft, crankshaft and injection pump timing marks. See
Fig. 1. Install timing belt on pulleys in order of crankshaft sprocket,
injection pump sprocket and camshaft sprocket.
8) 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.
9) 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.
10) Tighten upper (slot-side) bolt first. Then tighten lower (fulcrum-side)
bolt. Tightening bolts out of specified sequence will over-tighten belt.
After tightening tensioner mounting bolts, check sprocket alignment.
11) 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.
12) 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). Reverse removal procedure to
complete installation. Adjust drive belts to proper tension.

186

CHRYSLER & MITSUBISHI

2.3L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Tensioner Bolts ...................................................................... ................. 16-21 (22-29)
Camshaft Sprocket Bolts .............................................................. ................. 47-54 (64-73)
Crankshaft Pulley Bolt ................................................................... ................. 33-34 (45-47)
Crankshaft Sprocket Bolt .............................................................. ......... 123-137 (167-186)
Front Case Bolts
1983-84 ........................................................................................ ................. 15-19 (20-26)
1985 ............................................................................................. ..................................... 1
Silent Shaft Sprocket Bolt ............................................................. ................. 25-28 (34-39)
INCH Lbs. (N.m)
Valve Cover Bolts .......................................................................... ..................... 44-53 (5-6)
Courtesy of DaimlerChrysler Corp.

Fig. 3: Installing Crankshaft Sprocket

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Belt B Marks

Tighten to 108-120 INCH lbs. (12-14 N.m).

CHRYSLER & MITSUBISHI

187

2.4L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

2.4L 4-Cyl. SOHC

Pickup
1990-92
Balance Shaft ............... ..........
Camshaft ......................... 2 2.3
1993-96
Balance Shaft ............... ..........
Camshaft ......................... 2 2.3
Ram 50
1990-91
Balance Shaft ............... ..........
Camshaft ......................... 3 2.3
1992
Balance Shaft ............... ..........
Camshaft ......................... 3 2.3
1993
Balance Shaft ............... ..........
Camshaft ......................... 3 2.3
1
2

Component
Belt
Kit No.
Part No.

1
.......... ...... ..... ...... ..... T159
Hours .. .. TCK124 .. ..... T124
1
.......... ...... ..... ...... ..... T168
Hours .. ...... ..... ...... ..... T229

1
.......... ...... ..... ...... ..... T159
Hours .. .. TCK124 .. ..... T124
1
.......... ...... ..... ...... ..... T159
Hours .. .. TCK124 .. ..... T124
1
.......... ...... ..... ...... ..... T168
Hours .. ...... ..... ...... ..... T229

Balance shaft labor time included in camshaft labor time.

With Air Conditioning, add .2 hours.
With Power Steering, add .2 hours.
With Air Conditioning, add .7 hours.
With Power Steering, add .2 hours.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Front Timing Belt

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of DaimlerChrysler Corp.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove radiator
shroud, cooling fan and pulley. Remove all drive belts and crankshaft
pulley. Remove upper timing belt covers and gaskets. Note bolt length
and location.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed
from timing belt end of engine). If timing belt is to be reused, mark
direction of rotation before removing.
2) 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.
3) 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 removed.
4) 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.
5) Remove oil pump sprocket nut, and remove sprocket. Remove front
crankshaft sprocket and flange. Note direction and order of installation
for reassembly reference.
6) 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.

Fig. 2: Holding Silent Shaft In Stationary Position

Installation 1) Install rear crankshaft sprocket and flange. Install right
silent 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.
2) 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.
3) Install front timing belt tensioner, tension spring and spacer. 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. Install front timing belt (belt A) on crankshaft.
4) Apply pressure on tension side of timing belt while installing belt (in
order) on crankshaft, oil pump and camshaft sprockets. Loosen tensioner to apply spring pressure to timing belt.
5) 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.
6) 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 procedure. Adjust drive belts to proper tension.

188

CHRYSLER & MITSUBISHI

2.4L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Rear Timing Belt

Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
Engine Support Bracket Bolt ........................................................ ................. 36-47 (49-64)
Silent Shaft Sprocket Bolt ............................................................. ................. 25-29 (34-39)
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)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 5: Checking Timing Belt A Tension

CHRYSLER & MITSUBISHI

189

3.0L V6 DOHC
TIMING BELT APPLICATION
Application

3.0L V6 DOHC
Diamante
1992-95 ...............................
Stealth
1991-96
Non-Turbo ........................
Turbo ................................
3000GT
1991-99
Non-Turbo ........................
Turbo ................................
1

Labor Time Component

Belt
Kit No.
Part No.

4.7 Hours ... .. TCK195 .. ..... T195

3.4 Hours ... .. TCK195 .. ..... T195

3.6 Hours ... ...... ..... ...... ..... T195

sensor and crankshaft position sensor. Remove crankshaft pulley. On

vehicles with ABS, remove overflow tank and bracket. Remove
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.
2) 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 rotation direction if belt is to be
reused.

3.9 Hours ... .. TCK195 .. ..... T195

4.3 Hours ... ...... ..... ...... ..... T195

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
CHRYSLER
Up to 1993 model year, the manufacturer recommends 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 recommends the belt be
replaced every 60,000 miles.
For 1994-95 model years, the 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.
Replace timing belt at 100,000 miles, unless previously changed.
For 1996-97 model years, the manufacturer recommends the 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 previously changed.
For 1998 model year, 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, unless previously
changed.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Diamante) 1) 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 support bracket. Disconnect power
steering connections. On 1993-95 models, remove camshaft position

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Engine Support Bracket Bolts

Removal (Stealth & 3000GT) 1) Disconnect negative battery cable.
Remove lower splash shields. Remove cruise control actuator (if
equipped). Remove drive belts. Remove alternator. Remove drive belt
tensioner.
2) Using Holder (MB990767) and Adapter Bolts (MD998754) or equivalent, remove crankshaft pulley. See Fig. 2. Disconnect 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 removal.
3) Remove drive belt idler pulley. Remove engine support bracket bolts
in sequence. See Fig. 1. Remove engine support bracket. Remove
timing belt upper and lower covers, noting length and location of cover
bolts.
4) Rotate crankshaft to align all timing marks. See Fig. 3. Loosen
tensioner center bolt. Remove timing belt.
Installation (All Models) 1) 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.
2) 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.
CAUTION: Turning camshaft sprockets while No. 1 cylinder is at
TDC may damage valve and piston. Use care when aligning timing
marks.
3) To lower No. 1 piston from TDC and prevent valve and piston contact,
turn crankshaft back 3 sprocket teeth (measured 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.
4) If camshaft sprocket timing mark is within indicated area, carefully
rotate camshaft sprocket until timing mark is located in nearest safe
area. See Fig. 4.

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CHRYSLER & MITSUBISHI

3.0L V6 DOHC (Cont.)
7) Rotate timing belt tensioner pulley until pin holes are located above
center bolt. See Fig. 7. Push tensioner pulley against belt, and tighten
center bolt. Ensure all timing marks are aligned, and remove clips.
8) 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 lbs. (10 N.m) torque to tensioner pulley to
prevent it from turning. See Fig. 7. Retighten center bolt to specification.
See TORQUE SPECIFICATIONS. Ensure tensioner pulley does not
rotate while tightening center bolt.
9) 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 specification, repeat previous five steps. Remove
wire.
NOTE: Lubricate engine support bracket reamer bolt while it is
tightened slowly.
10) To complete installation, reverse removal procedure. Install 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 tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View of Timing Belt Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks to Prevent Valve & Piston Damage

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks (Initial Alignment)

5) 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 counterclockwise 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.
6) Repeat previous three steps and this step for rear cylinder bank
camshafts. Align crankshaft timing mark. Install timing 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 turning during belt installation.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Aligning Timing Marks (Final Alignment)

CHRYSLER & MITSUBISHI

191

3.0L V6 DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .......................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Pulley Bolt ........................................................................................... 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)
Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49)
Water Pump Bolt ....................................................................................................... 17 (23)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Timing Belt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Adjusting Timing Belt Tensioner

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CHRYSLER, EAGLE & MITSUBISHI

1.6L 4-Cylinder DOHC
Belt
Part No.

2) Inspect auto tensioner for leaks. Replace, if necessary. Inspect

tensioner pulley and idler pulley for smooth rotation. Replace if bearings
are worn.

3.6 Hours .. ..... T165

CAUTION: Install flange and crankshaft sprocket in correct direction to prevent damage to timing belt.

3.6 Hours .. ..... T165

3.4 Hours .. ..... T165

TIMING BELT APPLICATION

Application
1.6L 4-Cyl. DOHC
Colt & Summit
1989-90 ....................................................
Colt 100, Colt 200 & Vista (Canada)
1989-90 ....................................................
Mirage
1989 & 1991-92 .......................................
1

Labor Time

With Air Conditioning, add .2 hours.

With Power Steering, add .3 hours.
With Air Conditioning, add .4 hours.
With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: Replacement procedures include revised information from
Chrysler technical service bulletin 09-01-94; January 28, 1994.

TIMING BELT
Removal 1) Raise and support vehicle. Remove lower left engine
compartment splash shield. Support weight of engine from above with
Support Fixture (C-4852 or 7137) or equivalent. On timing belt end of
engine, remove engine mount bracket connecting engine to body.
2) Loosen, but do not remove, water pump pulley bolts. Remove
generator and power steering pump drive belts. Remove water pump
pulley.
NOTE: It is necessary to lower engine slightly to remove the
crankshaft pulley.
3) 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.
4) Remove upper and lower timing belt covers.
CAUTION: Crankshaft may need to be rotated up to 6 revolutions
before all sprockets are properly aligned.
5) 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.
6) 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 retaining bolt.
7) 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 1) Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and
idler pulley for grease leakage and roughness in rotation. Replace
components if damaged.

Installation 1) 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.
2) 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.
3) 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.
4) 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.
5) Install box wrench on both camshaft sprocket bolts. Install timing belt
around exhaust camshaft sprocket while holding camshaft sprocket bolt
to align timing mark on camshaft sprocket with timing mark.
6) 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.
7) Install timing belt in the following order: around idler pulley, oil pump
sprocket, crankshaft sprocket and tensioner pulley. 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.
8) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise,
then rotate clockwise until No. 1 cylinder is at TDC. Ensure timing marks
are aligned. Loosen center bolt on tensioner pulley.
9) 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 lbs. (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. lbs. (43-55 N.m).
10) SLOWLY rotate set screw until Allen wrench or pin can be removed
from auto tensioner. Remove set screw.
11) 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 Dimension A in illustration. See Fig. 6.
12) If distance is not correct, loosen timing belt tensioner pulley 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 distance of .15-.18 (3.8-4.5 mm) is obtained.
13) 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. 7.
14) Install crankshaft pulley. Install A/C compressor belt (if equipped).
Install accessory drive belt tensioner bracket. Install water pump pulley.
Install generator and power steering pump drive belts. Adjust drive belts
to correct tension.
15) Install engine mount bracket on timing belt end of engine. Remove
engine support fixture. Install lower splash shield.

CHRYSLER, EAGLE & MITSUBISHI

193

1.6L 4-Cylinder DOHC (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Timing Marks

194

CHRYSLER, EAGLE & MITSUBISHI

1.6L 4-Cylinder DOHC (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Retracting Auto Tensioner Rod

Courtesy of DaimlerChrysler Corp.

Fig. 7: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS
Fig. 4: Positioning Timing Belt Tensioner Pulley

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

Fig. 6: Measuring Timing Belt Auto Tensioner Protrusion

Application
Ft. Lbs. (N.m)
Accessory Drive Belt Tensioner Pulley Bracket Bolt ................... ................. 17-20 (23-27)
Auto Tensioner Bolt ....................................................................... ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
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)
Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Tensioner Pulley Center Bolt ........................................................ ................. 32-41 (43-55)
Timing Belt Cover
Left Lower Rear Cover Bolt ........................................................ ................. 22-30 (30-41)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 84-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

CHRYSLER, EAGLE & MITSUBISHI

195

1.8L 4-Cylinder VINs B & T

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.8L 4-Cyl.
Eclipse & Laser
1990-94
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.4 Hours .. .. TCK158 .. .....
Talon
1993-94
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ......................... 2 2.4 Hours .. .. TCK158 .. .....
1
2

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.
CAUTION: Ensure right silent shaft spacer is installed with chamfered side toward oil seal, or damage to oil seal will result.

T159
T158

T159
T158

Balance shaft labor time included in camshaft labor time.

With Air Conditioning, add .2 hours.
With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft
counterclockwise (as viewed from timing belt end of engine).
Removal 1) Disconnect negative battery cable. Disconnect power
steering hose clamp. Remove engine undercover. Place wooden block
between jack and oil pan. Raise engine slightly.
2) 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.
3) Remove upper and lower timing belt covers and gaskets. 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 upper
timing belt cover. See Fig. 2.
4) Loosen timing belt tensioner bolt for timing belt A. Move tensioner
toward water pump, and tighten tensioner bolt. Remove timing belt.
5) 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) diameter Phillips screwdriver
to hold left silent shaft. See Fig. 3.
6) Remove oil pump sprocket nut, and remove sprocket. Remove
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.

Installation 1) Coat outer diameter of right silent shaft spacer with

engine oil. Install spacer with chamfered side toward oil seal. Install right
silent shaft sprocket. Align crankshaft sprocket B and right silent shaft
timing marks. See Fig. 4. Install timing belt B on sprockets. Ensure belt
is installed in original direction of rotation and no slack exists in belt.
CAUTION: When tightening bolt, ensure tensioner does not rotate,
or excessive pressure will be applied to timing belt.
2) Install timing belt tensioner B so center of pulley is located left of
tensioner bolt. See Fig. 5. Ensure flange on tensioner pulley is toward
front of engine. Rotate tensioner inward toward timing belt until belt is
tight. Tighten tensioner bolt.
3) Check belt deflection at designated area. See Fig. 5. Belt deflection
should be .20-.28 (5.0-7.1 mm). Readjust timing belt if belt deflection is
not within specification.
4) Install flange in front of crankshaft sprocket B, with offset toward
crankshaft. See Fig. 1. Install crankshaft sprocket A. See Fig. 6. Install
camshaft and oil pump sprockets. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
5) Install tensioner spring, tensioner spacer and timing belt A tensioner. Ensure upper end of tensioner spring contacts water pump.
Rotate tensioner toward water pump, and temporarily tighten nut.
6) 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.
7) 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 timing belt is installed.
8) 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.
9) Loosen tensioner nut to allow spring tension to be applied to timing
belt. Ensure all timing marks are aligned. Remove screwdriver and
install plug. To apply tension on timing 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.
10) Rotate tensioner inward toward timing belt. Ensure timing belt fully
engages camshaft sprocket. Tighten timing belt tensioner bolt. Tighten
tensioner spacer nut. At midway location 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.
Clearance should be .47 (12.0 mm). Timing belt may need to be
readjusted.
11) To complete installation, reverse removal procedure. Ensure proper
length bolts are installed in designated areas in timing belt covers. See
Fig. 9. Adjust drive belts to proper tension.

196

CHRYSLER, EAGLE & MITSUBISHI

1.8L 4-Cylinder VINs B & T (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belts & Components

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Timing Belt A Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 3: Holding Silent Shaft In Stationary Position

CHRYSLER, EAGLE & MITSUBISHI

197

1.8L 4-Cylinder VINs B & T (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Checking Timing Belt A Tension

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Belt B Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 9: Identifying Timing Belt Cover Bolt Locations

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

Fig. 5: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Crankshaft Sprockets

Courtesy of DaimlerChrysler Corp.

Fig. 7: Applying Tension To Timing Belt A

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
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)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

198

CHRYSLER, EAGLE & MITSUBISHI

1.8L 4-Cylinder VINs C & D

TIMING BELT APPLICATION

Application
1.8L 4-Cyl.
Colt
1992-94 ..............................
Colt Vista
1992-94 ..............................
Expo
1992-94 ..............................
Mirage
1993-96 ..............................
1997-02 ..............................
Summit
1992-96 ..............................
Summit Wagon
1992-96 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.4 Hours .. ...... ..... ...... ..... T201

2.4 Hours .. ...... ..... ...... ..... T201

2.4 Hours .. .. TCK201 .. ..... T201

1
1

2.4 Hours .. .. TCK201 .. ..... T201

2.4 Hours .. ...... ..... ...... ..... T288

2.4 Hours .. ...... ..... ...... ..... T201

2.4 Hours .. ...... ..... ...... ..... T201

3) If timing belt is to be reused, mark direction of rotation before

removing. Loosen timing belt tensioner bolt. Using a screwdriver, move
tensioner away from timing belt. Tighten bolt to secure tensioner.
Remove timing belt.

With Air Conditioning, add .2 hours.

With Power Steering, add .3 hours.
With Air Conditioning, add .4 hours.
With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
CHRYSLER & EAGLE
The manufacturer recommends the belt be replaced every 60,000 miles.

MITSUBISHI
For 1992-93 models, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 models, the 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. In
California, replace timing belt at 100,000 miles, unless previously
changed.
For 1997-02 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, unless previously
changed.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove under cover.
On Expo, remove condenser tank. On all models, remove A/C and
power steering hose mounting bracket from upper engine mount at
timing belt cover. Remove all accessory drive belts. Using End Yoke
Holder (MB990767) and Crankshaft 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).
2) Remove upper and lower timing belt covers. See Fig. 1. Remove
flange. If necessary, remove power steering pump bracket stay and
engine support bracket. Rotate crankshaft clockwise (as viewed from
timing 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. 2 or 3.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Timing Marks (1992-96)

Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check belt tensioner for grease
leakage or roughness in tensioner rotation. See Fig. 1. Replace components if damaged.
Installation 1) Install timing belt tensioner, leaving bolt loose. Using a
screwdriver, push tensioner toward engine mount. Tighten timing belt
tensioner bolt.
2) Align camshaft sprocket and crankshaft sprocket timing marks with
timing marks on engine. Keeping tension applied between camshaft,
water pump and crankshaft sprockets, install timing belt in the following
sequence: crankshaft sprocket, water pump sprocket, camshaft
sprocket, then tensioner pulley.
3) Rotate camshaft in reverse direction and ensure that there is no slack
in timing belt. Ensure timing marks are still aligned. Loosen timing belt
tensioner to apply spring pressure to timing belt.

CHRYSLER, EAGLE & MITSUBISHI

199

1.8L 4-Cylinder VINs C & D (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Identifying Timing Belt Cover Bolt Locations

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT MIRAGE)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks (1997-02)

4) Rotate crankshaft 2 complete revolutions clockwise (as viewed from
timing belt end of engine) and ensure timing marks are still aligned.
Ensure timing belt teeth are properly seated in sprockets. Tighten timing
belt tensioner bolt.
5) Install flange. See Fig. 4. To complete installation, reverse removal
procedure. Ensure proper length bolts are installed in designated areas
in timing belt covers. See Fig. 5. Adjust drive belts to proper tension.

Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
Crankshaft Center Pulley Bolt ...................................................... ............. 80-94 (109-127)
Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
Front Cover Bolt .............................................................................................. 11-13 (15-18)
Timing Belt A Tensioner Bolt ...................................................... ................. 16-22 (22-30)
Timing Belt B Tensioner Bolt ........................................................................ 11-16 (15-24)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
TORQUE SPECIFICATIONS (MIRAGE)
Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ........................................................................... 18 (25)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Pulley Bolt ................................................................... ......... 131-139 (177-188)
Engine Support Bracket Bolt .................................................................................... 36 (49)
Power Steering Pump Bracket Stay Bolt ................................................................. 33 (44)
Timing Belt Tensioner Bolt ........................................................................................ 18 (24)
Water Pump Bolt ....................................................................................................... 18 (24)
INCH Lbs. (N.m)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Installing Flange

Timing Belt Cover Bolt .............................................................................................. 97 (11)

200

CHRYSLER, EAGLE & MITSUBISHI

2.0L 4-Cylinder DOHC, VIN Y

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC, VIN Y

Avenger, Neon & Sebring Coupe
1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246
Eclipse (Non-Turbo)
1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246
Talon (Non-Turbo)
1995-98 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246
1

With Air Conditioning. add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

2) Remove power steering pump (hoses attached) and mounting

bracket from engine. Move out of way.
3) Lower vehicle. Place jack under engine for support. Remove right
side engine mount. Remove engine mount bracket from front of engine.
Remove timing belt cover. Rotate engine clockwise to align the camshaft
and crankshaft timing marks. See Fig. 1.
CAUTION: To prevent pistons from hitting valves, do not rotate
camshaft or crankshaft after removing the timing belt.
4) 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 counterclockwise 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.
CAUTION: 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.

CHRYSLER
On Neon, the manufacturer recommends replacing the timing belt at
105,000 miles.
On Avenger and Sebring Coupe, 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 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. In
California, replace timing belt at 100,000 miles, unless previously
changed. For 1997-98 model years, 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, unless
previously changed.

MITSUBISHI
For 1995-97 model years, the 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. In
California, replace timing belt at 100,000 miles, unless previously
changed. For 1998-99 model years, 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, unless
previously changed.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Mechanical Timing Belt Tensioner) 1) On Avenger and
Sebring, remove coolant reservoir and place out of way. On all models,
raise and support vehicle. Remove right inner splash shield. Remove
center bolt from crankshaft pulley. Use gear puller to remove crankshaft
pulley.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Timing Marks & Adjusting Belt Tension

(Mechanical Timing Belt Tensioner)
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 (Mechanical Timing Belt Tensioner) 1) Ensure camshaft and crankshaft timing marks are aligned. Rotate crankshaft pulley
sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2.
2) Install timing belt starting from crankshaft pulley sprocket, go around
water pump sprocket, idler pulley, camshaft sprockets, and then around
tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack.
3) Remove Allen wrench from timing belt tensioner pulley. Rotate
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.
4) Continue installation in reverse of removal procedure. Adjust drive
belts to proper tension.
5) On Neon only, connect scan tool to Data Link Connector (DLC) under
lower left edge of instrument panel. Follow scan tool instructions to
access the cam/crank relearn procedure. Perform cam/crank relearn
procedure.

CHRYSLER, EAGLE & MITSUBISHI

201

2.0L 4-Cylinder DOHC, VIN Y (Cont.)

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.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Crankshaft Timing Mark (Hydraulic Timing Belt

Tensioner Shown; Mechanical Tensioner Is Similar)
Removal (Hydraulic Timing Belt Tensioner) 1) Raise and support
vehicle. Remove right inner splash shield. Remove center bolt from
crankshaft pulley. Use gear puller to remove crankshaft pulley.
2) Remove power steering pump (hoses attached) and mounting
bracket from engine. Move out of way.
3) Lower vehicle. Place jack under engine for support. Remove right
side engine mount. Remove engine mount bracket from front of engine.
Remove timing belt cover. Rotate engine clockwise to align the camshaft
and crankshaft timing marks. See Fig. 3.
CAUTION: To prevent pistons from hitting valves, do not rotate
camshaft or crankshaft after removing the timing belt.
4) Loosen timing belt tensioner to remove timing belt. If reusing old belt,
mark belt with arrow to indicated direction of rotation. Remove timing
belt.
5) Remove tensioner from engine. It will be necessary to compress the
center plunger and lock it in place.
6) 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.

Timing Belt Tensioner Bracket Precaution On models with hydraulic timing 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.
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 Timing Belt Tensioner) 1) Ensure camshaft
and crankshaft timing marks are aligned. Rotate crankshaft pulley
sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2.
2) Install timing belt starting from crankshaft pulley sprocket, go around
water pump sprocket, idler pulley, camshaft sprockets, and then around
tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack.
Install timing belt tensioner, but do not final tighten fasteners yet.
3) With 21 ft. lbs. (28 N.m) of torque applied to tensioner pulley, move
tensioner against pulley bracket and tighten bolts to specification. See
TORQUE SPECIFICATIONS. See Fig. 4.
4) Remove tensioner plunger locking pin. Pretension is correct when
locking pin can be removed and installed again.
5) Rotate crankshaft clockwise 2 revolutions and check timing belt
alignment marks. Reset belt if marks are not aligned. Install timing belt
covers.
6) Continue installation in reverse of removal procedure. Adjust drive
belts to proper tension.
7) On Neon only, connect scan tool to Data Link Connector (DLC) under
lower left edge of instrument panel. Follow scan tool instructions to
access the cam/crank relearn procedure. Perform cam/crank relearn
procedure.

Courtesy of DaimlerChrysler Corp.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks (Hydraulic Timing Belt Tensioner)

Fig. 4: Adjusting Timing Belt Tension (Hydraulic Timing Belt

Tensioner)

202

CHRYSLER, EAGLE & MITSUBISHI

2.0L 4-Cylinder DOHC, VIN Y (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 75 (101)
Crankshaft Pulley Bolt ........................................................................................... 105 (142)
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)
Timing Belt Tensioner Bolt
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)

CHRYSLER, EAGLE & MITSUBISHI

203

2.4L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

2.4L 4-Cyl.
Colt, Colt Vista & Colt Wagon (Canada)
1992
Balance Shaft ...................................... ..........
Camshaft ............................................... 2 2.4
1993
Balance Shaft ...................................... ..........
Camshaft ............................................... 2 2.4
1994
Balance Shaft ...................................... ..........
Camshaft ............................................... 2 2.4
Expo
1992
Balance Shaft ...................................... ..........
Camshaft ............................................... 3 2.4
1993-95
Balance Shaft ...................................... ..........
Camshaft ............................................... 3 2.4
Summit
1992
Balance Shaft ...................................... ..........
Camshaft ............................................... 2 2.4
1993-96
Balance Shaft ...................................... ..........
Camshaft ............................................... 2 2.4
1
2

Belt
Part No.

1
.......... ..... T159
Hours .. ..... T204
1
.......... ..... T159
Hours .. ..... T230
1
.......... ..... T168
Hours .. ..... T230

1
.......... ..... T159
Hours .. ..... T204
1
.......... ..... T168
Hours .. ..... T230

1
.......... ..... T159
Hours .. ..... T204
1
.......... ..... T168
Hours .. ..... T230

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Camshaft Timing Belt Marks

Balance shaft labor time included in camshaft labor time.

With Air Conditioning, add .2 hours.
With Power Steering, add .2 hours.
With Air Conditioning, add .4 hours.
With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Loosen left front wheel
lug nuts, then raise and support vehicle with jackstands. 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.
2) 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. Remove auto-tensioner assembly,
then remove camshaft timing belt.
3) 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 properly aligned. See Fig. 2.
Installation 1) Align crankshaft and balance shaft sprocket timing
marks with the marks on the timing case. See Fig. 2. Install balance
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 installation bolt and pulley flange is facing the front of engine.
2) 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

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Balance Shaft Marks

aligned, then check belt tension. See Fig. 2. There should be approximately .20-.28 (5.0-7.0 mm) slack on tension side of belt when belt is
moved by hand.
3) Install crankshaft sprocket flange with the raised side facing outward,
then install crankshaft sprocket. Measure protrusion 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.
4) Remove auto-tensioner from vise and install on engine. Ensure
crankshaft and camshaft timing marks are aligned. 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.
5) 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 timing belt has been installed.
6) 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

204

CHRYSLER, EAGLE & MITSUBISHI

2.4L 4-Cylinder (Cont.)

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 crankshaft
pulley 1/4 turn counterclockwise, then turn clockwise, aligning crankshaft and camshaft timing marks.
7) Loosen tensioner pulley retaining bolt, then position socket tool and a
suitable torque wrench to the pulley. Tighten to specification. See
TORQUE SPECIFICATIONS. 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.
8) Rotate engine in the clockwise direction two turns. After approximately 15 minutes, measure auto-tensioner plunger protrusion from
tensioner housing. Plunger protrusion should be .15-.18 (3.8-4.6 mm).
See Dimension A in illustration. See Fig. 4. If protrusion is not within
limits, readjust timing belt tension.
9) 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 belts to proper tension. Check and adjust
ignition timing as necessary.
10) Install right side engine mount, and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS. After completing installation of
engine mount, remove jack and wooden block supporting engine. Install
coolant reservoir. Install left front inner splash shield. Install left front
wheel and tire assembly, then lower vehicle. Connect negative battery
cable.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Holding Silent Shaft In Stationary Position (Typical)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Measuring Auto Tensioner Protrusion

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

DAEWOO

205

1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. DOHC
Lanos
1999-2002 ................................................
1

Labor Time

Belt
Part No.

2.3 Hours .. ..... T310

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

3) Rotate water pump until the adjust arm pointer on the automatic
tensioner is aligned with the pointer on the automatic tensioner bracket.
See Fig. 8. Final tighten water pump bolts. See TORQUE SPECIFICATIONS.
4) Remove crankshaft sprocket center bolt. Install power steering pump
(if equipped). Tighten bolts to specification. Install timing belt covers.
Install crankshaft pulley. Tighten center bolt to specification.
5) Install power steering pump pulley (if removed). Install accessory
drive belts. Install right front splash shield. Install right front wheel. Install
air filter housing. Connect air intake temperature sensor connector.
Connect negative battery cable. Adjust the drive belts to correct tension.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air
temperature sensor connector from intake air duct. Disconnect the air
intake tube from the throttle body. Disconnect the breather tube from the
valve cover. Remove the air filter housing.
2) Raise and support the vehicle. Remove right front wheel. Remove
right front splash shield from wheelwell. Remove accessory drive belts.
See Fig. 1.
3) Remove power steering pump pulley bolts (if equipped). Remove
power steering pump pulley. Remove crankshaft pulley center bolt.
Remove crankshaft pulley. Lower vehicle.
4) 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.
5) Using crankshaft center bolt, rotate crankshaft one full turn clockwise
(as viewed from timing belt end of engine).
6) 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.

Courtesy of Daewoo Motor America, Inc.

Fig. 1: Removing A/C Compressor Drive Belt

CAUTION: Engine damage could result if camshaft sprockets are

not properly aligned with notches on valve cover.
7) Slightly loosen water pump bolts. Using Timing Belt Adjuster
(J-42492), rotate water pump counterclockwise to relieve tension on the
timing belt. See Fig. 5. Remove timing belt.
Installation 1) Ensure crankshaft and camshaft timing marks are still
aligned. Install the timing belt. See Fig. 6. Turn water pump clockwise
until the adjust arm pointer on the automatic tensioner aligns with the
notch on the automatic tensioner bracket. See Fig. 7. Tighten water
pump bolts.
2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed
from timing belt end of engine) 2 full revolutions. Loosen water pump
bolts.

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Timing Belt Covers

DAEWOO

206

1.6L 4-Cylinder DOHC (Cont.)

Courtesy of Daewoo Motor America, Inc.

Fig. 3: Aligning Crankshaft Sprocket Timing Marks

Courtesy of Daewoo Motor America, Inc.

Fig. 5: Moving Water Pump To Relieve Timing Belt Tension

Courtesy of Daewoo Motor America, Inc.

Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Camshaft Sprocket Timing Marks

Fig. 6: Identifying Timing Belt Routing

DAEWOO

207

1.6L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 49 (68)
Crankshaft Pulley Center Bolt
Step 1 ...................................................................................................................... 70 (95)
Step 2 .................................................................................................................... Plus 30
Step 3 .................................................................................................................... Plus 15
Power Steering Pump Mount Bolt ............................................................................ 18 (25)
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)
Timing Belt Cover Bolt .............................................................................................. 89 (10)

Courtesy of Daewoo Motor America, Inc.

Fig. 7: Aligning Timing Belt Tensioner With Notch

Courtesy of Daewoo Motor America, Inc.

Fig. 8: Aligning Timing Belt Tensioner With Pointer

DAEWOO

208

2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cyl. DOHC

Nubira
1999-2002 ................................................. 1.8 Hours ... ..... T309
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends replacing the belt at 72,000 miles,
except in California. In California, inspect the belt at 60,000 miles and
replace the belt at 102,000 miles.

REMOVAL & INSTALLATION

Courtesy of Daewoo Motor America, Inc.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Supporting Engine Assembly

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air
temperature sensor connector from intake air duct. Disconnect the air
intake tube from the throttle body. Disconnect the breather tube from the
valve cover. Remove the air filter housing.
2) Raise and support the vehicle. Remove right front wheel. Remove
right front splash shield from wheelwell. Remove serpentine accessory
drive belt.
3) Remove crankshaft pulley bolts. It is NOT necessary to remove
crankshaft sprocket center bolt. Remove crankshaft pulley. Lower
vehicle.
4) 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.
5) Remove front timing belt cover. Using crankshaft center bolt, rotate
crankshaft one full turn clockwise (as viewed from timing belt end of
engine).
6) Align mark on crankshaft sprocket with notch at bottom of rear timing
belt cover. See Fig. 3. Align camshaft sprocket timing marks with
notches on valve cover. See Fig. 4.

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Engine Mount Bracket

CAUTION: Engine damage could result if camshaft sprockets are

not properly aligned with notches on valve cover.
7) 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 1) Ensure crankshaft and camshaft timing timing marks
are 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 TORQUE SPECIFICATIONS.
2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed
from timing belt end of engine) 2 full revolutions. Ensure timing belt
tensioner pointer is still aligned with notch.
3) 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 serpentine accessory drive belt. Install right
front splash shield. Install right front wheel.
4) Install air filter housing. Connect air intake temperature sensor
connector. Connect negative battery cable.
Courtesy of Daewoo Motor America, Inc.

Fig. 3: Aligning Crankshaft Sprocket Timing Marks

DAEWOO

209

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Camshaft Sprocket Timing Marks

Courtesy of Daewoo Motor America, Inc.

Fig. 6: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 .................................................................................................................... Plus 60
Step 3 .................................................................................................................... Plus 15
Crankshaft Pulley Bolt ............................................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................... 96 (130)
Step 2 ............................................................................................................... Plus 40-50
Engine Mount Bracket Bolt ....................................................................................... 44 (60)
Timing Belt Idler Pulley Bolt/Nut ............................................................................... 18 (25)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Water Pump Bolt ....................................................................................................... 15 (20)
Wheel Lug Nuts ...................................................................................................... 88 (120)
INCH Lbs. (N.m)
Courtesy of Daewoo Motor America, Inc.

Fig. 5: Locating Timing Belt Tensioner

Timing Belt Cover Bolt ................................................................................................ 53 (6)

DAEWOO

210

2.2L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 4-Cyl. DOHC

Leganza
1999-2002 ................................................. 1.8 Hours ... ..... T305
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends replacing the belt at 72,000 miles,
except in California. In California, inspect the belt at 60,000 miles and
replace the belt at 102,000 miles.

REMOVAL & INSTALLATION

Courtesy of Daewoo Motor America, Inc.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Supporting Engine Assembly

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air
temperature sensor connector from intake air duct. Disconnect the air
intake tube from the throttle body. Disconnect the breather tube from the
valve cover. Remove resonator from throttle body. Remove air filter
housing.
2) Raise and support the vehicle. Remove right front wheel. Remove
right front splash shield from wheelwell. Remove serpentine accessory
drive belt.
3) Remove crankshaft pulley bolts. It is NOT necessary to remove
crankshaft sprocket center bolt. Remove crankshaft pulley. Lower
vehicle.
4) 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.
5) Remove power steering hose clamp bolt, and position hose away
from timing belt cover. Remove front timing belt cover. See Fig. 3. Using
crankshaft center bolt, rotate crankshaft one full turn clockwise (as
viewed from timing belt end of engine).
6) Align mark on crankshaft sprocket with notch at bottom of rear timing
belt cover. See Fig. 4. Align camshaft sprocket timing marks with
notches on valve cover. See Fig. 5.

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Engine Mount Bracket

CAUTION: Engine damage could result if camshaft sprockets are

not properly aligned with notches on valve cover.
7) Loosen the automatic tensioner bolt. Use an Allen wrench to rotate
tensioner and relieve tension on timing belt. See Fig. 6. Remove timing
belt.
Installation 1) Ensure crankshaft and camshaft timing marks are still
aligned. Install the timing belt. See Fig. 7. Turn the timing belt tensioner
counterclockwise to tension the timing belt. Turn tensioner until the
pointer aligns with the notch on the rear timing belt cover. Tighten
automatic tensioner bolt to specification. See TORQUE SPECIFICATIONS.
2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed
from timing belt end of engine) 2 full revolutions. Ensure timing belt
tensioner pointer is still aligned with notch.
3) If timing belt tensioner is correctly aligned, install timing belt cover.
See Fig. 3. 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 serpentine accessory drive belt.
4) 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.

Courtesy of Daewoo Motor America, Inc.

Fig. 3: Identifying Front Timing Belt Cover & Bolts

DAEWOO

211

2.2L 4-Cylinder DOHC (Cont.)

Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Crankshaft Sprocket Timing Mark

Courtesy of Daewoo Motor America, Inc.

Fig. 7: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Daewoo Motor America, Inc.

Fig. 5: Aligning Camshaft Sprocket Timing Marks

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 .................................................................................................................... Plus 60
Step 3 .................................................................................................................... Plus 15
Crankshaft Pulley Bolt ............................................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................... 96 (130)
Step 2 ............................................................................................................... Plus 40-50
Engine Mount Bracket Bolt ....................................................................................... 44 (60)
Timing Belt Idler Pulley Bolt/Nut ............................................................................... 18 (25)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Water Pump Bolt ....................................................................................................... 15 (20)
Wheel Lug Nuts ...................................................................................................... 88 (120)
INCH Lbs. (N.m)
Power Steering Hose Clamp Bolt .............................................................................. 71 (8)
Timing Belt Cover Bolt ................................................................................................ 53 (6)

Courtesy of Daewoo Motor America, Inc.

Fig. 6: Identifying Timing Belt Tensioner

DAIHATSU

212

1.0L 3-Cylinder
TIMING BELT APPLICATION
Application
1.0L 3-Cyl.
Charade
1988-92 ....................................................
1

Labor Time

Belt
Part No.

1.8 Hours .. ..... T178

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

Courtesy of Daihatsu Motor Co., LTD.

Fig. 1: Removing Engine Front Mounting Bracket Nuts

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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 reference.
2) 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, remove alternator drive belt.
3) Remove right lower engine cover. Using a wooden block and jack,
apply slight pressure to oil pan to release pressure 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-cylinder head attaching bolts. See Figs. 1 and 2. Slightly
lower jack and remove front mount bracket.
4) Remove water pump pulley. Working from left side fenderwell, place
socket on crankshaft pulley bolt, and rotate 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.
5) Remove oil filter cap. Ensure exhaust valve rocker on No. 1 cylinder
is free. If rocker is not free, rotate crankshaft 360 degrees (one turn), and
align timing marks.
6) Insert screwdriver through bellhousing to hold ring gear, and remove
crankshaft pulley retaining bolt. Remove crankshaft pulley. Remove
upper and lower timing belt covers. Remove flange on front of crankshaft pulley. See Fig. 4.
7) 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 pulley and spring.
8) 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 1) Inspect idler pulley for smooth rotation. Replace if
necessary.
2) Inspect idler pulley tension spring for damage. Check tension spring
free length and tension. Replace spring if free length and tension are not
within specification. See TIMING BELT PULLEY SPECIFICATIONS
table.
3) Inspect all belt pulleys for wear in belt areas. Measure diameter of
crankshaft and camshaft belt pulleys. Replace pulleys if measurements
are not to specification.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 2: Removing Cylinder Head Mounting Bracket

Courtesy of Daihatsu Motor Co., LTD.

Fig. 3: Aligning Flywheel Timing Marks

Courtesy of Daihatsu Motor Co., LTD.

Fig. 4: Installing Crankshaft Pulley & Flanges

DAIHATSU

213

1.0L 3-Cylinder (Cont.)

TIMING BELT PULLEY SPECIFICATIONS
Application
Specification
Camshaft Belt Pulley Diameter ..................... ........................................... 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
Installation 1) Install camshaft belt pulley. Tighten retaining bolt to
specification. See TORQUE SPECIFICATIONS. Install crankshaft belt
pulley and inner flange in proper direction. See Fig. 4.
2) 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 direction. If installing new belt, align the mark on back
of belt with mating mark on each pulley.
3) After belt is installed, loosen idler pulley to apply spring tension on
idler pulley. Temporarily tighten idler pulley bolt.
4) 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.
5) Loosen idler pulley bolt to apply spring tension against timing belt.
Tighten idler pulley bolt to specification. Ensure all timing marks align.
6) Install outer flange on crankshaft pulley, with protruding side toward
crankshaft belt pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 5: Aligning Crankshaft & Camshaft Mating Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 22-33 (30-44)
Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98)
Timing Belt Tensioner Bolt ............................................................ ................. 25-33 (34-44)
Water Pump Bolts ........................................................................................... 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................................ ..................... 18-36 (2-4)
Water Pump Pulley Bolt ................................................................ ..................... 53-80 (6-9)

DAIHATSU

214

1.3L & 1.6L 4-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

1.3L 4-Cyl.
Charade
1989-92 ....................................................
1.6L 4-Cyl.
Rocky
1990-92 ....................................................
1

Belt
Part No.

1.8 Hours .. ..... T181

2.3 Hours .. ..... T182

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (1.3L) 1) Disconnect negative battery cable. Remove air
conditioner drive belt and idler assembly (if equipped). Remove air
conditioner compressor, leaving hoses attached.
2) Remove power steering pump from engine. Mark and remove all
hoses attached to air cleaner. Remove air cleaner. Remove oil pressure
switch wire harness brackets, and pull wire toward throttle body.
3) Loosen water pump pulley bolts. Remove water pump pulley 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 crankshaft pulley by removing 4 small attaching bolts.
4) Remove upper and lower timing belt covers. See Fig. 2. Rotate
engine until F mark on camshaft sprocket aligns with timing mark on
cylinder head cover. See Fig. 3. If reusing belt, mark arrow on belt to
indicate direction of rotation.
5) Loosen timing belt tensioner bolt, and move tensioner away from belt.
Tighten timing belt tensioner. Remove timing belt from engine. Remove
cylinder head cover.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 2: Identifying Timing Belt Components (1.3L)

Courtesy of Daihatsu Motor Co., LTD.

Fig. 3: Locating Timing Belt Alignment Marks

Courtesy of Daihatsu Motor Co., LTD.

Fig. 1: Locating Service Hole Cover (Charade)

Removal (1.6L) 1) Disconnect negative battery cable. Remove air
cleaner assembly. Loosen and remove drive belts. Remove radiator
reserve tank. Disconnect clutch cable clamps from upper radiator
shroud.
2) Disconnect fan clutch. Remove radiator fan shroud and fan clutch.
See Fig. 4. Remove water pump pulley and belt. Remove crankshaft
pulley attaching bolts and remove pulley. Remove 8 timing belt cover
bolts.

3) Remove timing belt cover. Rotate engine until F mark on camshaft

sprocket aligns with timing indicator on cylinder head cover. See Fig. 3.
If reusing belt, mark arrow on belt to indicate direction of rotation.
4) Loosen timing belt tensioner bolt, and move tensioner away from belt.
Tighten timing belt tensioner, and remove timing belt from engine.
Inspection (All Models) 1) 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 damaged, check sprocket
flange.
2) 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.

DAIHATSU

215

1.3L & 1.6L 4-Cylinder (Cont.)

sioner 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. 5.
CAUTION: DO NOT allow engine to rotate counterclockwise during
timing belt adjustment.
4) 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.
5) Check belt tension. At midpoint, belt should deflect 0.2 (5 mm) with
a pushing force of 1.8-3.5 lbs. (0.8-1.6 kg). To complete installation,
reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Daihatsu Motor Co., LTD.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 4: Identifying Timing Belt Components (1.6L)

Installation (All Models) 1) 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. 3. Tighten crankshaft
timing belt sprocket bolt to 65-72 ft. lbs. (88-98 N.m).
2) 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 aligned. See Fig. 3.
3) Install timing belt on sprockets. If installing used belt, ensure there are
35 teeth between sprocket timing notches (drilled marks), and belt
rotates in same direction. If installing new belt, align marks on belt with
timing notches (drilled marks) on sprockets. See Fig. 3. Loosen ten-

Fig. 5: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Idler Pulley Bolt ...................................................................... ................. 23-35 (31-47)
Camshaft Sprocket Bolts ................................................................................ 11-16 (15-22)
Crankshaft Pulley Bolts ................................................................. ................. 15-22 (20-30)
Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98)
Timing Belt Tensioner Bolt ............................................................ ................... 2-32 (30-44)
Water Pump Bolts ........................................................................................... 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................................ ..................... 18-35 (2-4)
Water Pump Pulley Bolt ................................................................ ..................... 53-80 (6-9)

EAGLE

216

2.2L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 4-Cyl.
Medallion
1989 ........................................................... 2.3 Hours ... ..... T140
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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.
2) 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. Remove water pump pulley bolt and pulley.
Remove water pump attaching bolts. Remove water pump, gasket,
timing belt and timing belt tensioner.
Installation 1) Use feeler gauge to measure clearance between
intermediate 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.
2) Position timing belt cover over sprockets and check camshaft timing
mark with index on cover. Remove TDC rod and install plug in cylinder
block. Rotate camshaft clockwise 2 complete revolutions. DO NOT
rotate counterclockwise. Remove timing belt cover and loosen timing
belt tensioner bolts a maximum of 1/4 turn.
3) Spring-loaded timing belt tensioner will automatically adjust to correct
position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004 (.10 mm). Tighten lower timing belt tensioner
bolt. Tighten upper 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.
4) Install timing belt cover, water pump pulley and water pump pulley
bolt. Reverse removal procedures to complete installation. Adjust the
drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Checking Timing Belt Tensioner Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 37 (50)
Crankshaft Pulley Bolt ............................................................................................. 96 (130)

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt

FIAT

217

1.3L & 1.5L 4-Cylinder

TIMING BELT APPLICATION
Application

1.3L 4-Cyl.
128
1973-78 .....................................................
1979 ...........................................................
X1/9
1974-78 .....................................................
1.5L 4-Cyl.
Strada
1979-82 .....................................................
X1/9
1979-83 .....................................................
1

Labor Time

Belt
Part No.

2.3 Hours ... ..... T018

2.4 Hours ... ..... T018
2.3 Hours ... ..... T018

2.0 Hours ... ..... T069

2.0 Hours ... ..... T069

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 1979-82 1.5L
4-cylinder, replace belt every 30,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (128 & Strada) 1) Disconnect negative battery cable.
Remove right guard and loosen timing belt cover retaining screws, from
under vehicle. 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. See Fig. 1. Index on crankshaft
sprocket should be in alignment with index on crankshaft seal case.
2) 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) 1) Disconnect negative battery cable. Rotate No. 4
cylinder into firing position at top dead center. Position transmission into
4th gear, to prevent crankshaft from turning. Apply parking brake.
CAUTION: If camshaft is turned independently of engine, valves
may hit pistons, causing engine damage.
2) 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.

Courtesy of Fiat Motor Co.

Fig. 1: Aligning Timing Marks

3) 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) 1) Install timing belt making sure that teeth are
properly engaged in sprockets. Start installation of timing belt at
crankshaft pulley. Release idler pulley lock nut and retighten after
tension is on belt.
NOTE: Never allow engine to rotate backwards, or slack will
develop in belt and belt will jump timing.
2) Rotate engine 2 turns in direction of engine rotation. Loosen idler
pulley lock nut to ensure all slack is removed. Retighten 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 tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 61 (85)
Crankshaft Pulley/Sprocket Nut ............................................................................ 101 (137)
Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45)

FIAT

218

1.6L & 1.8L 4-Cylinder

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

1

Application
1.6L 4-Cyl.
124
1971-74
1.8L 4-Cyl.
Brava
1974-78
124
1974-78
131
1975-78
1

Labor Time

Belt
Part No.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

..................................................... 1.9 Hours ... ..... T020

TIMING BELT
..................................................... 2.4 Hours ... ..... T020
..................................................... 1.9 Hours ... ..... T020
..................................................... 1.9 Hours ... ..... T020

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Removal 1) 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.
NOTE: Any time tension is relieved from timing belt, timing belt
must be replaced.

The manufacturer recommends that belt be replaced every 25,000 miles

or 24 months (1974-77 models) or every 25,000 miles (1978 models).

Courtesy of Fiat Motor Co.

Fig. 1: Aligning Timing Marks (1.6L)

FIAT

219

1.6L & 1.8L 4-Cylinder (Cont.)

2) 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 before No. 42577, pry pulley to release
tension. Tighten pulley nut and bracket bolt, and remove belt.
Installation 1) Install timing belt, making sure not to move sprockets.
Ensure hole in auxiliary shaft pulley is lined up with tensioner pulley bolt.
2) To adjust timing belt tension, loosen idler pulley tensioner nut and
allow pulley to tension timing belt. Rotate crankshaft pulley 2 full turns
and recheck timing marks. Tighten tensioner nut and bracket bolt. Adjust
drive belts to proper tension.

Courtesy of Fiat Motor Co.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks (1.8L)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 87 (118)
Tensioner Nut ............................................................................................................ 33 (45)

FIAT

220

2.0L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

2.0L 4-Cyl.
Brava
1979-81 ....................................................
Spider 2000
1979-82 ....................................................

2.4 Hours .. ..... T068

3.1 Hours .. ..... T068

Belt
Part No.

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 30,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Courtesy of Fiat Motor Co.

CAUTION: 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.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

TIMING BELT
Removal 1) 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.
2) Remove hot air hose from exhaust manifold to air intake. Remove all
drive belts from crankshaft pulley. Remove water pump pulley bolts and
remove pulley. Remove outer timing belt cover.
3) 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. See Fig. 2. Install belt and adjust
tensioner, then turn crankshaft 2 full turns, and recheck tension and
timing. To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 87 (118)
Timing Belt Tensioner Nut ........................................................................................ 33 (45)

Courtesy of Fiat Motor Co.

Fig. 2: Identifying Sprocket Alignment For Timing Belt

Installation

FORD

221

1.3L 4-Cylinder
TIMING BELT APPLICATION
Application
1.3L 4-Cyl.
Aspire
1994-97
Festiva
1988-89
1990-93
1

Labor Time

Component
Belt
Kit No.
Part No.

VIN H
..............................

2.0 Hours .. .. TCK185 .. ..... T185

..............................
..............................

2.0 Hours .. .. TCK141 .. ..... T141

2.0 Hours .. .. TCK185 .. ..... T185

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Ford Motor Co.

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 recommends the belt be
replaced every 60,000 miles.

Fig. 1: Removing Right Inner Fender Panel

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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.
2) Mark timing belt direction of rotation for installation reference.
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.

Courtesy of Ford Motor Co.

Fig. 2: Locating Timing Belt Upper & Lower Covers

Installation 1) 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.
2) Install timing belt tensioner spring, spring cover, and pulley. To
complete installation, reverse removal procedure. Tighten all bolts and
nuts to specification. See TORQUE SPECIFICATIONS. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 29-40 (39-54)
Camshaft Pulley Bolt ..................................................................... ................... 9-13 (12-17)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Crankshaft Pulley Bolts ................................................................. ................. 10-13 (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)
Courtesy of Ford Motor Co.

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)

Fig. 3: Aligning Timing Marks

FORD

222

1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. DOHC

Capri
1991-94 ............................... 3.6 Hours ... .. TCK179 .. ..... T179
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.

Tighten tension pulley to specification. See TORQUE SPECIFICATIONS. Rotate engine 2 full turns. Verify timing mark alignment.
4) 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 procedure. If correct tension cannot be
achieved, replace tension spring. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. 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. Remove accessory drive belts. Remove
dipstick. Remove water pump pulley. Remove crankshaft pulley, damper
and baffle plate. See Fig. 1.
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. 1.
Courtesy of Ford Motor Co.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

Installation 1) 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 letter 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. 2.
CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with
solvents. Wipe them clean only.
2) Unloaded free length of timing belt tension spring should be 2.315
(58.8 mm). 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.
3) 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.

Fig. 3: Checking Timing Belt Tension

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
exhibit 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.

FORD

223

1.6L 4-Cylinder DOHC (Cont.)

This procedure is also recommended when replacing a damaged
crankshaft to prevent timing belt noise.
When replacing the timing belt and crankshaft, all associated parts
MUST be replaced as a set. See TIMING BELT PULLEY PARTS (1990)
table. The crankshaft pulley center bolt listed in the TORQUE SPECIFICATIONS table is the revised bolt torque. Use Crankshaft Pulley
Holder (T92C-6316-AH).
TIMING BELT PULLEY PARTS (1990)
Application
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

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 29-40 (39-54)
Camshaft Pulley Bolt ..................................................................... ................. 37-45 (49-61)
Crankshaft Pulley Bolts ................................................................. ................. 10-13 (12-17)
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)
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)
Water Pump Pulley Bolt .................................................................................... 71-97 (8-11)

Courtesy of Ford Motor Co.

Fig. 4: Identifying New & Old Style Crankshaft & Timing Belt
Pulley

FORD

224

1.6L & 1.9L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

1.6L 4-Cyl. SOHC

Escort, EXP, LN7 & Lynx
1981-85 ...............................
Tracer (Includes Canadian)
1987-90 ...............................
1.9L 4-Cyl. SOHC
Escort & EXP
1985-90 ...............................
1991
Thru: 3-25-91 ...................
From: 3-26-91 ..................
1992-96 ...............................
Lynx
1985-87 ...............................
Tracer
1991
Thru: 3-25-91 ...................
From: 3-26-91 ..................
1992-96 ...............................
1

Labor Time Component

Belt
Kit No.
Part No.

2.2 Hours ... .. TCK067 .. ..... T067

2.0 Hours ... .. TCK141 .. ..... T141

2.2 Hours ... .. TCK067 .. ..... T067

2.3 Hours ... .. TCK067 .. ..... T067
2.3 Hours ... .. TCK194 .. ..... T194
2.3 Hours ... .. TCK194 .. ..... T194
2.2 Hours ... .. TCK067 .. ..... T067
Courtesy of Ford Motor Co.

2.3 Hours ... .. TCK067 .. ..... T067

2.3 Hours ... .. TCK194 .. ..... T194
2.3 Hours ... .. TCK194 .. ..... T194

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.
CAUTION: The 1.6L and 1985-91 1.9L engines are interference
engines. Do not rotate camshaft or crankshaft when timing belt is
removed, or engine damage may occur.

Courtesy of Ford Motor Co.

Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory
drive 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 timing mark aligns with oil
pump housing timing mark.
2) Loosen timing belt tensioner bolt. See Figs. 2, 3 and 4. Pry timing belt
tensioner away from timing belt, and tighten tensioner bolt. Remove
spark plugs. Support engine with floor jack. Remove engine mount at
timing belt end of engine.
3) 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 1) Install timing belt over sprockets in counterclockwise
direction, starting at crankshaft.
CAUTION: Maintain tension on timing belt between crankshaft and
camshaft sprockets when installing belt over remaining sprockets.
2) 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 crankshaft counterclockwise. See Figs. 5,
6 and 7. Tighten belt tensioner bolt to specification. To install remaining
components, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Fig. 3: Releasing Timing Belt Tension (Except Tracer)

FORD

225

1.6L & 1.9L 4-Cylinder SOHC (Cont.)

Courtesy of Ford Motor Co.

Fig. 4: Exploded View Of Timing Belt & Components

Courtesy of Ford Motor Co.

Fig. 6: Installing Timing Belt (Tracer)

Courtesy of Ford Motor Co.

Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)

Courtesy of Ford Motor Co.

TORQUE SPECIFICATIONS

Fig. 7: Aligning Crankshaft Sprocket Timing Marks (Tracer)

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

FORD

226

1.6L & 2.0L 4-Cylinder Bobcat, Capri & Pinto

TIMING BELT APPLICATION
Application
1.6L 4-Cyl.
Capri
1972 ..........................................................
2.0L 4-Cyl.
Bobcat
1974 ..........................................................
Capri
1971-74 ....................................................
Pinto
1971-74 ....................................................
1

Labor Time

Belt
Part No.

1.3 Hours .. ..... T013

1.3 Hours .. ..... T013

1.3 Hours .. ..... T013

1.3 Hours .. ..... T013

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

Courtesy of Ford Motor Co.

Fig. 1: Checking Camshaft Timing

REMOVAL & INSTALLATION

TIMING BELT
Removal Disconnect negative battery cable. Remove accessory drive
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
adjustment 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 adjustment bolt and pivot bolt to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper
tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

FORD

227

1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
1.8L 4-Cyl.
Escort & Tracer
1991-96 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.8 Hours .. .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
NOTE: Mark direction of timing belt rotation if timing belt is to be
reused.
Removal 1) Disconnect negative battery cable. Remove accessory
drive 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.

2) 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 3.
3) Remove crankshaft pulley and hub. See Fig. 4. 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 1) Temporarily position belt tensioner with spring fully
extended, and tighten tensioner bolt. Ensure timing marks on crankshaft
sprocket and oil pump align. See Fig. 5.
CAUTION: Ensure I and E camshaft sprocket timing marks are
facing up. Camshaft sprockets may be stamped with more than
one mark.
2) Ensure camshaft sprocket timing marks are still aligned. See Figs. 2
and 3. Install timing belt. If reusing timing belt, ensure belt is installed in
original direction of rotation.
3) Loosen tensioner bolt. Position tensioner so slack is removed from
timing belt. Tighten tensioner bolt. Rotate crankshaft 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.
4) Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft timing
mark with tension set mark (at approximately 10 oclock position). See
Fig. 5. Loosen tensioner bolt. Apply tension to the tensioner. Tighten
tensioner bolt to 27-38 ft. lbs. (37-52 N.m).

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

FORD

228

1.8L 4-Cylinder DOHC (Cont.)

5) Rotate crankshaft clockwise 2 1/6 revolutions. Ensure timing 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. 6.
6) Timing belt deflection should be .35-.45 (8.9-11 mm). 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.
7) To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

TORQUE SPECIFICATIONS
Courtesy of Ford Motor Co.

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30)
Belt Tensioner Bolt ........................................................................ ................. 17-22 (23-30)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Crankshaft Sprocket Bolt ............................................................................ 80-87 (109-118)
Power Steering Pump Bolt ........................................................... ................. 30-45 (40-62)
Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-52)
Water Pump Bolt ........................................................................... ................. 15-22 (20-30)

Fig. 4: Identifying Crankshaft Pulley & Guide Plates

INCH Lbs. (N.m)

Timing Belt Cover Nut .................................................................. ..................... 44-61 (5-7)
Valve Cover Bolt ........................................................................... ................. 48-106 (5-12)

Courtesy of Ford Motor Co.

Fig. 5: Aligning Crankshaft Sprocket Timing Marks

Courtesy of Ford Motor Co.

Fig. 2: Aligning Timing Marks

Courtesy of Ford Motor Co.

Fig. 6: Checking Timing Belt Deflection

Courtesy of Ford Motor Co.

Fig. 3: Identifying Camshaft Sprocket Timing Marks

FORD

229

2.0L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

2.0L 4-Cyl. Diesel

Escort & Lynx
1984-87
Camshaft ................................................
Injection Pump .......................................
Tempo & Topaz
1984-86
Camshaft ................................................
Injection Pump .......................................
1

Labor Time

Belt
Part No.

6.2 Hours ... ..... T103

1.3 Hours ... ..... T102

6.2 Hours ... ..... T103

1.3 Hours ... ..... T102

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

NOTE: DO NOT allow crankshaft to rotate with timing belt removed.

Installation 1) Align camshaft and crankshaft sprockets with their
respective timing marks. See Figs. 1 and 2. Remove tensioner spring
from front timing belt upper cover pocket, and install in tensioner lever
slot and over crankcase stud. See Fig. 3. Push tensioner lever as far as
possible toward water pump and tighten lock bolt.
2) Install timing belt. With tensioner pulley loose, adjust belt tension 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.
3) 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.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 100,000
miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

ENGINE
NOTE: Engine/transaxle must be removed to replace timing belt.
The engine/transaxle is removed as an assembly.
Removal & Installation 1) Disconnect negative battery cable. Mark
hinges for reinstallation and remove hood. Remove air cleaner assembly. Drain coolant. Remove upper and lower radiator hoses.
2) 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.
3) Disconnect all vacuum lines as necessary. Disconnect clutch cable at
transaxle, injection pump throttle linkage, and fuel hoses at engine.
4) Disconnect both engine harness connectors and glow plug relay
connectors at dash panel. Connectors are located under plastic shield
on dash panel. Remove and save plastic retainer pins. Disconnect
alternator connector on right-hand fender apron.
5) Disconnect power steering hoses at pump (if equipped). Remove
hose bracket from cylinder head. Attach engine support tool to lifting
eye. Raise vehicle. Disconnect exhaust 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.
6) Disconnect control arms at body. Remove stabilizer bar brackets.
Remove half-shaft assemblies and install alignment plugs in differential
side gears. On manual transaxle models, remove shift stabilizer bar-totransaxle bolts. Remove shift mechanism-to-shift shaft attaching bolt at
transaxle.
7) 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 intermediate bracket from engine bracket and
insulator. Remove bracket. Lower engine and transaxle assembly to
floor. To install, reverse removal procedures.

FRONT TIMING BELT

Removal 1) With engine out of vehicle, remove front upper timing belt
cover and flywheel timing mark case.
2) 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.

Courtesy of Ford Motor Co.

Fig. 1: Cross Section Of 2.0L Diesel Engine

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

FORD

230

2.0L 4-Cylinder Diesel (Cont.)

Courtesy of Ford Motor Co.

Fig. 3: Installing Front Timing Belt Tensioner Spring

Courtesy of Ford Motor Co.

REAR TIMING BELT

Removal 1) Remove rear timing belt cover and flywheel timing mark
case. Rotate crankshaft until No. 1 cylinder is at TDC (flywheel timing
mark at TDC, camshaft sprocket and injection pump timing marks
aligned). See Figs. 4, 5 and 6.
2) Loosen tensioner lock nut. Turn tensioner clockwise with a screwdriver to loosen timing belt. Tighten lock nut and remove timing belt.
Installation Install timing belt. See Fig. 7. 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.

Fig. 6: Aligning Camshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 7: Installing Rear Timing Belt

TORQUE SPECIFICATIONS
Courtesy of Ford Motor Co.

Fig. 4: Aligning Camshaft & Injection Pump Timing Marks

Courtesy of Ford Motor Co.

Fig. 5: Aligning Flywheel Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket (Front & Rear) .......................................................................... 45 (61)
Crankshaft Pulley .................................................................................................. 119 (165)
CV Hub Nut ................................................................................... ......... 180-200 (244-271)
Insulator Bracket-To-Body Bracket Bolts ...................................... ........... 75-100 (102-136)
Intermediate Bracket-To-Engine Bracket 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)

FORD

231

2.0L 4-Cylinder DOHC Escape

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. VIN B

Escape
2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Ford Motor Co.

Fig. 1: Removing Valve Cover

The manufacturer recommends the belt be replaced every 120,000

miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory
drive belt. Remove air cleaner outlet pipe. Disconnect ignition wires from
spark plugs. Remove spark plugs. Disconnect throttle cable and cruise
control actuator cable. On 2002-04 models, disconnect the catalyst
monitor and heated oxygen sensor connectors, and detach the connectors from the bracket. Remove wiring harness anchors from valve cover
studs, and position the wiring harness aside. On all models, remove
valve cover. See Fig. 1.
2) Remove catalytic converter. Remove coolant tube bolt and nut.
Position coolant tube to side. Remove right front wheel and tire
assembly. Remove right lower splash shield.
3) 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.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks Before TDC

NOTE: Make sure second notch in pulley is indexed to lower

cylinder block. See Fig. 2.
4) Rotate crankshaft clockwise against peg to bring it to TDC. Loosen
water pump pulley bolts.
5) Loosen crankshaft pulley bolt. Rotate tensioner and remove accessory drive belt. Remove crankshaft pulley. Remove bolts and lower
timing belt cover. See Fig. 4. Install Engine Support Bar (303-F072). See
Fig. 5.
6) Remove ground strap and engine mount upper bracket. See Fig. 6.
Remove upper timing belt cover studs. Disconnect the knock sensor
connector from upper timing cover, if necessary. Remove upper timing
belt cover bolts and cover. See Fig. 7.

Courtesy of Ford Motor Co.

Fig. 3: Removing Stud For Installation Of Crankshaft TDC Timing

Peg (303-574)

NOTE: Installation of Camshaft Alignment Tool (303-465) into

exhaust camshaft may require camshafts to be rotated slightly
clockwise.
7) Remove water pump pulley and accessory drive belt idler pulley.
Install Camshaft Alignment Tool (303-465) and align camshafts. See
Fig. 8.
8) Raise and support vehicle. Remove engine mount lower bracket. See
Fig. 9.
9) Loosen timing belt tensioner pulley, and allow it to slide down to
bottom of its travel. If timing belt is going to be reused, mark direction of
rotation for installation reference. Slide timing belt off of camshaft and
crankshaft sprockets.

Courtesy of Ford Motor Co.

Fig. 4: Removing Lower Timing Belt Cover

FORD

232

2.0L 4-Cylinder DOHC Escape (Cont.)

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 9: Removing Engine Mount Lower Bracket

Fig. 5: Installing Engine Support Bar (303-F072)

Courtesy of Ford Motor Co.

Fig. 6: Removing Engine Mount Upper Bracket

Installation 1) 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.
2) Ensure timing belt tensioner is installed correctly with tab positioned
in slot in inner timing cover. See Fig. 10.
3) Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under
tension. Adjust 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 specification. See TORQUE SPECIFICATIONS.
4) Install front engine mount lower bracket. Install accessory drive belt
idler pulley. Install water pump pulley, and hand tighten bolts. Install
timing belt covers. Install crankshaft pulley. Tighten water pump pulley
bolts to specification. See TORQUE SPECIFICATIONS.
5) Install splash shield, then wheel and tire assembly. Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install engine mount upper
bracket and ground strap. Remove Engine Support Bar (303-F072).
Install coolant tube and catalytic converter. Remove Camshaft Alignment Tool (303-465).
6) Install valve cover and spark plugs. On 2002-04 models, connect
wiring harness anchors to valve cover studs. Install and reconnect the
catalyst monitor and heated oxygen sensor connectors. On all models,
reconnect accelerator cable and cruise control actuator cable. Install
ignition wires, air cleaner outlet pipe and accessory drive belt. Reconnect negative battery cable.

Courtesy of Ford Motor Co.

Fig. 7: Removing Upper Timing Belt Cover

Courtesy of Ford Motor Co.

Fig. 10: Installing Timing Belt Tensioner

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Tool (303-465)

FORD

233

2.0L 4-Cylinder DOHC Escape (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt On Sprockets

Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45)
Camshaft Sprocket Bolts .......................................................................................... 50 (68)
Catalytic Converter Bracket Bolts ............................................................................. 18 (25)
Coolant Tube Attachments ........................................................................................ 15 (20)
Crankshaft Pulley Bolt ............................................................................................. 85 (115)
Engine Mount Lower Bracket Nuts .......................................................................... 37 (50)
Engine Mount Upper Bracket
Bolt ........................................................................................................................... 57 (77)
Nuts .......................................................................................................................... 72 (98)
Studs ........................................................................................................................ 25 (34)
Exhaust Camshaft Center Plug ................................................................................ 27 (37)
Ground Strap ............................................................................................................. 25 (34)
Spark Plugs ............................................................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) ................................................................... 18 (25)
Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Water Pump Pulley Bolt ............................................................................................ 18 (25)
Wheel Lug Nuts ...................................................................................................... 98 (133)
INCH Lbs. (N.m)
Timing Belt Cover Bolts
Inner ......................................................................................................................... 89 (10)
Lower ......................................................................................................................... 62 (7)
Upper ......................................................................................................................... 71 (8)
Splash Shield Bolts ..................................................................................................... 80 (9)
Valve Cover Bolts ........................................................................................................ 80 (9)

Courtesy of Ford Motor Co.

Fig. 12: Adjusting Timing Belt Tensioner

FORD

234

2.0L 4-Cylinder
DOHC, VIN 3 Contour & Mystique (1995-97)
TIMING BELT APPLICATION
Application

Labor Time

Timing Belt
Belt
Kit No.
Part No.

2.0L 4-Cyl.
Contour & Mystique
1995-97 ............................... 2.2 Hours ... .. TCK258 .. ..... T258
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Noting position for installation reference, disconnect
secondary wires from spark plugs. Remove spark plugs.
2) Disconnect negative battery cable. Remove air intake resonators.
Remove power steering pressure hose bracket from lifting eye, and
position aside.
3) Support engine from above using Three Bar Engine Support
(D88L-6000-A) or equivalent. Remove upper timing belt cover.
4) Mark position of upper front engine mount before removal. Remove
upper front mount. If equipped, disconnect coolant level sensor connector from coolant recovery reservoir. Remove retainers attaching recovery reservoir, and position aside. Remove upper front mount insulator.
5) Loosen water pump pulley bolts. Remove serpentine drive belt.
Remove drive belt idler pulley from alternator mounting bracket.
Remove water pump pulley.
6) Remove center timing belt cover. Raise and support vehicle. Remove
crankshaft pulley. See Fig. 3. Remove lower timing belt cover. Remove
valve cover.
7) 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.
8) Loosen timing belt tensioning pulley. See Fig. 4. Move pulley to
relieve tension on timing belt, and retighten pulley. If reusing timing belt,
mark direction of rotation before removal. Remove timing belt.
Installation 1) Temporarily install crankshaft pulley. Ensure crankshaft
pulley timing marks are aligned. See Fig. 1. Ensure camshaft alignment
tool is still installed.
2) Install tensioner and retaining bolt (if necessary). Remove crankshaft
pulley.
3) Install timing belt on crankshaft sprocket. Working in a clockwise
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.

4) 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.
5) 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 alignment tool. Rotate crankshaft clockwise 2
full revolutions.
6) 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.
7) If camshaft alignment tool cannot be installed on camshafts with
crankshaft at TDC, hold camshaft sprocket with Camshaft 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 camshaft sprocket
center bolts to specification.
8) Install timing belt covers. Install crankshaft pulley. Tighten bolt to
specification. Install valve cover. Install spark plugs.
9) Install upper front engine mount. Remove engine support tool. Install
water pump pulley. Install serpentine belt idler pulley and serpentine
bolt.
10) Install coolant recovery reservoir. To complete installation, reverse
removal procedure.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 2: Installing Camshaft Alignment Tool

FORD

235

2.0L 4-Cylinder
DOHC, VIN 3 Contour & Mystique (1995-97) (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30)
Alternator Mounting Bolt ............................................................... ................. 30-41 (41-56)
Camshaft Sprocket Bolt ................................................................ ................. 47-53 (64-72)
Crankshaft Pulley Bolt ................................................................................. 81-89 (110-121)
Serpentine Belt Idler Pulley Bolt .............................................................................. 35 (48)
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)

Courtesy of Ford Motor Co.

Fig. 3: Exploded View Of Timing Belt Components

Courtesy of Ford Motor Co.

Fig. 4: Identifying Timing Belt Tensioner

FORD

236

2.0L 4-Cylinder
DOHC, VIN 3 Cougar, Contour & Mystique (1998-02)
TIMING BELT APPLICATION
Application
2.0L 4-Cyl. VIN 3
Cougar
1999
Before 3/28/99 ..................
After 3/29/99 .....................
2000-02 ...............................
Contour & Mystique
1998 ....................................
1999
Before 3/28/99 ..................
After 3/29/99 .....................
2000 ....................................

Labor Time

Component
Belt
Kit No.
Part No.

3.2 Hours ... .. TCK294 .. ..... T294

3.2 Hours .... TCK294A . ..... T294
3.2 Hours .... TCK294A . ..... T294
3.2 Hours ... .. TCK294 .. ..... T294
3.2 Hours ... .. TCK294 .. ..... T294
3.2 Hours .... TCK294A . ..... T294
3.2 Hours .... TCK294A . ..... T294

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

CAUTION: DO NOT pull the spark plug cable when removing the
spark plug connectors. If necessary, remove the ignition cables
from the ignition coil to avoid kinking the cables. Turn the spark
plug connectors slightly before removing to loosen the seal.
8) Disconnect throttle cable and cruise control cable from engine
appearance cover. Disconnect solenoid valve electrical connector (1),
and remove the engine appearance cover (2). See Fig. 6. Pull off the
spark plug connectors in line with the spark plugs. Remove the PCV
hose. Loosen 10 valve cover bolts from the outside to the inside,
working diagonally. See Fig. 7. Remove the valve cover.
9) Remove the spark plugs. Turn the engine to TDC on cylinder No. 1.
To remove the tension on timing belt, unscrew the timing belt tensioner
bolt (1) 4 turns. See Fig. 8. Position the tensioner so the locating tab (2)
is at approximately the 4 oclock position. Line up the hex key slot (3) in
the tensioner adjusting washer with the pointer that is located behind the
pulley.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

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.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

10) Remove blanking plug (1) from center of exhaust camshaft pulley.
See Fig. 9. Loosen, but do not remove, exhaust camshaft sprocket bolt
(2). Loosen, but do not remove, intake camshaft sprocket bolt (3).
Remove timing belt.

For 1998-00 model years, the manufacturer recommends the belt be

inspected every 120,000 miles. Replace, if necessary. For 2001-02
model year, the manufacturer recommends the belt be replaced every
120,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right front wheel. Remove engine undercover, if
equipped. Remove engine splash shield from right wheelwell.
2) Loosen, but do not remove, water pump pulley bolts. If accessory
drive belt is to be reused, mark belt with arrow to indicate direction of
rotation. Turn accessory drive belt tensioner clockwise, and remove
accessory drive belt. See Fig. 1.
3) Remove water pump pulley. Remove serpentine belt idler pulley.
Using access hole in bottom of transaxle case to stop rotation of engine,
remove crankshaft pulley/vibration damper.

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

CAUTION: Removal of lower timing belt cover is necessary to

avoid damage to timing belt.
4) Remove lower timing belt cover. See Fig. 2. Working from under
vehicle, loosen center bolt of left-hand and right-hand engine support
insulators 2 turns. DO NOT remove center bolts.
5) Lower vehicle. Remove coolant reservoir tank with hoses attached,
and set aside. Disconnect cruise control cable (if equipped) from coolant
reservoir.
CAUTION: Use a block of wood between oil pan and floor jack, or
oil pan may be damaged.
6) Position floor jack under engine. Raise engine slightly to release
pressure from mounting insulator on front of engine. Marking installed
position for installation reference, remove engine front support insulator
from timing belt end of engine. See Fig. 3.
7) Remove power steering pressure hose bracket from engine lifting
eye, and position aside. Remove the timing belt upper cover bolts, but
leave the timing belt cover in its installed position. See Fig. 4. Remove
the timing belt center cover/front engine mounting bracket. See Fig. 5.
Remove the timing belt upper and center covers.

Courtesy of Ford Motor Co.

Fig. 2: Identifying Lower Front Timing Cover Bolts

FORD

237

2.0L 4-Cylinder
DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)

Courtesy of Ford Motor Co.

Fig. 3: Removing & Installing Front Support Insulator

Courtesy of Ford Motor Co.

Fig. 7: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co.

Fig. 4: Locating Upper Front Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 8: Removing Tension From Timing Belt

Courtesy of Ford Motor Co.

Fig. 5: Locating Center Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 9: Identifying Camshaft Sprocket Holding/Removing Tool

Courtesy of Ford Motor Co.

Fig. 6: Removing & Installing Appearance Cover

238

FORD
2.0L 4-Cylinder
DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)
11) Attach the timing belt center cover/front engine mounting bracket.
See Fig. 5. Install the valve cover. See Fig. 7. Tighten the valve cover
bolts in 2 stages:
Step 1: 18 INCH lbs. (2 N.m).
Step 2: 62 INCH lbs. (7 N.m).

NOTE: To achieve proper timing belt tension, camshaft sprocket

bolts must be loosened enough to permit sprockets to turn freely
on camshafts. With cam sprocket bolts loose and cylinder No. 1 at
TDC, crankshaft must be rotated to TDC in clockwise direction
(install camshaft alignment tool in cam slots). Cylinders No. 1 and 4
are at TDC when Woodruff key points straight up.

NOTE: Check the seating of the timing belt upper cover gasket and
correct it if necessary.

Installation 1) Rotate the crankshaft clockwise to TDC cylinder No. 1.

Remove the blanking plug, completely screw in the Crankshaft TDC
Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to
TDC. See Fig. 10.
2) Turn the camshafts to ignition position on cylinder No. 1, and insert
the Camshaft Alignment Plate (303-465, T94P-6256-CH) into the camshafts. See Fig. 11.

12) Install the timing belt upper cover. See Fig. 4. Install the front engine
mount. Connect the Power Assisted Steering (PAS) reservoir. Install the
coolant expansion tank.
13) Install the power steering pipe bracket to the engine lift eye. Install
the front support insulator. See Fig. 3. Remove the floor jack.
14) Install the coolant expansion tank. Attach the cruise control cable (if
equipped) to the coolant expansion tank. Raise and support the vehicle.

NOTE: DO NOT kink or bend the timing belt less than a diameter of
1.38 (35 mm). DO NOT rotate the crankshaft, and check that it is
still resting against the timing pin. The lug of the belt tensioner
must not be hooked into the sheet metal cover during timing belt
installation.

NOTE: Verify that the center bolt is centered in the support insulator.

3) Starting from the crankshaft timing belt pulley and working counterclockwise, position a NEW timing belt in place while keeping it under
tension. See Fig. 12.
4) Apply tension to the timing belt. Incorrect timing belt tension will cause
incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. See
Fig. 13.
5) Position the hex key slot in the tensioner adjusting washer to the 4
oclock position. Tighten the attaching bolt (3) enough to seat the
tensioner firmly against the rear timing cover, but still allow the tensioner
adjusting washer to be rotated using a 0.24 (6 mm) hex key.
6) Tension the timing belt, working counterclockwise. Using the hex key,
rotate the adjusting washer counterclockwise until the notch in the
pointer is centered over the index line on the locating tab (the pointer will
move clockwise during adjustment). See Fig. 14.
7) While holding the adjusting washer in position, tighten the bolt to
specification. See TORQUE SPECIFICATIONS. DO NOT tighten the
camshaft timing pulley bolts against the camshaft alignment plate. Use
the camshaft sprocket holding tool to prevent movement. See Fig. 9.
The crankshaft must remain at TDC on cylinder No. 1. Tighten the bolts
of the camshaft timing pulleys to specification.
8) Unscrew and remove crankshaft timing peg. Remove camshaft
alignment plate from the camshafts. Turn the crankshaft 2 revolutions in
the normal direction of rotation. Check the valve timing by inserting the
crankshaft timing peg. Correct it if necessary.
9) Screw in crankshaft timing peg and make sure that the crankshaft is
touching it. Insert camshaft alignment plate into the camshafts. If
necessary, loosen the timing pulleys and correct the camshaft alignment. Remove the crankshaft timing peg and camshaft alignment plate.
Screw in and tighten the blanking plug.

15) Tighten the center bolt of the right engine support insulator. Tighten
the center bolt of the left engine support insulator. Install the lower part
of the engine front cover. See Fig. 2. Tighten front cover bolts to
specification. See TORQUE SPECIFICATIONS.
NOTE: Use the access hole in the bottom of transaxle case to stop
engine rotating.
16) Install the crankshaft pulley/vibration damper and tighten to specification. See TORQUE SPECIFICATIONS. Install the accessory drive
belt. See Fig. 1. Note the accessory drive belt direction mark if belt is
being reused. Install the belt idler pulley. Install the water pump pulley.
17) Tension the belt tensioner clockwise, and position the accessory
drive belt in place. Tighten the water pump pulley bolts to specification.
See TORQUE SPECIFICATIONS.
18) Install the right front lower splash shield. Install the engine splash
shield (if equipped). Lower the vehicle. Install the right front wheel, and
tighten nuts to specification. See TORQUE SPECIFICATIONS.
19) Connect the negative battery cable. Check the fluid levels and
correct as necessary. Check the routing of the vacuum hoses and wiring
and secure them with cable ties.
20) 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.

NOTE: Coat the inside of the spark plug connectors with silicone
grease to a depth of 0.20-0.39 (5-10 mm). Use a blunt object (such
as a plastic cable tie) to apply the silicone grease, to avoid
damaging the spark plug connectors.
10) Attach the PCV hose. Coat the spark plug thread with Never Seize,
and screw in the spark plugs. Tighten spark plugs to specification. See
TORQUE SPECIFICATIONS. Push in the spark plug connector until it
engages. Install appearance cover, and tighten bolts to specification.
Connect solenoid valve electrical connector and press in rubber seal.
Connect throttle and cruise control cables to appearance cover. Put the
upper timing belt cover together with the center timing belt cover in
place.

Courtesy of Ford Motor Co.

Fig. 10: Aligning Crankshaft Timing Marks

FORD

239

2.0L 4-Cylinder
DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)

Courtesy of Ford Motor Co.

Fig. 11: Installing Camshaft Alignment Tool

Courtesy of Ford Motor Co.

Fig. 14: Setting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Ford Motor Co.

Fig. 12: Identifying Timing Belt Installed Position

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Intake ....................................................................................................................... 50 (68)
Exhaust
Step 1 .................................................................................................................... 44 (60)
Step 2 .................................................................................................................. 89 (120)
Center Bolt-Left & Right-Hand Support Insulator Bolts ......................................... 89 (120)
Crankshaft Pulley Bolt ............................................................................................. 85 (115)
Engine Front Support Insulator Bolt/Nut .................................................................. 61 (83)
Engine Lifting Eye With Coolant Hose Brackets ..................................................... 13 (18)
Exhaust Camshaft Center Blanking Plug ................................................................. 27 (37)
Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40)
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25)
Water Pump Bolt ....................................................................................................... 13 (18)
Water Pump Pulley Bolt ............................................................................................ 18 (24)
Wheel Lug Nut ........................................................................................................ 94 (128)
INCH Lbs. (N.m)
Lower Engine Front Cover Bolt .................................................................................. 71 (8)
Timing Belt Tensioner Spring Retaining Pin ............................................................ 89 (10)
Upper Engine Front Cover Bolt ................................................................................ 89 (10)
Valve Cover
Step 1 ........................................................................................................................ 18 (2)
Step 2 ........................................................................................................................ 62 (7)
Valve Cover Appearance Cover ................................................................................. 62 (7)

Courtesy of Ford Motor Co.

Fig. 13: Applying Pre-Tension To Timing Belt

FORD

240

2.0L 4-Cylinder DOHC, VIN 3 Escort & ZX2

TIMING BELT APPLICATION
Application
2.0L 4-Cyl. DOHC, VIN 3
Escort
1998 ....................................
1999
Before 2/9/99 ....................
After 2/10/99 .....................
2000-02 ...............................
ZX2
2000-03 ...............................

Labor Time

Component
Belt
Kit No.
Part No.

2.8 Hours ... .. TCK294 .. ..... T294

2.8 Hours ... .. TCK294 .. ..... T294
2.8 Hours .... TCK294A . ..... T294
2.8 Hours .... TCK294A . ..... T294
2.8 Hours .... TCK294A . ..... T294

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.
Courtesy of Ford Motor Co.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Fig. 1: Installing Crankshaft TDC Timing Peg

For 1998-00 model years, the manufacturer recommends the belt be

inspected every 120,000 miles. Replace, if necessary. For 2001-03
model year, the manufacturer recommends the belt be replaced every
120,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal 1) Disconnect negative battery cable. Remove spark plugs.
Raise and support vehicle. Remove catalytic converter. Remove splash
shield. Rotate crankshaft to TDC of No. 1 cylinder. Install TDC Timing
Peg (T97P-6000-A) in hole at lower right of block. See Fig. 1. Rotate
crankshaft clockwise against timing peg. See Fig. 2. Lower vehicle.
2) Drain cooling system. Loosen water pump pulley bolts. Remove
accessory drive belt. Remove drive belt idler pulley from generator
mounting bracket. Remove bolts and position A/C compressor out of the
way. Remove water pump pulley.
3) . Disconnect wiring connector at Variable Camshaft Timing (VCT)
solenoid. Disconnect crankcase ventilation hose from fitting on valve
cover. Position accelerator and speed control cables aside. Disconnect
spark plug wires from spark plug wire brackets on valve covers. Remove
bolt, nut and front support isolator damper. Remove upper timing belt
cover. Remove valve cover bolts in a diagonal pattern working inward.
Remove valve cover and gasket.
4) Raise and support vehicle. Remove center timing belt cover. Remove
crankshaft pulley. Remove lower timing belt cover. Use Camshaft
Alignment Timing Tool (T94P-6256-CH) to align camshafts. Install tool in
slots on camshafts at rear of engine. See Fig. 3.
5) Loosen timing belt tensioning pulley bolt. Disconnect tensioner tab
from timing cover back plate to relieve tension on timing belt. If reusing
timing belt, mark direction of rotation before removal. Remove timing
belt.
CAUTION: Do not use camshaft alignment tool to hold camshafts
in place when removing or installing camshaft sprocket bolts, or
damage to camshaft ears may result. Use open-end wrench to keep
camshaft from rotating.
6) Remove camshaft alignment tool. Remove bolt and intake camshaft
timing sprocket. Remove VCT oil plug, bolt and exhaust camshaft
sprocket.
Installation 1) Ensure crankshaft pulley timing marks are aligned. See
Fig. 2. Use Camshaft Alignment Timing Tool (T94P-6256-CH) to align
camshafts. Install tool in slots on camshafts at rear of engine. See Fig. 3.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 3: Installing Camshaft Alignment Timing Tool

Ensure camshafts are aligned. Install intake timing sprocket and loosely
install bolt. Rotate oil control bushing one complete turn and check for
binding. Position bushing with single hole in 12 oclock position.
CAUTION: The VCT sprocket has a rectangular tab on the backside
of the sprocket which must align with the hole on the front face of
the thrust bushing. Failure to align may result in poor engine
performance.
2) Install NEW exhaust sprocket O ring. Install exhaust sprocket.
Ensure tab on sprocket engages hole in oil control bushing. Loosely
install sprocket bolt. Loosely install timing belt tensioner. Install timing

FORD

241

2.0L 4-Cylinder DOHC, VIN 3 Escort & ZX2 (Cont.)

belt. See Fig. 4. Engage timing belt tensioner tab into upper timing cover
backplate. Using 6-mm Allen wrench, adjust timing belt tensioner until
marks are aligned. See Fig. 5. Tighten bolt to 17-20 ft. lbs. (22-28 N.m).
NOTE: Camshaft must be held stationary with an open end wrench.
DO NOT use alignment tool to hold camshaft in position, as
damage to camshaft may occur.
3) Tighten intake camshaft sprocket bolt to 50 ft. lbs. (68 N.m). Tighten
exhaust camshaft sprocket bolt to 36 ft. lbs. (50 N.m). Remove camshaft
alignment tool and timing peg. Retighten exhaust camshaft sprocket bolt
to 85-92 ft. lbs. (115-125 N.m). Install Variable Cam Timing (VCT) oil
plug, if necessary.
4) Ensure second crankshaft timing mark is aligned with raised mark on
oil pan. Position crankshaft just prior to TDC. Install TDC timing peg. See
Fig. 1. Rotate crankshaft clockwise against peg. Ensure camshafts are
aligned. If crankshaft and camshaft are misaligned, repeat procedure
until alignment is correct.
5) When alignment is correct, complete installation by reversing removal
procedure. When installing valve cover, clean gasket mating surfaces
before installing NEW gasket. Install and tighten valve cover bolts in a
diagonal pattern starting from the inside working outward. See Fig. 6.
Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS.

Courtesy of Ford Motor Co.

Fig. 6: Identifying Valve Cover Torque Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Intake ....................................................................................................................... 50 (68)
Exhaust .................................................................................................................. 88 (120)
Catalytic Converter
Bracket Bolts ............................................................................... ................. 41-47 (55-64)
To-Exhaust Manifold Bolts .......................................................... ................. 41-47 (55-64)
To-Muffler Pipe Flange Bolts ...................................................... ................. 34-39 (46-54)
Crankshaft Pulley Bolt ................................................................................. 81-89 (110-120)
Crossmember Bolts ....................................................................... ............... 69-93 (94-126)
Engine Front Support Isolator Nut & Bolt .................................... ................. 50-68 (67-93)
Exhaust Camshaft (VCT) Sprocket Plug .................................................................. 27 (37)
Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 35 (40)
Spark Plugs ................................................................................... ................. 10-12 (13-17)
Timing Belt Idler Pulley Bolt ..................................................................................... 35 (48)
Timing Belt Tensioner Bolt ............................................................ ................. 17-20 (22-28)
Water Pump Bolt ....................................................................................................... 17 (24)
Wheel Lug Nut
Alloy Wheel ................................................................................. ........... 74-100 (100-135)
Steel Wheel ................................................................................................. 66-87 (89-117)
INCH Lbs. (N.m)

Courtesy of Ford Motor Co.

Fig. 4: Identifying Timing Belt Installed Position

Courtesy of Ford Motor Co.

Fig. 5: Index Marks For Timing Belt Tensioner

Splash Shield Assembly .................................................................................... 62-97 (7-11)

Timing Belt Backplate Bolt ................................................................................ 80-97 (9-11)
Timing Belt Cover Bolt
Center .......................................................................................... ..................................... 1
Lower ......................................................................................................................... 61 (7)
Upper ........................................................................................... ..................... 27-44 (3-5)
Valve Cover Bolt ........................................................................... ..................... 54-70 (6-8)
Valve Cover Appearance Cover ................................................................................. 62 (7)
1

Tighten bolts to 10 ft. lbs. (13 N.m).

FORD

242

2.0L 4-Cylinder DOHC, VIN 3 Focus

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC, VIN 3

Focus
2000-04 ............................... 2.8 Hours .... TCK294A . ..... T294

Position the tensioner so the locating tab (2) is at approximately the 4

oclock position. Line up the hex key slot (3) in the tensioner adjusting
washer with the pointer that is located behind the pulley.
7) Remove the timing belt. Loosen the camshaft pulley retaining bolts.
Prevent sprocket from turning using the Cam Sprocket Holding/
Removing Tool (303-098, T74P-6256-B). See Fig. 7.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 120,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

TIMING BELT
NOTE: The positions of the engine mounting and the engine roll
restrictor are described looking from the transmission towards the
engine. If necessary, use Coolant Hose Remover (412-108) to
remove coolant and ventilation hoses. Owing to special model
variants, some steps DO NOT apply to all vehicles. These are
clearly marked in the text. If necessary, cut the cable tie and install
new on installation.
NOTE: Numbers in parenthesis refer to numbers in figures.

Courtesy of Ford Motor Co.

Fig. 2: Identifying Lower Front Timing Cover Bolts

Removal 1) Disconnect the negative battery cable. Raise and support

the vehicle. Remove the drive belt cover. Mark the drive belt running
direction. Loosen the bolts on the water pump pulley (1). See Fig. 1.
2) Slacken the drive belt by turning tensioner clockwise. Remove the
drive belt. Remove the water pump belt pulley (2). Remove the
multi-groove belt idler pulley (3). Remove the crankshaft pulley/vibration
damper.
CAUTION: The removal of the lower part of the engine front cover
is necessary to avoid damage to the timing belt.
3) Remove the lower timing belt cover. See Fig. 2. Lower the vehicle.
Remove the coolant expansion tank and lay it to one side. Remove the
Power Assisted Steering (PAS) reservoir and lay it to one side. Position
the jack with the wooden block under the oil pan, and raise so that the
front engine mounting is free from load.

Courtesy of Ford Motor Co.

Fig. 3: Locating Upper Front Timing Cover Bolts

NOTE: Mark the position of the engine mounting.

4) Remove the front engine mounting. Remove the timing belt upper
cover bolts, but leave the timing belt cover in its installed position. See
Fig. 3. Remove the timing belt center cover/front engine mounting
bracket. See Fig. 4. Remove the timing belt upper cover.
CAUTION: DO NOT pull the spark plug cable when removing the
spark plug connectors. If necessary, remove the ignition cables
from the ignition coil to avoid kinking the cables. Turn the spark
plug connectors slightly before removing to loosen the seal. Pull
off the spark plug connectors in line with the spark plugs.
5) Pull off the spark plug connectors. Remove the PCV hose. Loosen 10
valve cover bolts from the outside to the inside, working diagonally. See
Fig. 5. Remove the valve cover. Remove the spark plugs.
6) Turn the engine to TDC on cylinder No. 1. Remove the tension on
timing belt. Unscrew the timing belt tensioner bolt 4 turns (1). See Fig. 6.

Courtesy of Ford Motor Co.

Fig. 4: Locating Center Timing Cover Bolts

FORD

243

2.0L 4-Cylinder DOHC, VIN 3 Focus (Cont.)

NOTE: The lug of the belt tensioner must not be hooked into the
sheet metal cover during timing belt installation.

Courtesy of Ford Motor Co.

Fig. 5: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co.

Fig. 6: Removing Tension From Timing Belt

3) Position a NEW timing belt in place and starting from the crankshaft
timing belt pulley and working counterclockwise, position the timing belt
in place while keeping it under tension. See Fig. 11.
4) Apply tension to the timing belt. Incorrect timing belt tension will cause
incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab (1) into the slot in the rear timing cover.
See Fig. 12.
5) Position the hex key slot (2) in the tensioner adjusting washer to the
4 oclock position. Tighten the attaching bolt (3) enough to seat the
tensioner firmly against the rear timing cover, but still allow the tensioner
adjusting washer to be rotated using a 0.24 (6 mm) hex key.
6) Tension the timing belt, working counterclockwise. Using the hex key,
rotate the adjusting washer counterclockwise until the notch in the
pointer is centered over the index line on the locating tab (the pointer will
move clockwise during adjustment). See Fig. 13.
7) While holding the adjusting washer in position, tighten the bolt to
specification. See TORQUE SPECIFICATIONS. DO NOT tighten the
camshaft timing pulley bolts against the camshaft alignment plate. Use
the camshaft sprocket holding tool to prevent movement. See Fig. 7.
The crankshaft must remain at TDC on cylinder No. 1. Tighten the bolts
of the camshaft timing pulleys to specification.
8) Unscrew and remove crankshaft timing peg. Remove camshaft
alignment plate from the camshafts. Turn the crankshaft 2 revolutions in
the normal direction of rotation. Check the valve timing by inserting the
crankshaft timing peg. Correct it if necessary:
Screw in crankshaft timing peg and make sure that the crankshaft is
touching it.
Insert camshaft alignment plate into the camshafts. If necessary,
loosen the timing pulleys and correct the camshaft alignment.
Remove the crankshaft timing peg and camshaft alignment plate.
9) Screw in and tighten the blanking plug to specification.
CAUTION: Use a blunt object (such as a plastic cable tie) to apply
the silicone grease, to avoid damaging the spark plug connectors.
Push on the spark plug connectors, keeping them in line with the
spark plugs.
NOTE: Coat the inside of the spark plug connectors with silicone
grease to a depth of 0.20-0.39 (5-10 mm).

Courtesy of Ford Motor Co.

Fig. 7: Identifying Cam Sprocket Holding/Removing Tool

NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must
be able to turn freely on the camshafts.
Installation 1) Turn the camshafts to ignition position on cylinder No. 1
and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into
the camshafts. See Fig. 8. Rotate the crankshaft clockwise to TDC
cylinder No. 1. See Fig. 9.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key
points straight up.
2) Remove the blanking plug. Completely screw in the Crankshaft TDC
Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to
TDC. See Fig. 10.
CAUTION: DO NOT kink or bend the timing belt less than a
diameter of 1.38 (35 mm). DO NOT rotate the crankshaft, and
check that it is still resting against the timing pin.

10) Install the valve cover. See Fig. 5. Tighten the valve cover bolts in 2
stages:
Step 1: 18 INCH lbs. (2 N.m).
Step 2: 62 INCH lbs. (7 N.m).
Attach the PCV hose. Coat the spark plug thread with Never Seize.
Screw in the spark plugs. Tighten spark plugs to specification. See
TORQUE SPECIFICATIONS.
11) Push in the spark plug connector until it engages. Put the upper
timing belt cover together with the center timing belt cover in place.
Attach the timing belt center cover/front engine mounting bracket. See
Fig. 4.
NOTE: Check the seating of the timing belt upper cover gasket, and
correct it if necessary.
12) Install the timing belt upper cover. See Fig. 3. Install the front engine
mount. Connect the Power Assisted Steering (PAS) reservoir. Install the
coolant expansion tank.
13) Pull the jack out towards the front of the vehicle. Raise and support
the vehicle. Install the lower timing belt cover. See Fig. 2. Attach the
crankshaft pulley/vibration damper and tighten to specification. See
TORQUE SPECIFICATIONS.
14) Install the drive belt. If reusing drive belt note the direction previously
recorded in removal procedure. See Fig. 1. Attach the multi-groove belt
idler pulley (3). Install but DO NOT tighten the water pump pulley bolts
(1). Install the drive belt by turning the tensioner (2) clockwise and
tensioning it.

FORD

244

2.0L 4-Cylinder DOHC, VIN 3 Focus (Cont.)

15) Tighten the bolts on the water pump pulley to specification. Attach
the drive belt cover. Lower the vehicle. Connect the negative battery
cable. Check fluid levels and correct if necessary. Check the routing of
vacuum hoses and cables, and secure them with cable ties.
NOTE: When the battery has been disconnected and reconnected,
some abnormal drive symptoms may occur while the vehicle
relearns its adaptive strategy. The vehicle may need to be driven 10
miles (16 km) or more to relearn the strategy.

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Timing Tool

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 9: Aligning Crankshaft Timing Marks

Fig. 12: Applying Pre-Tension To Timing Belt

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 10: Installing Crankshaft Position Timing Peg

Fig. 13: Setting Timing Belt Tension

FORD
2.0L 4-Cylinder DOHC, VIN 3 Focus (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24)
Camshaft Sprocket Bolt
Intake & Exhaust ..................................................................................................... 50 (68)
Crankshaft Pulley Bolt ............................................................................................. 85 (115)
Engine Front Support
To-Engine Bracket Nut ............................................................................................ 59 (80)
To-Frame Bolts ........................................................................................................ 35 (48)
Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40)
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Idler Pulley Bolt ..................................................................................... 17 (23)
Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25)
Water Pump Pulley Bolt ............................................................................................ 18 (24)
Wheel Lug Nuts ...................................................................................................... 94 (128)
INCH Lbs. (N.m)
Center Timing Belt Cover Bolt ...................................................... ..................... 53-71 (6-8)
Lower Timing Belt Cover Bolt ..................................................................................... 62 (7)
Upper Timing Belt Cover Bolt ..................................................................................... 8 (71)
Valve Cover Bolts
Stage 1 ...................................................................................................................... 18 (2)
Stage 2 ...................................................................................................................... 62 (7)

245

FORD

246

2.0L 4-Cylinder DOHC, VIN 5 Focus

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC, VIN 5

Focus
2002-04 ............................... 2.8 Hours .... TCK294A . ..... T294

CAUTION: DO NOT pull the spark plug cable when removing the
spark plug connectors. If necessary, remove the ignition cables
from the ignition coil to avoid kinking the cables. Turn the spark
plug connectors slightly before removing to loosen the seal. Pull
off the spark plug connectors in line with the spark plugs.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

6) Pull off the spark plug connectors. Remove the PCV hose. Loosen 10
valve cover bolts from the outside to the inside, working diagonally. See
Fig. 9. Remove the valve cover. Remove the spark plugs.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

NOTE: At TDC the crankshaft keyway is in the 12 oclock position.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 120,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

7) Turn the engine to 60 degrees BTDC on cylinder number 1. Using an

open-ended wrench to prevent the camshaft from rotating, remove the
intake camshaft pulley blanking plug. See Fig. 10. Using an open-ended
wrench to prevent the camshaft from rotating, loosen the camshaft
pulley retaining bolts.
8) Remove the tension on timing belt. Unscrew the timing belt tensioner
bolt 4 turns (1). See Fig. 11.
9) Position the tensioner so the locating tab (2) is at approximately the
4 oclock position. Line up the hex key slot (3) in the tensioner adjusting
washer with the pointer that is located behind the pulley. Remove the
timing belt.

TIMING BELT
CAUTION: The camshaft must be held stationary with an openended wrench or a suitable pair of locking pliers. Do not use the
alignment tool to hold the camshaft in position or damage to the
camshaft may occur.
NOTE: The positions of the engine mounting and the engine roll
restrictor are described looking from the transmission towards the
engine. If necessary, use Coolant Hose Remover (412-108) to
remove coolant and ventilation hoses. Owing to special model
variants, some steps DO NOT apply to all vehicles. These are
clearly marked in the text. If necessary, cut the cable tie and install
new on installation.

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

NOTE: Numbers in parenthesis refer to numbers in figures.

Removal 1) Disconnect the negative battery cable. Raise and support
the vehicle. Remove the drive belt cover. Mark the drive belt running
direction. Loosen the bolts on the water pump pulley (1). See Fig. 1.
2) Slacken the drive belt by turning tensioner clockwise. Remove the
drive belt. Remove the water pump belt pulley (2). Remove the
multi-groove belt idler pulley (3). Remove the crankshaft pulley/vibration
damper.
CAUTION: The removal of the lower part of the engine front cover
is necessary to avoid damage to the timing belt.

Courtesy of Ford Motor Co.

Fig. 2: Identifying Lower Front Timing Cover Bolts

3) Remove the lower timing belt cover. See Fig. 2. Lower the vehicle.
Remove the coolant expansion tank and lay it to one side. Remove the
Power Assisted Steering (PAS) reservoir and lay it to one side. Position
the jack with the wooden block under the oil pan, and raise so that the
front engine mounting is free from load.
NOTE: Mark the position of the engine mounting.
4) Remove the front engine mounting. Remove the accessory drive belt
idler pulley. Remove the timing belt upper cover bolts, but leave the
timing belt cover in its installed position. See Fig. 3. Remove the timing
belt center cover/front engine mounting bracket. See Fig. 4. Remove the
timing belt upper cover.
5) Detach the retaining clips (1). Detach the coolant pipe from the
retaining clip (2). See Fig. 5. Remove the ignition coil pack cover (3).
Remove the engine upper cover. See Fig. 6. Disconnect the Variable
Cam Timing (VCT) valve electrical connector. See Fig. 7.

Courtesy of Ford Motor Co.

Fig. 3: Locating Upper Front Timing Cover Bolts

FORD

247

2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)

Courtesy of Ford Motor Co.

Fig. 4: Locating Center Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 5: Identifying Ignition Coil Pack Cover

Courtesy of Ford Motor Co.

Fig. 8: Locating Center Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 9: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 10: Locating Intake Camshaft Pulley Blanking Plug

Fig. 6: Locating Engine Upper Cover

Courtesy of Ford Motor Co.

Fig. 7: Locating Variable Cam Timing Valve Electrical

Courtesy of Ford Motor Co.

Fig. 11: Removing Tension From Timing Belt

248

FORD
2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)

NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must
be able to turn freely on the camshafts.
Installation 1) Turn the camshafts to ignition position on cylinder No. 1
and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into
the camshafts. See Fig. 12. Remove the blanking plug. Completely
screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and
auto-align the crankshaft to TDC. See Fig. 13.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key
points straight up.
2) Rotate the crankshaft clockwise to TDC cylinder No. 1. See Fig. 14.
Make sure that the crankshaft contacts the timing peg.
CAUTION: DO NOT kink or bend the timing belt less than a
diameter of 1.38 (35 mm). DO NOT rotate the crankshaft, and
check that it is still resting against the timing pin.
NOTE: The lug of the belt tensioner must not be hooked into the
sheet metal cover during timing belt installation.
3) Position a NEW timing belt in place and starting from the crankshaft
timing belt pulley and working counterclockwise, position the timing belt
in place while keeping it under tension. See Fig. 15.
4) Apply tension to the timing belt. Incorrect timing belt tension will cause
incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab (1) into the slot in the rear timing cover.
See Fig. 16.
5) Position the hex key slot (2) in the tensioner adjusting washer to the
4 oclock position. Tighten the attaching bolt (3) enough to seat the
tensioner firmly against the rear timing cover, but still allow the tensioner
adjusting washer to be rotated using a 0.24 (6 mm) hex key.
6) Tension the timing belt, working counterclockwise. Using the hex key,
rotate the adjusting washer counterclockwise until the notch in the
pointer is centered over the index line on the locating tab (the pointer will
move clockwise during adjustment). See Fig. 17.
7) While holding the adjusting washer in position, tighten the bolt to
specification. See TORQUE SPECIFICATIONS. DO NOT tighten the
camshaft timing pulley bolts against the camshaft alignment plate. The
crankshaft must remain at TDC on cylinder No. 1. Using an open-ended
wrench to prevent the camshaft from rotating, tighten the bolts of the
camshaft timing pulleys to specification.
8) Unscrew and remove crankshaft timing peg. Remove camshaft
alignment plate from the camshafts. Turn the crankshaft 2 revolutions in
the normal direction of rotation. Check the valve timing by inserting the
crankshaft timing peg. Correct it if necessary:
Screw in crankshaft timing peg and make sure that the crankshaft is
touching it.
Insert camshaft alignment plate into the camshafts. If necessary,
loosen the timing pulleys and correct the camshaft alignment.
Remove the crankshaft timing peg and camshaft alignment plate.
9) Screw in and tighten the blanking plug to specification. Using an
open-ended wrench to prevent the camshaft from rotating, install the
intake camshaft pulley blanking plug.

Attach the PCV hose. Coat the spark plug thread with Never Seize.
Screw in the spark plugs. Tighten spark plugs to specification. See
TORQUE SPECIFICATIONS.
11) Push in the spark plug connector until it engages. Connect the VCT
valve electrical connector. Install the engine cover. Attach the retaining
clips. Attach the coolant pipe to the retaining clip. Install the ignition coil
pack cover. Put the upper timing belt cover together with the center
timing belt cover in place. Attach the timing belt center cover/front
engine mounting bracket. See Fig. 8.
NOTE: Check the seating of the timing belt upper cover gasket, and
correct it if necessary.
12) Install the timing belt upper cover and tighten bolts to specification.
See Fig. 3. Install the accessory drive belt idler and tighten bolt to
specification. Install the front engine mount and tighten bolts to specification. Connect the Power Assisted Steering (PAS) reservoir. Install the
coolant expansion tank.
13) Pull the jack out towards the front of the vehicle. Raise and support
the vehicle. Install the lower timing belt cover. See Fig. 2. Attach the
crankshaft pulley/vibration damper and tighten to specification. See
TORQUE SPECIFICATIONS.
14) Install the drive belt. If reusing drive belt note the direction previously
recorded in removal procedure. See Fig. 1. Attach the multi-groove belt
idler pulley (3). Install but DO NOT tighten the water pump pulley bolts
(1). Install the drive belt by turning tensioner (2) clockwise and tension
it.
15) Tighten the bolts on the water pump pulley to specification. Attach
the drive belt cover. Lower the vehicle. Connect the negative battery
cable. Check fluid levels and correct if necessary. Check the routing of
vacuum hoses and cables, and secure them with cable ties.
NOTE: When the battery has been disconnected and reconnected,
some abnormal drive symptoms may occur while the vehicle
relearns its adaptive strategy. The vehicle may need to be driven 10
miles or more to relearn the strategy.

Courtesy of Ford Motor Co.

Fig. 12: Installing Camshaft Alignment Timing Tool

CAUTION: Use a blunt object (such as a plastic cable tie) to apply

the silicone grease, to avoid damaging the spark plug connectors.
Push on the spark plug connectors, keeping them in line with the
spark plugs.
NOTE: Coat the inside of the spark plug connectors with silicone
grease to a depth of 0.20-0.39 (5-10 mm).
10) Install the valve cover. See Fig. 9. Tighten the valve cover bolts in 2
stages:
Step 1: 18 INCH lbs. (2 N.m).
Step 2: 62 INCH lbs. (7 N.m).

Courtesy of Ford Motor Co.

Fig. 13: Installing Crankshaft Position Timing Peg

FORD

249

2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)

Courtesy of Ford Motor Co.

Fig. 17: Setting Timing Belt Tension

Courtesy of Ford Motor Co.

Fig. 14: Aligning Crankshaft Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Bolt ................................................................................. 35 (48)
Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24)
Blanking Plug (Intake Camshaft Pulley Blanking Plug) ........................................... 17 (37)
Camshaft Sprocket Bolt
Exhaust .................................................................................................................... 50 (68)
Intake ..................................................................................................................... 89 (120)
Crankshaft Pulley Bolt ............................................................................................. 85 (115)
Engine Front Mount Bracket ..................................................................................... 37 (50)
Engine Front Support
To-Engine Bracket Bolts .......................................................................................... 59 (80)
To-Frame Bolts/Nuts ................................................................................................ 35 (48)
Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40)
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Idler Pulley Bolt ..................................................................................... 17 (23)
Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25)
Water Pump Pulley Bolt ............................................................................................ 18 (24)
Wheel Lug Nuts ...................................................................................................... 94 (128)
INCH Lbs. (N.m)
Center Timing Belt Cover Bolt ...................................................... ..................... 53-71 (6-8)
Engine Cover ............................................................................................................. 89 (10)
Lower Timing Belt Cover Bolt ..................................................................................... 62 (7)
Upper Timing Belt Cover Bolt ................................................................................... 10 (89)
Valve Cover Bolts
Stage 1 ...................................................................................................................... 18 (2)
Stage 2 ...................................................................................................................... 62 (7)

Courtesy of Ford Motor Co.

Fig. 15: Installing Timing Belt

Courtesy of Ford Motor Co.

Fig. 16: Applying Pre-Tension To Timing Belt

FORD

250

2.0L 4-Cylinder SOHC, VIN P

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cylinder SOHC, VIN P

Escort
1997-02 ............................... 2.2 Hours ... .. TCK283 .. ..... T283
Tracer
1997-99 ............................... 2.2 Hours ... .. TCK283 .. ..... T283
Focus
2000-04 ............................... 2.2 Hours ... .. TCK283 .. ..... T283
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Up to 2000 model year, the manufacturer recommends that the timing
belt be inspected at 120,000 miles. Replace, if necessary. For
2001-2004 model years, the manufacturer recommends that the timing
belt be replaced at 120,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal (Escort & Tracer) 1) 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 support
vehicle. Remove right hand splash shield. Remove crankshaft pulley.
Align timing marks. See Fig. 1.
2) 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.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

Installation 1) Ensure timing marks are still aligned. Install timing belt
in a counterclockwise direction starting at the crankshaft. If reusing old
belt, ensure it is installed in original direction of rotation. Keep belt span
between crankshaft and camshaft tight while installing timing belt over
camshaft.
2) Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. To complete installation, reverse removal procedure.

Courtesy of Ford Motor Co.

Fig. 2: Identifying Timing Belt Tensioner

Removal (Focus) 1) Disconnect negative battery cable. Detach
coolant expansion tank, and set to one side. Remove power steering
fluid reservoir from shock tower, and set aside with hoses attached.
2) Raise and support vehicle. Remove the accessory drive belt splash
shield. Lower the vehicle. Using a 3/8 inch square drive breaker bar in
the hole provided, rotate the tensioner clockwise to relieve tension, and
remove serpentine drive belt.
NOTE: Remove power steering pump, if necessary.
3) 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.
4) Raise and support vehicle. Remove right front wheel.
CAUTION: When removing spark plug connectors, do not pull on
ignition wire. If necessary, remove ignition coil plug to avoid
bending ignition wire. Turn spark plug connector slightly before
removing to loosen gasket.
5) Remove the crankshaft pulley and vibration damper. Lower vehicle.
Noting position for reassembly reference, disconnect spark plug secondary cables from spark plugs using a straight movement. Remove the
two ignition wire separators from the valve cover, if necessary.
6) Noting position for reassembly reference, remove spark plugs. Place
jack under engine to support weight. Remove front engine mount and
timing belt cover from timing belt end of engine. Remove engine mount
bracket from timing belt end of engine.
7) 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 1) 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 while
installing timing belt over camshaft. If reusing old belt, ensure it is
installed in original direction of rotation.
2) Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. If not correct,
readjust timing belt.
3) Install engine mount bracket and timing belt cover to engine. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Install engine
mount to engine and frame. Tighten nuts and bolts to specification.
Remove jack from under engine.
4) Install spark plugs in cylinders from which they were removed (new
spark plugs may be installed in any cylinder). Using a blunt object (such
as a plastic cable tie), coat inside of spark plug connector with silicone
grease to a depth of 5-10 mm. Install spark plug connectors using a
straight movement. Raise vehicle. Install crankshaft pulley and vibration
damper. Tighten center bolt to specification. Position drive belt on
crankshaft pulley.

FORD

251

2.0L 4-Cylinder SOHC, VIN P (Cont.)

5) Install lower drive belt cover. Install right front wheel. Lower vehicle.
Install power steering pump, if removed. Install power steering pump
pulley. Tighten center bolt to specification. See TORQUE SPECIFICATIONS. Install serpentine drive belt. Install power steering fluid reservoir
and coolant expansion tank. Connect negative battery cable.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ESCORT & TRACER)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................................ 70-85 (95-115)
Crankshaft Pulley Bolt ................................................................................. 81-96 (110-130)
Engine Mounting Bracket Bolts .................................................... ................. 31-42 (41-57)
Power Steering Pump
Mount Bolt ................................................................................... ................. 15-22 (20-30)
Pulley Bolt ................................................................................... ................. 15-22 (20-30)
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Tensioner Bolt ............................................................ ................. 15-22 (20-30)
Water Pump Bolts ......................................................................... ................. 15-22 (20-30)
Wheel Lug Nuts ............................................................................................ 66-86 (89-117)
INCH Lbs. (N.m)
Splash Shield Assembly Bolts .......................................................................... 71-97 (8-11)
Timing Belt Cover Bolts .................................................................................... 71-97 (8-11)

TORQUE SPECIFICATIONS (FOCUS)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 77 (105)
Crankshaft Pulley Bolt ............................................................................................. 89 (120)
Engine Mount
Bracket-To-Engine ................................................................................................... 35 (48)
To-Engine Nuts ........................................................................................................ 59 (80)
To-Frame Bolts ........................................................................................................ 35 (48)
Power Steering Pump
Mount Bolt ............................................................................................................... 17 (23)
Pulley Bolt ............................................................................................................... 35 (47)
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Cover Bolts
Lower ........................................................................................... ..................................... 1
Upper ....................................................................................................................... 35 (48)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Wheel Lug Nut ........................................................................................................ 94 (128)
INCH Lbs. (N.m)
Valve Cover Bolts ........................................................................................................ 80 (9)
1

Tighten bolt to 89 INCH lbs. (10 N.m).

FORD

252

2.0L & 2.2L 4-Cylinder Probe

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
2.0L 4-Cyl.
Probe
1993-97 ..............................
2.2L 4-Cyl.
Probe
1989-92 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.8 Hours .. .. TCK228 .. ..... T228

2.3 Hours .. .. TCK134 .. ..... T134

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 replaced at every 60,000 miles.

CAUTION: DO NOT rotate crankshaft or camshafts with timing belt

removed. Damage to valve/piston may result.
Removal 1) Disconnect negative battery cable. Remove accessory
drive 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. See Fig. 1 or 2.
2) Remove water pump pulley. Raise and support vehicle. Remove right
front wheel. Remove right upper and lower splash shield. Remove
crankshaft pulley and crankshaft pulley guide plate. Remove lower
timing belt cover. Temporarily install crankshaft pulley bolt.
NOTE: Mark direction of timing belt rotation if reusing belt.
3) Rotate crankshaft clockwise and align crankshaft sprocket timing
notch with line on oil pump. Ensure camshaft sprocket timing marks
align. See Fig. 3 or 4. Install Camshaft Pulley Holder (T92C-6256-AH) or
equivalent. Using an Allen wrench, turn timing chain tensioner and
remove tensioner spring. Remove timing belt.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt Components (2.0L)

FORD

253

2.0L & 2.2L 4-Cylinder Probe (Cont.)

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt Components (2.2L)

Courtesy of Ford Motor Co.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks (2.2L)

Courtesy of Ford Motor Co.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (2.0L)

Installation 1) Install timing belt. Rotate tensioner clockwise with an
Allen wrench, and install tensioner spring. See Fig. 1 or 5. Ensure timing
marks on crankshaft sprocket and engine block align.
2) Remove camshaft pulley holder, and ensure camshaft sprocket timing
marks are still aligned. Rotate crankshaft clockwise 2 full revolutions.
Ensure all timing marks align.
3) If timing marks do not align, remove timing belt. Repeat previous two
steps. To complete installation, reverse removal procedure. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Mounting Bolt .................................................... ................. 18-26 (24-35)
Alternator Mounting Bolt ............................................................... ................. 27-38 (37-52)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Crankshaft Sprocket Bolt ........................................................................ 116-123 (157-167)
Tensioner Bolt ................................................................................ ................. 27-38 (37-52)
Water Pump Bolt ........................................................................... ................. 14-19 (19-26)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................... 61-87 (8-10)
Valve Cover ................................................................................... ..................... 53-62 (6-7)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of Ford Motor Co.

Fig. 5: Locating Timing Belt Tensioner & Spring (2.2L)

FORD

254

2.0L & 2.3L 4-Cylinder 1974-94 Except Probe

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

2.0L 4-Cyl. OHC

Ranger
1983-88 .............................. 1 2.2
2.3L 4-Cyl. OHC
Aerostar
1987 ................................... 2 2.2
Bobcat & Pinto
1974-80 .............................. 3 2.0
Cougar
1981 ................................... 2 1.3
1984-86 .............................. 2 1.3
Courier
1977-82 .............................. 3 2.2
Fairmont & Zephyr
1978-83 .............................. 3 1.6
Granada
1981-82 .............................. 3 1.6
LTD & Marquis
1983 ................................... 3 1.6
1984-86 .............................. 3 1.5
Merkur XR4Ti
1985-89 .............................. 2 1.5
Mustang, Mustang II & Capri
1974-91 .............................. 3 1.6
1992
With Round Tooth
Sprockets .................... 2 2.0
With Square Tooth
Sprockets .................... 2 2.0
Mustang
1993 ................................... 3 2.0
Ranger
1983-91 .............................. 4 1.6
1992
With Round Tooth
Sprockets .................... 4 1.6
With Square Tooth
Sprockets .................... 4 1.6
1993-94 .............................. 4 1.6
Thunderbird
1983-88 .............................. 3 1.3
1

2
3
4

Component
Belt
Kit No.
Part No.

TIMING BELT

Hours .. ...... ..... ...... ..... T210

Removal 1) Disconnect negative battery cable. Rotate engine clockwise 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.
2) Looking through plug hole of outer timing belt cover, ensure camshaft
sprocket timing mark aligns with cover pointer. See Fig. 1.
3) Remove fan guard, cooling shroud, cooling fan and fan shroud.
Remove drive belt, water pump pulley and automatic 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.
Remove upper radiator hose. Remove thermostat housing and gasket.
4) Remove retaining bolt and crankshaft pulley. Remove hub assembly
retaining bolt from crankshaft. Remove outer timing belt cover. Ensure
camshaft sprocket timing mark aligns with cover pointer. See Fig. 1.
5) 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.
6) 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 timing belt.
Installation 1) 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.

Hours .. .. TCK014 .. ..... T014

CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt.

Hours .. .. TCK210 .. ..... T210

2) Install NEW camshaft sprocket bolt, and tighten to specification while

holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS.
3) Align camshaft sprocket timing mark with pointer. Properly position
crankshaft so timing mark aligns with notch in front cover casting. See
Fig. 2. Install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner
bolt, allowing tension to be applied on timing belt.

Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK210 .. ..... T210

Hours .. .. TCK014 .. ..... T014
Hours .. .. TCK210 .. ..... T210
Hours .. .. TCK014 .. ..... T014

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.
With Air Conditioning, add 1.0 hours.
With Air Conditioning, add .5 hours.
With Air Conditioning, add .9 hours.
With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

NOTE: It may be necessary to push belt tensioner against timing

belt, as spring tension may not move belt tensioner against timing
belt.
4) Remove one spark plug from each cylinder. Rotate engine clockwise
(viewed from front of engine) 2 complete revolutions. Tighten timing belt
tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Ensure all timing marks align properly. See Figs. 1 and 3. Install belt
guide on crankshaft.
5) Install crankshaft sensor over dowel pins. Tighten long crankshaft
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.
6) Install hub assembly and crankshaft pulley. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install crankshaft sensor
positioner. See Fig. 4. Rotate crankshaft clockwise approximately 90
degrees so outer vane of hub assembly engages with crankshaft sensor
positioner. Tighten short crankshaft sensor bolts to 14-22 ft. lbs. (19-30
N.m).
7) To install remaining components, reverse removal procedure. Tighten
bolts to specification. See TORQUE SPECIFICATIONS.
8) 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 coolant flows from fitting. Install
heater hose. Refill radiator. Adjust drive belts to proper tension.

FORD

255

2.0L & 2.3L 4-Cylinder 1974-94 Except Probe (Cont.)

Courtesy of Ford Motor Co.

Fig. 4: Positioning Crankshaft Sensor

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

Application
Ft. Lbs. (N.m)
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)
Camshaft Sprocket Bolt 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
2

Courtesy of Ford Motor Co.

Fig. 2: Positioning Crankshaft

Courtesy of Ford Motor Co.

Fig. 3: Aligning Camshaft & Oil Pump Timing Marks

Install NEW bolt. DO NOT reuse bolt.

Apply thread sealant on bolt threads.

FORD

256

2.3L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application
2.3L 4-Cyl. Diesel
Ranger
1985-87
Balance Shaft ........................................
Camshaft ...............................................
1

Labor Time

1
1

Belt
Part No.

1.6 Hours .. ..... T092

1.6 Hours .. ..... T091

With Air Conditioning, add .9 hours.

With Power Steering, add .5 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Ford Motor Co.

Fig. 1: Locating Silent Shaft Timing Belt Tensioner Nut

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove drive belts.
Remove 5 upper front timing belt cover retaining bolts. Remove upper
front cover. Remove cooling fan and shroud. Remove water pump
pulley. Remove crankshaft pulley attaching bolt. Rotate crankshaft until
No. 1 piston is at TDC on compression stroke.
2) 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.
3) 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.

Courtesy of Ford Motor Co.

Fig. 2: Timing Belt Tensioner

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 1) Fabricate timing belt tensioner, using a pivot nut from
rear brake adjuster and bar stock. See Fig. 2. Release tension on
tensioner spring using belt tensioner. Rotate tensioner toward water
pump and tighten top bolt.
2) 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 Figs. 3 and 4. Tighten tensioner
hold-down bolts. To complete installation, reverse removal procedure.
See Figs. 5 and 6. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Fig. 3: Removing Tensioner Bolt Access Cover

FORD

257

2.3L 4-Cylinder Diesel (Cont.)

Courtesy of Ford Motor Co.

Fig. 4: Loosening Belt Tensioner Bolts

Courtesy of Ford Motor Co.

Fig. 6: Aligning Mark On Timing Cover With Mark On

Camshaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 47-54 (64-73)
Crankshaft Pulley Bolts ................................................................. ......... 123-137 (167-186)
Injection Pump Sprocket Nut ........................................................ ................. 40-50 (54-68)
Silent Shaft Sprocket Bolt ............................................................. ................. 25-28 (34-39)
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)

Courtesy of Ford Motor Co.

Fig. 5: Identifying Timing Mark Alignment

FORD

258

2.3L 4-Cylinder Gasoline

TIMING BELT APPLICATION
Application
2.3L 4-Cyl.
Ranger
1995-97 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

1.6 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours.

With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components

Removal 1) 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.
2) Remove cooling fan and water pump pulley. Discharge A/C system (if
equipped) using approved refrigerant recovery/recycling equipment.
Remove A/C compressor and position aside. Remove A/C compressor
mounting bracket with power steering pump attached, and position
aside.
3) 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 1) 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.
2) Install NEW timing belt. Loosen tensioner bolt. Allow tensioner to
adjust itself, and retighten bolt. Rotate crankshaft clockwise 2 complete
revolutions to remove slack from belt.
3) Loosen tensioner bolt. Allow tensioner to adjust itself and retighten
bolt. To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolts .................................................................. ................. 15-21 (21-28)
Alternator Bracket Bolts ................................................................ ................. 30-40 (41-54)
Alternator Retaining Bolts ............................................................. ................. 30-40 (41-54)
Camshaft Sprocket Bolt ................................................................ ................. 50-71 (68-96)
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)

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

FORD

259

2.5L 4-Cylinder
TIMING BELT APPLICATION
Application
2.5L 4-Cyl.
Ranger
1998-01 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

1.6 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours.

With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1998-00 model years, the manufacturer recommends the belt be
inspected at 120,000 miles and replaced if necessary. For 2001 model
year, the manufacturer recommends the belt be replaced at 120,000
miles.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Timing Marks

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect battery ground cable. Remove exhaust side
spark plugs.
2) Remove fan shroud bolts and fan shroud, and position aside. Loosen,
but do not remove, water pump pulley bolts. Remove accessory drive
serpentine belt.
3) Remove fan and clutch assembly retaining screws. Remove fan and
clutch assembly. Remove fan shroud. Remove water pump pulley.
4) On models with A/C, discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C compressor from
mounting bracket. Remove A/C compressor mounting bracket with
power steering pump attached, and position aside.
5) Remove timing belt outer cover retaining bolt. Release 7 cover
interlocking tabs. Remove timing belt cover.
6) 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 crankshaft sprocket must align with notch in
engine front cover.
7) Holding timing belt tensioner with Camshaft Belt Tension Adjuster
(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 1) Ensure crankshaft is set at TDC and camshaft sprocket
timing mark and oil pump sprocket timing mark are aligned with inner
cover timing marks.
2) Install timing belt on crankshaft sprocket, oil pump sprocket and then
the camshaft sprocket. Loosen timing belt tensioner bolt.
3) 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.
4) Recheck timing alignment marks. If timing marks are not aligned,
reposition timing belt. Repeat timing belt tensioning procedure.
5) Tighten timing belt tensioner adjusting and pivot bolts to specification.
See TORQUE SPECIFICATIONS. Install crankshaft pulley. Tighten
center bolt to specification.
6) 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 installation, reverse removal procedure.
Recharge A/C system, if necessary.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Camshaft Sprocket Bolt ................................................................ ................. 52-70 (70-95)
Cooling Fan-To-Water Pump Bolts ............................................... ................. 13-16 (17-23)
Crankshaft Damper Bolt ................................................................ ........... 93-121 (125-165)
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

260

2.5L V6
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
2.5L V6
Probe
1993-97 ....................................................
1

Labor Time

Belt
Part No.

4.0 Hours .. ..... T214

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
for Federal vehicles and 105,000 miles for California vehicles.

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal 1) Disconnect negative battery cable. Disconnect engine
coolant temperature sensor and temperature gauge sender connectors
from coolant elbow. Disconnect crankshaft position sensor connector.
See Fig. 1. Remove accessory drive belts. Raise and support vehicle.
2) 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
Steering Pump Pulley Remover (D85L-6000-A) or equivalent, remove
power steering pump pulley.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

FORD

261

2.5L V6 (Cont.)
3) 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.
4) 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 engine rotation only. Remove timing belt
tensioner arm by removing lower and then upper tensioner arm bolts.
5) 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 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure upper and lower timing belt idlers rotate freely.
Replace damaged components.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists.
3) Measure timing belt tensioner rod protrusion (free length) from end of
rod to edge of housing. See Fig. 2. Replace timing belt tensioner if
distance is not .55-.63 (14-16 mm).

Installation 1) Place timing belt tensioner in a press, using a flat

washer to prevent damage to timing belt tensioner plug.
2) 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. 2.
3) 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.
4) 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.
5) Turn crankshaft 2 complete revolutions. Recheck timing marks to
ensure timing is still correct. See Fig. 3. To complete installation, reverse
removal procedure. Tighten bolts to specification. Check ignition timing.
Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 2: Checking & Compressing Automatic Timing Belt

Tensioner

Fig. 4: Positioning Crankshaft For Removing Slack

From Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 28-38 (38-51)
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)
Timing Belt Tensioner Bolt ............................................................ ................. 28-32 (38-43)
Water Pump Bolt ........................................................................... ................. 14-18 (19-24)
Wheel Lug Nut .............................................................................................. 65-87 (88-118)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................... 71-88 (8-10)
Valve Cover Bolt ........................................................................... ..................... 43-78 (5-8)
Water Pump Pulley Bolt ................................................................ ................... 71-88 (8-10)

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft To TDC

FORD

262

3.0L V6 SOHC Villager

TIMING BELT APPLICATION
Application

Labor Time

3.0L V6 SOHC
Villager (Mercury)
1993 ...................................
1994-98 ..............................

Component
Belt
Kit No.
Part No.

3.6 Hours .. .. TCK104 .. ..... T104

3.6 Hours .. .. TCH249 .. ..... T249

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 105,000
miles. This application is not an interference engine.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. 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.
2) Remove upper radiator hose and water inlet hose. Remove A/C
compressor idler pulley and bracket. Remove water pump pulley.
Remove upper and lower timing belt front covers. See Fig. 1.
3) 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 housing. See Fig. 2.
4) Loosen timing belt tensioner nut. Release tension on belt. Remove
timing belt. Check timing belt tensioner, spring and timing belt.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Timing Belt & Sprocket

crankshaft sprocket. White lines ensure correct number of teeth exist
between timing marks on sprockets.
3) 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.
4) 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.
5) 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 TORQUE SPECIFICATIONS.
6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression
stroke. Measure timing belt deflection halfway between camshaft
sprockets.
7) If deflection is not .51-.59 (13-15 mm), readjust timing belt tension.
To complete installation, reverse removal procedure. Adjust drive belts
to proper tension.

Courtesy of Ford Motor Co.

Fig. 3: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt Components

Installation 1) 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.
2) Install timing belt with arrow on timing belt facing front of engine. Align
White lines on timing belt with marks on camshaft sprockets and

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
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)
Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

FORD

263

3.0L & 3.2L V6 SHO

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 SHO
Taurus
1989-95 ..................................................... 3.0 Hours ... ..... T248
3.2L V6 SHO
Taurus
1993-95 ..................................................... 3.0 Hours ... ..... T248
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 100,000
miles.

Courtesy of Ford Motor Co.

Fig. 2: Locating Crankshaft Pulley Timing Marks

REMOVAL & INSTALLATION

TIMING BELT
Removal (3.0L SHO) 1) Remove battery. Remove engine roll damper,
located near timing belt cover. Disconnect ignition control module.
Remove intake manifold crossover tube. See Fig. 1. Remove accessory
drive belts. Remove alternator belt tensioner pulley and bracket.
2) Remove water pump tensioner pulley. Disconnect crankshaft sensor
wiring assembly at lower timing belt cover. Remove upper timing belt
cover. Ensure transaxle is in Neutral.
3) 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. 2.
4) 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. Disconnect crankshaft position
sensor wire and grommet from slot near water pump.
5) Ensure timing marks align. See Fig. 3. If reusing timing belt, place
reference mark on timing belt, camshaft sprockets, and crankshaft
sprocket. Mark direction of belt rotation for reassembly reference.
6) Loosen timing belt tensioner lock nut. Rotate tensioner pulley 180
degrees clockwise using 6-mm Allen wrench. See Fig. 4. Tighten lock
nut to hold tensioner in unloaded position. Lower vehicle. Remove
timing belt.

Courtesy of Ford Motor Co.

Fig. 3: Aligning Timing Marks

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Intake Manifold & Brackets

Courtesy of Ford Motor Co.

Fig. 4: Adjusting Timing Belt Tension (3.0L SHO)

264

FORD
3.0L & 3.2L V6 SHO (Cont.)

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) 1) Ensure No. 1 piston is at TDC of
compression stroke. Ensure camshaft timing marks align with timing belt
cover marks, and crankshaft sprocket timing mark aligns with mark on
oil pump housing. See Fig. 3.
2) Install timing belt on crankshaft, and route around left camshaft and
onto right camshaft sprockets. Ensure used timing belt is installed in
original direction of rotation. Loosen timing belt tensioner lock nut and
leave nut loose.
3) 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 SPECIFICATIONS.
4) Rotate crankshaft until Yellow mark on crankshaft damper aligns with
0 mark on lower timing belt cover. See Fig. 2.
5) Remove plastic access cover in lower timing belt cover. Tighten timing
belt tensioner lock nut to 25-37 ft. lbs. (34-50 N.m). Install plastic access
cover.
6) Rotate crankshaft clockwise 60 degrees until White mark on crankshaft damper aligns with 0 mark on lower timing belt cover. Lower
vehicle.
7) Ensure camshaft timing marks align with timing belt cover marks. See
Fig. 3. Install upper timing belt cover. Install intake manifold crossover
tubes. Connect ignition electrical connector.
8) Install splash shield and right front wheel. To install remaining
components, reverse removal procedure. Adjust drive belts to proper
tension.
Removal (3.2L SHO) 1) Remove battery. Remove engine roll damper,
located near timing belt cover. Disconnect ignition control module.
Remove intake manifold crossover tube. See Fig. 1. Remove serpentine
drive belt and tensioner.
2) Remove upper and lower idler pulleys. Using a strap wrench to hold
power steering pump pulley, remove power steering pump pulley nut
and pulley. Remove upper and center timing belt covers. Disconnect
crankshaft sensor wiring assembly at lower timing belt cover.
3) 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. 3.
4) Raise and support vehicle. Remove right front wheel and splash
shield. Using Puller (T67L-3600-A), remove crankshaft damper.
Remove lower timing belt cover. Remove timing belt guide located in
front of crankshaft sprocket. Ensure timing marks align. See Fig. 3.
5) If reusing timing belt, place reference mark on timing belt, camshaft
sprockets, and crankshaft sprocket. Mark direction of belt rotation for
reassembly reference. Slowly loosen timing belt tensioner bolt and
remove tensioner. Lower vehicle. Remove timing belt.
Installation (3.2L SHO) 1) Ensure No. 1 piston is at TDC of
compression stroke. Ensure camshaft timing marks align with timing belt
cover marks, and crankshaft sprocket timing mark aligns with mark on
oil pump housing. See Fig. 3. 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. 5.
2) 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.
3) Install timing belt tensioner while pushing tensioner pulley toward belt.
Install rubber grommets between tensioner and oil pump. See Fig. 6.
Remove Allen wrench from tensioner. If installing used belt, skip the next
step. If installing new timing belt, go to next step.

4) Mount Timing Belt Tensioner Tool (T93P-6254-B) or equivalent, 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. Remove tensioner tool. Tighten bolts to specification.
5) 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 crankshaft damper aligns with 0 mark on
lower timing belt cover.
6) Ensure camshaft timing marks align with timing belt cover marks. See
Fig. 3. Ensure crankshaft sensor wiring is properly routed. Install
remaining timing belt covers. To install remaining components, reverse
removal procedure. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Fig. 5: Compressing Timing Belt Tensioner (3.2L SHO)

Courtesy of Ford Motor Co.

Fig. 6: Installing Rubber Grommets (3.2L SHO)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)

GENERAL MOTORS

265

1.4L & 1.6L 4-Cylinder

TIMING BELT APPLICATION
1

Application

1.4L 4-Cyl.
Acadian & Chevette
1976 ...........................................................
1977 ...........................................................
1.6L 4-Cyl.
Acadian, Chevette, T-1000 & 1000
1976 ...........................................................
1977-78 .....................................................
1979-87 .....................................................
1

Labor Time

Belt
Part No.

1.4 Hours ... ..... T037

1.4 Hours ... ..... T039

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 procedure to complete installation. Adjust drive belts to proper
tension.
TIMING BELT ADJUSTMENT SPECIFICATIONS
Belt Size
Operating Range
Specification
3/4 (19 mm) ................. 50-80 Lbs. (110-176 kg) .................... 63-77 Lbs. (140-160 kg)

1.4 Hours ... ..... T037

1.4 Hours ... ..... T039
1.4 Hours ... ..... T061

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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. Remove front cover
retaining screws and nuts. Remove cover. Rotate crankshaft until timing
mark on pulley is at zero degrees (No. 1 cylinder at TDC). Remove A/C
compressor and brackets, if necessary.
2) Insert 1/8 drill bit or rod through hole in upper rear cover and through
hole in camshaft drive sprocket. This is provided to verify camshaft
timing. Remove timing belt front and lower cover. Loosen idler pulley,
and allow pulley to rotate clockwise. See Fig. 1. Remove timing belt from
sprockets.

Courtesy of General Motors Corp.

Fig. 2: Identifying Sprocket Timing Marks

Courtesy of General Motors Corp.

Fig. 3: Adjusting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of General Motors Corp.

Fig. 1: Locating Timing Belt Idler Pulley

Installation 1) 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.
See Fig. 2. DO NOT let timing belt back up.
2) Use belt tension gauge between camshaft sprocket and idler pulley.
See TIMING BELT ADJUSTMENT SPECIFICATIONS table. See Fig. 3.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts ........................................................................................ 75 (101)
Crankshaft Pulley Bolt ........................................................................................... 100 (135)
Idler Pulley Bolts ....................................................................................................... 15 (20)
Water Pump Bolts ..................................................................................................... 15 (20)
INCH Lbs. (N.m)
Front Cover (Nuts & Bolts) ......................................................................................... 70 (8)

266

GENERAL MOTORS
1.6L 4-Cylinder Aveo

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

1.6L 4-Cyl.
Aveo
2004 ........................................................... 1.5 Hours ... ..... T310
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer requires that the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect the negative battery cable. Disconnect the
Intake Air Temperature (IAT) sensor connector. Disconnect the air intake
tube from the throttle body. Disconnect the breather tube from the valve
cover.
2) Remove the air filter housing bolts and housing.
3) Remove the right front wheel. Remove the right front splash shield.
4) Remove the accessory drive belt. Remove the crankshaft pulley bolt
and pulley. See Fig. 1.
5) Remove the upper front timing belt cover bolts and cover. See Fig. 2.
Remove the lower front timing belt cover bolts and cover. Remove the
power steering mounting bolts, if equipped.
6) Install the crankshaft pulley bolt. Using the crankshaft pulley bolt,
rotate the crankshaft clockwise until the timing mark on the crankshaft
gear is aligned with the notch at the bottom of the rear timing belt cover.
See Fig. 3.
7) Slightly loosen the coolant pump retaining bolts. Using the Timing Belt
Adjuster (J-42492-A or KM-421-A), rotate the coolant pump counterclockwise to release the tension on the timing belt. See Fig. 4. Remove
the timing belt behind the power steering pump. See Fig. 5.

Courtesy of General Motors Corp.

Fig. 2: Removing Front Timing Belt Covers

Courtesy of General Motors Corp.

Fig. 3: Aligning Crankshaft Timing Mark

Courtesy of General Motors Corp.

Fig. 1: Removing Crankshaft Pulley

Inspection Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner and idler pulleys for
worn bearings.
Installation 1) Align the timing mark on the crankshaft gear to the
notch on the bottom of the rear timing belt cover. See Fig. 3. Align the
timing marks on the camshaft gears. See Fig. 6. Install the timing belt.
See Fig. 5.
2) Using the Timing Belt Adjuster (J-42492-A or KM-421-A), rotate the
coolant pump clockwise. See Fig. 4. Rotate the coolant pump clockwise
until the adjust arm of the timing belt automatic tensioner is aligned to
the notch in the timing belt automatic tensioner bracket. See Fig. 7.

Courtesy of General Motors Corp.

Fig. 4: Rotating Coolant Pump Using Timing Belt Adjuster

GENERAL MOTORS

267

1.6L 4-Cylinder Aveo (Cont.)

Courtesy of General Motors Corp.

Fig. 7: Aligning Automatic Tensioner With Bracket Notch

Courtesy of General Motors Corp.

Fig. 5: Removing & Installing Timing Belt

3) Tighten the coolant pump retaining bolts. Rotate the crankshaft 2 full
turns clockwise using the crankshaft pulley bolt. Loosen the coolant
pump retaining bolts. Rotate the coolant pump until the adjust arm
pointer of the timing belt automatic tensioner is aligned with the pointer
on the timing belt automatic tensioner bracket. See Fig. 8.
4) Tighten the coolant pump retaining bolts to specification. See
TORQUE SPECIFICATIONS.
5) Remove the crankshaft pulley bolt. Install the upper and lower front
timing belt covers and bolts. See Fig. 2. Tighten the bolts to specification. See TORQUE SPECIFICATIONS.
6) Install the crankshaft pulley and bolt. See Fig. 1. Tighten the bolt to
specification. See TORQUE SPECIFICATIONS.
7) Install the accessory drive belt, if equipped. Install the right front
splash shield. Install the right front wheel. Tighten wheel lug nuts to
specification. See TORQUE SPECIFICATIONS.
8) Install the air filter housing and bolts. Tighten bolts to specification.
See TORQUE SPECIFICATIONS.
9) Connect the air intake tube and breather tube to the throttle body.
Connect the IAT sensor connector. Connect the negative battery cable.

Courtesy of General Motors Corp.

Fig. 8: Aligning Automatic Tensioner With Bracket Pointer

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt
Step 1 1 .................................................................................................................... 70 (95)
Step 2 2 ............................................................................................................ Tighten 30,
Then An Additional 15
Wheel Lug Nuts ...................................................................................................... 88 (120)
INCH Lbs. (N.m)
Air Filter Housing Bolts ............................................................................................... 71 (8)
Coolant Pump Retaining Bolts .................................................................................. 89 (10)
Lower & Upper Front Timing Belt Cover Bolts ........................................................ 89 (10)
1
2

Courtesy of General Motors Corp.

Fig. 6: Aligning Camshaft Timing Marks

Tighten using torque wrench.

Tighten using Angle Meter (J-45059) or Angular Torque Gauge (KM-470-B).

GENERAL MOTORS

268

1.6L 4-Cylinder LeMans

TIMING BELT APPLICATION
Application

1.6L 4-Cyl.
LeMans
1988-89 ...............................
1990
With Tensioner Pulley .....
W/O Tensioner Pulley .....
1991-93 ...............................
1

Labor Time Component

Belt
Kit No.
Part No.

2.0 Hours ... .. TCK148 .. ..... T148

2.0 Hours ... ...... ..... ...... ..... T203
2.0 Hours ... .. TCK148 .. ..... T148
2.0 Hours ... ...... ..... ...... ..... T203

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: For 1990-93 models, this application is an interference
engine. Do not rotate camshaft or crankshaft when timing belt is
removed, or engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory
drive belts. Remove power steering pump and lines. Remove crankshaft
pulley. Remove timing belt covers starting with upper cover.
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.
2) Rotate engine to align timing marks on crankshaft and camshaft
sprockets with reference mark on lower timing belt cover. See Fig. 1.
Loosen water pump bolt to release belt tension. Remove timing belt.
Installation 1) Install timing belt. Align all timing marks. Carefully
rotate water pump to remove slack from timing belt. Tighten water pump
bolts.
2) Using Belt Tension Gauge (J-26486-B) or equivalent, measure belt
tension between water pump and camshaft sprocket. Adjust belt tension
to 35 lbs. (16 kg). To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 41 (56)
INCH Lbs. (N.m)
Timing Belt Cover Bolt (Front & Rear) .................................................................... 88 (10)
Water Pump Bolt ......................................................................................................... 71 (8)
Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt & Pulley Alignment

GENERAL MOTORS

269

1.6L 4-Cylinder Nova

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl.
Nova
DOHC
1988 .................................
SOHC
1985-88 ............................

3.1 Hours .. ...... ..... ............ T112

3.1 Hours .. .. TCK070 .. ..... T070

Component
Belt
Kit No.
Part No.

With Air Conditioning, add .4 hours. With Power Steering, add

.4 hours. With Cruise Control, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
Courtesy of General Motors Corp.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Camshaft Sprockets (DOHC)

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove 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.
2) 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).
3) 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 1) 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.
2) If installing new belt, align camshaft(s) timing marks and crankshaft
timing marks. See Figs. 1 and 2. Install timing belt. Release idler pulley
and place tension on belt.
3) 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 lbs. (2 kg), with a deflection of
.24-.28 (6-7 mm) on 8-valve engines and .16 (4 mm) on 16-valve
engines. To complete installation, reverse removal procedure. Adjust
drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 2: Identifying Timing Belt & Pulley Alignment

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 34 (46)
Crankshaft Pulley Bolt
8-Valve ................................................................................................................... 87 (117)
16-Valve ............................................................................................................... 137 (186)
Timing Belt Idler Mount Bolt ......................................................... ................. 26-36 (36-49)

Courtesy of General Motors Corp.

Fig. 3: Locating Timing Belt Deflection Points

GENERAL MOTORS

270

1.8L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl. Diesel

Acadian (Canadian)
1981-85 ....................................................
Chevette
1981-86 ....................................................

3.1 Hours .. ..... T076

3.1 Hours .. ..... T076

Belt
Part No.

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

3) Finger tighten tensioner bolts in sequence to prevent movement of

tensioner pulley. See Fig. 3. Tighten camshaft pulley bolt. Remove
injection pump gear lock bolt. Remove fixing plate on end of camshaft.
4) 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.
5) Loosen tensioner pulley and plate bolts. Concentrate belt looseness
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).
6) 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.

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove fan shroud, V-belt and pulley. Remove upper dust cover.
Disconnect by-pass hose.
2) 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.
3) Remove valve cover. Attach Fixing Plate (J-29761), or equivalent, 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.
4) 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.

Courtesy of General Motors Corp.

Fig. 2: Identifying Timing Belt Installation Sequence

Courtesy of General Motors Corp.

Fig. 3: Identifying Tension Pulley Bolt Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of General Motors Corp.

Fig. 1: Locating Injection Pump Gear Alignment Marks & Lock Bolt
Installation 1) 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.
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 tension pulley. Depress tension pulley with
finger and install tension spring.

Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ................................................................................................. 55 (75)
Damper Pulley Bolt ................................................................................................... 12 (20)
Tension Pulley
Center Bolt .............................................................................................................. 54 (73)
Side Bolts ................................................................................................................ 15 (20)
Water Pump Bolts ..................................................................................................... 15 (20)

GENERAL MOTORS

271

1.8L 4-Cylinder Gasoline

TIMING BELT APPLICATION
Application

1.8L 4-Cyl. OHC

Firenza
1982-86 ...............................
J2000
1982 ....................................
Skyhawk
1982-86 ...............................
Sunbird
1985-86 ...............................
2000
1983 ....................................
2000 Sunbird
1984 ....................................
1

Labor Time Component

Belt
Kit No.
Part No.

2.7 Hours ... .. TCK081 .. ..... T081

2.7 Hours ... .. TCK081 .. ..... T081
2.7 Hours ... .. TCK081 .. ..... T081
2.7 Hours ... .. TCK081 .. ..... T081
2.7 Hours ... .. TCK081 .. ..... T081

2) 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).
3) Reassemble components and run engine to operating temperature
(thermostat open). As new belt takes a set position, substantial tension
loss will occur. After belt has been run, recheck tension with gauge on
belt.
4) 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).
5) DO NOT leave tension gauge on belt during retightening, or reading
will be inaccurate. Tighten water pump bolts. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

2.7 Hours ... .. TCK081 .. ..... T081

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove belts, brackets and shields necessary to gain access to crankshaft pulley. Remove
timing belt front cover.
2) Rotate crankshaft so timing mark on crankshaft pulley lines up with
10 BTDC mark on indicator scale. Mark on camshaft sprocket must
align with mark on camshaft carrier. Remove crankshaft pulley.
3) Remove timing probe holder. Verify timing marks are aligned, and
loosen water pump retaining bolts to remove timing belt.
Installation 1) 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 tension
with engine at operating temperature. If new head gasket is
installed, cylinder head must be retightened AFTER initial warmup. Timing belt tension MUST then be rechecked.

Courtesy of General Motors Corp.

Fig. 1: Adjusting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 34 (45)
Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 20 (27)
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)

GENERAL MOTORS

272

2.0L 4-Cylinder
TIMING BELT APPLICATION
Application
2.0L 4-Cyl. OHC
Firenza
1987-88 ...............................
Grand Am
1987-88 ...............................
1989 ....................................
LeMans
1989
1st Design ........................
2nd Design .......................
1990 ....................................
Skyhawk
1987-88 ...............................
Sunbird
1987-88 ...............................
1989-94 ...............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.7 Hours ... ...... ..... ...... ..... T081

2.7 Hours .... TCK081A . ..... T081
2.7 Hours ... .. TCK163 .. ..... T163

2.7 Hours .... TCK081A . ..... T081

2.7 Hours ... .. TCK163 .. ..... T163
2.7 Hours ... .. TCK163 .. ..... T163
2.7 Hours .... TCK081A . ..... T081
2.7 Hours .... TCK081A . ..... T081
2.7 Hours ... .. TCK163 .. ..... T163

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of General Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1987-88) 1) Disconnect negative battery cable. Remove
belts, brackets and shields necessary to gain access to crankshaft
pulley. Remove timing belt front cover. See Fig. 1.
2) 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 carrier. Remove crankshaft pulley.
3) Remove timing probe holder. Verify timing marks are aligned, and
loosen water pump retaining bolts to remove timing belt.
Installation (1987-88) 1) 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. 2.
NOTE: If new timing belt has been installed, check final tension
with engine at operating temperature. If new head gasket is
installed, cylinder head must be retightened AFTER initial warmup. Timing belt tension MUST then be rechecked.
2) 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).
3) Reassemble components and run engine to operating temperature
(thermostat open). As new belt takes a set position, substantial tension
loss will occur. After belt has been run, recheck tension with gauge on
belt.
4) 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).
5) DO NOT leave tension gauge on belt during retightening, or reading
will be inaccurate. Tighten water pump bolts to specification. See
TORQUE SPECIFICATIONS. Reverse removal procedure to complete
installation. Adjust drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 2: Adjusting Timing Belt Tension

Removal (1989-94) 1) Disconnect negative battery cable. Remove
serpentine belt, brackets, and shields necessary to gain access to
crankshaft pulley. Remove front timing belt cover. See Fig. 1.
2) Remove crankshaft pulley. Loosen water pump retaining bolts. Using
Timing Belt Adjuster (J-33039-A) or equivalent, rotate water pump to
release timing belt tension. Remove timing belt.
Installation (1989-94) 1) To install camshaft and crankshaft sprockets
(if removed), reverse removal procedure. Tighten retaining bolts to
specification. See TORQUE SPECIFICATIONS.
2) 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 between the camshaft sprocket and
crankshaft sprocket.
NOTE: Adjust timing belt with engine coolant temperature at 68F
(20C).
3) Using timing belt tension adjuster, rotate water pump clockwise until
tensioner contacts the high torque stop. See Fig. 3. Slightly tighten water
pump retaining bolts.

GENERAL MOTORS

273

2.0L 4-Cylinder (Cont.)

4) Using crankshaft sprocket bolt, rotate engine clockwise 2 revolutions
to fully seat timing belt. Rotate water pump eccentric counterclockwise
until hole in tensioner arm aligns with hole in base.
5) Tighten water pump bolts to specification. See TORQUE SPECIFICATIONS. Ensure tensioner holes remain in alignment as stated.
Ensure all timing marks are properly aligned. To install remaining
components, reverse removal procedure. Adjust drive belts to proper
tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley-To-Sprocket Bolt
1987-88 .................................................................................................................... 20 (27)
1989-92 .................................................................................................................... 15 (20)
Serpentine Belt Tensioner Bolt ................................................................................. 35 (47)
Timing Belt Tensioner Bolt ........................................................................................ 18 (24)
Water Pump Bolt ....................................................................................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Carrier Cover Bolt .................................................................................... 84 (10)
Timing Belt Cover Bolt ................................................................................................ 62 (7)

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Tensioner (1989-94)

GENERAL MOTORS

274

3.0L V6
TIMING BELT APPLICATION
Component
Belt
Kit No.
Part No.

NOTE: Do not move camshafts with belt removed. Do not remove

Camshaft Holders (J42069) with timing belt removed.

3.0L V6 DOHC
Catera
1997-98 ............................... 2.6 Hours ... .. TCK285 .. ..... T285
1999-01 ............................... 2.6 Hours .... TCK285A . ..... T285

11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing
belt, mark belt with arrow to indicate original direction of rotation.
Remove timing belt.

Application

Labor Time

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 100,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Precautions 1) When servicing timing belt, always turn crankshaft in
normal direction of rotation (clockwise).
2) Install timing belt with engine at room temperature.
3) Never remove timing belt without first setting camshaft gears and
crankshaft drive gear to TDC and locking them in place.
4) Guide marks on timing belt are to aid in timing belt installation. If guide
marks cannot be identified, a new belt must be installed.

Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt Front Cover Components

NOTE: 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.
Removal 1) Disconnect negative battery cable. Remove air intake
resonator and ducting from throttle body.
2) 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 injection crossover pipe from hoses and
front cover.
3) Lower vehicle. Remove air injection crossover pipe from front cover.
4) 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 injection crossover bracket. Remove accessory
drive serpentine belt.
5) Release plastic retaining tabs, and remove wiring harness channel
cover from front of engine. Move wiring harness out of way.
6) Remove water pump pulley bolts and pulley. Remove power steering
pump pulley bolts and pulley. Remove accessory drive serpentine belt
tensioner.
7) Remove front timing belt cover. Remove 6 harmonic balancer-tocrankshaft bolts. Remove harmonic balancer. It is NOT necessary to
remove crankshaft center bolt.
8) Rotate crankshaft clockwise to 60 degrees before TDC. See Fig. 2.
Ensure timing marks are not 180 degrees from TDC.
9) Install Crankshaft Holder (J42069-10) and rotate crankshaft 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 Fig. 4 or 5. If not aligned,
crankshaft is 180 degrees (one half turn) off.
10) To lock camshafts in place, install Camshaft Gear Holders (J42069-1
and J42069-2). See Fig. 6. It may be necessary to loosen timing belt
idler pulley and turn eccentric until holder can be inserted.

Courtesy of General Motors Corp.

Fig. 2: Positioning Crankshaft At 60 Degrees BTDC

Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

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Courtesy of General Motors Corp.

Fig. 6: Installing Camshaft Gear Holders

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks

(Up To 1999 Early Design)

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 timing belt. For later design (mid-1999 to present),
use the remaining 3 Yellow marks on the timing belt. Correct belt
application MUST be used on each engine design.
2) 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 taut between idler pulley and left bank camshaft pulleys. See Fig. 4
or 5.
3) Ensure timing belt tension is taut (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 DEFLECTION
ADJUSTMENT.

Courtesy of General Motors Corp.

Fig. 5: Aligning Timing Belt Marks With Rear Cover Marks

(From 1999 Late Design)
Inspection Check timing belt for excessive wear, cracks, or missing
teeth. Inspect timing belt tensioner and idler pulleys for worn bearings.
Replace as necessary.
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
of rotation.
Installation 1) To install timing belt, remove crankshaft holder. Raise
and support vehicle. Start installation of belt at crankshaft pulley. 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.

Courtesy of General Motors Corp.

Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley

Timing Belt Deflection Adjustment 1) 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,
center 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.

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4) 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).
5) If timing belt readjustment is not necessary, go to FINAL TIMING
BELT TENSIONING & INSTALLATION. If timing belt readjustment is
necessary, go to TIMING BELT READJUSTMENT (LEFT BANK CAMSHAFTS).

Courtesy of General Motors Corp.

Fig. 8: Measuring Timing Belt Deflection

2) Apply additional tension to timing belt by loosening bolt for idler pulley
located between camshaft sprockets (top, center 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
ADJUSTMENT.
Timing Belt Tension Adjustment Loosen timing belt tensioner lock
nut. Turn tensioner eccentric counterclockwise to full stop. Turn eccentric back until reference mark is .039 (1 mm) from belt tension setting
flange. See Fig. 9. Tighten timing belt tensioner lock nut until snug. Lock
nut will be final tightened after final adjustments are made. Go to
CHECKING CAMSHAFT SPROCKET ALIGNMENT.

Courtesy of General Motors Corp.

Fig. 9: Adjusting Timing Belt Tension (New Design Engine

Shown; Early Design Engine Is Similar)
Checking Camshaft Sprocket Alignment 1) 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.
2) 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 revolutions.
3) Ensure crankshaft timing mark aligns with mark on oil pump housing.
Ensure camshaft timing marks align with notches on rear cover.

Courtesy of General Motors Corp.

Fig. 10: Installing Checking Gauge On Camshaft Sprockets

NOTE: When readjusting timing belt tension, Crankshaft Holder
(J42069-10) must be in position on engine.
Timing Belt Readjustment (Left Bank Camshafts) 1) If timing belt
readjustment is required, always start with left bank (drivers side)
camshafts first. Install Checking Gauge (J42069-20) to left bank camshafts.
2) 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 COUNTERCLOCKWISE 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 turning.
3) 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
properly aligned, go to TIMING BELT READJUSTMENT (RIGHT BANK
CAMSHAFTS). If not, repeat readjustment procedure.
Timing Belt Readjustment (Right Bank Camshafts) 1) 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.
2) Loosen bolt on idler pulley that is located in the center and below the
left bank and right bank camshafts.
3) 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 eccentric from turning.
4) 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
properly aligned, go to FINAL TIMING BELT TENSIONING & INSTALLATION. If not, repeat readjustment procedure.

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3.0L V6 (Cont.)
Final Timing Belt Tensioning & Installation 1) To set final timing belt
tension, loosen timing belt tensioner eccentric lock nut. Turn timing belt
eccentric counterclockwise 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 specification. See
TORQUE SPECIFICATIONS.
2) If timing belt idler pulley bolts were loosened, final tighten them to
specification. Inspect 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.
3) Remove crankshaft holding tool. Rotate crankshaft clockwise 2
revolutions, stopping at 60 degrees before TDC mark. Install Crankshaft
Holder (J42069-10) to crankshaft drive gear.
4) Turn crankshaft clockwise until lever of holder firmly contacts water
pump pulley flange. Secure moveable lever of tool to water pump pulley
flange.
5) 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 inspect alignment of left bank and right
bank camshaft gears.
6) 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 specification.
7) Install timing belt cover. Install accessory drive belt tensioner. Install
water pump and power steering pump pulleys. Install serpentine drive
belt.
8) Install air injection crossover pipe to front of engine. Install air intake
resonator and ducting. Install engine splash shield.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60
Step 3 ........................................................................................................... Additional 15
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45
Step 3 ........................................................................................................... Additional 15
Generator Bolt ........................................................................................................... 30 (40)
Power Steering Pump Pulley Bolt ............................................................................ 15 (20)
Serpentine Drive Belt Tensioner Bolt ....................................................................... 30 (40)
Timing Belt Idler Pulley 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)
Water Pump Pulley Bolt .............................................................................................. 71 (8)

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TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

3.2L V6
CTS
2003-04 ..................................................... 2.4 Hours ... ..... T285
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends that the timing belt be replaced at
100,000 miles or every 96 months, whichever occurs first.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Using scan tool, inspect the cold start counter (also
known as heavy duty register). If there are any cold starts below 20F
(28C), visually inspect timing belt for cracks and replace as necessary.
If belt is replaced, clear the cold start counter. If belt is not replaced, do
not clear the cold start counter.
2) Disconnect air intake duct hose from Mass Airflow (MAF)/Intake Air
Temperature (IAT) sensor. Remove bolt securing intake air resonator to
cooling fan assembly. Disconnect air intake duct hoses from throttle
body. Lift intake air resonator from front frame to access the electrical
connector and vacuum hoses. Disconnect intake resonance switchover
solenoid connector.
NOTE: Note vacuum hose routing for reassembly.
3) Disconnect vacuum hoses from the coolant by-pass solenoid, intake
plenum switchover solenoid and vacuum brake booster hose. Positioning the surge tank inlet and upper radiator hoses aside, remove intake
air resonator.
4) Remove intake plenum air inlet hose clamps and hoses from throttle
body. Disconnect fuel pressure regulator atmospheric vent tube from
bottom of throttle body. Remove throttle body from intake plenum and
crankcase vent adapter, and allow it to be supported by the throttle body
inlet heater hose. Remove throttle body O ring seals.
5) Remove 3 bolts holding crankcase vent adapter to intake plenum. Lift
crankcase vent adapter from intake plenum, and position aside. See
Fig. 1. Disconnect crankcase ventilation dirty air hose retainer from fuel
pipe. Remove remote power steering fluid reservoir bottom and side
mounting bolts, and position aside.
6) Disconnect electrical connector and vacuum hose from switchover
valve at rear of plenum. See Fig. 2. Remove bolt holding throttle body
heater inlet hose/pipe to intake plenum. Disconnect vacuum brake
booster hose from vacuum source. Remove 2 bolts securing Engine
Control Module (ECM) bracket to intake plenum. See Fig. 4.
7) Remove intake plenum bolt caps and bolts. Lift intake plenum from
intake manifold. Remove intake plenum O ring seals. Mask off intake
manifold ports to prevent foreign objects from entering engine.
8) Rotate drive belt tensioner clockwise to release drive belt tension.
Slide drive belt from water pump pulley. Allow drive belt tensioner to
return to relaxed position. Remove accessory drive belt. Remove drive
belt tensioner. Remove water pump pulley. See Fig. 3.
9) Remove power steering pump mounting bolts ONLY. Remove power
steering pump from accessory mounting bracket, and position aside.
Remove timing belt cover. Remove crankshaft balancer from crankshaft
sprocket.
10) Using Crank Hub Torx Socket (J-42098), rotate engine clockwise
until No. 1 cylinder is at TDC on the compression stroke. Timing marks

on camshaft gears should be aligned with corresponding notches on

rear timing belt cover, and marks on crankshaft sprocket and oil pump
housing should align. See Fig. 5.
11) Using crank hub torx socket, rotate crankshaft counterclockwise until
60 degrees BTDC. The 60 degree BTDC point can be identified by index
mark on oil pump cover. See Fig. 6.
NOTE: Ensure moveable lever is positioned toward crankshaft.
12) Install the Crankshaft Holder (J-42069-10) from Timing Belt Alignment Kit (J-42069) to the crankshaft sprocket with the knurled bolt. See
Fig. 7. Using crank hub torx socket, rotate crankshaft clockwise until
lever of crankshaft holder firmly contacts water pump pulley flange.
Ensure No. 1 cylinder is at TDC. Secure moveable lever of tool to water
pump pulley flange.
CAUTION: Ensure crankshaft is not 180 degrees off TDC. Reference marks on camshaft gears should be aligned with corresponding notches on rear timing belt cover at this point. If they are not
aligned, engine is 180 degrees off.
13) Install the Camshaft Gear Holders (J-42069-1 and J-42069-2) to
camshaft gears. See Fig. 8. If either tool does not fit into the teeth of the
camshaft gears, it may be necessary to loosen the upper idler pulley,
and turn the eccentric or camshaft gears until tool can be inserted.
14) Loosen timing belt tensioner nut. Loosen upper idler pulley bolt.
Remove lower idler pulley bolt. Remove lower idler pulley and spacer.
CAUTION: DO NOT turn camshaft and crankshaft independently
after timing belt is removed. If turned, interference may occur
among pistons and valves, and related components may be damaged.
CAUTION: DO NOT remove the camshaft gear holders from camshaft gears while timing belt is removed.
15) Remove the crankshaft holder from crankshaft sprocket. If belt is to
be reused, mark direction of rotation for reinstallation reference.
Remove timing belt.

Courtesy of General Motors Corp.

Fig. 1: Removing Crankcase Vent Adapter

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3.2L V6 (Cont.)

Courtesy of General Motors Corp.

Fig. 2: Disconnecting Electrical Connector & Vacuum Hose From

Switchover Valve

Courtesy of General Motors Corp.

Fig. 4: Removing & Installing ECM Bracket

Courtesy of General Motors Corp.

Fig. 3: Exploded View Of Timing Belt & Components

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3.2L V6 (Cont.)

Courtesy of General Motors Corp.

Fig. 5: Rotating Crankshaft Clockwise

Courtesy of General Motors Corp.

Fig. 7: Installing Crankshaft Holder & Other Tools

Courtesy of General Motors Corp.

Fig. 6: Positioning Crankshaft At 60 Degrees BTDC

Inspection 1) Check if a tooth is broken and/or a tooth root is cracked.
Possible causes are a jammed camshaft, damaged camshaft, damaged
crankshaft oil seal and/or coolant leak, old age or malfunctioning
tensioner.
2) Check if the back surface of the belt is cracked, worn, scratched or
scored. Possible causes are excessive cold starts, jammed tensioner,
overheated engine or belt cover interference.
3) Check if the side of the belt surface is worn. Possible causes are
improper belt installation, overload or misalignment of cam drive components, jammed tensioner, heavy thrust loading against idler guide
flanges or damaged idler guide.
4) Check if the teeth are worn. Possible causes are poor belt cover
sealing, excessive belt tension, jammed tensioner, or rough and/or
scored cam sprockets.
5) Check if there is a clean break across the fibers. Possible causes are
kinked belt before and/or during assembly or foreign material under belt.
6) Check if oil or coolant is impregnated and/or there is a swollen belt.
Possible causes are poor oil sealing, coolant leak at pump or poor belt
cover seal.

Courtesy of General Motors Corp.

Fig. 8: Installing Locking Tools To Camshaft Gears

CAUTION: Install timing belt with engine at room temperature.
Ensure directional arrows on timing belt are matched with the
clockwise rotation of the crankshaft, or excessive wear and timing
belt failure may occur.
Installation 1) Starting at crankshaft sprocket, align double dash TDC
mark on timing belt with marks on oil pump housing and crankshaft
sprocket. Wedge the Timing Belt Holder (J-42069-30) between oil pump
housing and timing belt in order to prevent the belt teeth from jumping
the crankshaft sprocket teeth. See Fig. 9.

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3.2L V6 (Cont.)
2) Route timing belt through timing belt tensioner. See Fig. 5. Slip the
timing belt through camshaft gears No. 1 and 2 simultaneously, ensuring
dash marks on timing belt align with marks on camshaft gears and
notches on rear timing belt cover. Route belt through upper idler pulley.
Slip belt through camshaft gears No. 3 and 4 simultaneously, ensuring
dash marks on timing belt align with marks on camshaft gears and
notches on rear timing belt cover.
3) Using Crank Hub Torx Socket (J-42098), rotate crankshaft counterclockwise to 3 degrees BTDC, allowing timing belt to slide on the timing
belt holder. See Fig. 10. Install lower idler pulley and spacer with the
timing belt. Install lower idler pulley bolt, and tighten to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft clockwise back to TDC.
4) Apply tension to timing belt at upper idler pulley by turning high point
of eccentric to approximately the 9 oclock position. While holding
eccentric with the Wrench (J-42069-40), tighten idler pulley locking bolt
until snug. See Fig. 5.
5) To set initial timing belt tension, rotate tensioner eccentric counterclockwise to full stop, then turn eccentric back until reference mark is
0.03 (1 mm) over the flange. See Fig. 11. Tighten tensioner locking nut
until snug.
6) Ensure alignment marks on timing belt are aligned with timing marks
on camshaft gears, rear timing belt cover and oil pump housing. See
Fig. 12. Remove the timing belt holder and the Camshaft Gear Holders
(J-42069-1 and J-42069-2) from engine. See Figs. 8 and 9.
7) Using crank hub torx socket, rotate crankshaft clockwise 2 revolutions
until No. 1 cylinder is 60 degrees BTDC. See Fig. 6. Install the
Crankshaft Holder (J-42069-10) to crankshaft sprocket with the knurled
bolt. See Fig. 7. Rotate crankshaft clockwise until lever of the crankshaft
holder firmly contacts water pump pulley flange, and secure lever to
flange.

Courtesy of General Motors Corp.

Fig. 9: Aligning Timing Belt Marks On Crankshaft Pulley

NOTE: After one or more engine revolutions, alignment marks on

timing belt will no longer align with marks on camshaft gears.
8) Ensure timing marks on camshaft gears are aligned with notches on
rear timing belt cover, and marks on crankshaft sprocket and oil pump
housing are aligned. See Fig. 13. Using the Checking Gauge
(J-42069-20), inspect alignment of camshaft gears No. 3 and 4, then
gears No. 1 and 2. See Fig. 7. If adjustment is required, see TIMING
BELT ADJUSTMENTS.
9) If adjustment is not required, loosen timing belt eccentric locking nut.
If installing a new belt, turn eccentric counterclockwise to full stop, then
back until reference mark is 0.118-0.157 (3-4 mm) above datum line.
See Fig. 14. If installing a used belt, turn eccentric counterclockwise to
full stop, then back until reference mark is aligned with the datum line.
Tighten timing belt tensioner eccentric locking nut to specification. See
TORQUE SPECIFICATIONS.
10) Using the wrench, hold upper idler pulley eccentric in place, and
tighten pulley bolt to specification. See Fig. 7. See TORQUE SPECIFICATIONS. Remove the checking gauge from camshaft gears. Remove
the crankshaft holder from engine.
11) For final inspection, repeat steps 7) and 8). If timing marks are
aligned, remove tools from engine. To complete installation, reverse
removal procedures. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS. Lightly coat intake plenum O ring seals
and crankcase vent adapter seal with clean engine oil. Adjust driving belt
tension.

Courtesy of General Motors Corp.

Fig. 10: Positioning Crankshaft At 3 Degrees BTDC

TIMING BELT ADJUSTMENTS

CAUTION: This procedure must not be performed as a stand-alone
operation.
NOTE: It is not uncommon to repeat steps and make several
engine revolutions to achieve the proper level of timing belt
adjustment.
Timing Belt Adjustment Check 1) Apply the Checking Gauge
(J-42069-20) to the camshaft gears No. 1 and 2. See Fig. 7.

Courtesy of General Motors Corp.

Fig. 11: Adjusting Timing Belt Tension

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3.2L V6 (Cont.)
2) Inspect the relationship of the marks on the camshaft gears to the
marks on the checking gauge. They must match exactly. If not, timing
belt adjustment is required. Go to next applicable procedure.
Timing Belt Readjustment (Left Bank Camshafts) 1) Loosen the
upper idler pulley bolt. Use the Wrench (J-42069-40) to turn the
eccentric on the upper idler pulley counterclockwise until the marks on
the camshaft gears and on the Checking Gauge (J-42069-20) are in
alignment. The high point of the idler pulley eccentric will be in
approximately the 9 oclock position. See Fig. 7.
2) Tighten the upper idler pulley bolt, while holding the eccentric in place
with the wrench to prevent movement. See TORQUE SPECIFICATIONS. Remove the Crankshaft Holder (J-42069-10) and the checking
gauge.
3) Rotate the crankshaft in the engine rotational direction (clockwise) 2
revolutions using the Crank Hub Torx Socket (J-42098) until reaching 60
degrees BTDC. See Fig. 6. The 60 degrees BTDC point can be
identified by the index mark on the oil pump cover.
NOTE: Ensure the moveable lever is positioned toward the crankshaft.

Courtesy of general motor corps.

Fig. 12: Aligning Timing Belt Marks With Rear Cover Marks

Courtesy of General Motors Corp.

Fig. 13: Inspecting Alignment Of Reference Marks

4) Install the crankshaft holder to the crankshaft sprocket with the

knurled bolt. See Fig. 7. Rotate the crankshaft in the engine rotational
direction (clockwise) using the crank hub torx socket until the lever of the
crankshaft holder firmly contacts the water pump pulley flange. The
No. 1 cylinder is at TDC at this point.
5) Secure the moveable lever of the tool to the water pump pulley flange.
Ensure that the crankshaft is not 180 degrees off TDC. The reference
marks on the camshaft gears should be aligned with the corresponding
notches on the rear timing belt cover at this point. If they are not aligned,
the engine is 180 degrees off.
6) Install the checking gauge to camshaft gears No. 1 and 2. Inspect the
alignment of the marks on the camshaft gears in reference to the marks
on the checking gauge.
7) Repeat the procedure again if the marks do not align. If camshaft
gears No. 1 and 2 are now properly aligned, go to FINAL TIMING BELT
TENSIONING & INSTALLATION.
Timing Belt Readjustment (Right Bank Camshafts) 1) Loosen the
upper idler pulley bolt. Slacken the timing belt by turning the eccentric on
the upper idler pulley clockwise with the Wrench (J-42069-40) until the
marks on the camshaft gears and the marks on the Checking Gauge
(J-42069-20) are in alignment. The high point of the idler pulley eccentric
will be in approximately the 9 oclock position. See Fig. 7.
2) Tighten the upper idler pulley bolt, while holding the eccentric in place
with the wrench to prevent movement. See TORQUE SPECIFICATIONS. Remove the Crankshaft Holder (J-42069-10) and the checking
gauge.
3) Rotate the crankshaft in the engine rotational direction (clockwise) 2
revolutions using the Crank Hub Torx Socket (J-42098) until reaching 60
degrees BTDC. See Fig. 6. The 60 degrees BTDC point can be
identified by the index mark on the oil pump cover.
NOTE: Ensure the moveable lever is positioned toward the crankshaft.

Courtesy of General Motors Corp.

Fig. 14: Setting Final Timing Belt Tension

4) Install the crankshaft holder to the crankshaft sprocket with the

knurled bolt. See Fig. 7. Rotate the crankshaft in the engine rotational
direction (clockwise) using the crank hub torx socket until the lever of the
crankshaft holder firmly contacts the water pump pulley flange. The
No. 1 cylinder is at TDC at this point.
5) Secure the moveable lever of the tool to the water pump pulley flange.
Ensure that the crankshaft is not 180 degrees off TDC. The reference
marks on the camshaft gears should be aligned with the corresponding
notches on the rear timing belt cover at this point. If they are not aligned,
the engine is 180 degrees off.
6) Install the checking gauge to camshaft gears No. 1 and 2. Inspect the
alignment of the marks on the camshaft gears in reference to the marks
on the checking gauge.

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3.2L V6 (Cont.)
7) Repeat the procedure again if the marks do not align. If camshaft
gears No. 1 and 2 are properly aligned, set the final timing belt tensioner
as outlined in FINAL TIMING BELT TENSIONING & INSTALLATION.
CAUTION: The following steps are the COMPLETION of adjusting
the timing belt, and must not be performed as a stand-alone
operation.
Final Timing Belt Tensioning & Installation 1) With the Crankshaft
Holder (J-42069-10) in place locking the crankshaft at TDC, loosen the
timing belt eccentric locking nut. Turn the eccentric counterclockwise to
full stop, then back to the following specification:
New Belt Until the reference mark is 0.118-0.157 (3-4 mm)
above the datum line. See Fig. 14.
Used Belt Until the reference is aligned with the datum line.
Tighten the timing belt tensioner eccentric locking nut. See TORQUE
SPECIFICATIONS.
2) If the timing belt upper idler pulley bolt has not been previously
torqued to specification, tighten the timing belt upper idler pulley bolt
while holding the eccentric in place with the Wrench (J-42069-40) to
prevent movement. See Fig. 7. See TORQUE SPECIFICATIONS.
3) Remove the crankshaft holder and the Checking Gauge
(J-42069-20). For final inspection, once again rotate the crankshaft in
the engine rotational direction (clockwise) 2 revolutions using the Crank
Hub Torx Socket (J-42098) until reaching 60 degrees BTDC. See Fig. 6.
4) Install the crankshaft holder to the crankshaft sprocket. Rotate the
crankshaft in the engine rotational direction (clockwise) using the crank
hub torx socket until the lever of the crankshaft holder firmly contacts the
water pump pulley flange.
5) Secure the moveable lever of the tool to the water pump pulley flange.
The alignment marks on the timing belt will no longer align with the
marks on the camshaft gears after one or more engine revolutions.
6) Inspect the alignment of the reference marks on the camshaft gears
with the notches on the rear timing belt cover, as well as the mark on the
crankshaft sprocket and oil pump housing. See Fig. 13.
7) Use the checking gauge to inspect the alignment of the camshaft
gears No. 3 and 4. Use the checking gauge to inspect the alignment of
the camshaft gears No. 1 and 2. Repeat the procedure again if the
marks do not align exactly.
8) If the reference marks match exactly, further timing belt adjustment is
not necessary. Continue with reassembly of the engine.
9) Remove the crankshaft holder and the checking gauge. To complete
installation, reverse removal procedures.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Balancer Bolts ........................................................................................ 15 (20)
Drive Belt Tensioner Bolts ........................................................................................ 26 (35)
Intake Plenum Bolts .................................................................................................. 15 (20)
Lower Idler Pulley Bolt .............................................................................................. 30 (40)
Power Steering Pump Mounting Bolts ..................................................................... 26 (35)
Timing Belt Tensioner Eccentric Locking Nut .......................................................... 15 (20)
Upper Idler Pulley Bolt .............................................................................................. 30 (40)
INCH Lbs. (N.m)
Crankcase Vent Tube Adapter Bolts .......................................................................... 71 (8)
Engine Control Module (ECM) Bracket Bolts ............................................................ 71 (8)
Intake Air Resonator Retaining Bolt ........................................................................... 80 (9)
Remote Power Steering Fluid Reservoir Mounting Bolts
To Cylinder Head ........................................................................ ..................................... 1
To Intake Plenum ...................................................................................................... 80 (9)
Throttle Body Bolts ...................................................................................................... 71 (8)
Throttle Body Heater Inlet Hose/Pipe Bolt ................................................................. 80 (9)
Timing Belt Cover Bolts .............................................................................................. 71 (8)
Water Pump Pulley Bolts ............................................................................................ 71 (8)
1

Tighten to 18 ft. lbs. (25 N.m).

GENERAL MOTORS

284

3.4L V6
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

3.4L V6 DOHC
Cutlass Supreme & Grand Prix
1991-95 ............................... 4.5
1996 .................................... 4.5
Lumina
1991-95 ............................... 4.5
1996-97 ............................... 4.5
Monte Carlo
1995 .................................... 4.5
1996-97 ............................... 4.5
1

Hours ... .. TCK192 .. ..... T192

Hours ... .. TCK273 .. ..... T273
Hours ... .. TCK192 .. ..... T192
Hours ... .. TCK273 .. ..... T273
Hours ... .. TCK192 .. ..... T192
Hours ... .. TCK273 .. ..... T273

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

10) Position timing belt tensioner actuator in vise with rod tip (rubber
boot end) pointing down.
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.
11) Straighten out a standard paper clip (.032 with no serrations) and
form a loop at one end. See Fig. 2. Remove rubber end plug from rear
of tensioner actuator. Push paper clip through end of vent plug and into
pilot hole. Insert a small screwdriver into the screw slot inside actuator,
behind rubber end plug.
12) 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 engages. Remove timing belt.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

NOTE: Remove timing marks from camshaft and intermediate shaft

sprockets.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

13) Rotate crankshaft so that No. 1 cylinder is at TDC of compression

stroke. Mark the timing indicator with White paint or equivalent on the
crankshaft balancer and front cover. See Fig. 3.
14) Position camshafts so that flat spots are UP for installation of
Camshaft Hold-Down Tools (J 38613-A). Install Camshaft Hold-Down
Tools (J 38613-A) on both camshaft carriers. See Fig. 4.
15) 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.

The manufacturer recommends the belt be replaced at 60,000 mile

intervals.

REMOVAL & INSTALLATION

CAUTION: For 1996-97 models, this application is an interference
engine. Do not rotate camshaft or crankshaft when timing belt is
removed, or engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
and duct assembly. Drain engine coolant.
2) Remove accelerator and cruise control cables from throttle body.
Remove fuel rail cover. Relieve fuel pressure. Remove fuel lines from
fuel rail. Remove fuel mounting bracket.
3) Remove heater hose and bracket from lower intake manifold.
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.
4) Remove wiring loom bracket for rear spark plug wires. Remove upper
intake manifold. Remove coolant recovery tank. Remove serpentine
drive belt and drive belt tensioner.
5) Siphon fluid from power steering pump. Disconnect power steering
lines and remove power steering pump.
6) On 1991-93 vehicles only, reposition Powertrain Control Module
(PCM) out of way. Remove PCM mounting bracket. On 1994-95
vehicles only, disconnect PCM connectors and secure out of way.
7) 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. Remove fuel line bracket.
8) Remove timing belt covers. Remove breather hose from rear camshaft cover and crankcase vent from breather manifold. 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.
9) 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.

Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt Assembly Components

GENERAL MOTORS

285

3.4L V6 (Cont.)

Courtesy of General Motors Corp.

Fig. 2: Reworking Paper Clip

Courtesy of General Motors Corp.

Fig. 5: Identifying Camshaft Timing Sprocket Designs

Inspection 1) To determine if timing belt length is within specifications,
measure tensioner actuator from centerline of tensioner actuator to end
of rubber boot. See Fig. 6. 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).
2) 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.

Courtesy of General Motors Corp.

Fig. 6: Measuring Timing Belt Tensioner Actuator Length

Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks

Courtesy of General Motors Corp.

Fig. 4: Installing Camshaft Hold-Down Tools (J 38613-A)

286

GENERAL MOTORS
3.4L V6 (Cont.)

Installation 1) Install camshaft sprockets with bolts and locks. Tighten

bolts finger tight. Install timing belt onto camshaft sprockets in a
counterclockwise direction. Continue installing timing belt, making sure
timing belt teeth are fully engaged with all sprockets.
2) Install timing belt tensioner pulley. Tighten timing belt tensioner pulley
bolt to 37 ft. lbs. (50 N.m).
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.
3) 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.
4) 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).
5) 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 actuator. Retighten pulley assembly
counterclockwise to seat pulley into belt.
6) 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.
7) Rotate crankshaft one full turn (360 degrees) clockwise, as viewed
from front of engine. Align crankshaft reference marks. See Fig. 3. 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 camshaft hold-down from left hand camshaft carrier.
8) 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.
9) Install camshaft carrier covers. Install breather hose and crankcase
vent onto rear cover. Install timing belt covers.
10) To complete installation, reverse removal procedure. Refill 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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 96 (130)
Crankshaft Balancer Bolt ........................................................................................ 79 (107)
Crankshaft Pulley Bolt ............................................................................................... 37 (50)
EGR Valve Bolts ....................................................................................................... 18 (25)
Front Cover Bolts
Large Bolts .............................................................................................................. 35 (47)
Small Bolts .............................................................................................................. 18 (25)
Intermediate Shaft Belt Sprocket Bolt .................................................................... 96 (130)
Serpentine Belt Tensioner Bolt ................................................................................. 33 (45)
Timing Belt Actuator Side Plate Bolt ........................................................................ 20 (27)
Timing Belt Tensioner Pulley Bolt ............................................................................. 37 (50)
Timing Chain Tensioner Bolt ..................................................................................... 18 (25)
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)

GEO

287

1.6L 4-Cylinder DOHC Prizm GSI

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. DOHC (VIN 5)

Prizm GSI
1990-92 ....................................................
1

Belt
Part No.

3.1 Hours .. ..... T176

With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be inspected and adjusted at
30,000 mile intervals, and replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. 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.
2) Remove center bolt and crankshaft pulley. Lower vehicle. Label spark
plug secondary cables for reassembly reference. Disconnect spark plug
cables from spark plugs.
3) Remove PCV valve from valve cover. Disconnect accelerator cable
from valve cover. Disconnect wiring harness from valve cover. Remove
valve covers.
4) Remove windshield washer reservoir. Remove engine wiring harness
from upper timing belt cover.
5) 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.
6) Remove water pump pulley. Remove upper, center and lower timing
belt covers. See Fig. 1. Remove timing belt guide. Turn crankshaft so
that camshaft and crankshaft timing marks are aligned. See Fig. 2.
Loosen timing belt idler pulley bolt. Remove timing belt.
NOTE: If timing belt is to be reused, mark direction of timing belt
rotation. Place mating marks on belt and sprockets for reference.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

hooked portion of spring (not coil length). Replace spring if free length is
greater than 1.618 (41.09 mm). See Fig. 3.

Fig. 3: Measuring Tensioner Spring Free Length

Installation 1) Ensure all timing marks are aligned. See Fig. 2. Install
timing belt. If reusing old timing belt, ensure belt is installed in original
rotating direction.
2) If removed, install timing belt idler pulley spring. Loosen timing belt
idler pulley bolt to allow tension to be applied on timing belt.
3) Temporarily install crankshaft pulley center bolt. Rotate crankshaft
clockwise 2 revolutions, to TDC. Ensure all timing marks are aligned.
4) 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.
5) Remove crankshaft bolt. Install timing belt guide. Install upper, center,
and lower timing belt covers. Install crankshaft pulley. Tighten center bolt
to specification. Install water pump pulley.
6) Install engine mount through-bolt and tighten to specification.
Remove engine support bar. Install valve cover with new gaskets. Apply
GM Sealant (1052917) or equivalent to valve cover mating surfaces.
7) Install accessory drive belts. Adjust drive belts to proper tension. To
install remaining components, reverse removal procedure.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts .......................................................................................... 35 (47)
Crankshaft Pulley Bolt ............................................................................................. 87 (118)
Engine Mount Through-Bolt ...................................................................................... 64 (87)
Timing Belt Idler Pulley Bolt ..................................................................................... 27 (37)
Water Pump Pulley Bolt ............................................................................................ 17 (23)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

Inspection 1) 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 damaged components.
2) Remove spring from timing belt idler pulley. Check free length of belt
tensioner spring. Free length is measured between inside diameters of

Timing Belt Cover Bolt ................................................................................................ 44 (5)

Valve Cover Nut .......................................................................................................... 53 (6)

GEO

288

1.6L 4-Cylinder SOHC Storm

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. SOHC
Storm
1990-93 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

1.5 Hours .. .. TCK177 .. ..... T177

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 30,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) Remove engine mount located at timing belt cover. Rotate crankshaft
and position No. 4 cylinder at TDC of compression stroke. Ensure timing
mark on crankshaft pulley aligns with O timing mark on timing belt
cover. Remove timing belt cover. See Fig. 1.
3) Ensure locating dowel on camshaft sprocket is at 12 oclock position
and timing mark is aligned with cylinder head surface. See Fig. 2.
4) Raise and support vehicle. Remove right side undercover. Remove
crankshaft pulley-to-sprocket bolts. See Fig. 1. Remove crankshaft
pulley.
5) Lower vehicle. Ensure timing mark (notch) on rear of crankshaft
sprocket is aligned with timing mark on oil pump. See Fig. 3. Loosen belt
tensioner bolt 1/2 turn. Rotate belt tensioner and remove timing belt.

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

Inspection Inspect timing belt for damaged teeth, cracking or oil

contamination. 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 1) Rotate camshaft so locating dowel on camshaft
sprocket is at 12 oclock position and timing mark aligns with cylinder
head surface. See Fig. 2.
2) Ensure timing mark (notch) on rear of crankshaft sprocket aligns with
timing mark on oil pump. See Fig. 3. Install timing belt over crankshaft
sprocket, tensioner pulley, water pump and camshaft sprocket. See
Fig. 4.
3) 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.
4) Rotate crankshaft 2 revolutions counterclockwise, and align crankshaft and camshaft timing marks. See Figs. 2 and 3.
5) 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).

Courtesy of General Motors Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

6) 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 camshaft sprocket timing mark with upper surface
of cylinder head.
7) 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. Ensure camshaft sprocket is still
aligned correctly.
8) Install timing belt cover. Install crankshaft pulley. Install engine
undercover. Install right engine mount. Install accessory drive belts.
Adjust drive belts to proper tension.

GEO

289

1.6L 4-Cylinder SOHC Storm (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Power Steering Pump Bolt ....................................................................................... 15 (20)
Timing Belt Tensioner Pulley Bolt ............................................................................. 37 (50)
Water Pump Bolt ....................................................................................................... 18 (25)
Wheel Lug Nut ........................................................................................................ 87 (118)
INCH Lbs. (N.m)
Courtesy of General Motors Corp.

Fig. 3: Locating Crankshaft Sprocket Timing Mark

Courtesy of General Motors Corp.

Fig. 4: Identifying Timing Belt Routing

Courtesy of General Motors Corp.

Fig. 5: Measuring Timing Belt Tension

Crankshaft Pulley-To-Flange Bolt ............................................................................. 89 (10)

Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Bolt ....................................................................................................... 89 (10)

GEO

290

1.6L & 1.8L 4-Cylinder DOHC Prizm

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. DOHC, VIN 6
Prizm (Except GSI)
1989-92 ..............................
1993-97 ..............................
1.8L 4-Cyl. DOHC, VIN 8
Prizm (Except GSI)
1993-97 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.2 Hours .. .. TCK036 .. ..... T036

2.2 Hours .. .. TCK236 .. ..... T236

2.2 Hours .. .. TCK235 .. ..... T235

With Air Conditioning, add .4 hours.

With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be inspected and adjusted at
30,000 mile intervals, and replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

TENSIONER SPRING FREE LENGTH SPECIFICATIONS
Application
Maximum Free Length In. (mm)
1989-92 .......................................................... ................................................... 1.512 (38.4)
1993-94 .......................................................... ................................................... 1.390 (35.3)
1995-97 .......................................................... ................................................... 1.453 (36.9)

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove windshield
washer reservoir.
2) On vehicles equipped with cruise control, remove cruise control
actuator cover. Disconnect cruise control electrical connector and
actuator cable. Remove cruise control actuator from vehicle.
3) On all vehicles, raise and support vehicle. Remove right front wheel.
Remove right wheel housing. Loosen, but do not remove, water pump
pulley bolts.
4) Lower vehicle. Remove accessory drive belts. Disconnect A/C
compressor electrical connector. Remove A/C compressor mounting
bolts. Set compressor aside with hoses attached. Remove mounting
bracket from engine.
5) Remove wiring harness from valve cover. Noting position for reassembly reference, remove spark plug secondary cables from spark
plugs. Remove spark plugs.
6) 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.
7) Using Support Fixture (J028467-A) or equivalent, support engine
from above. Remove engine mount from timing belt end of engine.
Remove water pump pulley.
8) Remove crankshaft pulley. Remove timing belt covers. See Fig. 1.
Noting installed position, remove timing belt guide from crankshaft.
9) Remove timing belt tensioner bolt, tensioner and tensioner spring.
Remove timing belt.
Inspection 1) 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 components if damaged.
2) Check free length of idler pulley spring. Free length is measured
between inside edge of hooked portions of spring (not the coil area). See
Fig. 2. Replace spring if free length is not as specified. See TENSIONER
SPRING FREE LENGTH SPECIFICATIONS table.

Courtesy of General Motors Corp.

Fig. 2: Measuring Timing Belt Tensioner Spring Free Length

Installation 1) 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.
2) 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.
3) Loosen timing belt tensioner bolt and allow tension to be applied on
timing belt. Rotate crankshaft CLOCKWISE 2 revolutions. DO NOT turn
crankshaft counterclockwise. Ensure all timing marks are aligned.
Tighten timing belt tensioner bolts to specification. See TORQUE
SPECIFICATIONS.
4) Measure timing belt deflection at midway point between camshaft and
crankshaft sprockets. See Fig. 4. With 4.4 lbs. (1.9 kg) applied on timing
belt, defection should be .20-.24 (5.1-6.9 mm). If belt deflection is not
within specification, repeat previous step.
CAUTION: Ensure all timing marks are aligned once timing belt is
adjusted.
5) Install timing belt guide with cupped side facing out. Install timing belt
covers, starting with bottom cover. Install crankshaft pulley. Tighten
center bolt to specification.
6) Install water pump pulley. Install engine mount. Install engine ground
wire (if equipped) to right fender apron. Install valve cover with new
gasket. Install spark plugs and spark plug secondary wires.
7) 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.
8) Install cruise control actuator (if equipped). Install windshield washer
reservoir. To install remaining components, reverse removal procedure.
Adjust accessory drive belts to proper tension.

GEO

291

1.6L & 1.8L 4-Cylinder DOHC Prizm (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket-To-Engine Bolt ................................................................. 35 (47)
A/C Compressor-To-Bracket Bolt .............................................................................. 18 (25)
Camshaft Sprocket Bolt ............................................................................................ 43 (59)
Crankshaft Pulley Bolt ............................................................................................. 87 (118)
Timing Belt Tensioner Bolt ........................................................................................ 27 (37)
Water Pump Bolt ....................................................................................................... 11 (15)
Water Pump Pulley Bolt ............................................................................................ 17 (23)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................................................................ 44 (5)
Valve Cover Cap Nuts ................................................................................................ 53 (6)

Courtesy of General Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (Typical)

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Marks & Checking Belt Deflection

GEO

292

1.6L & 1.8L 4-Cylinder DOHC Storm

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. DOHC

Storm
1990-91 ....................................................
1.8L 4-Cyl. DOHC
Asuna Sunfire (Canadian)
1993 ..........................................................
Storm
1992-93 ....................................................
1

Belt
Part No.

2.0 Hours .. ..... T169

2.4 Hours .. ..... T205

2.4 Hours .. ..... T205

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 60,000 mile
intervals.

6) Ensure crankshaft and camshaft timing marks are aligned. 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 1) Ensure all timing marks are aligned. See Fig. 1. Install
timing belt. If reusing old timing belt, ensure belt is installed in original
rotating direction.
2) 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.
3) 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.
4) 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 engine mount.
5) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory
drive belts or serpentine belt. Raise and support vehicle. Remove right
splash shield.
2) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Remove crankshaft pulley.
3) 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.
4) 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.
5) On 1.6L and 1.8L engines, remove engine mount bracket from timing
belt end of engine. Remove timing belt lower cover.

Courtesy of General Motors Corp.

Fig. 2: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 43 (59)
Crankshaft Pulley Center Bolt
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)
Timing Belt Tensioner Pulley Bolt ............................................................................. 31 (42)
Water Pump Bolt
1.6L .......................................................................................................................... 11 (15)
1.8L .......................................................................................................................... 18 (24)
Wheel Lug Nut ........................................................................................................ 87 (118)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Courtesy of General Motors Corp.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

GEO & ISUZU

293

1.5L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.5L 4-Cyl.
I-Mark
1985-87
Thru 6/30/86 .............. ... 1 1.5 Hours ... .. TCK118 ........
From 7/1/86 ............... ... 1 1.5 Hours ... .. TCK118 .. .....
1988-89 ........................ ... 1 1.5 Hours ... .. TCK118 .. .....
Spectrum (Chevrolet)
1985-86 ........................ .. 1, 2 1.5 Hours .. .. TCK118 ........
1987
Thru 4/30/87 .............. . 1, 2, 3 1.5 Hours . .. TCK118 ........
From 5/1/87 ............... . 1, 2, 3 1.5 Hours . .. TCK118 .. .....
1988 .............................. . 1, 2, 3 1.5 Hours . ...... ..... ............
Spectrum (Geo)
1989 .............................. .. 2, 4 1.5 Hours .. ...... ..... ...... .....
Sunburst (Canada)
1985-88 ........................ ... 1 1.5 Hours ... .. TCK118 ........
1

3
4

T118
T162
T162
T118
T118
T162
T118
T162
Courtesy of General Motors Corp.

T118

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.
With Engine removal, Automatic Transmission Non-Turbo,
labor time is 7.7 hours. With Engine removal, Standard Transmission Non-Turbo, labor time is 7.5 hours.
With Engine removal, Turbocharger, labor time is 8.2 hours.
With Air Conditioning, add .4 hours. With Cruise Control, add
.2 hours. With Power Steering, add .4 hours.

Fig. 1: Aligning Crankshaft Sprocket Timing Marks

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of General Motors Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

3) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT & SPROCKETS

Removal 1) Disconnect negative battery cable. Drain cooling system.
Place small piece of wood on jack under oil pan and carefully raise
motor. Remove rear side torque rod and right engine mount. Remove
body side and engine side mounts.
2) Remove drive belts, crank pulley and timing belt cover. Ensure timing
marks are aligned with TDC. Using Crank Holder (J-37376) or equivalent, 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.
3) 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 1) 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. See Fig. 3.
Tighten tensioner bolt, and rotate crankshaft 2 revolutions.
2) 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.

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt ........................................................................................... 108 (147)
Timing Belt Tensioner Bolt ........................................................................................ 37 (50)
Water Pump Bolts ..................................................................................................... 17 (24)
INCH Lbs. (N.m)
Timing Cover Bolts .................................................................................................... 86 (10)

GEO/CHEVROLET

294

1.0L 3-Cylinder
TIMING BELT APPLICATION
Application

1.0L 3-Cyl.
Firefly (Canadian)
1985-88 ...............................
1989-91 ...............................
1994-95 ...............................
1996-00 ...............................
Metro
1989-92 ...............................
1993 ....................................
1993 ....................................
1994-95 ...............................
1996-97 ...............................
1998-00 ...............................
Sprint (Includes Canadian)
1985-88 ...............................
1989-91 ...............................
1
2
3

Labor Time Component

Belt
Kit No.
Part No.

2.2
2.2
2.2
1.8

Hours
Hours
Hours
Hours

... ...... ..... ...... .....

... .. TCK166 .. .....
... .. TCK241 .. .....
.... TCK194A . .....

2.2
2.2
2.2
2.2
2.2
1.8

Hours
Hours
Hours
Hours
Hours
Hours

... .. TCK166
... .. TCK166
... .. TCK241
... .. TCK241
.... TCK194A
.... TCK194A

T095
T166
T241
T194

.. ..... T166
.. ... 2 T166
.. ... 3 T241
.. ..... T241
. ..... T194
. ..... T194

2.2 Hours ... ...... ..... ...... ..... T095

2.2 Hours ... ...... ..... ...... ..... T166

With Air Conditioning, add .4 hours.

Four bolt sprocket.
Five bolt sprocket.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of General Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (1985-97)

Up to 1997 model year, the manufacturer recommends the 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.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner.
Remove A/C suction pipe bracket (if equipped). Raise and support
vehicle. Remove lower right engine undercover. Remove lower generator cover plate. Remove all accessory drive belts.
2) Remove outer bolts retaining crankshaft pulley. Remove crankshaft
pulley. DO NOT remove crankshaft pulley center bolt. Remove wire
harness from timing belt cover.
3) Remove timing belt cover and seal. See Fig. 1 or 2. Rotate crankshaft
and align timing marks. See Fig. 3 or 4. Remove tensioner spring and
tensioner stud. Loosen, but DO NOT remove, tensioner bolt.
4) 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 Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure tensioner rotates freely. Replace damaged components.
CAUTION: Ensure concave side of timing belt guide faces oil
pump. Flat side of timing belt guide goes against crankshaft
sprocket.

Courtesy of General Motors Corp.

Fig. 2: Exploded View Of Timing Belt & Components (1998-00)

GEO/CHEVROLET

295

1.0L 3-Cylinder (Cont.)

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 1) 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.
2) Ensure all timing marks align. See Fig. 3 or 4. 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. 5.
CAUTION: Install timing belt so arrow on timing belt, or mark made
during removal, points in direction of crankshaft rotation. Crankshaft rotates clockwise.
3) 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.
4) 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 tension.

Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks (1985-97)

Courtesy of General Motors Corp.

Fig. 5: Rotating Camshaft & Crankshaft

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Marks (1998-00)

Application
Ft. Lbs. (N.m)
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 Cover Bolt .............................................................................................. 97 (11)
Timing Belt Tensioner Stud ....................................................................................... 97 (11)
Valve Cover Bolt ......................................................................................................... 44 (5)
Water Pump Bolt
1995-97 .................................................................................................................... 97 (11)
1998-00 .................................................................................................................. 115 (13)

GEO/CHEVROLET

296

1.3L 4-Cylinder
TIMING BELT APPLICATION
Application

1.3L 4-Cyl.
Firefly (Canadian)
1995-97 ...............................
1998-00 ...............................
Metro
1992-93 ...............................
1994 ....................................
1995-97 ...............................
1998-01 ...............................
1

Labor Time Component

Belt
Kit No.
Part No.

2.6 Hours ... .. TCK272 .. ..... T272

2.6 Hours ... ...... ..... ...... ..... T194
2.6
2.6
2.6
2.6

Hours
Hours
Hours
Hours

... ...... ..... ...... .....

... ...... ..... ...... .....
... .. TCK272 .. .....
... ...... ..... ...... .....

T095
T243
T272
T194

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of General Motors Corp.

Fig. 2: Locking Flywheel In Position

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Up to 1997 model year, the manufacturer recommends the 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.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right side fender apron extension. Do not push center
pin in too far, as it may fall into fender.
2) 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.
3) Remove timing belt outside cover. Rotate crankshaft to align camshaft and crankshaft timing marks. See Fig. 3 or 4. Loosen tensioner bolt
and stud. Push tensioner plate fully upward and temporarily tighten
tensioner bolt. Remove timing belt from sprockets.

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Marks (1992-97)

Courtesy of General Motors Corp.

Fig. 1: Using Screwdriver To Lock Flywheel

Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components.
NOTE: Ensure tensioner plate moves when tensioner is moved
toward timing belt. If tensioner plate does not move, ensure lug is
engaged in hole on rear of tensioner.
Installation 1) Ensure that tensioner rotates smoothly. Install tensioner plate on tensioner. Lug of tensioner plate must fit in hole of

tensioner. Install tensioner assembly. Hand tighten tensioner bolt. Plate

movement in upward direction should cause tensioner to move in same
direction.
2) 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 clockwise until timing mark on pulley
aligns with V mark on belt inside cover. See Fig. 3.
3) Turn crankshaft pulley bolt clockwise until punch mark on sprocket
aligns with arrow mark on oil pump case. See Fig. 3.
4) 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.
5) On 1998-01 models, ensure camshaft and crankshaft timing marks
are still aligned. See Fig. 4. If timing marks are not aligned, rotate
camshaft or crankshaft to align timing marks. DO NOT rotate camshaft

GEO/CHEVROLET

297

1.3L 4-Cylinder (Cont.)

Courtesy of General Motors Corp.

Fig. 5: Identifying Water Pump-To-Oil Case Seal

Courtesy of General Motors Corp.

Courtesy of General Motors Corp.

Fig. 4: Identifying Timing Marks (1998-01)

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.
6) Turn crankshaft 2 rotations clockwise to take up slack. Ensure timing
marks are still aligned. Tighten tensioner adjustment stud nut and
tensioner bolt. Ensure seal is between water pump and oil pump case.
See Fig. 5. Install timing belt outside cover.
7) On 1992-97 models, rotate crankshaft to position camshaft lobe and
rocker arm to adjust valve lash. See Fig. 6. Ensure clearance is .010
(.25 mm) at intake valves, and .011 (.28 mm) at exhaust valves. To
adjust clearance, turn adjusting screw until correct clearance is
obtained. Tighten lock nut to 11-13.5 ft. lbs. (15-18 N.m).
8) On all models, to complete installation, reverse removal procedure.
Adjust drive belts to proper tension.

Fig. 6: Adjusting Valve Lash (1992-97)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt (1998-01) .............................................................................. 12 (16)
Crankshaft Sprocket Bolt
1992-97 .................................................................................................................. 79 (110)
1998-01 .................................................................................................................. 96 (130)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Valve Adjustment Lock Nut ............................................................................. 11-13 (15-18)
Water Pump Pulley Bolt ............................................................................................ 18 (24)
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)

GEO/CHEVROLET

298

1.6L 4-Cylinder Tracker, 8-Valve

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. SOHC, VIN U

Tracker & Sunrunner (Asuna & Pontiac, Canada)
1989-95 .............................. 1 3.6 Hours .. .. TCK164 .. ..... T164
1

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Courtesy of General Motors Corp.

Fig. 2: Locking Camshaft During Sprocket Removal

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory
drive belts. Remove cooling fan, fan shroud and water pump pulley.
Remove outer bolts retaining crankshaft pulley.
2) Remove 5 crankshaft pulley-to-sprocket bolts. Remove crankshaft
pulley. DO NOT remove center bolt from crankshaft pulley. The center
bolt holds crankshaft sprocket to crankshaft.
3) Remove timing belt cover and seal. See Fig. 1. Loosen tensioner
stud, and remove tensioner spring from tensioner plate and tensioner
screw.
4) If reusing timing belt, mark timing belt with arrow to indicate rotation
direction. Remove timing belt.

Inspection Inspect timing belt for damaged teeth or cracking. Ensure

timing belt is not contaminated with oil. Check tensioner for freedom of
rotation. Replace components if damaged.
Installation 1) 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
toward timing belt. If tensioner plate does not move, ensure lug
engages in tensioner bolt.
2) 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.
3) Rotate crankshaft clockwise, and align timing mark on crankshaft
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 crankshaft rotation. Ensure no slack exists on side of
timing belt opposite tensioner.
4) 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.
5) Ensure camshaft and crankshaft timing marks are still aligned.
Tighten tensioner stud to specification. Tighten tensioner bolt to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks
align.
6) Adjust valve lash between rocker arm adjusting screw and valve
stem. See VALVE LASH SPECIFICATIONS table. Turn crankshaft 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.
7) Adjust valve lash on No. 1 and No. 2 intake valves. Adjust valve lash
on No. 1 and No. 3 exhaust valves. Rotate crankshaft one full revolution
(360 degrees). Adjust remaining intake and exhaust valves.
8) Install timing belt cover. Install crankshaft pulley. To complete
installation, reverse removal procedures. Adjust drive belts to proper
tension.
VALVE LASH SPECIFICATIONS
Valve
Clearance (Cold) In. (mm)
Clearance (Hot) In. (mm)
Intake ................ ............ .051-.067 (.13-.17) ............ ........................... .009-.011 (.23-.27)
Exhaust ............. .......... .0063-.0075 (.15-.19) .......... ....................... .0102-.0114 (.25-.29)

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

GEO/CHEVROLET

299

1.6L 4-Cylinder Tracker, 8-Valve (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Valve Adjusting Screw Locknut ................................................................................. 13 (17)
INCH Lbs. (N.m)
Fan Clutch Nuts ........................................................................................................ 97 (11)
Tensioner Stud .......................................................................................................... 97 (11)
Timing Belt Cover Bolt .............................................................................................. 97 (11)
Valve Cover Bolt ......................................................................................................... 44 (5)
Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks

GEO/CHEVROLET

300

1.6L 4-Cylinder Tracker, 16-Valve

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. SOHC, VIN 6

Tracker & Sunrunner (Canadian)
1994-02 .............................. 1 4.0 Hours .. .. TCK212 .. ...
1

T212

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 60,000 mile
intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove cooling fan
nuts and fan shroud fasteners. Remove accessory drive belts.
2) 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. Remove crankshaft pulley. DO NOT
remove center bolt from crankshaft pulley. The center bolt holds
crankshaft sprocket to crankshaft.

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

NOTE: It may be necessary to drain cooling system and disconnect

upper radiator hose to remove fan shroud.
3) 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.
4) Disconnect wiring harness from timing belt cover. Remove timing belt
cover. See Fig. 1.
5) Rotate crankshaft clockwise to align crankshaft and camshaft timing
marks. Stamped E on camshaft sprocket must face up and align with
mark on rear cover. See Fig. 2.
6) Loosen timing belt tensioner pulley center bolt and stud nut. See
Fig. 3. Remove tensioner spring. Push tensioner plate upward to relieve
tension on timing belt.
7) If reusing old timing belt, mark belt with arrow to indicate 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 Inspect timing belt for damaged teeth or cracking. Ensure
timing belt is not contaminated with oil. Check tensioner for freedom of
rotation. Replace components if damaged.
Installation 1) 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.
2) Ensure camshaft and crankshaft timing marks are still aligned. Install
timing belt. If reusing old belt, ensure it is installed in original rotation
direction.
3) Loosen timing belt tensioner bolt and nut so it places tension on belt.
Rotate crankshaft clockwise 2 revolutions. Ensure timing marks still
align. See Fig. 2.
4) Tighten tensioner stud nut and tensioner pulley bolt to specification.
See TORQUE SPECIFICATIONS. Install timing belt cover.
5) To complete installation, reverse removal procedures. Adjust drive
belts to proper tension. If cooling system was drained, refill and bleed air
from system.

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Marks

GEO/CHEVROLET

301

1.6L 4-Cylinder Tracker, 16-Valve (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 44 (60)
Crankshaft Pulley Center Bolt ................................................................................ 81 (110)
Crankshaft Pulley-To-Crankshaft Bolt ....................................................................... 12 (16)
Front Skid Plate Bolt ................................................................................................. 40 (55)
Power Steering Pump Mounting Bolt ....................................................................... 21 (29)
Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
INCH Lbs. (N.m)
Cooling Fan-To-Pulley Nut ........................................................................................ 97 (11)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11)

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Tensioner Assembly

HONDA

302

1.2L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

1.2L 4-Cyl.
Civic
1974 ..........................................................
1975-79 ....................................................

1
2

Belt
Part No.

1.5 Hours .. ..... T028

2.0 Hours .. ..... T028

With Air Conditioning, add .9 hours.

With Air Conditioning, add .4 hours. Where Cruise Control
interferes, add .3 hours. Where Power Steering Interferes, add
.3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove wheelwell
splash shield. Remove air conditioning compressor adjustment pulley,
complete with bracket drive belt. Remove remaining accessory drive
belt(s). Remove valve cover. Remove water pump pulley and crankshaft
pulley. See Fig. 2. Ensure that cylinder No. 1 is at TDC of compression
stroke and camshaft is aligned with mark. See Fig. 3.
2) Remove upper timing belt cover from cylinder head. Remove 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
excessively 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.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Camshaft Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Pulley Bolt .......................................................................................................... 17 (23)
Alternator
Adjustment Bolt ....................................................................................................... 17 (23)
Through-Bolt ............................................................................................................ 33 (45)
Crankshaft Pulley Bolt ............................................................................................... 61 (81)
Engine Support Bolts/Nut .......................................................................................... 40 (55)
Side Bracket .............................................................................................................. 33 (45)
Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover .................................................................................................... 84 (9.7)
Valve Cover .............................................................................................................. 84 (9.7)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

HONDA

303

1.3L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

1.3L 4-Cyl.
Civic
1980-83
Canada .......................... ...
US .................................. ...
1984-85 ............................ ...
1986-87 ............................ ...
Civic CRX
1984 ................................. ...
1

2.0
2.0
2.0
1
2.0
1
1

Hrs.
Hrs.
Hrs.
Hrs.

Component
Belt
Kit No.
Part No.

... ...... ..... ...... .....

... ...... ..... ...... .....
..... 2521610 .. .....
..... 2521610 .. .....

T028
T073
T099
T161

2.0 Hrs. ..... 2521610 .. ..... T099

With Air Conditioning, add .4 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components (1980-83)

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove wheelwell
splash shield. Remove A/C compressor or adjusting pulley and bracket.
Remove A/C belt. Remove accessory drive belts. Remove engine
support bolts and nut. Remove side mount rubber. Rotate crankshaft
counterclockwise to position No. 1 cylinder to TDC of compression
stroke.
2) Remove engine valve cover and upper timing belt cover. See Fig. 1
or 3. Ensure camshaft timing marks are aligned with valve cover
surface, and UP or ROUND mark is upward. See Fig. 4 or 5.
3) Remove crankshaft pulley. Remove lower timing belt cover from
engine block. Loosen timing belt tensioner to relieve timing belt tension.
4) 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 1) 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 Fig. 4 or 5.
CAUTION: Belt tension must be adjusted when engine temperature
is cold.
2) 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 counterclockwise 3 teeth on camshaft
pulley to create tension on belt. Tighten tensioner adjustment bolt to
specification. See TORQUE SPECIFICATIONS.
3) Install washer on crankshaft bolt with flat side toward the pulley. See
Fig. 1 or 3. Tighten retaining bolt to specification. Reverse removal
procedure to complete installation. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS. Valve cover bolts must be tightened in
proper sequence. See Fig. 2. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying Valve Cover Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Adjustment Bolt ........................................................................................ 17 (23)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Pulley Bolt ................................................................................................. 27 (37)
Crankshaft Pulley Bolt
1980-83 .................................................................................................................... 61 (81)
1984-87 .................................................................................................................. 83 (112)
Timing Belt Adjuster Bolt .......................................................................................... 35 (48)
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)

304

HONDA
1.3L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1984-87)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Marks (1980-83)

HONDA

305

1.3L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (1984-87)

HONDA

306

1.5L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

1.5L 4-Cyl.
Civic CVCC
1975 ................................. .....
1976-79 ............................ .....
Civic
1980-83 ............................ .....
1984-85 ............................ .....
1986-87 ............................ .....
1988-95 ............................ .....
Civic CRX
1984-85 ............................ .....
1986-87 ............................ .....
Civic VX
1992-95 ............................ .....
Civic Del Sol
1993-95
Exc. VX .......................... .....
VX .................................. .....
1

2.0 Hrs ..... ...... ..... ...... ..... T036

2.0 Hrs ..... .. TCK041 .. ..... T041
2.0
2.0
2.0
2.0

Hrs
Hrs
Hrs
Hrs

..... ...... ..... ...... .....

..... .. TCK161 .. .....
..... .. TCK161 .. .....
..... .. TCK143 .. .....

T041
T099
T161
T143

2.0 Hrs ..... .. TCK161 .. ..... T099

2.0 Hrs ..... .. TCK161 .. ..... T161
2.0 Hrs ..... ...... ..... ...... ..... T223

2.0 Hrs ..... .. TCK143 .. ..... T143

2.0 Hrs ..... ...... ..... ...... ..... T223

With Air Conditioning, add .4 hours. With Power Steering, add

.3 hours. Where Cruise Control interferes, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific 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 models, the manufacturer recommends the belt be replaced at
90,000 mile intervals for normal service and 60,000 miles for severe
service.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (1975-79) Disconnect negative battery cable. Remove
wheelwell 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 crankshaft 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.
Installation (1975-79) Ensure camshaft and crankshaft timing marks
are still aligned. See Figs. 1 and 2. Reverse removal procedure, using
care not to excessively twist or bend belt. Adjust drive belts to proper
tension.
Removal (1980-95) 1) Disconnect negative battery cable. Rotate
crankshaft counterclockwise 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 pulley bracket and belt.
Remove alternator belt. Remove power steering pump bracket.
2) 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.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt Components (1975-83)

3) Remove valve cover. Remove upper timing belt cover. Remove
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 Fig. 1, 3 or 4.
Installation (1980-95) 1) Ensure No. 1 cylinder is at TDC of
compression stroke. 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 timing mark
aligns with pointer on lower timing belt cover. See Fig. 2, 5, 6, 7 or 8.
2) 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. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT ADJUSTMENT

CAUTION: Always adjust timing belt tension with engine cold.
1) Remove cylinder head cover. Remove upper timing belt cover. Rotate
crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Loosen but do not remove, timing belt adjuster bolt. See
Fig. 9.
2) 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 TORQUE SPECIFICATIONS.

HONDA

307

1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks (1975-83)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt Components (1984-91)

308

HONDA
1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Exploded View Of Timing Belt Components (1992-95)

HONDA

309

1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (1984-87)

310

HONDA
1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Aligning Timing Marks (1988-91 Dual Point Injection)

HONDA

311

1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Timing Marks (1988-91 Civic Si &

4WD Civic Wagon Multipoint Injection)

Fig. 9: Locating Timing Belt Adjuster Bolt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt
SOHC
1975-79 .................................................................................................................. 22 (30)
1980-95 .................................................................................................................. 28 (33)
Crankshaft Pulley Bolt 1
SOHC ................................................................................................................... 134 (185)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
Timing Belt Adjuster Bolt .......................................................................................... 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
1

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Timing Marks (1992-95)

Lubricate bolt threads. Do not lubricate washer or washer mating surface of bolt.

HONDA

312

1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION
1

Application
1.6L 4-Cyl. DOHC
Civic
1999-00 ..............................
Civic Del Sol
1994-97 ..............................
1

Labor Time Component

Belt
Kit No.
Part No.

2.0 Hours .. .. TCK227 .. ..... T227

2.0 Hours .. .. TCK227 .. ..... T227

With Air Conditioning, add .4 hours. With Power Steering, add

.3 hours.
With Cruise Control, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1994 vehicles, the manufacturer recommends the belt be replaced
at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends
the belt be replaced at 90,000 miles for normal service and 60,000 miles
for severe service. 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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 counterclockwise to TDC of compression stroke. See Fig. 1.
2) Use jack to support engine. Working from front of engine, remove
engine mount bracket nuts and bracket. Remove power steering pump
lower bracket and heat shield from engine. Remove the crankshaft
pulley.
3) Remove valve cover. Remove middle and lower covers. See Fig. 2.
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.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Setting Crankshaft Pulley to TDC

Installation 1) 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. 3. Set intake and exhaust camshaft pulleys to TDC.
The TDC marks should align with each other with UP marks pointing
up. See Fig. 3.
2) Install timing belt in this sequence: timing belt drive pulley, tension
adjusting pulley, water pump pulley, intake camshaft 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.
3) Loosen and retighten adjusting bolt to tension timing belt. Install lower
and middle covers. Install crankshaft pulley. Tighten pulley bolt to
specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys.
CAUTION: Always adjust timing belt tension with engine cold.
4) To adjust timing belt tension, set No. 1 piston at TDC (White TDC
mark on crankshaft pulley aligned with pointer on cover). See Fig. 1.
Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise
3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque
crankshaft pulley bolt.
5) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If
not, timing belt will need to be removed and repositioned. To complete
installation, reverse removal procedure. When installing valve cover
gasket, apply liquid gasket to 8 corners where gasket meets camshafts.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 33 (44)
Alternator Mount Bolt ................................................................................................ 33 (45)
Camshaft Pulley Center Bolt .................................................................................... 41 (56)
Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177)
Engine Mount Bracket Nuts ...................................................................................... 54 (74)
Engine Mount Bracket-To-Engine Bolts .................................................................... 40 (54)
Power Steering Pump Bracket Bolt .......................................................................... 33 (44)
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)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nuts 2 .................................................................................................... 89 (10)
Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106 (12)
1
2

Lubricate bolt threads and bottom shoulder of bolt head.

Tighten nuts in 2-3 steps, starting from center outward.

HONDA

313

1.6L 4-Cylinder DOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

Fig. 4: Identifying Timing Belt Installation Sequence

HONDA

314

1.6L 4-Cylinder SOHC, 1976-95

TIMING BELT APPLICATION
Application

1.6L 4-Cyl.
Accord (Includes Canadian)
1976-78 ...............................
1979-83 ...............................
Civic
1988-91 .............................
1992
Except Si ..........................
Si .......................................
1993-95 ...............................
Civic del Sol
1993-95 ...............................
Civic CRX
1988-91 ...............................
Prelude
1980-82
Canada .............................
USA ...................................
1

Labor Time Component

Belt
Kit No.
Part No.

2.0 Hours ... .. TCK041 .. ..... T041

2.0 Hours ... ...... ..... ...... ..... T041
2.0 Hours ... .. TCK145 .. ..... T145
2.0 Hours ... .. TCK145 .. ..... T145
2.0 Hours ... .. TCK224 .. ..... T224
2.0 Hours ... .. TCK224 .. ..... T224
2.0 Hours ... .. TCK224 .. ..... T224
2.0 Hours ... .. TCK145 .. ..... T145

2.1 Hours ... ...... ..... ...... ..... T041

2.0 Hours ... ...... ..... ...... ..... T041

With Air Conditioning, add .4 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Locating Timing Belt Adjuster Bolt

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval for 1976-89 models, belt manufacturers suggest
the belt be replaced at 60,000 mile intervals. On 1990-94 models,
normal replacement interval is at 90,000 miles. For 1995 models,
recommended replacement interval is 90,000 for normal service and
60,000 for severe service.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

TIMING BELT
Removal 1) Disconnect battery negative cable. Rotate crankshaft
counterclockwise until No. 1 cylinder is at TDC of compression stroke.
Remove wheelwell splash shield. Remove power steering pump if
necessary, leaving hoses attached.
2) Remove A/C belt idler pulley bracket if necessary, and belt. Remove
alternator belt. Remove power steering pump bracket if necessary.
Remove water pump pulley if not cam-driven. Remove cruise control
actuator (if equipped).
3) Remove power steering reservoir bracket if necessary. Use jack to
support engine, and then remove engine mount nuts. Loosen engine
mount bolt. Pivot side engine mount-cushion aside.
CAUTION: Crankshaft pulley bolt may stick to the crankshaft
threads when properly torqued. A properly torqued pulley bolt may
require up to two or three times the installation torque to remove.
4) Remove valve cover. Remove upper timing belt cover. Insert the
appropriate crank pulley holder into the pulley. Support crank pulley
holder handle with a jack stand or transmission jack to get the weight of

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

(Accord & Prelude)
the car working for you. Use a high-strength, long-handled, breaker bar
with an impact socket to remove the bolt (which has right-hand threads).
Remove crankshaft pulley.

HONDA

315

1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1992-95 Civic)

5) Remove lower timing belt cover bolts and timing belt cover. Remove
crankshaft position sensor from oil pump (if equipped). Loosen tension
adjuster bolt pivot bolt 180 degrees (if equipped). Loosen timing belt
tension adjuster bolt 180 degrees. See Fig. 1. 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. 2 and 3.
Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke.
On Civic models, crankshaft keyway will be at 12 oclock position, and
sprocket groove or mark will align with pointer on oil pump housing. See
Fig. 4. On Accord and Prelude models, pointer on crankcase will align
with marks on flywheel. See Fig. 5 or 6.

2) Install timing belt onto crankshaft pulley, tension adjuster pulley, water
pump pulley (if cam-driven), and camshaft sprocket. DO NOT bend or
twist belt excessively. Take note of spacer installation. See Figs. 2 and 3.
Ensure arrow on used belt points in original rotation direction. Ensure
crankshaft and camshaft timing marks are still aligned.
3) 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. Ensure beveled edge of crankshaft pulley is
away from pulley surface. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension.

316

HONDA
1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (Civic)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Aligning Crankshaft & Camshaft Timing Marks (Prelude)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks (Accord)

HONDA

317

1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

TIMING BELT ADJUSTMENT
1) Remove valve cover. Remove upper timing belt cover. Rotate
crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove timing belt tensioner adjustment bolt access
plug(s) in lower timing belt cover. Loosen but do not remove, timing belt
adjuster bolt. See Figs. 1 and 2.
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 loosened during crankshaft rotation. See
TORQUE SPECIFICATIONS.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt
Accord & Prelude .................................................................................................... 22 (30)
Civic, Civic del Sol & Civic CRX ............................................................................ 27 (38)
Crankshaft Pulley Bolt 1
1976-78 Accord ........................................................................... ................. 58-65 (79-88)
1979-83 Accord & 1980-82 Prelude ........................................... .......................... 83 (115)
1988 Civic & Civic CRX ....................................................................................... 83 (115)
1989-91 Civic & Civic CRX ................................................................................ 119 (165)
1992-95 Civic & Civic del Sol ............................................................................ 134 (185)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
Timing Belt Adjuster Bolt
1976-78 Accord 2 ......................................................................... ................. 29-33 (39-45)
1979-83 Accord & 1980-82 Prelude 2 ..................................................................... 22 (30)
1988-95 Civic, Civic del Sol & Civic CRX ............................................................. 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt
Accord & Prelude .................................................................................................. 108 (12)
1
2

Lubricate bolt threads but do not lubricate washer or mating surface of bolt.
Pivot bolt and adjuster bolt.

HONDA

318

1.6L 4-Cylinder SOHC, 1996-00

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. SOHC

Civic
1996-00 ..............................
Civic Del Sol
1996-97 ..............................

2.0 Hours .. .. TCK224 .. ..... T224

2.0 Hours .. .. TCK224 .. ..... T224

Component
Belt
Kit No.
Part No.

With Air Conditioning, add .4 hours. With Power Steering, add

.3 hours. With Cruise Control, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1996 vehicles, manufacturer recommends replacing belt at 90,000
miles for normal service and 60,000 miles for severe service. 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine lower
splash shield. Remove power steering, alternator, and A/C compressor
drive belts. Rotate crankshaft counterclockwise to TDC of compression
stroke. See Fig. 1.
2) 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.
3) Use jack to support engine. Working from front of engine, remove
engine mount bracket nuts. Remove crankshaft pulley. Remove lower
cover and dipstick tube.

4) 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. 2.
Inspection 1) Inspect timing belt tensioner pulley for worn bearing.
Replace as necessary.
NOTE: The following revised timing belt tensioner information is
from Honda technical service bulletin 96-057; August 4, 1998.
2) 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 available for all 1996, 1997 and some 1998 engines.
3) The timing belt tensioner kit is available under part number
14520-P2A-305.
Installation 1) 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. 3.
2) Set camshaft pulley to TDC. TDC marks should align with top surface
of cylinder head. See Fig. 4.
3) 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 direction. Ensure crankshaft and camshaft pulley timing
mark are aligned with TDC marks.
4) Loosen and retighten adjusting bolt to tension timing belt. Install lower
cover. Install crankshaft pulley. Tighten pulley bolt to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys.
CAUTION: Always adjust timing belt tension with engine cold.
5) 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. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary,
retorque crankshaft pulley bolt.
6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If
not, timing belt will need to be removed and repositioned. To complete
installation, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

HONDA

319

1.6L 4-Cylinder SOHC, 1996-00 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

HONDA

320

1.6L 4-Cylinder SOHC, 1996-00 (Cont.)

TORQUE SPECIFICATIONS
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 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)
Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft TDC Mark & Oil Pump Mark

CKF Sensor Bolt ..................................................................................................... 106

Engine Lower Splash Shield ..................................................................................... 89
Timing Belt Cover Bolt .............................................................................................. 89
Water Pump Bolt ..................................................................................................... 106
1

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Bolt

Lubricate bolt threads and bolt head shoulder.

(12)
(10)
(10)
(12)

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321

1.7L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application
1.7L 4-Cyl. SOHC
Civic
2001-04 ....................................................
1

Labor Time

Belt
Part No.

2.7 Hours .. ..... T312

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Normal replacement interval is at 110,000 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine lower
splash shield. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. Remove front wheels. Remove splash shield.
Remove power steering adjusting plate mounting bolts and lock nut,
then remove power steering pump belt and pump without disconnecting
hoses. Remove alternator.
2) Remove four (4) ignition coils, throttle cable clamps and harness
holder from cylinder head cover. Remove cylinder head cover. See
Fig. 2.
3) Holding crankshaft pulley with Holder Handle (07JAB-001020A) and
Holder Attachment (07MAB-PY3010A), 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.
4) Remove grommet from upper timing belt cover, and disconnect TDC
sensor connector. Remove both upper and lower timing belt covers. See
Fig. 4.
5) Remove side engine mount bracket. Remove CKP sensor from oil
pump without disconnecting connector. See Fig. 5. Check autotensioner before removing belt. Apply a force of 22 ft. lbs. (98 N.m) to

timing belt between camshaft pulley and water pump pulley. Autotensioner should move smoothly. Replace auto-tensioner if it does not
move smoothly. Using socket on small allen at side of auto-tensioner,
move auto tensioner to remove tension from timing belt, and remove
timing belt. See Fig. 6.
Installation 1) Clean timing belt pulleys and covers. 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. 7.
2) Set camshaft pulley to TDC. TDC marks should align with top surface
of cylinder head. See Fig. 8.
3) Install timing belt counterclockwise in this sequence: timing belt drive
pulley, 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. Ensure crankshaft and camshaft
pulley timing marks are aligned with TDC marks.
4) Install CKP sensor, side engine mount bracket, lower timing belt
cover, and crankshaft pulley. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.
5) Turn crankshaft pulley so No. 1 piston is at TDC (White TDC mark on
crankshaft pulley aligns with pointer on cover). See Fig. 1.
6) Ensure camshaft pulley marks are aligned at TDC. See Fig. 8. If not,
timing belt will need to be removed and repositioned. To complete
installation, reverse removal procedure. Tighten all nuts and bolts to
specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Crankshaft Pulley TDC Marks

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322

1.7L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Removing Crankshaft Pulley

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing Timing Belt Covers

HONDA

323

1.7L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Removing CKP Sensor From Oil Pump

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Camshaft TDC Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Removing Tension From Timing Belt

Courtesy of American Honda Motor Co., Inc.

Fig. 9: Identifying Timing Belt Installation Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Crankshaft TDC Mark & Oil Pump Mark

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)
Auto Tensioner Mounting Bolt ................................................................................... 33 (44)
Camshaft Pulley Center Bolt .................................................................................... 27 (37)
Crankshaft Pulley Bolt 1
Step 1 .................................................................................................................. 181 (245)
Step 2 .......................................................................................... ........ Plus 90 Clockwise
Engine Side Mount Bracket Nuts ............................................................................. 33 (44)
Engine Upper Bracket Nuts ...................................................................................... 40 (54)
Power Steering Pump Bracket Bolt .......................................................................... 17 (24)
Power Steering Pump Lock Bolt .............................................................................. 17 (24)
INCH Lbs. (N.m)
CKP Sensor Bolt ..................................................................................................... 106
Engine Lower Splash Shield ..................................................................................... 89
Harness Holder & Cable Clamps ............................................................................. 89
Timing Belt Cover Bolt .............................................................................................. 89
Water Pump Bolt ..................................................................................................... 106
1

Lubricate bolt threads and bolt head shoulder.

(12)
(10)
(10)
(10)
(12)

HONDA

324

1.8L 4-Cylinder
TIMING BELT APPLICATION
Application
1.8L 4-Cyl.
Accord
1979-83
1984-85
Prelude
1979-82
1983-85
1986-87
1

Labor Time

............................ ...
............................ ...

............................ ...
............................ ...
............................ ...

Component
Belt
Kit No.
Part No.

2.0 Hrs. ... ...... ..... ...... ..... T041

2.0 Hrs. ... .. TCK160 .. ..... T094

2.0 Hrs. ... ...... ..... ...... ..... T041

2.0 Hrs. ... .. TCK160 .. ..... T094
1
2.0 Hrs. ... .. TCK160 .. ..... T160
1

With Air Conditioning, add .4 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

(1979-83 Accord & 1979-82 Prelude)

TIMING BELT
Removal (1979-83 Accord & 1979-82 Prelude) 1) Disconnect
negative battery cable. Remove engine support bolts and nuts. Remove
side rubber mount. Remove side mount bracket. Remove cruise control
actuator. Remove engine splash guard. Remove water pump drive belt,
water pump pulley and crankshaft pulley. See Fig. 1. Remove alternator,
belt, A/C compressor and belt.
CAUTION: Crankshaft pulley bolt may stick to the crankshaft
threads when properly torqued. A properly torqued pulley bolt may
require up to two or three times the installation torque to remove.
2) Remove valve cover. Ensure cylinder No. 1 is at TDC of compression
stroke and camshaft is aligned to mark. See Fig. 2. Remove upper
timing belt cover from cylinder head. Remove crankshaft pulley.
Remove lower timing belt cover from engine block. Loosen, but do not
remove, timing belt adjusting and pivot bolts. If reusing belt, mark
direction of belt rotation. Slide belt off pulleys.
Inspection (1979-83 Accord & 1979-82 Prelude) Inspect timing belt
for wear or 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 (1979-83 Accord & 1979-82 Prelude) To install, reverse
removal procedure, using care not to excessively bend or twist belt. If
reinstalling old belt, install belt so same direction of rotation will be
maintained. Adjust drive belts to proper tension.
Removal (1984-85 Accord & 1983-87 Prelude) 1) Disconnect
negative battery cable. Remove engine support bolts and nuts. Remove
side rubber mount. Remove side mount bracket. Remove cruise control
actuator. Remove engine splash guard. Remove water pump drive belt,
water pump pulley. Remove alternator, belt, A/C compressor and belt.
Rotate crankshaft counterclockwise to position No. 1 cylinder to TDC of
compression stroke. Remove all drive belts.
2) Remove engine valve cover and upper timing belt cover. See Fig. 1
or 3. Ensure camshaft timing marks are aligned with valve cover
surface, and UP or ROUND mark is upward. See Fig. 2, 4 or 5.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

(1979-83 Accord & 1979-82 Prelude)

HONDA

325

1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1984-85 Accord & 1983-87 Prelude)
CAUTION: Crankshaft pulley bolt may stick to the crankshaft
threads when properly torqued. A properly torqued pulley bolt may
require up to two or three times the installation torque to remove.
3) Remove crankshaft pulley. Remove lower timing belt cover from
engine block. Loosen timing belt tensioner to relieve timing belt tension.
4) If timing belt is being reused, mark direction of belt rotation before
removing. Remove timing belt from camshaft and crankshaft gears.
Inspection (1984-85 Accord & 1983-87 Prelude) Inspect timing belt
for wear or 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 (1984-85 Accord & 1983-87 Prelude) 1) Ensure cylinder

No. 1 is at TDC of compression stroke. Ensure camshaft timing marks
are aligned with valve cover surface, and UP or ROUND mark is
upward. See Fig. 2, 4 or 5.
2) 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 counterclockwise 3 teeth on camshaft
pulley to create tension on belt. Tighten tensioner adjustment bolt to
specification. See TORQUE SPECIFICATIONS.

HONDA

326

1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

(1984-85 Accord)
CAUTION: Belt tension must be adjusted when engine temperature
is cold.
3) Install washer on crankshaft bolt with flat side toward the pulley.
Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS.
Reverse removal 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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt
1979-83 Accord & 1980-82 Prelude ....................................................................... 22 (23)
1984-85 Accord & 1983-87 Prelude ....................................................................... 27 (37)
Crankshaft Pulley Bolt 1 .......................................................................................... 83 (115)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
Timing Belt Adjuster Bolt
1979-83 Accord & 1980-82 Prelude 2 ..................................................................... 22 (23)
1984-85 Accord & 1983-87 Prelude ....................................................................... 31 (42)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
1
2

Lubricate bolt threads but do not lubricate washer or mating surface of bolt.
Pivot bolt and adjuster bolt.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

(1983-87 Prelude)

HONDA

327

2.0L 4-Cylinder CR-V

TIMING BELT APPLICATION
Application

Labor Time

2.0L 4-Cyl.
CR-V
1997-01 ..............................
1

Component
Belt
Kit No.
Part No.

2.7 Hours .. .. TCK184 .. ..... T184

With Air Conditioning, add .3 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

Installation 1) 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. 3.
2) Set intake and exhaust camshaft pulleys to TDC. The TDC marks
should align with cylinder head surface with UP marks pointing up. See
Fig. 3.
3) Install timing belt in this sequence: timing belt drive pulley, tension
adjusting pulley, water pump pulley, exhaust camshaft 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 crankshaft and camshaft pulleys remained aligned with TDC marks.
4) Loosen and retighten adjusting bolt to tension timing belt. Install lower
and middle covers. Install crankshaft pulley. Tighten pulley bolt to
specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.
5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC
mark on crankshaft pulley aligned with pointer on cover). See Fig. 1.
Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise
3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque
crankshaft pulley bolt.
6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If
not, timing belt will need to be removed and repositioned.
7) To complete installation, reverse removal procedure. When installing
cylinder head cover gasket, apply liquid gasket (Part No. 08718-0001 or
-0003) to 8 corners where gasket meets camshafts. Tighten fasteners to
specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

TIMING BELT
Removal 1) Disconnect battery negative cable. Remove engine guard
bar and lower splash shield. Remove power steering, alternator, 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 counterclockwise to TDC of compression stroke. See Fig. 1.
2) Use jack to support engine. Working from front of engine, remove
engine mount bracket nuts and bracket. Remove the crankshaft pulley.
3) Remove cylinder head cover. Remove middle and lower covers. See
Fig. 2. 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.

Application
Ft. Lbs. (N.m)
A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 33 (44)
Alternator Adjusting Lock Nut ................................................................................... 17 (24)
Alternator Mount Bolt ................................................................................................ 33 (45)
Camshaft Pulley Center Bolt .................................................................................... 27 (37)
Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177)
Engine Mount Bracket Nuts ...................................................................................... 54 (74)
Engine Underguard Bar Bolts ................................................................................... 17 (24)
Power Steering Pump Bracket Bolt .......................................................................... 33 (44)
Power Steering Pump Lock Bolt .............................................................................. 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
Engine Lower Splash Shield ..................................................................................... 89
Timing Belt Cover Bolt .............................................................................................. 89
Water Pump Bolt ..................................................................................................... 106
1
2

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Setting Crankshaft Pulley To TDC

Lubricate bolt threads and bottom shoulder of bolt head.

Tighten nuts in 2-3 steps, starting from center outward.

(10)
(10)
(10)
(12)

HONDA

328

2.0L 4-Cylinder CR-V (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

HONDA

329

2.0L 4-Cylinder SOHC Accord & Prelude

TIMING BELT APPLICATION
Application

Labor Time

2.0L 4-Cyl. SOHC

Accord
1986-89 ............................ ...
Prelude
1985 ................................. ...
1986-87 ............................ ...
1988-90 ............................ ...
1

Component
Belt
Kit No.
Part No.

2.7 Hrs. ... .. TCK160 .. ..... T160

2.7 Hrs. ... .. TCK160 .. ..... T094

2.7 Hrs. ... .. TCK160 .. ..... T160
1
2.7 Hrs. ... ...... ..... ...... ..... T144
1

With Air Conditioning, add .3 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

(Except 1988-90 Prelude)

TIMING BELT
Removal (Except 1988-90 Prelude) 1) Disconnect negative battery
cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC
of compression stroke. Remove drive belts. Remove left engine mount
bolts/nuts, engine mount and bracket. Remove cruise control actuator (if
equipped).
2) Remove 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. 1. Ensure
timing marks align and UP mark is facing upward. See Fig. 2.
3) Remove crankshaft pulley. Remove lower timing belt cover. If timing
belt is going to be reused, mark belt rotation direction before removing.
Loosen timing belt tensioner adjustment bolt. Push tensioner to release
belt tension, retighten adjustment bolt. Remove timing belt.
Inspection (Except 1988-90 Prelude) Inspect timing belt for wear
and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear. Inspect water pump for excessive
bearing play or coolant leakage. Replace as necessary.
Installation (Except 1988-90 Prelude) 1) 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.
2) Adjust timing belt tension by rotating crankshaft counterclockwise
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 camshaft pulley to create tension on timing belt. Tighten
adjustment bolt to specification. See TORQUE SPECIFICATIONS.
3) Apply non-hardening sealant to rounded surfaces of front and rear
camshaft caps before installing valve cover gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
Removal (1988-90 Prelude) 1) Turn crankshaft counterclockwise (as
viewed from timing belt end of engine) so that No. 1 cylinder is at TDC
of compression stroke. Ensure TDC mark (White paint) is at rear of
engine on transaxle mating flange. See Fig. 2.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

(1985-87 Prelude Shown; Others Are Similar)

HONDA

330

2.0L 4-Cylinder SOHC Accord & Prelude (Cont.)

2) 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 actuator (if equipped).
3) 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.
4) Remove valve cover. Remove crankshaft pulley center bolt. Remove
crankshaft pulley. Remove upper and lower timing 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 (1988-90 Prelude) Inspect timing belt for wear and for
signs of oil contamination. Replace belt if damaged or contaminated.
Inspect all drive gears for wear. Inspect water pump for excessive
bearing play or coolant leakage. Replace as necessary.
Installation (1988-90 Prelude) 1) Ensure crankshaft is still at TDC.
Ensure camshaft sprocket is correctly aligned. See Fig. 2. UP mark on
camshaft should be facing straight up, and grooves on sprocket should
align with top surface of cylinder head.
2) Install timing belt on engine. See Fig. 3. 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 bolt to
specification. See TORQUE SPECIFICATIONS.
3) 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.
4) Install generator, power steering pump and A/C compressor. Install
accessory drive belts and adjust to proper tension. Install engine mount
and cruise control actuator.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Adjusting Timing Belt Tension (1988-90 Prelude)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE)
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Adjustment Bolt ........................................................................... 51 (69)
Alternator Bracket Bolt .............................................................................................. 18 (24)
Camshaft Pulley Bolt ................................................................................................. 27 (37)
Crankshaft Pulley Bolt ........................................................................................... 108 (146)
Timing Belt Adjuster Bolt .......................................................................................... 31 (42)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................................................................ 84 (9)
Valve Cover Nut .......................................................................................................... 84 (9)
Water Pump Bolt ..................................................................................................... 106 (12)
TORQUE SPECIFICATIONS (1988-90 PRELUDE)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Identifying Timing Belt Installed Position

(1988-90 Prelude)

Application
Ft. Lbs. (N.m)
A/C Compressor Mounting Bolt ................................................................................ 18 (25)
Camshaft Pulley Bolt ................................................................................................. 27 (37)
Crankshaft Pulley Bolt ........................................................................................... 108 (146)
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)
Timing Belt Adjuster Bolt .......................................................................................... 31 (42)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 106 (12)

HONDA

331

2.0L & 2.1L 4-Cylinder DOHC Prelude

TIMING BELT APPLICATION
Application
2.0L 4-Cyl.
Prelude
1988-91
2.1L 4-Cyl.
Prelude
1990-91
1

Labor Time

Component
Belt
Kit No.
Part No.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

DOHC
............................ ...
DOHC

3.3 Hrs. ... .. TCK142 .. ..... T142

............................ ...

3.3 Hrs. ... .. TCK142 .. ..... T142

With Air Conditioning, add .5 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval for 1988-89 models, belt manufacturers suggest
the belt be replaced at 60,000 mile intervals. On 1990-91 models, the
manufacturer recommends belt be replaced every 90,000 miles.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

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332

2.0L & 2.1L 4-Cylinder DOHC Prelude (Cont.)

REMOVAL & INSTALLATION
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft
counterclockwise until cylinder No. 1 is at TDC of compression stroke.
Remove drive belts. Remove left engine mount bolts/nuts, engine mount
and bracket. Remove cruise control actuator (if equipped).
2) Remove engine splash shield. Remove power steering adjusting
pulley. Remove power steering pump with hoses attached, and set
aside. Remove alternator.
3) Remove A/C compressor (if equipped). Remove engine valve cover
and upper timing belt cover. See Fig. 1. Ensure timing marks align, and
UP marks on camshaft sprockets are positioned at the top. See Fig. 2.
4) 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 adjustment bolt and remove timing belt.
Inspection Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears
for wear in drive belt area. Inspect water pump for excessive bearing
play or coolant leakage. Replace if necessary.
Installation 1) 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.
2) Adjust timing belt tension by rotating crankshaft counterclockwise
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 camshaft pulley to create tension on timing belt. Tighten
adjustment bolt to specification. See TORQUE SPECIFICATIONS.
3) To complete installation, reverse removal procedure. Apply nonhardening sealant to rounded surfaces of front and rear camshaft caps
before installing valve cover gasket. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Adjustment Bolt ........................................................................... 20 (27)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Pulley Bolt ................................................................................................. 27 (37)
Crankshaft Pulley Bolt ........................................................................................... 108 (146)
Power Steering Adjustment Nut ................................................................................ 31 (42)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
Timing Belt Adjustment Bolt ...................................................................................... 31 (42)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 90 (10)
Valve Cover Nut ........................................................................................................ 90 (10)
Water Pump Bolt ..................................................................................................... 108 (12)

HONDA

333

2.2L 4-Cylinder DOHC Prelude

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl. DOHC (H22A)

Prelude
1993-01
Balancer Shaft Belt ...... .......... 1 .......... .. TCK186 .. ..... T186
Camshaft Timing Belt .. ... 1 3.3 Hrs. ... .. TCK186 .. ..... T226
1

Balancer shaft belt included in camshaft belt labor time. With

Air Conditioning, add .5 hours. With Cruise Control, add .3
hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1993-94 vehicles, 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 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).

REMOVAL & INSTALLATION

4) Install auto-tensioner on engine with stopper in place. Install 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.
5) Remove the auto-tensioner stopper. Install balancer belt drive pulley.
Temporarily install lower cover, crankshaft pulley, and crankshaft pulley
bolt. Tighten bolt.
6) 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.
7) Remove crankshaft pulley and lower cover. Loosen belt tension
adjusting nut about one turn. Verify balancer belt adjuster moves freely.
Retighten tension adjusting nut.
8) Remove sealing bolt from maintenance hole in side of engine block.
See Fig. 5. Insert a 6 x 100 mm bolt into maintenance 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.
9) Install balancer belt. Loosen adjusting nut to tension balancer belt.
Remove 6 x 100 mm bolt from side of engine block. Install sealing bolt.
10) Install lower cover and crankshaft pulley. Lubricate crankshaft pulley
bolt and underside of bolt shoulder. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS.
11) Turn crankshaft pulley about one turn counterclockwise. Tighten belt
tension adjusting nut. Install rubber seal around adjusting nut. Install
accessory drive belts, and adjust tension.
12) 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 removal procedure to complete
installation.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

TIMING & BALANCER SHAFT BELTS

Removal 1) Disconnect the negative battery cable. Rotate crankshaft
counterclockwise so that cylinder No. 1 is at TDC of compression stroke.
Timing marks are viewed through window on transaxle-to-engine mating
flange. See Fig. 1.
2) Remove engine lower splash shield. Remove power steering pump
and alternator drive belts. Remove alternator terminal and connector. If
equipped, disconnect cruise control actuator electrical connector. Move
cruise control actuator out of way with cable attached.
3) 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.
4) Remove middle timing belt cover. See Fig. 2. Remove crankshaft
pulley. 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 1) 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 position. See Fig. 1.
2) Remove the auto-tensioner from front of engine. Place auto-tensioner
in soft-jawed vise with maintenance bolt facing up. See Fig. 4. DO NOT
grip housing.
3) Remove maintenance bolt from top of auto-tensioner. Use a flatbladed screwdriver to compress auto-tensioner to bottomed out position. Place stopper on auto-tensioner. Refill any oil that may have spilled
out, and install maintenance bolt with new gasket.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Identifying Camshaft & Crankshaft TDC Marks

HONDA

334

2.2L 4-Cylinder DOHC Prelude (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Compressing Auto-Tensioner

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Timing Belt Drive Pulley With TDC Mark

HONDA

335

2.2L 4-Cylinder DOHC Prelude (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Mount Bolt ................................................................................................ 33 (45)
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)
Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)
Cylinder Head Cover Nut .......................................................................................... 90 (10)
Timing Belt Cover Bolt ............................................................................................ 106 (12)
Water Pump Bolt ..................................................................................................... 106 (12)
1

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning & Locking Balancer Shaft

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Aligning Balancer Shaft Pulley

Lubricate bolt threads and underside of bolt shoulder.

HONDA

336

2.2L 4-Cylinder SOHC Odyssey

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl. RA1

Odyssey
1995-97
Balance Shaft ............... .......... 1 .......... .. TCK186 .. ..... T186
Camshaft ....................... ... 2 2.7 Hrs. ... .. TCK186 .. ..... T187
1
2

Balance shaft belt included in camshaft belt labor time.

With Air Conditioning, add .3 hours. With Cruise Control, add
.3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balance Belt &

Related Components

NOTE: If the radio has a coded theft protection circuit, be sure to

get the customers code before disconnecting battery.

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft
counterclockwise 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. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a
jack, with cushion between oil pan and jack, to support engine. Remove
side engine mount.
2) Remove cylinder head cover. See Fig. 1. Remove crankshaft pulley.
Remove upper and lower timing belt covers. See Fig. 2. Loosen timing
belt tensioner adjuster nut 145-180 degrees. See Fig. 3. Push tensioner
to release belt tension from timing belt and balancer belt. Retighten
tensioner adjuster nut. Mark rotation direction of timing belt if it is to be
reused. Remove timing belt from pulleys.
Installation Ensure cylinder No. 1 is at TDC of compression stroke.
See Figs. 4 and 5. Install timing belt in sequence shown. See Fig. 6.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

HONDA

337

2.2L 4-Cylinder SOHC Odyssey (Cont.)

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

Fig. 3: Loosening Tensioner Adjusting Nut

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
Courtesy of American Honda Motor Co., Inc.

TORQUE SPECIFICATIONS

Fig. 6: Identifying Timing Belt Installation Sequence

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt ............................................................................................ 28 (38)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Power Steering Pump Mounting Nut ........................................................................ 16 (22)
Timing Belt Adjuster Bolt .......................................................................................... 49 (67)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............. 86-104 (7.2-8.7)
Valve Cover Nut ....................................................................................................... 86 (9.8)

HONDA

338

2.2L & 2.3L 4-Cylinder DOHC & SOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl. SOHC

Accord
1990-93
Balance Shaft ............... .......... 1 .......... .. TCK186 .. .....
Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. .....
1994-95
EX Model
Balance Shaft ............. .......... 1 .......... ...... ..... ...... .....
Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... .....
Except EX Model
Balance Shaft ............. .......... 1 .......... .. TCK186 .. .....
Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. .....
1996-97
W/VTEC
Balance Shaft ............. .......... 1 .......... ...... ..... ...... .....
Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... .....
W/O VTEC
Balance Shaft ............. .......... 1 .......... .. TCK186 .. .....
Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. .....
Prelude
1992-96
Balance Shaft ............... .......... 1 .......... .. TCK186 .. .....
Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. .....
2.3L 4-Cyl. DOHC
Prelude
1992-96
Balance Shaft ............... .......... 1 .......... .. TCK216 .. .....
Camshaft ....................... ... 1 3.3 Hrs. ... .. TCK216 .. .....
1

T186
T187

T186
T244
T186
T187

T186
T244
T186
T187

T186
T187

T186
T216

3) 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 tension adjuster nut. Remove lower
timing belt cover.
CAUTION: DO NOT rotate crankshaft or camshaft when removing
timing belts.
4) Lock timing belt adjuster arm into position by installing one lower
cover retaining bolt. Loosen belt tension adjuster bolt. See Fig. 5. Push
belt tensioner to release tension from belt. Tighten adjuster bolt.
Remove balance 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.
Installation 1) Align White mark on flywheel or drive plate (flexplate)
with pointer on block. Ensure camshaft(s) is at TDC for No. 1 cylinder.
See Fig. 1, 2 or 3. Install camshaft timing belt. See Fig. 6. Align rear
timing balance shaft belt pulley by inserting a 6 x 100 mm bolt 2.9 (74
mm) into alignment access hole. Align groove on front balance shaft
pulley with pointer on oil pump body. See Fig. 7.
2) Adjust timing belt tension by rotating crankshaft counterclockwise
until No. 1 piston is at TDC of compression stroke. Loosen, but do not
remove, timing belt adjustment bolt. Rotate crankshaft counterclockwise
3 teeth on camshaft pulley to create tension on timing belt. Tighten
adjustment bolt to specification. See TORQUE SPECIFICATIONS.
3) Reverse removal procedure to complete installation. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

Balance shaft belt included in camshaft belt labor time. With

Air Conditioning, add .5 hours. With Cruise Control, add .3
hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-94 vehicles, the manufacturer recommends camshaft and
balance 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 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING & BALANCE SHAFT BELTS

Removal 1) Disconnect negative battery cable. Position crankshaft
with cylinder No. 1 at TDC of compression stroke. See Fig. 1, 2 or 3.
Disconnect battery negative cable. Remove splash shield. Remove
cruise control actuator, leaving cable connected. Remove power steering pump, leaving hoses connected.
2) 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. Remove crankshaft pulley. See Fig. 4.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Positioning Camshaft Sprocket for Valve Adjustment

(2.2L SOHC Accord)

HONDA

339

2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing & Installing Crankshaft Pulley (Typical)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Positioning Camshaft Sprocket for Valve Adjustment

(2.2L SOHC Prelude)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Positioning Camshaft Sprockets for Valve Adjustment (Prelude 2.3L DOHC)

HONDA

340

2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Nut (Typical)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Removing & Installing Timing & Balance Shaft Belts

HONDA

341

2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 37 (50)
Alternator Bracket Adjuster Bolt ................................................................................ 16 (22)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Balance Shaft Pulley Bolt ......................................................................................... 22 (30)
Camshaft Pulley Bolt
2.2L DOHC .............................................................................................................. 37 (51)
2.2L SOHC & 2.3L .................................................................................................. 27 (37)
Crankshaft Pulley Bolt ........................................................................................... 184 (250)
Power Steering Belt Adjuster Nut ................................................. ............................ 11 (15)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
Power Steering Pump Mounting Bolt ....................................................................... 16 (22)
Shift Cable Bracket Bolt ............................................................................................ 16 (22)
Timing Belt Tension Adjuster .................................................................................... 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ............................................................................................ 108 (12)
Valve Cover Nut ........................................................................................................ 90 (10)
Water Pump Bolt ..................................................................................................... 108 (12)

Fig. 7: Aligning Balancer Belt Driven Pulley

HONDA

342

2.3L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.3L 4-Cyl. F23A, SOHC

Accord
1998-02
Balance Shaft ...................................... .......... 1 .......... .....
Camshaft ............................................... 2 3.1 Hours .. .....
Odyssey
1998
Balance Shaft ...................................... .......... 1 .......... .....
Camshaft ............................................... 2 3.3 Hours .. .....
1
2

T186
T244

T186
T244

Balance shaft belt included in camshaft belt labor time.

With Air Conditioning, add .5 hours. With Cruise Control, add
.3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: f the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balancer Belt &

Related Components

TIMING & BALANCER SHAFT BELTS

Removal 1) Disconnect negative battery cable, then positive battery
cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC
of compression stroke. While rotating crankshaft, check water pump for
signs of seal leakage. Raise and support vehicle. Remove front tires.
Remove engine lower splash shield.
2) 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 support engine. Remove upper
bracket. Remove dipstick tube from front of engine.
3) Remove cylinder head cover. Remove crankshaft pulley. Remove
upper and lower timing belt covers. See Figs. 1 and 2.
4) 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.
5) Loosen belt tensioner adjusting nut about one 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.
6) Loosen belt tensioner adjusting nut about one 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 1) 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.
2) Install camshaft timing belt counterclockwise 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.
3) Rotate crankshaft pulley COUNTERCLOCKWISE about 5-6 turns so
timing belt positions on pulley. Set No. 1 piston at TDC of compression

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

stroke. Loosen belt tensioner adjusting nut about one turn. Rotate
crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt
tensioner adjusting nut to specification. See TORQUE SPECIFICATIONS.
4) Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC
position. Ensure camshaft UP mark is facing up. If it is not, timing belt
will have to be repositioned.

HONDA

343

2.3L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

Fig. 3: Loosening Tensioner Adjusting Nut

5) Remove crankshaft pulley and lower cover. Set timing belt drive
pulley to TDC position.
6) Lock camshaft timing belt adjuster arm in place by installing a 6 x 10
mm timing cover bolt. Loosen belt tensioner adjusting nut about one
turn. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push
balancer belt tensioner up, then retighten belt tensioner adjusting nut.
7) Remove sealing bolt from maintenance hole on side of engine block.
See Fig. 7. Scribe a line 2.9 (74 mm) from end of 6 x 100 mm bolt.
Install 6 x 100 mm bolt into sealing bolt hole to lock balancer shaft in
place.
8) Align front balancer shaft pulley groove with pointer on oil pump
housing. See Fig. 8. Install balancer belt. Loosen tensioner adjusting nut
about one turn to tension balancer shaft belt. Remove 6 x 100 mm bolt
from rear of balancer shaft. Install sealing bolt with new washer.
9) Temporarily install crankshaft pulley and bolt. Turn crankshaft pulley
about one turn counterclockwise, then tighten tensioner adjusting nut.
Remove the 6 x 10 mm bolt that locked camshaft timing belt adjuster
arm in place.
10) Remove crankshaft pulley. Install lower cover with new gasket or
liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO
NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley
bolt and underside of bolt shoulder. Install and tighten crankshaft pulley
bolt to specification. See TORQUE SPECIFICATIONS.
11) Install dipstick tube with new O ring. When installing cylinder head
cover gasket, apply liquid gasket (Part No. 08718-0001 or -0003) to 4
corners where gasket meets camshafts.
12) Install alternator and harness. Install accessory drive belts. Install
engine mount bracket to engine and frame. Connect negative and
positive battery cables. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

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344

2.3L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Locking Balancer Shaft In Place

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Adjusting Lock Nut ................................................................................... 16 (22)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt ............................................................................................ 43 (59)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
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)
Power Steering Pump Mounting Nut ........................................................................ 16 (22)
Timing Belt Tensioner Adjusting Nut ........................................................................ 33 (44)
INCH Lbs. (N.m)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Balancer Belt Drive Pulley

Cylinder Head Cover Nut ......................................................................................... 86 (9.8)

Dipstick Tube Bolt ................................................................................................... 106 (12)
Engine Lower Splash Shield ..................................................................................... 89 (10)
Timing Belt Cover Bolt ............................................................................................ 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

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345

2.6L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

2.6L 4-Cyl.
Passport
1994-96
A/T .................................... 1.6 Hours ... .. TCK147 .. ..... T147
M/T .................................... 1.6 Hours ... .. TCK147 .. ..... T147
1

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
Removal 1) 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.
2) 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 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 1) 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.
2) 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.
3) Check timing sprockets. See TIMING SPROCKET SPECIFICATIONS
table. Replace, if necessary.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Marks

TIMING SPROCKET SPECIFICATIONS
Application
Standard In. (mm)
Limit In. (mm)
Camshaft ............................... .......... 5.202 (132.03) ................................. 5.198 (131.93)
Crankshaft ............................. ........... 2.574 (65.33) .................................... 2.570 (65.23)
Oil Pump ............................... .......... 4.485 (113.84) .......... ....................... 4.481 (113.74)
Installation 1) Pull tensioner fully toward water pump side, and
temporarily 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).
2) Rotate camshaft until timing mark on cam gear (arrow) aligns with
mark on upper camshaft cover (notch). See Fig. 1.
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 adjusting bolt, allowing spring tension to tighten belt.
Tighten adjusting bolt temporarily.
4) Temporarily install crankshaft pulley bolt and rotate crankshaft 2
complete revolutions in opposite direction of engine 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.
5) Install timing belt covers. To complete installation, reverse removal
procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

HONDA

346

2.6L 4-Cylinder (Cont.)

Courtesy of Isuzu Motor Co.

Fig. 2: Exploded View of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 43 (58)
Crankshaft Pulley Bolt ............................................................................................. 90 (122)
Front Cover ............................................................................................................... 14 (19)
Tensioner Pulley
Bolts ......................................................................................................................... 18 (24)
Nut ........................................................................................................................... 10 (14)
Water Pump Bolt ....................................................................................................... 14 (19)
Courtesy of Isuzu Motor Co.

Fig. 3: Installing Belt Guide

INCH Lbs. (N.m)

Timing Belt Cover Bolt ................................................................................................ 53 (6)

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347

2.7L V6
TIMING BELT APPLICATION
1

Application

Labor Time

Belt
Part No.

2.7L V6
Accord
1996-97 ..................................................... 4.0 Hours ... ..... T263
1

With Air Conditioning, add .3 hours. With Cruise Control, add

.3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Inspection Inspect camshaft and crankshaft seals, and replace if

leaking. Inspect timing belt for wear or rounded edges of drive teeth.
Inspect belt for signs of oil contamination. Replace belt if damaged or
contaminated.
Installation 1) 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. 2.
2) To adjust timing belt, rotate crankshaft clockwise 5-6 revolutions 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. 2. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1996 vehicles, the manufacturer recommends the belt be replaced
at 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 car is regularly driven in extreme
temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) Remove A/C, P/S and alternator belt. Remove dipstick and pipe.
Remove crankshaft pulley. Remove timing belt covers. See Fig. 1.
3) If timing belt is being reused, mark direction of belt rotation before
removing. Rotate crankshaft clockwise until No. 1 piston is at TDC of
compression stroke. See Fig. 2.
4) Loosen timing belt adjusting bolt 180 degrees, and push tensioner to
remove tension from timing belt. Retighten adjusting bolt and remove
timing belt.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying TDC Marks, Timing Belt Adjusting Bolt &

Installation Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Camshaft Pulley Bolts ............................................................................................... 23 (31)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Mount Bolts ................................................................................................... 43 (59)
Idler Pulley Center Nut ............................................................................................. 33 (44)
Timing Belt Adjuster Bolt .......................................................................................... 31 (42)
INCH Lbs. (N.m)
Dipstick Bracket Bolts ................................................................................................. 84 (9)
Timing Belt Cover Bolts .............................................................................................. 84 (9)

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing & Installing Lower & Upper Timing Belt Covers

HONDA

348

3.0L & 3.5L V6

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.0L V6 (J30A1)
Accord
1998-00 .............................. 1 4.4 Hours .. . 2 TCK286 . .....
2001-02 .............................. 1 4.4 Hours .. ...... ..... ...... .....
2003-04 .............................. 1 4.0 Hours .. ...... ..... ...... .....
3.5L V6 (J35A1 & J35A4)
Odyssey
1999-04 .............................. 1 4.0 Hours .. ...... ..... ...... .....
Pilot
2003-04 ............................... 4.0 Hours ... ...... ..... ...... .....
1

T286
T286
T329

T286
T286

With Cruise Control, add .3 hours.

With Power Steering, add .3 hours.
Timing component kit does not include camshaft tensioner
hydraulic assembly.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing Crankshaft Pulley Bolt

NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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
110F, or under 20F).

CAUTION: Handle auto-tensioner carefully so oil does not spill or

leak out. Replace any oil that may leak out. Capacity is 0.22 fl. oz.
(6.5 ml.).
3) Hold auto-tensioner with maintenance bolt pointing up. Remove
maintenance bolt. See Fig. 5. Clamp auto-tensioner in soft-jawed vise.
DO NOT grip auto-tensioner housing. Insert flat-bladed screwdriver into
maintenance hole. Place stopper on auto-tensioner while turning screwdriver clockwise to compress tensioner to bottom.
4) 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.

REMOVAL & INSTALLATION

NOTE: When compressing sealed auto-tensioners, compression

pressure should not exceed 2200 lbs. (9800 N).

CAUTION: The 3.0L is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage
may occur.

5) Place sealed auto-tensioner in press. SLOWLY compress tensioner

until pin can be inserted through tensioner body, and insert pin. See
Fig. 6. Install auto-tensioner onto engine.
6) Install battery clamp bolt into back cover. On 2003-04 Accord and
Pilot, apply liquid thread lock to idler pulley bolt and loosely install idler
pulley. On all models, install timing belt in counterclockwise direction in
the following sequence: Crankshaft pulley, idler pulley, front camshaft
pulley, water pump pulley, rear camshaft pulley and tension adjust
pulley. See Fig. 7. Ensure crankshaft and camshaft pulleys remained
aligned with marks on back cover. Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS.
7) Remove stopper or pin from auto-tensioner. Remove battery clamp
bolt from back cover. Install engine mount bracket to the front of engine
(above water pump pulley). If removed, install timing belt guide plate
with concave surface facing out. Install lower cover, then upper front and
rear covers. Install crankshaft pulley. Lubricate crankshaft pulley bolt
threads and install bolt. Tighten crankshaft pulley bolt to specification.
See TORQUE SPECIFICATIONS.
8) 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 rubber plugs from upper covers to check camshaft pulley
positions.
9) 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 belts to proper tension.

TIMING BELT
Removal 1) 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 right
front wheel, if necessary. Remove lower engine splash shield. Remove
the generator and power steering pump drive belts.
2) Support engine with a jack and wood block under the oil pan. Remove
ground cable (if necessary), then remove engine side mount bracket.
Remove dipstick tube from front of engine. Using Holder, remove
crankshaft pulley. See Fig. 1.
3) Remove upper and lower timing belt covers. See Fig. 2. If reusing
timing belt, mark direction of belt rotation for installation reference.
4) Remove one of the battery clamp bolts from battery tray. Grind
threaded end of bolt to a partial point (about 45 degree chamfer). Thread
battery bolt into rear cover to hold timing belt adjuster in installed
position. Hand tighten ONLY. See Fig. 3.
5) Remove engine mount bracket from front of engine (above water
pump pulley). On 2003-04 Accord and Pilot, remove idler pulley bolt and
idler pulley, then remove timing belt. On all other models, loosen timing
belt idler pulley bolt 5-6 turns and remove timing belt.
Installation 1) Ensure that engine is at TDC. Align dimple on timing
belt drive pulley with pointer on oil pump. See Fig. 4. Align camshaft
pulleys with pointers on back covers.
2) Remove battery clamp bolt from back cover. Remove the timing belt
auto-tensioner. For auto-tensioner with removable bolt, go to next step.
For models with sealed auto-tensioner, go to step 5). For identification,
see Figs. 5 and 6.

HONDA

349

3.0L & 3.5L V6 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner

HONDA

350

3.0L & 3.5L V6 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Compressing Auto-Tensioner (2000-03 Odyssey & Pilot)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Center Bolt 1 .............................................................................. 67 (90)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Mount Bracket (Front)
10 x 1.25 mm Bolts ................................................................................................ 33 (44)
6 x 1.0 mm Bolt .......................................................................... ..................................... 2
Engine Side Mount Bracket
10 x 1.25 mm Bolts 3 .............................................................................................. 33 (44)
12 x 1.25 mm Bolts ................................................................................................ 40 (54)
Idler Pulley Bolt ......................................................................................................... 33 (44)
Power Steering Pump Lock Nut ............................................................................... 17 (24)
Power Steering Pump Mount Bolt ............................................................................ 17 (24)
INCH Lbs. (N.m)
Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)
Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
Dipstick & Tube 4 ..................................................................................................... 106 (12)
Ground Cable Bolt .................................................................................................. 106 (12)
Lower Engine Splash Shield Bolts ......................................................................... 106 (12)
Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Compressing Auto-Tensioner (Accord & 1999 Odyssey)

1
2
3
4

Apply engine oil to bolt threads.

Tighten bolt to 106 INCH lbs. (12 N.m).
Tighten these bolts first.
Use a NEW O ring.

HONDA

351

3.2L V6 DOHC
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.2L V6
Passport
1998-02 ..................................................... 3.2 Hours ... ..... T303
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Normal replacement interval is at 75,000 miles for 1998-99 model years.
For 2000-02 model year vehicles, recommended replacement interval is
100,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly. Remove upper fan shroud. Remove serpentine drive belt.
2) Remove cooling fan and drive pulley. Remove serpentine drive belt
idler pulley assembly. Remove serpentine drive belt tensioner assembly.
3) Remove power steering pump with hoses attached, and set aside.
Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent,
remove crankshaft pulley.
4) Remove timing belt covers. Rotate crankshaft to align timing marks.
See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be
at TDC.
5) If reusing timing belt, mark belt with arrow to indicate original rotation
direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove 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.

Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

3) 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 alignment 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.
4) Install timing belt around idler pulley and tensioner pulley. Temporarily
install crankshaft pulley, and tighten center bolt by hand. 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.
5) 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.
6) Install tensioner on engine with locking pin in place. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Remove locking pin from timing belt tensioner. Remove clips from
camshaft and crankshaft sprockets.
8) Rotate crankshaft 2 turns clockwise. Ensure timing marks are still
aligned.
9) Remove crankshaft pulley and install timing belt covers. Ensure
rubber sealing bushings are installed on timing belt cover bolts. See
Fig. 6.
10) Install crankshaft pulley. Tighten center bolt to specification. See
TORQUE SPECIFICATIONS. Install cooling fan pulley. Install power
steering pump. Install cooling fan. Install serpentine drive belt idler
pulley and tensioner assemblies. Install radiator fan shroud. Connect
negative battery cable.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks

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 1) Align groove 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.
2) Align timing mark on right hand (passenger side) camshaft sprocket
with alignment mark on valve cover. See Fig. 3. Install timing belt on
right hand camshaft sprocket, aligning 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
removal. Secure belt with spring clip.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

HONDA

352

3.2L V6 DOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt Cover Bushings

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 72 (98)
Cooling Fan Pulley Bolt ............................................................................................ 16 (22)
Crankshaft Pulley Bolt ........................................................................................... 123 (167)
Power Steering Pump Bolt
M8 Bolt .................................................................................................................... 16 (22)
M10 Bolt .................................................................................................................. 34 (46)
Timing Belt Cover Bolt .............................................................................................. 14 (19)
Timing Belt Idler Pulley Bolt ..................................................................................... 38 (52)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42)
Water Pump Bolt ....................................................................................................... 18 (25)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

HYUNDAI

353

1.5L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
1.5L 4-Cyl.
Accent
1996-97 ....................................................
1

Labor Time

Belt
Part No.

7) Ensure belt cog will reach half the width of timing belt tensioner bolt
on slot-side of belt tensioner. Install crankshaft flange. Install timing belt
cover. To install remaining components, reverse removal procedure.
Adjust drive belts to proper tension.

1.8 Hours .. ..... T282

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1996 vehicles, the manufacturer recommends the belt be replaced
every 60,000 miles. For 1997 vehicles, the 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Loosen, but do not remove water pump pulley bolts.
Remove all accessory drive belts. Remove pulleys from crankshaft 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.

Courtesy of Hyundai Motor Co.

2) 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.
3) 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 1) Ensure camshaft and crankshaft timing marks are still
aligned. See Fig. 1. Move timing belt tensioner toward water pump and
tighten bolt. Install crankshaft sprocket (if removed) with chamfer
(flange) toward engine.
2) Install timing belt on crankshaft and camshaft sprockets. Make sure
there is no slack in belt. If reusing old belt, ensure belt is installed in
original direction of rotation.
3) Apply counterclockwise force on camshaft sprocket to apply tension
on tension side of belt. Ensure all timing marks are aligned. See Fig. 1.

Fig. 1: Aligning Timing Marks

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.

TORQUE SPECIFICATIONS

4) Loosen timing belt tensioner bolts to place tension on timing belt. See
Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE
SPECIFICATIONS.
5) Smoothly rotate crankshaft clockwise for one full revolution. 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. See TORQUE SPECIFICATIONS.
6) To check belt tension, hold belt tensioner and timing belt together and
apply slight thumb pressure (about 11 lbs.) at center point of belt
tensioner. See Fig. 2.

Courtesy of Hyundai Motor Co.

Fig. 2: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

HYUNDAI

354

1.5L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application
1.5L 4-Cyl.
Accent
1995-99
2000-02
Excel
1986-89
1990-94
Scoupe
1991-93
1994-95
1
2

Labor Time

............................ ...
............................ ...

............................ ...
............................ ...

............................ ...
............................ ...

Component
Belt
Kit No.
Part No.

1.8 Hrs. ... .. TCK191 .. ..... T191

2.0 Hrs. ... ...... ..... ...... ..... T324
2.2 Hrs. ... .. TCK073 .. ..... T073
2.2 Hrs. ... .. TCK128 .. ..... T128
2.2 Hrs. ... .. TCK128 .. ..... T128
2.2 Hrs. ... .. TCK191 .. ..... T191

With Air Conditioning, add .2 hours.

With Air conditioning, add .2 hour (1995-99) or .3 hour
(2000-02). With Power Steering, add .2 hour.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1986-96 vehicles, the manufacturer recommends the belt be
replaced every 60,000 miles. For 1997-02 vehicles, the 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.

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Marks

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove all accessory drive belts. Remove pulleys from
crankshaft 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.
2) Remove timing belt covers and gaskets, noting bolt length and
location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Figs. 1 and 2.
3) If reusing old belt, place mark on belt to indicate direction of belt
rotation. Move tensioner inward toward water pump, and 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 for worn bearing.
Installation 1) Ensure camshaft and crankshaft timing marks are still
aligned. See Figs. 1 and 2. Move timing belt tensioner toward water
pump and tighten bolt.
2) Install timing belt on crankshaft and camshaft sprockets. Make sure
there is no slack in belt. If reusing old belt, ensure belt is installed in
original direction of rotation.
3) Apply counterclockwise force on camshaft sprocket to apply tension
on tension side of belt. Ensure all timing marks are aligned. See Figs. 1
and 2.

Courtesy of Hyundai Motor Co.

Fig. 2: Locating Camshaft & Crankshaft Sprocket Marks

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.
4) Loosen timing belt tensioner bolts to place tension on timing belt. See
Fig. 3. Tighten timing belt tensioner bolts to specification. See TORQUE
SPECIFICATIONS.
5) Smoothly rotate crankshaft clockwise for one full revolution. 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. See TORQUE SPECIFICATIONS.
6) To check belt tension, hold belt tensioner and timing belt together and
apply slight thumb pressure (about 11 lbs.) at center point of belt
tensioner. See Fig. 3.
7) Ensure belt cog will reach half the width of timing belt tensioner bolt
on slot-side of belt tensioner. Install timing belt cover. To install remaining components, reverse removal procedure. Adjust drive belts to proper
tension.

HYUNDAI

355

1.5L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ............... 59-74 (80-100)
Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150)
Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt ................................................................ ............. 106-133 (12-15)

Courtesy of Hyundai Motor Co.

Fig. 3: Checking Timing Belt Tension

HYUNDAI

356

1.6L 4-Cylinder DOHC 2001-04

TIMING BELT APPLICATION
Application
1.6L 4-Cyl.
Accent
2001-04 ....................................................
1

Labor Time

Belt
Part No.

2.0 Hours .. ..... T282

With Air Conditioning, add .3 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Loosen, but do not remove water pump pulley bolts.
Remove all accessory drive belts. Remove pulleys from crankshaft 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.
2) 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.
3) 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 1) Ensure camshaft and crankshaft timing marks are still
aligned. See Fig. 1. Move timing belt tensioner toward water pump and
tighten bolt. Install crankshaft sprocket (if removed) with chamfer
(flange) toward engine.
2) Install timing belt on crankshaft and camshaft sprockets. Make sure
there is no slack in belt. If reusing old belt, ensure belt is installed in
original direction of rotation.
3) Apply counterclockwise force on camshaft sprocket to apply 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 overtightened.
4) Loosen timing belt tensioner bolts to place tension on timing belt. See
Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE
SPECIFICATIONS.
5) Smoothly rotate crankshaft clockwise for one full revolution. Realign
crankshaft and camshaft timing marks. To check belt tension, hold belt
tensioner and timing belt together and apply slight thumb pressure
(about 11 lbs.) at center point of belt tensioner. See Fig. 2.
6) Ensure belt cog will reach half the width of timing belt tensioner bolt
on slot-side of belt tensioner. Install crankshaft flange. Install timing belt
cover. To install remaining components, reverse removal procedure.
Adjust drive belts to proper tension.

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 2: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ............... 59-74 (80-100)
Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150)
Timing Belt Idler Pulley Bolt ......................................................... ................. 32-41 (43-55)
Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

HYUNDAI

357

1.6L & 1.8L 4-Cylinder DOHC 1992-95

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. DOHC

Elantra
1992 ................................. ... 1 3.0 Hrs. ... ..
1993-95
Balance Shaft ............... .......... 2 .......... ..
Camshaft ....................... ... 1 3.0 Hrs. ... ..
1.8L 4-Cyl. DOHC
Elantra
1993-95
Balance Shaft ............... .......... 2 .......... ..
Camshaft ....................... ... 1 3.0 Hrs. ... ..
1

TCK165 .. ..... T165

TCK165 .. ..... T168
TCK165 .. ..... T165

TCK167 .. ..... T168

TCK167 .. ..... T167

With Air Conditioning, add .2 hours.

With Power Steering, add .3 hours.
Balance shaft belt included in camshaft belt labor time.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove cover from under engine (if equipped). Support
engine weight with floor jack. Remove engine mount located near timing
belt cover. Remove all accessory drive belts. Remove water pump
pulley and crankshaft pulley. Remove timing belt covers and gaskets,
noting bolt lengths and locations.
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.
2) Rotate engine clockwise to align all timing marks so No. 1 cylinder is
at TDC of compression stroke. See Fig. 2. Remove automatic tensioner.
Place mark on timing belt to indicate direction of belt rotation. Remove
timing belt.
3) On models equipped with balance shaft, remove outer crankshaft
sprocket. See Fig. 1. Align oil pump sprocket timing mark with mark on
oil pump case. See Fig. 2.
CAUTION: Leave screwdriver inserted in block until timing belt is
installed. This will lock left side balance shaft in correct position.
4) Remove plug at left side of cylinder block. See Fig. 3. 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.
5) Loosen balance belt tensioner bolt. Remove balance belt.
Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and
idler pulley for grease leakage and roughness in rotation. Replace
components if damaged.
2) Check end of automatic tensioner rod for wear. Measure distance
from end of automatic tensioner rod to top of automatic tensioner
housing. Distance should be .47 (12 mm). If out of specification, replace
automatic tensioner.

Compressing Automatic Tensioner 1) 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 assembly in a
soft-jawed vise.
2) SLOWLY squeeze rod back into automatic tensioner. Replace
tensioner if rod can be retracted easily into automatic tensioner. Align
holes in rod and automatic tensioner body. See Fig. 4. 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) 1) Ensure crankshaft sprocket and
right side balance shaft sprocket timing marks are aligned with marks on
oil pump housing. See Fig. 5. Install balance shaft belt. If removed,
install balance shaft tensioner pulley and center bolt.
2) 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. 6.
3) While tightening balance shaft tensioner center bolt, ensure tensioner
and sprockets DO NOT rotate. Ensure timing marks are still aligned.
Check belt tension by applying finger pressure to side of belt opposite
tensioner. See Fig. 6. Deflection should be .20-.28 (5-7 mm). If not,
readjust belt tension.
4) Install crankshaft flange and outer sprocket. Install flange in correct
direction to prevent damage to timing belt. See Fig. 7.
Installation (Camshaft Timing Belt) 1) If crankshaft sprocket was
removed, ensure sprocket, spacer and flange are installed correctly.
See Fig. 8.
2) 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. 9. 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).
3) Rotate camshaft sprockets so dowel pins face up and timing marks on
sprockets align. See Fig. 2. Inner 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, compensate for rotation.
4) 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.
5) 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.
6) Install timing belt around intake camshaft sprocket. Ensure exhaust
timing mark on camshaft sprocket aligns with cylinder head surface. See
Fig. 2. Using both hands, install timing belt around exhaust camshaft
sprocket.
7) 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.
8) 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.
9) Install Socket Wrench (MD998752) into pin holes offset to left center
of pulley. See Fig. 10. Using INCH-lb. torque wrench and socket wrench,
apply a clockwise torque of 23-25 INCH lbs. (2.6-2.8 N.m) on tensioner
pulley. With torque applied to tensioner pulley, tighten tensioner pulley
center bolt to 31-40 ft. lbs. (42-54 N.m). DO NOT allow pulley to rotate
while tightening center bolt.

358

HYUNDAI
1.6L & 1.8L 4-Cylinder DOHC 1992-95 (Cont.)

NOTE: If engine is in vehicle, it may be necessary during tensioner

pulley adjustment to jack up engine slightly for clearance.
10) Install Set Screw (09244-28000) or equivalent, in left engine support
bracket until screw end contacts tensioner arm. See Fig. 11. Turn set
screw further until wire can be removed from automatic tensioner.
Remove set screw.
11) 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. 12, Dimension A. Repeat timing belt
tensioning procedure until correct distance is obtained. If correct distance can be measured, go to step 14). If correct distance CANNOT be
measured, go to next step.

12) 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.
13) 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 correct distance is obtained. Remove set screw.
14) 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. 13. Adjust drive belts to proper tension.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)

HYUNDAI

359

1.6L & 1.8L 4-Cylinder DOHC 1992-95 (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Crankshaft & Balance Shaft Sprockets

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 6: Checking Balance Shaft Tension Pulley Alignment

Courtesy of Hyundai Motor Co.

Fig. 3: Holding Silent Shaft In Stationary Position

Courtesy of Hyundai Motor Co.

Fig. 7: Installing Flange & Crankshaft Sprocket

(Engines With Balance Shaft Belt)

Courtesy of Hyundai Motor Co.

Fig. 4: Retracting Automatic Tensioner Rod

Courtesy of Hyundai Motor Co.

Fig. 8: Installing Flange & Crankshaft Sprocket

(Engines Without Balance Shaft Belt)

HYUNDAI

360

1.6L & 1.8L 4-Cylinder DOHC 1992-95 (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 9: Installing Tensioner Pulley

Courtesy of Hyundai Motor Co.

Fig. 13: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

Fig. 10: Adjusting Camshaft Belt Tension

Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100)
Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30)
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)
Idler Pulley Bolt ............................................................................. ................. 22-30 (30-42)
Tensioner Pulley Bracket Bolt ....................................................... ................. 12-19 (17-26)
Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (43-55)
Timing Belt Cover
Left Lower Rear .......................................................................... ................. 22-30 (30-42)
Except Left Lower Rear .............................................................. ..................................... 1
1

Courtesy of Hyundai Motor Co.

Fig. 11: Removing Timing Belt Automatic Tensioner Lock Wire

Courtesy of Hyundai Motor Co.

Fig. 12: Measuring Timing Belt Tensioner Protrusion

Tighten to 89-106 INCH lbs. (10-12 N.m).

HYUNDAI

361

1.8L & 2.0L 4-Cylinder

DOHC 1996-04 (Except Sonata & 2004 Elantra)
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.8L 4-Cyl. DOHC

Elantra
1996-98 .............................. 1 2.4 Hours .. .. TCK278 .. .....
Tiburon
1997 ................................... 1 2.4 Hours .. .. TCK278 .. .....
2.0L 4-Cyl. DOHC
Elantra
1999-01 ............................... 2.8 Hours ... .. TCK284 .. .....
2002-03 ............................... 2.8 Hours ... ...... ..... ...... .....
Tiburon
1997 .................................... 3.0 Hours ... ...... ..... ...... .....
1998-01 ............................... 3.0 Hours ... .. TCK284 .. .....
2003-04 ............................... 3.0 Hours ... ...... ..... ...... .....
1

T278
T278

T284
T284
T284
T284
T284

With Air Conditioning, add .2 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Inspection Check belt teeth for cracks, damage, and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and worn bearings. Replace components if
damaged.
Installation 1) Ensure camshaft and crankshaft timing marks are still
aligned. Outer marks on sprockets should be aligned with rocker cover
surface. Verify timing chain timing mark alignment, if necessary. See
Fig. 2. Install timing belt tensioner pulley. Install timing belt. If reusing old
belt, ensure belt is installed in original direction of rotation.
2) Loosen timing belt tensioner bolt, allowing tensioner pulley to contact
belt. Tighten timing belt tensioner pulley bolt. Rotate crankshaft one turn
clockwise. Realign camshaft and crankshaft timing marks.
3) 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.
4) 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 to proper tension.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer requires that 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.

Fig. 2: Aligning Timing Chain Marks

REMOVAL & INSTALLATION

TECHNICAL SERVICE BULLETIN

Courtesy of Hyundai Motor Co.

TIMING BELT NOISE: FRONT CASE

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: On some models, engine is equipped with a timing belt and
timing chain. Inspect timing chain when replacing timing belt.
Removal 1) Remove all drive belts and drive pulleys from crankshaft
and water pump. Remove generator bolt, if necessary. Remove crankshaft pulley and water pump pulley.
2) Remove timing belt covers and gaskets, noting bolt lengths and
locations. DO NOT rotate engine counterclockwise, as viewed from
timing belt side of engine. Remove timing belt tensioner pulley.
3) Rotate engine clockwise to align all timing marks so No. 1 cylinder is
at TDC of compression stroke. See Fig. 1. If reusing belt, place mark on
timing belt to indicate direction of belt rotation. Remove timing belt.

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
machined 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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ............. 74-89 (100-120)
Crankshaft Pulley Bolt ................................................................... ......... 125-133 (170-180)
Front Case Bolts ........................................................................... ................. 14-20 (20-27)
Generator Brace Mounting Bolt .................................................... ................. 14-20 (20-27)
Generator Support Bolt/Nut .......................................................... ................. 14-18 (20-25)
Timing Belt Idler Bolt .................................................................... ................. 31-41 (43-55)
Timing Belt Tensioner Bolt ............................................................ ................. 31-41 (43-55)
Water Pump Bolt
1996-97 ............................................................................................................ 9-11 (12-15)
1998-04 ........................................................................................ ................. 14-20 (20-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................... 71-86 (8-10)
Water Pump Pulley Bolt ................................................................ ................... 71-86 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Belt Marks

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2.0L 4-Cylinder DOHC Elantra

TIMING BELT APPLICATION
Application
2.0L 4-Cyl. DOHC
Elantra
2004 ..........................................................
1

Labor Time

Belt
Part No.

2.4 Hours .. ..... T284

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer requires that 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: On some models, engine is equipped with a timing belt and
timing chain. Inspect timing chain when replacing timing belt.
Removal 1) Remove the engine cover. See Fig. 1.
2) Remove right front wheel.
3) Remove right side cover. See Fig. 2.
NOTE: Place wooden block between the jack and engine oil pan.
4) Set the jack to the engine oil pan. Remove the engine mount bracket.
See Fig. 3. Remove the stay plate. See Fig. 4.
5) Temporarily loosen the water pump pulley bolts.
6) Remove alternator belt.
7) Remove air compressor belt.
8) Remove power steering belt.
9) Remove water pump pulley.
10) Remove timing belt upper cover. See Fig. 5.
11) Turn the crankshaft pulley, and align its groove with timing mark T
on the timing belt cover. See Fig. 6.
12) Remove the crankshaft pulley bolt and crankshaft pulley. See Fig. 7.
13) Remove the crankshaft flange. See Fig. 8.
14) Remove the timing belt lower cover. See Fig. 9.
NOTE: If the timing belt is reused, make an arrow indicating the
turning direction to make sure that the belt is reinstalled in the
same direction as before.
15) Remove the timing belt tensioner and timing belt. See Figs. 10
and 11.
16) Remove the bolt and timing belt idler. See Fig. 12.
17) Remove the crankshaft sprocket. See Fig. 13.
18) Remove the cylinder head cover:
Remove the spark plug cable.
Remove the accelerator cable from the cylinder head cover. See
Fig. 14.

Remove the PCV hose and breather hose. See Fig. 15.
Remove the cylinder head cover. See Fig. 16.
CAUTION: Be careful not to damage the cylinder head and valve
lifter with the wrench.
19) Hold the hexagonal head wrench portion of the camshaft with a
wrench, and remove the bolt and camshaft sprocket. See Fig. 17.
Inspection Check belt teeth for cracks, damage, and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and worn bearings. Replace components if
damaged.
Installation 1) Install the camshaft sprocket and tighten the bolt to
specification. See TORQUE SPECIFICATIONS. Temporarily install the
camshaft sprocket bolt. Hold the hexagonal head wrench portion of the
camshaft with a wrench, and tighten the camshaft sprocket bolt. See
Fig. 17.
2) Install cylinder head cover. See Fig. 16. Install the PCV hose and
breather hose. See Fig. 15. Install the accelerator cable to the cylinder
head cover. See Fig. 14. Install the spark plug cable.
3) Install the crankshaft sprocket. See Fig. 13.
4) Align the timing marks of the camshaft sprocket and crankshaft
sprocket with the No. 1 piston placed at top dead center and its
compression stroke. See Figs. 18 and 19.
5) Install the idler pulley and tighten the bolt to the specified torque. See
Fig. 12. See TORQUE SPECIFICATIONS.
6) Temporarily install the timing belt tensioner with plain washer. See
Fig. 20.
7) Install belt so as not to give slack at each center of shaft. Install timing
belt starting with crankshaft sprocket, idler pulley, camshaft sprocket to
timing belt tensioner. See Fig. 21.
8) Temporarily fasten tensioner pulley by center bolt to add force at belt.
9) Adjust timing belt tension:
Rotate crankshaft in regular direction (clock wise view from front)
through angle equivalent to two teeth (18) of camshaft sprocket.
See Fig. 22.
Give tension to timing belt by rotating tensioner in arrow direction
with tool and set timing belt not to give slack to tension side.
Tighten tensioner bolt.
Recheck the belt tension. See Fig. 23. When the tension side of
timing belt is pushed horizontally with a moderate force, 5 ft. lbs. (20
N.m). The timing belt cog end sags in 0.16-0.24 (4-6 mm).
10) Turn the crankshaft two turns in the operating direction (clockwise)
and realign crankshaft sprocket and camshaft sprocket timing mark.
11) Install the timing belt lower cover. See Fig. 9. See TORQUE
SPECIFICATIONS.
12) Install the flange and crankshaft pulley. See Fig. 7. See TORQUE
SPECIFICATIONS. Make sure that crankshaft sprocket pin fits the small
hole in the pulley.
13) Install the timing belt upper cover. See Fig. 5.
14) Install the coolant pump pulley.
15) Install power steering belt.
16) Install air compressor bolt.
17) Install alternator belt.
18) Install the stay plate. See Fig. 4. See TORQUE SPECIFICATIONS.
Install engine mount bracket. See Fig. 3. See TORQUE SPECIFICATIONS.
19) Install right side cover. See Fig. 2.
20) Install right front wheel.
21) Install engine cover. See Fig. 1.

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2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 4: Removing & Installing Stay Plate

Courtesy of Hyundai Motor Co.

Fig. 1: Removing & Installing Engine Cover

Courtesy of Hyundai Motor Co.

Fig. 5: Removing & Installing Timing Belt Upper Cover

Courtesy of Hyundai Motor Co.

Fig. 2: Removing & Installing Side Cover

Courtesy of Hyundai Motor Co.

Fig. 6: Identifying Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 3: Removing & Installing Engine Mount Bracket

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2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 7: Removing & Installing Crankshaft Pulley

Courtesy of Hyundai Motor Co.

Fig. 10: Removing Timing Belt Tensioner

Courtesy of Hyundai Motor Co.

Fig. 8: Removing Crankshaft Flange

Courtesy of Hyundai Motor Co.

Fig. 11: Removing Timing Belt

Courtesy of Hyundai Motor Co.

Fig. 9: Removing & Installing Timing Belt Lower Cover

Courtesy of Hyundai Motor Co.

Fig. 12: Removing & Installing Timing Belt Idler

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2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 13: Removing & Installing Crankshaft Sprocket

Courtesy of Hyundai Motor Co.

Fig. 16: Removing & Installing Cylinder Head Cover

Courtesy of Hyundai Motor Co.

Fig. 14: Removing & Installing Accelerator Cable

Courtesy of Hyundai Motor Co.

Fig. 17: Removing & Installing Camshaft Sprocket

Courtesy of Hyundai Motor Co.

Fig. 15: Locating PCV Hose & Breather Hose

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2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 20: Installing Timing Belt Tensioner

Courtesy of Hyundai Motor Co.

Fig. 18: Locating Camshaft Sprocket Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 19: Locating Crankshaft Sprocket Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 21: Locating Timing Belt Components

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2.0L 4-Cylinder DOHC Elantra (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ............. 74-89 (100-120)
Crankshaft Pulley Bolt ................................................................... ......... 125-133 (170-180)
Idler Pulley Bolt ............................................................................. ................. 32-40 (43-55)
Engine Mount Nuts
14mm Nut .................................................................................... ................. 37-48 (50-65)
17mm Nut .................................................................................... ................. 44-59 (60-80)
Generator Brace Mounting Bolt .................................................... ................. 14-20 (20-27)
Generator Support Bolt/Nut .......................................................... ................. 14-18 (20-25)
Stay Plate Bolt .............................................................................. ................. 31-41 (43-55)
Timing Belt Idler Bolt .................................................................... ................. 31-41 (43-55)
Timing Belt Tensioner Bolt ............................................................ ................. 31-41 (43-55)
Water Pump Bolt ........................................................................... ................. 14-20 (20-27)
Courtesy of Hyundai Motor Co.

INCH Lbs. (N.m)

Timing Belt Cover Bolt .................................................................. ................... 71-86 (8-10)
Water Pump Pulley Bolt ................................................................ ................... 71-86 (8-10)

Fig. 22: Adjusting Camshaft Sprocket

Courtesy of Hyundai Motor Co.

Fig. 23: Adjusting Timing Belt Tension

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2.0L 4-Cylinder Sonata

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC

Sonata
1992-98
Balance Shaft ............... .......... 1 .......... .. TCK167 .. ..... T168
Camshaft ......................... 2 3.8 Hours .. .. TCK167 .. ..... T167
1
2

Balance shaft belt included in camshaft belt labor time.

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove all drive belts. Remove crankshaft pulley and
water pump pulley. Remove upper and lower timing belt covers, noting
bolt lengths and locations.
2) 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. 1. Camshaft sprocket dowel pins
should face upward.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed
from timing belt end of engine). If reusing timing belt, mark
direction of belt rotation before removing.
3) Remove timing belt automatic tensioner. See Fig. 2. Mark timing belt
to indicate original direction of rotation. Remove timing belt.
4) 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 screwdriver can be inserted at least 2.36 (60
mm). If not, rotate oil pump sprocket so screwdriver can be inserted to
correct depth.
5) Loosen balance shaft belt tensioner bolt. Remove front crankshaft
sprocket and flange. Remove balance shaft timing belt.
Inspection 1) Check belt teeth for damage and oil contamination.
Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is
not cracked, separated or showing canvas fiber.
2) Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and roughness in rotation. Replace components if damaged.
3) 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.
4) Retract rod into tensioner housing by placing automatic tensioner
assembly in a soft-jawed vise. Close vise SLOWLY to push rod back into
tensioner. See Fig. 4.

5) 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 1) Align timing marks on balance shaft sprockets with
timing marks on engine case. Install balance shaft timing belt and
crankshaft flange. Install crankshaft flange in correct direction. See
Fig. 5.
2) Position balance shaft tensioner so that the center of the pulley is to
the left and above the tensioner bolt. See Hold tensioner tightly against
belt. Tighten tensioner pulley bolt without letting tensioner rotate.
3) To check balance shaft belt tension, depress belt with finger midway
between sprockets (opposite tensioner pulley). Deflection should be
between .20-.29 (57 mm). If not, readjust belt tension.
4) Place crankshaft sprocket on crankshaft. Tighten bolt to specification.
See TORQUE SPECIFICATIONS.
5) Ensure screwdriver is still installed through left side of cylinder block
to hold balance shaft in place. Install automatic tensioner on engine
block with rod locked in place.
6) 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.
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.
7) Align crankshaft sprocket timing marks and oil pump sprocket timing
marks. See Fig. 1. 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.
8) Install belt around idler pulley. Align timing mark on exhaust camshaft
sprocket with top of cylinder head. Pulling belt with both hands, install it
around exhaust camshaft sprocket.
9) Gently raise tensioner pulley so belt does not sag. Position timing belt
tensioner pin holes so that they face up. Temporarily tighten center bolt.
See Fig. 6.
10) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise,
and then rotate clockwise until No. 1 cylinder is at TDC. Ensure all timing
marks are aligned.
11) Loosen center bolt on tensioner pulley. Note location of pin holes in
tensioner pulley.
12) Using INCH-lb. torque wrench and Socket Wrench (09224-28100),
apply a torque of 22-24 INCH lbs. (2.6-2.8 N.m) on tensioner pulley. With
torque applied to tensioner pulley, tighten tensioner pulley center bolt to
specification. See Fig. 7. See TORQUE SPECIFICATIONS.
13) Install Set Screw (09244-28000), or equivalent, in left engine
support bracket until set screw end contacts tensioner arm. Rotate set
screw further until locking pin can be removed from automatic tensioner.
See Fig. 6. Remove set screw.
14) 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. 8, Dimension A. If distance is incorrect,
repeat timing belt tensioning procedure. If distance is okay, go to
step 17).
15) If distance between automatic tensioner and tensioner arm cannot
be measured easily, use this alternate method. Install Set Screw
(09244-28000) until it contacts tensioner arm.
16) 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. Remove set screw.
17) Install rubber plug in rear timing belt cover. Install timing belt covers.
Install timing belt cover bolts in correct locations. See Fig. 9.
18) To complete installation, reverse removal procedure. Apply 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 proper tension.

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2.0L 4-Cylinder Sonata (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt &

Related Components

Courtesy of Hyundai Motor Co.

Fig. 3: Locking Left Balance Shaft In Place

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2.0L 4-Cylinder Sonata (Cont.)

Courtesy of Hyundai Motor Co.

Courtesy of Hyundai Motor Co.

Fig. 8: Measuring Auto Tensioner Protrusion

Fig. 4: Retracting Automatic Tensioner Rod

Courtesy of Hyundai Motor Co.

Fig. 5: Installing Crankshaft Flange

Courtesy of Hyundai Motor Co.

Fig. 9: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Hyundai Motor Co.

Fig. 6: Tensioning Camshaft Timing Belt

Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Automatic Tensioner Bolt .............................................................. ................. 15-20 (20-27)
Balance Shaft Sprocket Bolt ......................................................... ................. 32-36 (43-49)
Balance Shaft Tensioner Retaining Bolt ......................................................... 11-16 (15-22)
Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100)
Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 15-22 (20-30)
Crankshaft Sprocket Center Bolt ................................................................ 81-96 (110-130)
Front Tensioner Pulley Bolt ........................................................... ................. 32-41 (43-55)
Idler Pulley Bolt ............................................................................. ................. 25-31 (34-42)
Oil Pump Sprocket Nut ................................................................. ................. 37-44 (50-60)
Water Pump Mounting Bolt ............................................................................... 9-11 (12-15)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 7: Adjusting Timing Belt Tensioner Pulley

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2.4L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cylinder DOHC

Sonata
1999-03
Balance Shaft Belt ................................ 1 3.0 Hours .. .....
Camshaft Belt ........................................ 2.4 Hours ... .....
Santa Fe
2001-04
Balance Shaft Belt ................................ 1 3.1 Hours .. .....
Camshaft Belt ........................................ 2.3 Hours ... .....
1

T314
T313

T314
T313

Includes camshaft belt.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles,
except in California. In California, inspect timing belt at 60,000 miles,
and replace as necessary.

REMOVAL & INSTALLATION

Courtesy of Hyundai Motor Co.

Fig. 1: Identifying Timing Belt Alignment Marks

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING & COUNTERBALANCE SHAFT BELTS

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.
Removal 1) Remove drive belts and drive pulleys from crankshaft and
water pump. Remove timing belt covers. To align timing marks, rotate
engine clockwise so No. 1 cylinder is at TDC of compression stroke.
Ensure camshaft sprocket timing marks align with upper surface of
rocker cover. Dowel pin of camshaft sprocket should be pointing
upward. See Figs. 1 and 2.
2) Remove timing belt auto tensioner. If reusing timing belt, place mark
on timing belt to indicate direction of belt rotation. Remove timing belt.
Remove camshaft sprockets.
3) Remove plug at left side of block and insert a screwdriver to hold left
counterbalance shaft in position. Screwdriver will have to be inserted at
least 2.36 (60 mm). Remove oil pump sprocket nut and sprocket. See
Fig. 2.
4) Loosen right counterbalance shaft sprocket mounting bolt. Remove
tensioner B and timing belt B. See Fig. 2. Remove crankshaft
sprocket B from crankshaft.
Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and roughness in rotation. Check sprockets
and pulleys for wear, cracks or damage. Replace components if
necessary.
2) Measure protrusion of auto tensioner rod. From end of housing, auto
tensioner rod should extend .55 (14 mm) on Sonata or .57 (15 mm) on
Santa Fe. Replace auto tensioner rod, if not within specification. Place
tensioner in a soft-jawed vise, and test resistance of rod. If rod can be
easily pushed in with light vise pressure, replace auto tensioner.
Installation 1) Install crankshaft sprocket B onto crankshaft. Ensure
flange is properly positioned. Lightly oil outer surface of spacer, and then
install spacer onto right counterbalance shaft, with rounded edge of
spacer inward.
2) Install counterbalance shaft sprocket. Tighten flange bolt tightly by
hand. Align timing marks on each sprocket and on front case.

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components

3) When installing timing belt B, ensure there is no slack in tension
side. Install tensioner B in center of pulley of left side of mounting bolt,
and in pulley flange toward front of engine. See Fig. 3. Align timing mark
of right counterbalance shaft sprocket with timing mark on front case.

372

HYUNDAI
2.4L 4-Cylinder DOHC (Cont.)

4) To tighten timing belt B, lift tensioner B so tension side is pulled

tight. Tighten bolt to secure tensioner B. DO NOT turn shaft, or belt will
be over-tightened.
5) Ensure timing marks are aligned. Ensure center of span on tension
side of timing belt B can be depressed by hand. Ensure belt deflection
is .20-.30 (5-7 mm).
6) Install crankshaft sprocket flange and sprocket. Ensure flange is
mounted in proper direction, with chamfered side toward block. Install
special washer and sprocket bolt to crankshaft. Tighten sprocket bolt to
specification. See TORQUE SPECIFICATIONS.
7) Insert long screwdriver through plug hole in left side of cylinder block
to hold counterbalance shaft in position. Install oil pump sprocket, and
tighten nut to specification. See TORQUE SPECIFICATIONS. Install
camshaft sprockets, and tighten bolts. See TORQUE SPECIFICATIONS.
8) If auto tensioner rod is fully extended, place it in soft-jawed vise, and
compress rod until hole in rod lines up with hole in auto tensioner
housing. Insert stiff wire to hold rod in this position. Install auto tensioner,
leaving wire in place.

Courtesy of Hyundai Motor Co.

Fig. 4: Measuring Auto Tensioner Protrusion

CAUTION: If timing marks on camshaft sprockets do not line up

properly, DO NOT rotate sprocket more than 2 teeth in either
direction, or valve and piston will touch. If necessary, remove and
reposition camshaft sprocket.
9) Install crankshaft sensor. Set timing marks of camshaft sprockets with
notches on upper side of rocker cover and dowel pins straight up. Align
crankshaft sprocket timing marks. Align oil pump sprocket timing marks.
10) Install timing belt around tensioner pulley and crankshaft sprocket.
Secure belt onto tensioner pulley by hand. Pull other side of belt, and
install it around oil pump sprocket. Install belt around idler pulley.
11) Install belt around intake camshaft sprocket. Turn exhaust camshaft
sprocket one tooth clockwise to align its timing mark with cylinder head
top surface. Pull belt with both hands, and install around exhaust
camshaft sprocket.
12) Gently raise tensioner pulley so belt will not sag, and then temporarily tighten center bolt. Ensure timing mark of each sprocket is still
aligned. Remove wire from auto tensioner.
13) Rotate crankshaft 2 complete turns clockwise. Leave in this position
for about 15 minutes. Measure auto tensioner protrusion A (distance
between tensioner arm and auto tensioner body). Ensure auto tensioner
protrusion is .24-.31 (6-8 mm). See Fig. 4. Install timing belt lower cover
and upper cover. Note proper location of each bolt. See Fig. 5 or 6.

Courtesy of Hyundai Motor Co.

Fig. 3: Installing Tensioner B

Courtesy of Hyundai Motor Co.

Fig. 5: Identifying Timing Belt Cover Bolts

(Santa Fe & 2002-03 Sonata)

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2.4L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ....................................................................... ................. 14-20 (20-27)
Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100)
Crankshaft Damper Mounting Bolt ......................................................... 116-123 (157-167)
Crankshaft Pulley-To Crankshaft Sprocket Bolt ........................... ................. 14-22 (20-30)
Front Case Bolt ............................................................................. ................. 14-20 (20-27)
Front Case Plug Cap .................................................................... ................. 14-20 (20-27)
Tensioner Arm Assembly ............................................................... ................. 12-19 (17-26)
Tensioner Pulley Bolt .................................................................... ................. 31-40 (42-54)
Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
Timing Belt Cover Bolts
Lower & Upper Cover ................................................................. ..................................... 1
Rear Left Cover
Lower ......................................................................................... ................. 22-30 (30-42)
Upper ......................................................................................... ..................................... 2
Right Rear Cover ........................................................................ ..................................... 2
Timing Belt Idler Pulley Bolt
Sante Fe & 2002-04 Sonata ...................................................................... 22-30 (30- 42)
All Other Models ......................................................................... ................. 33-40 (45-55)
Water Pump Mounting Bolt
Sante Fe & 2002-04 Sonata ...................................................... ................. 14-20 (20-27)
All Other Models ........................................................................................... 11-15 (15-22)
Courtesy of Hyundai Motor Co.

Fig. 6: Identifying Timing Belt Cover Bolts (1999-01 Sonata)

INCH Lbs. (N.m)

Valve Cover Bolts .......................................................................... ................... 71-89 (8-10)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
1
2

Tighten to 71-89 INCH lbs. (8-10 N.m).

Tighten to 89-106 INCH lbs. (10-12 N.m).

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2.4L 4-Cylinder SOHC

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

2.4L 4-Cyl. SOHC

Sonata
1989-91
Balance Shaft ............... .......... 1 .......... .. TCK124 .. ..... T159
Camshaft ......................... 2 2.7 Hours .. .. TCK124 .. ..... T124
1
2

Balance Shaft Belt included in Camshaft Belt labor time.

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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. See Fig. 1.
2) Remove crankshaft sprocket bolt access cover. Remove crankshaft
sprocket bolt and washer. Rotate engine clockwise to align timing mark
on camshaft sprocket with mark on cylinder head. See Fig. 2. Loosen
front timing belt tensioner adjustment bolt, and move tensioner toward
water pump.
3) 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 screwdriver to block left silent (counterbalance) shaft. See Fig. 3. Remove oil pump sprocket nut to remove
sprocket.
4) 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.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

HYUNDAI

375

2.4L 4-Cylinder SOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 4: Positioning Timing Belt Crankshaft Flange

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Front Timing Belt

Courtesy of Hyundai Motor Co.

Fig. 5: Aligning Rear Timing Belt Marks

Courtesy of Hyundai Motor Co.

Fig. 3: Blocking Left Silent Shaft

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 1) 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. See Fig. 4. 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. 2.
2) Install rear tensioner. Hold tensioner tight against belt while tightening
bolts. Depress belt with finger to ensure deflection 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. See TORQUE SPECIFICATIONS.
3) Install belt tensioner, tension spring and spacer. Ensure spring is
properly engaged against front case. Rotate tensioner toward water
pump, and temporarily tighten retaining bolts. Ensure camshaft and
crankshaft timing marks are aligned. See Fig. 2. Install timing belt on
crankshaft.
4) 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.
5) 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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
INCH Lbs. (N.m)
Crank Angle Sensor Nut ............................................................... ................. 84-108 (9-12)
Timing Belt Cover Bolt
Left Lower Rear Cover Bolt ........................................................ ..................... 44-61 (5-7)
All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

HYUNDAI

376

3.0L V6
TIMING BELT APPLICATION
Application

Labor Time

3.0L V6
Sonata
1990-98 ............................ ...
1

Component
Belt
Kit No.
Part No.

3.1 Hrs. ... .. TCK139 .. ..... T139

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Support engine oil pan with jack and block of wood.
Remove 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.
2) Ensure engine is on No. 1 cylinder compression stroke and timing
marks are aligned. Remove crankshaft pulley and timing belt covers.
See Fig. 2.
3) Rotate crankshaft clockwise to align camshaft and crankshaft 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.

Courtesy of Hyundai Motor Co.

Fig. 1: Identifying Engine Support Loosening & Tightening

Sequence
Inspection Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner for worn bearing.
Installation 1) 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.
2) 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.
3) Apply force counterclockwise to rear camshaft sprocket, applying
tension to right side of belt. Ensure timing marks are aligned.
4) Loosen tensioner bolt, allowing tensioner to take up slack in left side
of timing belt. Tighten tensioner bolt. Rotate crankshaft 2 turns clockwise.
5) Realign timing marks. Measure timing belt tension using belt tension
gauge midway between crankshaft and camshaft sprockets, on side
opposite tensioner. For new belt, tension should be 57-84 lbs. (26-38
kg).
6) Install flange on crankshaft sprocket with flat side facing timing belt.
Install front timing belt cover. Install crankshaft pulley and tighten bolt to
specification. See TORQUE SPECIFICATIONS.
7) Install engine support bolts and tighten in sequence. See Fig. 1. To
complete installation, reverse removal procedure. Tighten nuts and bolts
to specfication. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

HYUNDAI

377

3.0L V6 (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100)
Crankshaft Sprocket Bolt .............................................................. .......... 111-118 (150-160)
Timing Belt Tensioner Bolt ............................................................ ................. 16-22 (22-30)
Water Pump Bolt
Headmark 4 Bolt ........................................................................................... 9-11 (12-15)
Headmark 7 Bolt ....................................................................... ................. 15-20 (20-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

Courtesy of Hyundai Motor Co.

Fig. 3: Aligning Timing Belt Marks

HYUNDAI

378

3.5L V6 DOHC
TIMING BELT APPLICATION
Application
3.5L V6 DOHC
XG350
2004 ..........................................................
1

Labor Time

Belt
Part No.

4.0 Hours .. ..... T323

Includes Upper and Lower Timing Covers removal and installation.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles,
except in California. In California, inspect timing belt at 60,000 miles,
and replace as necessary.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove the wheel of passenger side.
2) Remove the side cover.
3) Remove the engine cover.
4) Disconnect the power steering hose fixing on the engine mounting
bracket.

CAUTION: Before removing the engine mounting bracket support

the engine oil pan with a jack or equivalent.
5) Remove the engine mounting bracket. See Fig. 1.
6) Disconnect the connectors from the timing belt upper cover and
remove the upper cover.
7) Remove the drive belt and loosen the 2 alternator mounting nuts (14
mm) and 2 bolts (12 mm) connecting the engine support bracket.
8) Loosen the 5 engine support bracket bolts.
9) Remove the engine support bracket bolt by moving the engine up and
down slightly and remove the bracket upward.
NOTE: Rotate the crankshaft clockwise and align the timing mark
to set the No.1 cylinders piston to TDC (compression stroke). See
Fig. 2. At this time, the timing marks of the camshaft sprocket and
cylinder head cover should coincide with each other.
10) Remove the auto tensioner. See Fig. 3.
NOTE: If you plan to use the timing belt again, mark the rotation
direction on the belt so you reinstall it correctly.
11) Unbolt the tensioner to remove the timing belt.
Inspection Inspect timing belt for wear on edges of drive teeth.
Inspect the 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 pulley for smooth
rotation. Replace if defective. Check timing belt auto tensioner for leaks.
Replace if necessary.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

HYUNDAI

379

3.5L V6 DOHC (Cont.)

Installation 1) Install idler pulley to engine support lower bracket. See
Fig. 4.
2) Install tensioner arm, shaft and plane washer to cylinder block.
CAUTION: Be careful not to bend crankshaft sensing blade. See
Fig. 5.
3) Install crankshaft sprocket and align the timing mark. See Fig. 6.
4) Install camshaft sprocket and adjust. See Fig. 7.

Courtesy of Hyundai Motor Co.

Fig. 2: Rotating Crankshaft

NOTE: If the auto tensioner rod is in its fully extended position,

reset it as follows:
Clamp it in a vise equipped with soft jaws, in a level position.
Use a plain washer if there is a plug at the bottom of the auto
tensioner.
Compress the rod slowly with the vise until the set hole in the
rod is aligned with set hole in the cylinder.
Insert a set pin through the auto tensioner body and rod. Leave
the set pin installed in the auto tensioner.
5) Install auto tensioner to oil pump case.
NOTE: In this step, No. 1 piston is in TDC (Compression stroke).
CAUTION: Do not insert fingers.

Courtesy of Hyundai Motor Co.

Fig. 3: Removing Auto Tensioner

6) Align the timing marks of each sprocket and install the timing belt in
this order:
Crankshaft sprocket.
Idler pulley.
Exhaust camshaft sprocket (left).
Intake camshaft sprocket (left).
Water pump pulley.
Intake camshaft sprocket (right).
Exhaust camshaft sprocket (right).
Tensioner pulley.

Courtesy of Hyundai Motor Co.

Fig. 4: Aligning Camshaft Timing Marks

HYUNDAI

380

3.5L V6 DOHC (Cont.)

7) After installing the timing belt, reconfirm the timing mark.
8) Pull out the set pin of auto tensioner.
NOTE: Rotate the crankshaft two rotations clockwise and measure
the projected load of auto tensioner in the TDC (#1 piston compression stroke) after 5 minutes. Check for projected length of
3.8-4.5 mm. See Fig. 8. Check again to verify the timing marks of
each sprocket are within specified position.
9) Install the engine support bracket.
10) Install the timing belt cover.
11) Install the alternator and drive belt.
12) Install the engine mounting bracket.
13) Install the side cover.
14) Install the wheel of passenger side.

Courtesy of Hyundai Motor Co.

Fig. 7: Camshaft Sprocket Initial Installation

Courtesy of Hyundai Motor Co.

Fig. 8: Checking Timing Belt Tensioner Projected Length

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Hyundai Motor Co.

Fig. 5: Identifying Crankshaft Sprocket Components

Application
Ft. Lbs. (N.m)
Auto Tensioner Fixed Bolt ............................................................. ................. 15-20 (20-27)
Camshaft Sprocket Bolt ................................................................................ 66-81 (90-110)
Crankshaft Pulley Bolt ................................................................... ......... 133-140 (180-190)
Drive Belt Pulley Bolt .................................................................... ................. 26-41 (35-55)
Drive Belt Tensioner Bolt/Nut ........................................................ ................. 33-37 (45-50)
Timing Belt Cover Bolt
6 mm ........................................................................................... ..................................... 1
8 mm ........................................................................................... ................. 15-20 (20-27)
Timing Belt Idler Pulley Bolt ......................................................... ................. 37-44 (50-60)
Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 26-41 (35-55)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 32-41 (43-55)
1

Courtesy of Hyundai Motor Co.

Fig. 6: Aligning Crankshaft Sprocket Timing Marks

Tighten bolts to 89-106 INCH lbs. (10-12 N.m).

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381

2.5L V6 DOHC
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.5L V6 DOHC
Optima
2001 .......................................................... 1 2.4 Hours .. ..... T315
Sonata
1999-01 ..................................................... 2.6 Hours ... ..... T315
1

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles,
except in California. For California Sonata models, inspect timing belt at
60,000 miles, and replace as necessary. For California Optima models,
inspect timing belt at 60,000 miles and 90,000 miles, and replace belt at
105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove engine trim cover. Using 16-mm spanner
wrench, rotate serpentine belt tension arm clockwise about 14 degrees
to relieve belt tension. Remove serpentine drive belt. Remove water
pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
Remove upper and lower timing belt covers.
2) Support engine with padded jack, and remove engine mount insulator
and bracket in front of timing belt. Rotate engine clockwise to align
timing mark so No. 1 cylinder is at TDC of compression stroke. Ensure
camshaft sprocket timing marks line up with marks on upper surface of
rocker cover. See Fig. 1. If reusing timing belt, place mark on timing belt
to indicate direction of belt rotation. Remove timing belt auto tensioner.
Remove timing belt.
Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and roughness in rotation. Check sprockets
and pulleys for wear, cracks or damage. Replace components if
necessary.
Installation 1) Install idler pulley onto pin spring pressed into water
pump boss. Install tensioner arm and flat washer to cylinder block. Install
pulley on tensioner arm.
2) Before installing timing belt, ensure camshaft and crankshaft timing
marks are aligned. See Fig. 1. If timing marks are not aligned, DO NOT
turn camshaft sprockets more than 3 teeth in either direction to align

Courtesy of Hyundai Motor Co.

Fig. 1: Identifying Timing Belt Components &

Aligning Belt Timing Marks
(this will result in valves touching pistons). If camshaft sprocket is
accidentally rotated more than 3 teeth, rotate crankshaft counterclockwise 3 teeth before rotating camshaft sprocket.
3) Compress timing belt auto tensioner, and install set pin to hold in
retracted position. Install timing belt auto tensioner to front case. Align
timing marks of each sprocket and install timing belt around pulleys and
sprockets in the following order: crankshaft sprocket, idler pulley, left
intake cam sprocket, water pump pulley, right intake cam sprocket and
tensioner pulley. See Fig. 1.
4) Pull set pin from timing belt auto tensioner to apply tension to timing
belt. Adjust tension and seat timing belt by rotating crankshaft 2
complete revolutions clockwise. Check auto tension pin extended
length. Extended length should be .24-.32 (6.1-8.1 mm). If length is
greater than specification, belt is stretched. Install NEW timing belt.
Ensure sprocket timing marks are properly aligned. If marks are not
properly aligned, repeat installation procedure.
5) Install engine mount bracket and insulator. Install upper and lower
timing belt covers. Install all external pulleys. Rotate auto tensioner arm
about 14 degrees clockwise, and install serpentine drive belt onto
pulleys. See Fig. 2. Release tensioner. Tensioner indicator mark should
be between range marks. See Fig. 3. If tensioner indicator is not within
range marks, replace serpentine drive belt. Install engine cover.

382

HYUNDAI & KIA

2.5L V6 DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 3: Identifying Tensioner Mark Location

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner Arm Bolt ............................................................... ................. 26-40 (35-55)
Camshaft Sprocket Bolt ................................................................................ 65-80 (90-110)
Crankshaft Pulley Bolt ................................................................... ......... 130-138 (180-190)
Drive Belt Pulley Bolt .................................................................... ................. 26-40 (35-55)
Drive Belt Tensioner Bolt .............................................................. ................. 14-20 (20-27)
Timing Belt Assembly
Auto Tensioner Fixed Bolt ........................................................... ................. 14-20 (20-27)
Auto Tensioner Pulley Bolt .......................................................... ................. 31-40 (43-55)
Idler Pulley Bolt ........................................................................... ................. 36-43 (50-60)
Water Pump Mounting Bolt ............................................................................. 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Assembly Cover Bolt ................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 2: Identifying Drive Belt Routing & Pulley Locations

HYUNDAI & KIA

383

2.7L V6 DOHC
TIMING BELT APPLICATION
Application
2.7L V6
Optima
2002-04
Santa Fe
2001-04
Sonata
2002-04
Tiburon
2003-04
1
2

Labor Time

....................................................

Belt
Part No.

2.4 Hours .. ..... T315

..................................................... 2.6 Hours ... ..... T315

....................................................

2.4 Hours .. ..... T315

....................................................

2.7 Hours .. ..... T315

With Air Conditioning, add .2 hours.

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles,
except in California. In California, for all models except Optima, inspect
timing belt at 60,000 miles, and replace as necessary. For Optima,
inspect timing belt at 60,000 miles and 90,000 miles, and replace at
105,000 miles.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt Components

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: To prevent pistons from contacting valves, DO NOT
rotate camshaft or crankshaft with timing belt removed.
Removal 1) Remove engine cover. Using 16-mm spanner wrench,
rotate serpentine belt tension arm clockwise about 14 degrees to relieve
belt tension. Remove serpentine drive belt. Remove power steering
pump pulley, drive belt idler pulley, drive belt tensioner pulley, and
crankshaft pulley. See Fig. 1.
2) Remove timing belt covers. If necessary, support engine using
wooden block on jack, and remove engine mounting insulator and
engine mount bracket. Rotate crankshaft clockwise until engine is on
No. 1 cylinder compression stroke. Ensure camshaft timing marks are
aligned. See Fig. 2.
3) If reusing timing belt, mark direction of rotation on belt. Remove timing
belt auto tensioner. Remove timing belt.
Inspection Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner and idler pulleys for
worn bearings.
Installation 1) Install idler pulley onto roll pin pressed into water pump
boss. Install tensioner arm and flat washer onto cylinder block. Install
pulley onto tensioner arm.
2) Before installing timing belt, ensure camshaft and crankshaft timing
marks are aligned. See Fig. 2. If timing marks are not aligned, DO NOT
turn camshaft sprockets more than 3 teeth in either direction to align
(this will result in valves touching pistons). If camshaft sprocket is
accidentally rotated more than 3 teeth, rotate crankshaft counterclockwise a bit before rotating camshaft sprocket.
3) Compress timing belt auto tensioner, and install set pin to hold in
retracted position. Install timing belt auto tensioner onto front case. Align
timing marks of each sprocket, and install timing belt around pulleys and
sprockets as follows: crankshaft sprocket, idler pulley, left intake camshaft sprocket, water pump pulley, right intake camshaft sprocket and
tensioner pulley. See Fig. 2.

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Timing Belt Marks

4) Pull set pin from timing belt auto tensioner to apply tension to timing
belt. Adjust tension and seat timing belt by rotating crankshaft 2
complete revolutions clockwise. Check auto tension pin extended length
after 5-minute wait. Extended length should be .24-.32 (6.1-8.1 mm). If
length is greater than specification, belt is stretched. Install NEW timing
belt. Ensure sprocket timing marks are properly aligned. If marks are not
properly aligned, repeat installation procedure.
5) Install engine mount bracktet and mounting insulator, if necessary.
Install upper and lower timing belt covers. Install all external pulleys.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Rotate auto tensioner arm about 14 degrees clockwise, and install
serpentine drive belt onto pulleys. See Fig. 3. Release tensioner.
Tensioner indicator mark should be between range marks. See Fig. 4. If
tensioner indicator is not within range marks, replace serpentine drive
belt. Install engine cover.

HYUNDAI & KIA

384

2.7L V6 DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 4: Identifying Tensioner Mark Location

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner Fixed Bolt ............................................................. ................. 14-20 (20-27)
Camshaft Sprocket Bolt ................................................................................ 65-80 (90-110)
Crankshaft Sprocket Bolt .............................................................. ......... 130-138 (180-190)
Drive Belt Pulley Bolt .................................................................... ................. 25-40 (35-55)
Drive Belt Tensioner Bolt .............................................................. ................. 14-20 (20-27)
Engine Mount Bracket Bottom Bolt (3) ........................................ ................. 43-58 (60-80)
Engine Mount Bracket Stud
Santa Fe, Sonata & Tiburon ....................................................... ................. 22-29 (30-40)
Engine Mount Insulator Bolt
Optima ......................................................................................................... 65-80 (90-110)
Santa Fe, Sonata & Tiburon ....................................................... ................. 29-40 (40-55)
Power Steering Pump ................................................................... ................. 12-19 (17-26)
Timing Belt Idler Pulley Bolt ......................................................... ................. 36-43 (50-60)
Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 25-40 (35-55)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 31-40 (43-55)
Water Pump Bolt ............................................................................................. 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

Courtesy of Hyundai Motor Co.

Fig. 3: Drive Belt Routing & Pulley Locations

HYUNDAI & KIA

385

3.0L & 3.5L V6 DOHC

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

3.0L V6 DOHC
XG300
2001 ........................................................... 4.0 Hours ... .....
3.5L V6 DOHC
Amanti
2004 ........................................................ ........ N/A ........ .....
Sedona
2002-04 .................................................... 1 3.1 Hours .. .....
Sorento
2003-04 .................................................... 1 3.1 Hours .. .....
XG350
2002-03 ..................................................... 4.0 Hours ... .....
1

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

T322

TIMING BELT
T323
T323
T323
T323

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For Sorento, the manufacturer recommends the belt be inspected every
20,000 miles, and replaced at 40,000 miles (severe service) or 60,000
miles (normal service). For all other models, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In
California, inspect timing belt at 60,000 miles, and replace as necessary.

Removal 1) Disconnect negative battery cable. Remove engine cover.

Using 16-mm spanner wrench, rotate serpentine belt tension arm
clockwise about 14 degrees to relieve belt tension. Remove serpentine
drive belt. Remove power steering pump pulley, idler pulley, tensioner
pulley and crankshaft pulley. Remove upper and lower timing belt
covers. See Fig. 1 or 2.
NOTE: Rotate crankshaft clockwise and align timing mark to set
No. 1 cylinder to TDC on compression stroke.
2) Ensure timing marks of camshaft sprocket and cylinder head cover
are matching. See Fig. 5. On Sedona, support engine with jack and
remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3.
NOTE: If timing belt is to be reused, mark rotational direction on
belt for reinstallation reference.
3) Unbolt timing belt tensioner pulley, and remove timing belt.
CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the
compression stroke and the corresponding camshaft on the same
cylinder head is rotated 180 degrees while the timing belt is
removed, intake and exhaust valves may contact each other.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components (Amanti, Sedona, XG300 & XG350)

386

HYUNDAI & KIA

3.0L & 3.5L V6 DOHC (Cont.)

Courtesy of Kia Motors America, Inc.

Fig. 2: Exploded View Of Timing Belt & Components (Sorento)

Inspection Inspect timing belt for wear on edges of drive teeth.
Inspect the 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 pulley for smooth
rotation. Replace if defective. Check timing belt auto tensioner for leaks.
Replace if necessary.
Installation 1) Install timing belt idler pulley to engine support lower
bracket. Install tensioner arm, shaft and washer to cylinder block.
Tighten tensioner arm bolt to specification. See TORQUE SPECIFICATIONS.
CAUTION: Use care to avoid bending crankshaft sensing blade of
crank angle sensor.
2) Install crankshaft sprocket and align timing mark. See Fig. 4. Install
camshaft sprocket and adjust installation positions as shown. See
Figs. 5 and 6. Install auto tensioner to oil pump case. Ensure that auto
tensioner set pin is completely assembled. Align timing marks of each
sprocket.
3) Install timing belt in this order: crankshaft sprocket, idler pulley, left
exhaust camshaft sprocket, left intake camshaft sprocket, water pump
pulley, right intake camshaft sprocket, right exhaust camshaft sprocket,
and tensioner pulley.
4) Ensure timing marks are correctly aligned. Install tensioner pulley.
Pull set pin from auto tensioner.
5) Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Measure
projected load of auto tensioner in TDC. Ensure projected length is
.15-.18 (3.8-4.5 mm). See Fig. 7. Recheck timing marks at each
sprocket to ensure each sprocket is in correct position. If not, repeat
installation of timing belt and auto tensioner.

Courtesy of Hyundai Motor Co.

Fig. 3: Removing Auto Tensioner

Courtesy of Hyundai Motor Co.

Fig. 4: Aligning Crankshaft Sprocket Timing Marks

HYUNDAI & KIA

387

3.0L & 3.5L V6 DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 5: Aligning Camshaft Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Hyundai Motor Co.

Fig. 6: Camshaft Sprocket Initial Installation

Application
Ft. Lbs. (N.m)
Auto Tensioner Fixed Bolt ............................................................. ................. 15-20 (20-27)
Camshaft Sprocket Bolt
Amanti, Sedona & Sorento ......................................................... ................. 58-72 (79-98)
XG300 & XG350 ......................................................................................... 66-81 (90-110)
Crankshaft Pulley Bolt ................................................................... ......... 133-140 (180-190)
Drive Belt Pulley Bolt .................................................................... ................. 26-41 (35-55)
Drive Belt Tensioner Bolt/Nut
Amanti .......................................................................................... ................. 25-40 (34-54)
Except Amanti ............................................................................. ................. 33-37 (45-50)
Timing Belt Cover Bolt
6-mm ............................................................................................ ..................................... 1
8-mm ............................................................................................ ................. 15-20 (20-27)
Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 26-41 (35-55)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 32-41 (43-55)
Timing Belt Idler Pulley Bolt ......................................................... ................. 37-44 (50-60)
1

Courtesy of Hyundai Motor Co.

Fig. 7: Checking Timing Belt Tensioner Projected Length

Tighten bolts to 89-106 INCH lbs. (10-12 N.m).

INFINITI

388

3.0L V6 J30
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

3.0L V6
J30
1993 ........................................................... 4.4 Hours ... ..... T180
1994-97 ..................................................... 4.4 Hours ... ..... T251
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
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.
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove lower engine cover. Drain radiator and cylinder block.
Remove air intake ducts, radiator, drive belts, cooling fan assembly and

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

INFINITI

389

3.0L V6 J30 (Cont.)

starter. Remove crankshaft pulley bolt. Using puller, remove crankshaft
pulley. Remove coolant inlet and outlets for access to timing belt cover.
Remove upper and lower timing belt covers. See Fig. 1.
2) Install a 6 x 16 mm stopper bolt on automatic tensioner to prevent
tensioner from pushing outward. See Fig. 2. Rotate 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
camshaft sprockets and crankshaft sprocket are aligned. See Fig. 3.
Remove bolts and automatic tensioner. Remove timing belt. DO NOT
rotate crankshaft or camshafts with timing belt removed, or engine
damage may result.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Stopper Bolt On Automatic Tensioner

Fig. 3. Remove all spark plugs. Install timing belt with White marks on
timing belt aligned with timing mark on crankshaft sprocket and camshaft sprockets. Ensure arrow on timing belt points toward front of
engine.
CAUTION: Ensure stopper bolt is removed before adjusting clearance on automatic tensioner, or stopper bolt and automatic tensioner may be damaged.
2) 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.
3) Slightly push automatic tensioner inward against timing belt to
prevent timing belt from slipping. DO NOT push too hard, or timing belt
will be adjusted too tight. Rotate crankshaft 10 degrees clockwise.
Tighten automatic tensioner retaining nut and then the bolts to specification in sequence. See Fig. 4. See TORQUE SPECIFICATIONS.
4) Rotate crankshaft 120 degrees counterclockwise. Loosen automatic
tensioner retaining bolts and nut 1/2 turn. Rotate automatic tensioner
back as far as possible. Rotate crankshaft clockwise until No. 1 cylinder
is at TDC on compression stroke and all timing marks are aligned. See
Fig. 5.
5) Using Push-Pull Gauge (J-38387) or equivalent and Hook
(KV10112000) or equivalent, push end of pusher on automatic 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.
6) Rotate crankshaft clockwise 120 degrees clockwise from No. 1
cylinder TDC position. Rotate crankshaft counterclockwise 120 degrees
back to No. 1 cylinder TDC position. 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 lbs. (5 kg) force. See Fig. 7. Timing
belt deflection should be .24-.28 (6.0-7.0 mm).
7) If timing belt deflection is not within specification, repeat steps 3)-6)
until proper timing belt deflection is obtained. Ensure automatic tensioner retaining nut and bolts are tightened to specification. See
TORQUE SPECIFICATIONS. Remove stopper bolt from automatic
tensioner.
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.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Aligning Timing Marks

Inspection Inspect timing belt for cracks, worn teeth or oil contamination. Inspect crankshaft sprocket and camshaft sprockets for damaged teeth. Inspect automatic tensioner for signs of oil leakage around
the shaft that pushes the pulley outward. Check all idler pulleys for
smooth rotation. Replace components if damaged.

8) 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.
9) To install remaining components, reverse removal procedure. Tighten
all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
drive belts to proper tension.

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.
Installation 1) Ensure crankshaft sprocket, camshaft sprockets, idler
pulleys and timing belt are dry and clean. Ensure No. 1 cylinder is at
TDC of compression stroke and all timing marks are still aligned. See
Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Adjusting Automatic Tensioner Clearance & Identifying

Bolt/Nut Tightening Sequence

INFINITI

390

3.0L V6 J30 (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 7: Fabricating Belt Tension Plate & Checking Timing Belt

Deflection

TORQUE SPECIFICATIONS
Courtesy of Nissan Motor Co., U.S.A.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt/Nut ........................................................ ................. 12-15 (16-20)
Camshaft Sprocket Bolt
Exhaust .......................................................................................................... 11-14 (15-19)
Intake ........................................................................................... ............. 91-97 (123-132)
Crankshaft Position Sensor Brackets ........................................... ................. 12-15 (16-20)
Crankshaft Pulley Bolt ................................................................... ......... 159-174 (216-236)
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)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 6: Adjusting Automatic Timing Belt Tensioner

Crankshaft Position Sensor Bolt .................................................................................

Timing Belt Cover Bolt
Rear Cover Bolt ........................................................................................................
Upper & Lower ..........................................................................................................
Valve Cover Bolt/Screw
Exhaust Camshaft Cover ..........................................................................................
Intake Camshaft Cover .............................................................................................

44 (5)
53 (6)
27 (3)
71 (8)
27 (3)

INFINITI

391

3.0L V6 M30

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

2) Remove A/C drive belt idler bracket. Disconnect coolant inlet hose
from thermostat housing. Remove crankshaft pulley retaining bolt. Using
puller, remove crankshaft pulley. Remove front upper and lower timing
belt covers. See Fig. 1.
3) 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. 2. Loosen
timing belt tensioner retaining nut. Rotate timing belt tensioner to
release timing belt tension. Remove timing belt.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

NOTE: No. 1 cylinder is front cylinder on left when viewed from

front of engine.

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

3.0L V6
M30
1990-92 ............................... 4.0 Hours ... .. TCK104 .. ..... T104

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.

CAUTION: DO NOT rotate crankshaft or camshafts with timing belt

removed, or engine damage may result.
Inspection Inspect timing belt for damaged teeth, cracking or oil
contamination. Ensure timing belt tensioner rotates smoothly. Inspect
tensioner spring for damage. Replace components if damaged.
Installation 1) Ensure No. 1 cylinder is TDC on compression stroke
and all timing marks are aligned. See Fig. 2. 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.
2) Rotate timing belt tensioner fully outward (away from timing 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.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

INFINITI

392

3.0L V6 M30 (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks & Checking Belt Tension

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
sprocket. See Fig. 2.
3) Using an Allen wrench, hold tension on timing belt tensioner and
loosen retaining nut. Rotate timing belt tensioner clockwise 70-80
degrees, and tighten retaining nut. Rotate crankshaft 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. 1.
4) Loosen timing belt tensioner retaining nut while maintaining pressure
on timing belt tensioner using an Allen wrench. Insert a .0138 (.350
mm) thick and 1/2 wide feeler gauge between timing belt tensioner and
timing belt. Perform first step of installation. See Fig. 3.
5) 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 tensioner. Tighten timing
belt tensioner retaining nut to specification. See TORQUE SPECIFICATIONS.
6) Rotate crankshaft clockwise and remove feeler gauge. Rotate
crankshaft clockwise 2 full revolutions, and realign timing 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 point between camshaft sprockets.
7) To install remaining components, reverse removal procedure. Tighten
all bolts and nuts to specification. See TORQUE SPECIFICATIONS. Fill
and bleed cooling system. Adjust drive belts to proper tension.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Checking Timing Belt Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Locating Plate Bolt ....................................................... ................. 58-65 (79-88)
Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133)
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)

INFINITI, MERCURY & NISSAN

393

3.3L V6 SOHC
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.3L V6 VG33E & VG33ER (SOHC)

Frontier
1999-04 .............................. 1 3.1 Hours .. .. TCK249 .. .....
Pathfinder
1996-00 .............................. 1 3.3 Hours .. .. TCK249 .. .....
QX4
1997-00 ............................... 3.9 Hours ... .. TCK249 .. .....
Quest
1999-02 .............................. 1 2.6 Hours .. .. TCK249 .. .....
Villager
1999-02 ............................... 2.6 Hours ... ...... ..... ...... .....
Xterra
2000-04 .............................. 1 3.1 Hours .. .. TCK249 .. .....
1

T249
T249
T249
T249
T249
T249

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Setting Crankshaft To TDC

NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the timing belt be replaced at 105,000
mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. DO NOT
rotate camshaft or crankshaft when timing belt is removed, or
engine damage may occur.

TIMING BELT
Removal (Frontier, Pathfinder, QX4 & Xterra) 1) Disconnect negative battery cable. Remove the engine undercover. Drain coolant and
remove the radiator. Remove engine cooling fan and water pump pulley.
Remove accessory drive belts. Remove spark plugs.
2) Remove distributor protector. Remove A/C compressor drive belt idler
bracket. Remove fresh air intake tube from rocker cover. Remove
thermostat housing hose.
3) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke.
See Fig. 1. Remove crankshaft pulley bolt and remove crankshaft pulley.
Remove front upper and lower timing belt covers. See Fig. 2.
4) 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.
5) 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) 1) Install timing belt
when engine is cold. Ensure No. 1 cylinder 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.
2) 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 crankshaft sprocket. See Fig. 6. Point

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Exploded View Of Timing Belt & Components

arrow on timing belt toward front belt cover. There should be 40 teeth
between left and right camshaft sprockets, and 43 teeth between left
camshaft sprocket and crankshaft sprocket.
3) If engine was overhauled or reassembled (rocker covers removed),
go to step 6). If only the timing belt was replaced, go to next step.
4) 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 sprockets. Belt
deflection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension.
5) Install lower and upper belt covers. Install crankshaft pulley. Tighten
bolt to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedures. Fill and bleed cooling system.
See COOLING SYSTEM BLEEDING. Adjust drive belts to proper
tension.
6) Loosen rocker shaft bolts to relieve belt tension caused by camshafts.
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.
7) Slowly return cylinder No. 1 to TDC of compression stroke. Using
Push/Pull Gauge (J-38387), apply 22 lbs. (10 kg) of pressure to timing
belt between right camshaft sprocket and tensioner. Hold tensioner in
position with Allen wrench, and loosen tensioner lock nut.

394

INFINITI, MERCURY & NISSAN

3.3L V6 SOHC (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 5: Positioning Camshaft & Crankshaft Sprockets

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Aligning Camshaft & Crankshaft Punch Marks

Courtesy of Nissan Motor Co., U.S.A.

Fig. 6: Installing Timing Belt

Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Loosening Timing Belt Tensioner Nut

8) Place a .0206 (.5 mm) feeler gauge under tensioner pulley between
pulley and timing belt, and rotate crankshaft clockwise until feeler gauge
is centered between tensioner pulley and timing belt (timing belt will
move about 2.5 teeth). See Fig. 7. Tighten tensioner lock nut to
specification. See TORQUE SPECIFICATIONS.
9) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions, then slowly set cylinder No. 1 at TDC of
compression stroke. While applying 22 lbs. (10 kg) of pressure, measure
timing belt deflection halfway between camshaft sprockets. If deflection
is not .51-.59 (13-15 mm), repeat steps 6)-8). To complete installation,
reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING. Adjust drive belts to proper tension.
Removal (Quest & Villager) 1) Raise and support vehicle. Remove
the engine undercover. Remove right side wheel and engine side cover.
Drain coolant from radiator. Remove accessory drive belts.
2) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke.
See Fig. 1. Remove crankshaft pulley bolt, and remove crankshaft
pulley using a gear puller.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 7: Adjusting Timing Belt

3) 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. See Fig. 2.
4) 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. Temporarily install crankshaft
pulley bolt so that crankshaft can be rotated.
5) Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and
remove timing belt.

INFINITI, MERCURY & NISSAN

395

3.3L V6 SOHC (Cont.)

NOTE: After removing timing belt, DO NOT turn crankshaft or
camshaft separately, or valves will strike pistons.
Inspection (Quest & Villager) 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 & Villager) 1) Install timing belt when engine is
cold. Ensure No. 1 cylinder 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.
2) 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 crankshaft sprocket. See Fig. 6. Point
arrow on timing belt toward front belt cover. There should be 40 teeth
between left and right camshaft sprockets, and 43 teeth between left
camshaft sprocket and crankshaft sprocket.
3) 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 sprockets. Belt
deflection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension.
4) Install lower and upper belt covers. Install crankshaft pulley. Tighten
bolt to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedures. Fill and bleed cooling system.
See COOLING SYSTEM BLEEDING. Adjust drive belts to proper
tension.

COOLING SYSTEM BLEEDING

Frontier, Pathfinder, QX4 & Xterra (1999-02) 1) 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. 8. On Pathfinder,
remove heater hose from heater core inlet. See Fig. 9. On all models, 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). On Pathfinder, install heater
hose to heater core inlet.
2) On all models, 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.
3) 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.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 9: Locating Heater Core Inlet Hose (Frontier, Pathfinder,

QX4 & Xterra)
lbs. (8-12 N.m). If removed, apply sealant to threads of cylinder block
drain plugs, and tighten to 25-33 ft. lbs. (34-44 N.m). Install reservoir
tank, if necessary. Tighten air relief plug to 62-71 INCH lbs. (7-8 N.m).
See Fig. 8. Reattach upper radiator hose at engine side.
2) Set vehicle heater controls to full HOT and heater ON positions. Turn
ignition on (engine off) to activate heater mode. Install Coolant Refill Tool
(J-45695) by installing radiator cap adapter onto radiator neck opening.
Attach gauge body assembly with refill tube and venturi assembly to
radiator cap adapter. See Fig. 10.
CAUTION: Compressed air supply must be equipped with an air
dryer.
3) Insert refill hose into coolant mixture container that is placed at floor
level. Ensure ball valve is in closed position. Install air hose to venturi
assembly, and adjust air pressure to 80-120 psi (5.6-8.4 kg/cm2).
4) The vacuum gauge will begin to rise and there will be an audible
hissing noise. During this process, open ball valve on refill hose slightly.
Coolant will be visible rising in refill hose. Once refill hose is full of
coolant, close the ball valve. This will purge any air trapped in refill hose.
5) Continue to draw vacuum until gauge reaches 28 inches of vacuum.
In high altitude locations, the gauge may not reach 28 inches. See
VACUUM GAUGE SPECIFICATIONS table.
VACUUM GAUGE SPECIFICATIONS
Altitude Above Sea Level
Vacuum Gauge Reading
0-328 Ft. (0-100 m) ....................................... ....................................................... 28 Inches
984 Ft. (300 m) ............................................. ....................................................... 27 Inches
1641 Ft. (500 m) ........................................... ....................................................... 26 Inches
3281 Ft. (1000 m) ........................................................................................... 24-25 Inches
6) When vacuum gauge has reached specified amount, disconnect air
hose and wait 20 seconds to see if the system loses any vacuum. If
vacuum level drops, repair system as necessary and repeat steps 3)-5).
Recheck for leaks.
CAUTION: DO NOT allow coolant container to get too low when
filling, or air will be drawn into cooling system.
7) Place coolant container (with refill hose inserted) at same level as top
of radiator. Open ball valve on refill hose so the coolant will be drawn up
to fill cooling system. Cooling system is full when vacuum gauge reads
zero. Remove tool assembly from radiator neck opening.
8) Fill cooling system reservoir tank to specified level. See COOLING
SYSTEM SPECIFICATIONS table. Run engine to warm up the cooling
system, and top up as necessary before installing radiator cap.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 8: Locating Air Relief Plug (Frontier, Pathfinder,

QX4 & Xterra)
Frontier & Xterra (2003-04) 1) Ensure radiator is completely empty of
coolant and water. Install radiator drain plug, and tighten to 71-106 INCH

COOLING SYSTEM SPECIFICATIONS

Application
Specification
Engine Coolant Capacity (Without Reservoir Tank) .................... ...... 10 3/4 Qts. (10.15L)
Reservoir Tank ................................................................................................... 7/8 Qt. (0.8)

396

INFINITI, MERCURY & NISSAN

3.3L V6 SOHC (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 11: Holding Negative Pressure Relief Valve Open

(Quest & Villager)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Nissan Motor Co., U.S.A.

Fig. 10: Installing Coolant Refill Tool (J-45695)

Quest & Villager 1) Install radiator drain plug. If removed, apply
sealant to threads of cylinder block drain plug and tighten to 25-33 ft. lbs.
(34-44 N.m). Slowly add coolant through radiator filler neck allowing
several minutes for air to escape. Add fluid until filler neck is full.
2) Continue adding coolant while gently moving upper radiator hose up
and down until coolant no longer lowers in filler neck. Place wire under
radiator filler cap negative pressure relief valve. See Fig. 11. Install
radiator cap. Disconnect coolant reservoir hose from radiator neck
overflow port.
3) Attach clear hose to modified one gallon bottle. Using locking pliers,
clamp hose. Fill bottle with coolant and hang it from hood latch. Remove
locking pliers and let coolant flow until it comes out of radiator air relief
plug. Reclamp hose.
4) Close engine air relief plug if not already done. Tighten air relief plug
to specification. See TORQUE SPECIFICATIONS. Raise front wheel off
ground, with front bumper 22 (558 mm) off of ground. Ensure radiator
cap (with wire) is installed.
5) On vehicles with manual heater, ensure temperature control lever is
in full HOT position. Set fan speed to HIGH and airflow to head/feet
position. On vehicles with automatic heater, set temperature controls to
90F and fan speed to HIGH.
6) Remove locking pliers. Start and run engine at 1500 RPM, until
cooling fan turns on.
7) On all models, stop engine. Fill coolant reservoir to MAX mark.
Remove modified one gallon bottle. Lower vehicle. Let engine cool
down. Remove radiator cap and remove wire from negative pressure
valve. Fill radiator as necessary and reinstall radiator cap. Fill reservoir
as necessary and install reservoir cap. Check for leaks.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
Crankshaft Pulley Bolt ............................................................................. 141-156 (191-211)
Spark Plugs ................................................................................... ................. 14-22 (20-29)
Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58)
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)
Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

ISUZU

397

1.6L & 1.8L 4-Cylinder Gasoline

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. DOHC
I-Mark
1989 ....................................
Impulse
1990-92 Non-Turbo ............
1991-92 Turbo ....................
Stylus
1991 ....................................
1.6L 4-Cyl. SOHC
Stylus
1991-93 ...............................
1.8L 4-Cyl. SOHC
Impulse
1992 ....................................
Stylus
1992-93 ...............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.0 Hours ... ...... ..... ...... ..... T169

2.0 Hours ... ...... ..... ...... ..... T169
2.4 Hours ... ...... ..... ...... ..... T169
2.0 Hours ... ...... ..... ...... ..... T169

1.5 Hours ... .. TCK177 .. ..... T177

2.4 Hours ... ...... ..... ...... ..... T205

2.4 Hours ... ...... ..... ...... ..... T205

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Marks (DOHC)

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: The 1991-93 1.6L (SOHC) engine used in the Stylus is an
interference engine. Do not rotate camshaft or crankshaft when
timing belt is removed, or engine damage may occur.
Courtesy of Isuzu Motor Co.

TIMING BELT
Removal (DOHC) 1) Disconnect negative battery cable. Remove
accessory drive belts. Remove upper timing belt cover. Support engine.
Remove engine mounting bracket located at timing belt cover. Rotate
crankshaft and position No. 1 cylinder at TDC of compression stroke.
Ensure timing mark on crankshaft pulley aligns with 0 timing mark on
timing belt cover.
2) Ensure timing marks on camshaft sprockets are aligned with cylinder
head surface. See Fig. 1. 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.
3) Remove engine stiffener brace. See Fig. 2. Remove flywheel dust
cover. Hold flywheel while removing crankshaft pulley bolt. Remove
crankshaft pulley. Remove lower timing belt cover.
4) Ensure timing mark (notch) on crankshaft sprocket aligns with timing
mark on oil pump. See Fig. 1. 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) Inspect timing belt for damaged teeth, cracking or
oil contamination. Ensure tensioner pulley and idler pulley rotate freely.
Replace components if damaged.
Installation (DOHC) 1) 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. 1. Install timing belt in the
following order: over crankshaft sprocket, water pump, idler pulley,
exhaust camshaft, intake camshaft and belt tensioner. Ensure no slack
exists in belt. See Fig. 3.

Fig. 2: Removing Engine Stiffener Brace

2) 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.
3) Rotate crankshaft 2 revolutions in direction of engine rotation. Ensure
all timing marks align. Rotate crankshaft 60 degrees. Measure timing
belt deflection at midpoint between camshaft sprockets. Ensure timing
belt defection is within specification. See TIMING BELT DEFLECTION
SPECIFICATIONS table. If belt deflection is not within specification,
repeat the last two steps.
CAUTION: Ensure timing marks align after belt adjustment.
4) To install remaining components, reverse removal procedure. See
Fig. 4. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
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)

ISUZU

398

1.6L & 1.8L 4-Cylinder Gasoline (Cont.)

Courtesy of Isuzu Motor Co.

Courtesy of Isuzu Motor Co.

Fig. 3: Routing Timing Belt (DOHC)

Fig. 5: Aligning Timing Marks (SOHC)

Installation (SOHC) 1) Rotate camshaft so timing mark aligns with
cylinder head surface. Ensure dowel pin on camshaft pulley is in the up
position. See Fig. 5. Ensure timing mark (notch) on crankshaft sprocket
aligns with timing mark on oil pump. See Fig. 5. Install timing belt in the
following order: over crankshaft sprocket, camshaft pulley, water pump
and belt tensioner. See Fig. 6.
2) 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. 7. Ensure timing belt defection
is within specification. See TIMING BELT DEFLECTION SPECIFICATIONS table. If belt deflection is not within specification, repeat this step.
3) To install remaining components, reverse removal procedure. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive
belts to proper tension.

Courtesy of Isuzu Motor Co.

Fig. 4: Tightening Sequence For Valve Cover Bolts (DOHC)

Removal (SOHC) 1) Disconnect negative battery cable. Support
engine. Remove right side engine mount. Remove alternator and power
steering pump drive belts. Ensure engine is supported. Remove engine
mounting bracket located at timing belt cover.
2) Remove crankshaft pulley bolts. Remove crankshaft pulley from
crankshaft pulley hub. Remove timing belt cover. Rotate crankshaft and
position No. 4 cylinder at TDC of compression stroke. Ensure timing
mark on camshaft pulley aligns with cylinder head. See Fig. 5.
3) Ensure timing mark (notch) on crankshaft sprocket aligns with timing
mark on oil pump. See Fig. 5. 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) Inspect timing belt for damaged teeth, cracking or
oil contamination. Ensure tensioner pulley rotates freely. Replace components if damaged.
Courtesy of Isuzu Motor Co.

Fig. 6: Routing Timing Belt (SOHC)

ISUZU

399

1.6L & 1.8L 4-Cylinder Gasoline (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 43 (58)
Crankshaft Pulley Bolt
DOHC .................................................................................................................. 109 (148)
SOHC ....................................................................................................................... 62 (84)
Idler Pulley Bolt ......................................................................................................... 31 (42)
Left Engine Mount Bolt ............................................................................................. 51 (69)
Power Steering Pump Bolt ........................................................... ............................ 11 (15)
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)
Courtesy of Isuzu Motor Co.

Fig. 7: Checking Timing Belt Tension (SOHC)

INCH Lbs. (N.m)

Timing Belt Cover Bolt .............................................................................................. 89 (10)

ISUZU

400

1.8L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl. Diesel

I-Mark
1981-84 ....................................................
1

Belt
Part No.

3.1 Hours .. ..... T076

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Isuzu Motor Co.

Fig. 2: Camshaft Fixing Plate

TIMING BELT & VALVE TIMING

Removal 1) Disconnect negative battery cable. Remove lower engine
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.
2) 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.
3) 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.
4) Ensure that No. 1 piston is still at TDC, then remove crankshaft pulley.
Remove lower timing belt cover. Remove timing belt holder. See Fig. 3.
Remove tension spring located behind front plate. Loosen tensioner
pulley and pivot bolts. Remove timing belt.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Injection Pump Timing Marks

Installation 1) 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.

Courtesy of Isuzu Motor Co.

Fig. 3: Locating Timing Belt Holder

2) 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.
3) 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 crankshaft in an attempt to adjust timing mark on
pulley. Ensure that timing marks on injection pump sprocket and front
plate are still aligned.
4) Check that fixing plate fits smoothly into slot at rear of camshaft, 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 lbs.
(21-29 kg) tension between camshaft and injection pump sprockets.
5) Remove crankshaft pulley and install timing belt holder. Ensure that
timing belt holder does not rub against timing belt. Reverse removal
procedure to complete installation. Adjust drive belts to proper tension.

ISUZU

401

1.8L 4-Cylinder Diesel (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ................. 43-50 (58-68)
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)

Courtesy of Isuzu Motor Co.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of Isuzu Motor Co.

Fig. 5: Locating Tensioner Pulley

ISUZU

402

2.0L, 2.3L & 2.6L 4-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

2.0L 4-Cyl. Turbo

Impulse
1985-89
A/T ................................. ...
M/T ................................. ...
2.3L 4-Cyl.
Amigo
1989-93
A/T ................................. ...
M/T ................................. ...
Impulse
1988-89
A/T ................................. ...
M/T ................................. ...
Pickup
1986-95
A/T ................................. ...
M/T ................................. ...
Trooper II
1986-87
A/T ................................. ...
M/T ................................. ...
2.6L 4-Cyl.
Amigo
1989-94
A/T ................................. ...
M/T ................................. ...
Pickup
1988-95
A/T ................................. ...
M/T ................................. ...
Rodeo
1991-97
A/T ................................. ...
M/T ................................. ...
Trooper
1990-91
A/T ................................. ...
M/T ................................. ...
Trooper II
1988-89
A/T ................................. ...
M/T ................................. ...
1

1
1

1
1

Component
Belt
Kit No.
Part No.

3.6 Hrs. ... ...... ..... ...... ..... T121

3.4 Hrs. ... ...... ..... ...... ..... T121

1.9 Hrs. ... .. TCK122 .. ..... T122

1.6 Hrs. ... .. TCK122 .. ..... T122

3.6 Hrs. ... .. TCK122 .. ..... T122

1
3.4 Hrs. ... .. TCK122 .. ..... T122
1
1

1
1

1
1

1
1

1
1

1
1

1
1

1.9 Hrs. ... .. TCK122 .. ..... T122

1.6 Hrs. ... .. TCK122 .. ..... T122

1.9 Hrs. ... .. TCK122 .. ..... T122

1.6 Hrs. ... .. TCK122 .. ..... T122

1.9 Hrs. ... .. TCK147 .. ..... T147

1.6 Hrs. ... .. TCK147 .. ..... T147

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
Removal 1) 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.
2) 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 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.

1.9 Hrs. ... .. TCK147 .. ..... T147

1.6 Hrs. ... .. TCK147 .. ..... T147

1.9 Hrs. ... .. TCK147 .. ..... T147

1.6 Hrs. ... .. TCK147 .. ..... T147

1.9 Hrs. ... .. TCK147 .. ..... T147

1.6 Hrs. ... .. TCK147 .. ..... T147

1.9 Hrs. ... .. TCK147 .. ..... T147

1.6 Hrs. ... .. TCK147 .. ..... T147

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.
Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Marks

ISUZU

403

2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)

Courtesy of Isuzu Motor Co.

Fig. 2: Exploded View of Timing Belt & Components

Inspection 1) 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.
2) On 2.0L engines, measure outside diameter of crankshaft, camshaft
and oil pump sprockets. If specifications are exceeded, replace sprocket(s). See TIMING SPROCKET SPECIFICATIONS (2.0L) table.
3) 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).
4) 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 within specification.
TIMING SPROCKET SPECIFICATIONS (2.0L)
Application
Standard In. (mm)
Limit In. (mm)
Camshaft ............................... .......... 5.202 (132.03) ................................. 5.198 (131.93)
Crankshaft ............................. ........... 2.574 (65.33) .................................... 2.570 (65.23)
Oil Pump ............................... .......... 4.485 (113.84) .......... ....................... 4.481 (113.74)

Installation 1) Pull tensioner fully toward water pump side, and

temporarily 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.
2) 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 adjusting bolt allowing spring tension to tighten belt.
Tighten adjusting bolt temporarily.
3) Temporarily install crankshaft pulley bolt and rotate crankshaft 2
complete revolutions in opposite direction of engine 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.
4) Install timing belt covers. To complete installation, reverse removal
procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

404

ISUZU
2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 43 (58)
Crankshaft Pulley Bolt ............................................................................................. 90 (122)
Front Cover ............................................................................................................... 14 (19)
Tensioner Pulley
Bolts ......................................................................................................................... 18 (24)
Nut ........................................................................................................................... 10 (14)
Water Pump ............................................................................................................... 14 (19)
Courtesy of Isuzu Motor Co.

Fig. 3: Installing Belt Guide

INCH Lbs. (N.m)

Timing Belt Cover Bolt ................................................................................................ 53 (6)

ISUZU

405

2.2L 4-Cylinder Diesel

TIMING BELT APPLICATION
1

Application

2.2L 4-Cyl. Diesel

LUV (Chevrolet)
1981-82 .....................................................
Pickup (Isuzu)
1983-85 .....................................................
PUP
1981-87 .....................................................
S10 & S15 Pickup (Chevrolet/GMC)
1983-85 .....................................................
Trooper II
1984-87 .....................................................
1

Labor Time

Belt
Part No.

2.7 Hours ... ..... T075

2.7 Hours ... ..... T075
2.7 Hours ... ..... T075
1.0 Hours ... ..... T075
2.7 Hours ... ..... T075

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Isuzu Motor Co.

Fig. 2: Removing Tension Spring

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine
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 timing belt covers. See Fig. 1.
2) 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
assembly. Remove timing belt.

Courtesy of Isuzu Motor Co.

Fig. 1: Removing Timing Belt Covers

Courtesy of Isuzu Motor Co.

Fig. 3: Identifying Timing Belt Sprocket Alignment

Installation 1) 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, camshaft sprocket and
injection pump sprocket.
2) 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. lbs. (30-49 N.m). Turn crankshaft
2 complete revolutions 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.
3) Install and tighten injection pump pulley flange. Ensure hole in flange
lines up with triangular timing mark on pump sprocket. See Fig. 6. Turn
crankshaft 2 more turns, bringing No. 1 cylinder to TDC on compression
stroke. Check timing mark alignment. Check timing belt tension with
Tension Gauge (J-29771) or equivalent. Tension should be 33-55 lbs.
(15-25 kg). Reverse removal procedure to complete installation. Adjust
drive belts to proper tension.

ISUZU

406

2.2L 4-Cylinder Diesel (Cont.)

Courtesy of Isuzu Motor Co.

Courtesy of Isuzu Motor Co.

Fig. 6: Aligning Injection Pump Timing Marks

TORQUE SPECIFICATIONS

Fig. 4: Aligning Timing Marks

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................................ 72-87 (98-118)
Crankshaft Sprocket Bolt .............................................................. ......... 124-151 (168-205)
Injection Pump Timing Pulley Bolt ................................................ ................. 42-52 (57-71)
Tension Spring Nut ........................................................................ ................. 22-36 (30-49)
Timing Belt Tensioner Bolts .......................................................... ............. 79-94 (107-127)

Courtesy of Isuzu Motor Co.

Fig. 5: Installing Timing Belt Tensioner

ISUZU

407

2.2L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 4-Cyl. DOHC

Amigo
1998-00
Auto. Trans. ........................................... 1 1.9 Hours .. .....
Man. Trans. ............................................ 1 1.6 Hours .. .....
Rodeo
1998-03
Auto. Trans. ........................................... 1 1.9 Hours .. .....
Man. Trans. ............................................ 1 1.6 Hours .. .....
Rodeo Sport
2001-03
Auto. Trans. ............................................ 1.9 Hours ... .....
Man. Trans. ............................................. 1.6 Hours ... .....
1

T305
T305

T305
T305

T305
T305

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.
Courtesy of Isuzu Motor Co.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1998 vehicles, the manufacturer recommends the belt be replaced
every 75,000 miles. For 1999-00 vehicles, the manufacturer recommends the belt be replaced every 100,000 miles for normal service, or
75,000 miles for severe service. For 2001-03 vehicles, the manufacturer
recommends the belt be replaced every 75,000 miles for normal service,
or 60,000 miles for severe service.

Fig. 1: Aligning Timing Marks

4) 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.
5) Install timing belt cover. Install engine harness cover. Connect engine
harness electrical connectors. To complete installation, reverse removal
procedure.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove serpentine
drive belt. Remove engine wiring harness cover, and disconnect 3
connectors from left rear side of engine compartment.
2) 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.
3) Remove timing belt cover. If reusing old belt, place mark on belt to
indicate direction of belt rotation.
4) Rotate crankshaft clockwise so camshaft and crankshaft timing marks
are aligned. See Fig. 1. Remove timing belt tensioner pulley bolt, and
remove timing belt 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
bearings.
NOTE: Do not turn crankshaft in a counterclockwise direction, or
tensioner setting will not be correct.
Installation 1) Install timing belt tensioner, and temporarily tighten
bolt. Ensure camshaft and crankshaft timing marks are still aligned. See
Fig. 1. Place Camshaft Locking Tool (J-43037) between camshafts to
prevent movement.
2) 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 toward belt.
NOTE: Adjust timing belt tension with engine cold.
3) To tension timing belt, align timing belt tensioner arrow in correct
position for new or used belt. See Fig. 2. Tighten timing belt tensioner
bolt to specification. See TORQUE SPECIFICATIONS.

Courtesy of Isuzu Motor Co.

Fig. 2: Adjusting Timing Belt Tension

ISUZU

408

2.2L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt 1
Step 1 ...................................................................................................................... 36 (50)
Step 2 ........................................................................................................... Additional 60
Step 3 (1998-00 Engines Only) ................................................................... Additional 15
Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 14 (20)
Crankshaft Sprocket Center Bolt 1
Step 1 .................................................................................................................... 94 (130)
Step 2 ........................................................................................................... Additional 45
Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Water Pump Bolt ....................................................................................................... 18 (25)
INCH Lbs. (N.m)
Engine Harness Cover-To-Engine .............................................................................. 52 (6)
Timing Belt Cover Bolt ................................................................................................ 52 (6)
1

Replace bolt if loosened or removed.

ISUZU

409

2.2L 4-Cylinder Oasis

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl. RA1

Oasis
1996-97
Balancer Shaft .............. .......... 1 .......... .. TCK186 .. ..... T186
Camshaft ....................... ... 2 2.7 Hrs. ... .. TCK186 .. ..... T187
1
2

Balancer shaft belt included in camshaft belt labor time.

With Air Conditioning, add .3 hours. With Power Steering, add
.3 hours

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1996 vehicles, the manufacturer recommends the belt be 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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balance Belt &

Related Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft
counterclockwise until cylinder No. 1 is at TDC of compression stroke.
While rotating crankshaft, check water pump for signs of seal leakage.
2) Remove accessory drive belts. Remove alternator terminal and
connector. Raise and support vehicle. Remove wheelwell splash shield.
Using a jack with block of wood to support engine, remove side engine
mount.
3) Remove cylinder head cover. See Fig. 1. Remove crankshaft pulley.
Remove upper and lower timing belt covers. See Fig. 2. Loosen timing
belt tension adjusting nut 145-180 degrees. See Fig. 3. Push tensioner
to release belt tension from timing belt and balancer belt. Retighten
tension adjuster nut. Mark rotation direction of timing belt if it is to be
reused. Remove timing belt from pulleys.
Installation Ensure cylinder No. 1 is at TDC of compression stroke.
See Figs. 4 and 5. Install timing belt in sequence shown. See Fig. 6.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.
Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

ISUZU

410

2.2L 4-Cylinder Oasis (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Loosening Tensioner Adjusting Nut

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt ............................................................................................ 28 (38)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Power Steering Pump Mounting Nut ........................................................................ 16 (22)
Timing Belt Adjuster Bolt .......................................................................................... 49 (67)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............. 86-104 (7.2-8.7)
Valve Cover Nut ....................................................................................................... 86 (9.8)

ISUZU

411

2.3L 4-Cylinder Oasis

TIMING BELT APPLICATION
Application
2.3L 4-Cyl. F23A, SOHC
Oasis
1998-99
Balancer Shaft ......................................
Camshaft ...............................................
1

Labor Time

1
1

Belt
Part No.

2.7 Hours .. ..... T186

2.7 Hours .. ..... T244

Balance shaft belt included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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).

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to
get the customers code before disconnecting battery.

TIMING & BALANCER SHAFT BELTS

Removal 1) Disconnect negative battery cable. Rotate crankshaft
counterclockwise until cylinder No. 1 is at TDC of compression stroke.
While rotating crankshaft, check water pump for signs of seal leakage.
Raise and support vehicle. Remove engine lower splash shield.
2) Remove accessory drive belts. Remove alternator terminal and
connector. Remove alternator and alternator bracket. Using a jack with
a block of wood to support engine, remove side engine mount from front
of engine. Remove dipstick tube from front of engine.
3) Remove cylinder head cover. Remove crankshaft pulley. Remove
upper and lower timing belt covers. See Figs. 1 and 2.
4) 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.
5) Loosen belt tension adjusting nut about one turn. See Fig. 3. Push
outer balancer shaft belt tensioner pulley up to take tension off of the
balancer belt. Retighten belt tension adjusting nut. Remove balancer
shaft belt.
6) Loosen belt tension adjusting nut about one 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 1) 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.
2) 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.
3) 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 adjusting nut about one turn. Rotate
crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt
tensioner adjusting nut to specification. See TORQUE SPECIFICATIONS.
4) 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.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balancer Belt &

Related Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

5) Remove crankshaft pulley and lower cover. Set timing belt drive
pulley to TDC position.
6) Lock camshaft timing belt adjuster arm in place by installing a 6 x 10
mm timing cover bolt. Loosen belt tension adjusting nut about one turn.
See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push
balancer belt tensioner up, then retighten belt tensioner adjusting nut.

ISUZU

412

2.3L 4-Cylinder Oasis (Cont.)

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

Fig. 3: Loosening Tensioner Adjusting Nut

7) Remove sealing bolt from maintenance hole on side of engine block.
See Fig. 7. Scribe a line 2.9 (74 mm) from end of 6 x 100 mm bolt.
Install 6 x 100 mm bolt into maintenance hole to lock balancer shaft in
place.
8) Align front balancer shaft pulley groove with pointer on oil pump
housing. See Fig. 8. Install balancer belt. Loosen tensioner adjusting nut
about one turn to tension balancer shaft belt. Remove 6 x 100 mm bolt
from rear of balancer shaft. Install sealing bolt with new washer.
9) Temporarily install crankshaft pulley and bolt. Turn crankshaft pulley
about one turn counterclockwise, then tighten tensioner adjusting nut.
Remove the 6 x 10 mm bolt that locked camshaft timing belt adjuster
arm in place.
10) Remove crankshaft pulley. Install lower cover with new gasket or
liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO
NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley
bolt and underside of bolt shoulder. Install and tighten crankshaft pulley
bolt to specification. See TORQUE SPECIFICATIONS.
11) Install dipstick tube with new O ring. When installing cylinder head
cover gasket, apply liquid gasket (Part No. 08718-0001 or -0003) to 4
corners where gasket meets camshafts.
12) 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.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

ISUZU

413

2.3L 4-Cylinder Oasis (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Balancer Belt Drive Pulley

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Adjusting Lock Nut ................................................................................... 16 (22)
Alternator Bracket Bolt .............................................................................................. 33 (45)
Camshaft Sprocket Bolt ............................................................................................ 43 (59)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Block Sealing Bolt ........................................................................................ 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt ...................................................... 40 (54)
Engine Side Mount Through-Bolt ............................................................................. 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt ................................................................... 47 (64)
Power Steering Pump Mounting Nut ........................................................................ 16 (22)
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)
Timing Belt Cover Bolt ............................................................................................ 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Locking Balancer Belt Shaft In Place

ISUZU

414

3.2L V6 1992-97
TIMING BELT APPLICATION
Application
3.2L V6 DOHC
Trooper
1992-95 ............................ .
3.2L V6 SOHC
Rodeo
1993-97 ..............................
Trooper
1992-97 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.6. Hours . ...... ..... ...... ..... T220

2.8 Hours .. .. TCK221 .. ..... T221

2.8 Hours .. .. TCK221 .. ..... T221

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Isuzu Motor Co.

Fig. 3: Aligning Camshaft Timing Marks (SOHC)

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly. Remove upper fan shroud. Remove cooling fan assembly.
Remove all accessory drive belts.
2) Remove fan pulley assembly. Remove crankshaft pulley bolt. Using
Puller (J-8614-01) or equivalent, remove crankshaft pulley. Remove oil
cooler hose from timing cover. Remove timing belt cover. Align all timing
marks prior to belt removal. See Figs. 1-4. Remove belt tensioner
pusher and timing belt.

Courtesy of Isuzu Motor Co.

Fig. 4: Aligning Crankshaft Timing Marks (All Models)

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.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Belt Sprockets (DOHC)

Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Camshaft Timing Marks (DOHC)

Installation 1) Ensure all timing marks are aligned. Install belt over
one pulley at a time starting at crankshaft sprocket and working
counterclockwise. Belt should go over tensioner last. Secure belt at
each pulley during installation with pinch clips. See Fig. 5.
2) 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.
3) Loosen tensioner pulley bolt. Apply pressure on belt by rotating
tensioner. Tighten tensioner pulley bolt to specification.. See TORQUE
SPECIFICATIONS. Remove pin from timing belt tensioner pusher.
4) Remove pinch clips from timing belt (if used). Install crankshaft pulley,
tightening center bolt finger tight. Rotate crankshaft 2 turns clockwise.
Ensure timing belt tensioner pusher rod protrudes proper amount. See
Fig. 6.
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 procedure. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

ISUZU

415

3.2L V6 1992-97 (Cont.)

Courtesy of Isuzu Motor Co.

Fig. 5: Installing Pinch Clip On Timing Belt

Courtesy of Isuzu Motor Co.

Fig. 6: Adjusting Timing Belt Tensioner Pusher

Courtesy of Isuzu Motor Co.

Fig. 7: Exploded View Of Cylinder Head Components

(SOHC Shown; DOHC Is Similar)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ................................................................................................. 41 (56)
Camshaft Sprocket Bolt ............................................................................................ 41 (56)
Crankshaft Pulley Bolt ........................................................................................... 123 (167)
Fan Pulley Bolt .......................................................................................................... 16 (22)
Front Plate Bolt ......................................................................................................... 14 (19)
Idler Arm Retaining Bolt ............................................................................................ 33 (44)
Power Steering Pump Bolt ....................................................................................... 34 (46)
Timing Belt Cover Bolt .............................................................................................. 13 (18)
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)

ISUZU

416

3.2L & 3.5L V6 DOHC, 1998-04

TIMING BELT APPLICATION
Application
3.2L V6
Amigo
1998-00 ....................................................
Rodeo
1998-04 ....................................................
Rodeo Sport
2001-03 ....................................................
3.5L V6
Axiom
2002-04 ....................................................
Rodeo
2004 ..........................................................
Trooper
1998-02 ....................................................
VehiCROSS
1999-01 ....................................................
1

Labor Time

Belt
Part No.

3.2 Hours .. ..... T303

3.2 Hours .. ..... T303

3.2 Hours .. ..... T303

3.2 Hours .. ..... T303

3.2 Hours .. ..... T303

2.4 Hours .. ..... T303

2.0 Hours .. ..... T303

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks (3.2L Shown;

3.5L Is Similar)

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1998 models, the manufacturer recommends the belt be replaced
every 75,000 miles. For all other models, the manufacturer recommends
the belt be replaced at 100,000 miles for normal service, and 75,000
miles for severe service.
Courtesy of Isuzu Motor Co.

REMOVAL & INSTALLATION

CAUTION: This application may be an interference engine. DO NOT
rotate camshaft or crankshaft when timing belt is removed, or
engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly. Remove upper fan shroud. Relieve tension on serpentine
drive belt tensioner and remove serpentine drive belt.
2) Remove 4 cooling fan assembly mounting nuts and remove cooling
fan assembly. Remove cooling fan drive pulley. Remove serpentine
drive belt idler pulley assembly. Remove serpentine drive belt tensioner
assembly.
3) On Rodeo, remove power steering pump with hoses attached, and
set aside. On all models, using Crankshaft Holder (J-8614-01) or
equivalent, hold crankshaft from turning and remove crankshaft pulley
bolt. Remove crankshaft pulley.
4) Disconnect harness connector from right side timing belt cover (if
equipped). Remove timing belt covers. Remove fan bracket (if
equipped).
5) On all models, rotate crankshaft to align timing marks. See Figs. 1
and 2. When timing marks are aligned, No. 2 piston will be at TDC.
6) If reusing timing belt, mark belt with arrow to indicate original rotation
direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove 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.

Fig. 2: Aligning Crankshaft Timing Marks

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 1) 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.
2) Align timing mark on right hand (passenger side) camshaft sprocket
with alignment mark on valve cover. See Fig. 3. It may require up to 4
revolutions of camshaft pulley to achieve alignment of all timing marks.
Install timing belt on right hand camshaft sprocket, aligning 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 removal. Secure belt with spring clip.
3) 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 alignment mark on timing belt with camshaft sprocket
mark. Install spring clip to hold belt on sprocket. Ensure there is no slack
in belt between camshaft pulleys.
4) Install timing belt around idler pulley and tensioner pulley. Temporarily
install crankshaft pulley. Turn crankshaft 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.
5) 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.
6) Install tensioner on engine with locking pin in place. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.

ISUZU

417

3.2L & 3.5L V6 DOHC, 1998-04 (Cont.)

7) Remove locking pin from timing belt tensioner. Remove spring clips
from camshaft and crankshaft sprockets.
8) On Axiom, rotate crankshaft 6 turns clockwise. On Rodeo, rotate
crankshaft 2 turns clockwise. On all models, ensure timing marks are
still aligned.
9) Remove crankshaft pulley. Install fan bracket and tighten fan bracket
bolts to specification (if equipped). Install timing belt covers. Ensure
rubber sealing bushings are installed on timing belt cover bolts. See
Fig. 6.
10) Install crankshaft pulley. Using Crankshaft Holder (J-8614-01) or
equivalent, hold crankshaft from turning and tighten crankshaft pulley
bolt to specification. See TORQUE SPECIFICATIONS.
11) On Rodeo, install power steering pump. On all models, Install
cooling fan pulley and cooling fan assembly. Install serpentine drive belt
idler pulley and tensioner assemblies. Install serpentine belt.
12) Install radiator fan shroud. Install air cleaner assembly. Connect
negative battery cable.

Courtesy of Isuzu Motor Co.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

Courtesy of Isuzu Motor Co.

Courtesy of Isuzu Motor Co.

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

Fig. 6: Installing Timing Belt Cover Bushings

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 72 (98)
Cooling Fan Bracket Bolts ........................................................................................ 16 (22)
Cooling Fan Pulley Bolt ............................................................................................ 16 (22)
Cooling Fan & Clutch Assembly ................................................... ..................................... 1
Crankshaft Pulley Bolt ........................................................................................... 123 (167)
Power Steering Pump Bolt
M8 Bolt .................................................................................................................... 16 (22)
M10 Bolt .................................................................................................................. 34 (46)
Timing Belt Cover Bolt .............................................................................................. 14 (19)
Timing Belt Idler Pulley Bolt ..................................................................................... 38 (52)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42)
Water Pump Bolt ....................................................................................................... 18 (25)
1

Courtesy of Isuzu Motor Co.

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

Tighten cooling fan and clutch assembly nuts to 89 INCH lbs. (10 N.m).

KIA

418

1.5L & 1.6L 4-Cylinder DOHC 2001-04

TIMING BELT APPLICATION
Application
1.5L 4-Cyl.
Rio
2001-02
1.6L 4-Cyl.
Rio
2003-04
1

Labor Time

Belt
Part No.

DOHC
..................................................... 1.9 Hours ... ..... T318
DOHC
....................................................

1.9 Hours .. ..... T318

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles,
except in California. In California, inspect timing belt at 60,000 miles and
90,000 miles, and replace belt at 105,000 miles.

Courtesy of Kia Motors America, Inc.

Fig. 1: Removing & Installing Accessory Drive Belt

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Loosen power steering lock bolts and nuts, and remove tension from power steering and air
conditioning compressor drive belt. Remove power steering and air
conditioning drive belt. See Fig. 1.
2) Loosen and remove generator bolts. Remove water pump pulley.
Remove crankshaft pulley and timing belt guide plate. Remove upper
and lower timing belt covers.
3) Turn crankshaft so that timing mark on crankshaft sprocket is aligned
with timing mark on engine. See Figs. 2 and 3. Ensure I mark on intake
camshaft sprocket is aligned with mark on cylinder head cover, and E
mark on exhaust camshaft sprocket is aligned with mark on cylinder
head cover. See Fig. 4.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Crankshaft Timing Mark (1 Of 2)

CAUTION: DO NOT move camshaft or crankshaft once timing

marks have been correctly positioned.
4) Loosen tensioner pulley lock bolt. See Fig. 5. While protecting timing
belt with a rag, remove tensioner pulley. If belt is to be reused, mark
direction of timing belt rotation for proper reinstallation. Remove timing
belt.
Inspection Replace timing belt if it is contaminated with oil or grease.
Check belt for wear, fraying or other damage. Inspect idler pulley and
tensioner pulley for uneven wear and smooth bearing operation. Inspect
camshaft sprockets and crankshaft sprocket for broken teeth or damage.
NOTE: Replace tensioner spring whenever timing belt is replaced.
Replace any component that shows damage or excessive wear.
Installation 1) Install tensioner pulley. Pull tensioner pulley to its
furthest point, and tighten lock bolt. Check that timing mark on crankshaft sprocket is aligned with timing mark on engine. See Figs. 2 and 3.
Ensure that camshaft sprockets are aligned with marks on cylinder head
cover. See Fig. 4.
2) Install timing belt onto crankshaft sprocket first, then idler pulley,
exhaust camshaft sprocket, intake camshaft sprocket, and finally, tensioner pulley. See Fig. 6. Ensure there is no looseness in belt between
idler pulley and exhaust camshaft sprocket, or between intake and
exhaust camshaft sprockets.

Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Crankshaft Timing Mark (2 Of 2)

3) Loosen tensioner pulley lock bolt, and allow tensioner spring to apply
tension to timing belt. DO NOT add additional tension. Tighten tensioner
pulley lock bolt to specification. See TORQUE SPECIFICATIONS.
4) Rotate crankshaft two full turns (clockwise only), and align timing
mark on crankshaft sprocket with timing mark on engine block. See
Fig. 6. Ensure that marks on camshaft sprockets align with marks on
cylinder head cover. See Figs. 2, 3 and 4. If marks do not align, remove
timing belt and repeat process from tensioner installation.
5) Measure timing belt deflection by applying moderate pressure
midway between camshaft sprockets. If deflection is not 0.39-0.50
(11-13 mm) with 22 lbs. (10 kg) of force applied, repeat installation
process from tensioner installation.

KIA

419

1.5L & 1.6L 4-Cylinder DOHC 2001-04 (Cont.)

6) Install lower and upper timing belt covers, timing belt guide plate and
crankshaft pulley. Install water pump pulley. Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
7) Install generator belt and adjust tension. Install power steering and air
conditioning drive belt, and adjust tension. Connect negative battery
cable.

Courtesy of Kia Motors America, Inc.

Courtesy of Kia Motors America, Inc.

Fig. 4: Locating Camshaft Sprocket & Cylinder Head Cover

Marks

Fig. 6: Identifying Rotation & Routing Of Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt ................................................................... ................... 9-13 (12-17)
Crankshaft Sprocket Bolt ............................................................................ 80-87 (108-118)
Timing Belt Guide Plate Bolt ........................................................ ................... 9-13 (12-17)
Timing Belt Tensioner Pulley Lock Bolt ........................................ ................. 28-38 (38-51)
Water Pump Pulley Bolt ................................................................ ................... 9-13 (12-17)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .................................................................................... 70-97 (8-11)

Courtesy of Kia Motors America, Inc.

Fig. 5: Locating Timing Belt Components

KIA

420

1.6L & 1.8L 4-Cylinder DOHC 1995-97

TIMING BELT APPLICATION
Application
1.6L 4-Cyl.
Sephia
1996-97 ..............................
1.8L 4-Cyl.
Sephia
1995-97 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.4 Hours .. .. TCK179 .. ..... T179

2.4 Hours .. .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On California models, the manufacturer recommends inspecting the belt
at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For
all other models, the manufacturer recommends the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory
drive belts. Remove water pump pulley. Remove crankshaft pulley bolts,
and remove pulley only.
2) Remove upper and lower timing belt covers. See Fig. 1. 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.
3) If timing belt is to be reused, mark direction of timing belt rotation.
Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
away from belt with spring fully extended. Remove timing belt.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

Inspection Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or roughness of
rotation. Inspect tensioner spring for stretching. Replace parts as
necessary.
Installation 1) Ensure camshaft and crankshaft timing marks are still
aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt
pulled tight on right side (facing engine), route belt around camshaft
sprockets.
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2
complete turns. Ensure timing marks align. If timing marks are not
aligned, remove belt, realign all timing marks, and repeat installation
procedure.
3) 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 procedure
to complete installation.
4) Before installing valve cover, apply silicone sealer to areas next to
front camshaft journals and rear distributor mounting cap. Also apply thin
bead of silicone sealer around spark plug holes on underside of valve
cover. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Center Bolt ................................................................ 116-123 (157-167)
Spark Plug ..................................................................................... ................. 14-17 (19-23)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt ................................................................... ............. 106-152 (12-17)
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)

Courtesy of Kia Motors America, Inc.

Fig. 1: Identifying Timing Belt Covers

KIA

421

1.6L & 1.8L 4-Cylinder SOHC

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
1.6L 4-Cyl.
Sephia
1994-95 ..............................
1.8L 4-Cyl.
Sephia
1996-97 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.0 Hours .. .. TCK185 .. ..... T185

2.0 Hours .. .. TCK179 .. ..... T179

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Removal 1) Disconnect negative battery cable. Remove all accessory

drive belts. Remove water pump pulley. Remove crankshaft pulley bolts,
and remove pulley only. See Fig. 1. Remove upper and lower timing belt
covers. Disconnect spark plug wires and remove spark plugs. Rotate
crankshaft clockwise until No. 1 cylinder is at TDC of compression
stroke. Ensure camshaft sprocket and crankshaft sprocket timing marks
align. See Fig. 2.
2) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
away from belt with spring fully extended. Remove timing belt.
Inspection Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or roughness of
rotation. Inspect tensioner spring for stretching. Replace parts as
necessary.

On California models, the manufacturer recommends inspecting the belt

at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For
all other models, the manufacturer recommends the belt be replaced
every 60,000 miles.

Courtesy of Kia Motors America, Inc.

Fig. 1: Exploded View of Timing Belt & Components

KIA

422

1.6L & 1.8L 4-Cylinder SOHC (Cont.)

Installation 1) Ensure camshaft and crankshaft timing marks are still
aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt
pulled tight on right side (facing engine), route belt around camshaft
sprocket.
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2
complete turns. Ensure timing marks align. If timing marks are not
aligned, remove belt, realign all timing marks, and repeat installation
procedure.
3) Rotate crankshaft clockwise 2 more turns, and check timing belt
deflection. Check timing belt deflection with 22 lbs. (10 kg) of pressure
applied to belt, midway between camshaft and crankshaft pulleys, on
side opposite tensioner. Timing belt deflection should be .43-51
(10.9-13.0 mm).
4) If timing belt deflection is not within specification, repeat procedure or
replace tensioner spring. If timing belt deflection is within specification,
reverse removal procedure to complete installation. Adjust drive belts to
proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60)
Crankshaft Pulley Lock Bolt .................................................................... 116-123 (157-167)
Spark Plug ..................................................................................... ................. 14-17 (19-23)
Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ......................................................................................... 71 (8)
Crankshaft Pulley Bolt ................................................................... ............. 106-152 (12-17)
Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11)
Water Pump Pulley Bolt ................................................................................. 69-97 (7.8-11)

KIA

423

1.8L 4-Cylinder DOHC 1998-04

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl. DOHC

Sephia
1998-01 ....................................................
Spectra
2000-04 ....................................................

2.4 Hours .. ..... T302

2.4 Hours .. ..... T302

Belt
Part No.

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On California models, the manufacturer recommends inspecting the belt
at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For
all other models, the manufacturer recommends the belt be replaced
every 60,000 miles.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Camshaft Timing Marks

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory
drive belts. Remove generator bolts. Remove water pump pulley.
Remove crankshaft pulley bolt, and remove pulley and timing belt guide
plate. See Fig. 1.
2) Remove upper and lower timing belt covers. Rotate crankshaft
clockwise until No. 1 piston is at TDC of compression 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.
3) If reusing old timing belt, mark belt with arrow to indicate original
direction of rotation. Remove timing belt tensioner pulley. See Fig. 4.
Remove timing belt.

Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Crankshaft Timing Marks

Courtesy of Kia Motors America, Inc.

Courtesy of Kia Motors America, Inc.

Fig. 1: Removing Timing Belt Guide Plate

Fig. 4: Timing Belt Tensioner & Idler Pulley

424

KIA
1.8L 4-Cylinder DOHC 1998-04 (Cont.)

Inspection Check timing belt for cracks, peeling, abrasion or other

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 1) Install tensioner pulley with NEW spring. Move
tensioner away from timing belt, and tighten center bolt. Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 2 and 3.
2) Install timing belt around crankshaft sprocket. If reusing old belt,
ensure belt is installed in original direction of rotation. Keeping belt
pulled tight on right side (facing engine), route belt around idler pulley,
camshaft sprockets, and tensioner pulley.
3) Loosen timing belt tensioner center bolt, and allow spring to apply
tension on belt. Tighten tensioner center bolt. Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks
are not aligned, remove belt, realign all timing marks, and repeat
installation procedure.
4) Check timing belt deflection with 22 lbs. (10 kg) of downward pressure
applied to belt, midway between camshaft sprockets. Timing belt
deflection should be .36-.45 (9.0-11 mm).
5) If timing belt deflection is not within specification, repeat timing belt
tensioning procedure. If timing belt deflection is within specification,
install timing belt covers. Install crankshaft and water pump pulleys. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 5: Cross Section of Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft Bolt ........................................... ............. 106-152 (12-17)
Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11)
Water Pump Pulley Bolt ................................................................ ............. 106-152 (12-17)

KIA

425

2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
2.0L 4-Cyl.
Sportage
1995-02 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

3.2 Hours .. .. TCK281 .. ..... T281

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On California models, the manufacturer recommends inspecting the belt
at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For
all other models, the manufacturer recommends the belt be replaced
every 60,000 miles.
Courtesy of Kia Motors America, Inc.

REMOVAL & INSTALLATION

Fig. 2: Aligning Crankshaft Pulley Timing Marks

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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. Remove cooling fan clutch-to-pulley nuts.
2) Remove accessory drive belts. Remove cooling fan and pulley.
Remove lower engine splash guard. Remove crankshaft pulley from
crankshaft. It is NOT necessary to remove center bolt. Remove upper
and lower timing belt covers. See Fig. 1.
3) Rotate crankshaft to align camshaft and crankshaft timing marks. See
Figs. 2 and 3. Camshaft I and E marks should align with marks on
rear cover.
4) Loosen tensioner pulley bolt. Pivot tensioner pulley outward to
remove tension from timing belt, then retighten tensioner lock bolt. See
Fig. 4. Mark timing belt rotation direction if old belt is to be reinstalled.
Remove timing belt.
Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Camshaft Pulley Mating Marks

Courtesy of Kia Motors America, Inc.

Fig. 4: Loosening Tensioner

Courtesy of Kia Motors America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

426

KIA
2.0L 4-Cylinder DOHC (Cont.)

Installation 1) Ensure crankshaft and camshaft pulleys are still

aligned. See Fig. 3. 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.
2) Turn crankshaft 2 revolutions in normal direction of rotation. Check
that timing marks are correctly aligned. If timing marks are not correctly
aligned, remove belt and realign. After realigning belt, repeat rotation
prodecure.
3) Turn crankshaft to align S mark of exhaust camshaft pulley with rear
cover seal plate mating mark. Tighten tensioner pulley bolt.
4) Check that belt deflection is .30-.33 (7.5-8.5 mm) with 22 lbs. (10 kg)
of downward pressure on belt, midway between two camshaft pulleys.
5) Install timing belt guide plate with flat side toward belt. Install timing
belt covers.
6) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Center Bolt ........................................................ ................. 35-48 (47-65)
Cooling Fan Clutch-To-Pulley Nuts ........................................................................... 24 (32)
Crankshaft Center Bolt ............................................................................ 116-123 (157-167)
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)
Timing Belt Idler Pulley Bolt ......................................................... ................. 27-38 (37-52)
Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-52)
Water Pump Bolt ....................................................................................................... 16 (22)
INCH Lbs. (N.m)
Cooling Fan Shroud Bolts ........................................................................................... 74 (8)
Fresh Air Duct Mounting Bolts ................................................................................. 89 (10)
Timing Belt Cover Bolts ................................................................ ................... 61-87 (7-10)

KIA

427

2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application
2.0L 4-Cyl. SOHC
Sportage
1995 ..........................................................
1

Labor Time

Belt
Part No.

2.3 Hours .. ..... T264

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On California models, the manufacturer recommends inspecting the belt
at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For
all other models, the manufacturer recommends the belt be replaced
every 60,000 miles.

REMOVAL & INSTALLATION

Courtesy of Kia Motors America, Inc.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Identifying Timing Belt &

Related Components

TIMING BELT
Removal 1) 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.
2) 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 1) 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. See Fig. 2.
Install timing belt so that there is minimal slack from timing belt pulley to
water pump, and from water pump to camshaft pulley.
2) Loosen tensioner bolt to apply tension to timing belt. Turn crankshaft
2 turns clockwise, and verify that timing marks are correctly aligned. See
Fig. 3. 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
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 2: Camshaft Pulley Mating Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Timing Belt Cover Bolts ............................................................................................ 84 (10)
Courtesy of Kia Motors America, Inc.

Fig. 3: Crankshaft Pulley Mating Marks

KIA

428

2.4L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
2.4L 4-Cyl. DOHC
Optima
2001-04
Balance Shaft ......................................
Camshaft .............................................
1

Labor Time

1, 2
1, 2

Belt
Part No.

2.3 Hours . ..... T314

2.6 Hours . ..... T313

Balance Shaft Belt labor time included in

camshaft belt labor time.
With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles,
except in California. In California, inspect timing belt at 60,000 miles and
90,000 miles, and replace at 105,000 miles.

REMOVAL & INSTALLATION

Courtesy of Hyundai Motor Co.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Identifying Timing Belt Alignment Marks

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft
counterclockwise (as viewed from timing belt end of engine).
Removal 1) Disconnect negative battery cable. Remove drive belts
and drive pulleys from crankshaft and water pump. Remove timing belt
covers. To align timing marks, rotate engine clockwise so No. 1 cylinder
is at TDC of compression stroke. Ensure camshaft sprocket timing
marks align with upper surface of rocker cover. Dowel pin of camshaft
sprocket should be pointing upward. See Fig. 1.
2) Remove timing belt auto tensioner. If reusing timing belt, place mark
on timing belt to indicate direction of belt rotation. Remove timing belt.
Remove camshaft sprockets.
3) Remove plug at left side of block, and insert a screwdriver to hold left
counterbalance shaft in position. Screwdriver will have to be inserted at
least 2.36 (60 mm). Remove oil pump sprocket nut and sprocket. See
Fig. 2.
4) Loosen right counterbalance shaft sprocket mounting bolt. Remove
tensioner B and timing belt B. See Fig. 2. Remove crankshaft
sprocket B from crankshaft.
Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and roughness in rotation. Check sprockets
and pulleys for wear, cracks or damage. Replace components if
necessary.
2) Measure protrusion of auto tensioner rod. Auto tensioner rod should
extend .57 (14.5 mm) from end of housing. See Fig. 3. Replace auto
tensioner rod if not within specification. Place tensioner in a soft-jawed
vise, and test resistance of rod. If rod can be easily pushed in with light
vise pressure, replace auto tensioner.
Installation 1) Install crankshaft sprocket B onto crankshaft. Ensure
flange is properly positioned. Lightly oil outer surface of spacer, and then
install spacer to right counterbalance shaft, with rounded edge of spacer
inward.
2) Install right counterbalance shaft sprocket. Tighten flange bolt tightly
by hand. Align timing marks on each sprocket and on front case. See
Fig. 4.
3) When installing timing belt B, ensure there is no slack in tension
side. Install tensioner B in center of pulley on left side of mounting bolt,
and in pulley flange toward front of engine. See Fig. 5. Align timing mark
of right counterbalance shaft sprocket with timing mark on front case.

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt Components

4) To tighten timing belt B, lift tensioner B so tension side is pulled
tight. Tighten bolt to secure tensioner B. DO NOT turn shaft, or belt will
be over-tightened.

KIA

429

2.4L 4-Cylinder DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 4: Identifying Front Case Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 3: Measuring Auto Tensioner Protrusion

5) Ensure timing marks are aligned. Ensure center of span on tension
side of timing belt B can be depressed by hand. Ensure belt deflection
is .20-.30 (5-7 mm).
6) Install crankshaft sprocket flange and sprocket. Ensure flange is
mounted in proper direction, with chamfered side toward block. Install
special washer and sprocket bolt to crankshaft. Tighten sprocket bolt to
specification. See TORQUE SPECIFICATIONS.
7) Insert long screwdriver through plug hole in left side of cylinder block
to hold counterbalance shaft in position. Install oil pump sprocket, and
tighten nut to specification. See TORQUE SPECIFICATIONS. Install
camshaft sprockets, and tighten bolts.
8) If auto tensioner rod is fully extended, place it in soft-jawed vise, and
compress rod until hole in rod lines up with hole in auto tensioner
housing. Insert stiff wire to hold rod in this position. Install auto tensioner,
leaving wire in place.
CAUTION: If timing marks on camshaft sprockets do not line up
properly, DO NOT rotate sprocket more than 2 teeth in either
direction, or valve and piston will touch. If necessary, remove and
reposition camshaft sprocket.
9) Install crankshaft sensor. Set timing marks of camshaft sprockets with
notches on upper side of rocker cover and dowel pins straight up. Align
crankshaft sprocket timing marks. Align oil pump sprocket timing marks.
10) Install timing belt in order around crankshaft sprocket, oil pump
sprocket, idler pulley, exhaust camshaft sprocket, intake camshaft
sprocket and tensioner pulley.
11) Gently raise tensioner pulley so belt will not sag, and then temporarily tighten center bolt. Ensure timing mark of each sprocket is still
aligned. Remove wire from auto tensioner.
12) Rotate crankshaft 2 complete turns clockwise. Leave in this position
for about 5 minutes. Measure auto tensioner protrusion A (distance
between tensioner arm and auto tensioner body). Ensure auto tensioner
protrusion is .22-.35 (6-9 mm). See Fig. 3. Install timing belt lower cover
and upper cover.

Courtesy of Hyundai Motor Co.

Fig. 5: Installing Tensioner B

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ....................................................................... ................. 15-20 (20-27)
Block Plug Cap ............................................................................. ................. 15-20 (20-27)
Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100)
Crankshaft Pulley Bolt ................................................................... ................. 15-22 (20-30)
Crankshaft Sprocket Bolt ............................................................................ 80-94 (110-130)
Oil Pump Sprocket Nut ................................................................. ................. 36-43 (50-60)
Timing Belt Cover Bolts
Lower & Upper Cover Bolt ......................................................... ..................................... 1
Left Rear Cover Bolt
Lower ......................................................................................... ................. 22-30 (30-41)
Upper ......................................................................................... ..................................... 2
Right Rear Cover Bolt ................................................................. ..................................... 2
Timing Belt Idler Pulley Bolt ......................................................... ................. 33-40 (45-54)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 31-40 (42-54)
Timing Belt Tensioner Pulley Bracket Bolt ................................... ................. 17-20 (23-27)
Water Pump Mounting Bolt ............................................................................. 11-15 (15-20)
INCH Lbs. (N.m)
Rocker Cover Bolt ......................................................................... ................... 71-89 (8-10)
Valve Cover Bolts .......................................................................... ................... 71-89 (8-10)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
1
2

Tighten bolts to 71-89 INCH lbs. (8-10 N.m).

Tighten bolts to 89-108 INCH lbs. (10-12 N.m).

LANCIA

430

1.8L 4-Cylinder
TIMING BELT APPLICATION
Application
1.8L 4-Cyl.
Beta
1976-78 ....................................................
1

Labor Time

Belt
Part No.

2.7 Hours .. ..... T020

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 25,000 miles.

REMOVAL & INSTALLATION

Installation 1) Align reference mark on crankshaft pulley with timing

mark on Locking Fixture (88013039) or equivalent. When both marks
correspond exactly, cylinders No. 1 and 4 will be at TDC. Fixture
reference hole should also line up with ancillary drive shaft reference
hole. Check alignment by inserting dowel pin.
2) Install timing belt. Unlock the belt stretcher bolt while applying
pressure to the belt. Tighten bolt and nut to 33 ft. lbs. (45 N.m). Once
tensioning bolt is torqued, remove locking fixture. 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 tension.

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 bearings. See Fig. 2. If adjustment is necessary, use
Locking Fixture (88013039) or equivalent, as instructed under TIMING
BELT.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) Remove reference pointers bracket. Attach Locking Fixture
(88013039), or equivalent, by engaging dowel pins in camshaft gear
timing holes. Attach fixture to cylinder head. Remove belt tensioner nut
and bolt, and release tension from belt. Remove timing belt.

Courtesy of lancia motors, inc.

Fig. 2: Locating Valve Timing Reference Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Housing Nuts ............................................................................................ 16 (22)
Timing Belt Tensioner ................................................................................................ 33 (45)

Fig. 1: Aligning Camshaft Timing Marks With Bearing Reference

Marks

LAND ROVER

431

2.5L KV6 DOHC, 2002-04

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.5L KV6 VIN 2

Freelander
2002-04
Front Belt ............................................... 5.6 Hours ... ..... T327
Rear Belts ............................................ .......... 1 .......... ..... T326
1

Engine set (front/rear timing belts) labor time is 6.8 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

engine steady away from top arm. Install wooden block to jack, position
jack under engine sump to support engine.
3) Remove nut and 4 bolts securing engine top arm bracket to right
hydramount and to engine front mounting bracket. See Fig. 3. Release
power steering pipe support bracket from hydramount and position pipe
aside. Remove top arm.
4) Remove 4 bolts securing engine mounting bracket to engine front
plate and remove bracket. See Fig. 4. Using a 3/8 square drive socket
bar, raise ancillary drive belt tensioner and release drive belt from
alternator pulley. Release and remove ancillary drive belt from remaining pulleys.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends that belts be replaced every 72,000
miles or 72 months whichever is sooner. If any timing belt is removed for
other repairs, manufacturer requires replacement of timing belt if
mileage has exceeded 45,000 miles.

COMPONENT LOCATION
NOTE: Freelander 2.5L KV6 engine is equipped with 3 timing belts.
For location of timing belts and related components, see Fig. 1.

Courtesy of Land Rover North America, Inc.

Fig. 2: Removing Upper Right Engine Steady

Courtesy of Land Rover North America, Inc.

Fig. 3: Removing Top Engine Arm Bracket

Courtesy of Land Rover North America, Inc.

Fig. 1: Locating Timing Belts & Related Components (2.5L KV6)

REMOVAL & INSTALLATION

WARNING: This application is an interference engine. DO NOT
rotate camshafts or crankshaft when timing belt is removed, or
engine damage may occur.

ANCILLARY DRIVE BELT

Removal 1) Disconnect battery ground lead. Remove underbelly
panel. See UNDERBELLY PANEL. Remove engine acoustic cover. See
ENGINE ACOUSTIC COVER.
2) Remove bolt securing upper right engine steady to top arm. See
Fig. 2. Loosen bolt securing upper right engine steady to body, pivot

NOTE: Examine drive belt for signs of wear. A drive belt with
cracked ribs is acceptable. A drive belt that has loose or missing
parts of ribs must be changed.
Installation 1) Clean pulley grooves and tensioner pulley running
surface. Install new drive belt to crankshaft pulley. Raise belt tensioner
and connect drive belt to steering pump, alternator and compressor
pulleys. Ensure drive belt is correctly located in pulley grooves.
2) Position engine mounting front bracket to engine front plate and
tighten bolts to specification. See TORQUE SPECIFICATIONS. Position
top arm to front engine mounting bracket, install and tighten bolts to
specification.
3) Lower and remove jack supporting engine. Position power steering
pipe support bracket to hydramount. Install nut securing top arm to right
hydramount and tighten to specification. See TORQUE SPECIFICATIONS.

LAND ROVER

432

2.5L KV6 DOHC, 2002-04 (Cont.)

FRONT TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt
removed and cylinder heads installed.
CAUTION: Camshaft timing belt must be replaced if cylinder head
is to be removed or new drive gears, tensioner or coolant pump are
to be replaced. Camshaft timing belts must be stored and handled
with care. Always store a camshaft timing belt on its edge with a
bend radius greater than 2.0 (50 mm). DO NOT use a camshaft
timing belt that has been twisted or bent double as this will damage
reinforcing fibers. DO NOT use a camshaft timing belt if debris
other than belt dust is found in timing belt covers. DO NOT use a
camshaft timing belt if partial engine seizure has occurred. DO
NOT reuse a camshaft timing belt if mileage exceeds 45,000 miles.
DO NOT use an oil or coolant contaminated timing belt, cause of
contamination must be rectified.

Courtesy of Land Rover North America, Inc.

Fig. 4: Locating Engine Mounting Front Bracket & Ancillary Drive

Belt Tensioner
4) Position engine upper right steady to top arm, install and tighten bolt
to specification. See TORQUE SPECIFICATIONS. Tighten bolt securing
engine upper right steady to body to specification.
5) Install underbelly panel. See UNDERBELLY PANEL. Install engine
acoustic cover. See ENGINE ACOUSTIC COVER. Connect battery
ground lead.

ENGINE ACOUSTIC COVER

Removal & Installation 1) Loosen clip and disconnect fresh air intake
hose from acoustic cover. See Fig. 5. Loosen clip and disconnect air
intake hose from Mass Air Flow (MAF) sensor. Release 2 turnbuckles
securing acoustic cover to left camshaft cover. Release retaining strap
and remove acoustic cover.
2) To install, position and secure engine acoustic cover. Connect air
intake and air bypass hoses, secure clip. Connect fresh air intake hose
to acoustic cover and tighten clip screw.

Removal 1) Disconnect battery ground lead. Remove ancillary drive

belt. See ANCILLARY DRIVE BELT. Remove right front road wheel.
Remove 3 bolts securing right splash shield to body and remove shield.
2) Remove 3 bolts securing camshaft left rear timing belt cover and
remove cover. See Fig. 7.
3) On vehicles up to 2003, remove intake manifold chamber to gain
access to right rear timing belt cover. See INTAKE MANIFOLD CHAMBER. Remove 2 bolts securing right rear timing belt cover heat shield
and remove heat shield. Remove 3 bolts securing right rear timing belt
cover and remove cover. See Fig. 7.
CAUTION: DO NOT use camshaft gear bolts or timing belt to rotate
crankshaft. DO NOT use arrow on oil pump body as a timing
reference.
4) Using a socket on crankshaft pulley bolt, rotate crankshaft in a
clockwise direction. Align the engine SAFE position notch on crankshaft
pulley with the ARROW on front mounting plate and timing marks
aligned on the rear camshaft gears. See Fig. 8.
CAUTION: Ensure hole immediately adjacent to side of lower
crankcase is used.
5) Insert timing pin LRT-12-232 through hole in lower crankcase,
ensuring pin is located in hole in drive plate. See Fig. 9. Remove bolt
securing Power Assisted Steering (PAS) pipe to engine front mounting
plate. Remove 3 Torx screws securing PAS pump pulley and remove
pulley. Remove 3 bolts securing PAS pump to front mounting plate and
tie pump aside.
6) Release alternator battery lead terminal cover, loosen terminal nut
and disconnect lead from terminal. Disconnect connector from alternator. Remove lower bolt and upper nut and bolt securing alternator to front
mounting plate and remove alternator.
7) Remove Torx screw securing idler pulley to front mounting plate and
remove pulley. See Fig. 6. Loosen bolt securing lower engine steady to
front subframe. See Fig. 10. Remove bolt securing lower engine steady
to sump mounting, release lower engine steady from sump mounting.
CAUTION: Ensure crankshaft does not rotate during crankshaft
pulley removal.

Courtesy of Land Rover North America, Inc.

Fig. 5: Removing & Installing Engine Acoustic Cover

8) Remove 3 bolts securing camshaft timing belt front covers and

remove covers. See Fig. 6. Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. See Fig. 11. Remove tools
LRT-12-161 and LRT-12-199 from crankshaft pulley and remove pulley.

LAND ROVER

433

2.5L KV6 DOHC, 2002-04 (Cont.)

NOTE: It is not necessary to discharge A/C system.
9) Remove 3 bolts securing camshaft timing belt lower cover to cylinder
block and remove cover. Remove 2 bolts securing ancillary drive belt
tensioner and remove tensioner. See Fig. 4. Note position of heat shield
on A/C compressor and remove 3 bolts securing A/C compressor to front
mounting plate and cylinder block. Release A/C compressor and heat
shield and position aside.
10) Remove bolt securing dipstick tube to cylinder block. Depress and
hold down dipstick tube locking collar, remove dipstick tube from engine
sump. Remove rubber blanking plug from around camshaft front timing
belt tensioner assembly. See Fig. 12. Remove 3 bolts securing engine
front mounting plate and lifting bracket to cylinder block. Remove bolt
securing lifting bracket to right cylinder head and remove lifting bracket.
11) Remove 2 bolts securing Intermediate Reduction Drive (IRD)
support bracket to engine front mounting plate. Remove 5 bolts and 2
pillar bolts securing engine front mounting plate to cylinder block. See
Figs. 6 and 13. With care, release and remove front mounting plate from
engine.
NOTE: If holes in body and plunger are not aligned, move tensioner
backplate using a suitable broad bladed screwdriver; this will
move plunger sufficiently to enable pin to be inserted.
12) Insert a suitable 1.5-mm diameter pin through hole in tensioner body
and into hole in plunger. See Fig. 14.
CAUTION: Exercise great care when removing bolts, DO NOT apply
excessive torque. If bolts appear to be seized, apply suitable
anti-seize lubricant prior to removing bolts. DO NOT loosen Allen
screw securing tensioner pulley.
13) Remove and discard 2 Patchlok bolts securing tensioner to cylinder
block and remove tensioner. See Fig. 14.
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt
removed and cylinder heads installed.
14) If camshaft timing belt is to be reinstalled, mark direction of rotation
on timing belt before removal. With care, ease camshaft timing belt from
gears using fingers only and remove timing belt.
CAUTION: Special tools must be installed when tightening or
loosening gear retaining bolts, otherwise damage to camshafts
may occur.
15) Remove and discard left and right exhaust camshaft cap seals. See
Fig. 15. Position tools LRT-12-196 to left and right front intake camshaft
gears and into end of each exhaust camshaft. See Fig. 16.
16) Remove and discard bolts retaining front intake camshaft gears to
camshafts. Remove tools LRT-12-196 from both intake camshaft gears
and exhaust camshafts. Remove camshaft drive gears and hub assemblies.
NOTE: Following front or rear timing belt installation, it is possible
that, after rotating engine and positioning crankshaft pulley to
SAFE position, the timing marks on rear timing gears may be
misaligned. This misalignment is acceptable provided that the
timing belt installation procedure was carried out correctly.
CAUTION: If sintered gears have been subjected to prolonged oil
contamination, they must be soaked in a solvent bath and then
thoroughly washed in clean solvent before refitting. Because of the
porous construction of sintered material, oil impregnated in the
gears will emerge and contaminate the belt.
Installation 1) Clean camshaft gears and hubs, crankshaft gear,
tensioner and water pump pulleys. Install hubs to camshaft gears and
install gears to camshafts. Install NEW bolts and tighten sufficiently to
allow gears to rotate without tipping.

NOTE: To prevent timing belt from disengaging from crankshaft

gear during installation, install a suitable wedge between the belt
and oil pump belt guard.
2) Position timing belt to crankshaft gear. Install tool LRT-12-197 into
each exhaust camshaft in turn. See Fig. 17. Using assistance, rotate
each exhaust camshaft slightly clockwise and align timing marks on left
and right rear camshaft gears. See Fig. 18. Remove tool LRT-12-197
from exhaust camshaft. Install tools LRT-12-175 to left and right rear
camshaft gears.
CAUTION: Timing gears MUST NOT be rotated counterclockwise
more than one tooth.
3) Rotate both front intake camshaft gears fully clockwise as viewed
from front of engine. Using fingers only, install front timing belt to gears,
starting at the crankshaft gear and working in a counterclockwise
direction. Keep belt run as tight as possible and turn camshaft gears
only a minimum amount counterclockwise to install timing belt.
CAUTION: Ensure timing belt tensioner plunger is contacting
underside of tensioner backplate.
4) Position an Allen key in tensioner backplate and hold tensioner pulley
against timing belt. See Fig. 19. With assistance, position tensioner,
install NEW Patchlok bolts and tighten to specification. See TORQUE
SPECIFICATIONS. Remove tools LRT-12-175 from rear timing belt
gears.
CAUTION: Special tools must be installed when tightening or
loosening gear retaining bolts, otherwise damage to camshafts
may occur.
5) Install tools LRT-12-196 to intake camshaft front gears and into end
of each exhaust camshaft. See Fig. 16. Tighten front intake camshaft
gear bolts in 2 stages to specification. See TORQUE SPECIFICATIONS.
6) Remove tools LRT-12-196 from both intake camshaft gears and
exhaust camshafts. Remove wedge from between drive belt and oil
pump belt guard. Remove 1.5-mm diameter pin from tensioner. Install
rubber blanking plug around tensioner. Remove timing pin LRT-12-232.
CAUTION: The sealing edge of cap seal and mating face must be
clean and dry.
7) Clean exhaust camshaft front cap seal locations and install NEW cap
seals. Position engine front mounting plate and maneuver plate into
position. Install bolts but DO NOT tighten at this stage. Install bolts
securing front mounting plate to cylinder block and Intermediate Reduction Drive (IRD) bracket, but DO NOT tighten at this stage.
8) Tighten bolts in sequence shown and to specification by numbers
indicated. See Fig. 20. See TORQUE SPECIFICATIONS.
9) Position engine lifting bracket, install bolts securing lifting bracket and
front mounting plate to cylinder block and right cylinder head. Tighten
M10 bolts and M8 bolt to specification. See TORQUE SPECIFICATIONS.
10) Clean end of dipstick tube. Position dipstick tube to sump and
cylinder block, instal bolt and tighten to specification. See TORQUE
SPECIFICATIONS. Position A/C compressor to front mounting plate and
cylinder block, align heat shield, install and tighten bolts to specification.
11) Clean lower timing belt cover. Position lower timing belt cover, install
and tighten bolts to specification. See TORQUE SPECIFICATIONS.
Clean crankshaft pulley. Install crankshaft pulley to crankshaft gear and
ensure that indent on pulley locates over lug on crankshaft gear. Install
crankshaft pulley bolt and washer. Position LRT-12-161 with
LRT-12-199 tools into crankshaft pulley bolt and tighten to specification.
See Fig. 11.
12) Remove tools LRT-12-161 and LRT-12-199 from crankshaft pulley
bolt. Clean ancillary drive belt tensioner. Position ancillary belt tensioner,
install bolts and tighten to specification. See TORQUE SPECIFICATIONS.

434

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 6: Locating Front Timing Belt Components (2.5L)

13) Clean left and right front timing belt covers. Position left and right
front timing belt covers, install and tighten bolts to specification. See
TORQUE SPECIFICATIONS. Clean idler pulley, position pulley to
engine front mounting plate and tighten Allen bolt to specification.
14) Position alternator to front mounting plate. Install bolts and nut
securing alternator to front mounting plate and tighten to specification.
See TORQUE SPECIFICATIONS. Connect alternator connector. Connect battery lead to alternator, install and tighten nut to specification and
install terminal cover.
15) Position PAS pump to front mounting plate, install and tighten bolts
to specification. See TORQUE SPECIFICATIONS. Position PAS pipe to
engine front mounting plate, install and tighten bolt to specification.
Clean PAS pump pulley mating faces. Position PAS pump pulley, install
and tighten Torx screws to specification.
16) Position lower engine steady to sump mounting, install and tighten
bolt to specification. See TORQUE SPECIFICATIONS. Tighten bolt
securing lower engine steady to subframe to specification.
17) Clean rear timing belt covers. Position rear timing belt covers, install
and tighten bolts to specification. Position rear timing belt right cover
heat shield, install bolts and tighten M6 bolt and M8 bolt to specifications.

18) Install intake manifold chamber. See INTAKE MANIFOLD CHAMBER. Install right road wheel and tighten nuts to specification. Install
ancillary drive belt. See ANCILLARY DRIVE BELT.

INTAKE MANIFOLD CHAMBER

Removal (Up To 2003 Model Year) 1) Disconnect battery ground
lead. Remove vacuum enhancer. Remove engine acoustic cover. See
ENGINE ACOUSTIC COVER. Release enhancer from support clips.
Disconnect connector from solenoid valve, if equipped. Release and
disconnect servo pipe. Release clip and disconnect from intake hose.
Release and remove enhancer assembly from intake manifold.
WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire
and explosion.
2) Position absorbent cloth around fuel feed pipe connection to collect
spillage. Pull back rubber sleeve on fuel pipe connector, release
connector and disconnect fuel pipe from fuel rail pipe. See Fig. 21.
Install plugs to open connections to prevent contamination.
3) Release clip and disconnect hose from purge control valve. Install
plugs to open connections to prevent contamination. Disconnect con-

LAND ROVER

435

2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 9: Inserting Timing Pin LRT-12-232 Through

Lower Crankcase Hole

Courtesy of Land Rover North America, Inc.

Fig. 7: Removing Rear Timing Belt Covers

Courtesy of Land Rover North America, Inc.

Fig. 10: Locating Lower Engine Steady At Front Subframe

Courtesy of Land Rover North America, Inc.

Fig. 8: Aligning Front & Rear Timing Marks

nector from purge control valve. Depress locking collar and release
vacuum hose from Idle Air Control Valve (IACV) housing. Disconnect
connector from Throttle Position (TP) sensor.
4) Depress locking collars and release vacuum/breather hose from
purge control valve and left camshaft cover. See Fig. 22. Release clip
securing hose to T piece and remove hose. Depress locking collars
and release vacuum/breather hoses from throttle body, left and right
camshaft cover and remove hose.

Courtesy of Land Rover North America, Inc.

Fig. 11: Removing Or Installing Crankshaft Pulley Bolt

5) Disconnect connectors from IAT and MAF sensors. See Fig. 23.
Disconnect engine breather pipe from intake hose. Disconnect injector
air supply pipe from intake hose. Disconnect connector from throttle
body. See Fig. 24. Release clip and remove intake hose and MAF
sensor assembly. Disconnect cruise control actuator vacuum pipe.

LAND ROVER

436

2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 12: Removing Rubber Blanking Plug From

Front Timing Belt Tensioner
Courtesy of Land Rover North America, Inc.

Fig. 14: Locking Timing Belt Tensioner Before Removal

Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 13: Removing Engine Front Mounting Plate

Fig. 15: Removing Left Side Exhaust Camshaft Cap Seal,

Right Side Is Similar

6) Depress locking collar and disconnect brake servo hose from intake
manifold chamber. See Fig. 25. Disconnect connectors from Variable
Intake System (VIS) motors. Remove 2 screws securing engine harness
brackets to intake manifold chamber and position harness aside.
7) Remove 2 bolts securing intake manifold chamber rear support
brackets to right camshaft cover. Remove 4 bolts securing intake
manifold chamber to left intake manifold. Release and raise intake
manifold chamber from intake manifolds. Release 3 locking clips and
disconnect 3 connectors from right plug top coils.
8) Release 2 clips securing right plug top coil harness to intake manifold
camber rear support brackets. Remove intake manifold chamber.
Remove and discard seals from intake manifold chamber and O rings
from right intake manifold.
Installation 1) Clean seal faces on intake manifold chamber and
intake manifolds. Install NEW O rings to right intake manifold and NEW
seals to manifold chamber. Position intake manifold chamber, secure
right coil harness clips in intake manifold chamber support brackets.
2) Connect connectors to plug top coils and secure with locking clips.
Align intake manifold chamber to intake manifolds, install and tighten
bolts to specification. See TORQUE SPECIFICATIONS.

Courtesy of Land Rover North America, Inc.

Fig. 16: Positioning LRT-12-196 To Left Side Camshafts,

Right Side Is Similar

LAND ROVER

437

2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 20: Engine Front Mounting Plate-To-Cylinder Block &

IRD Bracket Tightening Sequence

Fig. 17: Installing LRT-12-197 Tools To Front Of

Exhaust Camshafts

Courtesy of Land Rover North America, Inc.

Fig. 21: Locating Fuel Pipe Connector (Up To 2003)

Courtesy of Land Rover North America, Inc.

Fig. 18: Aligning Rear Timing Marks & Positioning LRT-12-175

Between Rear Camshaft Gears

Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 19: Installing Front Timing Belt Tensioner

3) Align intake manifold chamber support brackets to right camshaft
cover, install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Position engine harness brackets to intake manifold chamber, install and tighten screws. Connect connectors to Variable Intake
System (VIS) motors.

Fig. 22: Locating Purge Control Valve & Left Camshaft Cover
Vacuum/Breather Hoses (Up To 2003)
4) Connect engine breather pipe. Connect connectors to IAT and MAF
sensors. Connect brake servo vacuum hose to intake manifold chamber.
Connect vacuum/breather hoses to left and right camshaft covers and to
throttle body. Connect cruise control actuator vacuum pipe.

438

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)
6) Install enhancer to intake manifold. Connect to intake hose and
secure with clip. Connect servo hose. Connect connector to solenoid
valve if equipped. Install enhancer into clips. Install engine acoustic
cover. See ENGINE ACOUSTIC COVER. Connect battery ground lead.
WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire
and explosion.

Courtesy of Land Rover North America, Inc.

Fig. 23: Locating IAT & MAF Sensors (Up To 2003)

Courtesy of Land Rover North America, Inc.

Fig. 24: Removing Intake Hose & MAF Sensor (Up To 2003)

Removal (From 2003 Model Year) 1) Disconnect battery ground lead.

Remove vacuum enhancer. Position absorbent cloth around fuel feed
pipe connection to collect spillage. Pull back rubber sleeve on fuel pipe
connector, release connector and disconnect fuel pipe from fuel rail
pipe. See Fig. 26. Install plugs to open connections to prevent contamination.
2) Release and disconnect EVAP hose from purge control valve. Install
plugs to open connections to prevent contamination. Disconnect connector from purge control valve. Disconnect connector from Idle Air
Control Valve (IACV).
3) Remove clip securing vacuum/breather pipe to engine air intake hose
and disconnect vacuum/breather pipe from air intake hose. See Fig. 27.
Discard clip. Install plugs to open connections to prevent contamination.
Depress locking collars and release vacuum/breather pipe from left
camshaft cover, right camshaft cover link pipe and intake manifold
chamber.
4) Remove pipe. Install plugs to open connections to prevent contamination. Disconnect connector from IAT and MAF sensors. See Fig. 28.
Disconnect connector from throttle body. Remove clip securing intake
hose to throttle body. Remove intake hose and MAF sensor assembly.
Discard clip.
5) Release harness and fuel feed pipe from clip on intake manifold
chamber. Disconnect connectors from Variable Intake System (VIS)
motors. Remove 2 screws securing engine harness brackets to intake
manifold chamber and position harness aside. Remove 2 bolts securing
intake manifold chamber rear support brackets to right camshaft cover.
6) Remove 4 bolts securing intake manifold chamber to left intake
manifold. Release 3 locking clips and disconnect 3 connectors from right
plug top coils. See Fig. 29. Release and raise intake manifold chamber
from intake manifolds. Release 2 clips securing right plug top coil
harness to intake manifold chamber support brackets. Remove intake
manifold chamber. Remove and discard seals from intake manifold
chamber and O rings from right intake manifold.

Courtesy of Land Rover North America, Inc.

Fig. 25: Locating VIS Motors Connectors & Brake Servo Hose
(Up To 2003)
5) Connect vacuum/breather hoses to left camshaft cover, T piece and
purge control valve. Connect connector to purge control valve. Connect
EVAP hose to purge control valve. Connect fuel hose to fuel rail pipe,
install rubber sleeve over hose connector. Remove absorbent cloth.

Courtesy of Land Rover North America, Inc.

Fig. 26: Locating Fuel Pipe & EVAP Hose Connections

(From 2003)

LAND ROVER

439

2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 27: Locating Vacuum/Breather Pipes (From 2003)

2) Align intake manifold chamber support brackets to right camshaft

cover, install and tighten bolts to specification. Connect connectors to
plug top coils and secure with locking clips. Position engine harness
brackets to intake manifold chamber, install and tighten screws.
3) Connect connectors to Variable Intake System (VIS) motors. Align
harness and fuel feed pipe. Secure harness and pipe in clip on manifold
chamber. Using a NEW clip, install intake hose to throttle body and
secure hose with clip. Connect connector to throttle body. Connect
connectors to IAT and MAF sensors.
4) Install vacuum/breather pipe and connect to left camshaft cover, right
camshaft cover link pipe and intake manifold chamber. Using a NEW
clip, install vacuum/breather pipe to engine air intake hose and secure
pipe with clip. Connect vacuum/breather pipe to left and right camshaft
covers.
5) Connect connector to purge control valve. Connect EVAP hose to
purge control valve. Connect fuel hose to fuel rail pipe, install rubber
sleeve over hose connector. Install pipe into clip. Install vacuum
enhancer. Connect the battery ground lead.

REAR TIMING BELT

CAUTION: Camshaft timing belts must be stored and handled with
care. Always store a camshaft timing belt on its edge with a bend
radius greater than 2.0 (50 mm). DO NOT use a camshaft timing
belt that has been twisted or bent double as this will damage the
reinforcing fibres. DO NOT use a camshaft timing belt if debris
other than belt dust is found in timing belt covers. DO NOT use a
camshaft timing belt if partial engine seizure has occurred. DO
NOT use a camshaft timing belt if mileage exceeds 45,000 miles.
DO NOT use an oil or coolant contaminated timing belt, cause of
contamination must be rectified.

Courtesy of Land Rover North America, Inc.

Fig. 28: Disconnecting IAT & MAF Sensors Connectors

(From 2003)

Removal 1) Disconnect battery ground lead. Remove underbelly

panel. See UNDERBELLY PANEL. On left side, remove engine acoustic
cover. See ENGINE ACOUSTIC COVER. Remove 3 bolts securing left
rear timing belt cover and remove cover. See Fig. 7.
2) On vehicles up to 2003, remove intake manifold chamber to gain
access to right rear timing belt cover. See INTAKE MANIFOLD CHAMBER. On all vehicles, remove 2 bolts securing right rear timing belt cover
heat shield and remove heat shield. See Fig. 7. Remove 3 bolts securing
right rear timing belt cover and remove cover.
CAUTION: DO NOT use camshaft gear bolts or timing belt to rotate
crankshaft. DO NOT use arrow on oil pump body as a timing
reference.
3) Using a socket on crankshaft pulley bolt, rotate crankshaft in a
clockwise direction. Align the engine SAFE position notch on crankshaft
pulley with the ARROW on front mounting plate and timing marks
aligned on the rear camshaft gears. See Fig. 8.
CAUTION: Ensure hole immediately adjacent to side of lower
crankcase is used.
4) Insert timing pin LRT-12-232 through hole in lower crankcase,
ensuring pin is located in hole in drive plate. See Fig. 9.
CAUTION: DO NOT turn crankshaft or camshafts while rear timing
belt is removed.

Courtesy of Land Rover North America, Inc.

Fig. 29: Releasing Plug Top Coil Connector (From 2003)

Installation 1) Clean seal faces on intake manifold chamber and
intake manifolds. Install NEW O rings to right intake manifold and NEW
seals to intake manifold chamber. Position intake manifold chamber,
secure right coil harness clips in intake manifold chamber support
brackets. Align intake manifold chamber to intake manifolds, install and
tighten bolts to specification.

5) Remove and discard front exhaust camshaft cap seal from cylinder
head. See Fig. 15. Position LRT-12-175 to rear camshaft gears. See
Fig. 30. Remove and discard bolts securing gears to camshafts.
Remove rear camshaft gears, timing belt and special tool as an
assembly.
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt
removed and cylinder heads installed.
6) If camshaft timing belt is to be reinstalled, mark direction of rotation on
timing belt. Remove LRT-12-175 from camshaft gears and remove
timing belt from gears.

440

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 31: Rear Camshaft Gear Positions For Installation

Courtesy of Land Rover North America, Inc.

Fig. 30: Positioning LRT-12-175 To Rear Camshaft Gears

(Left Shown; Right Is Similar)
NOTE: Following front or rear timing belt installation, it is possible
that after rotating engine and positioning crankshaft pulley to the
SAFE position, timing marks on rear timing gears may be misaligned. This misalignment is acceptable provided that timing belt
reinstalling procedure was carried out correctly.
CAUTION: If sintered gears have been subjected to prolonged oil
contamination, they must be soaked in a solvent bath and then
thoroughly washed in clean solvent before reinstalling. Because of
the porous construction of sintered material, oil impregnated in
gears will emerge and contaminate belt.
Installation 1) Clean camshaft gears and mating faces on camshafts.
Place gears inverted on a flat surface, with the locating lugs on the gears
facing each other. See Fig. 31.
2) Keeping timing marks aligned, position timing belt onto gears.
Position LRT-12-195 between gears, turn center nut sufficiently to
spread drive belt. Invert gears and timing belt and position LRT-12-175
to camshaft gears. See Fig. 32.
3) Check that locating lugs are still aligned and remove LRT-12-195 from
between camshaft gears. Install LRT-12-198 alignment pins into end of
each camshaft. See Fig. 33. Position timing belt and gears over
LRT-12-198 and locate gears onto camshafts.
4) Position LRT-12-197 into front end of exhaust camshaft. See Fig. 17.
With assistance, using a 30-mm socket on LRT-12-197, turn exhaust
camshaft clockwise sufficiently to align camshaft gears to drive slots in
each camshaft.
5) Remove LRT-12-198 alignment pins and install NEW camshaft gear
retaining bolts. See Fig. 34. Tighten camshaft gear bolts to specification.
See TORQUE SPECIFICATIONS.
6) Remove LRT-12-175 from camshaft gears. Remove LRT-12-197 from
front end of exhaust camshaft. Clean exhaust camshaft cap seal recess
and install NEW cap seal. See Fig. 15. Remove timing pin LRT-12-232
from lower crankcase.
7) Install splash shield and secure with bolts. Install right road wheel and
tighten nuts to specification. See TORQUE SPECIFICATIONS. Clean
rear timing belt cover. Position rear timing belt cover, install bolts and
tighten to specification.
8) Install engine acoustic cover. See ENGINE ACOUSTIC COVER.
Install underbelly panel. See UNDERBELLY PANEL. Connect battery
earth lead.

UNDERBELLY PANEL
Removal & Installation 1) Raise and support front of vehicle. DO
NOT work on or under a vehicle supported only by a jack. Always
support the vehicle on safety stands. Remove 2 screws securing
bumper valance to underbelly panel brackets.

Courtesy of Land Rover North America, Inc.

Fig. 32: Installing LRT-12-195 & LRT-12-175 To

Rear Camshaft Gears

Courtesy of Land Rover North America, Inc.

Fig. 33: Installing Rear Camshaft Gears To Camshafts

2) Remove 4 screws securing wheel arch liners to bumper valance, if
equipped. Remove 2 bolts securing rear of underbelly panel. Remove 6
bolts securing underbelly panel frame. Remove underbelly panel.
3) To install, position underbelly panel. Install bolts securing underbelly
panel frame and tighten to specification. See TORQUE SPECIFICATIONS. Install bolts securing rear of underbelly panel and tighten to
specification.
4) Install and tighten screws securing wheel arch liners to bumper
valance, if equipped. Install and tighten screws securing bumper valance to brackets. Remove stands and lower vehicle.

LAND ROVER

441

2.5L KV6 DOHC, 2002-04 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Land Rover North America, Inc.

Fig. 34: Installing NEW Camshaft Gear Retaining Bolts

Application
Ft. Lbs. (N.m)
A/C Compressor-To-Front Mounting Plate & Cylinder Block ................................... 18 (25)
Alternator-To-Front Mounting Plate ........................................................................... 33 (45)
Ancillary Drive Belt Tensioner Bolts ......................................................................... 18 (25)
Camshaft Rear Gear Bolts 1
Stage 1 .................................................................................................................... 20 (27)
Stage 2 ........................................................................................ ..................... 90 Further
Crankshaft Pulley Bolt ........................................................................................... 118 (160)
Engine Lifting Bracket & Front Mounting Plate Bolts-To-Engine Block
M8 ............................................................................................................................ 18 (25)
M10 .......................................................................................................................... 33 (45)
Engine Lower Steady-To-Subframe Bolt ................................................................ 74 (100)
Engine Lower Steady-To-Sump Mounting Bolt ...................................................... 74 (100)
Engine Mounting Bracket-To-Engine Front Plate Bolts ........................................... 33 (45)
Engine Upper Right Steady-To-Top Arm Bolts ....................................................... 74 (100)
Engine Upper Right Steady-To-Body Bolt .............................................................. 74 (100)
Engine Front Mounting Plate-To-Cylinder Block & IRD Bracket 2
M10 Bolt No. 1 ........................................................................................................ 18 (25)
M12 Bolts No. 2, 3, 4, 6 & 7 ................................................................................. 63 (85)
M10 Bolt No. 5 ........................................................................................................ 33 (45)
Heat Shield Rear Timing Belt Right Cover Bolts
M6 ................................................................................................................................ 7 (9)
M8 ............................................................................................................................ 18 (25)
Idler Pulley-To-Engine Front Mounting Plate Allen Bolt ........................................... 33 (45)
Intake Camshaft Front Gear Bolts
Stage 1 .................................................................................................................... 20 (27)
Stage 2 ........................................................................................ ..................... 90 Further
Intake Manifold Chamber-To-Intake Manifolds Bolts ............................................... 13 (18)
Intake Manifold-To-Cylinder Head Nuts & Bolts ...................................................... 18 (25)
PAS Pipe-To-Engine Front Mounting Plate Bolt ...................................................... 18 (25)
PAS Pipe Support Bracket-To-Right Hydramount Nut ............................................. 63 (85)
Road Wheel Lug Nuts ............................................................................................ 85 (115)
Timing Belt Front Tensioner Plunger Patchlok Bolts ............................................... 18 (25)
Top Arm Bracket-To-Engine Front Plate & Right Mounting
Bracket Bolts ......................................................................................................... 74 (100)
Top Arm-To-Right Hydramount Nut ........................................................................... 63 (85)
Underbelly Panel Frame Bolts .................................................................................. 33 (45)
INCH Lbs. (N.m)
Battery Lead-To-Alternator .......................................................................................... 71 (8)
Battery Lead-To-Starter Solenoid .............................................................................. 88 (10)
Dipstick Tube-To-Sump & Cylinder Block Bolt ........................................................... 80 (9)
Fuel Rail-To-Intake Manifold Bolts .............................................................................. 80 (9)
Ground Lead-To-Right Camshaft Cover Bolt ............................................................. 80 (9)
Intake Manifold Chamber Support Brackets-To-Right Camshaft
Cover Bolts ............................................................................................................... 88 (10)
PAS Pump Pulley Torx Screws .................................................................................. 80 (9)
Timing Belt Front Cover Bolts .................................................................................... 35 (4)
Timing Belt Front Cover Backplate-To-Cylinder Block Bolts 3 ................................... 80 (9)
Timing Belt Rear Cover Backplate-To-Cylinder Block Bolts 3 .................................... 80 (9)
Timing Belt Rear Cover Bolts ..................................................................................... 35 (4)
Underbelly Rear Panel Bolts ...................................................................................... 71 (8)
1
2
3

NEW bolts must be installed.

Tighten bolts in sequence to specified torque value for each bolt. See Fig. 20.
Apply sealant No. STC50552 to bolt threads.

LEXUS

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2.5L & 3.0L V6 1990-98

TIMING BELT APPLICATION

TIMING BELT

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Removal (2.5L & 1992-93 3.0L V6) 1) Disconnect negative battery

cable. Remove cruise control actuator and vacuum pump. Remove
power steering reservoir with hoses attached, and secure them aside.
Raise and support vehicle. Remove right front wheel. Remove right
lower engine cover. Remove all drive belts.
2) 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 engine mount assembly. Remove spark
plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right
engine mount bracket. See Fig. 1. Note bolt length and location of No. 2
timing belt cover bolts for reassembly reference.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

CAUTION: If timing belt is to be reused, mark direction of timing

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.

Application

Labor Time

Component
Belt
Kit No.
Part No.

2.5L V6
ES 250
1990-91 ............................... 3.8 Hours ... .. TCK157 .. ..... T157
3.0L V6
ES 300
1992-93 ............................... 3.0 Hours ... .. TCK200 .. ..... T200
1994-98 ............................... 3.0 Hours ... ...... ..... ...... ..... T257

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 manufacturer recommends the belt be replaced at 60,000 miles or 96 months for
severe operating conditions.

REMOVAL & INSTALLATION

WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.

3) 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. Ensure timing marks on camshaft sprockets
are aligned with timing marks on No. 3 timing belt cover. See Fig. 2.
Remove retaining bolts and timing belt tensioner.
4) Install Camshaft Sprocket Holder (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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS

443

2.5L & 3.0L V6 1990-98 (Cont.)

5) Using Pulley Holder (09213-54014) or equivalent, and Handle
(09330-00021), hold crankshaft pulley, and remove 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
crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover.
6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft 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).

6) Remove retaining bolts, timing belt tensioner and dust boot. Remove
crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder
(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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Timing Marks (1994-98 3.0L)

Inspection (2.5L & 3.0L V6) 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. Ensure idler pulleys rotate freely. Replace
damaged 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.
2) Measure timing belt tensioner rod protrusion from end of rod to edge
of timing belt tensioner housing. See Fig. 4. 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).
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)

Removal (1994-98 3.0L V6) 1) Disconnect negative battery cable.
Remove coolant reservoir. Raise and support vehicle. Remove right side
front wheel. Remove right lower engine cover. Remove accessory drive
belts.
2) 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.
3) Use Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, to hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1
timing belt cover. See Fig. 1.
4) Remove engine mounting bracket. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt guide.
5) Temporarily install crankshaft pulley bolt in crankshaft. Using 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 camshaft sprockets are aligned with
timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution (360 degrees).

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

Installation (2.5L & 1992-93 3.0L V6) 1) 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
SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates
smoothly.
2) 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.

LEXUS

444

2.5L & 3.0L V6 1990-98 (Cont.)

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.
3) Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure
idler pulley rotates smoothly. Rotate crankshaft 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.
4) 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 timing 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.
5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket
clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket.
6) Using camshaft sprocket holder, slightly rotate left camshaft 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.
7) Using camshaft sprocket holder, slightly rotate right camshaft
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.
8) Place washer on bottom side of timing belt tensioner. 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. 5.
Release press, and install dust boot on timing belt tensioner. Install
timing belt tensioner. Tighten retaining bolts to specification. See
TORQUE SPECIFICATIONS.
9) Remove hexagon wrench from timing belt tensioner. Rotate 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.

Installation (1994-98 3.0L V6) 1) Install timing belt plate. Install and
tighten bolt to specification. Install No. 1 and No. 2 idler pulleys (if
removed). Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly.
2) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
Fig. 3.
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. See
Fig. 6. Ensure front mark is pointing toward timing belt end of engine.
CAUTION: 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.
4) Install timing belt on crankshaft sprocket, water pump pulley, 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. 5. Release press and install dust boot on
timing belt tensioner. Install timing belt tensioner. Install and alternately
tighten bolts to specification. See TORQUE SPECIFICATIONS.
5) Remove hexagon wrench from timing belt tensioner. Rotate 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.
6) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install engine 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 to specification. See TORQUE SPECIFICATIONS.
7) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

CAUTION: Crankshaft must always be rotated clockwise. DO NOT

rotate crankshaft counterclockwise.
10) To install remaining components, reverse removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Retracting Timing Belt Tensioner Rod

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Identifying Timing Belt Reference Marks (1994-98 3.0L)

LEXUS

445

2.5L & 3.0L V6 1990-98 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.5L V6)

TORQUE SPECIFICATIONS (3.0L V6)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Crossmember-To-Body Bolt .......................................................................... 29 (39)
Engine Mount Through-Bolt ...................................................................................... 64 (87)
Engine Mount-To-Engine 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)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 14 (19)
Wheel Lug Nut ........................................................................................................ 76 (103)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 94 (127)
Crankshaft Pulley Bolt ........................................................................................... 159 (215)
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 Bolt ....................................................................................... 31 (42)
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)
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Wheel Lug Nut ........................................................................................................ 76 (103)

INCH Lbs. (N.m)

No. 3 Timing Belt Cover Bolt ..................................................................................... 65 (7)
Valve Cover Nut .......................................................................................................... 52 (6)

INCH Lbs. (N.m)

No. 1 & 2 Timing Belt Cover Bolt ...........................................................................
No. 3 Timing Belt Cover Bolt ..................................................................................
Timing Belt Plate Bolt ..............................................................................................
Valve Cover Bolt ......................................................................................................
Water Pump Bolt/Nu ................................................................................................

75
75
71
71
71

(8.5)
(8.5)
(8.0)
(8.0)
(8.0)

LEXUS

446

3.0L 6-Cylinder 1993-97

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L 6-Cyl.
GS 300
1993-97 ..................................................... 3.4 Hours ... ..... T215
SC 300
1993-97 ..................................................... 3.4 Hours ... ..... T215
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 manufacturer recommends the belt be replaced at 60,000 miles or 96 months for
severe operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal 1) Disconnect battery cables and remove battery. 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.
2) 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.
3) 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.
4) Timing marks on camshaft sprockets must align with timing marks on
No. 4 timing belt cover. See Fig. 2. If conditions are not as described,
rotate crankshaft clockwise one complete revolution clockwise.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

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.
5) Alternately loosen timing belt tensioner bolts. Remove bolts, timing
belt tensioner and dust boot. See Fig. 1. Remove timing belt from
camshaft sprockets.
6) Using Handle (09330-00021) or equivalent, and Pulley Holder
(09213-70010), or equivalent, hold crankshaft pulley and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.
7) Remove No. 1 timing belt cover and gaskets. Note direction of timing
belt guide installation for reassembly reference. See Fig. 1. Remove
timing belt guide.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

NOTE: Timing 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.

CAUTION: If reusing timing belt, place reference mark on timing

belt and crankshaft sprocket for reassembly reference.
8) Remove timing belt. Remove bolt, idler pulley and plate washer (if
necessary).
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Check
idler pulley and drive belt tensioner for smooth rotation. Replace idler
pulley or drive belt tensioner if defective.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists.
3) Hold timing belt tensioner body, and press rod against solid surface.
Replace timing belt tensioner if rod moves.
4) Measure timing belt tensioner rod protrusion from end of rod to edge
of housing. See Fig. 3. Replace timing belt tensioner if distance is not
.315-.343 (8.00-8.80 mm).

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

Installation 1) 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.

LEXUS

447

3.0L 6-Cylinder 1993-97 (Cont.)

2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark
on crankshaft sprocket with timing mark on oil pump body. See Fig. 1.
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 in
original direction of rotation.
3) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side against timing belt. Install gaskets and No. 1
timing belt cover.
4) Align crankshaft pulley key groove with crankshaft key. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
5) 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 SPECIFICATIONS.
6) 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.
7) Using sprocket holder, rotate camshaft sprockets so timing 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.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and camshaft sprockets align and timing belt is installed in
original direction of rotation.
8) Using press, apply pressure on rod of timing belt tensioner until rod is
retracted and holes in rod and housing are aligned. See Fig. 3.
9) Install hexagon wrench through holes in housing and rod 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 specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
10) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate
crankshaft counterclockwise.
11) Ensure timing marks on camshaft sprockets align with timing 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.
12) To install remaining components, reverse removal procedure. Use
care when installing drive belt tensioner bolts to avoid dropping bolts into
timing belt cover. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 22 (30)
Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
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)
Pulsation Damper ...................................................................................................... 29 (39)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt/Nut ................................................................................................ 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4)
Valve Cover Bolt ...................................................................................................... 52 (5.9)

LEXUS

448

3.0L 6-Cylinder 1998-04

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
3.0L 6-Cyl.
GS 300
1998-04
IS 300
2001-04
SC 300
1998-00

Labor Time

Belt
Part No.

2JZ-GE

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

..................................................... 3.4 Hours ... ..... T215

..................................................... 3.2 Hours ... ..... T215
..................................................... 3.4 Hours ... ..... T215

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

TIMING BELT
Removal 1) Raise and support vehicle. Remove engine undercover.
Drain cooling system.
2) On IS 300 M/T, remove drive belt tensioner absorber. On GS 300 and
all IS 300 models, remove air cleaner inlet, air cleaner, and MAF
assembly. Remove radiator and electric cooling fan assembly. On
1998-99 models, rotate serpentine drive belt tensioner COUNTERCLOCKWISE and remove belt. Tensioner bolt has LEFT-HAND threads.
On 2000-04 models, rotate tensioner CLOCKWISE to remove serpentine belt.

The manufacturer recommends the belt be replaced every 90,000 miles

or 72 months.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS

449

3.0L 6-Cylinder 1998-04 (Cont.)

3) On SC 300, 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. Remove cooling fan, fan clutch, and water pump
pulley.
4) 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. 1. Being careful not to
drop bolts inside timing belt cover, remove serpentine drive belt tensioner.
5) Using Handle (09330-00021) and Pulley Holder (09213-70011) 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 No. 1 timing belt cover. See Figs. 2 and 3.
6) Timing marks on camshaft timing pulleys must align with timing marks
on No. 4 timing belt cover. See Fig. 2. If not, rotate crankshaft
CLOCKWISE one complete revolution (360 degrees).
CAUTION: Crankshaft must be correctly positioned by aligning
sub-timing mark (60 degree mark BTDC) with 0 mark on timing
belt cover to prevent valves from contacting pistons.
7) 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: If reusing timing belt, place arrow on timing belt to
indicate direction of rotation. Place reference mark on timing belt
and each camshaft timing pulley for reassembly reference.
8) DO NOT allow the crankshaft pulley to rotate. Remove crankshaft
pulley bolt.
9) Alternately loosen timing belt tensioner bolts. Remove bolts, timing
belt tensioner, and dust boot. See Fig. 1. Remove timing belt from
camshaft sprockets.
10) 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 toward timing belt). See Fig. 1. Remove
timing belt guide. If reusing timing belt, place mating reference marks on
timing belt and crankshaft sprocket. Remove timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Sub-Timing Marks

Fig. 2: Aligning Camshaft Timing Marks
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. 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 exists.

LEXUS

450

3.0L 6-Cylinder 1998-04 (Cont.)

NOTE: Timing 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.
2) 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 timing belt tensioner if distance is not
.315-.346 (8.00-8.80 mm).
3) On IS 300 M/T, compress and extend drive belt tensioner absorber
rod. If there is abnormal resistance or operation, replace as necessary.

9) Ensure timing marks on camshaft timing pulleys align with timing

marks on timing belt cover, and timing mark on crankshaft pulley aligns
with 0 mark on timing belt cover. If timing marks are not aligned,
remove timing belt and reinstall.
10) 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.
11) Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill and bleed air from cooling system. See COOLING SYSTEM
BLEEDING.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

Installation 1) Install idler pulley and plate washer (if removed). Apply
Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and
tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure
idler pulley is clean and rotates smoothly, and idler pulley bracket moves
freely.
NOTE: The engine should be cold before adjusting timing marks.
2) Using crankshaft pulley bolt, rotate crankshaft and align 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 crankshaft timing pulley and around idler pulley.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and crankshaft timing pulley align, and timing belt is installed
in original direction of rotation.
3) Install timing belt guide with cupped side away from crankshaft timing
pulley and flat side against timing belt. Install gasket and No. 1 timing
belt cover. Align crankshaft pulley key groove with crankshaft key. Install
crankshaft pulley.
4) 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.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and camshaft timing pulleys align and timing belt is installed in
original direction of rotation.
5) If necessary, use spanner wrench to rotate camshaft timing pulleys so
timing marks on camshaft timing pulleys align with timing marks on No. 4
timing belt cover. See Fig. 2. Install timing belt on camshaft timing
pulleys. Ensure tension exists on timing belt between camshaft timing
pulleys.
6) Using press, SLOWLY apply pressure of 220-2205 lbs. (981-9807 N)
on push rod of timing belt tensioner until rod is retracted and holes in rod
and housing are aligned. See Fig. 5.
7) Install 1.5 mm hexagon wrench through holes in housing and rod to
hold rod in retracted position. See Fig. 5. Release press. Install dust
boot on timing belt tensioner. Install timing belt tensioner with 2 bolts.
Alternately tighten timing belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft CLOCKWISE. DO NOT rotate
crankshaft COUNTERCLOCKWISE.
8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft CLOCKWISE 2 full revolutions from TDC to TDC.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Retracting Timing Belt Tensioner Rod

COOLING SYSTEM BLEEDING

1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Timing Pulley Bolt .................................................................................... 60 (81)
Crankshaft Pulley Bolt ........................................................................................... 243 (330)
Drive Belt Tensioner Absorber Nut (IS 300 M/T) ..................................................... 14 (20)
Drive Belt Tensioner Bolt .......................................................................................... 15 (21)
Fan Clutch-To-Water Pump Nut (SC 300) ............................................................... 12 (16)
Idler Pulley Bolt ....................................................................................................... 1 26 (35)
Power Steering Pump Front Bracket Bolts
Bottom Bolt .............................................................................................................. 38 (52)
Top Bolts (2) ............................................................................................................ 43 (58)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 15 (21)
INCH Lbs. (N.m)
Fan-To-Fan Clutch Nuts (SC 300) .......................................................................... 65 (7.5)
Timing Belt Cover Bolts .............................................................................................. 71 (8)
Timing Belt Plate Bolt ................................................................................................. 71 (8)
1

Apply Loctite 242 or equivalent to bolt threads.

LEXUS

451

3.0L V6 1999-03
TIMING BELT APPLICATION
Application
3.0L V6 1MZ-FE
ES 300
1999-01 ...............................
2002-03 ...............................
RX 300
1999-01 ...............................
2002-03 ...............................
1

Labor Time

Component
Belt
Kit No.
Part No.

3.0 Hours ... ...... ..... ...... ..... T257

3.0 Hours ... ...... ..... ...... ..... T257
4.4 Hours ... . 1 TCK257 . ..... T257
4.4 Hours ... ...... ..... ...... ..... T257

Timing belt component kit does not include camshaft tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 90,000 miles
or 72 months.

REMOVAL & INSTALLATION

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

WARNING: To prevent air bag deployment, disconnect negative

battery cable at least 90 seconds before working on vehicle.

TIMING BELT
Removal (ES 300) 1) 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 connectors.
2) Remove engine moving control rod and engine mounting bracket
No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers.
3) Using Pulley Holder (09213-54015) or equivalent and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and
No. 2 timing belt covers and gaskets. See Fig. 1. Remove transverse
engine mounting bracket from front of engine. Note direction of timing
belt guide installation for reassembly reference. Remove timing belt
guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing
belt side of engine.
4) Temporarily install crankshaft pulley bolt and washer in crankshaft.
Using crankshaft pulley bolt, rotate crankshaft clockwise until timing
mark on crankshaft sprocket aligns with timing mark on oil pump body.
See Fig. 2.
5) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution (360 degrees).
Remove crankshaft pulley bolt.
6) 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 direction of rotation.
7) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. DO NOT hold tensioner with push rod facing downward. Remove
timing belt in the following sequence: No. 1 idler pulley, right camshaft
sprocket (firewall side), No. 2 idler pulley, left camshaft sprocket (front of
vehicle side), left camshaft sprocket (front of vehicle side), water pump
pulley, then crankshaft sprocket.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Inspection (ES 300) 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. 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.
2) Inspect timing belt tensioner for signs of oil leakage. Replace 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.
3) 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).

LEXUS

452

3.0L V6 1999-03 (Cont.)

8) 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 reinstall. Remove crankshaft pulley bolt.
9) Install timing belt guide with cupped side toward engine front. Install
transverse engine mounting bracket on front of cylinder block. Install
and tighten bolts to specification.
10) 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.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
12) Install generator bracket. Install engine mounting bracket No. 2 (right
side) and engine moving control rod. Install fender apron seal and right
front wheel.
13) To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Connect engine ground strap. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Identifying Timing Belt Reference Marks & Front Mark

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

NOTE: Engine should be cold when installing timing belt.
Installation (ES 300) 1) 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 rotate smoothly.
2) 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.
3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with timing mark on No. 3 timing belt cover.
See Fig. 2.
4) Install timing belt on crankshaft sprocket, water pump pulley, 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.
5) Using press, SLOWLY apply about 200-2200 lbs. of pressure 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.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) 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.

Fig. 5: Retracting Timing Belt Tensioner Rod

Removal (RX 300) 1) Remove the outer cowl top panel along with
ventilation louvers and windshield wiper arm assembly. See Fig. 6.
Remove shock tower suspension brace. Raise and support vehicle.
2) Remove right side front wheel. Remove right fender apron seal.
Remove accessory drive belts. Lower vehicle. Remove cruise control
actuator from right side of engine compartment.
3) Disconnect engine coolant reservoir hose from water outlet, if
necessary. Disconnect ground strap connectors.
4) Remove engine moving control rod and engine mounting bracket
No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers.
5) Using Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2
timing belt covers and gaskets. See Fig. 1. Remove transverse engine
mounting bracket from front of engine. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing
belt side of engine.
6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
Fig. 2.
7) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution (360 degrees).
Remove crankshaft pulley bolt.
8) 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 direction of rotation.

LEXUS

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3.0L V6 1999-03 (Cont.)

9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. DO NOT hold tensioner with push rod facing downward. Remove
timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

4) Install timing belt on crankshaft sprocket, water pump pulley, 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.
5) Using press, SLOWLY apply about 200-2200 lbs. of pressure 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.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) 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.
8) 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 reinstall. Remove crankshaft pulley bolt.
9) Install timing belt guide with cupped side facing outward. Install
transverse engine mounting bracket on front of cylinder block. Install
and tighten bolts to specification. See TORQUE SPECIFICATIONS.
10) Using new gaskets, install No. 1 and No. 2 timing belt covers.
Ensure there are no gaps in gasket. Cut off excess gasket. Install and
tighten bolts to specification.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.
12) Install generator bracket. Connect engine ground strap. Install
engine mounting bracket No. 2 (right side) and engine moving control
rod. Install cruise control actuator (if equipped).
13) To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS

Fig. 6: Exploded View Of Outer Cowl Top Panel (RX 300)

TORQUE SPECIFICATIONS

Inspection (RX 300) 1) Inspect timing belt for damaged teeth,

cracking or oil contamination. Ensure idler pulleys rotate freely and are
not leaking oil. Replace damaged components. Inspect water pump for
leaks or worn out bearing.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
ES 300 ................................................................................................................... 94 (125)
RX 300
Left Hand (Front End Of Vehicle Side) .............................................................. 94 (125)
Right Hand (Firewall Side Of Vehicle) ................................................................. 65 (88)
Crankshaft Pulley Bolt ........................................................................................... 159 (215)
Engine Mounting Bracket (Right Side) Bolts ........................................................... 47 (64)
Engine Moving Control Rod Bolts
Inboard Bolt (Small)
Except 2002-03 ES 300 ........................................................................................ 23 (32)
2002-03 ES 300 .................................................................................................... 17 (23)
All Other Bolts ......................................................................................................... 47 (64)
Generator Adjusting Lock Bolt .................................................................................. 13 (18)
Generator Bracket-To-Engine Bolts .......................................................................... 21 (28)
Generator Pivot Bolt .................................................................................................. 41 (56)
Power Steering Pump Bolt ....................................................................................... 32 (43)
Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43)
Shock Tower Brace-To-Shock Tower Nuts (RX 300) ............................................... 59 (80)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt .......................................................................................... 1 25 (34)
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Transverse Engine Mount Bracket-To-Engine Bolts ................................................ 21 (28)
Wheel Lug Nut ........................................................................................................ 76 (103)
Wiper Arm Nuts (RX 300) ........................................................................................ 18 (24)

CAUTION: Never hold timing belt tensioner with push rod facing
downward.
2) Inspect timing belt tensioner for signs of oil leakage. Replace 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.
3) 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).
Installation (RX 300) 1) 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 rotate smoothly.
2) 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.
3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with timing mark on No. 3 timing belt cover.
See Fig. 2.
NOTE: Engine should be cold when installing timing belt.

INCH Lbs. (N.m)

Timing Belt Cover Bolts ........................................................................................... 76 (8.5)
Timing Belt Plate Bolt ................................................................................................. 71 (8)
Water Pump Bolt/Nut .................................................................................................. 71 (8)
1

Apply Loctite 242 or equivalent to bolt threads.

LEXUS

454

4.0L V8 1990-97
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.0L V8 1UZ-FE
LS 400
1990-97 ..................................................... 4.5 Hours ... ..... T190
SC 400
1992-97 ..................................................... 4.8 Hours ... ..... T190
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 manufacturer recommends the belt be replaced at
60,000 miles or 96 months for severe operating conditions. For 1995-97
model years, the manufacturer recommends the belt be replaced at
90,000 miles for normal service and 60,000 miles for severe service.

6) Timing marks on camshaft sprockets must align with timing marks on

timing belt rear plates. See Fig. 3. 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. 2. Using Sprocket Holder (09278-54012) or equivalent, slightly
rotate right camshaft sprocket clockwise to release tension on timing
belt. Remove timing belt from camshaft sprockets.
7) Using Pulley Holder (09213-70010) or equivalent and Handle
(0933000021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt. Using puller, remove crankshaft pulley. On LS 400, remove
bolts/nuts and fan bracket. On SC 400, remove bolts/nuts and hydraulic
pump. On all models, remove No. 1 timing belt cover, gaskets, timing
belt cover spacer and gasket. See Fig. 2.
8) Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. Remove timing belt. Remove bolt, idler
pulleys and plate washer (if necessary).
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.

REMOVAL & INSTALLATION

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal 1) Remove battery. Remove lower engine cover Drain
cooling system. On LS 400, remove air duct located above top of
radiator and air cleaner cover. Remove air cleaner assembly. Remove
V-bank cover. Remove drive belt, fan clutch assembly and fan pulley. On
SC 400, rotate drive belt tensioner counterclockwise. Remove drive belt.
Remove coolant reservoir.
2) 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 covers located near valve covers. Remove No. 3 (upper)
timing belt covers. Remove spark plug wire clamps. Disconnect spark
plug wires from distributor caps.
3) Disconnect high-tension wire from ignition coils. Remove spark plug
wires and clamps. See Fig. 1. 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. 2. It may
be necessary to remove coolant pipe to access No. 2 timing belt covers.
4) Remove bolts, distributor caps and rotors. Mark component location
for reassembly reference. Disconnect electrical connector at distributor
housings. Remove bolts and distributor housings. See Fig. 2. 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 (LS 400) or hydraulic pump (SC 400).
5) 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 belt cover. See Fig. 3.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Removing/Installing Spark Plug Wires & Retainers

Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. 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 on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner.
2) Hold timing belt tensioner body and 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 housing. See Fig. 4.
Replace timing belt tensioner if distance is not .413-.453 (10.50-11.50
mm).

LEXUS

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4.0L V8 1990-97 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

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4.0L V8 1990-97 (Cont.)

8) Align installation mark on timing belt with timing mark on right
camshaft sprocket. See Fig. 3. Install timing belt on right camshaft
sprocket. Ensure timing mark on right camshaft 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 pressure
on rod of timing belt tensioner until rod is retracted and holes in rod and
housing are aligned. See Fig. 6.
9) Install hexagon wrench through holes in housing and rod to hold rod
in retracted position. See Fig. 6. Release press. Install dust boot on
timing belt tensioner. Install timing belt tensioner. Alternately tighten
bolts to specification. See TORQUE SPECIFICATIONS.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Checking Camshaft Timing Mark Alignment

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

Installation 1) Install No. 1 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. Install No. 2 idler
pulley and bolt. Tighten bolt to specification. Ensure idler pulleys are
clean and rotate smoothly. Ensure idler pulley bracket moves freely.
2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark
on crankshaft sprocket with timing mark on oil pump body. Install timing
belt on crankshaft sprocket so CR installation mark on timing belt aligns
with dot on crankshaft sprocket. See Fig. 5. Install timing belt on No. 1
and then No. 2 idler pulley.
3) Install timing belt guide with cupped side away from crankshaft
sprocket. Flat side should be against timing belt. Install gasket and
timing belt cover spacer. Install gaskets and No. 1 timing belt cover. On
LS 400, install fan bracket. Install and tighten bolts/nuts to specification.
See TORQUE SPECIFICATIONS.
4) On SC 400, install hydraulic pump. Install and tighten bolts/nuts to
specification. On all models, align crankshaft key with key groove of
crankshaft pulley. Using hammer and Pulley Installer (09223-46011) or
equivalent, install crankshaft pulley. Install and tighten crankshaft pulley
bolt to specification. See TORQUE SPECIFICATIONS.

CAUTION: Always rotate crankshaft clockwise as viewed from

front of engine. DO NOT rotate crankshaft counterclockwise.
10) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks
on camshaft sprockets align with timing marks on timing belt rear plate.
See Fig. 3. If timing marks are not aligned, remove timing belt and
reinstall. To install remaining components, reverse removal procedure.
11) Ensure distributor housings are installed in correct location 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.
12) 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. 1. Tighten all bolts/nuts to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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.
5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark
on timing belt cover. Using sprocket holder, rotate camshaft sprockets
and align timing marks on camshaft sprockets with timing marks on
timing belt rear plate. See Fig. 3. Align installation mark on timing belt
with end of fan bracket (LS 400) or hydraulic pump (SC 400).
6) Ensure timing mark on camshaft sprockets align with timing mark on
timing belt rear plate. See Fig. 3. Align installation mark on timing belt
with timing mark on left camshaft sprocket. See Fig. 3. Install timing belt
on left camshaft sprocket.
7) 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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Identifying Timing Belt Installation Marks

LEXUS

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4.0L V8 1990-97 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Retracting Timing Belt Tensioner Rod

Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 22 (30)
Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
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)
Pulsation Damper ...................................................................................................... 29 (39)
Power Steering Pump Pulley Nut ............................................................................. 32 (43)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt/Nut ................................................................................................ 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4)
Valve Cover Bolt ...................................................................................................... 52 (5.9)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Installing Rotors

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458

4.0L V8 1998-00
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.0L V8 1UZ-FE
GS 400
1998-00 ..................................................... 4.5 Hours ... ..... T298
LS 400
1998-00 ..................................................... 4.5 Hours ... ..... T298
SC 400
1998-00 ..................................................... 4.8 Hours ... ..... T298
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal 1) Disconnect negative battery cable. Remove lower engine
cover. Drain cooling system. Remove air cleaner inlet. Remove V bank
cover from top of engine. Remove air cleaner assembly and intake air
connector pipe.
2) On all models, drain engine coolant. Remove upper radiator hose.
3) On GS 400 and LS 400, remove serpentine drive belt by turning drive
belt tensioner pulley bolt counterclockwise. Tensioner pulley bolt is
LEFT HAND threaded. On SC 400, turn serpentine drive belt tensioner
bolt CLOCKWISE to relieve tension.
4) On LS 400, remove fan, fan clutch and fan pulley. On GS 400, remove
electric cooling fan assembly. On SC 400, disconnect hydraulic fan
motor pressure and return pipes from fan. Disconnect cooling fan inlet
pipe and reservoir tank from fan shroud.
5) On all models, remove the radiator assembly. Remove No. 2 drive
belt idler pulley. See Fig. 1. 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. 1.
6) On GS 400 and LS 400, disconnect power steering air hose from
clamp on No. 3 right side belt cover. On LS 400, disconnect 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. 1.
7) Remove A/C compressor from engine mount with hoses attached.
Move A/C compressor out of way. On GS 400, remove No. 1 drive belt
idler pulley and mount from engine. See Fig. 1. On LS 400, remove fan
bracket from front of engine. On SC 400, remove fan hydraulic pump
from front of engine. See Fig. 2.

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.
8) Using Pulley Holder (09213-70010) or equivalent and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Loosen, but do not
remove crankshaft pulley bolt.
9) 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 belt cover. See Fig. 3.
10) Timing marks on camshaft sprockets must align with timing marks
on timing belt rear plates. See Fig. 3. If timing marks are not aligned,
rotate crankshaft CLOCKWISE one complete revolution.
11) 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. 4.
CAUTION: If timing belt is disengaged, having crankshaft at incorrect angle can cause piston to contact valves while removing
crankshaft pulley.
12) Without moving crankshaft pulley, remove pulley bolt. Alternately
loosen 2 bolts, and remove timing belt tensioner. DO NOT hold timing
belt tensioner with push rod facing downward. See Fig. 1.
13) Using spanner wrench, slightly rotate right side camshaft pulley
clockwise to relieve tension on timing belt. Remove timing belt from
camshaft pulleys.
14) On GS 400, remove power steering pump pulley bolt and pulley. On
all models, remove generator. Remove serpentine drive belt tensioner.
Using gear puller, remove crankshaft pulley without rotating crankshaft.
15) Remove No. 1 timing belt cover. See Fig. 5. Noting installed direction
for reassembly reference, remove timing belt guide from end of crankshaft. Remove timing belt cover spacer.
16) If reusing timing belt, place mating mark on timing belt and
crankshaft timing pulley. Remove timing belt.
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Check
idler pulleys for smooth rotation and oil seal leakage. Replace idler
pulleys if defective.
CAUTION: Never hold timing belt tensioner facing downward.
NOTE: Timing belt tensioner may weep a small amount of oil on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if there are excessive oil leaks.
3) Hold timing belt tensioner body with push rod facing UPWARD. 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. 6. Replace timing belt tensioner if
distance is not .413-.453 (10.50-11.50 mm). Inspect water pump for
leaks or worn bearing.

LEXUS

459

4.0L V8 1998-00 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt Covers (GS 400 Shown; Others Are Similar)

LEXUS

460

4.0L V8 1998-00 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Setting Crankshaft At 50 Degrees ATDC

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Timing Belt Components (LS 400 & SC 400)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

Installation 1) Install No. 1 idler pulley and plate washer (if removed).
Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt.
Install and tighten bolt to specification. See TORQUE SPECIFICATIONS.
2) If removed, install No. 2 idler pulley and bolt. Tighten bolt to
specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are
clean and rotate smoothly. Ensure idler pulley bracket moves freely.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Exploded View Of Timing Belt & Idler Pulleys

NOTE: Engine should be cold when installing timing belt.

3) Clean any oil or water off of crankshaft timing pulley. DO NOT use
solvent. Temporarily install timing belt on crankshaft 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.
4) Install timing belt guide in original direction on end of crankshaft.
Install gasket and timing belt cover spacer. Install gaskets and No. 1
timing belt cover.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Measuring Timing Belt Tensioner Rod Protrusion

5) Without rotating crankshaft, align crankshaft key with key groove of
crankshaft pulley. Using hammer and Pulley Installer (09223-46011) or
equivalent, install crankshaft pulley.

LEXUS

461

4.0L V8 1998-00 (Cont.)

6) Install serpentine drive belt tensioner. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install generator. On GS 400, install
power steering pump pulley. On all models, ensure crankshaft is still at
50 degrees ATDC position. See Fig. 4.
7) Ensure camshaft timing pulleys are still aligned with mating marks on
rear plate. See Fig. 3. 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.
8) Using spanner wrench, turn left side camshaft pulley until there is
tension on timing belt between crankshaft timing pulley and left side
camshaft pulley.
9) 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 timing belt between left side and right
side camshaft pulleys.
10) Using press, SLOWLY apply about 200-2205 lbs. of pressure on
push rod of timing belt tensioner until rod is retracted. Ensure timing belt
tensioner is held with push rod facing upward. Holes in push rod and
housing must be aligned. See Fig. 7.
11) Install hexagon wrench through holes in housing and rod to hold rod
in retracted position. See Fig. 7. Release press. Install dust boot on
timing belt tensioner. Install timing belt tensioner. Alternately tighten
bolts to specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise as viewed from
front of engine. DO NOT rotate crankshaft counterclockwise.
12) Remove hexagon wrench from timing belt tensioner. Temporarily
install crankshaft pulley bolt. Slowly rotate crankshaft 2 full revolutions
clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets align with timing marks on timing belt rear plate. See Fig. 3. If timing
marks are not aligned, remove timing belt and reinstall.
13) Tighten crankshaft pulley bolt to specification. On GS 400, install
No. 1 drive belt idler pulley. On LS 400, install fan bracket. On SC 400,
install fan hydraulic pump and attach lines.
14) On all models, install A/C compressor. Install No. 2 timing belt cover.
Install No. 3 timing belt covers. Connect camshaft position sensor
electrical connectors. Install serpentine drive belt idler pulley.
15) 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 until engine is warm. Stop engine.
When engine is cool, refill coolant reservoir.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 22 (30)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Fan Bracket-To-Engine Bolts (LS 400)
12 mm Head ........................................................................................................... 12 (16)
14 mm Head ........................................................................................................... 24 (32)
Generator Pivot & Lock Bolt ..................................................................................... 29 (39)
Hydraulic Pump-To-Engine Bolts (SC 400)
12 mm Head ........................................................................................................... 12 (16)
14 mm Head ........................................................................................................... 24 (32)
No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS 400)
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)
Timing Belt Tensioner Bolt ........................................................................................ 19 (26)
Water Pump Bolt
GS 400 & SC 400 .................................................................................................. 15 (21)
LS 400 ..................................................................................................................... 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.

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4.3L V8 GS 430 & LS 430

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.3L V8 3UZ-FE
GS 430
2001-04 ..................................................... 4.5 Hours ... ..... T298
LS 430
2001-04 ..................................................... 4.5 Hours ... ..... T298
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine
cover. Drain cooling system. Remove air cleaner inlet. Remove V bank
cover from top of engine. On 2001-03 LS 430, also remove engine room
side covers. On all models, remove air cleaner assembly and intake air
connector pipe.
2) Remove serpentine drive belt by turning drive belt tensioner pulley
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND
threads.
3) Remove radiator hoses and disconnect ECM outlet duct. Disconnect
electric cooling fan wiring connectors and ECT switch connector for
cooling fan. Disconnect automatic transmission oil cooler hoses from
radiator. Remove upper radiator supports, and remove radiator and
cooling fan assembly.
4) Remove No. 2 drive belt idler pulley. See Fig. 1. Remove water
by-pass pipe from left side No. 3 timing belt cover. Remove No. 3 left
side timing belt cover. See Fig. 1. On 2004 LS 430, disonnect power
steering hoses from clamp on No. 3 right side timing belt cover. On all
models, remove No. 3 right side timing belt cover and No. 2 timing belt
cover.
5) Remove A/C compressor from engine with hoses attached. Move A/C
compressor out of way. Remove No. 1 drive belt idler pulley. See Fig. 1.
CAUTION: If reusing timing belt, check that there are 3 mating
marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 2. If marks are missing, place
installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original
direction of rotation.
6) Using Pulley Holder (09213-70010 or 09213-70011) or equivalent and
Handle (09330-00021) or equivalent, hold crankshaft pulley. Loosen, but
do not remove crankshaft pulley bolt.

7) Rotate crankshaft clockwise so cylinder No. 1 is about 50 degrees

after 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 belt cover. See Fig. 3.
8) Timing marks on camshaft sprockets must align with timing marks on
timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate
crankshaft CLOCKWISE one complete revolution (360 degrees).
CAUTION: If the timing belt is disengaged with the crankshaft
pulley at the wrong angle, this can cause the piston head and valve
head to come into contact with each other when you remove the
camshaft timing pulley, causing damage. Always set the crankshaft pulley at the correct angle.
9) Rotate crankshaft CLOCKWISE about 50 degrees. 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.
NOTE: When re-using timing belt: If the installation marks have
disappeared, before removal of the timing belt, place 2 new
installation marks on the timing belt to match the timing marks of
the camshaft timing pulleys.
NOTE: When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt, secure one of them with
string. Place matchmarks on the timing belt and right side camshaft timing pulley.
10) Without moving crankshaft pulley, remove pulley bolt. Alternately
loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT
hold timing belt tensioner with push rod facing DOWN. See Fig. 1.
11) Using spanner wrench, slightly rotate right side camshaft sprocket
CLOCKWISE to relieve tension on timing belt. Remove timing belt from
camshaft sprockets.
12) Remove camshaft timing sprockets, power steering pump pulley and
generator. Remove serpentine drive belt tensioner. Using gear puller,
remove crankshaft pulley without rotating crankshaft.
13) 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.
14) If not present, place mating mark on timing belt and crankshaft
timing sprocket. Remove timing belt.
NOTE: Note size and location of idler pulley bolts for reassembly
reference.
15) If necessary, use a 10-mm hexagon wrench to remove No. 1 idler
pulley bolt, idler pulley and plate washer. To remove No. 2 idler pulley,
remove the bolt and idler pulley. To remove crankshaft timing sprocket,
use Puller (0995050013). Do not turn the timing pulley during removal.

LEXUS

463

4.3L V8 GS 430 & LS 430 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS

464

4.3L V8 GS 430 & LS 430 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Locating Timing Belt Installation Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Exploded View Of Timing Belt & Idler Pulleys

3) Hold timing belt tensioner body with push rod facing UPWARD. 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. 5. Replace timing belt tensioner if
distance is not .374-.413 (9.50-10.50 mm). Inspect water pump for
leaks or worn bearing.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Crankshaft Pulley & Camshaft Timing Marks

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

Inspection 1) Inspect timing belt for damaged teeth, cracking or oil

contamination. Replace timing belt if damaged or contaminated. Check
idler pulleys for smooth rotation and oil seal leakage. Replace idler
pulleys if defective.

Installation 1) If removed, install crankshaft timing sprocket by

aligning sprocket set key with key groove of sprocket. Using Special Tool
(09223-46011) and a hammer, tap in timing sprocket with flange side
INWARD. See Fig. 6.
2) If removed, install No. 1 timing belt idler pulley, plate washer and pivot
bolt. Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt.
Install and tighten bolt to specification. See TORQUE SPECIFICATIONS.
3) If removed, install No. 2 timing belt idler pulley and bolt. Tighten bolt
to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys
are clean and rotate smoothly. Ensure idler pulley bracket moves
smoothly.

CAUTION: Never hold timing belt tensioner facing downward.

NOTE: Timing belt tensioner may weep a small amount of oil on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if there are excessive oil leaks.

LEXUS

465

4.3L V8 GS 430 & LS 430 (Cont.)

NOTE: The engine should be cold.
4) Clean any oil or water off of crankshaft timing sprocket and all pulleys.
DO NOT use solvent. Temporarily install timing belt on crankshaft timing
sprocket, 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
sprocket.
5) Install gasket and timing belt cover spacer. Install timing belt guide
(cup side OUT) on end of crankshaft. Install No. 1 timing belt cover.
Using Special Tool (09223-46011) and a hammer, tap in crankshaft
pulley. Install serpentine drive belt tensioner. Install generator. Install
power steering pump pulley. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
CAUTION: Check that crankshaft pulley timing mark is aligned with
centers of crankshaft pulley and No. 2 timing belt idler pulley bolt.
6) Install camshaft timing sprockets by aligning camshaft timing tube
knock pin with pin groove of timing sprocket. Attach timing sprocket to
camshaft timing tube with L or R marks facing FORWARD. Install
bolts and tighten to specification. See TORQUE SPECIFICATIONS.
7) Ensure camshaft timing sprockets are still aligned with mating marks
on rear plate. See Fig. 3. Clean camshaft timing sprockets (do not use
solvent). Install timing belt on left side camshaft sprocket. If reusing old
timing belt, ensure mating mark on belt aligns with mark on left side
camshaft sprocket.
8) Using spanner wrench, turn left side camshaft sprocket COUNTERCLOCKWISE until there is tension on timing belt between crankshaft
timing sprocket and left side camshaft sprocket.
9) Install timing belt on right side camshaft sprocket. If reusing old belt,
ensure mating mark on belt aligns with mark on right side camshaft
sprocket. Ensure there is tension on timing belt between left side and
right side camshaft sprockets.
10) Using press, slowly apply about 200-2205 lbs. (981-9807 N) of
pressure on push rod of timing belt tensioner until rod is retracted.
Ensure timing belt tensioner is held with push rod facing upward. Holes
in push rod and housing must be aligned. See Fig. 7.
11) Install 1.27 mm hexagon wrench through holes in housing and rod to
hold rod in retracted position. See Fig. 7. Release press. Install dust
boot on timing belt tensioner. Install timing belt tensioner. Alternately
tighten bolts to specification. See TORQUE SPECIFICATIONS.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Installing Crankshaft Timing Sprocket

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Retracting Timing Belt Tensioner Rod

CAUTION: Always rotate crankshaft CLOCKWISE as viewed from

front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE.
12) Remove hexagon wrench from timing belt tensioner. Temporarily
install crankshaft pulley bolt. Slowly rotate crankshaft 2 full revolutions
CLOCKWISE from TDC to TDC. Ensure timing marks on camshaft
sprockets align with timing marks on timing belt rear plate. See Fig. 8. If
timing marks are not aligned, remove timing belt and reinstall.
13) Tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install No. 1 drive belt idler pulley.
14) Install A/C compressor, No. 2 timing belt cover, No. 3 timing belt
cover and connect Camshaft Position (CMP) sensor electrical connectors. Install No. 2 drive belt idler pulley.
15) Install radiator assembly. Fill cooling system. Bleed cooling system
and check for leaks. See COOLING SYSTEM BLEEDING. To install
remaining components, reverse removal procedure. Tighten all bolts/
nuts to specification. See TORQUE SPECIFICATIONS.

COOLING SYSTEM BLEEDING

1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 8: Checking Timing Marks

LEXUS

466

4.3L V8 GS 430 & LS 430 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 21 (29)
Crankshaft Sprocket Bolt ...................................................................................... 181 (245)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Generator Pivot & Lock Bolt ..................................................................................... 29 (39)
No. 1 Drive Belt Idler Pulley Bolts
12 mm Head ........................................................................................................... 12 (16)
14 mm Head ........................................................................................................... 24 (32)
No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 25 (35)
No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16)
Power Steering Pump
Bolt ........................................................................................................................... 29 (39)
Nut ........................................................................................................................... 32 (43)
Power Steering Pump Pulley Center Nut ................................................................ 32 (43)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Idler Pulley Bolts ................................................................................. 1 25 (35)
Timing Belt Tensioner Bolt ........................................................................................ 19 (26)
Water Pump Bolt, Nut Or Stud Bolt ......................................................................... 13 (18)
INCH Lbs. (N.m)
Air Cleaner Assembly Bolts ........................................................................................ 41 (5)
Air Cleaner Inlet Bolts ................................................................................................. 41 (5)
Camshaft Timing Sprocket Bolts ............................................................................. 66 (7.5)
No. 1 & No.3 Timing Belt Cover Bolts .................................................................... 66 (7.5)
Radiator Support Nuts ......................................................................................... 119 (13.5)
V Block Cover ........................................................................................................... 41 (5)
1

Apply Loctite 242 or equivalent on threads of No. 1 idler pulley bolt.

LEXUS

467

4.3L V8 SC 430
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.3L V8
SC 430
2002-04 ..................................................... 3.6 Hours ... ..... T298
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine
cover. Drain cooling system. Remove air cleaner inlet. Remove V bank
cover from top of engine. Remove intake air connector pipe.
2) Remove radiator hoses and oil cooler tubes from radiator. Remove air
cleaner assembly. Disconnect electric cooling fan wiring connectors.
Remove upper radiator supports, and remove radiator and cooling fan
assembly.
3) Remove serpentine drive belt by turning drive belt tensioner pulley
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND
threads.
4) Remove power steering pump assembly with hoses attached, and
position out of way. Remove generator. Remove A/C compressor from
engine with hoses attached. Move A/C compressor out of way.
NOTE: Note size and location of idler pulley bolts for reassembly
reference.
5) Remove No. 2 right side timing belt cover. See Fig. 1. Remove water
by-pass pipe from No. 3 left side timing belt cover. Remove No. 3 left
side timing belt cover. Remove No. 2 timing belt cover sub-assembly.
Remove serpentine drive belt tensioner. Remove No. 1 drive belt idler
pulley.
6) Using Pulley Holder (09213-70011) and Handle (09330-00021),
remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller
Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt
cover. See Fig. 2. Noting installed direction for reassembly reference,
remove timing belt guide (Crankshaft Position (CKP) sensor plate) from
end of crankshaft.

CAUTION: If reusing timing belt, check that there are 3 mating

marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 3. If marks are missing, place
installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original
direction of rotation.
7) Using crankshaft damper bolt, rotate crankshaft CLOCKWISE so
cylinder No. 1 is about 50 degrees BTDC on compression stroke.
Ensure timing marks on crankshaft sprocket and oil pump body are
aligned. See Fig. 4.
8) Turning hexagon wrench head portion of camshaft, align timing marks
on camshaft sprockets with timing marks on timing belt rear plates. See
Fig. 5. If timing marks are not aligned, rotate crankshaft CLOCKWISE
one complete revolution (360 degrees).
CAUTION: If the timing belt is disengaged with the crankshaft
sprocket at the wrong angle, this can cause the piston head and
valve head to come into contact with each other when you remove
the camshaft sprocket, causing damage. Always set the crankshaft
sprocket at the correct angle.
9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCKWISE about 50 degrees. See Fig. 6. Alternately loosen 2 bolts, and
remove timing belt tensioner and dust boot. DO NOT hold timing belt
tensioner with push rod facing DOWN. See Fig. 1.
10) Using spanner wrench, slightly rotate right side camshaft sprocket
COUNTERCLOCKWISE to relieve tension on timing belt. See Fig. 7.
Remove timing belt.
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Check
idler pulleys for smooth rotation and oil seal leakage. Replace idler
pulleys if defective.
CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
NOTE: Timing belt tensioner may weep a small amount of oil on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if there are excessive oil leaks.
3) Hold timing belt tensioner body with push rod facing UPWARD. 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. 8. Replace timing belt tensioner if
distance is not .374-.413 (9.50-10.50 mm). Inspect water pump for
leaks or worn bearing, and replace as necessary.

LEXUS

468

4.3L V8 SC 430 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS

469

4.3L V8 SC 430 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Camshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Exploded View Of Timing Belt & Idler Pulleys

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Aligning Crankshaft Sprocket For Timing Belt Removal

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Locating Timing Belt Installation Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Removing Timing Belt

LEXUS

470

4.3L V8 SC 430 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 8: Measuring Timing Belt Tensioner Rod Protrusion

Installation 1) Turn camshaft and set No. 1 cylinder to TDC. Timing
marks on camshaft sprockets must align with timing marks on timing belt
rear plates. See Fig. 9. To ease installation of timing belt, turn left
camshaft sprocket CLOCKWISE 1/2 tooth and turn right camshaft
sprocket CLOCKWISE one tooth. See Fig. 10. Turn crankshaft CLOCKWISE to align timing marks of crankshaft sprocket and oil pump body.
See Fig. 11.
2) Face the front mark (arrow) on timing belt forward. While aligning
installation marks on timing belt with mark on appropriate sprocket,
install timing belt in the following sequence:
a) Crankshaft sprocket
b) Idler No. 2
c) Left camshaft sprocket
d) Water pump pulley
e) Right camshaft sprocket
f) Idler No. 1
See Fig. 3.
3) Using press, slowly apply about 220-2205 lbs. (100-1000 kg) of
pressure on push rod of timing belt tensioner until rod is retracted.
Ensure timing belt tensioner is held with push rod facing UPWARD.
Holes in push rod and housing must be aligned. See Fig. 12.
4) Install 1.27 mm hexagon wrench through holes in housing and rod to
hold rod in retracted position. See Fig. 12. Release press. Install dust
boot on timing belt tensioner. Install timing belt tensioner. Alternately
tighten bolts to specification. See TORQUE SPECIFICATIONS.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 9: Aligning Camshaft Sprocket Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 10: Positioning Camshaft Sprockets For Timing Belt

Installation

CAUTION: Always rotate crankshaft CLOCKWISE as viewed from

front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE.
5) Remove hexagon wrench from timing belt tensioner. Slowly rotate
crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. Ensure all
timing marks are aligned. See Figs. 4 and 5. If timing marks are not
aligned, remove timing belt and reinstall. Remove crankshaft damper
bolt. Install timing belt guide plate (CKP sensor plate). See Fig. 13.
6) Install timing belt No. 1 cover, and tighten bolts to specification. See
TORQUE SPECIFICATIONS. Using Replacer (09223-46011) and a
hammer, tap in crankshaft pulley, aligning sprocket set key with key
groove of sprocket. Using Pulley Holder (09213-70011) and Handle
(09330-00021), install crankshaft sprocket bolt. Tighten crankshaft
sprocket bolt to specification.
7) Install No. 1 drive belt idler pulley assembly. Install serpentine drive
belt tensioner. Install No. 2 timing belt cover sub-assembly, matching
claws and pin with each part. See Fig. 14. To install remaining
components, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS. Fill cooling system, and
check for leaks. See COOLING SYSTEM BLEEDING.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 11: Aligning Crankshaft Sprocket Timing Marks

COOLING SYSTEM BLEEDING

1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 12: Retracting Timing Belt Tensioner Rod

LEXUS

471

4.3L V8 SC 430 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 13: Installing Timing Belt Guide

Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 21 (29)
Crankshaft Sprocket Bolt ...................................................................................... 181 (245)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Generator Pivot & Lock Bolt ..................................................................................... 29 (39)
No. 1 Drive Belt Idler Pulley Bolts
12-mm Head ............................................................................................................ 12 (16)
14-mm Head ............................................................................................................ 24 (32)
No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 29 (39)
No. 2 Timing Belt Cover Sub-Assembly Bolt ........................................................... 12 (16)
Power Steering Pump
Bolt ........................................................................................................................... 29 (39)
Nut ........................................................................................................................... 32 (43)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Idler Pulley Bolt ................................................................................... 1 25 (35)
Timing Belt Tensioner Bolt ........................................................................................ 19 (26)
Water Pump Bolt ....................................................................................................... 13 (18)
INCH Lbs. (N.m)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Air Cleaner Assembly .................................................................................................. 41 (5)

Air Cleaner Inlet No. 1 ................................................................................................ 41 (5)
Camshaft Timing Sprocket Bolt ............................................................................... 66 (7.5)
Intake Air Connector Pipe ........................................................................................... 41 (5)
No. 1, 2 & 3 Timing Belt Cover Bolts ..................................................................... 66 (7.5)
Radiator Support Nuts ......................................................................................... 119 (13.5)
V Bank Cover ........................................................................................................... 41 (5)
1

Fig. 14: Installing No. 2 Timing Belt Cover Sub-Assembly

Apply Loctite 242 or equivalent to No. 1 idler pulley bolt threads.

472

LEXUS & TOYOTA

3.3L V6 2004

TIMING BELT APPLICATION

Application
3.3L V6 3MZ-FE
Camry
2004 ...........................................................
Camry Solara
2004 ...........................................................
ES 330
2004 ...........................................................
Highlander
2004 ...........................................................
RX 330
2004 ...........................................................
Sienna
2004 ...........................................................

Labor Time

Belt
Part No.

3.0 Hours ... ..... T257

3.0 Hours ... ..... T257
3.0 Hours ... ..... T257
2.5 Hours ... ..... T257
4.4 Hours ... ..... T257
4.0 Hours ... ..... T257

CAUTION: If timing belt is disengaged, having crankshaft pulley at

wrong angle can cause piston and valve to come in contact with
each other when you remove crankshaft or camshaft pulleys,
causing damage. Always set crankshaft pulley at correct angle.
8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. DO NOT hold tensioner with push rod facing DOWN. Remove
timing belt in the following sequence:
a) No. 1 idler pulley
b) Right camshaft sprocket (firewall side)
c) No. 2 idler pulley
d) Left camshaft sprocket (front of vehicle side)
e) Water pump pulley
f) Crankshaft sprocket

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 90,000 miles
or 72 months.

REMOVAL & INSTALLATION

WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Camry, Camry Solara & ES 330) 1) 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 connectors.
2) Remove engine moving control rod and engine mounting bracket
No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers.
3) Using Pulley Holder (09213-54015) or equivalent and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft
pulley bolt. Using puller and crankshaft pulley bolt, remove crankshaft
pulley. Remove No. 2 timing belt cover and gasket. See Fig. 1. Remove
right side engine mounting bracket. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing
belt side of engine.
4) Temporarily install crankshaft pulley bolt and washer in crankshaft.
Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing
mark on crankshaft sprocket aligns with timing mark on oil pump body.
See Fig. 2.
5) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 2. If timing marks are not
aligned, rotate crankshaft CLOCKWISE one full revolution (360
degrees). Remove crankshaft pulley bolt.
6) 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
timing belt contacts crankshaft and camshaft sprockets. Also, mark belt
with arrow showing direction of rotation.
7) Turning crankshaft pulley, set cylinder No. 1 to about 60 degrees
BTDC. See Fig. 4.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Inspection (Camry, Camry Solara & ES 330) 1) Inspect timing belt
for damaged teeth, cracking or oil contamination. 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
DOWN.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists. Hold timing belt tensioner body with
push rod facing UP. Press rod against solid surface. Replace timing belt
tensioner if push rod moves.
NOTE: Engine should be cold when installing timing belt.
Installation (Camry, Camry Solara & ES 330) 1) 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
rotate smoothly.
2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,
use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE
until timing mark on crankshaft sprocket is about 60 degrees BTDC. See
Fig. 4.

LEXUS & TOYOTA

473

3.3L V6 2004 (Cont.)

CAUTION: If timing belt is disengaged, having crankshaft pulley at
wrong angle can cause piston and valve to come in contact with
each other when you remove crankshaft or camshaft pulleys,
causing damage. Always set crankshaft pulley at correct angle.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Identifying Timing Belt Reference Marks & Front Mark

3) Using spanner wrench, rotate each camshaft sprocket so timing mark

on camshaft sprocket align with appropriate timing mark on No. 3 timing
belt rear cover. See Fig. 2.
4) Turn crankshaft sprocket to align with mark on oil pump body. Install
timing belt in following order:
Crankshaft sprocket
Water pump pulley
Left camshaft sprocket (front of vehicle side)
No. 2 idler pulley
Right camshaft sprocket (firewall side)
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.
5) Using press, SLOWLY apply about 200-2200 lbs. of pressure 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 1.5 mm hexagon wrench through
housing and push rod hole to secure push rod. Release press and install
dust boot on timing belt tensioner.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) 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.
8) Ensure timing mark on each camshaft sprocket is aligned with
appropriate timing mark on No. 3 timing belt rear cover. See Fig. 2. If all
timing marks are not aligned, remove timing belt and reinstall. Remove
crankshaft pulley bolt.
9) Install timing belt guide with cup facing out. Install engine mounting
bracket on front of cylinder block. Install and tighten bolts to specification.
10) 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.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
12) Install generator bracket. Install engine mounting bracket No. 2 (right
side) and engine moving control rod. Install fender apron seal and right
front wheel.
13) To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Connect engine ground strap. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Crankshaft For Removal/Installation Of

Timing Belt

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Retracting Timing Belt Tensioner Rod

474

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3.3L V6 2004 (Cont.)

Removal (Highlander, Sienna & RX 330) 1) Remove windshield

wiper arms, cowl top ventilator louver sub-assembly and windshield
wiper link assembly. Remove cowl top panel outer sub-assembly. See
Fig. 6.
2) Raise and support vehicle. Remove right front wheel. Remove right
fender apron seal. Remove accessory drive belts. Lower vehicle.
3) Remove engine moving control rod and engine mounting bracket
No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers.
4) Using Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2
timing belt covers and gaskets. See Fig. 1. On RX330, remove nut and
separate engine mounting insulator. Place wooden block on jack and
jack up engine enough to remove right side engine mounting bracket.
On Highlander and Sienna, lifting engine is not required. On all models,
Remove engine mounting bracket. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing
belt side of engine.
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
Fig. 2.
6) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not
aligned, rotate crankshaft CLOCKWISE one full revolution (360
degrees). Remove crankshaft pulley bolt.
7) 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 direction of rotation.
8) Turning crankshaft pulley COUNTERCLOCKWISE, set cylinder No. 1
to about 60 degrees BTDC. See Fig. 4.
CAUTION: If timing belt is disengaged, having crankshaft pulley at
wrong angle can cause piston and valve to come in contact with
each other when you remove crankshaft or camshaft pulleys,
causing damage. Always set crankshaft pulley at correct angle.
9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. DO NOT hold tensioner with push rod facing DOWN. Remove
timing belt in following sequence:
a) No. 1 idler pulley
b) Right camshaft sprocket (firewall side)
c) No. 2 idler pulley
d) Left camshaft sprocket (front of vehicle side)
e) Water pump pulley
f) Crankshaft sprocket
Inspection (Highlander, Sienna & RX 330) 1) Inspect timing belt for
damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate
freely and are not leaking oil. Replace damaged components. Inspect
water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing
downward.
2) Inspect timing belt tensioner for signs of oil leakage. Replace 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.
Installation (Highlander, Sienna & RX 330) 1) 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 rotate
smoothly.

2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,

use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE
until timing mark on crankshaft sprocket is about 60 degrees BTDC. See
Fig. 4.
CAUTION: If timing belt is disengaged, having crankshaft pulley at
wrong angle can cause piston and valve to come in contact with
each other when you remove crankshaft or camshaft pulleys,
causing damage. Always set crankshaft pulley at correct angle.
3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with timing mark on No. 3 timing belt rear
cover. See Fig. 2.
NOTE: Engine should be cold when installing timing belt.
4) Install timing belt in following order:
Crankshaft sprocket
Water pump pulley
Left camshaft sprocket (front of vehicle side)
No. 2 idler pulley
Right camshaft sprocket (firewall side)
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.
5) Using press, SLOWLY apply about 200-2200 lbs. of pressure 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 1.5 mm hexagon wrench through housing and push rod hole to
secure push rod. Release press and install dust boot on timing belt
tensioner.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Remove 1.5 mm 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.
8) Ensure timing mark on each camshaft sprocket is aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 2. If all timing marks are
not aligned, remove timing belt and reinstall. Remove crankshaft pulley
bolt.
9) Install timing belt guide with cup facing out. On RX330, place wooden
block on jack and jack up engine enough to install right side engine
mounting bracket. On all models, Install engine mounting bracket on
front of cylinder block. Install nut on engine mounting insulator. Install
and tighten bolts and nut to specification. See TORQUE SPECIFICATIONS.
10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure
there are no gaps in gasket. Cut off excess gasket. Install and tighten
bolts to specification.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.
12) Install generator bracket. Connect engine ground strap. Install
engine mounting bracket No. 2 (right side) and engine moving control
rod. Install cruise control actuator (if equipped).
13) To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

LEXUS & TOYOTA

475

3.3L V6 2004 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Exploded View Of Outer Cowl Top Panel (Highlander & RX-330)

476

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3.3L V6 2004 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 92 (125)
Crankshaft Pulley Bolt ........................................................................................... 162 (220)
Engine Mounting Bracket (Right Side) Bolts ........................................................... 21 (28)
Engine Mounting Stay Bolts ..................................................................................... 47 (64)
Engine Moving Control Rod Bolts
Inboard Bolt (Small) ................................................................................................ 17 (23)
All Other Bolts ......................................................................................................... 47 (64)
Generator Adjusting Lock Bolt .................................................................................. 13 (18)
Generator Bracket-To-Engine Bolts .......................................................................... 21 (28)
Generator Pivot Bolt .................................................................................................. 43 (58)
Power Steering Pump Bolt ....................................................................................... 32 (43)
Power Steering Pump Bracket-To-Cylinder Head Bolt ............................................ 32 (43)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Pivot Bolt ................................................................................. 1 25 (34)
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Wheel Lug Nut ........................................................................................................ 76 (103)
Wiper Arm Nuts ......................................................................................................... 18 (24)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ........................................................................................... 75 (8.5)
Timing Belt Plate Bolt ................................................................................................. 71 (8)
Water Pump Bolt/Nut .................................................................................................. 71 (8)
Wiper Link Assembly Bolts ......................................................................................... 62 (7)
1

Apply Loctite 242 or equivalent to bolt threads.

LEXUS & TOYOTA

477

4.7L V8 Except GX 470 & 4Runner

TIMING BELT APPLICATION
Application
4.7L V8
Land Cruiser
1998-04 .....................................................
LX 470
1998-04 .....................................................
Sequoia
2001-03 .....................................................
Tundra
2000-03 .....................................................

Labor Time

Belt
Part No.

4.5 Hours ... ..... T298

4.5 Hours ... ..... T298
3.6 Hours ... ..... T298
3.6 Hours ... ..... T298

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal (Land Cruiser & LX 470) 1) Raise and support vehicle.
Remove oil pan protector. Remove lower engine cover. Drain cooling
system. Remove battery clamp cover. Remove V bank cover located
on top of engine. Remove air cleaner assembly with air intake hose that
goes to throttle body.
2) Loosen 4 bolts/nuts holding fluid coupling to cooling fan bracket. See
Fig. 1. Remove serpentine drive belt, cooling fan fluid coupling assembly, and fan pulley.
3) Remove radiator assembly. Remove pulley bolt, cover plate and drive
belt idler pulley. Remove No. 3 timing belt cover from front of passengers side camshaft.
4) 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 (CMP) sensor on No. 3 timing belt
cover. Remove No. 3 timing belt cover. See Fig. 1.
5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C
compressor with hoses attached, and set aside. Remove cooling fan
bracket.

CAUTION: If the timing belt is disengaged with the crankshaft

pulley at the wrong angle, this can cause the piston head and valve
head to come into contact with each other when you remove the
camshaft timing pulley, causing damage. Always set the crankshaft pulley at the correct angle.
8) On 1998-2002 models only, 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
crankshaft pulley bolt and No. 2 idler pulley bolt. See Fig. 4. This
prevents valves from contacting pistons. On all models, remove crankshaft pulley bolt.
NOTE: When re-using timing belt: If the installation marks have
disappeared, before removal of the timing belt, place 2 new
installation marks on the timing belt to match the timing marks of
the camshaft timing pulleys.
NOTE: When replacing timing belt tensioner only: To maintain
meshing of the timing pulley and timing belt, secure one of them
with string. Place matchmarks on the timing belt and passengers
side camshaft timing pulley.
9) 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 timing belt from camshaft sprockets.
10) Remove serpentine drive belt tensioner. See Fig. 1. Remove
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 reference, remove timing belt guide
(Crankshaft Position (CKP) sensor plate) 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 & LX 470) 1) Inspect timing belt for
damaged teeth, cracking or oil contamination. Replace timing belt if
damaged or contaminated. 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 on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner. NEVER hold timing belt tensioner
with push rod facing DOWN.
2) Hold timing belt tensioner body and press rod against solid surface.
Replace timing belt tensioner if rod moves.
3) Measure timing belt tensioner rod protrusion from end of rod to edge
of housing. See Fig. 5. Replace timing belt tensioner if distance is not
0.413-0.453 (10.5-11.5 mm). Inspect water pump for leaks or bearing
failure.
NOTE: Install timing belt with engine cold.

CAUTION: If reusing timing belt, ensure installation mark exists at

crankshaft and camshaft sprockets. If installation mark does not
exist, place mating marks on timing belt and crankshaft sprocket.
See Fig. 3. Also, place arrow on belt indicating direction of rotation.
6) Using Pulley Holder (09213-70010 or 09213-70010) and Handle
(09330-00021), hold crankshaft pulley. Loosen crankshaft pulley bolt.
7) 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. 2. Ensure timing marks on camshaft
sprockets align with marks on the timing belt rear plates. See Fig. 3. 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.

Installation (Land Cruiser & LX 470) 1) If No. 1 idler pulley was

removed, apply Loctite 242 or equivalent to bolt threads. Ensure pulley
bracket moves freely.
2) Install timing belt on crankshaft sprocket. If reusing old belt, ensure
match marks made on removal are properly aligned.
3) 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
facing out away from crankshaft sprocket.
4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with
key in crankshaft. Tap crankshaft pulley until seated on crankshaft.
5) Install serpentine drive belt tensioner. Install generator. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Ensure
timing mark on crankshaft pulley aligns with timing mark 0 of No. 1
(lower) timing belt cover. See Fig. 4.

478

LEXUS & TOYOTA

4.7L V8 Except GX 470 & 4Runner (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Locating Timing Belt Alignment Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS & TOYOTA

479

4.7L V8 Except GX 470 & 4Runner (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Positioning Crankshaft Pulley

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

6) 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 matching marks are aligned. Rotate drivers
side camshaft sprocket COUNTERCLOCKWISE until tension exists on
timing belt between crankshaft sprocket and drivers side camshaft
sprocket.
7) Ensure passengers side camshaft sprocket timing mark is still
aligned. Install timing belt on passengers side camshaft sprocket. If
reusing old belt, ensure matching marks are aligned. See Fig. 6.
8) Using press, SLOWLY apply about 220-2200 lbs. (100-1000 kg) of
pressure on timing belt tensioner rod until rod is retracted and holes in
rod and housing are aligned. See Fig. 7. Install 1.27 mm hexagon
wrench through holes in housing and rod to hold rod in retracted
position.
9) Release press and install dust boot on timing belt tensioner. Install
timing belt tensioner on engine. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: When checking valve timing, only rotate crankshaft
CLOCKWISE as viewed from front of engine. DO NOT rotate
crankshaft COUNTERCLOCKWISE.
10) Remove 1.27 mm 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.
11) With crankshaft at TDC position, ensure camshaft sprockets align
with timing marks on rear plates. If installing old belt, ensure belt
matching marks are aligned with camshaft sprockets. If timing marks are
not aligned, timing belt will have to be removed and repositioned.
12) Tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install
No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install
radiator. Install cooling fan assembly.
13) To install remaining components, reverse removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Fill and bleed air from cooling system. See COOLING SYSTEM
BLEEDING.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Installing Timing Belt On Camshaft Sprocket

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Retracting Timing Belt Tensioner Rod

Removal (Except Land Cruiser & LX 470) 1) Raise and support
vehicle. Remove engine undercover. Drain cooling system. Remove
radiator assembly. Remove throttle body cover. Remove intake air
connector assembly.
2) 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.
3) Remove power steering pump from engine with hoses attached, and
secure out of way. Remove serpentine drive belt idler pulley. Remove
No. 3 timing belt cover from front of passengers side camshaft.
4) 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.
5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C
compressor with hoses attached, and set aside. Remove cooling fan
bracket.

LEXUS & TOYOTA

480

4.7L V8 Except GX 470 & 4Runner (Cont.)

CAUTION: If reusing timing belt, ensure installation marks exist at
crankshaft and camshaft sprockets on timing belt. If installation
marks do not exist, place matching marks on timing belt before
removing timing belt. See Fig. 3. Also, place arrow on belt indicating direction of rotation.
6) Using Pulley Holder (09213-70011) and Handle (09330-00021), hold
crankshaft pulley. Loosen crankshaft pulley bolt.
7) 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. 2.
8) Ensure timing marks on camshaft sprockets align with marks on the
timing belt rear plates. See Fig. 3. 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). Remove
crankshaft pulley bolt.
NOTE: When re-using timing belt: If the installation marks have
disappeared, before removal of the timing belt, place 2 new
installation marks on the timing belt to match the timing marks of
the camshaft timing pulleys.
NOTE: When replacing timing belt tensioner only: To maintain
meshing of the timing pulley and timing belt, secure one of them
with string. Place matchmarks on the timing belt and passengers
side camshaft timing pulley.
9) Remove generator. 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 timing belt from camshaft
sprockets.
10) Remove serpentine drive belt tensioner. See Fig. 1. Without letting
crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1
timing belt cover. Noting direction of timing belt guide for installation
reference, remove timing belt guide (crankshaft position sensor plate)
and timing belt cover spacer. Remove timing belt.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft
sprockets. Wipe clean only.
Inspection (Except Land Cruiser & LX 470) 1) Inspect timing belt for
damaged teeth, cracking or oil contamination. Replace timing belt if
damaged or contaminated. 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. Check
timing belt cover gaskets and condition of covers.
NOTE: Timing belt tensioner may weep a small amount of oil on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner. NEVER hold timing belt tensioner
with push rod facing DOWN.
2) DO NOT allow tensioner push rod to face downward. Hold timing belt
tensioner body and press rod against solid surface. Replace timing belt
tensioner if rod moves.
3) Measure timing belt tensioner rod protrusion from end of rod to edge
of housing. See Fig. 5. Replace timing belt tensioner if distance is not
0.413-0.453 (10.5-11.5 mm). Inspect water pump for leaks or bearing
failure.
NOTE: Install timing belt with engine cold.
Installation (Except Land Cruiser & LX 470) 1) If idler pulleys were
removed, apply Loctite 242 or equivalent to bolt threads. Install idler
pulleys and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure pulley bracket moves freely.
2) Install timing belt on crankshaft sprocket. If reusing old belt, ensure
installation marks (made on removal) are properly aligned with crankshaft pulley.

3) 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.
4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with
key in crankshaft. Using Crankshaft Front Oil Seal Replacer (SST
09223-46011) and a hammer, tap crankshaft pulley until seated on
crankshaft.
5) Install serpentine drive belt tensioner. Install generator. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Ensure the
crankshaft pulley groove aligns with 0 timing mark on No. 1 timing belt
cover. See Fig. 2.
6) 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 matching marks are aligned. Rotate drivers
side camshaft sprocket COUNTERCLOCKWISE until tension exists on
timing belt between crankshaft sprocket and drivers side camshaft
sprocket.
7) Ensure passengers side camshaft sprocket timing mark is still
aligned. Install timing belt on passengers side camshaft sprocket. If
reusing old belt, ensure installation marks are aligned. See Fig. 6.
8) Using press, SLOWLY apply about 220-2200 lbs. (100-1000 kg) of
pressure on timing belt tensioner rod until rod is retracted and holes in
rod and housing are aligned. See Fig. 7. Install a 1.27 mm hexagon
wrench through holes in housing and rod to hold rod in retracted
position.
9) Release press and install dust boot on timing belt tensioner. Install
timing belt tensioner on engine. Install and alternately tighten bolts to
specification.
CAUTION: When checking valve timing, only rotate crankshaft
CLOCKWISE as viewed from front of engine. DO NOT rotate
crankshaft COUNTERCLOCKWISE.
10) Remove 1.27 mm 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.
11) With crankshaft at TDC position, ensure camshaft sprockets align
with timing marks on rear plates. If installing old belt, ensure belt
installation marks are aligned with camshaft sprockets. If installation
marks are not aligned, timing belt will have to be removed and
repositioned.
12) Tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install
No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install
radiator. Install cooling fan assembly.
13) To install remaining components, reverse removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Fill and bleed air from cooling system. See COOLING SYSTEM
BLEEDING.

COOLING SYSTEM BLEEDING

1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

LEXUS & TOYOTA

4.7L V8 Except GX 470 & 4Runner (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor-To-Mount Bolt ................................................................................ 36 (49)
Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Cooling Fan Bracket
12-mm Head ............................................................................................................ 12 (16)
14-mm Head ............................................................................................................ 24 (32)
Cooling Fan Fluid Coupling-To-Cooling Fan Bracket
Except Sequoia ....................................................................................................... 16 (21)
Sequoia .................................................................................................................... 21 (29)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Generator
Land Cruiser & LX 470
1998-02 .................................................................................................................. 29 (39)
2003-04
10-mm Bolt & Nut ............................................................................................... 29 (39)
8-mm Nut ............................................................................................................. 16 (11)
Sequoia
10-mm Bolt & Nut ................................................................................................. 29 (39)
8-mm Nut ............................................................................................................... 16 (11)
Tundra ...................................................................................................................... 29 (39)
No. 1 & No. 2 Idler Pulley Bolt .............................................................................. 1 25 (35)
No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16)
Power Steering Pump
Land Cruiser, LX 470 & Sequoia ........................................................................... 13 (17)
Tundra
Bolt & Nut .............................................................................................................. 33 (44)
Stud Bolt ................................................................................................................ 16 (22)
Radiator Bracket-To-Body Bolt .................................................................................. 12 (18)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Bolt ........................................................................................ 19 (26)
Water Pump
Stud Bolt & Nut ....................................................................................................... 13 (18)
Bolt ........................................................................................................................... 15 (21)
INCH Lbs. (N.m)
Fan Shroud ............................................................................................................... 44 (5.0)
No. 1 & No. 3 Timing Belt Cover Bolt .................................................................... 66 (7.5)
Radiator Mounting Bolt ........................................................................................... 106 (12)
V Bank Cover Bolt ................................................................................................. 66 (7.5)
1

Apply Loctite 242 or equivalent to idler pulley bolt threads.

481

LEXUS & TOYOTA

482

4.7L V8 GX 470 & 4Runner

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

4.7L V8
GX 470
2003-04 ..................................................... 3.5 Hours ... ..... T298
4Runner
2003-04 ..................................................... 3.5 Hours ... ..... T298
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove air cleaner hose assembly. Remove V bank cover from top of
engine. Remove 11 clips, and remove upper radiator support seal.
2) Remove serpentine drive belt by turning drive belt tensioner pulley
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND
threads.
3) Remove 2 oil cooler hoses from fan shroud. Remove 3 bolts, and
separate fan shroud from radiator. Remove 4 nuts, and separate fan
w/fluid coupling from engine. Remove fan shroud and fan w/fluid
coupling assembly from vehicle.
4) Remove power steering pump assembly with hoses attached, and
position out of way. Remove generator. Remove A/C compressor from
engine with hoses attached. Move A/C compressor out of way.
NOTE: Note size and location of idler pulley bolts for reassembly
reference.
5) Remove No. 2 idler pulley. See Fig. 1. Remove oil cooler pipe.
Disconnect Camshaft Position (CMP) sensor connector and wires, and
remove No. 3 left side timing belt cover. Remove No. 3 right side timing
belt cover. Remove No. 2 timing belt cover. Remove serpentine drive
belt tensioner. Remove cooling fan bracket assembly.
6) Using Pulley Holder (09213-70011) and Handle (09330-00021),
remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller
Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt
cover. See Fig. 1. Noting installed direction for reassembly reference,
remove timing belt guide from end of crankshaft.
CAUTION: If reusing timing belt, check that there are 3 mating
marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 2. If marks are missing, place
installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original
direction of rotation.
7) Using crankshaft damper bolt, rotate crankshaft CLOCKWISE so
cylinder No. 1 is about 50 degrees BTDC on compression stroke.
Ensure timing marks on crankshaft sprocket and oil pump body are
aligned. See Fig. 3.
8) Turning hexagon wrench head portion of camshaft, align timing marks
on camshaft sprockets with timing marks on timing belt rear plates. See
Fig. 4. If timing marks are not aligned, rotate crankshaft CLOCKWISE
one complete revolution.

CAUTION: If the timing belt is disengaged with the crankshaft

sprocket at the wrong angle, this can cause the piston head and
valve head to come into contact with each other when you remove
the camshaft sprocket, causing damage. Always set the crankshaft
sprocket at the correct angle.
9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCKWISE about 50 degrees. See Fig. 5. Alternately loosen 2 bolts, and
remove timing belt tensioner and dust boot. DO NOT hold timing belt
tensioner with push rod facing DOWN. See Fig. 1.
10) Using spanner wrench, slightly rotate right side camshaft sprocket
COUNTERCLOCKWISE to relieve tension on timing belt. See Fig. 6.
Remove timing belt.
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Check
idler pulleys for smooth rotation and oil seal leakage. Replace idler
pulleys if defective.
CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
NOTE: Timing belt tensioner may weep a small amount of oil on
rod seal under normal conditions. If excessive amount of oil exists,
replace timing belt tensioner.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if there are excessive oil leaks.
3) Hold timing belt tensioner body with push rod facing UP. 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. 7. Replace timing belt tensioner if
distance is not .440-.480 (11.20-12.20 mm). Inspect water pump for
leaks or worn bearing, and replace as necessary.
Installation 1) Turn camshaft and set No. 1 cylinder to TDC. Timing
marks on camshaft sprockets must align with timing marks on timing belt
rear plates. See Fig. 8. To ease installation of timing belt, turn left
camshaft sprocket CLOCKWISE 1/2 tooth and turn right camshaft
sprocket CLOCKWISE one tooth. See Fig. 9. Turn crankshaft CLOCKWISE to align timing marks of crankshaft sprocket and oil pump body.
See Fig. 10.
2) Face the front mark (arrow) on timing belt forward. While aligning
installation marks on timing belt with mark on appropriate sprocket,
install timing belt in the following sequence:
a) Crankshaft timing sprocket
b) Idler pulley No. 2
c) Left camshaft sprocket
d) Water pump pulley
e) Right camshaft sprocket
f) Idler pulley No. 1
See Fig. 2.
3) Using press, slowly apply about 220-2205 lbs. (100-1000 kg) of
pressure on push rod of timing belt tensioner until rod is retracted.
Ensure timing belt tensioner is held with push rod facing upward. Holes
in push rod and housing must be aligned. See Fig. 11.
4) Install 1.27 mm hexagon wrench through holes in housing and rod to
hold rod in retracted position. See Fig. 11. Release press. Install dust
boot on timing belt tensioner. Install timing belt tensioner. Alternately
tighten bolts to specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft CLOCKWISE as viewed from
front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE.
5) Remove hexagon wrench from timing belt tensioner. Slowly rotate
crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. Ensure all
timing marks are aligned. See Figs. 3 and 4. If timing marks are not
aligned, remove timing belt and reinstall. Remove crankshaft damper
bolt. Install timing belt guide. See Fig. 12.

LEXUS & TOYOTA

483

4.7L V8 GX 470 & 4Runner (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Locating Timing Belt Installation Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Camshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Crankshaft Sprocket For Timing Belt Removal

LEXUS & TOYOTA

484

4.7L V8 GX 470 & 4Runner (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Removing Timing Belt

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 9: Positioning Camshaft Sprockets for

Timing Belt Installation

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Measuring Timing Belt Tensioner Rod Protrusion

6) Install timing belt No. 1 cover, and tighten bolts to specification. See
TORQUE SPECIFICATIONS. Using Replacer (09223-46011) and a
hammer, install crankshaft pulley, aligning sprocket set key with key
groove of sprocket. Using Pulley Holder (09213-70011) and Handle
(09330-00021), install crankshaft sprocket bolt. Tighten crankshaft
sprocket bolt to specification.
7) Install cooling fan bracket assembly. Install serpentine drive belt
tensioner. Install No. 2 timing belt cover, matching claws and pin with
each part. See Fig. 13. To install remaining components, reverse
removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS. Fill cooling system, and check for leaks. See
COOLING SYSTEM BLEEDING.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 10: Aligning Crankshaft Sprocket Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 11: Retracting Timing Belt Tensioner Rod

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 8: Aligning Camshaft Sprocket Timing Marks

COOLING SYSTEM BLEEDING

1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 12: Installing Timing Belt Guide

LEXUS & TOYOTA

485

4.7L V8 GX 470 & 4Runner (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 13: Installing No. 2 Timing Belt Cover

Application
Ft. Lbs. (N.m)
A/C Compressor
Bolt ........................................................................................................................... 34 (47)
Nut ........................................................................................................................... 18 (25)
Cooling Fan Bracket Bolt
12-mm ...................................................................................................................... 12 (16)
14-mm ...................................................................................................................... 24 (32)
Crankshaft Sprocket Bolt ...................................................................................... 181 (245)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Fan W/Fluid Coupling Nut ........................................................................................ 21 (29)
Generator
Bolt ........................................................................................................................... 29 (39)
M8 Nut ..................................................................................................................... 11 (16)
M10 Nut ................................................................................................................... 29 (39)
No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 29 (39)
Power Steering Pump Bolt/Nut ................................................................................. 32 (43)
Timing Belt Idler Pulley Bolt ................................................................................... 1 25 (35)
Timing Belt Tensioner Bolt ........................................................................................ 19 (26)
Water Pump Bolt ....................................................................................................... 13 (18)
INCH Lbs. (N.m)
Camshaft Timing Sprocket Bolt ............................................................................... 66 (7.5)
Fan Shroud Bolts ........................................................................................................ 44 (5)
Timing Belt Cover Bolt ............................................................................................. 66 (7.5)
Oil Cooler Pipe Bolt/Nut ........................................................................................... 66 (7.5)
V Bank Cover ........................................................................................................ 66 (7.5)
1

Apply Loctite 242 or equivalent to No. 1 idler pulley pivot bolt threads.

MAZDA

486

1.5L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

1.5L 4-Cyl.
Protege
1995-97 ............................... 2.4 Hours ... .. TCK266 .. ..... T266
1998
Up To Engine
No. 194742 ..................... 2.4 Hours ... .. TCK266 .. ..... T266
From Engine
No. 194743 ..................... 2.4 Hours ... .. TCK266 .. ..... T308
1

With Air Conditioning, add .2 hours. With Power Steering, add

.2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right front wheel. Remove right side cover and
undercover.
2) Remove drive belts and water pump pulley. Align crankshaft pulley
timing mark with cylinder No. 1 at TDC of compression stroke. Hold
crankshaft stationary. Remove crankshaft pulley bolts and pulley.
Remove crankshaft pulley hub bolt and hub.
3) Remove spark plug wires. Remove valve cover bolts in reverse order
of tightening sequence. See Fig. 1. Remove valve cover. Remove
dipstick tube.
4) Remove upper timing belt cover. Support engine with jack. Remove
engine mount bracket from timing belt end of engine. If timing belt is to
be reused, mark timing belt rotation direction. Ensure timing marks on
camshaft and crankshaft sprockets are aligned. See Fig. 2.
5) Remove lower and middle timing belt covers. Loosen timing belt
tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timing belt.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Installation 1) Position notch on crankshaft sprocket to 12 oclock
position (aligned with mark on oil pump). Align timing marks on camshaft
sprocket and crankshaft. See Fig. 2. Ensure crankshaft timing mark is at
TDC of compression stroke. Install belt around crankshaft sprocket.
Working in a counterclockwise direction, route belt around pulleys and
camshaft sprocket.
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete
turns in direction of normal engine rotation. Ensure timing marks align.
3) 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 installation procedure.
4) Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to
belt. See Fig. 3. Ensure timing belt deflection is .28-.35 (7.0-9.0 mm).
5) 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. To complete installation, reverse removal procedure.

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Deflection

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Crankshaft Pulley-To-Pulley Boss Bolt ......................................... ................... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167)
Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-51)
Wheel Lug Nuts ...................................................................................................... 80 (110)
INCH Lbs. (N.m)
Courtesy of Mazda Motors Corp.

Fig. 1: Identifying Valve Cover Bolt Tightening Sequence

Inspection Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or roughness of
rotation. Inspect tensioner spring free length. Specified length is 2.80
(71 mm). Replace parts as necessary.

Timing Belt Adjuster Bolt .................................................................................. 71-97 (8-11)

Timing Cover Bolt ............................................................................................. 71-97 (8-11)
Valve Cover Bolt ............................................................................................... 62-97 (7-11)

MAZDA

487

1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application
1.6L 4-Cyl. DOHC
Protege
1999-01 ....................................................
1

Labor Time

Belt
Part No.

2.7 Hours .. ..... T308

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1999-00 vehicles, the manufacturer recommends belt replacement
interval at 60,000 miles except for vehicles registered in California,
Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, 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, inspect timing belt at 60,000 and replace at 105,000 miles,
UNLESS the vehicle is operated in outside temperatures under 0F
(-18C). Under this condition, replace timing belt at 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove camshaft
position sensor from left side (exhaust) of engine. Remove ignition coils.
Remove valve cover.
2) 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.
3) 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.
4) Support engine with jack or from above with support bar. Remove
engine mount from timing belt end of engine.
5) Remove timing belt covers. See Fig. 1. If timing belt is to be reused,
mark timing belt rotation direction.
6) 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.
7) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
away from belt with spring fully expanded. Remove timing belt.
Inspection Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or roughness of
rotation. Inspect tensioner spring for stretching. Tensioner spring free
length should be 2.43 (61.8 mm). Replace parts as necessary.
Installation 1) Install tensioner spring with damper rubber closing face
on side away from tensioner. See Fig. 3.
2) Ensure camshaft and crankshaft timing marks are still aligned. See
Fig. 2. Temporarily secure tensioner with spring fully extended. Install
belt around crankshaft sprocket, idler pulley, exhaust camshaft, intake
camshaft, then tensioner.
3) 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 complete turns.
4) 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.
5) While holding timing belt tensioner, tighten lock bolt to specification.
See TORQUE SPECIFICATIONS.
6) Install crankshaft boss, and tighten bolt to specification. See
TORQUE SPECIFICATIONS. Turn crankshaft clockwise 2 revolutions.
Face pin on crankshaft pulley boss straight up. Ensure camshaft

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

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.
7) Check timing belt deflection with 22 lbs. (10 kg) of downward 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.
8) To complete installation, reverse removal procedure. When installing
valve cover, tighten valve cover bolts in correct sequence. See Fig. 5.
9) 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.

MAZDA

488

1.6L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60)
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)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52)
INCH Lbs. (N.m)

Courtesy of Mazda Motors Corp.

Fig. 3: Installing Timing Belt Tensioner Spring

Courtesy of Mazda Motors Corp.

Fig. 4: Aligning Timing Belt At Tensioner Set Mark

Courtesy of Mazda Motors Corp.

Fig. 5: Identifying Valve Cover Bolt Tightening Sequence

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)
Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11)
Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)

MAZDA

489

1.6L & 1.8L 4-Cylinder 1986-95

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. DOHC

MX-3
1994-95 ................................
MX-5 Miata
1990-93 ............................ ...
323
1988-89 ............................ ...
1.6L 4-Cyl. SOHC
MX-3
1992-93 ............................ ...
323
1986 ................................. ...
1987-89 ............................ ...
1990-94 ............................ ...
1.8L 4-Cyl. DOHC
Protege
1990-94 ............................ ...
1.8L 4-Cyl. SOHC
Protege
1990-94 ............................ ...
1

Component
Belt
Kit No.
Part No.

2.9 Hrs .... .. TCK179 .. ..... T179

3.0 Hrs. ... .. TCK179 .. ..... T179

2.8 Hrs. ... ...... ..... ...... ..... T149

2.0 Hrs. ... .. TCK185 .. ..... T185

2.0 Hrs. ... ...... ..... ...... ..... T123

2.0 Hrs. ... .. TCK141 .. ..... T141
1
2.0 Hrs. ... .. TCK185 .. ..... T185
1

2.8 Hrs. ... .. TCK179 .. ..... T179

2.0 Hrs. ... .. TCK185 .. ..... T185

With Air Conditioning add .2 hours.

With Power Steering, add .2 hours.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (MX-5 Miata)

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1992 and earlier model years, the manufacturer recommends the
belt 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 vehicles sold in California,
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt
at 105,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal (MX-5 Miata) 1) Disconnect negative battery cable. Drain
cooling system. Remove radiator hose and by-pass hoses from thermostat housing. Remove air cleaner intake duct assembly from throttle
body to air cleaner filter housing. Remove splash shield.
2) Remove drive belt(s) and water pump pulley. See Fig. 1. Align
crankshaft pulley timing mark with cylinder No. 1 at TDC of compression
stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley
bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.
3) 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 camshaft sprockets are aligned. See
Fig. 2. Loosen timing belt tensioner lock bolt, and move tensioner away
from belt with spring fully expanded. Remove timing belt.
Removal (MX-3, Protege & 323) 1) Disconnect negative battery
cable. Raise and support vehicle. Remove right front wheel. Remove
right splash panels.
2) Remove drive belts and water pump pulley. See Fig. 3, 4 or 5. Align
crankshaft pulley timing mark with cylinder No. 1 at TDC of compression
stroke. Hold crankshaft stationary, and remove crankshaft pulley bolts
and pulley. Remove crankshaft pulley hub bolt and hub.
3) 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. 2 and 6. Loosen timing belt tensioner lock bolt. Temporarily secure
tensioner away from belt with spring fully expanded. Remove timing belt.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Camshaft Timing Marks (DOHC Engines)

Inspection (All Models) Check timing belt for cracks, peeling,
abrasion or other damage. Check tensioner bearing for looseness or
roughness of rotation. Inspect tensioner spring for stretching. Replace
parts as necessary.
Installation (All Models) 1) Position notch on crankshaft sprocket to
12 oclock position (aligned with mark on oil pump). Align timing marks
on camshaft sprocket(s). See Figs. 2 and 6. Ensure crankshaft timing
mark is at TDC. Install belt around crankshaft sprocket, then working in
a counterclockwise direction, route belt around camshaft sprocket(s).
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete
turns in direction of normal engine rotation. Ensure timing marks align.
If timing marks are not aligned, remove belt, realign all timing marks, and
repeat installation procedure.
3) 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 table. Adjust drive
belts to proper tension.

MAZDA

490

1.6L & 1.8L 4-Cylinder 1986-95 (Cont.)

TIMING BELT DEFLECTION
1
Deflection In. (mm)
Application
1986-89 .......................................................... ......................................... .47-.51 (11.9-13.0)
1990-95
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.

Courtesy of Mazda Motors Corp.

Fig. 5: Exploded View Of Timing Belt & Components

(DOHC Except MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 3: Exploded View Of Timing Belt & Components

(1989 SOHC)

Courtesy of Mazda Motors Corp.

Fig. 6: Aligning Camshaft Timing Marks (SOHC Engines)

Courtesy of Mazda Motors Corp.

Fig. 4: Exploded View Of Timing Belt & Components

(1990 & Later SOHC)

MAZDA

491

1.6L & 1.8L 4-Cylinder 1986-95 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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)
Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
Crankshaft/Timing Belt Sprocket Bolt
1986-91 ...................................................................................................... 80-87 (109-118)
1992-95 .................................................................................................. 116-123 (157-167)
Power Steering Pump-To-Bracket Bolt
MX-3, Protege & 323 .................................................................. ................. 27-38 (37-52)
Timing Belt Tensioner Bolt
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)

Courtesy of Mazda Motors Corp.

Fig. 7: Measuring Timing Belt Deflection

MAZDA

492

1.8L 4-Cylinder BP Engine

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl. DOHC

MX-5 Miata
1994-97 ............................ ...
1999-00 ............................ ...
2001-04 ............................ ...
Protege
1995-98 ............................ ...
1

Component
Belt
Kit No.
Part No.

2.6 Hrs. ... .. TCK179 .. ..... T179

2.5 Hrs. ... .. TCK179 .. ..... T179
1
2.7 Hrs. ... .. TCK179 .. ..... T179

10) Install pulley boss on crankshaft to temporarily tighten with pulley

lock bolt. Ensure timing marks on camshaft sprockets and crankshaft
sprockets are aligned. See Fig. 3.
11) Loosen timing belt tensioner lock bolt. Move tensioner away from
belt with spring fully expanded, and tighten lock bolt. Remove timing
belt.

2.4 Hrs. ... .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: Engine identification code is on machined pad at left rear
end of engine, at transmission mating flange.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1994-96 vehicles, the manufacturer recommends 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 1997-98 vehicles, the manufacturer recommends 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 1999-00 vehicles, the replacement interval is 60,000 miles except
for vehicles registered in California, Connecticut, Delaware, Maine,
Maryland, Massachusetts, New Hampshire, New Jersey, New York,
Pennsylvania, Rhode Island, Vermont, Virginia 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 2001-04 MX-5 Miata, the replacement interval is 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal (MX-5 Miata) 1) Disconnect negative battery cable. Drain
cooling system. Remove front strut bar and strut brackets, if equipped.
2) Disconnect Intake Air Temperature (IAT) sensor harness connector.
Remove air cleaner cover and necessary air hoses or pipes. Remove
drive belt(s).
3) Remove Camshaft Position (CMP) sensor, if equipped. Remove
Crankshaft Position (CKP) sensor.
4) Remove high tension leads and ignition coil(s). Remove spark plugs.
5) Remove upper radiator hose and by-pass hoses from thermostat
housing. See Fig. 1 or 2.
6) 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 (OCV)
case.
7) Remove water pump pulley, crankshaft pulley and crankshaft position
sensor plate. See Fig. 1 or 2.
8) Remove crankshaft pulley from crankshaft pulley boss. Remove plate
with crankshaft pulley. Ensure crankshaft pulley boss locating pin faces
straight up. Holding crankshaft pulley boss stationary, remove crankshaft pulley boss bolt. Remove pulley boss.
9) Remove upper, middle, and lower timing belt covers. If timing belt is
to be reused, mark timing belt with arrow to indicate rotation direction.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

(1994-00 MX-5 Miata)
Removal (Protege) 1) Disconnect negative battery cable. Raise and
support vehicle. Remove right front wheel. Remove right splash shield
from wheelwell.
2) Remove drive belts and water pump pulley. Align crankshaft pulley
timing mark with cylinder No. 1 at TDC of compression stroke. Hold
crankshaft stationary, and remove crankshaft pulley from crankshaft
pulley boss. See Fig. 4.
3) Remove spark plug wires from spark plugs. Remove valve cover.
Remove dipstick pipe. Remove upper timing belt cover. If timing belt is
to be reused, mark timing belt rotation direction.
4) Support engine from above, and remove engine mount bracket from
timing belt end of engine. Remove middle and lower timing belt covers.
5) Holding crankshaft stationary, remove crankshaft pulley boss. Align
timing marks on crankshaft and camshaft sprocket(s). See Fig. 3.
Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
away from belt with spring fully expanded. Remove timing belt.
Inspection (All Models) 1) Check timing belt for cracks, peeling,
abrasion or other damage. Check tensioner and idler pulley bearing for
looseness or roughness of rotation. Replace parts as necessary.
2) 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 edges of hooked portions of spring.

MAZDA

493

1.8L 4-Cylinder BP Engine (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 2: Exploded View Of Timing Belt & Components (2001-04 MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks

494

MAZDA
1.8L 4-Cylinder BP Engine (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 4: Exploded View Of Timing Belt & Components (Protege)

MAZDA

495

1.8L 4-Cylinder BP Engine (Cont.)

Installation (All Models) 1) Position notch on crankshaft sprocket to
12 oclock position (aligned with mark on oil pump). See Fig. 3. Align
timing marks on camshaft sprocket(s). Timing mark on intake camshaft
sprocket is an I; timing mark on exhaust camshaft is an E.
2) Install timing belt tensioner spring with damper rubber closing face
away from tensioner. See Fig. 5. Temporarily secure the timing belt
tensioner with tensioner spring fully expanded.
3) Install timing belt around crankshaft sprocket, then working 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.
4) Temporarily install the crankshaft pulley boss and bolt. Rotate
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.
5) Holding crankshaft 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 TORQUE SPECIFICATIONS.
6) Install crankshaft pulley boss, and final tighten bolt to specification.
Rotate crankshaft 1 5/6 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.
7) Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to
belt. See Fig. 7. Ensure timing belt deflection is .35-.45 (8.5-11.5 mm).
8) To install remaining components, reverse removal procedure. 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 sequence. See Fig. 8.
CAUTION: When installing OCV case, do not damage O ring of
OCV adopter on camshaft cap, or it may cause hydraulic leakage.
When installing oil pipe, no load should be applied on any connection part, or it may cause oil leakage.
9) On MX-5 Miata, install OCV case using several steps to tighten bolts
to specification in the sequence shown. See Fig. 9. Install OCV filter so
that it aligns with the projected part on flange end of oil pipe. See Fig. 10.
Apply engine oil to new washer. Temporarily install upper and side oil
pipe.
10) Using several steps, tighten top oil pipe bolts in the sequence
shown. See Fig. 11. Temporarily tighten lower side oil pipe bolt to 26-61
INCH lbs. (3-7 N.m). Tighten upper side oil pipe bolt to 9-13 ft. lbs.
(12-18 N.m). Using several steps, tighten side oil pipe bolts in the
sequence shown. See Fig. 12.
11) On all models, 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 at 3000 RPM for 5 minutes. Recheck
coolant level and fill as necessary. On Protege, check ignition timing.

Courtesy of Mazda Motors Corp.

Fig. 6: Aligning Timing Belt At Tensioner Set Mark

Courtesy of Mazda Motors Corp.

Fig. 7: Measuring Timing Belt Deflection

Courtesy of Mazda Motors Corp.

Fig. 8: Identifying Valve Cover Bolt Tightening Sequence

Courtesy of Mazda Motors Corp.

Courtesy of Mazda Motors Corp.

Fig. 5: Installing Timing Belt Tensioner Spring

Fig. 9: Identifying OCV Case Bolts Tightening Sequence

(MX-5 Miata)

MAZDA

496

1.8L 4-Cylinder BP Engine (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mazda Motors Corp.

Fig. 10: Installing OCV Filter (MX-5 Miata)

Application
Ft. Lbs. (N.m)
Alternator Pivot Bolt ...................................................................... ................. 28-38 (38-51)
Alternator Top Bolt ........................................................................ ................. 14-18 (19-25)
Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60)
Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167)
Crankshaft Pulley-To-Pulley Boss ................................................. ................... 9-13 (12-18)
Engine Mount Bracket Nuts (Protege) ......................................... ............... 55-77 (75-104)
Idler Pulley Bolt ............................................................................. ................. 28-38 (38-51)
Ignition Coil Mounting Bolt (1999-00) ........................................... ................. 14-18 (19-24)
Spark Plugs ..................................................................................................... 11-16 (15-22)
Strut Bar Bolt ................................................................................. ................. 12-16 (16-22)
Strut Bar Bracket Nut .................................................................... ................. 22-27 (30-37)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51)
Wheel Lug Nut (Protege) .............................................................. ............... 66-94 (89-127)
INCH Lbs. (N.m)
Ignition Coil Mounting Bolt (2001-2004) ........................................................... 70-95 (8-11)
Radiator Drain Plug ....................................................................... ................. 7-10 (0.7-1.1)
Timing Belt Cover Bolt ...................................................................................... 71-97 (8-11)
Valve Cover Bolt
Except 2001-03 MX-5 Miata ....................................................... ..................... 43-78 (5-9)
2001-03 MX-5 Miata ....................................................................................... 71-97 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 11: Identifying Top Oil Pipe Bolt Tightening Sequence

(MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 12: Identifying Side Oil Pipe Bolt Tightening Sequence

(MX-5 Miata)

MAZDA

497

1.8L 4-Cylinder FP Engine

TIMING BELT APPLICATION
Application
1.8L 4-Cyl. DOHC
Protege
1999-00 ....................................................
1

Labor Time

Belt
Part No.

2.4 Hours .. ..... T316

With Air Conditioning, add .2 hours.

NOTE: Engine code is stamped on machined pad on lower left end

of engine, on transaxle mating flange.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The replacement is 60,000 miles except for vehicles registered in
California, Connecticut, Delaware, Maine, Maryland, Massachusetts,
New Hampshire, New Jersey, 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.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove Crankshaft
Position (CKP) and Camshaft Position (CMP) sensors from front of
engine.
2) Remove accessory drive belt. Remove the water pump pulley. See
Fig. 1. 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.
3) Remove crankshaft pulley and guide plate (large washer). Loosen
valve cover bolts in 2-3 steps. See Fig. 2. Remove valve cover and
gasket.
4) Remove dipstick tube. Remove upper and lower timing belt covers.
Support engine from above. Remove engine mount at timing belt end of
engine.
5) If reusing timing belt, mark arrow on belt to indicate direction 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 are aligned. See Fig. 3.
6) 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 Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or roughness of
rotation. Inspect tensioner spring for stretching. Tensioner spring free
length should be 1.44 (36.6 mm). Replace parts as necessary.
Installation 1) Install tensioner, and idler pulley (if removed). Temporarily tighten tensioner with spring fully retracted. Ensure camshaft and
crankshaft timing marks are aligned. See Fig. 3.
2) 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.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt Components

MAZDA

498

1.8L 4-Cylinder FP Engine (Cont.)

5) To install remaining components, reverse removal procedure. Tighten
valve cover bolts in correct sequence. See Fig. 4. Install water pump
pulley with stamped F mark away from engine. Adjust drive belts to
proper tension.
6) 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 damaged parts.

Courtesy of Mazda Motors Corp.

Fig. 2: Identifying Valve Cover Bolt Loosening Sequence

Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Valve Cover Bolt Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks

3) 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 camshaft and crankshaft timing
marks are still correctly aligned. If not, timing belt will have to be
removed and repositioned.
4) 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 camshaft and crankshaft timing marks are
still aligned.

Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 37-44 (50-60)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
Timing Belt Idler Pulley Bolt ......................................................... ................. 28-38 (38-52)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52)
INCH Lbs. (N.m)
CKP & CMP Sensor Bolts ................................................................................
Timing Belt Covers ........................................................................ ...................
Valve Cover Bolts .......................................................................... ...................
Water Pump Pulley Bolts ..................................................................................

71-97 (8-11)
61-87 (7-10)
62-89 (7-10)
71-97 (8-11)

MAZDA

499

1.8L V6
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
1.8L V6
MX-3
1992-93 ....................................................
MX-3 (Canadian)
1995 ..........................................................
1

Labor Time

Belt
Part No.

3.8 Hours .. ..... T214

3.8 Hours .. ..... T214

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1992 model year, the manufacturer recommends the belt 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 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 1) 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 reservoir. Remove retaining bolts and power
steering reservoir with hoses attached, and secure reservoir aside.
2) Remove retaining nut and power steering pump pulley. Remove
retaining bolts and power steering pump with hoses attached, and
secure pump aside. Remove crankshaft pulley retaining bolt. Using
puller, remove crankshaft pulley.
CAUTION: DO NOT damage crank angle sensor rotor on rear of
crankshaft pulley during crankshaft pulley removal.
3) Unplug crank angle sensor, and unclip wires from oil dipstick tube.
Remove oil dipstick and oil dipstick tube. Remove crank angle sensor
harness bracket. Remove engine 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 (timing belt
side) engine mount. Remove retaining bolts, timing belt covers and
gaskets. See Fig. 1.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MAZDA

500

1.8L V6 (Cont.)
4) 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.
5) 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).

CAUTION: If reusing timing belt, ensure timing belt is installed in

original direction of rotation.
3) 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. Remove 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
camshaft sprockets and crankshaft sprockets are properly aligned. See
Fig. 2. If timing marks are not aligned, repeat entire timing belt
installation procedure.
4) Check timing belt deflection by applying 22 lbs. (10 kg) of force at
designated area on timing belt. Check timing belt deflection. See Fig. 5.
Timing belt deflection should be .24-.31 (6.0-8.0 mm). If timing belt
deflection is not within specification, replace timing belt tensioner.
5) Install timing belt covers using NEW gaskets. Tighten retaining bolts
to specification. See TORQUE SPECIFICATIONS. Install dipstick tube
with new O ring. To install remaining components, reverse removal
procedure. See Fig. 6. Tighten fasteners to specification. Adjust drive
belts to proper tension.

Courtesy of Mazda Motors Corp.

Courtesy of Mazda Motors Corp.

Fig. 4: Retracting Timing Belt Tensioner Rod

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure idler pulleys No. 1 and No. 2 and tensioner pulley
rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil
leakage exists. Measure timing belt tensioner rod protrusion from end of
rod to edge of the housing. See Fig. 3. Replace timing belt tensioner if
distance is not .550-.630 (13.97-16.00 mm).

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

Installation 1) Place timing belt tensioner in a press using a flat
washer to prevent damage to timing belt tensioner. See Fig. 4. Compress 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.
2) Install timing belt tensioner on cylinder block with the upper retaining
bolt only; do not fully tighten upper bolt. Install No. 2 idler pulley, and
tighten bolt 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.

Courtesy of Mazda Motors Corp.

Fig. 5: Measuring Timing Belt Deflection

MAZDA

501

1.8L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 27-38 (37-52)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-166)
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)
Right (Timing Belt Side) Engine Mount
Nut ............................................................................................... ............... 55-75 (74-102)
Through-Bolt ................................................................................ ................. 50-68 (67-92)
Tensioner Pulley Bolt .................................................................... ................. 28-32 (38-44)
Timing Belt Tensioner Bolt ............................................................ ................. 14-19 (19-26)
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)
Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11)
Valve Cover Bolt 2 ......................................................................... ..................... 43-78 (5-9)
Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
1

Courtesy of Mazda Motors Corp.

Fig. 6: Identifying Valve Cover Bolt Installation Sequence

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).
Tighten bolts to specification in sequence. See Fig. 6.

MAZDA

502

2.0L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cyl. Diesel

626
1984-85
Camshaft ................................................ 1.9 Hours ... ..... T103
Injection Pump ....................................... 1.0 Hours ... ..... T102
1

With Air Conditioning add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 100,000
miles.
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

REMOVAL & INSTALLATION

TIMING BELT (FRONT)
Removal 1) Disconnect negative battery cable. Remove right side
splash shield (if equipped). Remove drive belts and crankshaft 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.
2) 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 1) Ensure that timing mark on camshaft pulley is aligned
with mark on front seal plate. Make sure that notch on crankshaft pulley
is aligned with timing mark on oil pump housing. See Fig. 1.
2) 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.
3) 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.
4) 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 procedure to complete installation.
Adjust drive belts to proper tension.

Courtesy of Mazda Motors Corp.

Fig. 1: Aligning Front Camshaft & Crankshaft Pulley

Timing Marks
3) Install rear timing belt on injection pump pulley, around tensioner, and
then on camshaft pulley. Remove bolts securing injection pump pulley.
Loosen tensioner lock nut until tension is applied on belt. Turn crankshaft in a clockwise direction for 2 complete revolutions.
4) Check timing marks on rear camshaft and injection pump pulleys. See
Fig. 2. Tighten tensioner lock nut. Check timing 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 belts to proper tension.

TIMING BELT (REAR)

Removal 1) 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, using a screwdriver,
as far as it will go. Snug tensioner lock nut.
2) If reusing timing belt, mark an arrow on timing belt to indicate direction
of travel. Remove rear timing belt. Check belt for premature wear,
missing teeth, or cracks. Check turning smoothness of belt tensioner.
Installation 1) 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.
CAUTION: DO NOT remove bolts securing injection pump pulley at
this time. Remove bolts after installing timing belt.
2) If tensioner was removed, install tensioner lock nut and spring in fully
released position. Rotate belt tensioner clockwise, using a screwdriver,
as far as it will go. Snug tensioner lock nut.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Rear Camshaft & Injection Pump Pulley

Timing Marks

MAZDA
2.0L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 41-48 (56-65)
Crankshaft Pulley Bolts ................................................................. ................. 17-24 (23-33)
Fuel Injection Pump Pulley Bolts ................................................. ................. 43-51 (58-69)
Timing Belt (Front) Pulley Bolt ............................................................... 116-123 (157-167)
Timing Belt Tensioner Bolt
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)

503

MAZDA

504

2.0L 4-Cylinder DOHC Except Tribute

TIMING BELT APPLICATION
Application
2.0L 4-Cyl.
MX-6
1993-97
Protege
2001-03
Protege5
2002-03
626
1993-02
1

Labor Time

Component
Belt
Kit No.
Part No.

DOHC
............................ ...

2.5 Hrs. ... .. TCK228 .. ..... T228

............................ ...

2.4 Hrs. ... .. TCK228 .. ..... T228

............................ ...

2.4 Hrs. ... .. TCK228 .. ..... T228

............................ ...

2.5 Hrs. ... .. TCK228 .. ..... T228

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1993 model year, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 gasoline engine model years, the manufacturer recommends 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 1997-98 gasoline engine model years, 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 1999-00 gasoline engine model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles
registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania,
Rhode Island, Vermont, Virginia 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 2001-03 gasoline engine models, the manufacturer recommendsinspecting the belt at 60,000 miles and replaced at 105,000 miles,
UNLESS the vehicle is operated in temperatures under 0F (-18C).
Under this condition, replace belt at 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove Crankshaft
Position (CKP) and Camshaft Position (CMP) sensors from front of
engine (if equipped). See Fig. 1. Remove spark plugs.
2) Remove accessory drive belts. Leaving hoses attached, remove
power steering pump and position aside. Remove the water pump
pulley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on TDC of
compression stroke.

Courtesy of Mazda Motors Corp.

Fig. 1: Locating Camshaft & Crankshaft Position Sensor

MAZDA

505

2.0L 4-Cylinder DOHC Except Tribute (Cont.)

CAUTION: On models with a crankshaft position sensor, rotor is on
rear of crankshaft pulley. DO NOT damage rotor when removing
crankshaft pulley.
3) Using Coupling Flange Holder (49 S120 710) and adapter (49 E011
1A1), or equivalent, hold the crankshaft and remove crankshaft pulley
bolt. See Fig. 3. Remove crankshaft pulley and guide plate (large
washer).
4) Loosen valve cover bolts in 2-3 steps in order shown. See Fig. 4.
Remove valve cover and gasket.
5) Remove dipstick tube. Remove upper and lower timing belt covers.
Support engine from above. Remove No. 3 engine mount at timing belt
end of engine.
6) If reusing timing belt, mark arrow on belt to indicate direction 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 are aligned. See Fig. 5.
7) Turn tensioner clockwise using a Allen wrench to relieve spring
tension, and then disconnect spring from the hook pin. See Fig. 6.
Remove timing belt. Remove crankshaft sprocket, tensioner and idler
pulley (if necessary).

Courtesy of Mazda Motors Corp.

Fig. 3: Removing Crankshaft Pulley

Courtesy of Mazda Motors Corp.

Fig. 2: Removing Engine Front Components

MAZDA

506

2.0L 4-Cylinder DOHC Except Tribute (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Valve Cover Bolt Loosening Sequence

3) 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 (clockwise).
Ensure camshaft and crankshaft timing marks are still correctly aligned.
See Fig. 5. If not correctly aligned, timing belt will have to be removed
and repositioned.
4) If all timing marks are okay, turn tensioner clockwise using an Allen
wrench. Connect tensioner spring to pin on engine block. See Fig. 11.
Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing
marks are still aligned. See Fig. 5.
5) To install remaining components, reverse removal procedure. 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. See Fig. 12. Tighten valve cover bolts to specification in correct
sequence. See Fig. 13. Adjust drive belts to proper tension.
6) 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). See Fig. 14. Air gap is not adjustable. If
gap is incorrect, check for damaged parts.

Courtesy of Mazda Motors Corp.

Fig. 5: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Mazda Motors Corp.

Fig. 7: Inspecting Timing Belt

Courtesy of Mazda Motors Corp.

Fig. 6: Removing Tensioner Spring

Courtesy of Mazda Motors Corp.

Fig. 8: Measuring Tensioner Spring Free Length

CAUTION: Forcefully twisting the belt, turning it inside out, or

allowing oil or grease on it will damage the belt and shorten its life.
Inspection Check timing belt for cracks, peeling, abrasion or other
damage. See Fig. 7. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring
free length should be 1.44 (36.6 mm). Measure spring free length from
inside edge to inside edge of hooked portion of spring. See Fig. 8.
Replace parts as necessary. Install the tensioner. Rotate tensioner. See
Fig. 9. If tensioner rotates with no resistance or does not rotate, replace
tensioner.
Installation 1) Ensure all timing marks are aligned. See Fig. 10.
2) 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.

Courtesy of Mazda Motors Corp.

Fig. 9: Checking Timing Belt Tensioner

MAZDA

507

2.0L 4-Cylinder DOHC Except Tribute (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 13: Identifying Valve Cover Bolt Tightening Sequence

Courtesy of Mazda Motors Corp.

Fig. 10: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Mazda Motors Corp.

Fig. 14: Measuring Crankshaft Position Sensor-To-Crankshaft

Pulley Air Gap

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Mazda Motors Corp.

Fig. 11: Installing Tensioner Spring To Hook Pin

Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 37-44 (50-60)
Crankshaft Pulley Bolt ............................................................................. 116-122 (157-166)
Engine Mount Nut ......................................................................... ............... 55-77 (75-104)
Timing Belt Idler Pulley Bolt ......................................................... ................. 28-38 (38-51)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51)
INCH Lbs. (N.m)
CKP & CMP Sensor Bolts ............................................................ ............. 70-90 (7.9-10.7)
Dipstick Tube Bolt ......................................................................... ............. 70-90 (7.9-10.7)
Timing Belt Covers ........................................................................ ............. 70-95 (7.9-10.7)
Valve Cover Bolts .......................................................................... ............... 61-87 (6.9-9.8)
Water Pump Pulley Bolts .............................................................. ............. 70-95 (7.9-10.7)

Courtesy of Mazda Motors Corp.

Fig. 12: Identifying Sealant Locations

MAZDA

508

2.0L 4-Cylinder DOHC Tribute

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC

Tribute
2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Ford Motor Co.

Fig. 1: Removing Valve Cover

The manufacturer recommends the belt be replaced every 90,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
outlet pipe. Remove spark plugs. Disconnect cruise control actuator
cable. Disconnect accelerator cable. If necessary, disconnect catalyst
monitor and heated HO2S sensor connectors, and detach from bracket.
Remove wiring harness anchors from valve cover studs, and position
wiring harness aside. Remove valve cover. See Fig. 1.
2) Raise and support vehicle. Remove right wheel. Remove right lower
splash shield. Remove catalytic converter. Remove coolant tube bolt
and nut. Position coolant tube to side.
3) 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.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks Before TDC

NOTE: Ensure second notch in pulley is indexed to lower cylinder

block. See Fig. 2.
4) Rotate crankshaft clockwise against peg to bring it to TDC. Loosen
water pump pulley bolts. Loosen crankshaft pulley bolt. Rotate tensioner
and remove accessory drive belt.
5) Remove crankshaft pulley. Remove bolts and lower timing belt cover.
See Fig. 4.
6) Lower vehicle. Install Engine Support Bar (303-F072). See Fig. 5.
7) Remove ground strap and engine mount upper bracket and studs.
See Fig. 6. Disconnect knock sensor electrical connector, if necessary.
Remove upper timing belt cover bolts and cover. See Fig. 7.
NOTE: Installation of Camshaft Alignment Tool (303-465) into
exhaust camshaft may require camshafts to be rotated slightly
clockwise.
8) Remove water pump pulley and accessory drive belt idler pulley.
Install Camshaft Alignment Tool (303-465) and align camshafts. See
Fig. 8.
9) Raise and support vehicle. Remove engine mount lower bracket. See
Fig. 9.
10) 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.

Courtesy of Ford Motor Co.

Fig. 3: Removing Stud For Installation Of Crankshaft TDC

Timing Peg (303-574)

CAUTION: DO NOT reuse old timing belt. Replace with a NEW belt.
Installation 1) 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.
2) Lower vehicle. Ensure timing belt tensioner is installed correctly with
tab positioned in slot in inner timing cover. See Fig. 10.
3) Install new timing belt onto timing belt sprockets. See Fig. 11. Adjust
timing belt tensioner using a 6-mm Allen wrench to rotate adjuster

Courtesy of Ford Motor Co.

Fig. 4: Removing Lower Timing Belt Cover

MAZDA

509

2.0L 4-Cylinder DOHC Tribute (Cont.)

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 9: Removing Engine Mount Lower Bracket

Fig. 5: Installing Engine Support Bar (303-F072)

counterclockwise and align marks. See Fig. 12. Tighten tensioner pulley
bolt to specification. See TORQUE SPECIFICATIONS.
4) Raise and support vehicle. 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, but
hand tighten only. Rotate tensioner and install accessory drive belt.
Tighten crankshaft pulley and water pump pulley bolts to specification.
See TORQUE SPECIFICATIONS.
5) Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install
engine mount upper bracket and ground strap. Remove Engine Support
Bar (303-F072). Install coolant tube and catalytic converter.
6) Install right splash shield and wheel. Remove Camshaft Alignment
Tool (303-465). To complete installation, reverse removal procedure.
Reconnect negative battery cable.

Courtesy of Ford Motor Co.

Fig. 6: Removing Engine Mount Upper Bracket

Courtesy of Ford Motor Co.

Fig. 10: Installing Timing Belt Tensioner

Courtesy of Ford Motor Co.

Fig. 7: Removing Upper Timing Belt Cover

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt On Sprockets

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Tool (303-465)

MAZDA

510

2.0L 4-Cylinder DOHC Tribute (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Ford Motor Co.

Fig. 12: Adjusting Timing Belt Tensioner

Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45)
Coolant Tube Attachments ........................................................................................ 15 (20)
Crankshaft Pulley Bolt ............................................................................................. 85 (115)
Engine Mount Lower Bracket Nuts .......................................................................... 37 (50)
Engine Mount Upper Bracket
Bolt ........................................................................................................................... 57 (77)
Nuts .......................................................................................................................... 72 (98)
Exhaust Camshaft Center Plug ................................................................................ 27 (37)
Ground Strap Nut ...................................................................................................... 25 (34)
Spark Plugs ............................................................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) ................................................................... 18 (24)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Upper Timing Belt Cover Studs ................................................................................ 25 (34)
Water Pump Pulley Bolt ............................................................................................ 18 (24)
INCH Lbs. (N.m)
Lower Timing Belt Cover Bolts ...................................................................................
Splash Shield Bolts .....................................................................................................
Upper Timing Belt Cover Bolts ...................................................................................
Valve Cover Bolts ........................................................................................................

62
80
71
80

(7)
(9)
(8)
(9)

MAZDA

511

2.0L & 2.2L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

2.0L 4-Cyl. SOHC

B2000
1986
Thru: Chassis
No. 568707 ........................ 2.6
From: Chassis
No. 568708 ........................ 2.6
1987 ....................................... 2.6
626
1983 ....................................... 1.6
626 Coupe
1984-85
Thru: VIN
JM1GC221E1617 .............. 1.6
From: VIN
JM1GC221E16176 ............ 1.6
626 Hatchback
1984-85
Thru: VIN JM1GC241E1 ..... 1.6
From: VIN JM1GC241E1 .... 1.6
626 Sedan
1984-85
Thru: VIN
JM1GC221E1635511 ......... 1.6
From: VIN
JM1GC221E1635511 ......... 1.6
1986-87 .................................. 1.6
2.2L 4-Cyl. Non-Turbo & Turbo
B2200
1987-93 .................................. 2.6
MX-6
1988-92 .................................. 2.3
626
1988-92 .................................. 2.3
1

2
3

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 (63 mm). See Fig. 3.
NOTE: Never twist, turn inside out, or bend timing belt.

Hrs. ... ...... ..... ............ T113

Hrs. ... ...... ..... ............ T117
Hrs. ... .. TCK117 ........ T117
Hrs. ... ...... ..... ...... ..... T088

Hrs. ... ...... ..... ...... ...

T088

Hrs. ... ...... ..... ...... ...

T113

Hrs. ... ...... ..... ...... ...

Hrs. ... ...... ..... ...... ...

2
3

T088
T113

Hrs. ... ...... ..... ...... ...

T088

Hrs. ... ...... ..... ...... ... 3 T113

Hrs. ... .. TCK117 ........ T117

Hrs. ... .. TCK134 .. ..... T134

Hrs. ... .. TCK134 .. ..... T134
Hrs. ... .. TCK134 .. ..... T134

With Air Conditioning add .2 hours.

With Power Steering, add .2 hours.
With square tooth sprocket.
With round tooth sprocket.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of Mazda Motors Corp.

Fig. 1: Timing Belt Reference Marks & Deflection (2.0L)

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Mazda Motors Corp.

TIMING BELT

Fig. 2: Aligning Timing Marks (2.2L)

Removal 1) Disconnect negative battery cable. On B2200 models,

drain cooling system. Radiator removal may be required. Remove
cooling fan and shroud. Remove distributor from front housing. Remove
cooling fan pulley and bracket. Remove secondary air pipe assembly
(carbureted engines).
2) On all models, remove all accessory drive belts. Remove crankshaft
pulley. Remove timing belt covers. Remove baffle plate located in front
of crankshaft sprocket. Note direction of baffle plate installation. Align
camshaft pulley with front housing timing mark. See Fig. 1 or 2. Mark an

Installation 1) Align camshaft pulley with front housing timing mark.

Align crankshaft pulley with pointer on oil pump body. See Fig. 1 or 2.
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.
2) 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.

MAZDA

512

2.0L & 2.2L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.0L)

Courtesy of Mazda Motors Corp.

Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 35-48 (47-65)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52)
Torque Stopper Bolts .................................................................... ................. 45-56 (61-76)

Fig. 3: Measuring Free Length of Tensioner Spring

3) Loosen tensioner lock bolt to apply tension. 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.
4) Check for proper belt tension by measuring amount of deflection
midway between idler pulley and camshaft sprocket. Belt deflection
should be .30-.33 (7.6-8.4 mm) when force of 22 lbs. (10 kg) is applied.
See Fig. 1 or 2. Repeat adjustment if deflection is not within specification.
5) Reverse removal procedure to complete installation. Adjust drive
belts to proper tension.

INCH Lbs. (N.m)

Timing Belt Covers ........................................................................ ................... 61-87 (7-10)
Valve Cover ................................................................................... ..................... 26-35 (3-4)
TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo)
Application
Ft. Lbs. (N.m)
Coolant Inlet Pipe Bolt .................................................................. ................. 14-19 (19-26)
Crankshaft Sprocket Bolt ........................................................................ 116-123 (157-167)
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)

MAZDA

513

2.3L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

2.3L 4-Cyl.
B2300
1994 ...................................
1995-97 ..............................

Component
Belt
Kit No.
Part No.

1.7 Hours .. .. TCK210 .. ..... T210

1.7 Hours .. .. TCK276 .. ..... T276

With Air Conditioning add .9 hours.

With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Ford Motor Co.

REMOVAL & INSTALLATION

Fig. 2: Exploded View Of Timing Belt & Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Ensure crankshaft is
set at TDC and camshaft sprocket timing mark is aligned with cover
pointer. See Fig. 1. Disconnect negative battery cable.
2) Drain cooling system and remove upper radiator hose. Remove
alternator. Loosen water pump pulley bolts. Remove accessory drive
belt(s). Remove spark plugs to ensure belt does not jump time during
rotation.
3) Remove cooling fan and water pump pulley. Remove crankshaft
pulley, hub and belt guide. Remove crankshaft position 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. 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).
Installation 1) Ensure crankshaft is set at TDC and camshaft sprocket
timing mark is aligned with cover pointer. See Fig. 1. Install belt guide
with flat side toward the camshaft sprocket. See Fig. 2.
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.
3) Loosen tensioner bolt. Apply additional pressure to tensioner, as
spring pressure is insufficient. Retighten tensioner lock bolt. To complete
installation, reverse removal procedure. Fill and bleed cooling system.
Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 50-71 (68-96)
Crankshaft Damper Bolt ................................................................ ......... 103-133 (140-180)
Water Pump Bolt 1 ......................................................................... ................. 14-21 (19-29)
INCH Lbs. (N.m)
Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12)
Valve Cover Bolt ............................................................................................... 62-97 (7-11)
1

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

Apply sealant to bolt threads.

MAZDA

514

2.3L V6
TIMING BELT APPLICATION
Application
2.3L V6
Millenia
1995-02 ....................................................
1

Labor Time

Belt
Part No.

4.5 Hours .. ..... T267

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1995-96 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.

4) Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft

so No. 1 cylinder is at TDC on compression stroke. The crankshaft and
camshaft timing marks should align. See Fig. 2.
5) 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 timing belt.
Inspection 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Inspect timing belt auto tensioner for signs of oil leakage.
Replace timing belt auto tensioner if oil leakage exists. Measure timing
belt auto tensioner rod protrusion 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.

TIMING BELT

2) 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. 4. To repair the
oil leak, remove No. 3 engine mount bracket. Remove mounting stud
from engine. Clean all threads thoroughly. Apply Loctite PST Pipe
Sealant with Teflon (No. 565) to stud threads. Install stud on engine
block.
Installation 1) Place timing belt auto tensioner in a press using a flat
washer to prevent damage to timing belt tensioner. See Fig. 5. Using no
more than 2200 lbs. of pressure, compress tensioner rod until holes in
rod and housing are aligned. Install a .055-.063 (1.4-1.6 mm) diameter
pin through holes in housing and rod to hold rod in retracted position.
See Fig. 5.
2) Install timing belt on sprockets and around idler pulleys in the
sequence shown. See Fig. 6. Ensure all slack is on tensioner pulley
side. Install timing belt auto tensioner. Tighten timing belt auto tensioner
bolts to specification. See TORQUE SPECIFICATIONS. Ensure all
timing marks align. See Fig. 2.

Removal 1) Disconnect negative battery cable. Drain coolant. Raise

and support vehicle. Remove right front wheel. Remove lower engine
covers. Remove accessory drive belts.

CAUTION: If reusing timing belt, ensure timing belt is installed in

original direction of rotation.

For 1997-98 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 1999-00 vehicles, the replacement is 60,000 miles except for
vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, 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 2001-02 vehicles, the replacement interval is 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: DO NOT damage crank angle sensor rotor on rear of

crankshaft pulley during crankshaft pulley removal.
2) Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove power steering pump pulley. Remove water pump
pulley. Remove generator drive belt auto tensioner. See Fig. 1. Remove
camshaft position sensor from right hand camshaft.
3) 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.

3) Remove 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 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.
4) Install timing belt covers using NEW gaskets. Tighten retaining bolts
to specification. See TORQUE SPECIFICATIONS. Install dipstick tube
with new O ring.
5) To install remaining components, reverse removal procedure. Tighten
fasteners to specification. See TORQUE SPECIFICATIONS. Check
ignition timing. Adjust drive belts to proper tension.

MAZDA

515

2.3L V6 (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MAZDA

516

2.3L V6 (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 5: Retracting Timing Belt Tensioner Rod

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Marks

Courtesy of Mazda Motors Corp.

Fig. 6: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 27-38 (37-52)
Camshaft Position Sensor Bolt ..................................................... ................. 14-18 (19-25)
Crankshaft Pulley Bolts
Center Bolt ............................................................................................ 116-123 (157-166)
Except Center Bolt ...................................................................... ................. 19-22 (26-30)
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)
Power Steering Pump Pulley Nut ................................................. ................. 37-43 (50-58)
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)
Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11)
Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 4: Locating Engine Mount Bracket Stud

MAZDA

517

2.5L 4-Cylinder
TIMING BELT APPLICATION
Application
2.5L 4-Cyl.
B2500
1998-00 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

1.7 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours.

With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be inspected at 120,000 miles
and replaced if necessary.

REMOVAL & INSTALLATION

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove exhaust side
spark plugs. Rotate crankshaft clockwise so No. 1 piston is at TDC of
compression stroke.
2) Remove fan shroud. Loosen fan clutch-to-pulley bolts. Remove
accessory drive belt. Remove fan clutch and pulley. Remove crankshaft
center bolt, and remove crankshaft pulley.
3) Using recycling equipment, recover refrigerant from air conditioning
system (if equipped). Disconnect A/C clutch connector from A/C clutch.
Remove A/C compressor from mounting bracket. Remove A/C compressor mounting bracket with hoses attached, and position out of way.
4) Remove timing belt outer cover retaining bolt. Release 7 cover
interlocking tabs. Remove timing belt cover. Ensure crankshaft and
camshaft timing marks are aligned. See Fig. 1.
5) 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.
6) If reusing old timing belt, mark belt with arrow to indicate direction of
rotation. 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 1) 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.
2) Install timing belt on crankshaft sprocket. Working clockwise, install
belt over oil pump sprocket, camshaft sprocket, and tensioner pulley.
3) Loosen tensioner bolt and allow tensioner to adjust itself. Rotate
crankshaft clockwise 2 complete revolutions to remove slack from belt.
Recheck timing mark alignment. Readjust as necessary. Tighten timing
belt tensioner bolts.
4) 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).
5) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket Mount Bolts
M8 Bolt .................................................................................................................... 18 (25)
M10 Bolt .................................................................................................................. 35 (48)
A/C Compressor-To-Bracket Bolt .................................................. ................. 16-20 (21-28)
Camshaft Sprocket Bolt ................................................................ ................. 52-70 (70-95)
Cooling Fan-To-Pulley Bolts .......................................................... ................. 13-16 (17-23)
Crankshaft Damper Bolt ................................................................ ........... 92-122 (125-165)
Oil Pump Sprocket Bolt ................................................................ ................. 29-41 (40-55)
Timing Belt Tensioner Adjusting Bolt ............................................ ................. 35-45 (26-33)
Timing Belt Tensioner Pivot Bolt .................................................. ................. 29-41 (40-55)
INCH Lbs. (N.m)
Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12)
Spark Plug ....................................................................................................... 80-115 (9-13)

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

MAZDA

518

2.5L V6
TIMING BELT APPLICATION
Application
2.5L V6
Millenia
1995-02 ..............................
MX-6
1993-97 ..............................
626
1993-02 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

3.4 Hours .. .. TCK214 .. ..... T214

4.0 Hours .. .. TCK214 .. ..... T214

4.0 Hours .. .. TCK214 .. ..... T214

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1993 model year, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 model years, the manufacturer recommends 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 1997-98 model years, 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 1999 626 models and 1999-00 Millenia models, the manufacturer
recommends the belt be replaced at 60,000 mile intervals except for
vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia 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 2000 626 models, the manufacturer recommends the belt be
replaced at 60,000 mile intervals except for vehicles registered in
California, Maine, Massachusetts and Vermont. For these states,
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt
at 105,000 miles.
For 2001-02 model year, inspect timing belt at 60,000 and replace timing
belt at 105,000 miles, UNLESS the vehicle is operated in temperatures
that are under 0F (-18C). In this case, replace timing belt at 60,000
miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. On Millenia, raise and
support vehicle. Remove right front wheel. Remove lower engine
covers.
2) On all models, remove accessory drive belts. Remove water pump
pulley. Remove drive belt idler pulley bracket. Remove retaining bolts
and power steering pump with hoses attached, and secure pump out of
way. Remove spark plugs.
CAUTION: DO NOT damage crankshaft position sensor rotor on
rear of crankshaft pulley during crankshaft pulley removal.
3) Holding crankshaft stationary, remove the crankshaft pulley retaining
bolt. Using gear puller, remove crankshaft pulley.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MAZDA

519

2.5L V6 (Cont.)
4) Remove oil dipstick and oil dipstick tube. Remove crankshaft position
sensor from front of engine. See Fig. 1. Support engine using hoist or
floor jack. Remove right (timing belt side) engine mount. Remove
retaining bolts, timing belt covers, and gaskets. See Fig. 1.
5) Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft
so No. 1 cylinder is at TDC on compression stroke. Ensure groove on
crankshaft sprocket aligns with indicator on oil pump body. See Fig. 2.
Ensure camshaft sprocket timing marks are aligned with marks on rear
cover.
6) 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.
Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Timing Belt Tensioner Types

Installation 1) 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. of pressure, SLOWLY compress tensioner rod until
holes in rod and housing are aligned. Install 0.055 (1.4 mm) diameter
pin through holes in housing and rod to hold rod in retracted position.
2) Install timing belt tensioner on cylinder block with the upper retaining
bolt only; do not fully tighten upper bolt.
CAUTION: If reusing timing belt, ensure timing belt is installed in
original direction of rotation.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Inspection 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure idler pulleys (No. 1 and No. 2) and tensioner
pulley rotate freely. Replace damaged components.
2) Inspect timing belt tensioner for signs of oil leakage. Replace 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 tensioners 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

3) Ensure crankshaft and camshaft timing marks align. See Fig. 2. 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.
4) 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.
5) 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 sprockets are properly aligned. See Fig. 2. If
timing marks are not aligned, remove and repeat entire timing belt
installation procedure.
6) Install right (timing belt side) engine mount. Install timing belt covers
using NEW gaskets. Tighten retaining bolts to specification. See
TORQUE SPECIFICATIONS.
7) Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. Tighten fasteners to specification.
See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
8) 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 components. Air gap is not adjustable.

Application
In. (mm)
Type A
2001-02 Millenia .......................................... ................................. 0.511-0.551 (13.0-14.0)
Except 2001-02 Millenia .............................. ................................. 0.473-0.511 (12.0-13.0)
Type B .......................................................................................... 0.563-0.594 (14.3-15.1)

Courtesy of Mazda Motors Corp.

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

Fig. 5: Retracting Timing Belt Tensioner Rod

520

MAZDA
2.5L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mazda Motors Corp.

Fig. 6: Installing Timing Belt

Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-166)
Drive Belt Idler Pulley Bracket Bolt .............................................. ................. 14-18 (19-23)
No. 1 & No. 2 Idler Pulley Bolt .................................................... ................. 28-38 (38-52)
Power Steering Pump Bracket Bolt
Millenia
1995-98 ...................................................................................... ................. 23-34 (31-46)
1999-02 ...................................................................................... ..................................... 1
MX-6 & 626 ................................................................................. ................. 28-38 (38-52)
Power Steering Pump Pulley Nut ................................................. ................. 37-43 (50-58)
Right (Timing Belt Side) Engine Mount
Nut (All Models) .......................................................................... ............... 55-75 (74-102)
Through-Bolt (626) ...................................................................................... 63-86 (86-116)
Tensioner Pulley Bolt .................................................................... ................. 28-32 (38-44)
Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25)
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)
Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11)
Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
1

Tighten bracket-to-steering pump bolt to 14-19 ft. lbs. (19-26 N.m). Tighten all other
bolts to 23-34 ft. lbs. (31-46 N.m.).

MAZDA

521

3.0L V6 DOHC
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

3.0L V6 DOHC
929
1990-91 ............................... 3.9 Hours .... TCK183A . ..... T183
1992-95 ............................... 3.9 Hours ... .. TCK183 .. ..... T183
Serenia (Canadian)
1992-95 ............................... 3.9 Hours ... ...... ..... ...... ..... T183
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
for Federal vehicles, and 105,000 miles on California vehicles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain engine coolant.
Remove spark plug cables and spark plugs. Remove air intake hose.
Remove cooling fan and fan shroud.

2) 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 damage sensor rotor. Remove coolant by-pass and
upper radiator hoses.
3) Remove distributor. Remove timing belt covers and gasket. 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 1) Using flat washer to prevent damage to tensioner body
plug, place automatic tensioner in vise or arbor press. Compress
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.
2) 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 direction of rotation, and ensure match marks
still align. Remove automatic tensioner pin, and repeat steps to confirm
match marks are still in alignment.
3) 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.
4) To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust the drive
belts to proper tension.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MAZDA

522

3.0L V6 DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Belt Match Marks

Application
Ft. Lbs. (N.m)
A/C Compressor-To-Bracket Bolt .................................................. ................. 21-29 (29-39)
Alternator-To-Bracket Bolt ............................................................. ................. 27-38 (37-52)
Camshaft Pulley Bolt
Left Head ..................................................................................... ................. 14-18 (19-25)
Right Head .................................................................................. ................. 52-59 (71-80)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
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 Tensioner Bolt ............................................................ ................. 14-18 (19-25)
Timing Belt Upper Idler Bolt ......................................................... ................. 27-38 (37-52)
Water Pump Bolt/Nut .................................................................... ................. 14-18 (19-25)
INCH Lbs. (N.m)
Timing Belt Cover Bolt
Right Side Cover (Top 3 Bolts) .................................................. ..................................... 1
All Other Bolts ................................................................................................. 71-97 (8-11)
Valve Cover Bolt ........................................................................... ............... 30-39 (3.4-4.4)
1

Tighten 3 top bolts on right side cover to 14-18 ft. lbs. (19-25 N.m).

MAZDA

523

3.0L V6 SOHC
TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

3.0L V6 SOHC
MPV
1989-98 ............................ .... 3.0 Hrs. .... .. TCK146 .. ..... T146
929
1988-91 ............................ .... 3.1 Hrs. .... .. TCK146 .. ..... T146
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1988-93 model years, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 model years, the manufacturer recommends 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 1997-98 model years, the manufacturer recommends 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.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
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 coolant bypass and upper radiator hoses. Remove
timing belt covers and gaskets. See Fig. 1. Rotate crankshaft and align
all timing marks. See Fig. 2.
2) If reusing timing belt, place reference mark on timing belt 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 1) Measure timing belt tensioner rod protrusion from end
of rod to edge of timing belt tensioner housing. Replace timing belt
tensioner if distance is not .47-.55 (12.0-14.0 mm).
2) Inspect timing belt for damaged teeth, cracking or oil contamination.
Ensure idler pulleys and tensioner pulley rotate freely. Inspect timing belt
tensioner for signs of oil leakage. Replace worn components.
NOTE: The following information on tensioner pulley inspection is
from Mazda technical service bulletin 002/00R; March 9, 2000.
3) During the 60,000 mile inspection or timing belt replacement on MPV,
inspect tensioner pulley pivot bushing 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 1) 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.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Marks

CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure
on timing belt tensioner rod.
2) Place timing belt tensioner in press with flat washer to prevent
damage to timing belt tensioner plug. See Fig. 3. Apply pressure on rod
of timing belt tensioner until rod is retracted and holes in rod and housing
are aligned. See Fig. 3. Install pin through holes in housing and rod to
hold rod in retracted position. Release press and remove timing belt
tensioner.
CAUTION: If reusing timing belt, ensure timing belt is installed in
original direction of rotation.
3) Install timing belt tensioner on cylinder block with pin installed.
Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Rotate camshafts and crankshaft to ensure all timing marks are
aligned. See Fig. 2. With upper idler pulley removed, install timing belt
on crankshaft sprocket, lower idler pulley, left camshaft sprocket, right
camshaft sprocket and tensioner pulley in sequence.

MAZDA

524

3.0L V6 SOHC (Cont.)

4) Install upper idler pulley. Tighten retaining bolt to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure all timing marks are aligned. See Fig. 2.
If timing marks are not aligned, remove timing belt and reinstall.
5) Remove pin from timing belt tensioner, allowing pressure to be
applied to timing belt. Rotate crankshaft 2 full revolutions 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).
6) If timing belt deflection is not within specification, repeat installation
procedure. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper
tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt .................................................................... ................. 13-20 (18-27)
A/C Compressor Bracket-To-Cylinder Block Bolt ......................... ................. 27-38 (37-52)
Camshaft Sprocket Bolt ................................................................ ................. 52-59 (71-80)
Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
Lower Idler Pulley Bolt .................................................................. ................. 27-38 (37-52)
Power Steering Pump Bolt ........................................................... ................. 23-34 (31-46)
Power Steering Pump Pulley Nut ................................................. ................. 29-43 (39-58)
Tensioner Pulley Bolt .................................................................... ................. 17-22 (23-30)
Timing Belt Cover Bolt
6 mm Bolt .................................................................................... ..................................... 1
10 mm Bolt .................................................................................. ................. 27-38 (37-52)
Timing Belt Tensioner Bolt ............................................................ ................. 14-19 (19-26)
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

Courtesy of Mazda Motors Corp.

Fig. 3: Retracting Timing Belt Tensioner Rod

Tighten to 69-95 INCH lbs. (8-11 N.m).

MITSUBISHI

525

1.5L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

1.5L 4-Cyl.
Mirage
1985 ................................. ....
1986
Before 5/31/86 ............... ....
After 6/1/86 .................... ....
1987-90 ............................ ....
1991-96 ............................ ....
1997-99 ............................ ....
2000-02 ............................ ....
Precis
1987-89 ............................ ....
1990-94 ............................ ....
1

Labor Time Component

Belt
Kit No.
Part No.

2.4 Hrs. .... .. TCK073 .. ..... T073

2.4
2.4
2.4
2.4
2.4
2.4

Hrs.
Hrs.
Hrs.
Hrs.
Hrs.
Hrs.

.... .. TCK073 .. .....

.... ...... ..... ...... .....
.... .. TCK128 .. .....
.... .. TCK191 .. .....
.... .. TCK289 .. .....
.... ...... ..... ...... .....

T073
T073
T128
T191
T289
T289

2.2 Hrs. .... .. TCK073 .. ..... T073

2.2 Hrs. .... .. TCK128 .. ..... T128

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
Courtesy of DaimlerChrysler Corp.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1985-93 models, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 models, the 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. In
California, replace timing belt at 100,000 miles, unless previously
changed.
For 1997-02 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, unless previously
changed.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Aligning Timing Marks (1985-96)

Inspection (1985-96) 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 (1985-96) 1) Ensure crankshaft and camshaft timing
marks are aligned. 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 crankshaft 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 overtightened.
2) Rotate crankshaft one full revolution clockwise, until crankshaft
sprocket timing mark aligns with TDC position. Recheck 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.
3) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

TIMING BELT
Removal (1985-96) 1) Disconnect negative battery cable. Remove air
cleaner assembly, then disconnect accelerator cable and oxygen lead
sensor. Mark position of spark plug wires for installation, 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 pulleys.
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.
2) Remove timing belt covers and gaskets, noting bolt lengths and
locations as they are removed. Rotate engine clockwise to align timing
mark on camshaft sprocket with mark on cylinder head. Ensure all timing
marks are aligned. See Fig. 1.
3) 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. Remove crankshaft pulley, and
timing belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Installing Timing Belt Tensioner (1985-96)

MITSUBISHI

526

1.5L 4-Cylinder SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension (1985-96)

Fig. 5: Exploded View Of Timing Belt & Components

Courtesy of DaimlerChrysler Corp.

Fig. 4: Checking Timing Belt Tension (1985-96)

Removal (1997-02) 1) Disconnect negative battery cable. Remove
under cover. Remove all accessory drive belts. Rotate crankshaft
clockwise so that No. 1 cylinder is at TDC of compression stroke.
Holding crankshaft stationary, remove crankshaft pulley.
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.
2) Place jack under engine. Support engine so there is no weight on
engine mount bracket (timing belt end of engine). On vehicles equipped
with A/C, move A/C relay box and drier assembly (hoses attached) out
of way to remove engine mount bracket. On all vehicles, remove engine
mount bracket-to-engine bolt and nut. Remove engine mount bracketto-body through-bolt. Remove engine mount bracket.
3) 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. See Fig. 5.
4) Rotate crankshaft clockwise to align timing mark on camshaft
sprocket with mark on cylinder head. Ensure crankshaft sprocket timing
marks are aligned. See Fig. 6.
5) Loosen timing belt tensioner adjusting bolt. Move tensioner toward
water pump to relieve tension on timing belt. Temporarily tighten
tensioner adjusting bolt. Remove timing belt.
Inspection (1997-02) 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 (1997-02) 1) Ensure crankshaft and camshaft timing
marks are aligned. See Fig. 6. If timing belt tensioner and spring were
removed, install with tensioner spring in correct position. See Fig. 7.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Aligning Timing Marks (1997-02)

2) 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.
3) After installing timing belt, ensure timing belt is tensioned between
crankshaft and camshaft sprockets. Check that all timing marks are still
aligned.
4) Loosen tensioner adjusting bolt. Rotate crankshaft two full revolutions
clockwise, until crankshaft sprocket timing mark aligns with TDC position. Tighten tensioner adjusting bolt.
5) Ensure timing belt teeth are fully seated in camshaft sprocket. Install
timing belt covers. Install crankshaft pulley. Tighten bolt to specification.
See TORQUE SPECIFICATIONS.
6) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

MITSUBISHI

527

1.5L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (1985-96 MIRAGE)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
1985-91 ........................................................................................ ................. 47-54 (65-75)
1992-96 ........................................................................................ ............... 52-74 (70-100)
Crankshaft Pulley Bolt
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)
Timing Belt Tensioner Bolt
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)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Water Pump Pulley Bolt
1985-88 ........................................................................................ ............. 108-120 (12-14)
1989-96 ........................................................................................ ..................... 72-84 (8-9)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Installing Timing Belt Tensioner (1997-02)

TORQUE SPECIFICATIONS (1991-94 PRECIS)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 48-55 (65-75)
Camshaft Thrust Case Bolt .......................................................... ................. 14-20 (19-27)
Crankshaft Sprocket Bolt .............................................................. ............... 52-74 (70-100)
Front Cover Bolt .............................................................................................. 10-11 (14-15)
Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27)
INCH Lbs. (N.m)
Camshaft Rear Cover Bolts .......................................................... ................... 70-86 (7-10)
Rocker Cover Bolt ......................................................................... ............... 13-18 (1.5-2.0)
Timing Belt Cover Bolt .................................................................. ............... 86-104 (10-12)
TORQUE SPECIFICATIONS (1997-02)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 64 (88)
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)
Water Pump Pulley Bolt .............................................................................................. 80 (9)
1
2

Apply engine oil to bolt thread before installation.

Final tighten with full weight of engine on bolt.

MITSUBISHI

528

1.6L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. SOHC

Mirage
1985-88 ....................................................
1

Belt
Part No.

2.8 Hours .. ..... T093

With Air Conditioning, add .4 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Remove splash panel in left side wheel house. Remove
air intake duct to air cleaner housing. Noting installed position for
reassembly reference, remove spark plug cables from spark plugs.
2) 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 engine mount.
3) Remove power steering pump pulley (if equipped). Remove water
pump pulley. See Fig. 1. Remove upper timing belt cover.
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.
4) 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.
5) Loosen timing belt tensioner adjusting bolt and nut. Move tensioner
inward toward water pump. Temporarily tighten tensioner adjusting bolt.
Remove timing belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components

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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Camshaft Timing Marks

Installation 1) 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.
2) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 2.
Install timing belt onto crankshaft sprocket, and keeping tension tight,
install timing belt on camshaft sprocket.
3) After installing timing belt, ensure timing belt is tensioned between
crankshaft and camshaft sprockets. Check that all timing marks are still
aligned.
4) Loosen tensioner adjusting bolt and nut about one turn so that timing
belt tensioner contacts timing belt. Turn crankshaft 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.
5) 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 to specification first, and then the tensioner
nut. See TORQUE SPECIFICATIONS. Turn crankshaft one full revolution.
6) Ensure camshaft and crankshaft timing marks are still 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 edge of timing belt cover
must be .23 (6 mm). Readjust belt tension, if necessary.
7) Install timing belt covers. Ensure bolts are installed in correct position.
See Fig. 7. Install crankshaft pulley. Tighten bolt to specification. See
TORQUE SPECIFICATIONS.
8) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

MITSUBISHI

529

1.6L 4-Cylinder SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Installing Crankshaft Sprocket, Flange & Spacer

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Checking Timing Belt Tension Adjustment

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Installing Tensioner Spring

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Identifying Timing Belt Cover Bolt Length

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Camshaft Sprocket Position For Tension Adjustment

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100)
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)
Water Pump Pulley Bolt .............................................................................................. 80 (9)
1

Apply engine oil to bolt thread before installation.

MITSUBISHI

530

1.8L & 2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.8L 4-Cyl.
Cordia & Tredia
1983-84
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... .....
1985-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... .....
1987-88
Balance Shaft ............... .......... 1 .......... .. TCK158 .. .....
Camshaft ....................... ... 2 3.2 Hrs. ... .. TCK158 .. .....
2.0L 4-Cyl.
Cordia & Tredia
1984
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... .....
1985-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... .....
1987-88
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... .....
Galant
1989-92
Balance Shaft ............... .......... 1 .......... .. TCK155 .. .....
Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK155 .. .....
1993
Balance Shaft ............... .......... 1 .......... .. TCK232 .. .....
Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK232 .. .....
Pickup
1983-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... .....
Camshaft ....................... ... 2 2.3 Hrs. ... ...... ..... ...... .....
1987-89
Balance Shaft ............... .......... 1 ........... TCK158A . .....
Camshaft ....................... ... 2 2.3 Hrs. .... TCK158A . .....
1

3) Remove plug on left side of cylinder block. Insert a screwdriver to

keep left silent shaft in position. See Fig. 1. Remove 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.

T090
T089
T159
T089
T159
T158

T090
T089
T159
T089
T159
T158

T159
T155
T168
T232

T090
T089
T159
T158

Balance Shaft Belt labor time included in

Camshaft Belt labor time.
With Air Conditioning, add .4 hours.
With Power Steering, add .3 hours.
With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1983-88) 1) Disconnect negative battery cable. On models
equipped with A/C, remove upper radiator shroud and cooling fan/clutch
assembly. On models equipped with power steering, remove power
steering pump and pulley. On all models, position No. 1 cylinder at TDC
of compression stroke. Loosen pulley bolts. Remove drive belts.
2) Remove crankshaft, water pump and power steering pulleys. Remove
upper and lower front timing belt covers. Relieve 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Camshaft Timing Marks (16-Valve Engine)

Inspection (1983-88) 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, flaking, peeling,
cracking and separating rubber. Cracks are most evident at base of
tooth.
Installation (1983-88) 1) Install timing belt B ensuring tension side
has no slack. Install tensioner B so only light pressure is on belt.
Ensure flange on tensioner is mounted away from engine and fingertighten 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.
2) Check belt tension by pressing center of tension side inward, using
index finger and measuring belt deflection. 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. 2 or 3. To
ensure oil pump sprocket is in correct alignment, insert screwdriver shaft
in hole on left side of block. See Fig. 1.
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
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.
4) 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. Remove 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.
5) 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. Adjust drive belts to proper tension.
Removal (1989-93) 1) Disconnect negative battery cable. Remove
A/C and power steering hose mounting bracket or oxygen sensor
connector 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.

MITSUBISHI

531

1.8L & 2.0L 4-Cylinder SOHC (Cont.)

3) 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. 2 or 3.
4) 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 apply spring pressure to timing
belt. Ensure timing marks are still aligned. To apply tension on belt,
rotate crankshaft clockwise until camshaft sprocket timing mark is offset
by 2 teeth. Tighten tensioner bolt. Tighten tensioner nut.
5) To check belt tension, apply slight thumb pressure and measure
deflection between camshaft and oil pump sprocket. Belt deflection
should be .55 (14 mm). To complete installation, reverse removal
procedure. Adjust drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

(8-Valve Engine)

Courtesy of DaimlerChrysler Corp.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Oil Pump Sprocket

Fig. 4: Aligning Rear Timing Belt

2) Remove drive belt tensioner. Remove upper and lower timing belt
covers. Note bolt lengths and locations. Longer (2) bolts are located
above crankshaft seal. Remove crankshaft sprocket bolt access cover,
crankshaft sprocket bolt and washer. If necessary, remove rocker arm
cover for clearance.

TORQUE SPECIFICATIONS

CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed

from timing belt end of engine). If timing belt is to be reused, mark
direction of rotation before removing.
3) 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 timing mark on cylinder head. See
Fig. 2 or 3. Loosen timing belt tensioner adjustment bolt, and move
tensioner toward water pump. Tighten bolt to secure tensioner. Remove
front timing belt and camshaft sprocket.
4) If oil pump sprocket removal is necessary, remove left silent 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.
Inspection (1989-93) 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.
Installation (1989-93) 1) 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.
2) 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).

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt
1983-85 .......................................................................................................... 11-15 (15-20)
1986-93 ........................................................................................ ................. 15-21 (20-29)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
Front Cover Bolts
M8 X 30 Bolt ............................................................................... ................. 20-26 (27-35)
Except M8 X 30 Bolt .................................................................. ................. 14-20 (19-27)
Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
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)
Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
Timing Belt Cover Bolt
Left Lower Rear Cover ............................................................... ................. 22-30 (30-41)
All Others ..................................................................................... ..................................... 1
Timing Belt Tensioner Nut
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)
Timing Belt Cover Bolt
All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)
1

All except Left Lower Rear Cover Bolt tighten to 84-108 INCH lbs. (9-12 N.m).

MITSUBISHI

532

2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cyl. DOHC

Lancer Evolution Turbo
2003-04
Balance Shaft ...................................... .......... 1 .......... ..... T168
Camshaft ............................................. ... 2 3.1 Hrs. ... ..... T167
1

With Air Conditioning, add .2 hour.

With Power Steering, add .2 hour.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles
except in California, Massachusetts 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
miles, unless previously changed.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Remove undercover and side cover. Remove accessory
drive belt. Remove crankshaft pulley bolts. Remove crankshaft pulley.
Remove crossmember bar for access to front exhaust pipe.
2) Remove front exhaust pipe. Remove timing belt upper cover. See
Figs. 1 and 2. Remove water pump pulley. Remove idler pulley.
3) Remove auto-tensioner. Remove timing belt lower cover. Raise
engine and transaxle assembly until its weight is not supported by front
engine mount. Remove front engine mount.
4) Rotate crankshaft clockwise to align each timing mark and to set
cylinder No. 1 at TDC of compression stroke. See Fig. 3.
5) Remove timing belt under cover rubber plug. See Fig. 4. Screw in
Adjusting Bolt (MD998738) until it comes in contact with timing belt
tensioner arm. See Fig. 5.
CAUTION: Adjusting Bolt will bend if it is screwed in too fast.
6) Gradually screw in adjusting bolt at a rate of 30 degrees per second
to align timing belt tensioner adjuster rod set hole A with timing belt
tensioner adjuster cylinder set hole B. See Fig. 6.
7) Insert a suitable pin or wire into set hole, and remove adjusting bolt.
If timing belt is to be reused, mark rotation direction on belt. Loosen
timing belt tensioner pulley mounting bolt, and remove timing belt. See
Fig. 7.
8) Disconnect power steering pressure switch connector. Remove
power steering pump heat shield. Remove power steering pump with
hoses attached, and secure aside. Remove power steering pump
bracket. Remove timing belt idler pulley.
9) Remove crankshaft position sensor. Using Special Spanner
(MB991367) and Pins (MB991385) to hold crankshaft timing belt
sprocket, remove crankshaft center bolt.
10) Using Crankshaft Sprocket Puller (MD998778), remove crankshaft
timing belt sprocket. Remove crankshaft angle sensing blade. If balancer belt is to be reused, mark rotation direction on belt.
11) Ensure balancer timing marks are aligned. See Fig. 8. Loosen
balancer belt tensioner bolt. Remove balancer belt tensioner. Remove
balancer belt.

Inspection 1) 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 pulleys for smooth rotation.
Replace if defective.
2) Remove timing belt tensioner adjuster. Check timing belt tensioner
adjuster for leaks. Hold timing belt tensioner adjuster upright. Measure
rod extension length above edge of housing. See Fig. 9. Length should
be .5 (12 mm). If length is not as specified, replace timing belt tensioner
adjuster.
3) Apply 22-44 lbs. (10-20 kg.) of force to end of rod. See Fig. 10. If rod
moves more than 0.39 (1 mm), replace timing belt tensioner adjuster.
Installation 1) Ensure balancer timing marks are aligned. See Fig. 8.
Install timing belt on crankshaft balancer sprocket and balancer
sprocket. Ensure there is no slack on tension side.
2) Temporarily install balancer belt tensioner. With your fingers, lift
balancer belt tensioner in direction of arrow. See Fig. 11.
CAUTION: When tightening balancer belt tensioner bolt, ensure
tensioner does not rotate with the bolt. Allowing it to rotate can
cause excessive belt tension.
3) Apply 22-30 INCH lbs. (2.6-4.4 N.m) to balancer belt, then tighten
balancer belt tensioner bolt to specification. See TORQUE SPECIFICATIONS.
4) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing
marks are aligned. See Fig. 8.
5) Apply about 22 lbs. (10 kg.) of pressure at center (arrow area)
between sprockets as shown. See Fig. 12. Ensure belt deflection is
.20-.27 (5.0-7.0 mm).
6) Clean front of crankshaft. Clean and install crankshaft angle sensing
blade and crankshaft timing belt sprocket. Apply engine oil to crankshaft
center bolt threads and both sides of washer. Install crankshaft center
bolt.
7) Using Special Spanner (MB991367) and Pins (MB991385) to hold
crankshaft timing belt sprocket, tighten crankshaft center bolt to specification. See TORQUE SPECIFICATIONS.
8) If timing belt tensioner adjuster was removed and rod is fully
extended, slowly compress timing belt tensioner adjuster rod with a vise
or press to align timing belt tensioner adjuster rod set hole A with
timing belt tensioner adjuster cylinder set hole B.
9) Insert a suitable pin or wire into set hole. Install timing belt tensioner
adjuster, and tighten bolts to specification. Install idler pulley, and tighten
bolt to specification. See TORQUE SPECIFICATIONS.
10) Ensure timing marks are aligned. See Fig. 3. To ensure oil
pump/balancer shaft is properly aligned, remove cylinder block plug,
and insert a phillips screwdriver as shown. See Fig. 13.
11) If screwdriver cannot be inserted 2.36 (60.0 mm) or more, remove
screwdriver and rotate oil pump/balancer shaft one revolution. Ensure
screwdriver can be inserted 2.36 (60.0 mm) or more. Do not remove
screwdriver until timing belt is installed.
12) Install timing belt on crankshaft timing belt sprocket, oil pump/
balancer shaft sprocket, and idler pulley in that order. Install timing belt
on exhaust camshaft sprocket. Secure timing belt to exhaust camshaft
sprocket with paper clamp.
13) Use 2 wrenches on camshaft sprocket bolts to align timing marks on
camshaft sprockets with timing marks on valve cover. Install timing belt
on intake camshaft sprocket. Secure timing belt to intake camshaft
sprocket with paper clamp.
14) Pass timing belt around timing belt tensioner pulley. Apply counterclockwise pressure to intake camshaft. Ensure timing marks are aligned
while tension side of belt is tight. Remove paper clamps.
15) Using Tensioner Wrench (MD998767), turn timing belt tensioner in
direction shown to apply tension to timing belt. See Fig. 14. Pre-tighten
timing belt tensioner pulley bolt.
16) Ensure timing marks are still aligned. Remove Phillips screwdriver
installed in step 10). Install cylinder block plug, and tighten to specification. See TORQUE SPECIFICATIONS.

MITSUBISHI

533

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt Components (1 Of 2)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt Components (2 Of 2)

MITSUBISHI

534

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Retracting Timing Belt Tensioner Adjuster

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Identifying Timing Belt Tensioner Pulley Mounting Bolt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Locating Timing Belt Under Cover Hole

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Aligning Balancer Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Measuring Tensioner Adjuster Rod Extension Length

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Inserting Adjusting Bolt

MITSUBISHI

535

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Measuring Timing Belt Tensioner Adjuster Retraction

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Checking Balancer Belt Deflection

CAUTION: When crankshaft is rotated counterclockwise, crankshaft center bolt may loosen. Retighten if it comes loose.
17) Gradually screw in Adjusting Bolt (MD998738) until wire or pin
inserted in timing belt tension adjuster set hole lightly moves. Rotate
crankshaft 1/4 turn counterclockwise. Rotate crankshaft clockwise until
timing marks are aligned.
CAUTION: When tightening timing belt tensioner bolt, ensure timing belt tensioner pulley does not rotate. Allowing it to rotate with
bolt can cause insufficient timing belt tension.
18) Loosen timing belt tensioner pulley bolt. Using Tensioner Wrench
(MD998767) and torque wrench, apply 31 INCH lbs. (3.5 N.m) tension
torque, and tighten timing belt tensioner pulley bolt to specification. See
TORQUE SPECIFICATIONS.
19) Remove wire or pin from timing belt tension adjuster set hole.
Remove Adjusting Bolt (MD998738), and install rubber plug into timing
belt under cover. Rotate crankshaft clockwise 2 turns, and wait about 15
minutes.
20) Insert wire or pin again, and ensure that it can be pulled out easily.
If wire or pin can be easily removed, appropriate tension is applied to
timing belt. If wire or pin cannot be easily removed, repeat steps 17)-19).
21) Measure distance A between timing belt tensioner adjuster and
timing belt tensioner arm. See Fig. 15. Appropriate timing belt tension is
applied when distance is .15-.17 (3.8-4.5 mm).
22) Ensure timing marks are still aligned. To complete installation,
reverse removal procedure. Tighten bolts and nuts to specification.
When tightening engine mount bolts, ensure weight of engine is on
vehicle body. See TORQUE SPECIFICATIONS.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Installing Balancer Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Aligning Oil Pump/Balancer Shaft

Courtesy of Mitsubishi Motor Sales of America.

Fig. 14: Tightening Timing Belt

MITSUBISHI

536

2.0L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 15: Checking Timing Belt Tension

Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84)
Balancer Belt Tensioner Bolt ........................................................ ................. 12-16 (16-22)
Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98)
Crankshaft Center Bolt 1 ....................................................................................... 123 (167)
Crankshaft Pulley Bolt ................................................................... ................. 15-21 (20-28)
Crossmember Bar Bolt .................................................................. ................. 30-47 (39-59)
Cylinder Block Plug ....................................................................... ................. 21-25 (28-33)
Drive Belt Auto-Tensioner
Center Bolt .................................................................................. ................. 26-40 (34-54)
Except Center Bolt ...................................................................... ................. 15-21 (20-28)
Engine Mount-To-Body Bolt/Nut 2 ................................................. ............... 66-80 (88-108)
Engine Mount-To-Engine Mounting Bracket Nut .......................... ................. 45-55 (60-74)
Exhaust Pipe-To-Manifold Bolt ...................................................... ................. 33-41 (45-55)
Exhaust Pipe-To-Catalyst Bolt ...................................................... ................. 30-44 (41-59)
Power Steering Pump Heat Shield Mounting Bolt ....................... ................. 13-19 (18-26)
Power Steering Pump Mounting Bolt ........................................... ................. 27-33 (35-45)
Power Steering Pump Bracket Mounting Bolt ............................. ................. 29-43 (40-58)
Timing Belt Idler Pulley Mounting Bolt ......................................... ................. 22-30 (29-41)
Timing Belt Tensioner Adjuster Mounting Bolt ............................. ................. 15-19 (20-26)
Timing Belt Tensioner Arm Mounting Bolt .................................... ................. 14-18 (17-25)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 33-39 (45-53)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ................................................... ...............
Exhaust Pipe Hanger Bolt ............................................................................
Timing Belt Cover Bolt .................................................................. ...............
Water Pump Pulley Bolt ................................................................ ...............
1
2

Before installing, apply engine oil to threads and bolt flange.

Tighten with full weight of engine on vehicle body.

69-87 (7.8-9.8)
89-133 (11-15)
90-106 (10-12)
69-87 (7.8-9.8)

MITSUBISHI

537

2.0L 4-Cylinder DOHC Eclipse & Galant

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. DOHC (4G6)

Eclipse Turbo & Non-Turbo
1990-94
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK167 .. .....
Eclipse Turbo
1995-99
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 2 3.0 Hrs. .......... .... ....... .....
Galant
1989-92
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 3 3.6 Hrs. ... .. TCK167 .. .....
1993
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK232 .. .....
1
2

T168
T167

For 1995-97 vehicles, the 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. In
California, replace belt at 100,000 miles, unless previously changed.
For 1998-99 vehicles, 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
California, replace belt at 100,000 miles, unless previously changed.

T168
T167

REMOVAL & INSTALLATION

T168
T167

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

T168
T232

TIMING BELT & BALANCE SHAFT BELT

Balance Shaft labor time included in Camshaft labor time.

With Air Conditioning, add .7 hours.
With Power Steering, add .2 hours.
With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1989-94 vehicles, the manufacturer recommends the belt be
replaced every 60,000 miles.

Removal 1) Disconnect negative battery cable. Remove engine

undercover. Place wooden block between jack and oil pan, and raise
engine slightly. Remove engine mount assembly near timing belt cover.
2) 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 crankshaft
pulley.
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
timing marks are aligned. If reusing timing belts, mark timing belts
for direction of rotation.
3) 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belts & Components

538

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Belt A Marks (1990-93 Models)

NOTE: Camshaft sprocket dowel pins will be in 12 oclock position
when timing marks are correctly aligned.
4) Ensure camshaft, crankshaft and oil pump sprocket timing marks are
aligned. See Fig. 2 or 3. Loosen tensioner pulley center bolt. Move
tensioner to relieve timing belt tension. Remove timing belt. Remove
timing belt auto tensioner. See Fig. 1.
5) 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. 4. 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 position.
6) To remove timing belt B (balance shaft belt), hold crankshaft
sprocket stationary with a spanner wrench. Remove crankshaft sprocket
bolt. Using gear puller, remove outer crankshaft sprocket.
7) Remove crankshaft sensing blade (if equipped). See Fig. 5. Loosen
timing belt B tensioner bolt. If reusing timing belt B, mark direction of
belt rotation for reassembly reference. Remove timing belt B.
Inspection 1) Inspect timing belts for damaged teeth and cracking.
Ensure 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.
2) 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. (10-20 kg) of
force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm),
replace the auto tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Belt A Timing Marks (1994-99 Models)

Installation 1) 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.
2) Align balance shaft and crankshaft timing marks with rear cover. See
Fig. 7 or 8. Install timing belt B on sprockets. If using old belt, install belt
in original direction of rotation. Ensure there is no slack in tension side
of belt.

MITSUBISHI

539

2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions, or timing belt may be damaged.
4) 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. Install idler pulley (if removed).
5) Ensure camshaft, crankshaft and oil pump timing marks are still
aligned. See Fig. 2 or 3. Do not remove screwdriver from side of engine
block until timing belt is installed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Holding Balance Shaft Stationary

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.
6) 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 Fig. 2 or 3.
7) 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.
8) 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. Go to TIMING BELT TENSION ADJUSTMENT
(1990-92) or TIMING BELT TENSION ADJUSTMENT (1993-99).

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Timing Belt B (Balance Shaft Belt) Components

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Aligning Timing Belt B (1990-92 Models)

Fig. 6: Inspecting Timing Belt Auto Tensioner

CAUTION: Ensure tensioner pulley shaft does not rotate when bolt
is tightened, or excessive pressure will be applied to timing belt.
3) Install timing belt B tensioner so center of tensioner pulley 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
deflection at designated area. Belt deflection should be .20-.28 (5.0-7.0
mm). Readjust timing belt if belt deflection is not within specification.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Aligning Timing Belt B (1993-99 Models)

Timing Belt Tension Adjustment (1990-92) 1) 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.

MITSUBISHI

540

2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 12: Adjusting Timing Belt Tension (1990-92)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Installing Crankshaft Sprocket &

Crankshaft Sensing Blade

Fig. 13: Installing Set Screw On Tensioner Pulley

Courtesy of DaimlerChrysler Corp.

Fig. 11: Installing Timing Belt On Intake Sprockets

2) Remove screwdriver from balance shaft hole in side of engine block.
Install plug.
3) 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.
4) 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. 12. With torque applied to eccentric,
tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m).
5) Insert Set Screw (MD998738) through inner timing belt cover until it
contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin
can be removed. Remove set screw from engine.
6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes
without turning crankshaft. Measure distance between top of auto
tensioner body and tensioner arm. See Fig. 14, Dimension A. The
distance should be .15-.18 (3.8-4.5 mm). If distance is incorrect, repeat
tensioning procedure until distance is correct. Go to FINAL ASSEMBLY.
Timing Belt Tension Adjustment (1993-99) 1) 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. 13. 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).
2) 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 timing marks align.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion

3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or
equivalent to tensioner eccentric. Install torque wrench on adapter. See
Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH
lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley.
4) Hold tensioner pulley at specified torque, and tighten tensioner center
bolt to specification. DO NOT let tensioner pulley turn with bolt. See
TORQUE SPECIFICATIONS.
5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are
aligned. Allow engine to stand for 15 minutes without turning crankshaft.
Distance between top of auto tensioner housing and tensioner arm
should be .15-.18 (3.8-4.5 mm). If distance is incorrect, repeat tensioning procedure until distance is correct. Go to FINAL ASSEMBLY.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 15: Adjusting Timing Belt Tension (1993-99)

MITSUBISHI

541

2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

Final Assembly To install remaining components, reverse removal
procedure. Ensure proper length bolts are installed in timing belt covers.
See TIMING COVER BOLT LENGTH & TORQUE table. See Fig. 16.
Adjust the drive belts to proper tension.
TIMING COVER BOLT LENGTH & TORQUE
Bolt Length
INCH Lbs. (N.m)
A: 6 x 16 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)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ................................................................................................... 17 (24)
Balance Shaft Sprocket Bolt ..................................................................................... 33 (46)
Camshaft Sprocket Bolt ............................................................................................ 65 (90)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (108-127)
Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26)
Engine Mount-To-Engine Bolt/Nut (1990-92) ................................ ................. 36-47 (50-65)
Engine Mount-To-Engine Bolt/Nut (1993-99) ............................................................ 49 (67)
Engine Mount-To-Body Through-Bolt (1990-92) ........................... ................. 43-58 (60-80)
Engine Mount-To-Body Through-Bolt (1993-99) ........................................... 72-87 (98-118)
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)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 16: Installing Timing Belt Cover Bolts

MITSUBISHI

542

2.0L 4-Cylinder SOHC

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

2.0L 4-Cyl. SOHC

Lancer
2002-04 ..................................................... 3.1 Hours ... ..... T201
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles
except in California, Massachusetts 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
miles, unless previously changed.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove left undercover. Raise engine and transaxle
assembly until its weight is off front engine mount, and support securely.
Remove front engine mount and bracket.
2) Remove drive belts. Using Crankshaft Pulley Holder (MD998719) and
End Yoke Holder (MB990767), remove crankshaft pulley bolt. Remove
crankshaft pulley.
3) Remove generator belt tension adjustment bracket, power steering
pump bracket support and engine support bracket. See Fig. 1.
4) Disconnect crankshaft position sensor electrical connector. Remove
upper and lower timing belt covers.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Removing & Installing Timing Belt

MITSUBISHI

543

2.0L 4-Cylinder SOHC (Cont.)

CAUTION: Only rotate crankshaft clockwise.
5) Rotate crankshaft clockwise to align each timing mark and to set
cylinder No. 1 at TDC of compression stroke. See Fig. 2.
6) If timing belt is to be reused, mark rotation direction on belt. Loosen
tensioner bolt. Insert a Phillips screwdriver into tensioner arm hole, and
pry tensioner away from timing belt. Temporarily tighten tensioner bolt.
Remove flange and timing belt.
Inspection Inspect timing belt rubber backing for hardening or surface
cracks. Check for cracks or peeling of canvas, cracks on belt sides or
bottom of teeth. Check for abnormal wear on belt sides and teeth. Check
for missing teeth. Check tensioner pulley for smooth rotation without
noise or play.
Installation 1) Ensure timing marks are aligned. See Fig. 2. Install
timing belt on crankshaft sprocket, water pump sprocket, camshaft
sprocket, then tensioner.
CAUTION: DO NOT rotate crankshaft counterclockwise.
2) Loosen tensioner bolt 1/4 to 1/2 turn. Rotate crankshaft clockwise 2
revolutions. Ensure timing marks are still aligned and teeth in each
sprocket are engaged. Tighten tensioner bolt to specification. See
TORQUE SPECIFICATIONS.
3) To complete installation, reverse removal procedure. Tighten bolts
and nuts to specification. When tightening engine mount bolts, ensure
weight of engine is on vehicle body. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98)
Crankshaft Pulley Bolt 1 ................................................................ ......... 131-137 (178-186)
Engine Mount Bracket-To-Engine Mount Bolt .............................. ............... 49-75 (67-101)
Engine Mount Bracket-To-Engine Support Bracket Nut 2 ............ ................. 45-55 (60-74)
Engine Mount-To-Body Bolt 2 ........................................................ ................. 26-40 (34-54)
Engine Support Bracket Bolt ........................................................ ................. 32-40 (44-54)
Generator Belt Tension Adjustment Bracket Bolt ......................... ................. 16-18 (21-25)
Power Steering Pump Bracket Support Bolt ................................ ................. 32-40 (44-54)
Timing Belt Tensioner Bolt ............................................................ ................. 15-19 (21-25)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................. 72-106 (8-12)
1
2

Before installing, apply engine oil to threads and bolt flange.

Tighten with full weight of engine on vehicle body.

MITSUBISHI

544

2.4L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.4L 4-Cyl. DOHC

Galant
1994
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T168
Camshaft
Thru 5/94 ....................... 2 3.9 Hours .. .. TCK256 .. ..... T256
From 6/94 ...................... 2 3.9 Hours .. ...... ..... ...... ..... T230
1

Balance Shaft belt labor time included in

Camshaft belt labor time.
With Air Conditioning, add .4 hour.
With Power Steering, add .3 hour.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The 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. In California, replace timing
belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Timing Marks

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft
counterclockwise (as viewed from timing belt end of engine).
Removal 1) 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.
2) Remove drive belt tensioner. Remove upper and lower timing 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.
3) Remove rocker cover and semi-circular packing (located at rear of
rocker cover). Remove rubber plug. Rotate crankshaft 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.
4) Remove automatic tensioner. See Fig. 2. If timing belt is to be reused,
mark timing belt to indicate original direction of rotation. Remove timing
belt. Remove tensioner pulley, tensioner arm and idler pulley (if necessary). Inspect sprockets for damage.
5) 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.
6) Remove bolt, washer, crankshaft sprocket and flange. Note direction
of flange installation. Remove rear timing belt tensioner assembly.
Remove rear timing belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Holding Silent Shaft In Stationary Position

MITSUBISHI

545

2.4L 4-Cylinder DOHC (Cont.)

Inspection 1) Check belt teeth for damage and oil contamination.
Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is
not cracked, separated or showing canvas fiber. Inspect all sprockets for
damage. Check tensioner pulley and idler pulley for grease leakage and
roughness in rotation. Replace components if damaged.
2) 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 (11.9 mm).
3) 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 assembly if rod can be easily
pushed into automatic tensioner.

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. 8, Dimension A.
12) 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.
13) To complete installation, reverse removal procedure. Apply 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 proper tension.

NOTE: If 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 1) Align timing marks on silent shaft rear crankshaft
sprockets with timing marks on engine case.
2) Install rear timing belt and tensioner. Hold tensioner tightly against
belt while tightening bolts. To check tension, depress belt with finger
midway between sprockets. Deflection 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 hexagon
area of camshaft. See TORQUE SPECIFICATIONS. Install idler pulley.
3) 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. 4. Install a .055 (1.39 mm) diameter wire into holes.
Remove automatic tensioner from vise with wire attached.
4) 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.
5) When exhaust camshaft sprocket is released, camshaft 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.
6) 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 screwdriver. See Fig. 3. If screwdriver can be
inserted 2.36 (59.9 mm) or more, timing mark alignment is okay.
7) If screwdriver cannot be inserted at least 2.36 (59.9 mm), 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 camshaft sprocket. Use spring clip to hold belt on
sprocket. See Fig. 5.
8) Install wrench on both camshaft sprocket bolts. Install timing 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 pulley, oil
pump sprocket, crankshaft sprocket and tensioner pulley.
9) Remove both spring clips. Rotate tensioner pulley inward toward
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 access hole. Install plug. Remove wrench
from camshaft sprocket bolts.
10) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise,
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 lbs. (2.6 N.m)
on tensioner pulley. See Fig. 6. With torque applied to tensioner pulley,
tighten tensioner pulley center bolt to 35 ft. lbs. (48 N.m).
11) Install set screw in support bracket until set screw end contacts
tensioner arm. See Fig. 7. Rotate set screw further until wire can be
removed from automatic tensioner. Remove set screw. Rotate crankshaft clockwise 2 complete revolutions, and allow to remain in this

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Retracting Automatic Tensioner Rod

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Installing Timing Belt On Camshaft Sprockets

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Adjusting Timing Belt Tensioner Pulley

MITSUBISHI

546

2.4L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Measuring Timing Belt Adjustment

Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Auto Tensioner Bolt ....................................................................... ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ................................................................... ................. 14-22 (19-30)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Engine Support Bracket Bolt
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)
Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Rear Tensioner Retaining Bolt ........................................................................ 11-16 (15-22)
Silent Shaft Sprocket Bolt ............................................................. ................. 31-35 (42-47)
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)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 24-36 (3-4)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Measuring Automatic Tensioner Protrusion

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Installing Crankshaft Sprockets

MITSUBISHI

547

2.4L 4-Cylinder Lancer & Outlander

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. SOHC, VIN G

Lancer
2004 ........................................................... 3.1 Hours ... .....
Outlander
2003-04
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt (2003) ............................. 2.7 Hours ... .....
Camshaft Belt (2004) ............................. 2.7 Hours ... .....
1

T332

T168
T232
T332

Balance shaft belt labor time included in

camshaft belt labor time.
Balance shaft belt labor time included in
camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends replacing timing belt at 60,000 miles except
in California, Vermont and Maine. In these states, manufacturer recommends replacing timing belt at 100,000 miles. If timing belt was already
replaced at 60,000 miles, it is not required to be replaced at 100,000
miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: Do not remove tape securing Crankshaft Position (CKP)
sensor harness connector and control wiring harness, since control wiring harness may contact power steering pump pulley. See
Fig. 1.

2) Remove power steering oil pressure hose clamps. See Fig. 6.

Disconnect Crankshaft Position (CKP) sensor connector. Remove upper
timing belt cover and water pump pulley. Remove drive belt idler pulley.
Remove end cap and drive belt auto-tensioner. Remove lower timing
belt cover. Raise engine and transaxle assembly until its weight is off
front engine mount, and support securely. Remove engine front mounting bracket. See Fig. 7. Turn crankshaft clockwise, and align each timing
mark to set No. 1 cylinder to TDC of its compression stroke. See Fig. 8.
CAUTION: Adjusting Bolt (MD998738) can be gradually installed at
a rate of a 30-degree turn per second. If Adjusting Bolt (MD998738)
is screwed in all at once, timing belt tensioner adjuster rod will not
easily retract and adjusting bolt may bend.
3) Remove timing belt under cover rubber plug and install Adjusting Bolt
(MD998738). See Fig. 9. Screw in Adjusting Bolt (MD998738) until it
comes in contact with timing belt tensioner arm. See Fig. 10.
4) Gradually screw in Adjusting Bolt (MD998738) until timing belt
tensioner adjuster rod set hole A aligns with timing belt tensioner
adjustor cylinder set hole B. See Fig. 11. Insert a wire or pin through set
holes. See Fig. 12. Remove Adjusting Bolt (MD998738). Loosen timing
belt tensioner pulley mounting bolt, and remove timing belt.
Inspection (Timing Belt) Inspect timing belt for the following conditions:
Hardening of rubber backing (rubber backing will be glossy without
resilience and leave no indentation when pressing with fingernail).
Cracks on rubber back.
Cracks or peeling of canvas.
Cracks on bottom of ribs.
Cracks on belt sides.
If any of these conditions are present, replace timing belt.
Inspection (Timing Belt Tensioner Adjuster) 1) Check for oil leak
from timing belt tensioner adjuster seal, and replace it if leak is detected.
2) Check for wear or damage at tip of timing belt tensioner adjuster rod.
Replace as necessary.
3) Hold timing belt tensioner adjuster by hand, and press top end of rod
onto metal (e.g., cylinder block) under a pressure of 22-44 lbs. (10-20
kg) to measure movement of rod. Movement should be within 0.039
(1.00 mm) of length when it is free (not pressed) and length when it is
pressed. See Fig. 13. If measured value is not within standard value,
replace timing belt tensioner adjuster.
NOTE: After installing timing belt, apply reverse rotation (counterclockwise rotation) pressure to camshaft sprocket. Recheck to see
that each timing mark is in proper location while belt is tight.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Identifying Crankshaft Position Sensor Connector

Securing Tape
NOTE: If reusing timing belt, draw an arrow indicating rotating
direction (clockwise) on back of belt using chalk.
NOTE: Crankshaft drive sprocket may also be referred to as crankshaft camshaft sprocket.
Removal 1) Remove right side under cover (Outlander shown, Lancer
is similar). See Fig. 2. Using 1/2 drive ratchet, turn drive belt autotensioner counterclockwise until it hits stopper. Align hole A and hole
B of drive belt auto-tensioner. See Fig. 3. Insert an L-shaped hexagonal wrench through holes. See Fig. 4. This will fix drive belt autotensioner in place to allow drive belt removal. Remove crankshaft pulley.
See Fig. 5.

Installation 1) Ensure timing marks on camshaft, crankshaft drive and

engine oil pump sprockets are aligned. See Fig. 8.
2) Adjust timing mark of engine oil pump sprocket. Remove cylinder
block plug. See Fig. 14. Insert a M6 x 45 mm bolt into plug hole and
check. If bolt comes in contact with oil pump balancer shaft, turn oil
pump sprocket one rotation. Oil pump balancer shaft is gear driven off of
oil pump sprocket. Align timing mark and check to see bolt fits past oil
pump balancer shaft. DO NOT remove bolt until timing belt is
assembled.
3) Place timing belt on timing belt tensioner pulley and crankshaft drive
sprocket. See Fig. 15. Support timing belt with your hand so it does not
slide. Place timing belt on engine oil pump sprocket while pulling it with
your other hand. Place timing belt on timing belt idler pulley. Place timing
belt on camshaft sprocket.
4) Turn timing belt tensioner in direction shown using Tensioner Wrench
(MD998767) to apply tension to timing belt. See Fig. 16. Pre-tighten
timing belt tensioner pulley. Ensure timing marks are aligned. Remove
bolt installed in step 2). Reinstall cylinder block plug and tighten to
specification. See TORQUE SPECIFICATIONS. Adjust timing belt tension.
5) Install Adjusting Bolt (MD998738) used when removing timing belt.
See Fig. 9. Gradually screw in Adjusting Bolt (MD998738) until wire or
pin inserted in timing belt tensioner adjuster slightly moves.

MITSUBISHI

548

2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Removing Under Covers (Outlander)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Drive Belt Auto-Tensioner Holes

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Locking Drive Belt Auto-Tensioner Into Place

MITSUBISHI

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2.4L 4-Cylinder Lancer & Outlander (Cont.)

6) Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft in clockwise direction until you align each timing mark to set No. 1 cylinder to
TDC of its compression stroke.
7) Loosen timing belt tensioner pulley mounting bolt.
NOTE: When tightening timing belt tensioner pulley bolts, ensure
that timing belt tensioner pulley does not rotate with bolts. Allowing it to rotate with bolts can cause deficient tension of belt.

Courtesy of Mitsubishi Motor Sales of America.

8) With Tensioner Wrench (MD998767) and torque wrench, apply

tension torque of 31 INCH lbs. (3.5 N.m), and tighten timing belt
tensioner pulley bolt to specification. See Fig. 17. See TORQUE
SPECIFICATIONS. Remove wire or pin inserted into timing belt tensioner. See Fig. 12. Remove Adjusting Bolt (MD998738), and install
rubber plug to timing belt under cover. Rotate crankshaft clockwise 2
turns, and leave it for about 15 minutes.
9) Insert wire or pin removed in step 8) into set hole in timing belt
tensioner and ensure it can be pulled out easily. When wire or pin can be
easily removed, appropriate tension is applied on timing belt. In this
case, remove wire or pin. If projection of timing belt tensioner adjuster
rod is within standard value, appropriate tension is applied. See Fig. 18.
Standard value A should be 0.15-0.17 (3.8-4.5 mm). If wire or pin
cannot be easily pulled out, repeat steps 5)-8) to reach proper timing belt
tension.

Fig. 5: Removing Crankshaft Pulley

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Removing Timing Belt

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2.4L 4-Cylinder Lancer & Outlander (Cont.)

NOTE: Always check tightening torque of crankshaft pulley center
bolt after turning crankshaft pulley center bolt counterclockwise.
Retighten if it is loose.
10) Ensure timing marks on sprockets are aligned.
11) Install NEW drive belt auto-tensioner end cap. To complete installation, reverse removal procedures. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Installing Adjusting Bolt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Applying Pressure With Adjusting Bolt Against

Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Removing Engine Front Mounting Bracket

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Aligning Timing Belt Tensioner Adjuster Rod With Cylinder

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Timing Belt Aligning Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Identifying Timing Belt Tensioner Adjuster Wire Or Pin

MITSUBISHI

551

2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Checking Timing Belt Tensioner Rod Movement

Courtesy of Mitsubishi Motor Sales of America.

Fig. 16: Pre-Tightening Timing Belt Tensioner Pulley

Courtesy of Mitsubishi Motor Sales of America.

Fig. 17: Tightening Timing Belt Tensioner Pulley Bolt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 14: Identifying Oil Pump Balancer Shaft Cylinder Block Plug

Courtesy of Mitsubishi Motor Sales of America.

Fig. 18: Checking Timing Belt Tensioner Adjuster Rod Projection

Courtesy of Mitsubishi Motor Sales of America.

Fig. 15: Installing Timing Belt

MITSUBISHI

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2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 19: Removing Crankshaft Position Sensor

BALANCER TIMING BELT

NOTE: Before performing balancer timing belt removal procedure,
remove timing belt. See REMOVAL under TIMING BELT.
NOTE: Crankshaft drive sprocket may also be referred to as crankshaft camshaft sprocket.
NOTE: If reusing balancer timing belt, draw an arrow indicating
rotating direction (clockwise) on back of belt using chalk.
Removal 1) Disconnect Power Steering Pressure (PSP) switch and
A/C compressor harness connectors. See Fig. 19. Remove A/C compressor connector clamp. With hose connected, remove power steering
pump assembly from bracket. Remove power steering pump bracket.
Remove CKP sensor harness connector bracket and CKP sensor.
2) Hold crankshaft drive sprocket using Special Spanner (MB991367 or
MB991367-01) and 2 Pins (MB991385 or MIT217213). See Fig. 20.
Loosen crankshaft pulley center bolt, and remove crankshaft drive
sprocket. It may be necessary to use Crankshaft Sprocket Puller
(MD998778). See Fig. 21.
3) Remove crankshaft angle sensing ring.
4) Loosen center bolt on balancer timing belt tensioner pulley. Remove
balancer timing belt tensioner pulley. Remove balancer timing belt.
Inspection Inspect balancer belt for the following conditions:
Hardening of rubber backing (rubber backing will be glossy without
resilience and leave no indentation when pressing with fingernail).
Cracks on rubber back.
Cracks or peeling of canvas.
Cracks on bottom of ribs.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 20: Holding Crankshaft Drive Sprocket With Special Spanner

(MB991367 Or MB991367-01) & Pins (MB991385 Or
MIT217213)
Cracks on belt sides.
If any of these conditions are present, replace timing belt.
Installation (Without Scan Tool) 1) Ensure crankshaft balancer drive
sprocket and balancershaft sprocket timing marks are aligned. See
Fig. 22.
2) Install balancer timing belt on crankshaft balancer drive sprocket and
balancershaft sprocket. There should be no slack on tension side.
3) Loosely install balancer timing belt tensioner so that it is at top left
from center of assembling bolt. Ensure pulley flange is at front side of
engine.
4) Using your fingers, lift balancer timing belt tensioner in direction of
arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to
specification. See TORQUE SPECIFICATIONS.

MITSUBISHI

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2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 21: Removing Crankshaft Sprocket With Crankshaft

Sprocket Puller (MD998778)

Fig. 24: Checking Balancer Belt Deflection

5) Connect Belt Tension Meter Set (MB991668) to Scan Tool
(MB991502). Connect Battery Harness (MB991704) to scan tool. See
Fig. 25.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 22: Aligning Balancer Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 23: Installing Balancer Belt Tensioner

5) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing
marks are aligned.
6) Apply about 22 lbs. (10 kg) of pressure at center (arrow area)
between sprockets as shown. See Fig. 24. Ensure belt deflection is
.20-.27 (5-7 mm).
7) If not within specification, readjust balancer timing belt tension. If
measurement is within specification, go to CRANKSHAFT ANGLE
SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET.
Installation (With Scan Tool) 1) Ensure crankshaft balancer drive
sprocket and balancershaft sprocket timing marks are aligned. See
Fig. 22.
2) Install balancer timing belt on crankshaft balancer drive sprocket and
balancershaft sprocket. There should be no slack on tension side.
3) Loosely install balancer timing belt tensioner so that it is at top left
from center of assembling bolt. Ensure pulley flange is at front side of
engine.
4) Using your fingers, lift balancer timing belt tensioner in direction of
arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to
specification. See TORQUE SPECIFICATIONS.

Fig. 25: Identifying Scan Tool & Balancer Timing Belt Deflection
Measuring Components (MB991668, MB991502 &
MB991704)
6) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing
marks are aligned.
7) Select BELT TENSION on menu screen of scan tool.
8) Hold Belt Tension Meter Set (MB991668) to middle of balancer timing
belt between sprockets (at place indicated by arrow), about 0.40-0.78
(10-20 mm) away from rear surface of belt so that it is perpendicular to
belt (within an angle of 15 degrees). See Fig. 26.
9) While performing rest of test, ensure the following conditions are met:
Temperature of belt should be as close to normal as possible.
Do not allow contaminants such as water or oil to get into microphone.
If gusts of wind blow against microphone or if there are any loud
sources of noise nearby, values measured by microphone may not
correspond to actual values.
If microphone is touching belt while measurement is being made,
values measured by microphone may not correspond to actual
values.
10) Gently tap middle of balancer timing belt between sprockets (place
indicated by arrow) with your finger as shown in figure, and measure that
vibration frequency of belt is within 76-92 Hz. See Fig. 26.

554

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)
4) Clean screw hole of crankshaft.
5) Place larger chamfer side of crankshaft pulley washer in direction
shown and then assemble on crankshaft pulley center bolt. See Fig. 27.
6) Apply some engine oil to crankshaft pulley center bolt bearing surface
and screw.
7) Hold crankshaft drive sprocket using Special Spanner (MB991367 or
MB991367-01) and 2 Pins (MB991385 or MIT217213).
8) Tighten crankshaft pulley center bolt to specification. See TORQUE
SPECIFICATIONS.
9) After tightening crankshaft pulley center bolt to specification, go to
INSTALLATION under TIMING BELT.

TORQUE SPECIFICATIONS
Courtesy of Mitsubishi Motor Sales of America.

TORQUE SPECIFICATIONS
Fig. 26: Measuring Balancer Timing Belt Deflection With
Belt Tension Meter Set (MB991668)
11) If measurement is not with 76-92 Hz, readjust balancer timing belt.
If measurement is within specification, go to CRANKSHAFT ANGLE
SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET.

CRANKSHAFT ANGLE SENSING BLADE OR

CRANKSHAFT DRIVE SPROCKET
Installation 1) Degrease and clean crankshaft angle sensing blade
and crankshaft drive sprocket.
2) Degrease and clean crankshaft drive sprocket on installation side of
crankshaft.
3) Install crankshaft angle sensing blade and crankshaft drive sprocket
in direction shown. See Fig. 27.

Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84)
Balancer Timing Belt Tensioner Bolt ............................................ ................. 12-16 (16-22)
Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98)
Crankshaft Center Bolt 1 ......................................................................... 117-123 (157-167)
Crankshaft Pulley Bolt ................................................................... ................. 15-21 (20-28)
Cylinder Block Plug ....................................................................... ................. 21-25 (28-33)
Drive Belt Auto-Tensioner (Center Bolt)
Center Bolt .................................................................................. ................. 26-40 (34-54)
Except Center Bolt ...................................................................... ................. 13-18 (18-24)
Engine Mount-To-Body Bolt/Nut 2 ................................................. ................. 26-40 (34-54)
Engine Mount-To-Engine Mounting Bracket Nut .......................... ................. 49-55 (66-74)
Power Steering Pump Bracket Mounting Bolt ............................. ................. 29-43 (40-58)
Power Steering Pump Mounting Bolt ........................................... ................. 13-19 (18-20)
Timing Belt Idler Pulley Mounting Bolt ......................................... ................. 22-30 (29-41)
Timing Belt Tensioner Adjuster Mounting Bolt ............................. ................. 15-19 (20-26)
Timing Belt Tensioner Arm Mounting Bolt .................................... ................. 14-18 (17-24)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 33-39 (43-53)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ................................................... ............... 69-87 (7.8-9.8)
Crankshaft Position Sensor Harness Connector Mounting Bolt .. ............. 107-133 (13-15)
Power Steering Pressure Hose Clamp Mounting Bolt ................ ............... 80-132 (10-14)
Timing Belt Cover Bolt .................................................................. ............... 90-106 (10-12)
Water Pump Pulley Bolt ................................................................ ............... 69-87 (7.8-9.8)
Wiring Harness Mounting Bolt ...................................................... ............. 107-124 (13-15)
1
2

Courtesy of Mitsubishi Motor Sales of America.

Fig. 27: Preparing & Installing Crankshaft Angle Sensing Blade

Or Crankshaft Drive Sprocket

Before installing, apply engine oil to threads and bolt flange.

Tighten with full weight of engine on vehicle body.

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2.4L 4-Cylinder SOHC 1985-90 Galant & Van

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.4L 4-Cyl. SOHC

Galant
1985-87
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 2 2.7 Hrs. ... .. TCK124 .. .....
Van
1987-90
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... .....
Camshaft Belt ............... ... 2 3.2 Hrs. ... .. TCK124 .. .....
1

T159
T124

T159
T124

Balance shaft belt labor time included in

camshaft belt labor time.
With Air Conditioning, add .4 hours on Galant. With Air
Conditioning, add .7 hours on Van. With Power Steering, add .4
hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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 pressure, and secure tensioner toward
water pump.
2) 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 screwdriver to keep left silent shaft in position. See Figs. 1
and 2.
3) Remove 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. See Fig. 3.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Oil Pump Sprocket

Inspection 1) 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, peeling, cracking and rubber from
canvas also indicates belt warrants replacement. Cracks are most
evident at base of tooth.
2) 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 missing tooth warrant belt replacement.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Holding Silent Shaft In Stationary Position

Installation 1) 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 crankshaft sprocket and silent
shaft sprocket timing marks with corresponding marks on front case.
See Figs. 4 and 5.
2) Install timing belt B, ensuring tension side has no slack. Install
tensioner B so only light pressure is on belt. Ensure flange on
tensioner is mounted away from engine, and finger-tighten bolt.
3) 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.
4) Check belt tension by pressing center of tension side inward, using
index finger and measuring belt deflection. Deflection should be .20-.30
(5.0-7.0 mm). Readjust if not within specification.
5) 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. 1 and 2.
6) 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.
Install crankshaft sprocket. See Fig. 7 or 8.
7) With tensioner secured fully toward water pump, install timing 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.
8) Tighten slot-side bolt before tightening nut. Otherwise, tension
bracket will turn and belt will be over-tensioned. Ensure all timing marks
are in correct alignment. Remove 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.
9) 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.

MITSUBISHI

556

2.4L 4-Cylinder SOHC 1985-90 Galant & Van (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Exploded View Of Timing Belt Components

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Rear Timing Belt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks For Timing Belt B

MITSUBISHI

557

2.4L 4-Cylinder SOHC 1985-90 Galant & Van (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Checking Timing Belt A Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Aligning Camshaft Timing Marks

Application
Ft. Lbs. (N.m)
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ................................................................... ................. 14-22 (19-30)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Engine Support Bracket Bolt
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)
Timing Belt Tensioner Nut
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)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Installing Crankshaft Sprockets (Galant)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Installing Crankshaft Sprockets (Van)

Timing Belt Cover Bolt .................................................................. ................. 22-29 (30-39)

Valve Cover Bolt ........................................................................... ................. 84-108 (9-12)
Water Pump Pulley Bolt ................................................................ ..................... 48-60 (5-7)

MITSUBISHI

558

2.4L 4-Cylinder
SOHC, VIN G Except Outlander & Lancer
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. SOHC

Eclipse
1996-99
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ....................................... 2 3.0 Hours .. .....
2000-03
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ....................................... 2 2.7 Hours .. .....
2004
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ....................................... 2 2.7 Hours .. .....
Galant
1994-98
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ....................................... 2 2.7 Hours .. .....
1999-03
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ........................................ 3.1 Hours ... .....
2004
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ........................................ 3.1 Hours ... .....
Montero Sport
1997-99
Balance Shaft Belt .............................. .......... 1 .......... .....
Camshaft Belt ....................................... 2 2.2 Hours .. .....
1

T168
T230
T168
T232
T168
T332

T168
T230
T168
T232
T168
T332

T168
T230

Balance shaft belt labor time included in

camshaft belt labor time.
With Air Conditioning, add .4 hour for 1994-98 Galant and
1997-99 Montero Sport. With Air Conditioning, add .1 hour for
1996-99 Eclipse. With Power Steering, add .3 hour for 1994-98
Galant.

NOTE: Engine VIN is eighth character of vehicle VIN.

NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1994-96 and 2001 models, the 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. In
California, replace timing belt at 100,000 miles, unless previously
changed.
For 1997-00 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.
For 2002-04 models, the manufacturer recommends the belt be
replaced every 60,000 miles except in California, Massachusetts, Maine
and Vermont. In California, Massachusetts, Maine and Vermont, timing
belt replacement is recommended, but not required, at 60,000 miles. In
these states, replace timing belt at 100,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Eclipse & Galant) 1) Raise and support vehicle. Remove
engine splash shield from right side wheelwell.
2) Lower vehicle. Support weight of engine with floor jack. If necessary,
remove coolant reservoir. Remove upper engine mount located near
timing belt cover. Remove all drive belts. If necessary, remove drive belt
tensioner pulley bracket and power steering pump pulley. See Fig. 1.
Remove water pump pulley.
3) Remove crankshaft pulley. Noting bolt lengths and locations, remove
upper and lower timing belt cover with gasket.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Eclipse & Galant)

MITSUBISHI

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2.4L 4-Cylinder
SOHC, VIN G Except Outlander & Lancer (Cont.)
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed
from timing belt end of engine). If timing belt is to be reused, mark
direction of rotation before removing.
4) 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 timing mark on cylinder head. See
Fig. 2.
5) Loosen timing belt tensioner center bolt, and move tensioner pulley
toward water pump. Tighten center bolt to secure tensioner. Remove
front timing belt. Remove tensioner pulley and timing belt auto tensioner.
6) To remove balance shaft 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.
7) If reusing old balance shaft timing belt, mark belt with arrow to
indicate rotation direction. Holding crankshaft stationary, remove front
crankshaft sprocket bolt. Use gear puller to remove crankshaft sprocket
from crankshaft.
8) Noting direction of installation, remove crankshaft sensing blade.
Loosen balance shaft tensioner pulley center bolt. Remove balance
shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION.

Installation (Eclipse & Galant) 1) Align crankshaft rear sprocket and

balance shaft sprocket timing marks. See Fig. 4. Install balance shaft
timing belt. Ensure there is no slack in belt. If reusing old belt, install in
original direction of rotation.
2) Install crankshaft sensing blade in correct direction. See Fig. 6. Install
crankshaft sprocket. Apply engine oil to threads of crankshaft sprocket
bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS.
3) 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. 5. The tensioner pulley flange should face toward
the front of the engine.
CAUTION: When tightening balance shaft tensioner pulley center
bolt, ensure tensioner pulley shaft does not rotate with bolt. This
will place excessive tension on bolt.
4) Using your hand, place pressure on balance shaft tensioner pulley in
direction of balance shaft timing belt. Loosen balance shaft tensioner
pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and
tighten balance shaft tensioner pulley center bolt.
5) Press balance shaft belt on side opposite tensioner to check belt
deflection. See Fig. 4. Balance shaft belt deflection should be .20-.28
(5.0-7.0 mm). Adjust as necessary.
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed.
6) 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. Install tensioner pulley.
7) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt
on crankshaft sprocket, oil pump sprocket, then camshaft sprocket. 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.
8) Set the timing belt tensioner pulley so that pin holes are at the bottom
of the pulley. See Fig. 7. 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Front Timing Belt Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Locking Balance Shaft

9) Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7.
Screw in set screw by hand until tensioner bracket arm makes contact
with auto tensioner push rod end.
10) Remove Phillips screwdriver from engine block and install plug. To
adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned.
11) Loosen the tensioner pulley center bolt. Install Adapter (MD998767)
and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs.
(3.5 N.m) of torque while tightening tensioner pulley center bolt to
specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner
pulley turn while tightening center bolt.
12) Remove locking pin from auto tensioner. Remove set screw.
13) 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.
14) Install timing belt covers. Ensure bolts are installed in original
locations. See Fig. 9. Continue installation in reverse order of removal
procedure. Adjust drive belts to proper tension.
Removal (Montero Sport) 1) 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.

MITSUBISHI

560

2.4L 4-Cylinder
SOHC, VIN G Except Outlander & Lancer (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Adjusting Timing Belt Tension

Fig. 4: Aligning Balance Shaft Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Balance Shaft Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Timing Belt Cover Bolt Installation Locations

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Crankshaft Sensing Blade (Eclipse & Galant)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Installing Set Screw On Tensioner Pulley

CAUTION: Never rotate crankshaft counterclockwise.
2) Rotate crankshaft clockwise so that No. 1 piston is at TDC of
compression stroke. Leaving secondary wires attached, remove distributor cap and set aside.
3) Note installed position of distributor and distributor rotor. Unplug
distributor electrical connector. Remove distributor housing and set
aside.

4) Disconnect ignition power transistor and ignition coil connector.

Remove ignition coil. Remove timing belt upper cover.
5) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
crankshaft pulley. Remove distributor bracket. See Fig. 10.
6) Remove timing belt lower cover. Align timing mark on camshaft
sprocket with timing mark on cylinder head. See Fig. 2.
7) 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.
8) 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.
9) If reusing old balance shaft timing belt, mark belt with arrow to
indicate rotation direction. Loosen balance shaft tensioner pulley center
bolt. Remove balance shaft timing belt. Inspect timing belt. See TIMING
BELT INSPECTION.
Installation (Montero Sport) 1) Align crankshaft sprocket and
balance shaft sprocket timing marks. See Fig. 4. Install balance shaft
timing belt. If reusing old belt, install in original direction of rotation.
2) 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. 5. The tensioner pulley flange should face toward
the front of the engine.
3) Using your hand, place pressure on balance shaft tensioner pulley in
direction of balance shaft timing belt. Loosen balance shaft tensioner
pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and
tighten balance shaft tensioner pulley center bolt.

MITSUBISHI

561

2.4L 4-Cylinder
SOHC, VIN G Except Outlander & Lancer (Cont.)
12) 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. 11, Dimension A. Protrusion should be .150-.177
(3.8-4.5 mm). If protrusion is not as specified, repeat timing belt
tensioning procedure.
13) Install timing belt lower cover, distributor bracket, and timing belt
upper cover. Install distributor, distributor cap, and ignition coil.
14) Install cooling fan clutch, pulley, fan shroud, and upper radiator
hose. Continue installation in reverse order of removal procedure. Fill
and bleed cooling system. Adjust ignition timing.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Timing Belt & Components

(Montero Sport)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Measuring Timing Belt Auto Tensioner Protrusion

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.
4) Press balance shaft belt on side opposite tensioner to check belt
deflection. See Fig. 4. Balance shaft belt deflection should be .20-.28
(5.0-7.0 mm). Adjust as necessary.
5) 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.
6) Ensure all timing marks are still aligned. See Fig. 2. Install 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.
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed.

TIMING BELT INSPECTION

1) 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, cracking rubber from canvas also
indicates that belt should be replaced. Cracks are most evident at base
of tooth.
2) 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 missing tooth warrant belt replacement.
3) Check timing belt and balance shaft belt tensioner pulleys for worn
bearings. Replace as necessary.
4) Check timing belt auto tensioner for leaks. Hold timing belt auto
tensioner upright. Measure rod protrusion above edge of housing. See
Fig. 12. Length should be .47 (12 mm). 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.

7) Set the timing belt tensioner pulley so that pin holes are at the bottom
of the pulley. See Fig. 7. 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.
8) Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7.
Screw in set screw until tensioner bracket arm makes contact with auto
tensioner push rod end.
9) Remove Phillips screwdriver from engine block and install plug. To
adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned.
10) Loosen the tensioner pulley center bolt. Install Adapter (MD998767)
and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs.
(3.5 N.m) of torque while tightening tensioner pulley center bolt to
specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner
pulley turn while tightening center bolt.
11) Remove locking pin from auto tensioner. Remove set screw.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Inspecting Timing Belt Auto Tensioner

MITSUBISHI

562

2.4L 4-Cylinder
SOHC, VIN G Except Outlander & Lancer (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ECLIPSE & GALANT)

TORQUE SPECIFICATIONS (MONTERO SPORT)

Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ................................................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24)
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
Eclipse (2000-03) ...................................................................... ................. 56-72 (74-98)
Galant (1999-03) ................................................................................................... 63 (86)
All Other Models ................................................................................................... 49 (67)
Mount-To-Body Through-Bolt
Eclipse (2000-03) ...................................................................... ................. 51-69 (69-93)
Galant (1999-03) ................................................................................................... 60 (81)
All Other Models ....................................................................................... 71-85 (98-118)
Power Steering Pump Pulley Bolt ............................................................................ 45 (61)
Tensioner Pulley Center Bolt
Balance Shaft Belt Pulley ....................................................................................... 14 (19)
Camshaft Belt Pulley ............................................................................................... 35 (48)
Water Pump Bolt ....................................................................................................... 10 (14)

Application
Ft. Lbs. (N.m)
Auto Tensioner Bolt ................................................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (90)
Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24)
Distributor Bracket Bolt
Except M6 x 18 mm ................................................................... ..................................... 1
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)

Timing Belt Cover Bolt
6-mm (Except Flange Bolts) .................................................................................. 78 (8.8)
6-mm (Flange Bolt) ..................................................................... ............... 89-106 (10-12)
8-mm Bolt .............................................................................................................. 120 (14)
Water Pump Pulley Bolt ................................................................ ..................... 71-80 (8-9)
1

Apply engine oil to bolt threads.

INCH Lbs. (N.m)

Cooling Fan Clutch-To-Stud Nut ................................................... ............... 89-106 (10-12)
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)
1

Tighten bolt to 97 INCH lbs. (11 N.m).

MITSUBISHI

563

3.0L V6 SOHC, 12-Valve Engine

TIMING BELT APPLICATION
Application

Labor Time

3.0L V6 SOHC
Diamante
1992-96 ............................ ...
Galant Sigma
1988-90 ............................ ...
Montero (12-Valve Engine)
1989-91 ............................ ...
1992-94 ............................ ...
Pickup (4WD)
1990-94 ............................ ...
Sigma
1989-90 ............................ ...
3000GT
1997-99 ............................ ...
1

Component
Belt
Kit No.
Part No.

3.8 Hrs. ... .. TCK139 .. ..... T139

3.8 Hrs. ... .. TCK139 .. ..... T139

2
1

3.5 Hrs. ... .. TCK139 .. ..... T139

3.5 Hrs. ... .. TCK139 .. ..... T139

3.5 Hrs. ... .. TCK139 .. ..... T139

3.8 Hrs. ... .. TCK139 .. ..... T139

3.5 Hrs. ... .. TCK139 .. ..... T139

With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.
With Air Conditioning, add .5 hours.
With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1988-93 models, the manufacturer recommends the belt be
replaced at 60,000 miles.
For 1994-96 models, the 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. In
California, replace timing belt at 100,000 miles, unless previously
changed.
For 1997-99 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, unless previously
changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Removing & Installing Engine Support Bracket

REMOVAL & INSTALLATION

TIMING BELT REMOVAL
Removal (Diamante) 1) 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.
2) Remove engine mount bracket bolts in sequence. Lubricate reamer
bolt with penetrating oil before and during removal. See Fig. 1. Remove
power steering pump, leaving hoses attached. On 1996 models, remove
crankshaft position sensor and right oxygen sensor. Remove crankshaft
pulley. On vehicles with ABS, remove overflow tank and bracket.
3) On all models, remove engine support bracket. Remove crankshaft
pulley. Remove timing belt covers. Remove flange from crankshaft. See
Fig. 2. Rotate crankshaft to align all timing marks. See Figs. 3 and 4.
Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to
release belt tension.
4) If reusing timing belt, mark belt to indicate direction of belt rotation.
Loosen tensioner bolt. Pry tensioner counterclockwise to relieve belt
tension. While holding tensioner, tighten tensioner bolt. Remove timing
belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View of Timing Belt & Components

Removal (Galant) 1) Disconnect negative battery cable. Remove all
accessory 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.

MITSUBISHI

564

3.0L V6 SOHC, 12-Valve Engine (Cont.)

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, remove 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.
4) Remove flange. See Fig. 2. Rotate crankshaft and align all timing
marks. See Figs. 3 and 4. Loosen belt tensioner bolt, and rotate belt
tensioner counterclockwise to release belt tension.
5) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt and belt tensioner.
Removal (Sigma) 1) Disconnect negative battery cable. Remove all
accessory 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.
Courtesy of DaimlerChrysler Corp.

Fig. 3: Locating Timing Belt & Sprocket

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks

CAUTION: Apply spray lubricant on reamer bolt during removal, as
bolt is sometimes seized in engine support.
2) 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. 1.
3) Remove A/C tensioner pulley and mounting bracket. Remove No. 1
upper outer cover and gaskets. See Fig. 2. Remove engine support
bracket bolts in proper sequence. See Fig. 1. Remove engine support
bracket.
4) Remove cover cap and No. 2 upper outer cover and gaskets. Remove
under cover. Using Holder (MB990767-01) and Adapter Bolts
(MD998719) or equivalent, remove crankshaft pulley.
5) Remove lower outer cover, gaskets and flange. See Fig. 2. Rotate
crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt
tensioner bolt, and rotate belt tensioner counterclockwise to release belt
tension.
6) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt and belt tensioner.
Removal (Montero & Pickup) 1) Disconnect negative battery cable.
Drain cooling system. Disconnect upper radiator hose. Remove upper
radiator shroud. Remove cooling fan and fan clutch assembly. Remove
cooling fan pulley. Remove all accessory drive belts. Remove power
steering pump with pressure and return hoses connected and set aside.
2) Remove power steering pump brackets. Remove A/C tensioner pulley
and mounting bracket. Remove A/C compressor with hoses connected
and mounting bracket. Remove cooling fan bracket assembly. Remove
timing belt No. 1 upper outer cover and gaskets. See Fig. 2.

2) Remove A/C tensioner pulley and mounting bracket. Remove timing

belt No. 1 upper outer cover and gaskets. See Fig. 2. Remove engine
support bracket bolts in proper sequence. See Fig. 1. Remove engine
support bracket.
3) Remove cover cap and timing belt No. 2 upper outer cover and
gaskets. Remove under cover. Using Holder (MB990767-01) and
Adapter Bolts (MD998719) or equivalent, remove crankshaft pulley.
4) Remove lower outer cover, gaskets and flange. See Fig. 2. Rotate
crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt
tensioner bolt, and rotate belt tensioner counterclockwise to release belt
tension. If timing belt is to be reused, place arrow on belt to indicate
rotation direction.
Removal (3000GT) 1) Remove engine lower splash shields. Remove
cruise control actuator (if equipped) from right side fenderwell.
2) Remove all drive belts. Remove A/C drive belt tensioner pulley
assembly. Remove power steering and generator drive belt tensioner
pulley bracket.
3) Place floor jack under engine to support weight of engine. Remove
engine-to-body mount from timing belt end of engine.
4) Unplug power steering pump pressure switch electrical connector.
Remove power steering pump with hoses attached, and set out of way.
CAUTION: Reamer bolt may be heat-seized to engine support
bracket. Reamer bolt has R marking on bolt head.
5) Remove engine support bracket bolts, in specified sequence, from
front of engine. See Fig. 1. Note position of reamer bolt for reassembly
reference.
6) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
crankshaft pulley.
7) Remove all timing belt covers. Noting position for reassembly
reference, remove front flange from crankshaft. See Fig. 5.
8) Rotate crankshaft to align all timing marks. See Figs. 3 and 4. Loosen
belt tensioner bolt. Rotate belt tensioner pulley counterclockwise to
relieve belt tension. Tighten tensioner pulley bolt.
9) If reusing timing belt, place arrow on belt to indicate belt running
direction. Remove timing belt.

TIMING BELT INSPECTION

All Models 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
parts, if defective.

TIMING BELT INSTALLATION

Installation (Diamante) 1) 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

MITSUBISHI

565

3.0L V6 SOHC, 12-Valve Engine (Cont.)

3) Install timing belt. Ensure belt is installed in original direction of
rotation and all timing marks are aligned. Install flange on crankshaft.
Loosen belt tensioner bolts slightly, and allow tensioner to apply belt
tension.
4) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign
all timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt
tension half way between crankshaft sprocket and camshaft sprocket on
side opposite belt tensioner.
CAUTION: Engine support bracket reamer bolt must be tightened
slowly while spraying lubricant on bolt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Exploded View Of Timing Belt & Components

(3000GT SOHC)
sprocket, and tensioner. Apply torque to rear camshaft pulley to tighten
belt. Ensure all timing marks are aligned.
2) Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and
allow tensioner to apply belt tension. Using Crankshaft Socket
(MD998716-01) or equivalent, rotate crankshaft 2 revolutions clockwise.
DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt
tensioner bolts to specification. See TORQUE SPECIFICATIONS. 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 lbs. (20-30 kg).
3) Install proper length bolts in timing belt covers. See Fig. 6. Tighten all
bolts and nuts to specification. See TORQUE SPECIFICATIONS.
NOTE: Engine support bracket reamer bolt must be tightened
slowly while spraying lubricant on bolt.
4) Install engine support bracket and tighten bolts in sequence. See
Fig. 1. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Identifying Timing Belt Cover Bolt Lengths

(Diamante, Galant & Sigma)
Installation (Galant) 1) 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.
2) 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 Figs. 3 and 4.

5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining

components, reverse removal procedure. Install proper length bolts in
timing belt covers and engine support bracket. See Figs. 1 and 6.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust
drive belts to proper tension.
Installation (Montero & Pickup) 1) 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.
2) 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 Figs. 3 and 4.
3) Install timing belt on crankshaft sprocket and then left camshaft
sprocket with all slack removed from tension side of belt. Route timing
belt onto water pump pulley, right camshaft sprocket and tensioner.
Remove any slack from belt by rotating left and then right camshaft
sprockets counterclockwise. Ensure all timing marks are aligned. Install
flange on crankshaft. Loosen belt tensioner bolts slightly, and allow
tensioner to apply belt tension.
4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions
clockwise. DO NOT rotate counterclockwise. Realign all timing marks.
Tighten belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway
between crankshaft sprocket and camshaft sprocket on side opposite
belt tensioner.
5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining
components, reverse removal procedure. Install proper length bolts in
timing belt covers. See Fig. 7. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
CAUTION: 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.
6) 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).
7) Start engine and run to normal operating temperature. Race engine to
3000 RPM several times. Stop engine. After engine cools, refill radiator.
Installation (Sigma) 1) 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.
2) 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 Figs. 3 and 4.
3) Install timing belt on crankshaft sprocket, rear head camshaft
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.

MITSUBISHI

566

3.0L V6 SOHC, 12-Valve Engine (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Timing Belt Cover Bolt Lengths (3000GT)

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS (DIAMANTE)

Fig. 7: Identifying Timing Belt Cover Bolt Lengths
(Montero & Pickup)
4) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign
all timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt
tension halfway between crankshaft sprocket and camshaft sprocket on
side opposite belt tensioner.
5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining
components, reverse removal procedure. Install proper length bolts in
timing belt covers. See Fig. 6.

Application
Ft. Lbs. (N.m)
Automatic Tensioner Bolt .......................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Pulley Bolt
1991 ....................................................................................................... 108-116 (146-157)
1992-96 ................................................................................................................ 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)
Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49)
Water Pump Bolt ....................................................................................................... 17 (23)

NOTE: Engine support bracket reamer bolt must be tightened

slowly while spraying lubricant on bolt.

Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)

6) Install engine support bracket. Tighten bolts in sequence to specification. See Fig. 1. See TORQUE SPECIFICATIONS. Adjust drive belts
to proper tension.
Installation (3000GT) 1) Ensure all timing belt marks are aligned. See
Figs. 3 and 4. If not already done, loosen tensioner center bolt. Turn
tensioner counterclockwise. Temporarily tighten tensioner center bolt.
2) Install timing belt on crankshaft sprocket, left hand camshaft sprocket
(side away from tensioner pulley), water pump pulley, right hand
camshaft sprocket, and timing belt tensioner. Apply counterclockwise
force to right hand camshaft sprocket (camshaft closest to firewall) to
remove any belt slack. Ensure all timing marks are still aligned.
3) 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.
4) 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 pulley). Belt tension should be 46.3-68.3 lbs.
(21-31 kg).
5) Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and
allow tensioner to apply belt tension.
6) 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.
7) Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install engine support bracket
on engine block. Install bolts in correct location, and tighten in sequence.
See Fig. 1.
8) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

INCH Lbs. (N.m)

TORQUE SPECIFICATIONS (GALANT)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ............................................................................. 108-116 (146-157)
Engine Support Bracket Bolt
10 X 40 mm ................................................................................ ................. 25-36 (34-49)
10 X 53 mm ................................................................................ ................. 47-54 (64-73)
12 X 56 mm .............................................................................................. 76-83 (103-113)
Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29)
Water Pump Bolt ........................................................................... ................. 14-19 (19-26)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)
TORQUE SPECIFICATIONS (MONTERO & PICKUP)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt
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)
Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29)
Water Pump Bolt ........................................................................... ................. 14-20 (19-27)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)

MITSUBISHI

567

3.0L V6 SOHC, 12-Valve Engine (Cont.)

TORQUE SPECIFICATIONS (SIGMA)

TORQUE SPECIFICATIONS (3000GT)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
Crankshaft Pulley Bolt ............................................................................. 110-118 (150-160)
Engine Mount Bracket Nut ............................................................ ................. 44-57 (60-77)
Engine Support Bracket Bolt
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)
Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29)
Water Pump Bolt ........................................................................... ................. 14-20 (19-27)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Pulley Bolt ............................................................................. 108-116 (150-160)
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)

Timing Belt Cover Bolt .................................................................. ............... 90-102 (10-12)

INCH Lbs. (N.m)

Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
1

Spray lubricant on reamer bolt while tightening.

MITSUBISHI

568

3.0L V6 SOHC, 24-Valve Engine

Component
Belt
Kit No.
Part No.

4) Remove power steering pump belt tensioner. See Fig. 1. Remove

upper and lower timing belt covers. Remove engine support bracket
from front of engine.

3.0 Hours .. .. TCK259 .. ..... T259

CAUTION: Always turn crankshaft in clockwise direction (as

viewed from front of engine).

3.0 Hours .. .. TCK259 .. ..... T259

3.4 Hours .. .. TCK259 .. ..... T259

2.8 Hours .. .. TCK259 .. ..... T259

2.8 Hours .. ...... ..... ...... ..... T259

TIMING BELT APPLICATION

Application
3.0L V6 SOHC
Eclipse
2000-04 ..............................
Galant
1999-03 ..............................
Montero (24-Valve Engine)
1995-96 ..............................
Montero Sport
1997-02 ..............................
2003 ...................................
1
2

Labor Time

5) If timing belt is to be reused, place arrow on belt to indicate 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 timing belt. Remove timing belt autotensioner from engine block.

With Air Conditioning, add .3 hours for Montero Sport.

With Air Conditioning, add .4 hours for Montero.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1995-96 and 2001 Eclipse and Galant models, the 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. In California, replace timing belt at 100,000
miles, unless previously changed.
For 1997-00 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, unless previously
changed.
For 2002-04 Eclipse and 2002-03 Galant models, the manufacturer
recommends the belt be replaced every 60,000 miles except in California, Massachusetts, Maine and Vermont. In California, Massachusetts,
Maine and Vermont, timing belt replacement is recommended, but not
required, at 60,000 miles. In these states, replace timing belt at 100,000
miles.
For 2001-03 Montero Sport 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, unless
previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components

(Eclipse & Galant)

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Eclipse & Galant) 1) Disconnect negative battery cable.
Raise and support vehicle. Remove engine splash shield from right
wheelwell.
2) 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 steering pump drive belt.
3) Lower vehicle. Support weight of engine with jack. Remove engine
mount from timing belt end of engine. Using Tensioner Wrench
(MB990767) and Crankshaft Pulley Holder Pin (MD998715), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove
crankshaft pulley.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner)

Removal (Montero & Montero Sport) 1) Disconnect negative battery
cable. Drain cooling system. Disconnect upper radiator hose from
engine. Remove upper radiator shroud. Loosen cooling fan clutch-topulley nuts. Relieve tension on accessory drive belts.

MITSUBISHI

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3.0L V6 SOHC, 24-Valve Engine (Cont.)

2) Remove cooling fan and fan clutch assembly. Remove cooling fan
pulley. Remove all accessory drive belts. Remove generator with wires
attached, and secure out of way.
3) 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 timing indicator bracket. Remove
accessory mount assembly. See Fig. 3.
4) Remove upper timing belt upper cover. See Fig. 4. Using Crankshaft
Pulley Holder Pin (MD998715) and End Yoke Holder (MD990767) hold
crankshaft pulley stationary and remove crankshaft pulley bolt. Remove
crankshaft pulley.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
5) Remove lower timing belt cover. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner
pulley center bolt.
6) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Exploded View Of Timing Belt & Components

(Montero & Montero Sport)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Exploded View Of Accessory Mount Assembly

(Montero & Montero Sport)
Inspection (All Models) 1) 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 pulley for
smooth rotation. Replace if defective.
2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner 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.
Installation (Eclipse & Galant) 1) Place auto-tensioner in soft-jawed
vise to SLOWLY compress 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.
2) 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.

Fig. 5: Checking Timing Belt Auto-Tensioner Movement

WARNING: Right bank camshaft can turn easily due to applied
spring force, so keep fingers out of the way.
3) Ensure all timing marks are still aligned. See Fig. 2. Install 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.
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
Socket Wrench (MD998767), rotate tensioner pulley against timing belt.
Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
aligned.
5) For 1999-00 models, loosen tensioner pulley center bolt. Position
tensioner pin holes at BOTTOM of tensioner. Install Tensioner Pulley
Socket Wrench (MD998767) on tensioner pulley. See Fig. 6. Use 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. See TORQUE SPECIFICATIONS.
6) For 2001 and later models, loosen tensioner pulley center bolt.
Position tensioner pin holes at TOP of tensioner. Install Tensioner Pulley
Socket Wrench (MD998767) on tensioner pulley. See Fig. 7. Use a

570

MITSUBISHI
3.0L V6 SOHC, 24-Valve Engine (Cont.)

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 stationary. See TORQUE SPECIFICATIONS.
7) On all models, remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate
counterclockwise.
8) 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 timing belt tensioning procedure.
9) Install engine support bracket on engine block. Tighten top bolt first,
then working in a counterclockwise direction, tighten the remaining
bolts. See Fig. 8. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt, then tighten bolt to specification. See TORQUE SPECIFICATIONS.
10) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse & Galant;

1995-03 Montero & Montero Sport)

Installation (Montero & Montero Sport) 1) Place auto-tensioner in

soft-jawed vise to SLOWLY compress 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.
2) 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.
WARNING: Right bank camshaft can turn easily due to applied
spring force, so keep fingers out of the way.
3) Ensure all timing marks are still aligned. See Fig. 2. Install 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.
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
Socket Wrench (MD998767), rotate tensioner pulley against timing belt.
Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
aligned.
5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
bottom of tensioner. Install Tensioner Pulley Socket Wrench
(MD998767) on tensioner pulley. See Fig. 6. Using torque wrench, 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. See TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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 timing belt tensioning procedure.
8) Install timing belt covers. Install crankshaft pulley. Install accessory
mount assembly on front of engine. To install remaining components,
reverse removal procedure. Adjust drive belts to proper tension.
CAUTION: 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Adjusting Timing Belt Tension (2001-04 Eclipse &

2001-03 Galant)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Engine Support Bracket Tightening Sequence

(Eclipse & Galant)

9) 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).
10) Start engine and run to normal operating temperature. Race engine
to 3000 RPM several times. Stop engine. After engine cools, refill
radiator.

MITSUBISHI

571

3.0L V6 SOHC, 24-Valve Engine (Cont.)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (MONTERO & MONTERO SPORT)

TORQUE SPECIFICATIONS (ECLIPSE & GALANT)

Application
Ft. Lbs. (N.m)
Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
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 ................................................................... 33 (44)
Generator Pivot Bolt .................................................................................................. 33 (44)
Generator Top Bolt .................................................................................................... 15 (21)
Power Steering Pump Belt Tensioner Bolt ............................................................... 33 (44)
Timing Belt Tensioner Center Bolt ............................................................................ 35 (48)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Water Pump Bolt
M8 Bolt .................................................................................................................... 17 (23)
M10 Bolt .................................................................................................................. 30 (41)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ............................................................................................ 106 (12)
1
2

Apply engine oil to bolt threads before installation.

Final tighten bolt with full weight of engine on mount.

Application
Ft. Lbs. (N.m)
Accessory Mount Assembly Bolt
12 x 100 Bolt ........................................................................................................... 54 (74)
All Other Bolts ......................................................................................................... 33 (44)
Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Pulley Bolt ......................................................................................... 1 134 (181)
Generator ................................................................................................................... 16 (22)
M8 Bolt .................................................................................................................... 15 (21)
M10 Bolt .................................................................................................................. 30 (51)
Power Steering Pump Bolt
1995-96 ........................................................................................ ................. 29-33 (39-44)
1997-03 .................................................................................................................... 17 (24)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Timing Belt Tensioner Center Bolt ............................................................................ 35 (48)
Water Pump Bolt ....................................................................................................... 18 (24)
INCH Lbs. (N.m)
Cooling Fan Clutch-to-Pulley Nut ................................................. ............... 89-106 (10-12)
Power Steering Pump Cover Bolt .............................................................................. 43 (5)
Radiator Shroud Bolt ................................................................................................... 43 (5)
Timing Belt Cover Bolt
M6 Bolt .................................................................................................................... 97 (11)
M8 Bolt .................................................................................................................. 117 (13)
Timing Indicator Bracket Bolt .................................................................................... 97 (11)
1

Apply engine oil to bolt threads before installation.

MITSUBISHI

572

3.5L V6 DOHC
TIMING BELT APPLICATION
Application
3.5L V6
Montero
1994-96 ....................................................
1

Labor Time

Belt
Part No.

4.4 Hours .. ..... T253

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION

Courtesy of Mitsubishi Motor Sales of America.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 1: Exploded View Of Accessory Mount Components

TIMING BELT
NOTE: Ensure timing marks are aligned. Mark timing belt direction
of rotation.
Removal 1) Disconnect negative battery cable. Drain engine coolant.
Remove engine coolant reservoir tank, fan shroud and radiator.
2) Remove generator with wires attached, and secure out of way.
Remove battery and battery tray. Remove engine lower splash shields.
3) Remove accessory drive belts. Remove cooling fan clutch assembly.
See Fig. 1. Remove cooling fan pulley. Remove A/C compressor with
hoses attached, and secure out of way. Remove A/C compressor
bracket.
4) Remove power steering pump mount cover. Remove power steering
pump with hoses attached, and secure out of way. Remove accessory
mount. See Fig. 1.
5) Remove timing belt upper cover. See Fig. 2. Disconnect crankshaft
position sensor connector. Using Holder (MB990767) and Bolts
(MB998754) or equivalent, hold crankshaft stationary while remove
crankshaft pulley center bolt.
6) If reusing timing belt, place arrow on belt to indicate running direction.
Rotate crankshaft to align all timing marks. See Fig. 3. Loosen timing
belt tensioner center bolt. Remove timing belt and timing belt automatic
tensioner.
NOTE: Revised auto-tensioner procedure is from Mitsubishi technical service bulletin 96-11-006; June, 1996.
Inspection 1) 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 pulley for smooth rotation.
2) Check timing belt automatic tensioner for leaks. Hold timing 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 1) 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.
2) Remove automatic tensioner from vise, and install assembly on
engine with wire in place. Install crankshaft sprocket (if removed). Align
timing marks on crankshaft and camshaft sprockets. See Fig. 3.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt & Components

CAUTION: Turning camshaft sprockets while No. 1 piston is at TDC
may damage valve and piston. Use care when aligning timing
marks.
3) To lower No. 1 piston from TDC and prevent valve and piston contact,
turn crankshaft back 3 sprocket teeth (measured at timing mark). See
Fig. 4.
4) Starting with left (drivers side) bank of cylinders, verify intake 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.
5) 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

MITSUBISHI

573

3.5L V6 DOHC (Cont.)

17) Start engine and run to normal operating temperature. Race engine
to 3000 RPM several times. Stop engine. After engine cools, refill
radiator.
18) To complete installation, reverse removal procedure. Tighten all nuts
and bolts to specification. See TORQUE SPECIFICATIONS. Adjust
drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

sprocket timing marks aligned with marks on rear timing belt cover,
install timing belt on right bank camshaft sprockets. Hold camshaft
sprockets in place with spring clips. See Fig. 5.
6) 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 sprockets with spring clips.
7) 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.
8) Rotate timing belt tensioner pulley until pin holes are located 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.
9) Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft
clockwise until timing marks are realigned. Loosen tensioner center bolt.
10) Using Tensioner Pulley Socket (MD998767) or equivalent, apply
approximately 83 INCH lbs. (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.
11) 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.
12) 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.
13) If push rod protrusion is out of specification, timing belt tension
adjustment will have to be repeated.
14) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft
pulley bolt to specification. See TORQUE SPECIFICATIONS.
15) 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.
16) Install radiator. 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).

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Positioning Crankshaft For Timing Belt Installation

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Securing Timing Belt With Spring Clips

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Adjusting Timing Belt Tension

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3.5L V6 DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
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)
Camshaft Sprocket Bolt ............................................................................................ 64 (88)
Crankshaft Pulley Center Bolt ...................................................... ......... 130-137 (177-186)
Power Steering Pump Bolt ........................................................... ................. 26-30 (38-41)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Timing Belt Tensioner Pulley Bolt ............................................................................. 35 (48)
INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Measuring Push Rod Protrusion

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)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

MITSUBISHI

575

3.5L V6 SOHC
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.5L V6 SOHC
Diamante
1997-02 .............................. 1 3.4 Hours .. .. TCK287 .. .....
2003-04 .............................. 1 3.4 Hours .. ...... ..... ...... .....
Montero
1997-00 .............................. 1 3.4 Hours .. .. TCK287 .. .....
2001-02 ............................... 3.9 Hours ... ...... ..... ...... .....
Montero Sport
1999-00 .............................. 1 2.8 Hours .. ...... ..... ...... .....
2001-02 .............................. 1 2.8 Hours .. .. TCK287 .. .....
2003-04 .............................. 1 2.8 Hours .. ...... ..... ...... .....
1

T287
T287
T287
T320
T287
T287
T287

With Air Conditioning, add .4 hour for Montero. With Air

Conditioning, add .3 hour for Montero Sport.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1997-00 models and 2002-04 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,
unless previously changed.
For 2001 models, the manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts 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 miles, unless previously changed.

REMOVAL & INSTALLATION

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components (Diamante)

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Replacement procedure for Diamante includes revised
information
from
Mitsubishi
technical
service
bulletin
No. 00-11-005; April, 2000.
Removal (Diamante) 1) Disconnect negative battery cable. Remove
accessory drive belts. Remove generator with wires attached, and
secure out of way.
2) Holding crankshaft pulley stationary, remove crankshaft pulley bolt.
Remove crankshaft pulley.
3) 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.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
4) If timing belt is to be reused, place arrow on belt to indicate 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 timing belt. Remove timing belt autotensioner from engine block. Inspect timing belt. See TIMING BELT
INSPECTION.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks

576

MITSUBISHI
3.5L V6 SOHC (Cont.)

Installation (Diamante) 1) Place auto-tensioner in soft-jawed vise to

SLOWLY compress 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.
2) 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.
WARNING: Right bank camshaft can easily turn from applied
spring pressure. Be careful not to pinch fingers when installing
timing belt.
3) Ensure all timing marks are still aligned. See Fig. 2. Install 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.
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
aligned.
5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
bottom of tensioner. Install Tensioner Pulley Wrench (MD998767)) on
tensioner pulley. See Fig. 3. Using torque wrench, apply 39 INCH lbs.
(4.4 N.m) of torque (counterclockwise direction) to tensioner pulley.
Tighten tensioner center bolt to specification while holding tensioner
pulley stationary. See TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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. For
2000 and earlier models, clearance should be 0.15-0.20 (3.8-5.0 mm).
For 2001 and later models, clearance should be 0.20-0.24 (4.8-6.0
mm). If protrusion is not correct, repeat timing belt tensioning procedure.
8) Install engine support bracket on engine block. Tighten top bolt first,
then working in a counterclockwise direction, tighten the remaining
bolts. See Fig. 4. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt, then tighten bolt to specification. See TORQUE SPECIFICATIONS.
9) To install remaining components, reverse removal procedure. Adjust
drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Engine Support Bracket Tightening Sequence (Diamante)

3) Remove cover and 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 all models,
remove accessory mount assembly. See Fig. 5.
4) Remove upper timing belt cover. See Fig. 6. Using Crankshaft Pulley
Holder Pin (MD998715) and End Yoke Holder (MB990767), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove
crankshaft pulley.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
5) Remove lower timing belt cover. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner
pulley center bolt.
6) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.
Inspect timing belt. See TIMING BELT INSPECTION.

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension (Except 2001-02 Montero)

Removal (1997-00 Montero & 1999-04 Montero Sport) 1) Disconnect negative battery cable. Drain cooling system. Remove upper
radiator hose. Remove radiator shroud. Loosen cooling fan clutch-topulley nuts. Relieve tension on accessory drive belts.
2) Remove cooling fan and fan clutch assembly. Remove cooling fan
pulley. Remove all accessory drive belts. Remove generator with wires
attached, and secure out of way.

Fig. 5: Exploded View Of Accessory Mount Assembly

(1997-00 Montero & 1999-04 Montero Sport)
Installation (1997-00 Montero & 1999-04 Montero Sport) 1) Place
auto-tensioner in soft-jawed vise to SLOWLY compress 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.

MITSUBISHI

577

3.5L V6 SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Exploded View Of Timing Belt & Components

(1997-00 Montero & 1999-04 Montero Sport)
CAUTION: Never compress the auto-tensioner too fast, or the push
rod will be damaged.
2) 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.
WARNING: Right bank camshaft can easily turn from applied
spring pressure. Be careful not to pinch fingers when installing
timing belt.
3) Ensure all timing marks are still aligned. See Fig. 2. Install 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.
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
aligned.
5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
bottom of tensioner. Install Tensioner Pulley Wrench (MD998767)) on
tensioner pulley. See Fig. 3. Using torque wrench, apply 39 INCH lbs.
(4.4 N.m) of torque (counterclockwise direction) to tensioner pulley.
Tighten tensioner center bolt to specification while holding tensioner
pulley stationary. See TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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 timing belt tensioning procedure.

8) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft

pulley bolt to specification. See TORQUE SPECIFICATIONS. Install
accessory mount assembly on front of engine. To install remaining
components, reverse removal procedure. Adjust drive belts to proper
tension.
9) 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.
Removal (2001-02 Montero) 1) Disconnect negative battery cable.
Remove undercover skid plate. Drain cooling system. Remove battery
and battery tray. Remove intake air ducts. Remove air intake hose,
resonator and volume airflow sensor. See Fig. 7. Remove air cleaner
assembly.
2) Remove upper and lower radiator shroud covers. Remove A/T oil
cooler hose, and plug hose and radiator nipple to prevent contamination.
Remove upper and lower radiator hoses. Remove radiator shroud.
Remove accessory drive belt. See Fig. 8. Remove cooling fan and
cooling fan pulley.
3) Insert an 1/2 (12.7 mm) breaker bar into the square hole on drive belt
auto tensioner, and rotate it clockwise until tensioner touches the
stopper. Align hole B with hole A, and insert a 0.20 (5.0 mm) Allen
wrench to hold tensioner. See Fig. 9. Remove drive belt auto tensioner.
4) Remove accessory mount stay. See Fig. 8. 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. Remove cooling fan bracket assembly. Remove accessory
mount assembly.
5) Remove upper timing belt cover. See Fig. 10. Using Pulley Holder
(MB991800) and Pin B (MD991802), hold crankshaft pulley stationary
and remove crankshaft pulley bolt. Remove crankshaft pulley.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
6) Remove timing belt indicator bracket. Remove lower timing belt cover.
Remove timing belt auto-tensioner. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks, and set the No. 1 cylinder to
compression TDC. See Fig. 11. Loosen belt tensioner pulley center bolt.
7) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Remove timing belt. Inspect timing belt. See TIMING
BELT INSPECTION.
Installation (2001-02 Montero) 1) Place auto-tensioner in soft-jawed
vise to SLOWLY compress 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.
2) 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.
WARNING: Right bank camshaft can easily turn from applied
spring pressure. Be careful not to pinch fingers when installing
timing belt.
3) Ensure all timing marks are still aligned. See Fig. 11. Install 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.
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
aligned.

578

MITSUBISHI
3.5L V6 SOHC (Cont.)

5) Loosen tensioner pulley center bolt. Position tensioner pin holes at

bottom of tensioner. Install Tensioner Pulley Wrench (MD998767) on
tensioner pulley. See Fig. 12. Using torque wrench, apply 39 INCH lbs.
(4.4 N.m) of torque (counterclockwise direction) to tensioner pulley.
Tighten tensioner center bolt to specification while holding tensioner
pulley stationary. See TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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 timing belt tensioning procedure. Ensure all timing marks
are aligned.
8) Install timing belt covers. See Fig. 10. Install crankshaft pulley.
Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install accessory mount assembly on front of engine. See
Fig. 13. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedures. See Figs. 7 and 8. Adjust drive belts
to proper tension.
9) 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.

TIMING BELT INSPECTION

Inspection (All Models) 1) 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 pulley for
smooth rotation. Replace if defective.
2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner upright. Measure rod protrusion above edge of housing. See
Fig. 14. 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), replace the auto-tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Exploded View Of Air Cleaner Assembly (2001-02 Montero)

MITSUBISHI

579

3.5L V6 SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Exploded View Of Drive Belt Components (2001-02 Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Removing Drive Belt Auto Tensioner (2001-02 Montero)

MITSUBISHI

580

3.5L V6 SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Timing Belt Components (2001-02 Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Aligning Timing Marks (2001-02 Montero)

MITSUBISHI

581

3.5L V6 SOHC (Cont.)

TORQUE SPECIFICATIONS (1997-00 MONTERO & 1999-04 MONTERO SPORT)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Adjusting Timing Belt Tensioner (2001-02 Montero)

Application
Ft. Lbs. (N.m)
Accessory Mount Assembly Bolt
12 x 100 Bolt ........................................................................................................... 54 (74)
All Other Bolts ......................................................................................................... 33 (44)
Auto-Tensioner Bolt ................................................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Pulley Bolt ......................................................................................... 1 134 (181)
Generator Bottom Bolt .............................................................................................. 16 (22)
Generator Pivot (Upper) Bolt .................................................................................... 38 (52)
Power Steering Pump Bolt ....................................................................................... 17 (24)
Timing Belt Idler Pulley Bolt ..................................................................................... 35 (48)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Timing Belt Tensioner Center Bolt ............................................................................ 35 (48)
Water Pump Bolt ....................................................................................................... 17 (23)
INCH Lbs. (N.m)
Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 89-106 (10-12)
Power Steering Pump Cover Bolt .............................................................................. 43 (5)
Radiator Shroud Bolt ................................................................................................... 43 (5)
Timing Belt Cover Bolt .............................................................................................. 97 (11)
Timing Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1

Apply engine oil to bolt threads before installation.

TORQUE SPECIFICATIONS (2001-02 MONTERO)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Installing Accessory Mount Assembly Bolts

(2001-02 Montero)

Courtesy of Mitsubishi Motor Sales of America.

Application
Ft. Lbs. (N.m)
Accessory Mount Assembly Bolt
Bolt A (10 x 100 mm) .............................................................. ................. 24-36 (33-49)
Bolt B (10 x 30 mm) ................................................................ ................. 24-36 (33-49)
Bolt C (10 x 100 mm) .............................................................. ................. 26-40 (34-54)
Bolt D (12 x 100 mm) .............................................................. ................. 47-61 (65-83)
Bolt E (8 x 30 mm) .................................................................. ................. 13-19 (18-26)
Bolt F (10 x 106 mm) ............................................................... ................. 26-40 (34-54)
Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186)
Power Steering Pump Bolt ........................................................... ................. 13-19 (18-26)
Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49)
Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54)
Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54)

Fig. 14: Checking Timing Belt Auto-Tensioner Movement

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (DIAMANTE)
Application
Ft. Lbs. (N.m)
Auto-Tensioner Bolt ................................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Pulley Bolt ......................................................................................... 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 ................................................................... 33 (44)
Generator Pivot Bolt .................................................................................................. 33 (44)
Generator Top Bolt .................................................................................................... 15 (21)
Power Steering Pump Belt Tensioner Bolt ............................................................... 33 (44)
Timing Belt Idler Pulley Bolt ..................................................................................... 33 (44)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Timing Belt Tensioner Center Bolt ............................................................................ 35 (48)
Water Pump Bolt
M8 Bolt .................................................................................................................... 17 (23)
M10 Bolt .................................................................................................................. 30 (41)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 97 (11)
Timing Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1
2

Apply engine oil to bolt threads before installation.

Arrow on engine mount plates must face toward front of vehicle.

INCH Lbs. (N.m)

Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 88-104 (10-12)
Radiator Shroud Bolt ..................................................................... ..................... 35-53 (4-6)
Timing Belt Cover Bolt .................................................................. ............... 88-104 (10-12)
Timing Mark Indicator Plate Bolt .................................................. ............... 88-104 (10-12)
Water Pump Pulley Nuts .............................................................. ............... 88-104 (10-12)
1

Apply engine oil to bolt threads before installation.

MITSUBISHI

582

3.8L V6 SOHC Endeavor & Galant

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.8L V6 SOHC
Endeavor & Galant
2004 ........................................................... 3.0 Hours ... ..... T287
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles
except in California, Massachusetts 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
miles, unless previously changed.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) On Galant, remove engine cover. On all models, remove
skid plate and under cover. Remove accessory drive belts. Using Pulley
Holder (MB991800) and Pins B (MB001802), remove crankshaft
pulley.
2) Disconnect harness connectors on connector bracket. See Fig. 1 or 2.
Remove connector bracket. Remove engine mount support bracket.
Remove both upper timing belt covers.
3) Remove tensioner pulley and tensioner bracket. Remove crankshaft
position sensor harness clamp. Remove lower timing belt cover.
Remove front engine mount and front engine mount bracket.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
4) Turn crankshaft clockwise to align camshaft and crankshaft timing
marks. See Fig. 3. If timing belt is to be reused, place arrow on belt to
indicate direction of belt rotation.
5) Loosen belt tensioner pulley center bolt. Remove timing belt. Remove
timing belt auto-tensioner.

Inspection 1) 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 back surface. Replace belt if worn, damaged
or contaminated. Inspect belt tensioner pulley for smooth rotation.
Replace if defective.
2) Check timing belt auto-tensioner for leaks. Check for wear or damage
at end of rod. Hold timing belt auto-tensioner upright. Measure rod
protrusion above edge of housing. See Fig. 4. 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.
Installation 1) Place auto-tensioner in soft-jawed vise to SLOWLY
compress the push rod. If there is a plug at the base of the autotensioner 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.
2) 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.
3) Ensure all timing marks are still aligned. See Fig. 3. Install 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.
4) Loosen the tensioner pulley center bolt. Rotate tensioner pulley
against timing belt. Temporarily tighten tensioner pulley center bolt. Turn
crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned.
5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
bottom of tensioner. Install Adapter (MD998767) on tensioner pulley.
See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque
(counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley stationary. See
TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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 0.19-0.24 (4.8-6.0 mm). If protrusion is not
correct, repeat timing belt tensioning procedure.
8) Install timing belt covers. Install crankshaft pulley. Using Pulley Holder
(MB991800) and Pins B (MB001802), tighten crankshaft pulley bolt to
specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

MITSUBISHI

583

3.8L V6 SOHC Endeavor & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt Components (Endeavor)

584

MITSUBISHI
3.8L V6 SOHC Endeavor & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt Components (Galant)

MITSUBISHI

585

3.8L V6 SOHC Endeavor & Galant (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Crankshaft Pulley Bolt ................................................................... ....... 1 134-140 (180-190)
Engine Mount Bracket-To-Engine Bolt .......................................... ................. 31-37 (42-48)
Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49)
Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54)
Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 97 (11)
1

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Checking Timing Belt Auto-Tensioner Movement

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Timing Belt Tension

Apply engine oil to bolt threads before installation.

MITSUBISHI

586

3.8L V6 SOHC Montero

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.8L V6 SOHC
Montero
2003-04 ..................................................... 3.9 Hours ... ..... T320
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends the belt be replaced every 60,000 miles
except in California, Massachusetts 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
miles, unless previously changed.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove skid plate and under cover. Drain engine coolant.
Remove battery and battery tray. Remove air cleaner and intake air
duct. Remove upper radiator hose. Remove radiator shroud. Loosen
cooling fan clutch-to-pulley nuts.

2) Remove accessory drive belt. Remove cooling fan and pulley.

Remove drive belt auto tensioner. Remove accessory mount support.
See Fig. 1.
3) 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. Remove cooling fan bracket.
Remove accessory mount assembly.
4) Remove upper timing belt cover. See Fig. 2. Using Pulley Holder
(MB991800 or MB991800-01) and Pin (MB991802 or MB991802-01) to
hold crankshaft pulley stationary, remove crankshaft pulley bolt.
Remove crankshaft pulley.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).
5) Remove timing belt indicator bracket. Remove lower timing belt cover.
Turn crankshaft clockwise to align camshaft and crankshaft timing
marks. See Fig. 3.
6) If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation. Loosen belt tensioner pulley center bolt. Remove timing
belt. Remove timing belt auto-tensioner.
Inspection 1) 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 back surface. Replace belt if worn, damaged
or contaminated. Inspect belt tensioner pulley for smooth rotation.
Replace if defective.
2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner upright. Measure rod protrusion above edge of housing. See
Fig. 4. 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), replace the auto-tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Accessory Mount Assembly

MITSUBISHI

587

3.8L V6 SOHC Montero (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Checking Timing Belt Auto-Tensioner Movement

Installation 1) Place auto-tensioner in soft-jawed vise to SLOWLY
compress the push rod. If there is a plug at the base of the autotensioner 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

2) 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.
3) Ensure all timing marks are still aligned. See Fig. 3. Install 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.
4) Loosen the tensioner pulley center bolt. Rotate tensioner pulley
against timing belt. Temporarily tighten tensioner pulley center bolt. Turn
crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned.

MITSUBISHI

588

3.8L V6 SOHC Montero (Cont.)

5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
bottom of tensioner. Install Adapter (MD998767) on tensioner pulley.
See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque
(counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley stationary. See
TORQUE SPECIFICATIONS.
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise.
7) 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 timing belt tensioning procedure.
8) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft
pulley bolt to specification. See TORQUE SPECIFICATIONS. Install
accessory mount assembly on front of engine.
9) To complete installation, reverse removal procedure. 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.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Timing Belt Tension

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Identifying Accessory Mount Assembly Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Accessory Mount Assembly Bolt 1
Bolt A (10 x 100 mm) .............................................................. ................. 24-36 (33-49)
Bolt B (10 x 30 mm) ................................................................ ................. 24-36 (33-49)
Bolt C (10 x 100 mm) .............................................................. ................. 26-40 (34-54)
Bolt D (12 x 100 mm) .............................................................. ................. 47-61 (65-83)
Bolt E (8 x 30 mm) .................................................................. ................. 15-19 (20-26)
Bolt F (10 x 100 mm) ............................................................... ................. 32-40 (44-54)
Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Cooling Fan Bracket Bolt .............................................................. ................. 24-36 (33-49)
Crankshaft Pulley Bolt ................................................................... ....... 2 134-140 (180-190)
Power Steering Pump Bolt ........................................................... ................. 13-19 (18-26)
Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49)
Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54)
Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54)
INCH Lbs. (N.m)
Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 89-106 (10-12)
Timing Belt Cover Bolt .............................................................................................. 97 (11)
1
2

For bolt identification and locations, see Fig. 6.

Apply engine oil to bolt threads before installation.

NISSAN

589

1.5L & 1.6L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

1.5L 4-Cyl. SOHC

Sentra
1982-83 ............................ .... 2.8
Pulsar NX (Includes Canadian)
1983-84 ............................ .... 3.0
310
1982 ................................. .... 5.8
1.6L 4-Cyl. SOHC
Pulsar & Pulsar NX
1983-88 ............................ .... 2.3
Sentra
1983-88 ............................ .... 2.8
1

Hrs. .... .. TCK077 .. ..... T077

Hrs. .... .. TCK077 .. ..... T077
Hrs. .... .. TCK077 .. ..... T077

Hrs. .... .. TCK077 .. ..... T077

Hrs. .... .. TCK077 .. ..... T077

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View of Timing Belt & Components

On 1982-85 models, although 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshaft separately with
timing belt removed. Valves will contact piston and may cause
damage.
Removal 1) Disconnect negative battery cable. Place crankshaft on
TDC of compression stroke. Remove spark plugs. Remove right front
under engine cover and splash cover. Remove accessory 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.
2) On all models, remove upper and lower timing belt cover. See Fig. 1.
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 necessary). See Fig. 1.
CAUTION: Camshaft sprockets have 2 marks on them. Ensure the
correct mark is aligned. See Fig. 2.
Installation 1) 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 removal.
2) Install timing belt, keeping belt tight on jackshaft and camshaft
sprockets side. Loosen tensioner and allow tension to be applied to
timing belt. Rotate camshaft sprocket 20 degrees (2 cogs) clockwise.
3) 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 to proper tension.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (1.5L)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 29-35 (39-48)
Crankshaft Pulley Bolt ................................................................... ......... 108-145 (147-197)
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)
TORQUE SPECIFICATIONS (1.6L)
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt ................................................................................ 80-94 (108-127)
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)
Timing Belt Cover ......................................................................................... 46-58 (5.2-6.6)
Valve Cover Bolt
1st Step ....................................................................................................... 17-35 (1.9-4.0)
2nd Step ..................................................................................................... 35-52 (4.0-5.9)
Water Pump Bolt .......................................................................................... 46-58 (5.2-6.6)
Water Pump Pulley Bolt ............................................................................. 74-96 (8.4-10.9)

NISSAN

590

1.6L & 1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.6L 4-Cyl. DOHC

Pulsar
1987 ........................................................... 3.8 Hours ... ..... T137
1.8L 4-Cyl. DOHC
Pulsar NX
1988-89 ..................................................... 3.8 Hours ... ..... T137
1

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove upper radiator hose. Remove undertray from right side.
Remove accessory drive belts. Remove water pump pulley.
2) 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.
3) 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.
4) Using dial indicator, check camshaft sprocket runout. Replace
sprocket if runout exceeds .004 (.10 mm). To remove camshaft
sprocket, remove camshaft cover and hold hex area of camshaft.
Remove sprocket retaining bolts. See Fig. 3.
5) Remove camshaft sprocket. If crankshaft sprocket requires removal,
note direction of sprocket plates prior to removal. See Fig. 1. Remove
plates and sprocket.
Inspection 1) Inspect timing belt for wear on rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if
damaged or contaminated.
2) Check tensioner and idler pulleys for smooth rotation. Inspect
tensioner pulley return spring for distortion or corrosion.
Installation 1) Install crankshaft sprocket and sprocket plates.
Sprocket plates must be installed with flat side against crankshaft
sprocket.
2) Ensure No. 1 cylinder is at TDC of compression stroke. Align
camshaft and crankshaft sprockets. See Fig. 2. Install timing belt.
Ensure 39 teeth exist between marks on camshaft sprockets, and 48
teeth between crankshaft and camshaft sprockets. See Fig. 2.
3) Loosen tensioner pulley nut. Install crankshaft bolt and a spacer.
Rotate crankshaft 2 revolutions. Tighten tensioner pulley nut to specification. See TORQUE SPECIFICATIONS. Ensure all marks are aligned.
Install timing belt covers.
4) 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. See
TORQUE SPECIFICATIONS.
5) Install accessory drive belts. Adjust drive belts to proper tension.
Install upper radiator hose and refill cooling system.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Removing Camshaft Sprocket

NISSAN
1.6L & 1.8L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 10-14 (14-19)
Crankshaft Pulley Bolt ............................................................................. 105-112 (142-152)
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)

591

NISSAN

592

1.7L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.7L 4-Cyl. Diesel

Sentra (Includes Canadian)
1983-87
Camshaft ................................................ 4.0 Hours ... ..... T096
Injection Pump ....................................... 4.2 Hours ... ..... T097
1

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1984-85 models, although the manufacturer does not recommend a
specific scheduled maintenance interval, belt manufacturers suggest
the belt be replaced at 60,000 mile intervals. On 1986-87 models, the
manufacturer recommends the belt be replaced at 60,000 mile intervals.
Courtesy of Nissan Motor Co., U.S.A.

REMOVAL & INSTALLATION

Fig. 1: Installing Camshaft Timing Belt

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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 1) Ensure No. 1 cylinder is at TDC of compression stroke.
Install timing belt ensuring timing marks are aligned. See Fig. 1. Ensure
reference marks are 39 cogs apart.
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.
3) Adjust drive belts to proper tension.

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.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Injection Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 68-75 (18-22)
Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132)
Front Tensioner Bolt ...................................................................... ................. 27-33 (36-34)
Rear Tensioner Bolt ...................................................................... ................. 12-15 (16-21)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................................ ..................... 27-43 (3-5)

NISSAN

593

1.8L & 2.0L 4-Cylinder

TIMING BELT APPLICATION
Application
1.8L 4-Cyl. Turbo
200SX (Includes Canadian)
1984-87 ..............................
2.0L 4-Cyl.
Stanza & Stanza Wagon
1982-89 ..............................
200SX (Includes Canadian)
1984-87 ..............................
1988 ...................................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.0 Hours .. ...... ..... ...... ..... T100

4.4 Hours .. .. TCK078 .. ..... T078

2.0 Hours ... TCK078A . ..... T078

2.0 Hours .. .. TCK078 .. ..... T078

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Timing Belt Alignment Procedure

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1982-85 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.

REMOVAL & INSTALLATION

CAUTION: The 2.0L is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage
may occur.

TIMING BELT

Courtesy of Nissan Motor Co., U.S.A.

Removal (1982-88) 1) Disconnect negative battery cable. Turn

crankshaft until No. 1 cylinder is at TDC on compression stroke.
Remove cooling fan, radiator shroud and accessory drive belts.

Fig. 2: Adjusting Timing Belt Tension

NOTE: After timing belt is removed, do not rotate crankshaft or

camshaft.

TORQUE SPECIFICATIONS (1982-88)

2) 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) 1) Disconnect negative battery cable. Raise and
support vehicle. 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.
2) Support engine with a chain hoist. Remove right side engine mount
and bracket. Remove upper and lower timing belt covers and gaskets.
Remove timing belt tensioner, bracket and timing belt.
Installation (All Models) 1) 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.
2) 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.
3) 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 installation by reversing removal procedure.
Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ..................................................................... ................. 10-14 (14-19)
Crankshaft Pulley Bolt ............................................................................. 105-112 (142-152)
Engine Mount Bolt ......................................................................... ................. 29-40 (39-54)
Idler Nut ......................................................................................... ................. 23-31 (31-42)
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)
Front Cover Bolts .......................................................................... ..................... 27-43 (3-5)
Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8)
TORQUE SPECIFICATIONS (1989)
Application
Ft. Lbs. (N.m)
Camshaft Lock Plate Bolt ............................................................. ................. 58-65 (78-88)
Camshaft Sprocket Bolt ................................................................ ................. 58-65 (78-88)
Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132)
Engine Mount Bolt ......................................................................... ................. 29-40 (39-54)
Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30)
INCH Lbs. (N.m)
Crank Angle Sensor Bolt .............................................................. ..................... 61-70 (7-8)
Front Cover Bolts .......................................................................... ..................... 27-43 (3-5)
Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8)
Water Pump Pulley Bolt ................................................................ ................... 54-86 (6-10)

NISSAN

594

3.0L V6 DOHC
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 DOHC
300ZX
1990-93 ..................................................... 4.6 Hours ... ..... T180
1994-96 ..................................................... 4.6 Hours ... ..... T251
1

With Air Conditioning, add .3 hours.

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-92 models, the manufacturer recommends the belt be
replaced every 60,000 miles. On 1993 convertible models, the manufacturer recommends the belt be replaced every 60,000 miles. On 1993
non-convertible models, the manufacturer recommends the belt be
replaced every 105,000 miles. On 1994-96 turbocharged models, the
manufacturer recommends the belt be replaced every 60,000 miles. On
1994-96 non-turbocharged models, the manufacturer recommends the
belt be replaced every 105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine
undercover. Drain coolant from radiator and cylinder block. Remove
radiator. Remove accessory drive belts. Remove cooling fan and
coupling. Remove starter.

2) 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.
3) 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 1) Ensure cylinder No. 1 is at TDC of compression stroke.
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 3). If clearance is not .16 (.4 mm), go to next
step.
2) Remove tensioner. Remove stopper bolt. Using a vise, adjust
clearance until it is as specified. Install stopper bolt in tensioner to
maintain clearance. Install tensioner. Hand-tighten tensioner nut and
bolts.
3) Install timing belt with arrow on timing belt facing front of engine. Align
White lines on timing belt with marks on camshaft sprockets and
crankshaft sprocket. White lines ensure correct number of teeth exist
between timing marks on sprockets.
4) Push tensioner gently toward timing belt to prevent belt from slipping
(excessive pressure will overtighten belt). Maintain light pressure on
tensioner.
5) Turn crankshaft clockwise 10 degrees. Tighten tensioner bolts and
nut. See TORQUE SPECIFICATIONS. Turn crankshaft counterclockwise 120 degrees. Turn crankshaft clockwise until cylinder No. 1 is at
TDC of compression stroke.
6) 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.
7) Turn crankshaft 120 degrees clockwise, then turn it 120 degrees
counterclockwise to TDC. Fabricate a small steel plate. See Fig. 3. Set
plate at each position shown (A, B, C and D).

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Installing Timing Belt & Tensioner

NISSAN

595

3.0L V6 DOHC (Cont.)

8) Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Measure and
record timing belt deflection in each position. Divide sum of measurements (A + B + C + D) by 4 to obtain average.
9) Average timing belt deflection should be .24-.28 (6-7 mm). If
deflection is not as specified, repeat steps 4)-8). If timing belt deflection
is excessive, change amount of pushing force applied in step 6).
10) 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 complete installation, reverse removal
procedure. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts
Exhaust ........................................................................................ ................. 10-14 (14-19)
Intake ........................................................................................... ............. 90-98 (122-133)
Crankshaft Pulley Bolt ................................................................... ......... 159-174 (216-236)
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)
Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Adjusting Timing Belt Tensioner

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Checking Timing Belt Deflection

NISSAN

596

3.0L V6 SOHC
TIMING BELT APPLICATION
Application

Labor Time

3.0L V6 SOHC
Maxima
1985-88 ............................ ... 1 6.0 Hrs.
1989-91 ............................ .... 5.7 Hrs.
1992-94
With Round Tooth
Sprocket .................... .... 5.7 Hrs.
With Square Tooth
Sprocket .................... .... 5.7 Hrs.
Pathfinder & Pickup
1986-92 ............................ .... 4.5 Hrs.
1993-94
With Round Tooth
Sprocket .................... .... 4.5 Hrs.
With Square Tooth
Sprocket .................... .... 4.5 Hrs.
1995-96 ............................ .... 4.5 Hrs.
Quest
1993-94
With Round Tooth
Sprocket .................... .... 3.6 Hrs.
With Square Tooth
Sprocket .................... .... 3.6 Hrs.
1995-98 ............................ .... 3.6 Hrs.
200SX
1987-88 ............................ .... 4.8 Hrs.
300ZX
1984-89 ............................ .... 6.0 Hrs.
1

Component
Belt
Kit No.
Part No.

... .. TCK104 .. ..... T104

.... .. TCK104 .. ..... T104

.... .. TCK249 .. ..... T249

.... .. TCK104 .. ..... T104
.... .. TCK104 .. ..... T104

.... .. TCK249 .. ..... T249

.... .. TCK104 .. ..... T104
.... .. TCK249 .. ..... T249

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

.... .. TCK249 .. ..... T249
.... .. TCK104 .. ..... T104
.... .. TCK249 .. ..... T249
.... .. TCK104 .. ..... T104
.... .. TCK104 .. ..... T104

With Air Conditioning add .3 hours.

With Power Steering, add .3 hours.

2) 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.
3) Using Allen wrench, slowly turn tensioner clockwise and counterclockwise 2 or 3 times. When camshafts and crankshaft marks are
aligned, tighten tensioner lock nut. See Fig. 2. Ensure that camshaft
lobes are correctly positioned. Tighten rocker shaft bolts in 2 stages.
4) Refill and bleed air from cooling system. To complete installation,
reverse removal procedures. Adjust drive belts to proper tension.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1984-85 models, although 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (200SX & 300ZX) 1) Disconnect negative battery cable.
Release fuel pressure from system. Raise and support vehicle. Remove
right wheel and engine side cover (if necessary). Drain cooling system.
Remove cooling fan duct. Remove engine coolant reservoir. Remove
actuator and remove radiator hoses. Do not allow coolant to contact
drive belts.
2) Remove front upper and lower belt covers. See Fig. 1. Remove drive
belts and set No. 1 cylinder at TDC of compression stroke. Remove idler
bracket of compressor drive belt and crankshaft pulley. Remove timing
belt by removing timing belt tensioner and return spring.
Inspection (200SX & 300ZX) Visually inspect condition of timing belt.
Inspect for cracks, wear, breaks, and oil/coolant saturation.
Installation (200SX & 300ZX) 1) 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.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Adjusting Timing Belt

Removal (Maxima & Quest) 1) Disconnect negative battery cable.
Raise and support vehicle. 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.
2) Remove upper radiator hose and water inlet hose. Remove A/C
compressor idler pulley and bracket. Remove water pump pulley.
Remove upper and lower timing belt front covers. See Fig. 1.
3) 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 housing. See Fig. 3.
4) Loosen timing belt tensioner nut. Release tension on belt. Remove
timing belt. Check timing belt tensioner, spring and timing belt.
Installation (Maxima & Quest) 1) Ensure cylinder No. 1 is at TDC of
compression stroke. See Fig. 3. 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.

NISSAN

597

3.0L V6 SOHC (Cont.)

6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression
stroke. Measure timing belt deflection halfway between camshaft
sprockets. If deflection is not .51-.59 (13-15 mm), repeat procedure. To
complete installation, reverse removal procedure.
7) Refill and bleed air from cooling system. Adjust drive belts to proper
tension.
NOTE: Manufacturer has revised the timing belt specifications for
the VG30E engine. If timing belt is to be replaced, ensure that new
timing belt is compatible with camshaft sprocket, crankshaft
sprocket and tensioner spring. Refer to Nissan Technical Service
Bulletin NTB93-154.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Installing Timing Belt & Sprocket

2) Install timing belt with arrow on timing belt facing front of engine. Align
White lines on timing belt with marks on camshaft sprockets and
crankshaft sprocket. White lines ensure correct number of teeth exist
between timing marks on sprockets.
3) 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.
4) 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.
5) 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. 2. Tighten timing belt tensioner
lock nut to specification. See TORQUE SPECIFICATIONS.

CAUTION: DO NOT bend or twist timing belt. Prevent oil and

coolant from contacting timing belt and sprockets. Install timing
belt when engine is cold. If cylinder head is installed and timing
belt is disconnected, DO NOT rotate camshaft or crankshaft;
valves will contact pistons, resulting in bent valves.
Removal (Pathfinder & Pickup) 1) Remove covers from below
engine. Drain and remove radiator. Remove cooling fan and water pump
pulley. Remove accessory drive belts. Remove spark plugs. Remove
distributor protector. Remove A/C compressor idler pulley and bracket.
2) Remove fresh air tube from cylinder head cover. Remove thermostat
housing coolant hose. Remove crankshaft pulley bolt and pulley.
Remove upper and lower timing belt front covers. See Fig. 4. Temporarily install crankshaft pulley bolt to rotate crankshaft.
3) Set cylinder No. 1 at TDC of compression stroke by aligning 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. 5. Loosen timing belt tensioner. Remove timing belt. Check timing
belt tensioner, spring and timing belt.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Removing & Installing Timing Belt Covers

598

NISSAN
3.0L V6 SOHC (Cont.)

Installation (Pathfinder & Pickup) 1) Ensure cylinder No. 1 is at TDC

of compression stroke. See Fig. 5. 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.
2) Install timing belt with arrow on timing belt facing front of engine. Align
White lines on timing belt with marks on camshaft sprockets and
crankshaft sprocket. White lines ensure correct number of teeth exist
between timing marks on sprockets.
3) 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.
4) Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull
Gauge (J-38387), 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.
5) 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. 2. Tighten timing belt tensioner
lock nut to specification. See TORQUE SPECIFICATIONS.
6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression
stroke. Measure timing belt deflection halfway between camshaft
sprockets. If deflection is not .51-.59 (13-15 mm), repeat steps 4) and
5). To complete installation, reverse removal procedure.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 5: Installing Timing Belt & Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
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)
Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

OPTIMA

599

1.6L & 2.0L 4-Cylinder

TIMING BELT APPLICATION
Application
1.6L 4-Cyl.
Optima (Canadian)
1988-91 ..............................
2.0L 4-Cyl.
Optima (Canadian)
1988-89 ..............................
1990-91 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.9 Hours .. ...... ..... ...... ..... T148

2.9 Hours .. ...... ..... ...... ..... T081

2.9 Hours .. .. TCK163 .. ..... T163

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1.6L) Disconnect negative battery cable. Remove accessory drive 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 procedure. Adjust drive belts to proper tension.
Removal (2.0L) 1) Disconnect negative battery cable. Remove drive
belt. Remove power steering pump and bracket. Remove serpentine
drive belt tensioner as an assembly. Remove timing belt cover. See
Fig. 1.
2) Loosen water pump attaching bolts. On water pump eccentric, use
special tool (J-33039-A) or equivalent to release tension. Remove
crankshaft pulley. Remove timing belt from camshaft and crankshaft
sprockets.

Courtesy of General Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (2.0L)

Installation (2.0L) 1) 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 water pump attaching bolts.
2) 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 attaching bolts and make sure tensioner
holes are still aligned. To complete installation, reverse removal procedure. Adjust drive belt to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Water Pump Bolts ..................................................................................................... 18 (24)

PEUGEOT

600

1.9L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cyl.
405
1989-91
DOHC ...................................................... 4.0 Hours ... ..... T188
SOHC ...................................................... 4.0 Hours ... ..... T189
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal (DOHC) 1) 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 bottom of engine compartment.
2) Remove alternator drive belt, then alternator. Support engine.
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.
3) Remove lower flywheel housing cover. Hold flywheel in position with
Peugeot Lock Tool (J-36358) or equivalent. Remove right mud shield.
Remove 4 crankshaft pulley retaining bolts, then crankshaft pulley.
Remove lower cover. Remove flywheel locking tool.
4) Rotate engine, using crankshaft pulley bolt, to align crankshaft 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.
5) Loosen timing belt tensioner bolts, then turn tensioner to relieve
tension on timing belt. Remove timing belt from sprockets.
Installation (DOHC) 1) 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. 2.
2) 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. 2.
Without changing tensioner position, tighten tensioner bolt to 18 ft. lbs.
(25 N.m), then remove belt tensioning meter.
3) Rotate tensioner counterclockwise until 21 SEEM units are displayed
on belt tensioning tool meter. See Fig. 2. Without changing tensioner
position, tighten tensioner bolt to 18 ft. lbs. (25 N.m). Remove three
locking pins and rotate crankshaft two turns in normal direction of engine
rotation.
4) 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 reinstalled.
5) 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.
6) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

Courtesy of Peugeot Motors of America, Inc.

Fig. 1: Installing Camshaft & Crankshaft Sprocket Locking Pins

(DOHC)

Courtesy of Peugeot Motors of America, Inc.

Fig. 2: Installing Timing Belt & Tensioning Tool (DOHC)

Removal (SOHC) 1) 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,

PEUGEOT

601

1.9L 4-Cylinder (Cont.)

aligning holes in camshaft sprocket and crankshaft 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. 3 and 4.
2) 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 crankshaft pulley. Remove stop tool
that was used to lock flywheel in position.
3) Remove upper portion of timing belt lower cover. Remove lower
portion of timing belt lower cover. Loosen three timing 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 pulley to hold tensioner in position.
4) Remove timing belt from sprockets.

Installation (SOHC) 1) Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. Insert Peugeot
Locking Pin Tool (No. 0-0163), or equivalent, through camshaft sprocket
and crankshaft pulley locking pin holes. See Figs. 3 and 4.
2) Remove crankshaft retaining bolt and pulley. Install timing belt over
camshaft sprocket, crankshaft sprocket and water pump sprocket, then
position timing belt on tensioner pulley. Ensure timing belt is properly
seated on sprockets. Loosen tensioner nut, then turn tensioner square
to release spring.
3) 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 timing belt. After timing belt has tensioned, tighten
tensioner retaining bolts. Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt.
4) Insert Peugeot Locking Pin Tool (No. 0-0163), or equivalent, through
camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 3
and 4. If pins are not aligned with holes, timing belt must be removed
and reinstalled. Remove crankshaft retaining bolt and pulley.
5) 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 installation, reverse removal procedure.
Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Peugeot Motors of America, Inc.

Fig. 3: Installing Camshaft Sprocket Timing Pin (SOHC)

Courtesy of Peugeot Motors of America, Inc.

Fig. 4: Installing Crankshaft Sprocket Timing Pin (SOHC)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts .......................................................................................... 11 (15)
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)

PEUGEOT

602

2.2L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 4-Cyl.
505
1986-91 ..................................................... 2.7 Hours ... ..... T140
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect battery. Drain cooling system including
cylinder block. Remove radiator and fan shroud. Remove thermostat
housing and auxiliary air device.
2) Align timing marks for crankshaft, camshaft and intermediate shaft.
See Fig. 1. Remove crankshaft pulley bolt and pulley. Ensure that
crankshaft does not rotate. Remove timing belt cover. Loosen timing belt
tensioner bolts, and position tensioner out of way. Remove camshaft
pulley and timing belt.
Installation 1) Ensure timing marks remain in alignment. See Fig. 1.
Remove 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.
2) Install timing belt, centered on pulleys and tensioner. Loosen belt
tensioner mounting bolts, and allow spring to adjust timing belt. Tighten
belt tensioner bolts.
3) To complete installation, reverse removal procedures. Crankshaft
pulley bolt must be reinstalled using Loctite. Adjust drive belts to proper
tension.

Courtesy of Peugeot Motors of America, Inc.

Fig. 1: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolts .......................................................................................... 11 (15)
Crankshaft Pulley Bolts ........................................................................................... 98 (133)
Timing Belt Tensioner Nut/Bolt ................................................................................. 18 (26)

PORSCHE

603

2.0L 4-Cylinder
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl.
924
1977-82 ............................... 1.0 Hours ... .. TCK017 .. ..... T017
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal Disconnect negative battery cable. Remove accessory drive
belts and any components as necessary to access camshaft 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 crankshaft and camshaft. Adjust
drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 58 (79)
Crankshaft Pulley .................................................................................................. 180 (245)
Tensioner Pulley ........................................................................................................ 29 (39)
INCH Lbs. (N.m)
Camshaft Sprocket Cover ......................................................................................... 84 (10)

PORSCHE

604

2.5L, 2.7L & 3.0L 4-Cylinder

TIMING BELT APPLICATION
Application

2.5L 4-Cyl.
924
1987-88
Balance Shaft .........................................
Camshaft ................................................
944
1983-86
Balance Shaft .........................................
Camshaft ................................................
1987-88
Balance Shaft .........................................
Camshaft ................................................
1989
Balance Shaft .........................................
Camshaft ................................................
944S
1987-88
Balance Shaft .........................................
Camshaft ................................................
2.7L 4-Cyl.
944
1989
Balance Shaft .........................................
Camshaft ................................................
3.0L 4-Cyl.
944
1989-91
Balance Shaft .........................................
Camshaft ................................................
968
1992-95
Balance Shaft .........................................
Camshaft ..................................................
1

Labor Time

Belt
Part No.

3.2 Hours ... ..... T293

3.2 Hours ... ..... T107

2.4 Hours ... ..... T293

2.4 Hours ... ..... T107

2) Turn crankshaft clockwise to align camshaft sprocket TDC mark with

mark in distributor cap console. See Fig. 2. Ensure mark on upper and
lower balance shaft sprockets align with mark on rear timing belt cover.
See Fig. 3.
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, mechanical belt tensioner must be removed.
See Fig. 4. Remove balance shaft drive belt. Loosen camshaft belt
tensioning sprocket lock nut and then sprocket by turning it clockwise.
Remove camshaft timing belt.

3.2 Hours ... ..... T293

3.2 Hours ... ..... T107
3.5 Hours ... ..... T293
3.5 Hours ... ..... T107

3.5 Hours ... ..... T293

3.5 Hours ... ..... T152

3.5 Hours ... ..... T293

3.5 Hours ... ..... T107

Courtesy of Porsche of North America, Inc.

Fig. 1: Loosening Pressure Rod

3.5 Hours ... ..... T293
3.5 Hours ... ..... T152

3.4 Hours ... ..... T293

3.4 Hours ... ..... T152

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 45,000 miles.

REMOVAL & INSTALLATION

Courtesy of Porsche of North America, Inc.

Fig. 2: Aligning Camshaft Sprocket Timing Mark

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
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
WARNING: 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 1) Disconnect negative battery cable. Remove splash
shield. Remove air cleaner assembly with airflow sensor. Disconnect
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 slightly loose prior to loosening
lock nuts. See Fig. 1. Remove accessory drive belts.

Courtesy of Porsche of North America, Inc.

Fig. 3: Aligning Upper Balance Shaft Timing Mark

PORSCHE

605

2.5L, 2.7L & 3.0L 4-Cylinder (Cont.)

Courtesy of Porsche of North America, Inc.

Fig. 4: Removing Mechanical Belt Tensioner

Installation (Camshaft Belt) Ensure No. 1 cylinder is at TDC, and that
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. 5. Adjust drive belts
to proper tension. After drive belt tension is adjusted, install balance
shaft belt. See INSTALLATION (BALANCE SHAFT BELT). To complete
installation, reverse removal procedure.
Tension Adjustment 1) 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. 4. Using thumb pressure,
press downward on camshaft belt between water pump pulley and
camshaft sprocket. Force camshaft belt against belt cover.
NOTE: On 944S, intake camshaft is chain driven from the exhaust
camshaft.
2) 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 Shaft Belt) Ensure No. 1 cylinder is at TDC,
and that marks on flywheel and cast clutch housing are aligned. Align
mark on camshaft sprocket with mark on rear drive belt cover. Install
balance shaft belt with color coded tooth facing out. See Fig. 6. Adjust
drive belts to proper tension. To complete installation, reverse removal
procedure.
Adjustment 1) 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.
2) 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.
3) 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.
4) Use Adjusting Gauge (9207) or a .020 (.50 mm) feeler gauge to
ensure a .020 (.50 mm) clearance exists between 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).
5) Tighten idler pulley. See Fig. 3. If correct gap cannot be reached,
rotate idler pulley 180 degrees and repeat adjustment. Tighten mounting
nut. Install and adjust poly-rib belt.

Courtesy of Porsche of North America, Inc.

Fig. 5: Identifying Drive Belt Positioning

Courtesy of Porsche of North America, Inc.

Fig. 6: Installing Balance Shaft Drive Belt

PORSCHE

606

2.5L, 2.7L & 3.0L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
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 tightening step.

PORSCHE

607

4.5L, 4.7L, 5.0L & 5.4L V8

TIMING BELT APPLICATION
Application
4.5L V8
928
1978-82
4.7L V8
928
1983-84
5.0L V8
928
1985-86
1987-91
5.4L V8
928
1993-95

Labor Time

Belt
Part No.

..................................................... 4.6 Hours ... ..... T196

..................................................... 4.6 Hours ... ..... T196

..................................................... 5.8 Hours ... ..... T196

..................................................... 6.5 Hours ... ..... T196

..................................................... 6.5 Hours ... ..... T196

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Porsche of North America, Inc.

Fig. 1: Identifying Camshaft Sprocket & Timing Belt Types

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 1) Disconnect negative battery cable. Remove air cleaner
intake 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.
2) On 4.5L V8, align TDC mark on vibration damper with red indicator on
cover. On 4.7L, 5.0L and 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 camshaft sprockets align with marks cast on camshaft
bearing caps.
3) On 4.7L, 5.0L and 5.4L V8, lock crankshaft by installing Porsche Tool
(9161/1) or equivalent. Secure tool with slave cylinder mounting bolts.
4) Remove crankshaft pulley mounting bolt, both pulleys, vibration
damper and collar. Remove oil dipstick tube. Remove alternator.
Remove left upper and center timing belt covers. Loosen timing belt
tensioner. Loosen tensioning roller. Remove timing belt.
Installation 1) On 4.5L V8, align TDC mark on vibration damper with
Red indicator on cover. On 4.7L, 5.0L and 5.4L V8, align mark for 45
degrees BTDC on vibration damper with Red needle. Turn crankshaft

Courtesy of Porsche of North America, Inc.

Fig. 2: Installing Camshaft Drive Belt

clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until
timing marks (notches) on camshaft sprockets align with marks cast on
camshaft bearing caps.
NOTE: Manufacturer indicates sufficient clearance exists so pistons and valves will not collide when crankshaft is turned with
camshaft timing belt removed.
2) 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 camshaft counterclockwise until teeth match.
Tighten timing belt to specification. Rotate engine 2 revolutions and align
cylinder No. 1 at TDC of compression stroke.
3) Check camshaft timing marks for proper alignment and retighten
camshaft drive belt. Ensure tester is not turned or pushed during tension
measurement. Recheck belt adjustment at least once. Adjust drive belts
to proper tension.

608

PORSCHE
4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)

Adjustment 1) With both upper drive belt guards removed, rotate

crankshaft (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.
2) Ensure each camshaft sprocket timing mark is in alignment with mark
cast on camshaft bearing cap. Turn engine over 2 more times until TDC
is reached again.
3) 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 telltale to 0 position on
gauge. See Fig. 3.
4) 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.
5) 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.
6) Pull out lock pin to disengage gauge needle again. Remove tester
from timing belt and read measured value. Correct belt tension if
necessary. See TIMING BELT TENSION table. Adjustment screw is
located 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.

Courtesy of Porsche of North America, Inc.

Fig. 3: Using Drive Belt Tension Tester

TIMING BELT TENSION

Application
Scale Value
New Or Used ................................................. .................................................................. 4.5

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.
1) When installing tensioner, ensure sealing surface on block is in good
condition. Apply Locktite (No. 574) to sealing surface before installation.
When filling tensioner, damping chamber may be bled by pumping
tension roller carrier. Ensure belt is loose and oil filler bolt and bleeder
are open.
2) 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.
3) Install and tighten filler and bleeder screws. Check fluid level after
1000 miles and at 15,000 mile intervals thereafter. To check, remove
filler bolt. If oil can be seen, level is okay. If not, add oil as necessary.

Courtesy of Porsche of North America, Inc.

Fig. 4: Exploded View of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Housing Mounting Bolt ............................................................................. 14 (20)
Camshaft Pulley Mounting Bolt ................................................................................ 33 (45)
Front Pulley Mounting Nut ............................................................ ......... 181-188 (250-260)

RENAULT

609

1.7L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.7L 4-Cyl.
Alliance & Encore
1985-87 ..................................................... 2.3 Hours ......... T119
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

Courtesy of American Motors/Renault Corp.

Fig. 1: Identifying Camshaft Sprocket Alignment Marks

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal Disconnect negative battery cable. Remove accessory drive
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.
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt
removed.
Installation 1) 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 crankshaft sprocket, then
intermediate shaft sprocket, and then camshaft sprocket. See Fig. 2.
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.
3) 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 crankcase 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.
4) There should be 66 timing belt teeth (cogs) between camshaft
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 intermediate 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).
5) 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, tighten tensioner pulley lock nut to specification.
To complete installation, reverse removal procedure. Adjust drive belts
to proper tension.

Courtesy of American Motors/Renault Corp.

Fig. 2: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Tensioner Pulley Lock Nut ........................................................................................ 30 (41)

RENAULT

610

2.2L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.2L 4-Cyl.
Fuego
1984-85 ..................................................... 2.2 Hours ... ..... T140
Sportwagon
1984-86 ..................................................... 2.0 Hours ... ..... T140
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, manufacturers suggest the belt be replaced at
60,000 mile intervals.

Installation & Adjustment 1) Position camshaft sprocket timing index

in line with static timing mark. See Fig. 1. 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. 2.
2) Position timing belt cover over sprockets and check camshaft timing
mark with index on cover. See Fig. 3. Remove TDC rod and install plug
in cylinder block. Rotate crankshaft clockwise 2 complete revolutions.
DO NOT rotate counterclockwise. Remove timing belt cover and loosen
timing belt tensioner bolts a maximum of 1/4 turn.
3) Spring loaded timing belt tensioner will automatically adjust to correct
position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004 (.10 mm). See Fig. 4. Tighten bottom timing
belt tensioner bolt. Tighten top bolt. Test belt tension with Tension Gauge
(Ele. 343) or equivalent. See Fig. 5. Deflection should be .216-.276
(5.5-7.0 mm). Install timing belt cover. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove radiator upper support. Remove upper and lower hoses from
radiator. Disconnect wiring harness connectors from cooling fan and
thermo switch. Remove radiator and A/C condenser as an assembly.
2) Release tension and remove serpentine drive belt. Remove timing
belt cover. Remove hose from water pump. Remove water pump pulley
bolt and pulley. Remove water pump.
3) 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.

Courtesy of American Motors/Renault Corp.

Fig. 2: Installing Timing Belt

Courtesy of American Motors/Renault Corp.

Fig. 1: Aligning Camshaft & Crankshaft Sprockets

RENAULT

611

2.2L 4-Cylinder (Cont.)

Courtesy of American Motors/Renault Corp.

Fig. 5: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 37 (50)
Crankshaft Pulley Bolt ............................................................................................. 96 (130)
Courtesy of American Motors/Renault Corp.

Fig. 3: Identifying Timing Belt Cover TDC Marks

Courtesy of American Motors/Renault Corp.

Fig. 4: Adjusting Intermediate Shaft Cover Clearance

SAAB

612

2.5L & 3.0L V6 1994-97

TIMING BELT APPLICATION
Application

Labor Time

Timing Belt
Belt
Kit No.
Part No.

2.5L V6
900
1994-97 ............................... 2.3 Hours ... ...... ..... ...... ..... T285
3.0L V6
9000
1995-97 ............................... 2.3 Hours ... .. TCK285 .. ..... T285
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Courtesy of Saab-Scania of America, Inc.

The manufacturer recommends the belt be replaced every 60,000 miles.

Fig. 1: Aligning Camshaft Sprocket Timing Marks

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) 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.
3) 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.
4) 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.
5) 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 timing belt. Correct belt marks
MUST be used.
Installation 1) Ensure crankshaft and camshaft timing marks are still
aligned. Install timing belt. Adjust lower roller counterclockwise to belt
tension of 205-221 ft. lbs. (275-300 N.m). Adjust tensioning pulley with
a hex head wrench until 2 marks are aligned. Tighten bolt.
2) Remove locking tool for camshaft sprockets No. 1 and 2. Adjust upper
adjusting roller counterclockwise until No. 2 sprocket moves .03-.07
(1-2 mm) clockwise. Remove camshaft locking tools.
3) Turn engine 2 revolutions in normal direction of rotation. Recheck
camshaft and crankshaft timing mark alignment. To complete installation, reverse removal procedure.

Courtesy of Saab-Scania of America, Inc.

Fig. 2: Installing Camshaft Belt Holders

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 37 (50)
Crankshaft Pulley Bolt ............................................................................................... 15 (20)
INCH Lbs. (N.m)
Valve Cover Nuts ...................................................................................................... 86 (10)

SAAB

613

3.0L V6 DOHC 1999-03

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

9-5
1999-03 ....................................................... 2.4 Hours ... ..... T285
1

With Air Conditioning, add .2 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends belt be replaced every 90,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Raise vehicle and remove lower spoiler sections. See
Fig. 1.
2) Insert a wedge between the oil sump and subframe. Insert a wedge
between the gearbox and subframe.
3) Lower car.
4) Remove mass airflow sensor with hose. Detach power steering hose
from holder. See Fig. 2.
5) Remove right engine attachment with bracket and engine mount. See
Fig. 3.
6) Undo retaining bolts from coolant pump pulley and power steering
pump pulley. See Fig. 4.
7) Release timing belt tension. See Fig. 5.
8) Remove coolant pump pulley and power steering pump pulley.
9) Remove belt tensioner and generator air intake. Remove timing
cover. Remove crankshaft pulley.
10) Turn crankshaft clockwise to align timing marks and set No. 1
cylinder to TDC of its compression stroke. Markings on camshaft
sprockets and timing cover must be aligned as must be crankshaft
marking. If reusing belt, mark direction of rotation on belt. Install Locking
Tool (KM-800-1 and KM-800-2) for camshaft sprockets, and Locking
Tool (KM-800-10) for crankshaft. See Fig. 6.
11) Undo tensioning pulley and adjusting rollers. Use Adjusting Wrench
(83 94 983) as a counterstay on adjusting rollers.
12) Remove Locking Tool (KM-800-10) from crankshaft. Keep Locking
Tools (KM-800-1 and KM-800-2) in place. Remove lower adjusting roller.
Remove washer behind roller. Remove timing belt.

Courtesy of Saab-Scania of America, Inc.

Fig. 2: Locating Mass Air Flow Sensor & Power Steering Hose

Courtesy of Saab-Scania of America, Inc.

Fig. 3: Removing Right Engine Attachment With Bracket & Mount

Courtesy of Saab-Scania of America, Inc.

Fig. 1: Removing Lower Spoiler Sections

Inspection Inspect timing belt for wear on rounded edges of drive

teeth. Inspect belt for signs of oil contamination. Replace belt if it is
damaged or contaminated.
Installation 1) Install timing belt using markings on belt and indicated
rotation direction. Use Assembly Kit (83 95 006) for camshaft sprockets
and camshaft drive belt. Use Adjustment Tool (KM-800-30) to hold belt
in place. Adjust tensioning pulley by hand so belt does not disengage.
Adjust counterclockwise and check to see that markings on timing belt
match markings on camshaft drive and crankshaft. Remove Adjustment
Tool (KM-800-30). Install Locking Tool (KM-800-10), position a piece of
camshaft belt, and install Belt Tension Meter (83 93 985) to measure belt
tension. See Fig. 7.

SAAB

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3.0L V6 DOHC 1999-03 (Cont.)

NOTE: Adjustment of belt tension is only a preparatory measure,
and must NOT be used as a check when belt is finally adjusted.
2) Tighten center bolts of adjuster rollers loosely. Adjust lower adjuster
roller counterclockwise until a tension of 275-300 N.m is obtained. Using
Adjusting Wrench (83 94 983), tighten adjuster roller bolt to specification. See TORQUE SPECIFICATIONS. Use Adjusting Wrench (83 94
983) as a counterstay. Check belt tension again and adjust as necessary.
3) Remove belt-tension meter and piece of toothed belt.
4) Ensure adjusting nut on upper adjusting roller rotates freely and is not
tight. Adjust tensioning pulley with a 5-mm Allen key until the two lines on
tensioning pulley correspond with each other. Tighten nut to specification. See TORQUE SPECIFICATIONS.
5) Remove Locking Tool for camshaft sprockets No. 1 and 2. Install
Adjustment Tool (KM-800-20). Adjust upper adjusting roller counterclockwise with Adjusting Wrench (83 94 983) until markings on camshaft
sprocket are aligned with markings on Adjustment Tool (KM-800-20).
Use Adjusting Wrench (83 94 983) as a counterstay, and tighten to
specification. See TORQUE SPECIFICATIONS.
6) Remove Adjustment Tool (KM-800-20) and other locking tools.

Courtesy of Saab-Scania of America, Inc.

Fig. 5: Releasing Timing Belt Tension

NOTE: Check that marking A is about 2 mm above marking B.

See Fig. 8. If this distance is smaller, adjust again.
7) Rotate engine 2 revolutions in direction of rotation until just before
zero mark, and install Locking Tool (KM-800-10) on crankshaft. Carefully
rotate crankshaft in direction of rotation of engine until arm is lying
against coolant pump and tighten bolt. Install Adjustment Tool
(KM-800-20) and ensure markings on camshaft sprocket are opposite
markings on tool. Ensure edge of belt is aligned with edge of sprocket.
8) Install crankshaft pulley and tighten bolt to specification. See
TORQUE SPECIFICATIONS.
9) Install timing cover and tighten bolts to specification. See TORQUE
SPECIFICATIONS.
10) Install belt tensioner and generator air intake. Install coolant pump
pulley and power steering pump pulley. Use Loctite. Do NOT tighten
bolts.
11) Install timing belt. Tighten retaining bolts on pulleys to specification.
See TORQUE SPECIFICATIONS.
12) Install right engine attachment with bracket and engine mount.
13) Install power steering hose in holder. Install mass airflow sensor with
hose.
14) Raise car. Lower engine by carefully removing wedges. Install lower
spoiler sections. Lower car.

Courtesy of Saab-Scania of America, Inc.

Fig. 6: Locking Camshaft & Crankshaft Sprockets

Courtesy of Saab-Scania of America, Inc.

Fig. 7: Installing Timing Belt

Courtesy of Saab-Scania of America, Inc.

Fig. 4: Locating Timing Belt Components

SAAB

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3.0L V6 DOHC 1999-03 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Adjuster Roller Bolt ................................................................................................... 30 (40)
Camshaft Sprockets .................................................................................................. 30 (40)
Crankshaft Pulley ...................................................................................................... 15 (20)
Engine Attachment W/Bracket & Engine Mount ................................................... 46.5 (63)
Power Steering Pump Retaining Bolts ..................................................................... 15 (20)
Upper Adjusting Roller Nut ....................................................................................... 15 (20)
INCH Lbs. (N.m)
Coolant Pump Retaining Bolts ................................................................................. 70.8 (8)
Timing Cover ............................................................................................................ 70.8 (8)
Courtesy of Saab-Scania of America, Inc.

Fig. 8: Measuring Tension Roller Position

SATURN

616

3.0L V6 DOHC L-Series After VIN 578512 & Vue

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 DOHC VIN B

Vue
2002-03 ..................................................... 3.0 Hours ... ..... T285
3.0L V6 DOHC VIN R (After S/N 578512)
L300
2002-04 ..................................................... 3.2 Hours ... ..... T285
LW300
2002-03 ..................................................... 3.2 Hours ... ..... T285

CAUTION: DO NOT remove Camshaft Holders (J-42069) with timing

belt removed.
CAUTION: DO NOT rotate crankshaft unless camshafts are properly locked in place, or valves may contact pistons.
CAUTION: DO NOT rotate camshafts unless crankshaft in at 60
BTDC, or valves may contact pistons.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 100,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of General Motors Corp.

Fig. 1: Positioning Crankshaft At 60 BTDC

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly.
2) Raise and support vehicle. Remove right front wheel. Remove lower
front splash shield.
3) Lower vehicle. Loosen, but DO NOT remove, water pump pulley
bolts. Rotate accessory serpentine belt tensioner clockwise using a 15
mm wrench, and remove accessory serpentine belt from pulleys.
NOTE: Right engine mount must be removed before accessory
drive belt can be removed from vehicle.
4) Install the 3 Bar Engine Support Fixture (SA9105E) and the Engine
Support Fixture Adapter (J-43405) to support weight of engine from
above or from below with a floor jack. Remove front engine mount
(timing belt end of engine) from engine and frame.
5) Remove water pump pulley bolts and pulley. Remove the power
steering pump pulley bolts and pulley. Remove accessory drive belt
tensioner from engine block.
6) Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic
balancer. It is NOT necessary to remove crankshaft center bolt.
7) 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.
8) Rotate crankshaft clockwise to 60 degrees Before Top Dead Center
(BTDC). See Fig. 1.
9) Install Crankshaft Locking Tool (J-42069-10). Rotate the crankshaft in
the engine rotational direction, clockwise, using the Crank Hub TORX
Socket (J-42098) until the No. 1 cylinder is at TDC and tighten the lever
arm to the water pump pulley flange. See Fig. 3.
NOTE: Ensure timing marks are not 180 degrees from TDC. Camshaft timing marks should be aligned with marks on rear cover. See
Fig. 2.
10) To lock camshafts in place, install Camshaft Gear Holders 1-2
(J-42069-1) and 3-4 (J-42069-2). See Fig. 4. It may be necessary to
loosen timing belt idler pulley and turn eccentric until holder can be
inserted.
11) Loosen timing belt tensioner. Remove timing belt.

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks

Inspection Check timing belt for excessive wear, cracks, missing
teeth, oil contamination or damage. Inspect timing belt tensioner and
idler pulleys for grease leaks or worn bearings. Replace as necessary.
CAUTION: DO NOT kink belt or a NEW belt will be required.
Installation 1) Remove crankshaft holder. This will ease installation of
the timing belt.
NOTE: With the camshaft locks installed, verify the distance
between the camshaft sprockets with the Green test belt located in
the Timing Belt Alignment Kit (J-42069).
2) Starting at the No. 1 and No. 2 camshaft sprockets, route the belt
around the No. 1 and No. 2 sprockets while aligning the belt marks to the
marks on the sprockets and the rear cover. See Fig. 2. Keeping slack out
of belt, route timing belt around tensioner and upper idler pulley.

SATURN

617

3.0L V6 DOHC L-Series After VIN 578512 & Vue (Cont.)

4) With belt firmly engaged on crankshaft sprocket, carefully rotate
crankshaft counterclockwise to allow slack at lower idler pulley side of
belt. Install belt over lower idler pulley. Remove plastic wedge holding
timing belt against crankshaft sprocket.
5) Install the crankshaft locking tool and tighten the lever arm to the
water pump pulley flange. Perform the following in sequence:
a) Install the camshaft checking gage to cams 3 and 4 and verify the
alignment marks are within 0.08 (2 mm) of each other.
b) Install the 3 and 4 camshaft lock, if properly aligned.
c) Install the camshaft checking gage to cams 1 and 2.
6) Rotate the No. 1 camshaft sprocket counterclockwise to remove the
slack between 1 and 2, and 3 and 4 cams.
NOTE: Ensure that the camshaft timing marks are to the left
(retard) side of the checking gage.
Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

7) Rotate upper timing belt idler pulley counterclockwise so that marks

are aligned within 0.08 (2.0 mm) of each other. Install 1-2 camshaft lock
after aligning idler pulley. Tighten idler pulley bolt to specification. See
TORQUE SPECIFICATIONS.
8) Turn tensioner eccentric until center alignment mark is about 1/8 (3.0
mm) above alignment mark on spring loaded idler pulley. See Fig. 6.

Courtesy of General Motors Corp.

Courtesy of General Motors Corp.

Fig. 6: Setting Timing Belt Tension Setting

Fig. 4: Installing Camshaft Gear Holders

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 timing belt. Correct belt marks
MUST be used.
3) Route the belt around the No. 3 and the No. 4 camshaft sprockets
while aligning the belt marks to the marks on the sprockets and the rear
cover. Route the belt around the crankshaft hub sprockets while aligning
the marks on the belt to the marks on the sprockets and the rear cover.
See Fig. 5. Hold timing belt in place against crankshaft sprocket using
Plastic Wedge (J-42069-30).

Courtesy of General Motors Corp.

Fig. 5: Aligning Timing Belt Marks On Crankshaft 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.
9) Remove camshaft holders from camshaft sprockets. Remove crankshaft locking tool. Rotate crankshaft 1-3/4 turns clockwise, install
crankshaft locking tool and then stop rotating crankshaft at TDC. Secure
crankshaft locking tool arm to water pump pulley flange.
10) Install Checking Gauge (J-42069-20) to left hand (drivers side)
camshafts. See Fig. 7. Verify marks are within 0.08 (2.0 mm) of each
other. Adjust timing belt tensioner so center alignment mark is approximately 1/8 (3.0 mm) above mark on spring loaded idler pulley. Tighten
tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS.
11) Verify the timing marks are still aligned. Remove Crankshaft Holder
(J-42069-10). Remove Checking Gauge (J-42069-20). Install timing belt
front cover. Install crankshaft harmonic balancer. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
12) Install water pump and accessory drive belt idler pulleys. Install
accessory drive belt tensioner. Install accessory drive belt. Tighten
pulley and idler bolts to specification. Install engine mount. Connect
negative battery cable.
13) Raise vehicle. Install splash shield. Install wheel. Lower vehicle and
install air cleaner assembly.

SATURN

618

3.0L V6 DOHC L-Series After VIN 578512 & Vue (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (L-SERIES)

Courtesy of General Motors Corp.

Fig. 7: Positioning Timing Belt On Left Hand Camshafts

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60
Step 3 ........................................................................................................... Additional 15
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45
Step 3 ........................................................................................................... Additional 15
Engine Mount-To-Bracket Bolt .................................................................................. 41 (55)
Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55)
Generator Bolt ........................................................................................................... 30 (40)
Power Steering Pump Pulley Bolt ............................................................................ 15 (20)
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)
Water Pump Pulley Bolt .............................................................................................. 71 (8)
TORQUE SPECIFICATIONS (VUE)
Application
Ft. Lbs. (N.m)
Accessory Drive Belt Idler Pulley ............................................................................. 15 (20)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60
Step 3 ........................................................................................................... Additional 15
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45
Step 3 ........................................................................................................... Additional 15
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)
Water Pump Pulley Bolt .............................................................................................. 71 (8)

SATURN

619

3.0L V6 DOHC L-Series Before VIN 578511

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.0L V6 DOHC VIN R

LS2 & LW2
2000 ........................................................... 3.2 Hours ... ..... T285
L300 & LW300
2001 ........................................................... 3.2 Hours ... ..... T285
2002-03 (Before S/N 578511) .................. 3.2 Hours ... ..... T285
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 100,000 mile
intervals.

Courtesy of General Motors Corp.

Fig. 1: Positioning Crankshaft At 60 BTDC

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner
assembly.
2) Raise and support vehicle. Remove right front wheel. Remove lower
front splash shield.
NOTE: Right engine mount must be removed before accessory
drive belt can be removed from vehicle.
3) Lower vehicle. Loosen, but do not remove, water pump pulley bolts.
Loosen, but do not remove, power steering pump pulley bolts. Rotate
accessory serpentine belt tensioner clockwise using a 15mm wrench,
and remove accessory serpentine belt from pulleys.
4) Support weight of engine from above or below with floor jack. Remove
front engine mount (timing belt end of engine) from engine and frame.
Remove engine mount bracket from engine block.
5) Remove water pump pulley bolts and pulley. Remove power steering
pump pulley bolts and pulley. Remove accessory drive belt tensioner
from engine block.
6) Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic
balancer. It is NOT necessary to remove crankshaft center bolt.
7) 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.
8) 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. 2.
9) Install Crankshaft Holder (J42069-10), and rotate crankshaft clockwise until holder contacts the water pump. See Fig. 3. Secure moveable
lever of tool to water pump pulley flange.
10) To lock camshafts in place, install Camshaft Gear Holders (J42069-1
and J42069-2). See Fig. 4. It may be necessary to loosen timing belt
idler pulley and turn eccentric until holder can be inserted.
11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing
belt, mark belt with arrow to indicate original direction of rotation.
Remove timing belt.
NOTE: DO NOT move camshafts with belt removed. DO NOT
remove Camshaft Holders (J42069) with timing belt removed.
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.

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks

Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

SATURN

620

3.0L V6 DOHC L-Series Before VIN 578511 (Cont.)

Courtesy of General Motors Corp.

Fig. 4: Installing Camshaft Gear Holders

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 1) 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. 5. The idler pulleys provide adjustment by
rotating on an eccentric circle around the mounting bolt.

Courtesy of General Motors Corp.

Fig. 6: Aligning Timing Belt Marks On Crankshaft Pulley

5) 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.
6) Ensure timing belt tension is taut (no slack). Loosen timing belt
tensioner lock nut. Turn tensioner eccentric until center alignment mark
is about .118 (3 mm) above alignment mark on spring loaded idler
pulley. See Fig. 7. Remove 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.

Courtesy of General Motors Corp.

Fig. 7: Setting Timing Belt Tension Setting

Courtesy of General Motors Corp.

Fig. 5: Positioning Timing Belt Idler Pulleys

2) 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 timing belt. Correct belt marks
MUST be used.
3) Install timing belt onto left hand camshafts (as viewed from rear of
engine), matching marks on timing belt with corresponding marks on
camshaft sprockets. See Fig. 2. Keeping 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. See
Fig. 6.
4) Hold timing belt in place against crankshaft sprocket using Plastic
Wedge (J42069-30). 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.

7) 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 (10 oclock).
See Fig. 5. Temporarily tighten Torx mounting bolt.
8) Adjust lower timing belt idler pulley so that the largest part of the
eccentric is above and to the left of the mounting Torx bolt (11 oclock).
See Fig. 5. Temporarily tighten Torx mounting bolt.
9) Remove camshaft holders from camshaft sprockets. Install 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.
10) 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.

SATURN

621

3.0L V6 DOHC L-Series Before VIN 578511 (Cont.)

Courtesy of General Motors Corp.

18) 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).
19) Adjust timing belt tensioner so that the center alignment mark is
about 3 mm above alignment mark on spring-loaded idler. See Fig. 7.
Tighten timing belt tensioner pulley nut. Verify all timing marks are still
aligned.
20) Remove Crankshaft Holder (J42069-10). Remove Checking Gauge
(J42069-20). Install timing belt front cover. Install crankshaft harmonic
balancer. Tighten bolts to specification.
21) Install water pump and power steering pump pulleys. Install accessory drive belt tensioner. Install accessory drive belt. Tighten pulley and
idler bolts to specification. Install engine mount. Connect negative
battery cable.
22) Raise vehicle. Install splash shield. Install wheel. Lower vehicle and
install air cleaner assembly.

Fig. 8: Positioning Timing Belt On Left Hand Camshafts

TORQUE SPECIFICATIONS

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.

TORQUE SPECIFICATIONS

11) 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 revolutions.
Timing marks on timing belt are used for initial installation only.
12) 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).
13) Remove Crankshaft Holder (J42069-10). Rotate crankshaft 1 3/4
turns clockwise. DO NOT rotate crankshaft counterclockwise. Install
Crankshaft Holder (J42069-10) to crankshaft flange, and then stop at
TDC. Tighten lever arm to water pump pulley flange.
14) Inspect left hand camshaft timing marks for alignment. Sprocket
timing marks should align with marks on rear cover. Realign, if necessary.
15) Remove Checking Gauge (J42069-20) from left hand camshaft
sprockets. Install checking gauge on right hand sprockets (passenger
side). Install Camshaft Gear Holder (J42069-2, Green) between left
hand camshaft sprockets.
16) 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 holding idler pulley eccentric in this
position, tighten upper idler pulley Torx mounting bolt to 15 ft. lbs. (20
N.m).
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.
17) 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.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60
Step 3 ........................................................................................................... Additional 15
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45
Step 3 ........................................................................................................... Additional 15
Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55)
Engine Mount-To-Bracket Bolt .................................................................................. 41 (55)
Generator Bolt ........................................................................................................... 30 (40)
Power Steering Pump Pulley Bolt ............................................................................ 15 (20)
Serpentine Drive Belt Tensioner Unit Bolt ............................................................... 30 (40)
Timing Belt Idler Pulley Torx Bolt ............................................................................. 15 (20)
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)
Water Pump Pulley Bolt .............................................................................................. 71 (8)

SATURN

622

3.5L V6
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

3.5L V6
Vue
2004 ........................................................... 3.0 Hours ... ..... T329
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 100,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

Installation 1) Clean the belt pulleys and covers. Rotate the crankshaft and align the Top Dead Center (TDC) mark on the sprocket with
the pointer on the oil pump housing. See Fig. 2.
2) Rotate the left camshaft sprocket to TDC by aligning the mark on the
sprocket with the pointer on the cover. See Fig. 3.
3) Rotate the right camshaft sprocket to TDC by aligning the mark on the
sprocket with the pointer on the cover. See Fig. 4.
4) Install the Timing Belt Tensioner Pulley Retaining Bolt (EN-46331).
Screw the timing belt tensioner pulley retaining bolt all the way in by
hand, until it contacts the timing belt tensioner. See Fig. 5.
5) Install the belt onto the sprockets. Install the timing belt in a clockwise
sequence starting with the tensioner pulley. See Fig. 6.
6) Tighten the idler pulley bolt to specifications. See TORQUE SPECIFICATIONS. Remove the Timing Belt Tensioner Retaining Pin
(EN-46330) and timing belt tensioner pulley retaining bolt.
7) Install the guide, balancer and bolt. See Fig. 7. Tighten the bolt until
snug. Using the Camshaft Sprocket/Balancer Holder (EN-46337), rotate
the crankshaft clockwise about 5 or 6 complete revelations to position
the timing belt on the sprockets.
8) Align the mark on the sprocket with the pointer on the oil pump
housing. See Fig. 2. Inspect the left camshaft sprocket for proper
alignment. The TDC mark on the sprocket should align with the pointer
on the cover. See Fig. 3. Inspect the right camshaft sprocket for proper
alignment. The TDC mark on the sprocket should align with the pointer
on the cover. See Fig. 4.
9) Remove the guide, balancer and bolt. See Fig. 7. Install the timing
belt cover.

CAUTION: The Powertrain Control Module (PCM) has to perform

the crankshaft position learn process under the following conditions:
The crankshaft position (CKP) sensor is removed for replacement or during disassembly.
The timing belt is removed for replacement or during disassembly.
The CKP Pattern Clear is executed from the Tech II.
The PCM is replaced.
Removal 1) Remove the air cleaner assembly. Remove the engine
drive belt. Remove the right splash shield. Using Camshaft Sprocket/
Balancer Holder (EN-46337), remove the engine balancer.
2) Remove the timing belt cover bolts. Remove the timing belt cover.
3) Using Timing Belt Tensioner Pulley Retaining Bolt (EN-46331),
secure the tensioner pulley. See Fig. 1. Loosen the idler pulley bolt
about 5 or 6 turns.
4) Remove timing belt from the pulleys.

Courtesy of General Motors Corp.

Fig. 2: Identifying Crankshaft Timing Marks

Courtesy of General Motors Corp.

Fig. 1: Identifying Idler Pulley Bolt

SATURN

623

3.5L V6 (Cont.)

Courtesy of General Motors Corp.

Fig. 5: Identifying Timing Belt Tensioner Pulley Retainer Bolt

Courtesy of General Motors Corp.

Fig. 3: Identifying Left Camshaft Sprocket Timing Mark

Courtesy of General Motors Corp.

Fig. 6: Identifying Timing Belt Alignment

Courtesy of General Motors Corp.

Fig. 4: Identifying Right Camshaft Sprocket Timing Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Timing Belt
Idler Pulley Bolt ....................................................................................................... 33 (44)
Rear Cover Bolts ..................................................................................................... 16 (22)
Tensioner Bolt .......................................................................................................... 18 (25)
Tensioner Pulley Bolt .............................................................................................. 18 (25)
Tensioner Pulley Nut ............................................................................................... 59 (80)
INCH Lbs. (N.m)
Timing Belt Auto-Tensioner Bolts ............................................................................ 106 (12)
Timing Belt Front Cover Bolts ................................................................................ 106 (12)

Courtesy of General Motors Corp.

Fig. 7: Identifying Balancer Components

STERLING

624

2.5L & 2.7L V6

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.5L V6
825
1987-88 ............................... 4.1 Hours ... .. TCK129 .. ..... T129
2.7L V6
827
1989-91 ............................... 4.1 Hours ... .. TCK129 .. ..... T129
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove negative battery cable. Turn crankshaft clockwise to bring No. 1 cylinder 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 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.
2) Remove alternator. Leaving hoses connected, remove power steering
pump and secure out of way. Remove upper 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 1) Remove spark plugs. Turn crankshaft clockwise to
bring No. 1 cylinder to TDC of compression stroke. Advance crankshaft
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 degrees to TDC position.
2) 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. Install pulley guides so guides form a V groove for belt to
ride in. Loosen timing belt tensioner bolt. To complete installation,
reverse removal procedure. Adjust drive belts to proper tension.
NOTE: Always adjust timing belt tension with engine cold.
3) 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.
4) Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt.
Reverse removal procedure to complete installation.
NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolts .............................................................................................. 16 (22)
A/C Compressor Bracket Bolts ................................................................................. 33 (45)
Alternator Bracket Bolts ............................................................................................ 33 (45)
Alternator Mount Bolts .............................................................................................. 16 (22)
Camshaft Pulley Bolts ............................................................................................... 23 (31)
Crankshaft Pulley Bolt ........................................................................................... 123 (170)
Engine Mount Bolts ................................................................................................... 40 (54)
Power Steering Pump Mount Bolt ............................................................................ 33 (45)
Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ............................................................................................ 86 (10)
Valve Cover Bolts .................................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

STERLING

625

2.5L & 2.7L V6 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

SUBARU

626

1.2L 3-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.2L 3-Cyl.
Justy
1987-95 ..................................................... 1.4 Hours ... ..... T135
1

With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) 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.
2) Remove outer timing belt cover. Loosen tensioner retaining bolts.
Move tensioner toward outside of engine. Tighten bolts to hold tensioner. See Fig. 1. Mark timing belt for direction of rotation. Remove
crankshaft belt drive sprocket plate and timing belt.
Inspection Inspect timing belt for wear on rounded edges of drive
teeth. 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 1) Using Pulley Holder (499205500) or equivalent, rotate
camshaft to align camshaft sprocket alignment mark with alignment
mark on timing belt cover. See Fig. 2. Install crankshaft belt drive
sprocket (if removed) with flanged side facing 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.
2) 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 remaining components. Tighten all bolts to specification.
See TORQUE SPECIFICATIONS. Adjust valve clearance. Adjust drive
belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 1: Exploded View Of Timing Belt Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolt ................................................................... ................. 58-72 (78-98)
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)

Courtesy of Subaru of America, Inc.

Fig. 2: Aligning Timing Marks

SUBARU

627

1.8L & 2.2L 4-Cylinder Impreza & Legacy

TIMING BELT APPLICATION
Application
1.8L 4-Cyl.
Impreza
1993 ...................................
1994-95 ..............................
1996-97 ..............................
2.2L 4-Cyl.
Impreza
1995-96 ..............................
1997 ...................................
1998 ...................................
Legacy
1990-93 ..............................
1994-95 ..............................
1996 ...................................
1997-98 ..............................
1

Labor Time

Component
Belt
Kit No.
Part No.

2.2 Hours .. .
2.2 Hours .. .
1
2.8 Hours .. .

TCK172 . ..... T172

TCK254 . ..... T254
2
TCK254 . ..... T254

2.8 Hours .. . 2 TCK254 . ..... T254

2.8 Hours .. ...... ..... ...... ..... T254
1
2.3 Hours .. ...... ..... ...... ..... T254
1

2.8
2.8
1
2.3
1
2.3
1

Hours
Hours
Hours
Hours

.. . 2 TCK172 . .....
.. . 2 TCK254 . .....
.. . 2 TCK254 . .....
.. ...... ..... ...... .....

T172
T254
T254
T254

With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.
Does not include camshaft tensioner hydraulic assembly.

CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992

kg). DO NOT release pressure until stopper pin is completely
installed.
Installation 1) 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 exceed 2205 lbs. (992 kg). Install
a stopper pin with a diameter of .059 (1.5 mm) through holes in adjuster
body and rod. See Fig. 2.
2) Temporarily tighten mount bolts while tension adjuster is pushed
completely right. Install belt tensioner. Ensure belt direction of rotation is
correct.
3) Install timing belt, being careful not to move sprockets. Install belt idler
No. 2 and belt idler. Loosen tension adjuster mount bolts and push
tension adjuster completely left. Tighten adjuster mount bolts.
4) 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 contain air. To complete installation,
reverse removal procedure. Adjust drive belts to proper tension.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-94 model years, the manufacturer recommends belt be
replaced every 60,000 miles. For 1995-97 model years, the manufacturer recommends belt be replaced at 60,000 miles on Federal vehicles,
and 105,000 miles on California vehicles.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing & Installing Timing Belt

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator
drive 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 equivalent for A/T models.
2) Remove front, left and right timing belt covers. If timing belt is to be
reused, mark belt to indicate original direction of rotation before removal.
Use Crankshaft Socket (499987500) to turn crankshaft pulley.
3) Align crankshaft and camshaft timing notches with corresponding
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 mounting bolts. Remove belt idler. Remove belt idler No. 2.
Remove timing belt.
Inspection 1) Inspect timing belt for wear on rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if it 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).
2) Slight trace of oil at rod oil seal does not indicate a problem. 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.
3) 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.

Courtesy of Subaru of America, Inc.

Fig. 2: Installing Tension Adjuster Rod Stopper Pin

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 55-61 (75-83)
Camshaft Support Bolt .............................................................................................. 12 (16)
Crankshaft Pulley Bolt ................................................................... ............... 69-76 (93-103)
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)

SUBARU

628

1.8L 4-Cylinder Except Impreza & Legacy

TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

1.8L 4-Cyl.
DL, GL & RX (Coupe, Sedan & Station
1985-89
Left Side ........................ .... 2.7 Hrs.
Right Side ..................... .... 2.7 Hrs.
Loyale
1990-94
Left Side ........................ .... 2.7 Hrs.
Right Side ..................... .... 2.7 Hrs.
XT
1985-91
Left Side ........................ .... 2.7 Hrs.
Right Side ..................... .... 2.7 Hrs.
1

Wagon)
.... .. TCK299 .. ..... T299
.... .. TCK299 .. ..... T300

.... .. TCK299 .. ..... T299

.... .. TCK299 .. ..... T300

.... .. TCK299 .. ..... T299

.... .. TCK299 .. ..... T300

Both Belts. With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 52,500 miles.

REMOVAL & INSTALLATION

by hand to ensure smooth operation 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 counterclockwise
direction.
4) While applying torque, tighten tensioner bolts. Ensure all timing marks
are aligned. See Figs. 3, 4 and 5.
NOTE: After installing left side timing belt, crankshaft is rotated
one 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. 6.
5) To install right (outer) timing belt, rotate crankshaft clockwise 360
degrees and align center line on flywheel with timing mark on flywheel
housing. Align camshaft sprocket timing mark with notch in housing. See
Figs. 4 and 5.
6) Install right timing belt over crankshaft and camshaft sprockets,
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
counterclockwise, 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, 5 and 6.
7) While applying torque, tighten inner and then outer tensioner retaining
bolts. Ensure all timing marks are aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator
drive belt. Remove water pump pulley. Remove dipstick and tube.
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 equivalent) for A/T
models.
CAUTION: If reusing timing belt, mark belt to indicate normal
direction of rotation.
2) Remove center, left and right timing belt covers. To remove right side
timing belt, loosen tensioner bolts on No. 1 cylinder 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.
3) Loosen left side timing belt tensioner bolts on No. 2 cylinder 1/2 turn.
See Fig. 1. Using tensioner wrench, rotate tensioner until belt is slack.
Tighten tensioner bolts. If reusing timing belt, mark belt to indicate
normal direction of rotation. Remove outer crankshaft sprocket. Remove
timing 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 1) 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. Temporarily install
crankshaft pulley.
2) Align center mark on flywheel with mark on flywheel housing. See
Fig. 3. Align timing mark on left camshaft sprocket (sprocket for timing
belt closest to engine) with notch in belt cover. See Figs. 4 and 5. 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.
3) If reusing belt, install it in original direction of rotation. Loosen left
tensioner retaining bolt to apply tension to timing belt. Push timing belt

Courtesy of Subaru of America, Inc.

Fig. 1: Identifying Timing Belts & Engine Components

SUBARU

629

1.8L 4-Cylinder Except Impreza & Legacy (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 2: Measuring Tensioner Squareness

Courtesy of Subaru of America, Inc.

Fig. 5: Identifying Camshaft Position For Installing Timing Belts

(Right Camshaft Sprocket)

Courtesy of Subaru of America, Inc.

Fig. 3: Aligning Flywheel Timing Marks

Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Final Installed Position Of Left Timing Belt

Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Idler Bolt ................................................................................. ................. 29-35 (39-47)
Belt Tensioner Bolt ........................................................................ ................. 13-15 (18-20)
Camshaft Case Bolt ...................................................................... ................. 13-15 (18-20)
Crankshaft Pulley Bolt 1 ................................................................ ............... 66-79 (90-107)
Oil Pump Pulley Nut ..................................................................... ................. 13-15 (18-20)
INCH Lbs. (N.m)
Courtesy of Subaru of America, Inc.

Fig. 4: Identifying Camshaft Position For Installing Timing Belts

(Left Camshaft Sprocket)

Camshaft Sprocket Bolt ................................................................ ................... 80-89 (9-10)

Camshaft Support Bolt .................................................................. ..................... 53-62 (6-7)
Timing Belt Cover Bolt .................................................................. ..................... 35-44 (4-5)
Valve Cover Bolt ........................................................................... ..................... 35-44 (4-5)
Water Pump Pulley Bolt ................................................................ ................... 80-89 (9-10)
1

Coat bolt threads with oil before installation.

SUBARU

630

2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cylinder DOHC (Turbocharged)

Impreza
2002-04 ..................................................... 2.4 Hours ... ..... T328
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 105,000
miles.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing Drive Belt Cover

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable.
2) Remove accessory drive belt cover. See Fig. 1. Remove accessory
drive belts.
3) Hold crankshaft pulley stationary using Crank Pulley Wrench
(499977100 or 499977400), and remove crankshaft pulley center bolt.
See Fig. 2. Remove crankshaft pulley.
4) Remove timing belt covers. See Fig. 3.
5) Using Crankshaft Socket (499987500), turn crankshaft to align marks
on crankshaft sprocket, left side intake camshaft sprocket, left side
exhaust camshaft sprocket, right side intake camshaft sprocket and right
side exhaust camshaft sprocket with notches on belt cover and cylinder
block. See Fig. 4.
6) On manual transmission models, remove timing belt guides from
around crankshaft and camshaft pulleys. See Fig. 5.
7) On all models, if reusing old belt, check for timing and rotation marks
on timing belt before removing. If marks are missing or worn off, use
White paint to mark timing belt in relation to sprocket timing marks and
direction of belt rotation. See Fig. 6. Count number of teeth between
crankshaft sprocket and camshaft sprockets so that belt can be reinstalled in same position. See INSTALLATION MARK MEASUREMENT
SPECIFICATIONS table. For location of measurement points, refer to
illustration. See Fig. 7.
CAUTION: After timing belt has been removed, NEVER rotate
intake and exhaust camshaft sprockets. If camshaft sprocket is
rotated, intake and exhaust valve heads will strike together and
valve stems will bend.

Courtesy of Subaru of America, Inc.

Fig. 2: Identifying Crank Pulley Wrench (499977400 Shown)

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Timing Belt Covers & Bolts

8) Remove timing belt idler pulley A. See Fig. 8. Remove timing belt.
9) Remove idler pulleys B and C, if necessary. See Fig. 8. Remove
automatic belt tension adjuster assembly with adjuster rod facing up.
See Fig. 9.
INSTALLATION MARK MEASUREMENT SPECIFICATIONS
Location
Number Of Teeth
Z-1 .................................................................. ................................................................ 54.5
Z-2 .................................................................. ................................................................... 51
Z-3 .................................................................. ................................................................... 28
Courtesy of Subaru of America, Inc.

Inspection 1) Inspect timing belt teeth for breaks, cracks or wear.

Inspect belt for signs of oil contamination. When inspecting timing belt,
do not bend less than a radius of 2.36 (6.0 mm). Replace belt if any fault
is present.
2) Inspect automatic belt tension adjuster oil seal for leaks. Slight trace
of oil at adjuster rod oil seal does not indicate a problem. Inspect
adjuster rod end for abnormal wear and scratches.

Fig. 4: Identifying Crankshaft Socket (499987500)

3) Measure extension of adjuster rod beyond tensioner body. Holding
tensioner with adjuster rod facing up, adjuster rod extension should be
.204-.244 (5.2-6.2 mm). See Fig. 10. Replace automatic timing belt
tensioner assembly if adjuster rod extension is not as specified.

SUBARU

631

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Timing & Directional Arrow Marks On

Timing Belt & Sprockets

Courtesy of Subaru of America, Inc.

Fig. 7: Identifying Tooth Measurement Locations On Timing Belt

Courtesy of Subaru of America, Inc.

Fig. 5: Identifying Location of Timing Belt Guides

Courtesy of Subaru of America, Inc.

Fig. 8: Identifying Timing Belt Idler Pulley Location

632

SUBARU
2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 9: Removing Automatic Timing Belt Tension Adjuster

Assembly
CAUTION: DO NOT use a bench vise to compress adjuster rod.
Always use a vertical type pressing tool to compress adjuster rod.
It should take more than 3 minutes to compress adjuster rod.
4) Place automatic belt tension adjuster assembly in a press with
adjuster rod facing up. Apply 66 lbs. (30 kg) of pressure on rod. If
adjuster rod moves down easily, replace automatic timing belt tensioner
assembly.
5) Inspect automatic belt tension adjuster and idler pulleys for abnormal
surface wear, oil leakage, rough rotation, noise and excessive play.
Replace if any fault is present.

Courtesy of Subaru of America, Inc.

Fig. 11: Identifying DOHC Valve Position In Cylinder Head

Courtesy of Subaru of America, Inc.

Fig. 10: Checking Automatic Timing Belt Tension Adjuster Rod

Extension
Precaution 1) Intake and exhaust camshafts for this DOHC engine
can be independently rotated with timing belt removed. As can be seen
from figure, if intake and exhaust valves are lifted simultaneously, their
heads will interfere with each other, resulting in bent valves. See Fig. 11.
2) When timing belts are not installed, four camshafts are held at Zero
Lift position, where all cams on camshafts do not push the intake and
exhaust valves down. Under this condition, all valves remain unlifted.
3) When camshafts are rotated to install the timing belts, No. 2 intake
and No. 4 exhaust cam of left-hand camshafts are held to push their
corresponding valves down. Under this condition, these valves are held
lifted. Right-side camshafts are held so that their cams do not push
valves down.
4) Left-hand camshafts must be rotated from Zero Lift position where
timing belt is to be installed at as small an angle as possible, in order to
prevent mutual interference of intake and exhaust valve heads.
5) Do not allow camshafts to rotate in direction shown in figure, as this
causes both intake and exhaust valves to lift simultaneously, resulting in
interference with their heads. See Fig. 12.
Installation 1) Align mark on crankshaft sprocket with mark on oil
pump cover at cylinder block. See Fig. 6.
2) Align single mark on right hand exhaust camshaft sprocket with notch
on belt cover.

Courtesy of Subaru of America, Inc.

Fig. 12: Rotating Camshafts To Align Timing Marks

3) Align single mark on right hand intake camshaft sprocket with notch
on belt cover. Ensure double line marks on intake and exhaust camshaft
sprockets are aligned.
4) Align single line mark A on left hand exhaust camshaft sprocket with
notch B on belt cover by turning sprocket counterclockwise (as viewed
from front of engine). See Fig. 13.
5) Align single line mark A on left hand intake camshaft sprocket with
notch B on belt cover by turning sprocket clockwise (as viewed from
front of engine). Ensure double line marks C on intake and exhaust
camshaft sprockets are aligned. See Fig. 14.

SUBARU

633

2.0L 4-Cylinder DOHC (Cont.)

CAUTION: To prevent damage, DO NOT apply more than 2205 lbs.
(1000 kg) to automatic adjuster rod. DO NOT press automatic
adjuster rod past top surface of housing. Always use a vertical type
press to move adjuster rod down.
6) Install automatic belt tension adjuster assembly into vertical pressing
tool. Slowly apply 66 lbs. (30 kg) pressure to adjuster rod (taking more
than 3 minutes) until hole in adjuster rod is aligned with hole in cylinder.
See Fig. 15.
CAUTION: Do not release pressure on adjuster rod until stopper
pin is completely inserted.
7) Use a 0.08 (2.0 mm) diameter stopper pin or hex wrench, and insert
it through stopper pin hole in cylinder and adjuster rod to secure adjuster
rod. See Fig. 15.
8) Install automatic belt tension adjuster assembly on engine with
stopper pin in place. Install idler pulleys. Tighten bolts to specification.
See TORQUE SPECIFICATIONS.
9) Ensure crankshaft and camshaft timing marks are still aligned. See
Figs. 6 and 16. Install timing belt on sprockets in alphabetical order
shown in figure. See Fig. 16. Ensure installation marks align with
crankshaft and camshaft sprockets. Count number of teeth between
crankshaft sprocket and camshaft sprockets so that belt will be installed
in same position. See Fig. 16. If reusing old belt, ensure direction of belt
rotation arrow is correct and installation marks are aligned with crankshaft and camshaft sprockets.
10) Install timing belt idler pulleys (if removed). Ensure timing marks are
aligned. Remove stopper pin from automatic timing belt tensioner
assembly. On manual transmission models, install timing belt guides
over crankshaft pulley and at corners by camshaft pulleys. See Fig. 5.
Adjust clearance between all belt guides and timing belt to .020-.058
(.5-1.5 mm). See Fig. 17.

Courtesy of Subaru of America, Inc.

Fig. 13: Aligning Left Exhaust Camshaft

Courtesy of Subaru of America, Inc.

Fig. 14: Aligning Left Intake Camshaft

CAUTION: If tightening angle of crankshaft pulley bolt is less than

45 degrees, bolt is damaged. Bolt must be replaced.
11) Install timing belt covers. Clean crankshaft pulley bolt and bolt hole.
Install crankshaft pulley. Coat crankshaft pulley bolt threads with engine
oil. Install crankshaft pulley bolt. Hold crankshaft pulley stationary using
Crank Pulley Wrench (499977400), and tighten bolt to specification. See
TORQUE SPECIFICATIONS.
12) Install accessory drive belts. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 15: Installing Adjuster Rod Stopper Pin

SUBARU

634

2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 16: Identifying Order For Installing Timing Belt

Courtesy of Subaru of America, Inc.

Fig. 17: Checking Clearance Between Timing Belt Guides & Timing Belt

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (Cont.)

TORQUE SPECIFICATIONS

Application
Ft. Lbs. (N.m)
Timing Belt Automatic Tensioner Bolt ....................................................................... 29 (39)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 72 (98)
Crankshaft Pulley Bolt ............................................................................................. 94 (127)
Idler Pulley Bolt ......................................................................................................... 29 (39)

INCH Lbs. (N.m)

Timing Belt Cover Bolt ................................................................................................ 44 (5)
Timing Belt Guide Bolt (M/T)
Center Guide ........................................................................................................... 89 (10)
Corner Guides
2002 ....................................................................................................................... 89 (10)
2003 ......................................................................................................................... 44 (5)
2004 ................................................................................................................... 61.2 (6.4)

SUBARU

635

2.2L & 2.5L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

2.2L 4-Cyl.
Impreza
1999-01 .....................................................
Legacy
1999 ...........................................................
2.5L 4-Cyl.
Baja
2003-04 .....................................................
Forester
1999-04 .....................................................
Impreza
1999-04 .....................................................
Legacy & Outback
2000-04 .....................................................

Belt
Part No.

2.3 Hours ... ..... T304

2.3 Hours ... ..... T304
2.3 Hours ... ..... T307
2.3 Hours ... ..... T304
2.3 Hours ... ..... T304
2.3 Hours ... ..... T307

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 105,000
miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

Courtesy of Subaru of America, Inc.

Removal 1) Disconnect negative battery cable. Raise and support

vehicle. Remove engine under cover.
2) Lower vehicle. Remove radiator coolant reservoir, and set aside.
Remove electric cooling fan and radiator shroud.
3) On Impreza and Forester, remove accessory drive belt cover. On all
models, remove accessory drive belts.
4) Hold crankshaft pulley stationary, and remove crankshaft pulley
center bolt. Remove crankshaft pulley. Remove timing belt covers.
5) 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, remove timing belt guide from top of
crankshaft pulley.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Subaru of America, Inc.

Fig. 3: Removing No. 2 Timing Belt Idler Pulley

2) 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.
3) Measure extension of rod beyond tensioner body. Holding tensioner
with rod facing up, rod extension should be .204-.244 (5.2-6.2 mm).
See Fig. 4. Replace automatic tensioner if rod extension is not as
specified.
Courtesy of Subaru of America, Inc.

Fig. 1: Identifying Timing Belt Routing & Timing Marks

6) On all models, if reusing old belt, use White paint to mark timing belt
in relation to sprocket timing marks. Also mark timing belt direction of
rotation.
7) Remove No. 2 timing belt idler pulley. See Fig. 3. Remove timing belt.
Remove timing belt automatic tensioner with rod facing up.
Inspection 1) Inspect timing belt for wear on rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if it is
damaged or contaminated.

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.
4) 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.
5) Inspect automatic tensioner and idler pulleys for worn bearings or
lubricant leaks. Replace as necessary.

SUBARU

636

2.2L & 2.5L 4-Cylinder SOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 4: Checking Automatic Tensioner Rod Extension

CAUTION: To prevent damage, DO NOT apply more than 2205 lbs.
(9807 N) of pressure to automatic adjuster rod. Do NOT press
automatic tensioner rod past the top surface of the housing.
Installation 1) Ensure crankshaft and camshaft timing marks are still
aligned. Place automatic adjuster in a press with rod facing up. Apply 66
lbs. (294 N) pressure to end of rod. SLOWLY compress rod (taking more
than 3 minutes) into housing until rod and housing holes are aligned.
Insert locking pin through holes. See Fig. 5.
2) Install automatic tensioner on engine with locking pin in place. Install
idler pulleys (if removed).
3) Ensure crankshaft and camshaft timing marks are still aligned. See
Fig. 2. Install timing belt. If reusing old belt, ensure belt direction of
rotation is correct and mating marks are aligned. If using new belt,
ensure arrows on belt match direction of rotation. See Fig. 6.
4) Install No. 2 idler pulley on engine. Remove automatic tensioner
locking pin. On manual transmission models, install timing belt guide
over crankshaft pulley. Adjust clearance between belt guide and belt to
.020-.058 (.5-1.5 mm). See Fig. 7.

Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Timing Belt Direction Of Rotation (New Belt)

CAUTION: If tightening angle of crankshaft pulley bolt is less than

65 degrees, bolt is damaged. Bolt must be replaced.
5) On all models, install timing belt covers. Clean crankshaft pulley bolt
and bolt hole. Install crankshaft pulley. Coat crankshaft pulley bolt
threads with engine oil. Install bolt. While holding crankshaft pulley
stationary, tighten bolt to specification. See TORQUE SPECIFICATIONS.
6) Install accessory drive belts. Install radiator fan assembly. To complete installation, reverse removal procedures. Adjust drive belts to
proper tension.

Courtesy of Subaru of America, Inc.

Fig. 7: Checking Timing Belt Guide Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 58 (78)
Crankshaft Pulley Bolt
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 (10-14)

Courtesy of Subaru of America, Inc.

Fig. 5: Installing Automatic Tensioner Pin

SUBARU

637

2.5L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.5L 4-Cyl. DOHC

Forester
1998 .................................... 2.3 Hours ... ...... ..... ...... ..... T277
Impreza
1998 ................................... 1 2.8 Hours .. .. TCK277 .. ..... T277
Legacy & Outback
1996-99 .............................. 1 2.8 Hours .. .. TCK277 .. ..... T277
1

6) Check mating surfaces of timing belt and contact point of tension

adjuster rod for abnormal wear or scratches. Replace belt tensioner if
faulty. Check spacer and tensioner bushing for wear. Check tensioner
for smooth rotation. Replace if noise or excessive play is noted. Check
tensioner for grease leakage.

With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
on 1996-97 Federal vehicles. Replace belt at 105,000 miles on all
1998-99 vehicles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Remove drive belt cover. See Fig. 2. Remove drive belt.
Remove A/C compressor belt tensioner assembly (if equipped). Holding
crankshaft stationary, remove crankshaft pulley bolt. See Fig. 3.
Remove crankshaft pulley.
2) Remove left and right timing belt covers. Remove front belt cover. See
Fig. 4. Rotate crankshaft and align crankshaft and camshaft timing
notches. See Figs. 5 and 6. If alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade away, put new marks on
belt before removing timing belt. See Fig. 1.
3) 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 direction of rotation. Also, place mating marks
on timing belt and crankshaft and camshaft sprockets.
4) Remove both timing belt idler pulleys. Remove timing belt automatic
tensioner and spacer. Remove timing belt.
CAUTION: To prevent intake and exhaust valves from contacting
each other, DO NOT rotate crankshaft or camshafts with timing belt
removed.
Inspection 1) Check timing belt teeth for breaks, cracks, and wear. If
any fault is found, replace belt. Check the condition of back side of belt;
if any crack is found, replace belt. Inspect timing belt for wear on
rounded edges of drive teeth. Inspect belt for signs of oil contamination.
Replace belt if it is damaged or contaminated.
2) 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.
3) Measure the extension of rod beyond the body. If it is not within
specifications, replace with a new one. Rod extension: 0.606-0.646 in
(15.4-16.4 mm). See Fig. 7.
4) Place automatic tensioner in a press with tensioner rod facing up.
Apply 33 lbs. (15 kg) of pressure on rod. If rod moves down easily,
replace automatic tensioner.
5) Apply a force of 33 to 110 lbs (15 to 50 kg,), the rod section should
maintain a projectionally acting force and should not sink within 8.5
seconds.

Courtesy of Subaru of America, Inc.

Fig. 1: Placing Alignment &/Or Rotation Marks On Timing Belt

Courtesy of Subaru of America, Inc.

Fig. 2: Removing Drive Belt Cover

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Crankshaft Pulley Bolt

SUBARU

638

2.5L 4-Cylinder DOHC (Cont.)

7) Check idler for smooth rotation. Replace if noise or excessive play is
noted. Check outer contacting surfaces of idler pulley for abnormal wear
and scratches. Check idler for grease leakage.
CAUTION: Do not allow press pressure to exceed 2205 lbs (1000
kg,). Do not release press pressure until stopper pin is completely
inserted. Push tension adjuster rod vertically. Press-in the push
rod gradually, taking 3 minutes or more.

Installation 1) Ensure crankshaft and camshaft timing marks are still

aligned. Place automatic adjuster in a press with rod facing up. Apply
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. 8.
2) 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.
3) Count number of teeth between crankshaft and camshaft pulleys to
ensure belt is correctly installed. See Fig. 6. When belt is correctly
installed, remove automatic tensioner locking pin.
4) On manual transmission models, install timing belt guide over
crankshaft pulley. Clearance between belt guide and belt should be
.039 (1.0 mm).
5) Install timing belt covers. Install crankshaft pulley, Holding crankshaft
stationary, tighten bolt to specification. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 4: Removing & Installing Front Belt Cover

Courtesy of Subaru of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Related Components

SUBARU

639

2.5L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 6: Aligning Timing Marks & Sprocket Alignment Marks

Courtesy of Subaru of America, Inc.

Fig. 7: Measuring Belt Tensioner Rod Extension (2.5L Engine)

SUBARU

640

2.5L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 58 (78)
Crankshaft Pulley Bolt ........................................................................................... 130 (177)
Timing Belt Idler Pulley Bolt ..................................................................................... 29 (39)
Timing Belt Tensioner Bolt ........................................................................................ 29 (39)
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)

Courtesy of Subaru of America, Inc.

Fig. 8: Installing Belt Tensioner Stopper Pin

SUBARU

641

2.7L 6-Cylinder
TIMING BELT APPLICATION
1

Application

Labor Time

Belt
Part No.

2.7L 6-Cyl.
XT6
1988-91
Left Side ................................................. 2.9 Hours ... ..... T151
Right Side ............................................... 2.9 Hours ... ..... T150
1

Both Belts. With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Subaru of America, Inc.

Fig. 2: Loosening Right Hand Timing Belt Tension

The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Loosen water pump pulley and alternator mounting bolts.
Loosen serpentine belt tensioner pulley lock nut, and release belt
tension. Ensure adjuster bolt is turned fully counterclockwise and
remove serpentine belt.
2) 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.
3) Unplug oil pressure switch connector. Remove oil level gauge guide
from front of engine. See Fig. 1. Remove center, left and right timing belt
covers.
4) 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 direction of belt rotation. Remove timing belt.
5) 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 Figs. 4
and 5.
6) 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 tension. Install Belt Adjuster
Stopper (13082AA000) or equivalent, on tension adjuster. See Fig. 7.
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.

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Left Timing Belt Idler Pulley

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 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 1) 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.
2) Using syringe, add engine oil through vent hole on top of rubber boot.
Add oil until it overflows. Install Phillips screw and new gasket.
3) Install belt tension adjuster on engine. Keep belt adjuster stopper in
place. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
4) Install rubber plug and retaining bolt on engine. Install left timing belt
idler pulley. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
5) 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 timing belt cover. See Fig. 9.
6) Install left (driver side) timing belt starting from the crankshaft
sprocket. If installing used belt, ensure belt is installed in original
direction of rotation. Install belt tension adjuster. See Fig. 7. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Remove belt
adjuster stopper 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.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing Oil Level Gauge Guide

SUBARU

642

2.7L 6-Cylinder (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 5: Removing Rubber Plug & Retaining Bolt

Courtesy of Subaru of America, Inc.

Fig. 6: Removing Phillips Screw From Belt Tension Adjuster

Courtesy of Subaru of America, Inc.

Fig. 4: Exploded View Of Timing Belt & Components

NOTE: After installing left (drivers side) timing belt, crankshaft is
rotated one full turn (360 degrees). This will be the position for
installing the right (passenger side) camshaft belt. The camshaft
timing mark for the left side timing belt will now be pointing
straight down (6 oclock position). See Fig. 10.
7) To install right (passenger side) timing belt, rotate crankshaft 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.
8) Install right hand timing belt tensioner. Rotate tensioner assembly
down and temporarily tighten retaining bolts.
9) 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.
10) Loosen right hand tensioner bolts, and allow tensioner to apply belt
tension. Install Belt Tension Wrench (499437100) on right camshaft
sprocket.

Courtesy of Subaru of America, Inc.

Fig. 7: Installing Belt Adjuster Stopper

SUBARU

643

2.7L 6-Cylinder (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 8: Checking Belt Tensioner Roller Squareness

11) Using torque wrench and belt tension wrench, apply 17-18 ft. lbs.
(24-25 N.m) of torque in a counterclockwise direction to right camshaft
sprocket. While applying torque, temporarily tighten tensioner bolt
closest to the tensioner pulley, and then the tensioner pivot bolt.
12) Check belt tension. Belt tension should be 33-55 lbs. (15-25 kg). If
belt tension is correct, tighten tensioner bolt closest to the tensioner
pulley, and then the tensioner pivot bolt to specification. See TORQUE
SPECIFICATIONS. Ensure all timing marks are still aligned.
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.
13) 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.
14) To install remaining components, reverse removal procedure.
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.

Courtesy of Subaru of America, Inc.

Fig. 9: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Subaru of America, Inc.

Fig. 10: Identifying Final Installed Position Of Left (Driver Side)

Camshaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27)
Crankshaft Pulley Center Bolt 1 .................................................... ............... 66-79 (90-107)
Timing Belt Tensioner Bolt
Left Hand Tensioner .................................................................... ................. 29-35 (39-47)
Right Hand Tensioner ................................................................. ................. 17-20 (23-27)
INCH Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................................ 97-108 (11-13)
Oil Level Guide Bolt ...................................................................... ..................... 40-48 (4-5)
Timing Belt Cover Bolt .................................................................. ..................... 40-48 (4-5)
Water Pump Pulley Bolt ................................................................ ................... 80-92 (9-10)
1

Coat bolt threads with oil before installation.

SUBARU

644

3.3L 6-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

3.3L 6-Cyl.
SVX
1992-97 ....................................................
1

Belt
Part No.

2.6 Hours .. ..... T209

With Air Conditioning, add .4 hours.

With Power Steering, add .2 hours.

Installation 1) 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.
2) While aligning marks on timing belt with marks on sprockets, position
timing belt properly. Ensure belt rotating direction is correct. Install idler
pulleys. Loosen tension adjuster attaching bolts and move adjuster fully
left.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

CAUTION: Readjust new alternator belt after 5 minutes of operation.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

3) Tighten adjuster bolts. Once all timing marks are aligned, remove
stopper pin from tension adjuster. Install front timing belt covers. To
complete installation, reverse removal procedure. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive
belts to proper tension.

For 1992-94 model years, the manufacturer recommends belt be

replaced every 60,000 miles. For 1995-97 model years, the manufacturer recommends belt be replaced at 60,000 miles on Federal vehicles,
and 105,000 miles on California vehicles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove undercover.
Disconnect power steering cooler hoses from body. Disconnect cooling
fan connectors. Remove drive belt cover. Remove 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.
2) 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, re-mark timing
belt before removing.
3) Turn crankshaft to align marks on crankshaft sprocket and camshaft
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.

Courtesy of Subaru of America, Inc.

Fig. 2: Setting Tension Adjuster

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Belt Idler Bolt ................................................................................. ................. 26-32 (35-43)
Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27)
Camshaft Sprocket Bolt ................................................................ ............. 80-94 (108-127)
Crankshaft Pulley Bolt 1 ................................................................ ......... 108-123 (147-167)
Tensioner Bolt ................................................................................ ................. 26-32 (35-43)
INCH Lbs. (N.m)

Courtesy of Subaru of America, Inc.

Fig. 1: View Of Timing Belt Components

Inspection 1) Inspect timing belt for wear on rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if it 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.
2) 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 adjuster if distance is not correct.
Inspect idler pulleys and tensioners for smooth rotation. Replace
components if noise or excessive play is noted.

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

Coat bolt threads with oil before installation.

SUZUKI

645

1.3L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

1.3L 4-Cyl. DOHC

Swift
1989-94 ....................................................
1

Belt
Part No.

2.6 Hours .. ..... T171

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1989-92 model years, although the manufacturer does 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.

Installation 1) 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 Figs. 2 and 3.
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.
2) 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.
3) Tighten tensioner bolt and nut. Ensure drive side of belt is free of
slack. Ensure timing marks are aligned. Install timing belt outer covers
and tighten to specification. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure. Tighten bolts to
specification. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) 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.
3) Align all sprocket timing marks with timing marks on engine. 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.

Courtesy of Suzuki of America Corp.

Fig. 1: Aligning Timing Belt Marks

Courtesy of Suzuki of America Corp.

Fig. 2: Securing Intake & Exhaust Camshaft Sprocket For

Timing Belt Installation

SUZUKI

646

1.3L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28)
Alternator Pulley Bolts
1992-94 ........................................................................................ ............... 70-96 (95-130)
Camshaft Sprocket Bolt ................................................................ ................. 41-47 (56-64)
Crankshaft Sprocket Bolt ............................................................................ 77-85 (105-115)
Timing Belt Tensioner Bolt ............................................................ ................. 18-22 (24-30)
INCH Lbs. (N.m)
Alternator Pulley Bolt
1989-91 ........................................................................................ ............... 90-108 (10-13)
Crankshaft Pulley Bolt ................................................................... ................. 80-106 (9-12)
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)
Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)

Courtesy of Suzuki of America Corp.

Fig. 3: Identifying Sprocket Movement Limits

SUZUKI

647

1.3L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

1.3L 4-Cyl. SOHC

Samurai
1985 ...................................
1986-93 ..............................
1994 ...................................
1994 ...................................
1995 ...................................
Sidekick
1989
8-Valve .............................
16-Valve ...........................
Swift
1989-93 ..............................
1994 ...................................
1995-97 ..............................
1998-01 ..............................
1
2
3

3.0
3.0
1
3.0
1
3.0
1
3.0
1

1
1

.. ...... ..... ...... ..... T095

.. .. TCK095 .. ..... T095
.. .. TCK095 .. ... 2 T095
.. ...... ..... ...... ... 3 T243
.. ...... ..... ...... ..... T243

3.6 Hours .. .. TCK095 .. ..... T095

4.0 Hours .. .. TCK095 .. ..... T095

2.6
2.6
1
2.6
1
2.6
1

Hours
Hours
Hours
Hours
Hours

Component
Belt
Kit No.
Part No.

Hours
Hours
Hours
Hours

.. .. TCK095 .. .....
.. ...... ..... ...... .....
.. .. TCK272 .. .....
... TCK194A . .....

T095
T243
T272
T194

With Air Conditioning, add .4 hours.

For VIN R4100375 and earlier.
For VIN R4100376 and later.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of Suzuki of America Corp.

Fig. 1: Adjusting Valve Clearance

NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1985-92 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1993-01 model
years, the manufacturer recommends the belt be replaced at 60,000
mile intervals.

ADJUSTMENTS
VALVE CLEARANCE SPECIFICATIONS
VALVE CLEARANCE SPECIFICATIONS
Valve
Cold In. (mm)
Hot In. (mm)
Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28)
Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28)

REMOVAL & INSTALLATION

TIMING BELT
Removal (Samurai & Sidekick) 1) Disconnect negative battery cable.
Remove cooling fan and fan shroud. Discharge A/C system using
approved refrigerant recovery/recycling equipment and disconnect compressor flexible suction hose from suction pipe (if equipped). Remove
A/C compressor belt (if equipped).
2) 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.
3) Mark belt with an arrow indicating direction of rotation for installation
reference. Remove timing belt from camshaft and crankshaft sprockets.
CAUTION: With timing belt removed, DO NOT turn camshaft
sprocket more than 20 degrees in either direction from aligned
position. DO NOT turn crankshaft more than 90 degrees in either
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) 1) Loosen all valve adjusting
screws fully before installing timing belt. Allow camshaft to rotate freely

during belt tension adjustment. Align timing mark on camshaft sprocket

with V mark on timing belt inner cover. See Figs. 2 and 3.
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 direction arrow mark on timing belt is pointed
in direction of crankshaft rotation. Ensure drive side of belt is free of
slack.
3) Move tensioner plate up with finger pressure, and loosely secure
tensioner bolt. Turn crankshaft 2 revolutions clockwise to remove all
slack from belt. Tighten tensioner nut and then tensioner bolt to
specification. See TORQUE SPECIFICATIONS.
4) Ensure timing marks are aligned. Install timing belt outer cover and
tighten to specification. See TORQUE SPECIFICATIONS. Reverse
removal procedure to complete installation. Adjust valve clearance. See
VALVE CLEARANCE SPECIFICATIONS under ADJUSTMENTS. Adjust
drive belts to proper tension.
Removal (Swift) 1) Disconnect negative battery cable. Raise and
support vehicle. Remove right side fender apron extension by pushing
center pin into clip. DO NOT push in too far as pin may fall into fender.
Lower vehicle.
2) 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.
3) Remove crankshaft pulley-to-crankshaft bolts. Remove crankshaft
pulley. It is NOT necessary to remove crankshaft center bolt.
4) Remove resonator and timing belt cover. Rotate crankshaft clockwise
to align camshaft and crankshaft timing marks. See Fig. 3. Camshaft
sprocket mark should align with V mark on rear cover. Punch mark on
crankshaft sprocket should align with mark on oil pump case.
5) If reusing timing belt, mark belt with an arrow indicating direction of
rotation for installation reference.
6) Loosen timing belt tensioner eccentric bolt and stud nut. Move
tensioner away from belt and snug bolt and nut. Remove timing belt.
CAUTION: With timing belt removed, DO NOT turn camshaft
sprocket more than 20 degrees in either direction from aligned
position. DO NOT turn crankshaft more than 90 degrees in either
direction from aligned position. Doing so could damage piston(s)
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components.

SUZUKI

648

1.3L 4-Cylinder SOHC (Cont.)

NOTE: It is NOT necessary to loosen valve adjusting screws on
1995 models.
2) 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 adjustment.
3) On all models, ensure all timing marks align. See Fig. 3. 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.
4) Install timing belt. If reusing old belt, ensure belt is installed in original
direction of rotation. Ensure there is no slack in belt.
5) Move timing belt tensioner plate up with finger pressure, and loosely
secure tensioner bolt. See Fig. 4. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Ensure timing marks are aligned.
Tighten tensioner stud nut and then tensioner bolt to specification. See
TORQUE SPECIFICATIONS.
6) 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 cylinder head. Install crankshaft
pulley.
7) On 1989-94 Swift with 8-valve engine, adjust valves. See VALVE
CLEARANCE SPECIFICATIONS under ADJUSTMENTS. Install valve
cover. Reverse removal procedure to complete installation. Adjust drive
belts to proper tension.
Courtesy of Suzuki of America Corp.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of Suzuki of America Corp.

Fig. 4: Releasing Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28)
Camshaft Sprocket Bolt ................................................................ ................. 41-47 (56-64)
Crankshaft Pulley-To-Crankshaft Bolt ........................................... ................... 7-10 (10-13)
Crankshaft Sprocket Center Bolt
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)
Courtesy of Suzuki of America Corp.

Fig. 3: Aligning Timing Belt & Tensioner

Installation (Swift) 1) If the tensioner was removed, install tensioner
plate on tensioner. Ensure tensioner plate lug engages hole on rear of
tensioner. Install tensioner spring. Tighten tensioner bolt finger tight to
allow movement of tensioner.

Timing Belt Cover Bolt .................................................................. ................. 80-106 (9-12)

Timing Belt Tensioner Stud Nut .................................................... ................. 80-106 (9-12)
Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)

SUZUKI

649

1.6L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

1.6L 4-Cyl. SOHC

Esteem
1995-99 ..............................
Esteem (Canadian)
2000-02 ..............................
Sidekick (8-Valve)
1989-95 ..............................
1996-98 ..............................
Sidekick (16-Valve)
1989-91 ..............................
1992-98 ..............................
Vitara (Includes Canadian)
1999-02 ..............................
X-90
1996-98 ..............................
1

Component
Belt
Kit No.
Part No.

2.3 Hours .. .. TCK212 .. ..... T212

2.3 Hours .. .. TCK212 .. ..... T212

3.6 Hours .. .. TCK164 .. ..... T164

3.6 Hours .. ...... ..... ...... ..... T212

1
1

4.0 Hours .. .. TCK164 .. ..... T164

4.0 Hours .. .. TCK212 .. ..... T212

4.0 Hours .. .. TCK212 .. ..... T212

4.0 Hours .. .. TCK212 .. ..... T212

CAUTION: With timing belt removed, DO NOT turn camshaft or

crankshaft sprocket more than 90 degrees in either direction from
aligned position. Doing so could damage pistons and valves.

With Air Conditioning, add .4 hours, except Esteem. For

Esteem, add .2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1989-92 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1993-01 model
years, the manufacturer recommends the belt be replaced at 60,000
mile intervals.

ADJUSTMENTS
VALVE CLEARANCE SPECIFICATIONS
VALVE CLEARANCE SPECIFICATIONS
Valve
Cold In. (mm)
Hot In. (mm)
Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28)
Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28)

REMOVAL & INSTALLATION

TIMING BELT
Removal (Esteem) 1) Disconnect negative battery cable. Remove
right side engine under cover. Remove power steering and A/C compressor drive belts.
2) 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.
3) From timing belt end of engine, remove engine mount and mounting
bracket. Loosen water pump pulley bolts. Remove water pump drive belt
and pulley.
4) 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.
5) 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 bolt and nut. See Fig. 4.
6) If reusing old belt, mark belt with an arrow indicating direction of
rotation for installation reference. Remove timing belt.

Courtesy of Suzuki of America Corp.

Fig. 1: Exploded View Of Timing Belt Components

Removal (Sidekick, Vitara & X-90) 1) Disconnect negative battery
cable. Remove accessory drive 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.
2) 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.
3) 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.
CAUTION: With timing belt removed, DO NOT turn camshaft 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.
Inspection (All Models) Inspect timing belt for damaged teeth,
cracking and oil contamination. Check timing belt tensioner for worn
bearing. Replace damaged components.
Installation (All Models) 1) If the tensioner was removed, install
tensioner plate on tensioner. Ensure tensioner plate lug engages hole
on rear of tensioner. Install tensioner spring. Tighten tensioner bolt finger
tight to allow movement of tensioner.
2) 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.
3) Loosen tensioner bolt and stud nut to place tension on timing belt.
Turn crankshaft 2 revolutions clockwise to remove all slack from belt.
Tighten tensioner stud nut and then tensioner bolt. See TORQUE
SPECIFICATIONS.

SUZUKI

650

1.6L 4-Cylinder (Cont.)

Courtesy of Suzuki of America Corp.

Fig. 3: Aligning Timing Marks

Courtesy of Suzuki of America Corp.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

4) Ensure timing marks are aligned. Install timing belt cover and tighten
bolts to specification. Reverse removal procedure to complete installation. If coolant was drained, fill and bleed air from system. Adjust drive
belts to proper tension. Adjust valve lash on 1989-94 Sidekick with
8-valve engine. See VALVE CLEARANCE SPECIFICATIONS under
ADJUSTMENTS.

Courtesy of Suzuki of America Corp.

Fig. 4: Releasing Timing Belt Tensioner

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (Cont.)

TORQUE SPECIFICATIONS

Application
Ft. Lbs. (N.m)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)

Application
Ft. Lbs. (N.m)
A/C Compressor Mounting Bolt (Esteem) ................................................................ 17 (23)
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28)
Camshaft Sprocket Bolt ............................................................................................ 43 (60)
Crankshaft Sprocket Center Bolt .................................................. .......................... 80 (110)
Engine Mount Bolt/Nut (Esteem) .............................................................................. 40 (55)
Power Steering Pump Bolt (Esteem) ....................................................................... 25 (35)

Crankshaft Pulley-To-Crankshaft Bolt ..................................................................... 106 (12)

Timing Belt Cover Bolt .............................................................................................. 97 (11)
Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11)
Water Pump Pulley Bolt ............................................................................................ 97 (11)

INCH Lbs. (N.m)

SUZUKI

651

2.0L 4-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.0L 4-Cylinder
Forenza
2004 ........................................................... 1.6 Hours ... ..... T309
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends that timing belt be inspected every 30,000
miles and be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Turn ignition off. Disconnect negative battery cable.
Disconnect manifold air temperature (MAT) sensor electrical connector.
Disconnect air cleaner outlet hose from throttle body. Disconnect
breather tube from camshaft cover.
2) Remove air cleaner housing bolts and air cleaner housing. Loosen
right front wheel lug nuts. Raise and support vehicle, and remove right
front wheel. Remove right front wheel splash shield.
3) Using socket wrench, turn drive belt tensioner bolt clockwise to
compress tensioner and release tension on serpentine drive belt. See
Fig. 1. Remove serpentine drive belt. Remove crankshaft pulley bolts
and crankshaft pulley.
4) Support engine assembly using Engine Assembly Support Fixture
(J-28467-B) and Engine Assembly Support Channel (X-28467-560).
See Fig. 2. Remove right engine mount bracket retaining bolts and right
engine mount bracket. See Fig. 3. Remove front timing belt cover bolts
and front timing belt cover.
5) Rotate crankshaft clockwise until timing mark on crankshaft gear is
aligned with notch at bottom of rear timing belt cover. See Fig. 4. Align
camshaft gears with respective notch on camshaft cover. See Fig. 5. If
reusing old belt, mark belt with an arrow indicating direction of rotation
for installation reference. Loosen timing belt automatic tensioner bolt.
Turn hex-key tab counterclockwise to relieve belt tension and remove
timing belt. See Fig. 6.

Courtesy of Suzuki of America Corp.

Fig. 2: Installing Engine Support Hardware

Courtesy of Suzuki of America Corp.

Fig. 3: Removing Right Engine Mount Bracket

Courtesy of Suzuki of America Corp.

Fig. 4: Aligning Crankshaft Gear Timing Mark

Courtesy of Suzuki of America Corp.

Fig. 1: Locating Drive Belt Tensioner

SUZUKI

652

2.0L 4-Cylinder (Cont.)

Courtesy of Suzuki of America Corp.

Fig. 5: Aligning Timing Marks On Camshaft Gears

Inspection Inspect timing belt for damaged teeth, cracking and oil
contamination. Check timing belt tensioner for wear and damage.
Replace damaged components.
Installation 1) Align crankshaft gear with notch at bottom of rear
timing belt cover. See Fig. 4. Align camshaft gears with respective notch
on camshaft cover. See Fig. 5. Install timing belt. If reusing old belt,
ensure direction arrow mark on timing belt is pointed in direction of
crankshaft rotation.
2) Turn hex-key tab clockwise to tension belt until adjusting arm pointer
aligns with notch. See Fig. 6. Install timing belt automatic tensioner bolt
and tighten to specification. See TORQUE SPECIFICATIONS. Rotate
crankshaft clockwise 2 full turns using crankshaft pulley bolt.
3) Recheck timing belt automatic tensioner pointer. If pointer is not
aligned with notch, repeat steps 1) and 2). Install front timing belt cover
and tighten bolts to specification. See TORQUE SPECIFICATIONS.
4) Install right engine mount bracket and tighten bolts to specification.
Ensure timing marks are aligned. Install timing belt cover and tighten
bolts to specification. Install crankshaft pulley and tighten crankshaft
pulley bolts to specification. See TORQUE SPECIFICATIONS.
5) Using socket wrench, turn drive belt tensioner bolt clockwise to
compress tensioner. With tensioner compressed, install serpentine drive
belt. Remove socket wrench and belt will tighten itself. Reverse removal
procedure to complete installation.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolts ............................................................................................. 15 (20)
Engine Mount Retaining Bolts .................................................................................. 33 (45)
Engine Mount Bracket Retaining Bolts .................................................................... 41 (55)
Timing Belt Automatic Tensioner Bolt ....................................................................... 18 (25)
Timing Belt Idler Pulley Bolt & Nut .......................................................................... 18 (25)
Wheel Lug Nuts ...................................................................................................... 74 (100)
INCH Lbs. (N.m)
Air Cleaner Housing Bolts ........................................................................................ 89 (10)
Front Timing Belt Cover Bolts .................................................................................... 53 (6)

Courtesy of Suzuki of America Corp.

Fig. 6: Identifying Timing Belt Tensioner Components

TOYOTA

653

1.5L 4-Cylinder 1A-C & 3A-C

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

1.5L 4-Cyl.
Corolla Tercel
1980-82
A/T ................................. .... 2.6 Hrs.
M/T ................................. .... 2.8 Hrs.
Tercel
1983-86 ............................ ... 1 2.7 Hrs.
1987-88
Wagon
3A-C ............................. ... 1 2.7 Hrs.
1

Component
Belt
Kit No.
Part No.

TIMING BELT
CAUTION: Do not bend or twist timing belt. Keep belt free of oil,
water or dust.

.... .. TCK070 .. ..... T070

.... .. TCK070 .. ..... T070
... .. TCK070 .. ..... T070

... .. TCK070 .. ..... T070

With Air Conditioning, add .3 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1980-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model
years, the manufacturer recommends the belt be replaced every 60,000
miles under severe service operating conditions.

Removal 1) Drain engine coolant. Remove radiator. Remove air

cleaner assembly. Remove accessory drive belts. Remove water pump
pulley.
2) If equipped with A/C, remove A/C drive belt idler pulley with bracket.
Remove PCV valve from valve cover. Remove valve cover.
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Timing notch on crankshaft pulley must align with 0 timing mark
on timing belt cover.
4) Ensure cylinder No. 1 rocker arms are loose and cylinder No. 4 rocker
arms are tight. If conditions are not as described, rotate crankshaft one
complete revolution.
5) Holding crankshaft stationary, remove crankshaft pulley center bolt.
Remove crankshaft pulley.
6) Remove timing belt covers and gaskets. Remove 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 timing pulley. Place mating marks on timing belt and crankshaft timing pulley.
7) Loosen idler pulley retaining bolt. Move idler pulley away from timing
belt and tighten retaining bolt. Remove timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View of Timing Belt & Components

TOYOTA

654

1.5L 4-Cylinder 1A-C & 3A-C (Cont.)

Inspection 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure idler pulley rotates freely. Inspect all sprockets
for damage. Replace damaged components.
2) 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. 2. Replace tension spring if free length is not as
specified.
3) 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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Installing Used Timing Belt

Fig. 2: Measuring Tensioner Spring Free Length

Installation 1) Ensure crankshaft and camshaft timing pulley timing
marks are correctly aligned. See Fig. 3.
2) Install idler pulley and tension spring (if removed). Secure idler pulley
as far to the left as possible and retighten bolt.
3) Install timing belt on engine. If reusing old belt, align mating marks
made on disassembly. Ensure belt is installed in original direction of
rotation. See Fig. 4.
4) Loosen idler pulley retaining bolt, allowing tension spring to move
pulley against timing belt. Use crankshaft retaining 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 reinstall timing belt.
5) Tighten idler pulley mounting bolt. Measure timing belt tension by
applying 4.4 lbs. (2 kg) pressure to belt. See Fig. 5. Timing belt
deflection should be .236-.276 (6-7 mm). If not, readjust timing belt
tension.
6) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley. Install and tighten crankshaft pulley center bolt to
specification. See TORQUE SPECIFICATIONS.
7) Install water pump pulley. Install A/C idler pulley (if equipped). Install
accessory drive belts. Adjust drive belts to proper tension.
8) Install valve cover and air cleaner assembly. Install radiator. Fill and
bleed cooling system.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 34 (47)
Crankshaft Pulley Bolt ............................................................................................. 87 (118)
Idler Pulley Retaining Bolt ........................................................................................ 27 (37)

TOYOTA

655

1.5L 4-Cylinder 3E
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time Component

Belt
Kit No.
Part No.

1.5L 4-Cyl. 3E
Tercel Sedan
1987 ................................. .... 2.3 Hrs. ............. ......... ..... T136
Tercel
1988-94 ............................ .... 2.3 Hrs. .... .. TCK233 .. ..... T233
1

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
under severe service operating conditions.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right side engine under cover (splash) shield. Lower
vehicle. Remove accessory drive belts.
2) Disconnect accelerator cable. On A/T models, disconnect throttle
cable. On all models, disconnect PCV hoses. On 1987-91 models,
remove air cleaner assembly.
3) On all models, remove bolt, ground strap and vacuum transmitting
valves with bracket on right engine mount. This is mount on timing belt
end of engine.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components (1991-94 Shown; 1987-90 Use One-Piece Crankshaft Pulley)

TOYOTA

656

1.5L 4-Cylinder 3E (Cont.)

4) Using floor jack, support weight of engine from below. Remove right
engine mount from timing belt end of engine. Remove valve cover.
Remove spark plugs.
5) 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 complete revolution.
6) On 1991-94 models with A/C and/or power steering, remove accessory drive pulley from crankshaft pulley. See Fig. 1.
7) 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.
8) Remove timing belt cover. Noting installed position for reassembly
reference, remove timing belt guide. See Fig. 1.
9) If reusing old timing belt, place arrow on belt to indicate direction of
rotation. Place mating marks on belt and crankshaft sprocket, and on
camshaft sprocket.
10) 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 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure No. 1 and No. 2 idler pulleys rotate freely. Inspect
all sprockets for damage. Replace damaged components.
2) Measure free length of tension spring. See Fig. 2. 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.
3) 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.

5) If timing marks do align, tighten No. 1 idler pulley bolt to specification.

See TORQUE SPECIFICATIONS. Install timing belt guide. Install timing
belt covers.
6) Install crankshaft pulley. Holding crankshaft pulley stationary, tighten
crankshaft pulley bolt to specification. On 1991-94 models, install
accessory drive pulley.
7) On all models, install spark plugs. Install valve cover. Install right
engine mount to engine and body. Install vacuum switching valves and
engine ground strap to engine mount (if equipped).
8) Connect negative battery cable. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Camshaft Knock Pin With Bearing Cap

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Measuring Tensioner Spring Free Length

NOTE: Before installing timing belt, remove any oil or water from
camshaft sprocket, crankshaft sprocket and idler pulleys.
Installation 1) If camshaft sprocket was removed, align knock pin with
No. 1 camshaft bearing cap mark. See Fig. 3. Install camshaft sprocket
with 3E mark facing up. See Fig. 4. Tighten camshaft sprocket bolt to
specification. See TORQUE SPECIFICATIONS.
2) Align crankshaft sprocket timing mark with mark on oil pump housing.
See Fig. 4. If removed, install No. 1 idler pulley. Move No. 1 idler pulley
as far left as it will go, and temporarily tighten bolt.
3) Install No. 2 idler pulley (if removed). Install timing belt on engine. See
Fig. 5. If reusing old belt, ensure all mating marks are aligned and belt
is installed in original direction of rotation.
4) Loosen No. 1 idler pulley bolt, and install pulley tension spring.
Temporarily install crankshaft pulley bolt. Turn crankshaft 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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

TOYOTA

657

1.5L 4-Cylinder 3E (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Routing Timing Belt

Application
Ft. Lbs. (N.m)
A/C Compressor Bolt ................................................................................................ 18 (24)
A/C Compressor Mounting Bracket Bolt .................................................................. 20 (27)
Accessory Drive Belt Pulley Bolt .............................................................................. 14 (19)
Alternator Bracket Bolt .............................................................................................. 13 (18)
Camshaft Sprocket Bolt ............................................................................................ 37 (51)
Crankshaft Pulley Bolt ........................................................................................... 112 (152)
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)
No. 2 Idler Pulley Bolt .............................................................................................. 20 (27)
Power Steering Bracket Bolt ..................................................................................... 32 (43)
Power Steering Pump Bolt ....................................................................................... 32 (43)
Spark Plugs ............................................................................................................... 13 (18)
Timing Belt Idler Mount Bolt ..................................................................................... 27 (37)
Water Pump Bolt/Nut ................................................................................................ 13 (18)
INCH Lbs. (N.m)
No. 1 Timing Belt Cover Bolt .................................................................................. 66 (7.5)
No. 2 Timing Belt Cover Bolt .................................................................................. 66 (7.5)
Valve Cover Nut ....................................................................................................... 61 (6.5)

TOYOTA

658

1.5L 4-Cylinder 5E-FE

TIMING BELT APPLICATION
Application

1.5L 4-Cyl.
Paseo (Includes Canadian)
1992-95 ...............................
1996-99 ...............................
Tercel (Includes Canadian)
1995-98 ...............................
1999 ....................................
1

Labor Time Component

Belt
Kit No.
Part No.

2.5 Hours ... .. TCK208 .. ..... T208

3.5 Hours ... .. TCK208 .. ..... T208
2.8 Hours ... .. TCK208 .. ..... T208
2.8 Hours ... .. TCK208 .. ..... T208

With Air Conditioning and Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1992-97 model years, the manufacturer recommends the belt be
replaced every 60,000 miles under severe service operating conditions.
For 1998 model year, the manufacturer recommends the belt be
replaced every 90,000 miles for severe service operating conditions. For
1999 model year, the manufacturer recommends the belt be replaced
every 90,000 miles or 72 months.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove right engine undercover. Remove accessory drive
belts. Remove charcoal canister for access to timing belt covers.
2) 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.
3) 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.
4) 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. 2. If timing mark is not aligned, rotate crankshaft
clockwise one revolution (360 degrees).
5) 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 equivalent, hold crankshaft pulley, and
remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.
6) 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. 2. Remove timing belt guide.

2) 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 1) 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 possible. 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 on crankshaft sprocket aligns with timing mark on oil pump body.
See Fig. 2 or 3.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt align with those placed on all sprockets and timing belt is
installed in original direction of rotation.
2) Remove crankshaft pulley bolt. Install timing belt on crankshaft
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.
3) Loosen No. 1 idler pulley bolt, allowing tension spring to move pulley
against timing belt. Rotate crankshaft clockwise 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
SPECIFICATIONS.
4) Install timing belt guide with cupped side away from crankshaft
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 specification.
5) Install accessory drive belt pulley on front of crankshaft and tighten
bolt to specification. See TORQUE SPECIFICATIONS. Install gasket
and No. 2 timing belt cover.
6) To install remaining components, reverse removal procedure. If valve
cover was removed, apply sealant at ends of camshafts. See Fig. 4. To
ensure proper mount alignment, install all right (timing belt side) engine
mount bolts/nuts before tightening to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension.

CAUTION: If reusing timing belt, mark direction of timing belt

rotation and place reference mark on timing belt at all sprockets for
reassembly reference.
7) 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 necessary).
8) 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 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Ensure idler pulleys rotate freely. Inspect all sprockets
for damage. Replace damaged components. Measure free length of
tension spring. Replace tension spring if free length is not 1.512 (38.40
mm).

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA

659

1.5L 4-Cylinder 5E-FE (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

Application
Ft. Lbs. (N.m)
A/C Compressor Bolt ................................................................................................ 18 (24)
A/C Compressor Mounting Bracket Bolt .................................................................. 20 (27)
A/C Idler Pulley Bolt
12 mm Bolt .............................................................................................................. 20 (27)
14 mm Bolt .............................................................................................................. 27 (37)
Accessory Drive Belt Pulley Bolts ............................................................................ 14 (19)
Camshaft Sprocket Bolt ............................................................................................ 37 (51)
Crankshaft Pulley Bolt ........................................................................................... 114 (155)
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)
Power Steering Pump Bolt
Lower Bolt ............................................................................................................... 29 (39)
Upper Bolt ............................................................................................................... 32 (43)
Spark Plugs ............................................................................................................... 13 (18)
Water Pump Bolt/Nut ................................................................................................ 13 (18)
INCH Lbs. (N.m)
Valve Cover Nut ....................................................................................................... 61 (6.9)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Cylinder Head Sealant Application Areas

TOYOTA

660

1.6L 4-Cylinder DOHC, 4A-GE

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. DOHC

Corolla FX-16, GTS & Sport (4A-GE)
1985-88 ............................ .......... 1 .......... ..
Corolla GTS (4A-GE, 4A-GELC)
1989-91 ............................ .... 1.6 Hrs. .... ..
MR2
1985-88 ............................ ... 2 2.7 Hrs. ... ..
1989 ................................. ... 2 2.7 Hrs. ... ..
1
2

TCK176 ........ T112

TCK176 .. ..... T176
TCK176 ........ T112
TCK176 .. ..... T176

Labor time is 2.2 hours with FWD, or 1.6 hours with RWD.
With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Timing Marks

NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1985 model year, although the manufacturer does not recommend
a specific scheduled maintenance interval, belt manufacturers suggest
the belt be replaced at 60,000 mile intervals. For 1986-91 model years,
the manufacturer recommends the belt be replaced at 60,000 mile
intervals for severe service operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1985-87 RWD Corolla) 1) 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.
2) Loosen water pump pulley bolts. Remove cooling fan belt. Remove
cooling fan assembly. Remove spark plugs.
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
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.
4) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
crankshaft pulley using gear puller. Remove timing belt covers and
gaskets. Noting installed position for reassembly reference, remove
timing belt guide from crankshaft.
5) If reusing timing belt, place mating marks on timing belt and camshaft
sprockets, and on timing belt and crankshaft sprocket. Also place arrow
on belt indicating original direction of rotation.
6) 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) 1) Check timing belt teeth for
cracks or damage. If tooth damage 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.
2) 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.
3) Check free length of idler pulley tension spring. See Fig. 2. Replace
spring if free length is not 1.713 (43.5 mm). Inspect 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) 1) If removed, install timing belt
idler pulley (tensioner) and spring. Secure pulley as far to the left as
possible and temporarily tighten bolt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Measuring Tensioner Spring Free Length

2) 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.
3) 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.
4) Measure timing belt deflection midway between camshaft sprockets.
See Fig. 3. If deflection is not correct, readjust timing belt tension.
5) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley. Install and tighten center bolt to specification. See
TORQUE SPECIFICATIONS.
6) Install water pump pulley and fan assembly. Install generator drive
belt. Install power steering pump pulley and drive belt. Adjust drive belt
to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Checking Timing Belt Deflection

Removal (1985-88 FWD Corolla) 1) Raise and support vehicle.
Remove right front wheel. Remove engine under cover. Drain engine
coolant.
2) If equipped with cruise control, disconnect accelerator cable and
cruise control cable from actuator. Disconnect cruise control electrical
connector. Remove cruise control actuator. Remove windshield washer
tank and set aside.

TOYOTA

661

1.6L 4-Cylinder DOHC, 4A-GE (Cont.)

3) On FX-16 models, remove ignition coil with wires attached and secure
out of way. On all models, remove the upper radiator hose.
4) 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. Remove oil filler cap from valve cover. Cavity in
camshaft should be visible in hole. If not, turn crankshaft one complete
revolution.
5) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
crankshaft pulley using gear puller. Remove timing belt covers and
gaskets. Noting installed position for reassembly reference, remove
timing belt guide from crankshaft.
6) If reusing timing belt, place mating marks on timing belt and camshaft
sprockets, and on timing belt and crankshaft sprocket. Also place arrow
on belt indicating original direction of rotation.
7) Support weight of engine with floor jack. Remove engine mount from
timing belt end of engine.
8) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley
as far left as possible and temporarily tighten bolt. Remove timing belt.
Inspection (1985-88 FWD Corolla) 1) Check timing belt teeth for
cracks or damage. If tooth damage 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.
2) Check free length of idler pulley tension spring. See Fig. 2. Replace
spring if free length is not 1.713 (43.5 mm). Inspect 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 (1985-88 FWD Corolla) 1) If removed, install timing belt
idler pulley (tensioner) and spring. Secure pulley as far to the left as
possible and temporarily tighten bolt.
2) 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.
3) 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.
4) Measure timing belt deflection midway between camshaft sprockets.
See Fig. 3. If deflection is not correct, readjust timing belt tension.
5) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley. Install and tighten center bolt to specification. See
TORQUE SPECIFICATIONS.
6) Install engine mount to timing belt end of engine. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Install water pump pulley. Install accessory drive belts. Adjust drive
belts to proper tension. Install right front wheel and engine under cover.
8) 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) 1) Raise and support vehicle. Remove right front
wheel. Remove engine under cover.
2) 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 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 revolution.
3) Support weight of engine with floor jack. Remove engine mount
through bolt from timing belt end of engine.
4) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
crankshaft pulley using gear puller. Remove timing belt covers and
gaskets. Noting installed position for reassembly reference, remove
timing belt guide from crankshaft.
5) If reusing timing belt, place mating marks on timing belt and camshaft
sprockets, and on timing belt and crankshaft sprocket. Also place arrow
on belt indicating original direction of rotation.

6) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley
as far left as possible and temporarily tighten bolt. Remove timing belt.
Inspection (MR2) 1) Check timing belt teeth for cracks or damage. If
tooth damage 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.
2) Check free length of idler pulley tension spring. See Fig. 2. Replace
spring if free length is not 1.713 (43.5 mm). Inspect 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 (MR2) 1) If removed, install timing belt idler pulley
(tensioner) and spring. Secure pulley as far to the left as possible and
temporarily tighten bolt.
2) 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.
3) 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.
4) Measure timing belt deflection midway between camshaft sprockets.
See Fig. 3. If deflection is not correct, readjust timing belt tension.
5) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley. Install and tighten center bolt to specification. See
TORQUE SPECIFICATIONS.
6) Install engine mount to timing belt end of engine. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Install right front wheel
and engine under cover.
7) Install water pump pulley. Install accessory drive belts. Adjust drive
belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 34 (47)
Crankshaft Pulley Bolt
Corolla (FWD) ..................................................................................................... 101 (137)
Corolla (RWD) ..................................................................................................... 105 (142)
MR2
1985-86 ................................................................................................................ 87 (118)
1987 ................................................................................................................... 105 (142)
1988-89 .............................................................................................................. 101 (137)
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
1985-87 .................................................................................................................. 58 (78)
1988-89 .................................................................................................................. 43 (58)
Power Steering Pump-To-Bracket Bolts ................................................................... 43 (58)
Power Steering Pump Pulley Bolt (Corolla RWD) ................................................... 29 (39)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Pulley Bolt ............................................................................. 27 (37)
Water Pump Bolts ..................................................................................................... 11 (15)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ..................................................................................................... 69 (7.8)

TOYOTA

662

1.6L 4-Cylinder SOHC

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.6L 4-Cyl. SOHC

Corolla (FWD)
1984-88 .............................. 1 3.1 Hours .. ..
Corolla (RWD)
1983 ................................... 2 2.5 Hours .. ..
1984-87 ............................... 1.6 Hours ... ..
Corolla FX
1987-88 ............................... 2.5 Hours ... ..
Corolla SR5
1985-87 ............................... 1.6 Hours ... ..
1988 (FWD) ........................ 3.1 Hours ... ..
1
2

TCK070 .. ..... T070

TCK070 .. ..... T070
TCK070 .. ..... T070
TCK070 .. ..... T070
TCK070 .. ..... T070
TCK036 .. ..... T036

With Air Conditioning and Power Steering, add .4 hours.

With Air Conditioning, add .2 hours.
With Power Steering, add .1 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Timing Marks For Timing Belt Installation

3) Measure tension of spring at installed length. Tension should be
1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if
necessary.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1983-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model
years, the manufacturer recommends the belt be replaced at 60,000
mile intervals for severe service operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
Removal (FWD Models) 1) Raise and support vehicle. Remove right
front wheel. Remove right undercover from wheelwell. Drain engine
coolant. Disconnect upper radiator hose.
2) Loosen water pump pulley bolts. Remove all accessory 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.
3) Remove upper and center timing belt covers. Turn crankshaft 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.
4) Hold crankshaft stationary and remove crankshaft pulley center bolt.
Remove crankshaft pulley using a gear puller. Remove lower timing belt
cover.
5) Noting installed position for reassembly reference, remove timing belt
guide from crankshaft.
6) If reusing timing belt, place mating marks on belt and sprockets for
reassembly reference. See Fig. 4. Place arrow on belt to indicate
original direction of rotation.
7) Loosen idler pulley bolt. Push idler pulley as far left as possible and
temporarily tighten center bolt.
8) Support weight of engine from below with a floor jack. Working from
below the vehicle, remove the 4 lower engine mount bolts from the
engine crossmember. Remove engine mount through-bolt from mount at
timing belt end of engine. Raise engine slightly and remove timing belt.
Inspection (FWD Models) 1) Inspect timing belt for damaged teeth,
cracking and oil contamination. Ensure idler pulley rotates freely. Inspect
all sprockets for damage. Replace damaged components.
2) Measure free length of tension spring. Free length should be 1.705
(43.3 mm). See Fig. 2. Replace tension spring if free length is not as
specified.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Measuring Tensioner Spring Free Length

Installation (FWD Models) 1) 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
TORQUE SPECIFICATIONS.
2) Align camshaft sprocket timing hole with camshaft bearing cap mark.
Align timing marks on oil pump body and crankshaft timing sprocket.
See Figs. 1 and 3.
3) Install idler pulley (tensioner) and spring (if removed). Pry idler pulley
toward left and temporarily tighten bolt. Install timing belt. If installing
used belt, ensure mating marks are aligned to camshaft sprocket and
crankshaft sprocket. See Fig. 4. Ensure arrow on belt points in original
direction of rotation.
4) 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 TORQUE SPECIFICATIONS.
5) Check timing belt deflection. See Fig. 5. If timing belt deflection is not
correct, readjust timing belt tension.
6) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley and tighten bolt to specification.
7) 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 cylinder head when installing valve
cover.
8) Install upper radiator hose. Refill cooling system.
9) Install right under cover. Install right front wheel. Adjust drive belts to
proper tension.
Removal (RWD Models) 1) 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.
2) On all models, remove air cleaner assembly. Loosen water pump
pulley bolts. Remove cooling fan drive belt. Remove cooling fan.
Disconnect PCV hose and remove valve cover.
3) Hold crankshaft stationary and remove crankshaft pulley center bolt.
Remove crankshaft pulley using a gear puller.
4) Remove timing belt covers and gaskets. Noting installed position for
reassembly reference, remove timing belt guide from crankshaft.
5) Rotate crankshaft so that No. 1 cylinder is at TDC on compression
stroke. Align crankshaft and camshaft timing marks. See Figs. 1 and 3.

TOYOTA

663

1.6L 4-Cylinder SOHC (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning TDC Marks On Crankshaft Sprocket & Oil Pump

Body

7) Loosen idler pulley bolt. Push idler pulley as far left as possible and
temporarily tighten center bolt. Remove timing belt.
Inspection (RWD Models) 1) Inspect timing belt for damaged teeth,
cracking and oil contamination. Ensure idler pulley rotates freely. Inspect
all sprockets for damage. Replace damaged components.
2) Measure free length of tension spring. Free length should be 1.705
(43.3 mm). See Fig. 2. Replace tension spring if free length is not as
specified.
3) Measure tension of spring at installed length. Tension should be
1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if
necessary.
Installation (RWD Models) 1) Align camshaft sprocket timing hole
with camshaft bearing cap mark. Align timing marks on oil pump body
and crankshaft timing sprocket. See Figs. 1 and 3.
2) Install idler pulley (tensioner) and spring (if removed). Pry idler pulley
toward left and temporarily tighten bolt. Install timing belt. If installing
used belt, ensure mating marks are aligned to camshaft sprocket and
crankshaft sprocket. See Fig. 4. Ensure arrow on belt points in original
direction of rotation.
3) 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 TORQUE SPECIFICATIONS.
4) Check timing belt deflection. See Fig. 5. If timing belt deflection is not
correct, readjust timing belt tension.
5) Install timing belt guide on crankshaft. Install timing belt covers. Install
crankshaft pulley and tighten bolt to specification. Install valve cover.
Install air cleaner assembly.
6) To complete installation, reverse removal procedure. Tighten bolts
and nuts to specification. See TORQUE SPECIFICATIONS. Apply
sealant to cylinder head when installing valve cover. Adjust drive belts to
proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Installing Timing Belt

6) If reusing timing belt, place mating marks on belt and sprockets for
reassembly reference. See Fig. 4. Place arrow on belt to indicate
original direction of rotation.

Application
Ft. Lbs. (N.m)
A/C Compressor-To-Block Bolts (4) .......................................................................... 18 (25)
Camshaft Sprocket Bolt ............................................................................................ 34 (47)
Crankshaft Pulley Bolt ............................................................................................. 87 (118)
Engine Mount Through-Bolt (FWD Models) ............................................................. 58 (78)
Engine Mount-To-Crossmember Bolt ........................................................................ 29 (39)
Timing Belt Idler Pulley Bolt ..................................................................................... 27 (37)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ..................................................................................................... 69 (7.8)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Timing Belt Tension Deflection

TOYOTA

664

1.6L & 1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time 1

1.6L 4-Cyl. DOHC

Celica
1990-92 ...............................
1993 ....................................
Corolla (4A-FE)
1988-92 ...............................
1993-97 ...............................
1.8L 4-Cyl. DOHC
Celica
1994-97 ...............................
Corolla
1993-97 ...............................
1

Component
Belt
Kit No.
Part No.

3.1 Hours ... .. TCK036 .. ..... T036

3.1 Hours ... ...... ..... ...... ..... T239
2.6 Hours ... .. TCK036 .. ..... T036
2.2 Hours ... .. TCK236 .. ..... T236

2.8 Hours ... .. TCK235 .. ..... T235

2.2 Hours ... .. TCK235 .. ..... T235

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced at 60,000 mile
intervals for severe service operating conditions.

REMOVAL & INSTALLATION

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Timing Marks (1.6L Shown; 1.8L Uses Same

Camshaft Sprocket Timing Mark)

TIMING BELT
Removal (Celica) 1) Raise and support vehicle. Remove right front
wheel and engine undercover. Lower vehicle. Remove cruise control
actuator from engine mount at timing belt end of engine (if equipped).
2) Support weight of engine with a floor jack. Remove engine mount at
timing belt end of engine.
3) Loosen water pump pulley bolts, then remove all accessory drive
belts.
4) On 1.8L (7A-FE engine), remove A/C compressor front engine mount
with hoses attached. Remove A/C compressor mount from engine.
5) On 1.6L and 1.8L engine, remove upper and center timing belt covers.
6) 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. Hole in camshaft timing pulley must align with mark on
bearing cap. See Fig. 1.
7) Remove water pump pulley. Remove crankshaft pulley bolt. Using
gear puller, remove crankshaft pulley. Remove lower timing belt cover.
See Fig. 2. Remove timing belt guide (large washer) from crankshaft
sprocket.
8) 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. 3. Place arrow on belt to indicate original direction of rotation.
9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left
as possible, and snug tighten bolt. Remove timing belt.
Inspection (Celica) 1) Check timing belt teeth for cracks or damage.
If tooth damage 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.
2) Check free length of idler pulley tension spring. See Fig. 4. Replace
spring if free length is not 1.51 (38.4 mm) for 1.6L (4A-FE engine), or
1.252 (31.8 mm) for 1.8L (7A-FE engine).
3) Check tension at installed length. Tension should be 8.8 lbs. at 1.976
(4 kg at 50.2 mm) for 1.6L (4A-FE engine), or 11.7 lbs. at 1.480 (5.3 kg
at 37.6 mm) for 1.8L (7A-FE engine). If tension is not as specified,
replace spring.
Installation (Celica) 1) Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft Woodruff key will be at 12 oclock position. On

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

(1993-97 1.6L & 1.8L)
1.6L engine, timing mark notch on crankshaft sprocket will align with
timing mark on oil pump housing. See Fig. 1. 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.
NOTE: Loosen idler pulley (tensioner) bolt and allow pulley to
move against belt. Install timing belt guide on crankshaft (dished
side facing away from belt).
2) 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.

TOYOTA

665

1.6L & 1.8L 4-Cylinder DOHC (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Placing Mating Marks On Timing Belt & Sprockets

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Checking Timing Belt Deflection

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Tensioner Spring Free Length

3) Loosen idler pulley (tensioner) bolt and allow pulley to move against
belt. Install timing belt guide on crankshaft (dished side facing away from
belt).
4) Install lower timing belt cover. Install crankshaft pulley. Install crankshaft pulley center bolt. Rotate crankshaft CLOCKWISE 2 revolutions
from TDC to TDC.
5) Ensure crankshaft pulley notch aligns with 0 timing mark on lower
timing belt cover. Ensure camshaft sprocket timing 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
SPECIFICATIONS.
6) With idler pulley bolt still loose, measure timing belt deflection at
midway point of belt longest run. See Fig. 5. Deflection should be
.20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deflection
is not as specified, readjust tension on belt by moving idler pulley
(tensioner).
7) Tighten idler pulley bolt. Install upper and center timing belt covers.
When installing valve cover, ensure sealant is apply in correct positions.
See Fig. 6.
8) Install water pump pulley. On 1.8L engine, install A/C compressor
mount to engine. Install A/C compressor.
9) On 1.6L and 1.8L engines, install all accessory drive belts. Adjust
belts to proper tension. Final tighten water pump pulley bolts.
10) 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) 1) Raise and support vehicle. Remove
right front wheel and engine undercover. Remove washer tank. Loosen
water pump pulley bolts, then remove all accessory drive belts. Remove
valve cover.
2) 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.
3) Support weight of engine with a floor jack. Remove engine mount at
timing belt end of engine.
4) Remove water pump pulley. Remove crankshaft pulley bolt. Using
gear puller, remove crankshaft pulley. Remove timing belt covers.
Remove timing belt guide (large washer) from crankshaft sprocket.
5) 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. 3. Place arrow on belt to indicate original direction of rotation.
6) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left
as possible, and snug tighten bolt. Remove timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Identifying Cylinder Head Sealant Application Areas

Inspection (1988-92 Corolla) 1) Check timing belt teeth for cracks or
damage. If tooth damage 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.
2) Check free length of idler pulley tension spring. See Fig. 4. 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) 1) Ensure No. 1 cylinder is at TDC on
compression stroke. 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. 1. Hole in camshaft sprocket must align with
mark on bearing cap.
NOTE: Engine should be cold when installing timing belt.
2) 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.
3) Loosen idler pulley (tensioner) bolt and allow pulley to move against
belt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC.
4) Recheck timing mark alignment. If timing marks are not aligned,
remove and reinstall timing belt.
5) With idler pulley bolt still loose, measure timing belt deflection at
midway point of belt longest run. See Fig. 5. Deflection should be
.20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deflection
is not as specified, readjust tension on belt by moving idler pulley
(tensioner).
6) Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Install timing belt guide to crankshaft sprocket.
7) Install timing belt covers. Install crankshaft pulley. Tighten center bolt
to specification. See TORQUE SPECIFICATIONS. When installing
valve cover, ensure sealant is apply in correct positions. See Fig. 6.

TOYOTA

666

1.6L & 1.8L 4-Cylinder DOHC (Cont.)

8) Install water pump pulley. Install accessory drive belts. Adjust drive
belts to proper tension. Final tighten water pump pulley bolts.
9) Install front wheel and engine undercover.
Removal (1993-97 Corolla) 1) Raise and support vehicle. Remove
right front wheel and engine undercover. Lower vehicle.
2) 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.
3) 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.
4) On all models, 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.
5) Remove upper timing belt cover. With No. 1 cylinder at TDC, hole in
camshaft sprocket must align with mark on bearing cap. See Fig. 1.
6) Support weight of engine with a floor jack. Remove engine mount at
timing belt end of engine.
7) Remove crankshaft pulley bolt. Using gear puller, remove crankshaft
pulley. Remove center and lower timing belt covers. Remove timing belt
guide (large washer) from crankshaft sprocket.
8) 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. 3. Place arrow on belt to indicate original direction of rotation.
9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left
as possible, and snug tighten bolt. Remove timing belt.
Inspection (1993-97 Corolla) 1) Check timing belt teeth for cracks or
damage. If tooth damage 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.
2) Check free length of idler pulley tension spring. See Fig. 4. See
TENSION SPRING FREE LENGTH (1993-97 COROLLA) table.
Replace spring if free length is not to specification.
3) Check tension at installed length. See TENSION SPRING
INSTALLED TENSION (1993-97 COROLLA) table. Replace spring if
tension is not to specification.
TENSION SPRING FREE LENGTH (1993-97 COROLLA)
Application
Free Length In (mm)
1993-94 1.6L
................................................................................................. 1.453 (36.9)
(4A-FE) .............
1995-97 1.6L
................................................................................................. 1.717 (43.6)
(4A-FE) .............
1993-97 1.8L
................................................................................................. 1.252 (31.8)
(7A-FE) .............
TENSION SPRING INSTALLED TENSION (1993-97 COROLLA)
Application
Tension At Installed Length Lbs. At In. (Kg At mm)
1993-94 1.6L
............................................................................ 13 at 1.988 (5.9 at 50.5)
(4A-FE) .............
1993-94 1.8L
....................................................................... 26.5 at 1.988 (12.4 at 50.5)
(7A-FE) .............
1995-97 1.6L
........................................................................... 8.6 at 1.717 (3.9 at 43.6)
(4A-FE) .............
1995-97 1.8L .......................................................................... 11.7 at 1.480 (5.3 at 37.6)
(7A-FE) .............
Installation (1993-97 Corolla) 1) 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. 1. 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.

NOTE: Engine should be cold when installing timing belt.

2) 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.
3) Loosen idler pulley (tensioner) bolt and allow pulley to move against
belt. Install timing belt guide on crankshaft (dished side facing away from
belt).
4) Install lower timing belt cover. Install crankshaft pulley. Install crankshaft pulley center bolt. Rotate crankshaft CLOCKWISE 2 revolutions
from TDC to TDC.
5) Ensure crankshaft pulley notch aligns with 0 timing mark on lower
timing belt cover. Ensure camshaft sprocket timing 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
SPECIFICATIONS.
6) With idler pulley bolt still loose, measure timing belt deflection at
midway point of belt longest run. See Fig. 5. Deflection should be
.20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deflection
is not as specified, readjust tension on belt by moving idler pulley
(tensioner).
7) Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS.
8) Install upper and center timing belt covers. When installing valve
cover, ensure sealant is apply in correct positions. See Fig. 6.
9) Install water pump pulley. Install A/C compressor mount to engine.
Install A/C compressor.
10) Install all accessory drive belts. Adjust belts to proper tension. Final
tighten water pump pulley bolts.
11) 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 undercover.
Install cruise control actuator (if equipped).

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Mount Bracket-To-Engine
Celica (1.8L) ............................................................................................................ 35 (47)
A/C Compressor-To-Mount Bolts
Celica (1.8L) ............................................................................................................ 18 (25)
Camshaft Sprocket Bolt ............................................................................................ 43 (58)
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)
Mount-To-Engine Bracket Nut ............................................................................... 38 (52)
Through-Bolt .......................................................................................................... 64 (87)
Corolla (1993-97)
Mount-To-Body Bolt ............................................................................................... 19 (25)
Mount-To-Engine Bracket Bolt .............................................................................. 47 (64)
Mount-To-Engine Bracket Nut ............................................................................... 38 (52)
Power Steering Pump-To-Bracket Bolts ................................................................... 29 (39)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Pulley Bolt ............................................................................. 27 (37)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................
Valve Cover Cap Nuts
1988-92 1.6L ..........................................................................................................
1993-97 1.6L & 1.8L ..............................................................................................
Water Pump Pulley Bolt ...........................................................................................

65 (7.4)
69 (7.8)
52 (5.9)
82 (9.3)

TOYOTA

667

1.8L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cyl. Diesel

Camry
1984-86 ..................................................... 5.0 Hours ... ..... T098
Corolla
1984-85 ..................................................... 2.7 Hours ... ..... T098
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1984) 1) 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.
2) If equipped with A/C, remove compressor pulley from crankshaft
pulley.
Using
Pulley
Holder
and
Socket
(09213-14010
and 09330-00020) or equivalent, remove crankshaft pulley set bolt and
washer.
3) Using a puller, remove crankshaft pulley. See Fig. 1. If equipped with
A/C, remove idler pulley. Remove timing belt cover mount bolts.
Remove timing belt cover and belt guide.
4) Disconnect glow plugs by removing 4 screw grommets and glow plug
connecting nuts. Disconnect current sensor by removing nut, plate
washer, insulator and current connector. Remove glow plug connector
and glow plugs.
5) 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 (1985-86) 1) 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.
2) 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.
3) Remove power steering pump with bracket (if equipped). Remove
drive belt and pulley. Remove 3 mounting bolts and power steering
pump with bracket. Place pump aside and suspend it. Remove alternator with bracket.
4) 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. See Fig. 1.
5) 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.
Inspection (All Models) 1) Check timing belt for wear, cracks or
missing teeth. If defective, check if injection pump camshaft is locked or
there are nicks on belt side of idler pulley lock. Replace belt and
components as needed.
2) Inspect belt for excessive wear on one side only. If damaged, 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 roughness.
3) 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.
4) 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 installation. Replace components as necessary.
Installation (All Models) 1) 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.
2) Install timing belt onto camshaft timing pulley. Ensure timing belt is
securely meshed and not loose. Align marks of injector pump drive
pulley and install timing belt onto pulley. Install timing belt over lower
idler pulley and under crankshaft timing belt pulley. Ensure timing belt is
not twisted or too tight.
3) 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.
4) 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 procedures to complete installation.
Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

668

TOYOTA
1.8L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ............... 69-75 (94-102)
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)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Camshaft, Crankshaft & Injection Pump Sprocket

Timing Marks

TOYOTA

669

2.0L 4-Cylinder Except RAV4

TIMING BELT APPLICATION
Application

2.0L 4-Cyl.
Camry
1983-86 ...............................
1987-91 ...............................
Celica
1986
GTS ...................................
Exc. GTS ..........................
1987-88
GTS ...................................
Exc. GTS ..........................
1989 ....................................
1990-93 ...............................
MR2
1991-95 ...............................
1

Labor Time Component

Belt
Kit No.
Part No.

3.6 Hours ... .. TCK087 .. ..... T087

3.0 Hours ... .. TCK199 .. ..... T138

3.2 Hours ... ...... ..... ...... ..... T125

2.8 Hours ... .. TCK087 .. ..... T087
3.0
2.8
3.0
4.3

Hours
Hours
Hours
Hours

... ...... ..... ...... .....

... .. TCK199 .. .....
... .. TCK199 .. .....
... ...... ..... ...... .....

T125
T138
T138
T125

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Oil Seal Retainer Mark With

Camshaft Sprocket Hole

4.0 Hours ... ...... ..... ...... ..... T125

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1983-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1986-95 model
years, the manufacturer recommends the belt be replaced at 60,000
mile intervals for severe service operating conditions.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Positioning Sprocket To BTDC Or ATDC

retaining bolt 1/2 turn and release spring tension on timing belt. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

REMOVAL & INSTALLATION

TIMING BELT
Removal (1983-86 Camry) 1) Disconnect negative battery cable.
Raise and support vehicle. Remove right front wheel. Remove fender
apron seal. Remove alternator drive belt. Remove cruise control actuator and bracket. Remove power steering oil reservoir tank and drive belt.
2) 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 retainer 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 compression
stroke. See Fig. 2.
3) Loosen No. 1 idler pulley retaining bolt and move pulley toward left as
far as possible, then temporarily tighten retaining bolt. Remove timing
belt from camshaft timing sprocket.
4) Using Drive Shaft Holding 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 Crankshaft Pulley and Companion Flange Holding Tools (09213-14010
and 09330-00020) or equivalents, remove crankshaft pulley retaining
bolt, then pulley.
5) Remove No. 1 timing belt cover and gasket assembly. Remove timing
belt and belt guide. Remove No. 2 idler pulley and crankshaft timing
sprocket.
Installation (1983-86 Camry) 1) Install crankshaft timing sprocket
over crankshaft key. See Fig. 3. Install No. 2 idler pulley. See Fig. 4.
Tighten idler pulley retaining bolt. Temporarily install timing belt onto
sprockets. Install timing belt guide. Install No. 1 timing belt cover and
gasket assembly.
2) Install crankshaft pulley. Pull timing belt upward and align preset mark
on No. 1 timing belt cover with crankshaft pulley groove. See Fig. 5.
Align camshaft oil seal retainer preset mark with center of small hole on
camshaft timing pulley. Install timing belt. Loosen No. 1 idler pulley

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Installing Crankshaft Sprocket

Removal (Celica With 3S-GE Engine) 1) Disconnect negative battery
cable. Raise and support vehicle. Remove right front wheel and engine
undercover. Remove radiator reservoir tank. Remove cruise control
actuator and bracket.
2) Remove the power steering oil reservoir bolts, and position reservoir
aside. Remove accessory drive belts. Remove alternator and bracket.
Raise the engine slightly with suitable jack with wooden block between
jack and engine. Remove the right engine mount through-bolt, then
mount.
3) 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 timing mark. See Fig. 6.
Ensure alignment marks of camshaft pulleys and No. 3 timing belt cover
are aligned. See Fig. 7.

TOYOTA

670

2.0L 4-Cylinder Except RAV4 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Installing No. 2 Idler Pulley

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Positioning Crankshaft Pulley At TDC (3S-GE)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Mark On No. 1 Timing Belt Cover With

Groove In Crankshaft Pulley
4) 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 installation reference before removing.
5) 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 pulley, tension spring and fixed idler pulley from
engine.
Installation (Celica With 3S-GE Engine) 1) Install fixed idler pulley.
Pry the idler pulley as far to the left as possible, then temporarily tighten
attaching bolt. Temporarily install the timing belt on crankshaft sprocket,
oil pump sprocket, fixed idler pulley and water pump pulleys.
2) 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. 6.
3) On models equipped with 2-hole camshaft flanges, use suitable
wrench to align camshaft knock pins and cam lobes as shown. See
Fig. 8. On models equipped with 5-hole camshaft flanges, use suitable
wrench to align camshaft alignment marks as shown. See Fig. 9.

Fig. 7: Aligning Camshaft Sprocket Marks With Marks On

No. 3 Timing Belt Cover (3S-GE)
4) 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. 7. On
models equipped with 2-hole camshaft flange, ensure camshaft knock
pin is aligned with sprocket hole.
5) 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
camshaft sprocket attaching bolts.
6) Loosen the spring-loaded idler pulley attaching bolt just enough to
allow pulley to move by itself under spring tension. Allow the pulley to
take up belt tension. Rotate the crankshaft clockwise 2 complete
revolutions. Tighten pulley bolt. Ensure that the timing belt has tension
between crankshaft sprocket and intake camshaft sprocket. See Fig. 10.
To complete installation, reverse removal procedure. Adjust drive belts
to proper tension.
Removal (1987-91 Camry & 1988-89 Celica With 3S-FE Engine) 1)
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.
CAUTION: Position a wooden block between jack and engine to
prevent damage.
2) Use a jack to raise engine slightly. Remove right side engine mount
through-bolt, and then mount.

TOYOTA

671

2.0L 4-Cylinder Except RAV4 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 8: Aligning Camshaft Sprocket With 2-Hole Camshaft Flange

(3S-GE)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 10: Installing Timing Belt

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 9: Aligning Marks On 5-Hole Camshaft Flange With

Marks On Camshaft Bearing Caps
3) 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 with
bearing cap No. 1 alignment mark. See Fig. 14.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 11: Installing Cylinder Head Packing (3S-GE)

NOTE: If reusing timing belt, place matchmarks on timing belt and

camshaft pulley. See Fig. 12.
4) Loosen spring-loaded idler pulley attaching bolt, then pry pulley as far
to left as possible. Temporarily tighten attaching bolt. Remove timing belt
from camshaft sprocket.
5) Remove crankshaft pulley attaching bolt, then using suitable puller,
remove crankshaft pulley. Remove lower timing belt cover and gasket.
NOTE: If reusing timing belt, mark a arrow on belt to show rotation
direction. Place matchmarks on timing belt and crankshaft
sprocket. See Fig. 13.
6) Remove timing belt and belt guide.
NOTE: If reusing timing belt, install timing belt with arrow in
direction of engine rotation and align matchmarks on timing belt
with matchmark on crankshaft sprocket. See Fig. 13.
Installation (1987-91 Camry & 1988-89 Celica With 3S-FE Engine)
1) Install timing belt on crankshaft sprocket, oil pump sprocket, fixed
idler pulley and water pump sprocket. Install camshaft sprocket, washer
and attaching bolts. Rotate camshaft by turning sprocket attaching bolt
to align bearing cap mark and camshaft sprocket. See Fig. 14.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 12: Marking Timing Belt & Camshaft Sprocket For

Reuse Of Timing Belt (3S-FE)

TOYOTA

672

2.0L 4-Cylinder Except RAV4 (Cont.)

3) 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.
4) Ensure alignment marks on camshaft sprockets and No. 3 timing belt
cover are aligned as shown. See Fig. 15. If not, turn crankshaft one
complete revolution (360) to align marks. Remove timing belt from
camshaft timing sprockets.
5) 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.
6) 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 crankshaft sprocket and No. 2 idler pulley.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 13: Marking Timing Belt & Crankshaft Sprocket For

Reuse Of Timing Belt (3S-FE)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 14: Camshaft Sprocket Alignment (3S-FE)

NOTE: If reusing timing belt, align matchmarks on timing belt with
matchmark on camshaft sprocket. See Fig. 12.
2) 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.
3) 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 installation, reverse removal procedure. Adjust drive belts to
proper tension.
NOTE: Air bag system must be disarmed before working on
vehicle. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 20 seconds before working on
vehicle.
Removal (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine) 1)
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.
2) Loosen power steering oil reservoir tank. Remove accessory drive
belts. Remove alternator and alternator brackets. Use a suitable jack to
raise engine slightly, and remove weight from engine mounting on right
side. Remove right engine mount insulator and bracket.

Fig. 15: Aligning Camshaft Sprocket Timing Marks (3S-GTE)

Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine)
1) Temporarily install No. 1 idler pulley and tension spring. See Fig. 16.
Install pulley attaching bolt. Do not tighten bolt. Install tension 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 pulley.
2) 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.
3) Place No. 1 cylinder at TDC of compression stroke by turning
crankshaft pulley and aligning its groove with 0 mark on No. 1 timing
belt cover. See Fig. 17. Turn camshaft and align marks on camshaft
sprockets and cylinder head cover.
4) Install timing belt. Ensure that tension between crankshaft and intake
camshaft timing sprockets exists. To complete installation, reverse
removal procedure. Adjust drive belts to proper tension.

TOYOTA

673

2.0L 4-Cylinder Except RAV4 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 16: Installing Tension Spring & Idler Pulley

Application
Ft. Lbs. (N.m)
A/C Compressor Bolt ................................................................................................ 20 (27)
Camshaft Timing Sprocket Bolt .................................................... ................. 40-43 (54-59)
Crankshaft Pulley Bolt ............................................................................................. 80 (109)
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)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 17: Identifying Crankshaft Pulley Angle

TOYOTA

674

2.0L 4-Cylinder RAV4

TIMING BELT APPLICATION
Application
2.0L 4-Cyl.
RAV4
1996-00
With ABS .........................
Without ABS ...................
1

Labor Time Component

Belt
Kit No.
Part No.

1
1

5.3 Hours .. .. TCK199 .. ..... T199

3.3 Hours .. .. TCK199 .. ..... T199

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1996-97 model years, the manufacturer recommends the belt be
replaced every 60,000 miles for severe service operating conditions. For
1998 model year, the manufacturer recommends the belt be replaced
every 90,000 miles for severe service operating conditions. For 1999-00
model years, the manufacturer recommends the belt be replaced every
90,000 miles or 72 months.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect power
steering reservoir, and remove reservoir bracket. Disconnect wire
harness bracket for Data Link Connector No. 1. Remove generator and
generator bracket.
2) 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 remove right engine mounting insulator.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

NOTE: Always turn crankshaft clockwise.

3) Remove spark plugs. Remove crankshaft pulley. See Fig. 1. 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.
4) 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 pulley and No. 1 timing belt cover.
5) If reusing timing belt, mark direction of rotation on belt. Also place
match marks on belt and camshaft pulley. See Fig. 5. Remove timing
belt from engine.
Inspection 1) Inspect idler pulleys for smoothness. Ensure free length
of tension spring is 1.653 (42.0 mm). See Fig. 6. Spring tension should
be 8.5 lbs. (3.85 kg) at length of 1.988. If not as specified, replace
spring. Inspect timing belt cover gaskets. Replace if gaskets are cracked
or peeling.
Installation 1) 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, ensure rotation direction and mating marks are in
correct position.
2) 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 revolutions from TDC to TDC.
3) Check that each pulley aligns with timing marks as shown. See Fig. 5.
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. 7. Tighten No. 1 idler pulley mounting bolt to specification.
4) Place right engine mounting bracket in position, but do not install
bolts. Install No. 2 timing belt cover. Disconnect engine wire protector

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Removing No. 2 Timing Belt Cover

between cylinder head cover and No. 3 timing belt cover. Install No. 2
timing belt cover. Install engine wire to No. 2 timing belt cover. Install
engine wire protector to mounting bolts of No. 2 timing belt cover.
5) Remove crankshaft pulley. Install engine mounting bracket-to-engine
bolts and tighten to specification. Install crankshaft pulley, and tighten
pulley bolt to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

TOYOTA

675

2.0L 4-Cylinder RAV4 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Setting No. 1 Cylinder To TDC

Fig. 7: Locating 45 Degree BTDC Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Timing Pulley Bolt .................................................................................... 40 (54)
Crankshaft Pulley Bolt ............................................................................................. 80 (108)
Generator Bracket Bolts ............................................................................................ 31 (42)
Engine Mount Bracket-To-Engine Bolts .................................................................... 38 (52)
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)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Matching Marks Of Timing Belt & Cams

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Measuring Tensioner Spring Free Length

TOYOTA

676

2.2L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

2.2L 4-Cyl. Diesel

Pickup
1981 ...........................................................
1982
Up To 5/31 ..............................................
From 6/1 .................................................
1983 ...........................................................
1

Labor Time

Belt
Part No.

2.2 Hours ... ..... T079

2.2 Hours ... ..... T079
2.2 Hours ... ..... T084
2.2 Hours ... ..... T084

With Air Conditioning, add .7 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 100,000
miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Cylinder Head & Timing Belt

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.

pulley bracket is moving. Ensure that each pulley aligns with marks. See
Fig. 3. Tighten timing belt idler pulley bolt. Reverse removal procedure
to complete installation. Adjust drive belts to proper tension.

Removal 1) 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 attaching bolt. Using puller,
remove damper.
2) Remove air cleaner assembly. Drain cooling system. Remove 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.
3) 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.
4) On late model 1982 engines, an extra idler pulley is used between the
crankshaft and oil pump timing pulleys. Remove center retaining bolt to
remove pulley.
Inspection 1) Check timing belt for wear, cracks, or missing teeth.
Replace belt if defective. Before installing a new belt, remove idler pulley
and spring. Check idler pulley bearing for smooth operation.
2) Check the free length of idler pulley spring. Length of spring should be
1.563 (39.70 mm). Under 8.8 lbs. (4 kg) tension, 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 1) 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.
2) Install timing belt and idler spring. Turn the crankshaft 2 revolutions
clockwise from TDC to TDC. While turning crankshaft make sure idler

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

TOYOTA

677

2.2L 4-Cylinder Diesel (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Camshaft Sprocket Bolt ................................................................ ...............
Camshaft-To-Timing Pulley ........................................................... ...............
Crankshaft Pulley Bolt ................................................................... ...............

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Realigning Timing Marks

Ft. Lbs. (N.m)

69-75 (94-102)
69-75 (94-102)
69-75 (94-102)

TOYOTA

678

2.2L 4-Cylinder Gasoline

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.2L 4-Cyl.
Camry
1992-01 ........................... .. 1 3.0 Hours .. ..
Camry Solara
1999-01 ........................... .. 1 3.0 Hours .. ..
Celica
1990-91 ........................... .. 1 3.1 Hours .. ..
1992-99 ........................... .. 1 2.4 Hours .. ..
Celica GT & GTS
1990-91 ............................ 1, 2 3.1 Hours . ..
1992-93 ............................ 1, 2 3.1 Hours . ..
MR2
1991-95 ........................... .. 1 3.5 Hours .. ..
1

9) 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.
10) Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing belt from
crankshaft sprocket. Remove idler pulleys (if necessary).

TCK199 .. ..... T199

TCK199 .. ..... T199
TCK199 .. ..... T199
TCK199 .. ..... T199
TCK199 .. ..... T199
TCK199 .. ..... T138
TCK199 .. ..... T199

With Air Conditioning, add .2 hours.

On MR2 with Turbo and Air Conditioning, time is 4.5 hours.
On Celica AWD, add 1.2 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-97 model years, the manufacturer recommends the belt be
replaced every 60,000 miles under severe service driving conditions.
For 1998-01 model years, the manufacturer recommends the belt be
replaced every 90,000 miles.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View of Timing Belt & Components

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support
vehicle. Remove lower engine cover. On Celica and Camry, remove
right front wheel. On all models, lower vehicle.
2) 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.
3) On all models, remove accessory drive belts. Using floor jack, slightly
raise engine to remove weight from right (timing belt side) engine mount
at timing belt cover.
4) 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.
5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine.
6) 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.
7) 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 timing belt from camshaft sprocket.
8) Using Pulley Holder (SST 09213-54015) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Camshaft Timing Marks

Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Ensure idler pulleys rotate freely. Replace components if
damaged or worn.
NOTE: For 1992-96 Camry, the timing belt tension spring procedure has been revised. See REVISED TIMING BELT TENSION
SPRING PROCEDURE (1992-96 CAMRY).
2) 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.
3) Measure tension needed to extend tension spring to specified
installed length. Replace spring if tension is not within specification. See
TENSION SPRING SPECIFICATIONS table.

TOYOTA

679

2.2L 4-Cylinder Gasoline (Cont.)

TENSION SPRING SPECIFICATIONS
Application
Free Length
Except 1999-00 Camry ................................ ........................................
1999-00 Camry ............................................ ........................................
Tension At Spring Installed Length 1
Camry (1992-95)
Green Spring ............................................. ........................... 7.2-8.3
Silver Spring ...................................................................... 10.5-11.6
Camry (1996-01) .......................................... ........................... 7.2-8.3
Camry Solara ............................................... ........................... 7.2-8.3
Celica & MR2 .............................................. ........................... 7.2-8.3
1

Specification

CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed

from timing belt end of engine.

1.811 (46.00 mm)

1.654 (42.00 mm)

9) Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full
revolutions clockwise from TDC to TDC.
10) 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.
11) 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.
12) Tighten No. 1 idler pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install No. 2 timing belt cover and gaskets. Install
and tighten spark plugs to specification.
13) To install remaining components, reverse removal procedure. Install
all bolts/nuts on right (timing belt side) engine mount before tightening to
specification.
14) 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 drive belts to proper tension.

Lbs.
Lbs.
Lbs.
Lbs.
Lbs.

(3.25-3.75
(4.75-5.25
(3.25-3.75
(3.25-3.75
(3.25-3.75

kg)
kg)
kg)
kg)
kg)

At 1.988 (50.50 mm).

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Measuring Tensioner Spring Free Length

Revised Timing Belt Tension Spring Procedure (1992-96 Camry)
From Toyota technical service bulletin EG001-99; January 29, 1999: For
1992-96 Camry, the timing belt tension spring procedure 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.
Installation 1) Install No. 2 idler pulley (if removed). Install and tighten
bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler
pulley is clean and rotates smoothly.
2) 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. Ensure idler pulley is clean and rotates
smoothly.
3) 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 crankshaft sprocket at 12 oclock
position.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Crankshaft Sprocket Timing Marks

CAUTION: If reusing timing belt, ensure reference marks on timing

belt align with reference marks placed on crankshaft and camshaft
sprockets. Ensure timing belt is installed in original direction of
rotation.
4) 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.
5) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install No. 1 timing belt cover
and new gasket.
6) Align crankshaft pulley key groove with key in crankshaft. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.
7) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft 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.
8) Rotate camshaft and align hole in camshaft sprocket with alignment
mark on camshaft bearing cap. See Fig. 2. Install timing belt on
camshaft sprocket. If reusing timing belt, ensure reference mark on
timing belt aligns with reference mark on camshaft sprocket. Ensure
tension exists on timing belt between crankshaft and camshaft sprockets.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC Mark

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Control Rod & Bracket Bolt Installation Sequence (Camry)

TOYOTA

680

2.2L 4-Cylinder Gasoline (Cont.)

TORQUE SPECIFICATIONS (CELICA)
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt ................................................................................................ 18 (24)
Alternator Bracket Bolt .............................................................................................. 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 40 (54)
Crankshaft Pulley Bolt ............................................................................................. 80 (109)
Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ................. 38 (52)
Right (Timing Belt Side) Engine Mount To-Bracket
Bolt ........................................................................................................................... 27 (37)
Nut ........................................................................................................................... 38 (52)
No. 1 Idler Pulley Bolt ............................................................................................... 31 (42)
No. 2 Idler Pulley Bolt ............................................................................................... 31 (42)
Power Steering Pump Bracket Bolt .......................................................................... 32 (43)
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)
No. 3 Timing Belt Cover Bolt .................................................................................. 69 (7.8)
Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8)
TORQUE SPECIFICATIONS (MR2)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts (MR2)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (CAMRY)
Application
Ft. Lbs. (N.m)
Alternator Bracket Bolt .............................................................................................. 31 (42)
Camshaft Sprocket Bolt ............................................................................................ 40 (54)
Coolant Outlet Bolt .................................................................................................... 11 (15)
Crankshaft Pulley Bolt ............................................................................................. 80 (109)
Engine Mounts & Brackets
Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ............... 38 (52)
No. 1 Idler Pulley Bolt ............................................................................................... 31 (42)
No. 2 Idler Pulley Bolt ............................................................................................... 31 (42)
Oil Pump Sprocket Nut ............................................................................................. 21 (29)
Power Steering Pump Bracket Bolt .......................................................................... 32 (43)
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 ............................................................
No 3 Timing Belt Cover Bolt ...................................................................................
Oil Pan Bolt/Nut .......................................................................................................
Oil Pump Body Cover Bolt ......................................................................................
Oil Pump Pick-Up Tube Bolt/Nut .............................................................................
Oil Pump-To-Cylinder Block Bolt .............................................................................
Water Pump-To-Water Pump Cover Bolt ................................................................

78
69
48
78
48
82
82

(8.8)
(7.8)
(5.4)
(8.8)
(5.4)
(9.3)
(9.3)

Application
Ft. Lbs. (N.m)
A/C Compressor Bolt ................................................................................................ 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 40 (54)
Crankshaft Pulley Bolt ............................................................................................. 80 (109)
Left (Flywheel Side) Engine Mount
Through-Bolt ............................................................................................................ 58 (79)
Bracket Bolt ................................................................................. ..................................... 1
Right (Timing Belt Side) Engine Mount
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)
No. 1 Idler Pulley Bolt .............................................................................................. 31 (42)
No. 2 Idler Pulley Bolt .............................................................................................. 31 (42)
Spark Plug ................................................................................................................. 13 (18)
Valve Cover Nut ........................................................................................................ 17 (23)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
No. 3 Timing Belt Cover Bolt .................................................................................. 68 (7.8)
Water Pump-To-Cylinder Block Bolt ............................................. ..................................... 2
Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8)
1
2

Tighten bolts to specification. See Fig. 7.

Tighten bolts to 78 INCH lbs. (8.8 N.m) in sequence. See Fig. 7. On models without A/C,
tighten large bracket bolt to 20 ft. lbs. (27 N.m).

TOYOTA

681

2.4L 4-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 4-Cyl. Diesel

Pickup
1984-87 ..................................................... 2.2 Hours ... ..... T084
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 100,000
miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) If equipped with A/C, remove compressor pulley from crankshaft
pulley. Using Crankshaft Pulley Holding Tool (09213-54011) and Companion Flange Holding Tool (09330-00020) or equivalent, remove
crankshaft pulley set bolt and washer.

3) Using Puller (09213-60017) or equivalent, remove crankshaft 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. On all models, disconnect glow plugs by removing 4
screw grommets and glow plug connecting nuts. Disconnect current
sensor by removing nut, plate washer, insulator and current connector.
Remove glow plug connector and glow plugs.
4) 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
camshaft pulley. Using Pulley Holder (09278-54011), and a wrench on
injection pump drive pulley, remove set bolt on pulley.
5) 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 1) Check timing belt for wear, cracks or missing teeth. If
defective, 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 pulleys and spring. Check idler pulley bearings for noise or
roughness.
2) Inspect spring for proper free length and tension. Standard free length
is 1.563 (39.70 mm). See Fig. 3. Installed tension is 8.8 lbs. at 2.05
(4.0 kg at 52 mm). Replace idler pulley and/or spring as necessary.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA

682

2.4L 4-Cylinder Diesel (Cont.)

4) Ensure that each pulley aligns with timing mark. See Fig. 4. 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.
5) 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.
6) If equipped with A/C, install idler pulley. On all models, 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 engine cooling system and connect
negative battery cable. Install drive belts. Adjust drive belts to proper
tension. Start engine and check for leaks.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

3) 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 necessary.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Measuring Tensioner Spring Free Length

Installation 1) 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.
CAUTION: When tightening idler pulley and timing sprocket mount
bolts, DO NOT move idler pulley bracket or apply tension to timing
belt.
2) Install timing belt onto camshaft timing pulley. Ensure timing belt is
securely meshed and not loose. Align marks of injector pump drive
pulley, and install timing belt onto pulley. Install timing belt over lower
idler pulley and under crankshaft timing belt pulley. Ensure timing belt is
not twisted or too tight.
3) 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
repeat the procedure in this step.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Realigning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Pulley Bolt ................................................................................................. 73 (98)
Crankshaft Pulley Bolt ........................................................................................... 101 (137)
Glow Plugs .................................................................................................................. 9 (13)
Injector Pump Drive Pulley Bolt ............................................................................... 47 (64)
Timing Belt Idler Pulley Bolt ..................................................................................... 29 (39)
Timing Belt Tensioner Pulley Bolts ........................................................................... 14 (19)

TOYOTA

683

2.5L & 3.0L V6 DOHC 1988-97

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
2.5L V6
Camry
1988-91
3.0L V6
Avalon
1995-97
Camry
1992-93
1994-97

Labor Time

Component
Belt
Kit No.
Part No.

............................... 3.8 Hours ... .. TCK157 .. ..... T157

............................... 3.0 Hours ... .. TCK257 .. ..... T257

............................... 3.0 Hours ... .. TCK200 .. ..... T200
............................... 3.0 Hours ... .. TCK257 .. ..... T257

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
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 manufacturer recommends the belt be replaced 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) 1) Disconnect negative battery
cable. Remove cruise control actuator and vacuum pump. Remove
power steering reservoir with hoses attached, and secure them aside.
Raise and support vehicle. Remove right front wheel. Remove right
lower engine cover. Remove all drive belts.
2) 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 engine mount assembly. Remove spark
plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right
engine mount bracket. See Fig. 1. Note bolt length and location of No. 2
timing belt cover bolts for reassembly reference.
CAUTION: If timing belt is to be reused, mark direction of timing
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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA

684

2.5L & 3.0L V6 DOHC 1988-97 (Cont.)

3) 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. Ensure timing marks on camshaft sprockets
are aligned with timing marks on No. 3 timing belt cover. See Fig. 2.
Remove retaining bolts and timing belt tensioner.
4) Install Camshaft Sprocket Holder (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.
5) Using Pulley Holder (09213-54014) or equivalent, and Handle
(09330-00021), hold crankshaft pulley, and remove 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
crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover.
6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft 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).

5) Temporarily install crankshaft pulley bolt in crankshaft. Using 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 camshaft sprockets are aligned with
timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution (360 degrees).
CAUTION: If reusing timing belt, ensure 3 reference marks and
front mark are on timing belt. See Fig. 4. If reference marks or front
mark are not apparent, place reference mark on timing belt at
timing mark area on camshaft sprockets or dot area on crankshaft
sprocket for reassembly reference. Place front mark on timing belt
to indicate direction of timing belt installation.
6) Remove retaining bolts, timing belt tensioner and dust boot. Remove
crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder
(09960-10010) 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. Remove idler pulleys (if necessary).
7) If removing camshaft sprocket, use Camshaft Sprocket Holder
(09960-10010) to hold camshaft sprocket. On right camshaft sprocket,
Adapter (09249-63010) must also be used. Remove bolt and camshaft
sprocket.
8) If removing crankshaft sprocket, remove timing belt plate. See Fig. 1.
Using Crankshaft Sprocket Puller (0921360017), remove crankshaft
sprocket.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Timing Marks (1994-97 3.0L)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)

Removal (1994-97 3.0L V6) 1) Disconnect negative battery cable.
Remove coolant reservoir. Raise and support vehicle. Remove right side
front wheel. Remove right lower engine cover. Remove accessory drive
belts.
2) 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.
3) Use Pulley Holder (09213-54015) or equivalent and Holder (09330
00021) to hold crankshaft pulley. Remove crankshaft pulley bolt. Using
puller, remove crankshaft pulley. Remove No. 1 timing belt cover.
4) Remove engine mounting bracket. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt guide.

Inspection (2.5L & 3.0L V6) 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. Ensure idler pulleys rotate freely. Replace
damaged 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.
2) 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) 1) 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
SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates
smoothly.

TOYOTA

685

2.5L & 3.0L V6 DOHC 1988-97 (Cont.)

7) Using camshaft sprocket holder, slightly rotate right camshaft
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.
8) Place washer on bottom side of timing belt tensioner. Using press,
apply pressure on rod of timing belt tension until rod is retracted, and
holes in rod and housing are aligned. Install 1.27 mm 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.
9) Remove hexagon wrench from timing belt tensioner. Rotate 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.
10) To install remaining components, reverse removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

2) 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.
3) Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure
idler pulley rotates smoothly. Rotate crankshaft 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.
4) 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 timing 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.
5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket
clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket.
6) Using camshaft sprocket holder, slightly rotate left camshaft 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.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Retracting Timing Belt Tensioner Rod

Installation (1994-97 3.0L V6) 1) Install No. 1 and No. 2 idler pulleys
(if removed). Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly.
2) If installing crankshaft sprocket, align crankshaft sprocket with key in
crankshaft. Using hammer and Sprocket Installer (09223-46011), install
crankshaft sprocket with flange toward cylinder block.
3) Install timing belt plate. Install and tighten bolt to specification. See
TORQUE SPECIFICATIONS. Install No. 1 and 2 idler pulleys (if
removed). Install and tighten bolts to specification. Ensure idler pulleys
are clean and rotate smoothly.
4) If installing camshaft sprockets, ensure camshaft sprockets are
installed with flange in correct direction. Right camshaft sprocket must
be installed with flange outward (away from cylinder head), while left
camshaft sprocket must be installed with flange inward (against cylinder
head). See Fig. 1.
5) Align hole in camshaft sprocket with pin in camshaft and install
sprocket. Install and tighten camshaft sprocket bolt to specification. See
TORQUE SPECIFICATIONS.
6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
Fig. 3.
7) 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. See
Fig. 4. Ensure front mark is pointing toward timing belt end of engine.
8) Install timing belt on crankshaft sprocket, water pump pulley, left
camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then
on No. 1 idler pulley.

686

TOYOTA
2.5L & 3.0L V6 DOHC 1988-97 (Cont.)

9) Using press, apply pressure on rod of timing belt tensioner until rod is
retracted and holes in rod and housing are aligned. Install 1.27 mm
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 specification. See TORQUE SPECIFICATIONS.
10) Remove 1.27 mm hexagon wrench from timing belt tensioner.
Rotate 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.
11) Install timing belt guide with cupped side away from crankshaft
sprocket. Install engine mounting bracket on front of cylinder block.
Install and tighten bolts to specification.
12) Ensure No. 1 and No. 2 timing belt cover gaskets do not have any
cracks, peeling or damage. Install No. 1 and No. 2 timing belt covers.
Install and tighten bolts to specification. See TORQUE SPECIFICATIONS.
13) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification using Pulley Holder (09213-54015) and Holding Tool (09330
00021) or equivalent. To complete installation, reverse removal procedures. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.5L V6)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Crossmember-To-Body Bolt .......................................................................... 29 (39)
Engine Mount Through-Bolt ...................................................................................... 64 (87)
Engine Mount-To-Engine 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)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
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)
TORQUE SPECIFICATIONS (3.0L V6)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 94 (127)
Crankshaft Pulley Bolt ........................................................................................... 159 (215)
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 Bolt ....................................................................................... 31 (42)
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)
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
No. 1 & 2 Timing Belt Cover Bolt ...........................................................................
No. 3 Timing Belt Cover Bolt ..................................................................................
Timing Belt Plate Bolt ..............................................................................................
Valve Cover Bolt ......................................................................................................
Water Pump Bolt/Nut ...............................................................................................

75
75
71
71
71

(8.5)
(8.5)
(8.0)
(8.0)
(8.0)

TOYOTA

687

2.8L 6-Cylinder
TIMING BELT APPLICATION
Application
2.8L 6-Cyl.
Celica Supra
1982-83
A/T ....................................
M/T ....................................
1984-85
A/T ....................................
M/T ....................................
Cressida
1983 ....................................
1984-88 ...............................
Supra
1986 ....................................

Labor Time

Component
Belt
Kit No.
Part No.

3.5 Hours ... ...... ..... ...... ..... T074

3.3 Hours ... ...... ..... ...... ..... T074
3.5 Hours ... .. TCK101 .. ..... T101
3.3 Hours ... .. TCK101 .. ..... T101
3.1 Hours ... ...... ..... ...... ..... T074
3.1 Hours ... .. TCK101 .. ..... T101
3.4 Hours ... .. TCK101 .. ..... T101

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1982-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model
years, the manufacturer recommends the belt be replaced at 60,000
mile intervals for severe service operating conditions.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Camshaft Pulley Match Marks

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
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. 1. Remove camshaft covers and No. 3
timing cover. See Fig. 2.
2) 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.
3) If necessary, remove camshaft timing pulley or oil pump drive pulley
by holding the pulley with Holding Tool (09278-54011) and loosening set
bolt. See Fig. 3. Remove exhaust valve cover and oil filler cap. If
necessary, use Puller (09308-10010) to remove crankshaft timing pulley.
See Fig. 4.
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 operation. Idler pulley
tension spring free length must be 2.72 (69.0 mm) or less. See Fig. 5.
Replace spring if not within specification.
Installation 1) Install oil pump drive pulley (if removed). Tighten bolt to
specification. See TORQUE SPECIFICATIONS. Install idler pulley and
tension spring. Position idler pulley to alternator side of engine as far as
possible. Using Pulley Installer (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. 2.
2) Install crankshaft pulley, and tighten bolt to specification. Ensure
No. 1 cylinder is on TDC of compression stroke. Install timing belt on
crankshaft pulley.
3) Rotate engine 2 complete revolutions in direction of rotation, and
position No. 1 cylinder at TDC of compression stroke. Recheck alignment of match marks.
4) Install timing belt cover and crankshaft pulley. To complete installation, reverse removal procedure. See Figs. 6, 7 and 8. Adjust drive belts
to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Exploded View of Timing Belt & Components

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. 2.

TOYOTA

688

2.8L 6-Cylinder (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Camshaft Housing Bolt Tightening Sequence

Fig. 3: Identifying Pulley Holding Tool

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Identifying Crankshaft Sprocket Puller

Fig. 7: Aligning Camshaft Match Hole

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Tensioner Spring Free Length

TORQUE SPECIFICATIONS
Courtesy of Toyota Motor Sales, U.S.A., Inc.

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Housing Bolt ........................................................................................... 1 16 (22)
Camshaft Timing Pulley Bolt .................................................................................... 51 (69)
Crankshaft Pulley Bolt ........................................................................................... 195 (265)
Idler Pulley Bolt ......................................................................................................... 36 (49)
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. 6.

Fig. 8: Aligning Camshaft & Pulley

TOYOTA

689

3.0L 6-Cylinder 2JZ, 1993-97

TIMING BELT APPLICATION
Application
3.0L 6-Cyl. 2JZ
Supra
1993-97 ....................................................
1

Labor Time

Belt
Part No.

2.7 Hours .. ..... T215

With Turbo, add .9 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
or 96 months for severe operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
WARNING: To prevent air bag deployment which may cause personal injury, disconnect negative battery cable at least 90 seconds
before working on vehicle.
Removal 1) 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.
2) 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.
3) 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.
4) Timing marks on camshaft sprockets must align with timing marks on
No. 4 timing belt cover. See Fig. 2. If conditions are not as described,
rotate crankshaft clockwise one complete revolution.
5) Alternately loosen timing belt tensioner bolts. Remove bolts, timing
belt tensioner and dust boot. See Fig. 1. Remove timing belt from
camshaft sprockets.
6) Using Handle (09330-00021) and Pulley Holder (09213-70010), or
equivalent, hold crankshaft pulley and remove crankshaft pulley bolt.
Using puller, remove crankshaft pulley.
7) Remove No. 1 timing belt cover and gaskets. Note direction of timing
belt guide installation for reassembly reference. See Fig. 1. Remove
timing belt guide.
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Check
idler pulley and drive belt tensioner 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 exists.
NOTE: Timing 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.
2) Hold timing belt tensioner body, and 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 housing. See Fig. 3.
Replace timing belt tensioner if distance is not .315-.343 (8.00-8.80
mm).
Installation 1) 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.
2) 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.
3) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side against timing belt. Install gaskets and No. 1

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

timing belt cover. Align crankshaft pulley key groove with crankshaft key.
Install crankshaft pulley, and tighten pulley bolt to specification. See
TORQUE SPECIFICATIONS.

690

TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97 (Cont.)

4) 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.
5) Using sprocket holder, rotate camshaft sprockets so timing 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.
6) Using press, apply pressure on rod of timing belt tensioner until rod is
retracted and holes in rod and housing are aligned. See Fig. 4.
7) Install hexagon wrench through holes in housing and rod 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 specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate
crankshaft counterclockwise.
9) Ensure timing marks on camshaft sprockets align with timing 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.
10) To install remaining components, reverse removal procedure. Use
care when installing drive belt tensioner bolts to avoid dropping bolts into
timing belt cover.
11) Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust fluid levels and check ignition timing. Adjust drive belts to
proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bolt/Nut .......................................................................................... 38 (52)
Alternator Mount Bolt ................................................................................................ 27 (37)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Crankshaft Pulley Bolt ........................................................................................... 239 (324)
Drive Belt Tensioner Bolt .......................................................................................... 15 (20)
Fan Clutch-To-Water Pump Nut ............................................................................... 12 (16)
Idler Pulley Bolt ......................................................................................................... 25 (34)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 15 (20)
INCH Lbs. (N.m)
No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8)
Valve Cover Bolt/Nut ................................................................................................ 73 (8.3)

TOYOTA

691

3.0L 6-Cylinder 2JZ, 1998

TIMING BELT APPLICATION
Application
3.0L 6-Cyl. 2JZ-GE & 2JZ-GTE
Supra
1998 ..........................................................
1

Labor Time

Belt
Part No.

2.7 Hours .. ..... T215

With Turbo, add .9 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 90,000 miles
or 72 months for severe operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal (Non-Turbo) 1) Remove battery and battery tray. Raise and
support vehicle. Drain cooling system.
2) Remove air cleaner duct located above radiator. Remove lower fan
shroud and radiator assembly. Rotate drive belt tensioner clockwise.
Remove drive belt.
3) Place reference mating marks on fan clutch, water pump pulley, and
water pump stud for reassembly reference. Remove cooling fan, fan
clutch, and water pump pulley.
4) Remove power steering pump with hoses attached, and 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.
5) 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.
6) Timing marks on camshaft sprockets must align with timing marks on
No. 4 timing belt cover. See Fig. 1. If not, rotate crankshaft clockwise
one complete revolution (360 degrees).
CAUTION: Crankshaft must be correctly positioned by aligning
sub-timing mark with 0 mark on timing belt cover to prevent
valves from contacting pistons.
7) Rotate crankshaft pulley 60 degrees counterclockwise. Align subtiming mark with 0 mark on timing belt cover. Perform STEP 1. See
Fig. 2. Ensure dot marks of camshaft sprockets are aligned with timing
marks of No. 4 timing belt cover. See Fig. 2, STEP 2.
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.
8) Using Handle (09330-00021) and Pulley Holder (09213-70010) or
equivalent to hold crankshaft pulley, remove crankshaft pulley bolt. DO
NOT allow the crankshaft pulley to rotate.
9) Alternately loosen timing belt tensioner bolts. Remove bolts, timing
belt tensioner, and dust boot. See Fig. 3. Remove timing belt from
camshaft sprockets.
10) 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 toward timing belt). See Fig. 3. Remove
timing belt guide. If reusing timing belt, place mating reference marks on
timing belt and crankshaft sprocket. Remove timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Camshaft Timing Marks (Non-Turbo)

Inspection (Non-Turbo) 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. Replace timing belt if damaged or
contaminated. Check idler pulley and drive belt tensioner 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 exists.
NOTE: Timing 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.
2) Hold timing belt tensioner body, and 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 housing. See Fig. 4.
Replace timing belt tensioner if distance is not .315-.346 (8.00-8.80
mm).
Installation (Non-Turbo) 1) Install idler pulley and plate washer (if
removed). Apply Loctite 242 or equivalent 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.
2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark
on crankshaft sprocket with timing mark on oil pump body. See Fig. 2,
STEP 3. Clean oil or water off of crankshaft sprocket and install timing
belt on crankshaft sprocket and around idler pulley.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and crankshaft sprocket align, and timing belt is installed in
original direction of rotation.
3) Install timing belt guide with cupped side away from crankshaft
sprocket 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.
4) Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is
aligned with 0 timing mark of No. 1 timing belt cover. See Fig. 2, STEP
4. Temporarily install crankshaft pulley bolt.
CAUTION: If reusing timing belt, ensure reference marks on timing
belt and camshaft sprockets align and timing belt is installed in
original direction of rotation.
5) If necessary, use spanner wrench to rotate camshaft sprockets so
timing marks on camshaft sprockets align with timing marks on No. 4
timing belt cover. See Fig. 1. Install timing belt on camshaft sprockets.
Ensure tension exists on timing belt between camshaft sprockets.
6) Using press, apply pressure on rod of timing belt tensioner until rod is
retracted and holes in rod and housing are aligned. See Fig. 6.
7) Install hexagon wrench through holes in housing and rod to hold rod
in retracted position. See Fig. 6. Release press. Install dust boot on
timing belt tensioner. Install timing belt tensioner. Alternately tighten
timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.

TOYOTA

692

3.0L 6-Cylinder 2JZ, 1998 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Exploded View Of Typical Timing Belt & Components

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Sub-Timing Marks (Non-Turbo)

CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC.

9) Ensure timing marks on camshaft sprockets align with timing marks

on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns
with 0 mark on timing belt cover. If timing marks are not aligned,
remove timing belt and reinstall.
10) Tighten crankshaft pulley bolt to specification. 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.
11) Ensure water pump and fan clutch reference marks are aligned.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

TOYOTA

693

3.0L 6-Cylinder 2JZ, 1998 (Cont.)

7) Timing marks on camshaft sprockets must align with timing marks on
No. 4 timing belt cover. See Fig. 7. If not, rotate crankshaft clockwise
one complete revolution (360 degrees).
CAUTION: It 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.
8) Alternately loosen timing belt tensioner bolts. Remove bolts, timing
belt tensioner, and dust boot. See Fig. 3. Remove timing belt from
camshaft sprockets. On automatic transmission models, remove clamps
securing oil cooler lines near crankshaft pulley.
9) On all models, use Handle (09330-00021) and Pulley Holder
(09213-70010) or equivalent to hold crankshaft pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley.
10) Remove No. 1 timing belt cover and gaskets. Note direction of timing
belt guide installation for reassembly reference (flat side toward timing
belt). See Fig. 3. Remove timing belt guide. If reusing timing belt, place
mating reference marks on timing belt and crankshaft sprocket. Remove
timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Aligning Camshaft Timing Marks (Turbo)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Retracting Timing Belt Tensioner Rod

WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
Removal (Turbo) 1) Disconnect the negative battery cable. Remove
battery and battery tray. Raise and support vehicle. Remove lower
engine cover. Drain cooling system.
2) 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.
3) On manual transmission models, remove drive belt tensioner damper
(located between drive belt tensioner and stud on front of engine). See
Fig. 3. Rotate drive belt tensioner clockwise. Remove drive belt.
4) On all models, place reference mating marks on fan clutch, water
pump pulley, and water pump stud for reassembly reference. Remove
cooling fan, fan clutch, and water pump pulley.
5) 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. 3. 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).
6) 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.

Inspection (Turbo) 1) Inspect timing belt for damaged teeth, cracking

or oil contamination. Replace timing belt if damaged or contaminated.
Check idler pulley and drive belt tensioner 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 exists.
NOTE: Timing 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.
2) Hold timing belt tensioner body, and 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 housing. See Fig. 4.
Replace timing belt tensioner if distance is not .315-.346 (8.00-8.80
mm).
3) 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) 1) Install idler pulley and plate washer (if
removed). Apply Loctite 242 or equivalent 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.
2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark
on crankshaft sprocket with timing mark on oil pump body. See Fig. 5.
Install timing belt on crankshaft sprocket.

694

TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)

CAUTION: If reusing timing belt, ensure reference marks on timing

belt and crankshaft sprocket align, and timing belt is installed in
original direction of rotation.
3) Install timing belt guide with cupped side away from crankshaft
sprocket 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, and tighten pulley bolt to specification while
holding crankshaft. See TORQUE SPECIFICATIONS.
4) On automatic transmission models, reinstall clamps for oil cooler lines
near crankshaft pulley.
5) On all models, 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.
6) Using spanner wrench, rotate camshaft sprockets so timing marks on
camshaft sprockets align with timing marks on No. 4 timing belt cover.
See Fig. 7. Clean oil or water off of crankshaft sprocket and install timing
belt on camshaft sprockets. Ensure tension exists on timing belt
between camshaft sprockets.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 60 (81)
Crankshaft Pulley Bolt ........................................................................................... 243 (330)
Drive Belt Tensioner Bolt .......................................................................................... 15 (21)
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)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
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)
No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8)
1

CAUTION: If reusing timing belt, ensure reference marks on timing

belt and camshaft sprockets align and timing belt is installed in
original direction of rotation.
7) Using press, apply pressure on rod of timing belt tensioner until rod is
retracted and holes in rod and housing are aligned. See Fig. 6.
8) Install hexagon wrench through holes in housing and rod to hold rod
in retracted position. See Fig. 6. Release press. Install dust boot on
timing belt tensioner. Install timing belt tensioner. Alternately tighten
timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
9) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate
crankshaft counterclockwise.
10) Ensure timing marks on camshaft sprockets align with timing marks
on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns
with 0 mark on timing belt cover. See Fig. 7. If timing marks are not
aligned, remove timing belt and reinstall.
11) To install remaining components, reverse removal procedure. Use
care when installing drive belt tensioner bolts to avoid dropping bolts into
timing belt cover.
12) Ensure water pump and fan clutch reference marks are aligned.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

Apply Loctite 242 or equivalent to bolt threads.

Right and left side as viewed from rear of engine.

TOYOTA

695

3.0L 6-Cylinder 7M-GE & 7M-GTE

TIMING BELT APPLICATION
Application
3.0L 6-Cyl. 7M-GE
Cressida
1989-91 .....................................................
1992 ...........................................................
Supra 7M-GE
1986-90 .....................................................
1991-92 .....................................................
Supra 7M-GTE
1987-90 .....................................................
1991-92 .....................................................

Labor Time

Belt
Part No.

3.1 Hours ... ..... T126

3.1 Hours ... ..... T237
3.4 Hours ... ..... T126
3.4 Hours ... ..... T237
3.8 Hours ... ..... T126
3.8 Hours ... ..... T237

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
for severe service operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove radiator. Remove all accessory drive belts. Remove power
steering pump with hoses attached, and secure aside (if equipped).
Remove spark plugs. Disconnect hoses from air pipe.
2) 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.
3) Rotate crankshaft so cylinder No. 1 is at TDC of compression stroke.
Ensure timing mark on crankshaft pulley aligns with 0 mark on timing
belt cover.
4) Ensure timing marks on camshaft sprockets align with timing marks
on No. 4 timing belt cover. See Fig. 2. If timing marks are not aligned,
rotate crankshaft 360 degrees and recheck alignment.
5) Remove power steering belt pulley. Using Pulley Holder
(09213-58011) and Handle (09330-00021), or equivalent, hold crankshaft pulley and remove retaining bolt.
6) Using puller, remove crankshaft pulley. Remove fan bracket, No. 1
timing belt cover and gasket. See Fig. 1.
7) Note direction of timing belt guide installation. Mark direction of timing
belt rotation. Remove timing belt guide and tension spring. See Fig. 1.
Loosen No. 1 idler pulley retaining bolt.
8) 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 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated. Inspect
idler pulleys and fan for smooth rotation. Replace component if defective.
2) 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 1) 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.
2) Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pulley 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.
3) Temporarily install crankshaft pulley retaining bolt. Using crankshaft
pulley retaining bolt, rotate crankshaft clockwise (viewed from front of
engine) 2 full revolutions.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks

CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
4) Ensure all timing marks are properly aligned. See Figs. 2 and 3.
Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37 N.m). Check
timing belt deflection.
5) 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.
6) Remove crankshaft pulley retaining bolt. Install timing belt guide with
cupped side toward front of engine.

TOYOTA

696

3.0L 6-Cylinder 7M-GE & 7M-GTE (Cont.)

CAUTION: Ensure timing belt guide is installed with cupped side
toward front of engine and flat side against crankshaft sprocket.
7) To install remaining components, reverse removal procedure. Apply
sealant to coolant outlet before installing. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Coolant By-Pass Outlet Bolt ..................................................................................... 13 (18)
Coolant Inlet Nut ....................................................................................................... 14 (19)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Fan Bracket Bolt ....................................................................................................... 30 (41)
Idler Pulley Bolt
No. 1 Pulley ............................................................................................................. 27 (37)
No. 2 Pulley ............................................................................................................. 13 (18)
Power Steering Pump Pulley Nut ............................................................................. 32 (43)
Spark Plug ................................................................................................................. 13 (18)
Tension Spring Bracket Bolt ..................................................................................... 13 (18)
INCH Lbs. (N.m)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Camshaft Sprocket Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Checking Timing Belt Tension

Fan Retaining Nut ....................................................................................................... 48 (5)

Timing Belt Cover Bolt
No. 1 & 2 Covers ...................................................................................................... 48 (5)
No. 3 & 4 Covers ...................................................................................................... 74 (8)

TOYOTA

697

3.0L V6 DOHC 1998-04

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application
3.0L V6 1MZ-FE
Avalon
1998-04 ...............................
Camry
1998-02 ...............................
2003-04 ...............................
Camry Solara
1999-03 ...............................
Highlander
2001-03 ...............................
Sienna
1998-00 ...............................
2001-03 ...............................

Labor Time

Component
Belt
Kit No.
Part No.

3.0 Hours ... .. TCK257 .. ..... T257

3.0 Hours ... .. TCK257 .. ..... T257
3.0 Hours ... ...... ..... ...... ..... T257
3.0 Hours ... .. TCK257 .. ..... T257
2.5 Hours ... .. TCK257 .. ..... T257
3.8 Hours ... .. TCK257 .. ..... T257
4.0 Hours ... .. TCK257 .. ..... T257

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 90,000 miles
or 72 months.

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
battery cable at least 90 seconds before working on vehicle.
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal (Avalon, Camry 1998-01 & Camry Solara) 1) Raise and
support vehicle. Remove right side front wheel. Remove right fender
apron seal. Remove accessory drive belts. Lower vehicle.
2) Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. On Camry Solara, remove shock tower
suspension brace.
3) On all models, remove engine moving control rod and No. 2 right
engine mounting bracket. Remove generator-to-engine bracket for
access to timing belt covers.
4) Using Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, hold crankshaft 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 right engine
mounting bracket from front (timing belt end) of engine. Note direction of
timing belt guide installation for reassembly reference. Remove timing
belt guide.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA

698

3.0L V6 DOHC 1998-04 (Cont.)

NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing
belt side of engine.
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2
or 3.
6) Ensure timing mark on each camshaft sprocket is aligned with
appropriate timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3.
If timing marks are not aligned, rotate crankshaft CLOCKWISE one full
revolution (360 degrees).
7) If reusing old belt, ensure there are 3 installation marks and front
arrow marked on belt. See Fig. 4. If not, place mating mark on belt where
it contacts the crankshaft and camshaft sprockets. Also, mark belt with
arrow showing direction of rotation.
8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. Do NOT hold tensioner with push rod facing DOWN. Remove
timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Aligning Timing Marks (1999-04)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks (1998)

Inspection (Avalon, Camry 1998-01 & Camry Solara) 1) Inspect
timing belt for damaged teeth, cracking or oil contamination. 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
DOWN.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists. Hold timing belt tensioner body with
push rod facing UP. Press rod against solid surface. Replace timing belt
tensioner if push rod moves.
3) Measure timing belt tensioner push rod protrusion from end of rod to
edge of timing belt tensioner housing. See Fig. 5. Replace timing belt
tensioner if distance is not .394-.425 (10.01-10.8 mm).

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Identifying Timing Belt Reference Marks & Front Mark

NOTE: Engine should be cold when installing timing belt.

Installation (Avalon, Camry 1998-01 & Camry Solara) 1) Install
No. 1 and 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 rotate smoothly.
2) 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 or 3.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with appropriate timing mark on No. 3
timing belt rear cover. See Fig. 2 or 3.

TOYOTA

699

3.0L V6 DOHC 1998-04 (Cont.)

CAUTION: Clean timing belt sprockets before installing timing belt.
Wipe off any oil or water with rag. DO NOT use any cleaning
solvents.
4) Install timing belt in following order:
a) Crankshaft sprocket
b) Water pump pulley
c) Left camshaft sprocket (front of vehicle side)
d) No. 2 idler pulley
e) Right camshaft sprocket (firewall side)
f) 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.
5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of
pressure on push rod of timing belt tensioner until rod is retracted and
holes in rod and housing are aligned. See Fig. 6. Align holes in housing
and push rod. Install 1.5 mm hexagon wrench through housing and push
rod hole to secure push rod. Release press and install dust boot on
timing belt tensioner.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Remove 1.5 mm 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.
8) Ensure timing mark on each camshaft sprocket is aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If all timing marks
are not aligned, remove timing belt and reinstall. Remove crankshaft
pulley bolt.
9) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install engine mounting bracket
on front of cylinder block. Install and tighten bolts to specification. See
TORQUE SPECIFICATIONS.
10) 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.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten fasteners to specification.
Connect engine ground strap. Adjust drive belts to proper tension.

4) Using gear puller and crankshaft pulley bolt, 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 direction of
timing belt guide installation for reassembly reference. Remove timing
belt guide. See Fig. 4.
NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing
belt side of engine.
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
Fig. 3.
6) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 3. If timing marks are not
aligned, rotate crankshaft CLOCKWISE one full revolution (360
degrees).
7) If reusing old belt, ensure there are 3 installation marks and front
arrow marked on belt. See Fig. 4. If not, place mating mark on belt where
it contacts the crankshaft and camshaft sprockets. Also, mark belt with
arrow showing direction of rotation.
8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. Do NOT hold tensioner with push rod facing DOWN. Remove
timing belt in following order
a) No. 1 idler pulley
b) Right camshaft sprocket (firewall side)
c) No. 2 idler pulley
d) Left camshaft sprocket (front of vehicle side)
e) Water pump pulley
f) Crankshaft sprocket
Inspection (Camry 2002-04 & Highlander) 1) Inspect timing belt for
damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate
freely and are not leaking oil. Replace damaged components. Inspect
water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists. Hold timing belt tensioner body with
push rod facing UP. Press rod against solid surface. Replace timing belt
tensioner if push rod moves.
NOTE: Engine should be cold when installing timing belt.
Installation (Camry 2002-04 & Highlander) 1) Install No. 1 and 2
idler pulleys (if removed). Install and tighten bolts to specification. See
TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate
smoothly.
2) 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. 3.
3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with appropriate timing mark on No. 3
timing belt rear cover. See Fig. 3.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Retracting Timing Belt Tensioner Rod

Removal (Camry 2002-04 & Highlander) 1) Raise and support
vehicle. Remove right side front wheel. Remove right fender apron seal.
Remove accessory drive belts. Lower vehicle.
2) Remove control (torque) rod from timing belt end of engine. Remove
engine mount from timing belt end of engine. Remove generator
mounting bracket from engine for access to timing belt covers.
3) Using Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft
pulley bolt.

CAUTION: Clean timing belt sprockets before installing timing belt.

Wipe off any oil or water with rag. DO NOT use any cleaning
solvents.
4) Install timing belt in following order:
a) Crankshaft sprocket
b) Water pump pulley
c) Left camshaft sprocket (front of vehicle side)
d) No. 2 idler pulley
e) Right camshaft sprocket (firewall side)
f) 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.

700

TOYOTA
3.0L V6 DOHC 1998-04 (Cont.)

5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of

pressure on push rod of timing belt tensioner until rod is retracted and
holes in rod and housing are aligned. See Fig. 6. Align holes in housing
and push rod. Install 1.5 mm hexagon wrench through housing and push
rod hole to secure push rod. Release press and install dust boot on
timing belt tensioner.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) Remove 1.5 mm 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.
8) Ensure timing mark on each camshaft sprocket is aligned with
appropriate timing mark on No. 3 timing belt rear cover. See Fig. 3. If all
timing marks are not aligned, remove timing belt and reinstall. Remove
crankshaft pulley bolt.
9) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install right side engine
mounting bracket on front of cylinder block. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS.
10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure
there are no gaps in gasket. Cut off excess gasket. Install and tighten
bolts to specification.
11) Install generator bracket. Install crankshaft pulley. Install and tighten
crankshaft pulley bolt. See TORQUE SPECIFICATIONS.
12) Install engine mounting stay and engine moving control rod to
engine and body. Connect engine ground strap.
13) Install accessory drive belts. Adjust drive belts to proper tension.
Install right fender apron seal. Install right front wheel.
Removal (Sienna) 1) Remove the outer cowl top panel along with the
ventilation louvers and windshield wiper arm assembly. See Fig. 7.
Raise and support vehicle.
2) Remove right side front wheel. Remove right fender apron seal.
Remove accessory drive belts. Lower vehicle. Disconnect Data Link
Connector 1 (DLC-1) from right side engine mounting bracket.
3) Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors.
4) Remove engine stabilizer rod, engine mounting stay and engine
mounting bracket, located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers.
5) Using Pulley Holder (09213-54015) or equivalent, and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt. Using 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 direction of timing belt guide installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing
belt side of engine.
6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2
or 3.
7) Ensure timing marks on camshaft sprockets are aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If timing marks are
not aligned, rotate crankshaft CLOCKWISE one full revolution (360
degrees).
8) If reusing old belt, ensure there are 3 installation marks and front
arrow marked on belt. See Fig. 4. If not, place mating mark on belt where
it contacts the crankshaft and camshaft sprockets. Also, mark belt with
arrow showing direction of rotation.
9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
boot. Do NOT hold tensioner with push rod facing DOWN. Remove
timing belt.
Inspection (Sienna) 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. Ensure idler pulleys rotate freely and are
not leaking oil. Replace damaged components. Inspect water pump for
leaks or worn out bearing.

CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
belt tensioner if oil leakage exists. Hold timing belt tensioner body with
push rod facing UP. Press rod against solid surface. Replace timing belt
tensioner if push rod moves.
3) Measure timing belt tensioner push rod protrusion from end of rod to
edge of timing belt tensioner housing. See Fig. 5. 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 (Sienna) 1) Install No. 1 and 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 rotate smoothly.
2) 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 or 3.
3) Using spanner wrench, rotate each camshaft sprocket so timing mark
on camshaft sprocket aligns with timing mark on No. 3 timing belt rear
cover. See Fig. 2 or 3.
CAUTION: Clean timing belt sprockets before installing timing belt.
Wipe off any oil or water with rag. DO NOT use any cleaning
solvents.
4) Install timing belt on crankshaft sprocket, water pump pulley, left (front
of vehicle side) camshaft sprocket, No. 2 idler pulley, right (firewall side)
camshaft sprocket, 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.
5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of
pressure on push rod of timing belt tensioner until rod is retracted and
holes in rod and housing are aligned. See Fig. 6. 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.
6) Install timing belt tensioner. Install and alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS.
7) 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.
8) Ensure timing mark on each camshaft sprocket is aligned with timing
mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If all timing marks
are not aligned, remove timing belt and reinstall. Remove crankshaft
pulley bolt.
9) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install engine mounting bracket
on front of cylinder block. Install and tighten bolts to specification. See
TORQUE SPECIFICATIONS.
10) Using new gaskets, install No. 1 and 2 timing belt covers. Ensure
there are no gaps in gasket. Cut off excess gasket. Install and tighten
bolts to specification.
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.
12) Install generator bracket. Install engine stabilizer rod and engine
mounting bracket, located near timing belt cover. Connect engine
ground strap.
13) To install remaining components, reverse removal procedure.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Adjust drive belts to proper tension.

TOYOTA

701

3.0L V6 DOHC 1998-04 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Exploded View Of Outer Cowl Top Panel (Sienna)

Application
Ft. Lbs. (N.m)
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)
Crankshaft Pulley Bolt ........................................................................................... 159 (215)
Engine Mount Bracket-to-Engine Bolt ...................................................................... 21 (28)
Engine Mounting Stay ............................................................................................... 23 (32)
Engine Moving Control Rod Bolts ............................................................................ 47 (64)
Generator Adjusting Lock Bolt .................................................................................. 13 (18)
Generator Bracket No. 2 ........................................................................................... 21 (28)
Generator Pivot Bolt
Avalon ...................................................................................................................... 41 (56)
Except Avalon .......................................................................................................... 38 (52)
Power Steering Pump Bolt ....................................................................................... 32 (43)
Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43)
Right Engine Mount Brace Bolt ................................................................................ 23 (31)
Shock Tower Brace-to-Shock Tower Nuts
Camry Solara .......................................................................................................... 59 (80)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt 1 .......................................................................................... 25 (34)
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Wheel Lug Nut ........................................................................................................ 76 (103)
Wiper Arm Nuts
Sienna ...................................................................................................................... 15 (20)
INCH Lbs. (N.m)
No. 1 & 2 Timing Belt Cover Bolt ...........................................................................
No. 3 Timing Belt Cover Bolt ..................................................................................
Timing Belt Plate Bolt ..............................................................................................
Water Pump Bolt/Nut
Except Sienna ........................................................................................................
Sienna .....................................................................................................................
1

Apply Loctite 242 or equivalent to bolt threads.

75 (8.5)
75 (8.5)
71 (8.0)
71 (8.0)
69 (7.8)

TOYOTA

702

3.0L V6 SOHC
TIMING BELT APPLICATION
Application
3.0L V6
Pickup
1988-91 ..............................
1992
8/92 & Earlier ..................
9/92 & Later ....................
1993-95 ..............................
T100
1993-94 ..............................
4Runner
1988-91 ..............................
1992
8/92 & Earlier ..................
9/92 & Later ....................
1993-95 ..............................
1
2

Labor Time

Component
Belt
Kit No.
Part No.

4.1 Hours .. .

TCK240 . ..... T154

4.1 Hours .. . 2 TCK240 . ..... T154

4.1 Hours ... TCK240A . ..... T240
1
4.1 Hours ... TCK240A . ..... T240

7) Install Camshaft Sprocket Holder (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.
8) Remove timing belt from camshaft sprockets. Remove power steering
belt pulley. Using Pulley Holder (09213-58012) and Handle
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
pulley bolt.

4.1 Hours ... TCK240A . ..... T240

4.1 Hours .. .

TCK240 . ..... T154

4.1 Hours .. . TCK240 . ..... T154

1
4.1 Hours ... TCK240A . ..... T240
1
4.1 Hours ... TCK240A . ..... T240

With Air Conditioning, add .5 hours.

Timing belt component kit does not include camshaft
tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.

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.
9) Using puller, remove crankshaft pulley. Remove bolts, No. 1 timing
belt cover and gasket. Note direction of timing belt guide installation for
reassembly reference. Remove timing belt guide.
10) 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. 3.
11) If reference mark does not exist, install reference mark on timing belt
in alignment with timing mark (dot) on crankshaft sprocket for reassembly reference. See Fig. 3.
12) Remove timing belt. Remove bolt, No. 1 idler pulley and plate
washer (if necessary). See Fig. 1 or 2.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 60,000 miles
for severe operating conditions.

REMOVAL & INSTALLATION

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system.
Remove lower engine covers. Remove radiator. Remove all accessory
drive belts.
2) Remove power steering pump with hoses attached, and secure aside
(if equipped). Remove spark plugs. Disconnect hoses from air pipe.
NOTE: If separating fluid coupling from fan bracket, place reference mark on fluid coupling and fan bracket for reassembly
reference.
3) Remove coolant outlet. See Fig. 1 or 2. Remove fan. Remove spark
plug wire clamps across front of No. 2 timing belt cover. If necessary,
remove studs for coolant outlet from mount. Remove bolts, No. 2 timing
belt cover and gaskets.
CAUTION: If reusing timing belt, mark direction of timing belt
rotation and ensure reference marks are on timing belt. See Fig. 3.
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. 3.
4) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed
from rear of engine. Ensure timing mark on crankshaft pulley aligns with
0 mark on timing belt cover.
5) Ensure timing marks on camshaft sprockets align with timing marks
on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned,
rotate crankshaft clockwise one complete revolution and recheck alignment.
6) On 1988-92 models, remove timing belt guide and tension spring.
See Fig. 1. Loosen No. 1 idler pulley retaining bolt. Shift No. 1 idler
pulley to left as far as possible, and temporarily tighten bolt. Go to
step 8). On 1993-95 models, remove bolts and timing belt tensioner with
dust boot. Remove bolts/nuts, fan bracket and gasket. See Fig. 2.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View of Timing Belt & Components

(1988-92 Models)
Inspection 1) Inspect timing belt for damaged teeth, cracking or oil
contamination. Replace timing belt if damaged or contaminated.
2) On 1988-92 models, go to step 4). On 1993-95 models, inspect timing
belt tensioner for oil leakage. Replace timing belt tensioner if oil leakage
exists. Hold timing belt tensioner housing and press rod against solid
surface. Replace timing belt tensioner if rod moves.
3) Measure timing belt tensioner rod protrusion from end of rod to edge
of housing on timing belt tensioner. See Fig. 5. Replace timing belt
tensioner if distance is not .394-.413 (10.00-10.50 mm).
4) Inspect No. 1 and No. 2 idler pulleys and fan for smooth rotation.
Replace component if defective.

TOYOTA

703

3.0L V6 SOHC (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Exploded View Of Timing Belt & Components (1993-95 Models)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Aligning Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Identifying Timing Belt Reference Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

704

TOYOTA
3.0L V6 SOHC (Cont.)

Installation 1) Install plate washer and No. 1 idler pulley (if removed).
See Fig. 1 or 2. Install and tighten bolt to specification. See TORQUE
SPECIFICATIONS. Ensure No. 1 idler pulley is clean and rotates
smoothly.
2) Install crankshaft pulley bolt in end of crankshaft. Rotate crankshaft
and align timing mark on crankshaft sprocket with timing mark on oil
pump body. See Fig. 4.
3) Install timing belt on crankshaft sprocket with reference mark on
timing belt aligned with reference mark (dot) on crankshaft sprocket.
See Fig. 3. Install timing belt on water pump.
CAUTION: If reusing timing belt, ensure timing belt is installed in
original direction of rotation and reference mark on timing belt
aligns with reference mark (dot) on crankshaft sprocket.
4) Install timing belt guide with cupped side away from crankshaft
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.
5) Rotate crankshaft so cylinder No. 1 is at TDC on compression stroke.
Ensure timing mark on crankshaft pulley aligns with 0 mark on timing
belt cover.
6) Rotate left camshaft so timing mark on camshaft sprocket aligns with
timing mark on No. 3 timing belt cover. See Fig. 4. Rotate right camshaft
so pin hole in camshaft aligns with timing mark on No. 3 timing belt
cover.
7) 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. 3.
8) Using camshaft sprocket holder, slightly rotate left camshaft sprocket
clockwise. Install timing belt on left camshaft sprocket. Ensure reference
mark on timing belt aligns with timing mark on camshaft sprocket.
9) Using camshaft sprocket holder, slightly rotate left camshaft sprocket
and align timing mark on camshaft sprocket with timing mark on No. 3
timing belt cover. See Fig. 4. Ensure tension exists on timing belt
between crankshaft sprocket and left camshaft sprocket.
10) Align reference mark on timing belt with timing mark on right
camshaft sprocket. See Fig. 3. Ensure timing mark on right camshaft
sprocket aligns with timing mark on No. 3 timing belt cover.
11) Using new gasket, install fan bracket. Install and tighten bolt/nuts to
specification. See TORQUE SPECIFICATIONS. On 1988-92 models, go
to step 13). On 1993-95 models, use press to apply pressure on rod of
timing belt tensioner until rod is retracted and holes in rod and housing
are aligned. See Fig. 6.

12) Install hexagon wrench through holes in housing and rod to hold rod
in retracted position. Release press. Install dust boot on end of timing
belt tensioner. Install timing belt tensioner. Install and alternately tighten
bolts. See TORQUE SPECIFICATIONS.
CAUTION: Crankshaft must always be rotated clockwise. DO NOT
rotate crankshaft counterclockwise.
13) On 1993-95 models, remove hexagon wrench from timing belt
tensioner. On 1988-92 models, loosen No. 1 idler pulley retaining bolt.
Pry No. 1 idler pulley to right as far as possible and temporarily tighten
retaining bolt. Install tension spring. Loosen No. 1 idler pulley retaining
bolt until pulley moves with spring force tension. Tighten idler pulley bolt.
On all models, rotate crankshaft 2 full revolutions clockwise from TDC to
TDC. Ensure crankshaft pulley timing mark aligns with 0 mark on No. 1
timing belt cover.
14) Ensure timing marks on camshaft sprockets align with timing marks
on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned,
remove timing belt and reinstall using proper procedure.
15) Install No. 2 idler pulley gasket. See Fig. 1 or 2. Install No. 2 timing
belt cover and gaskets. Install crankshaft pulley.
16) To install remaining components, reverse removal procedure. Apply
sealant on coolant outlet before installing. Tighten all bolts/nuts to
specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling
system. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Alternator Bracket-To-Cylinder Head Bolt ................................................................. 27 (37)
Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Crankshaft Pulley Bolt ........................................................................................... 181 (245)
No. 1 Idler Pulley Bolt .................................................................. ................. 25-27 (34-37)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
INCH Lbs. (N.m)
Camshaft Housing Rear Cover Bolt ........................................................................
Fan Retaining Nut ....................................................................................................
No. 3 Timing Belt Cover Bolt ..................................................................................
No. 4 Timing Belt Cover Bolt ..................................................................................
Valve Cover Bolt ......................................................................................................

43
48
73
73
48

(4.9)
(5.4)
(8.3)
(8.3)
(5.4)

TOYOTA

705

3.4L V6
TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

3.4L V6
Tacoma
1995-04 .............................. 1 2.7 Hours .. ..
Tundra
2000-04
Automatic ........................ 2 2.9 Hours .. ..
Manual ............................. 2 2.7 Hours .. ..
T100
1995-98 .............................. 1 2.7 Hours .. ..
4Runner
1996-00 .............................. 1 2.7 Hours .. ..
2001-02 ............................... 3.2 Hours ... ..
1
2

TCK271 .. ..... T271

TCK271 .. ..... T271

TCK271 .. ..... T271
TCK271 .. ..... T271
TCK271 .. ..... T271
TCK271 .. ..... T271

With Air Conditioning, add .5 hours.

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1990-97 model years, the manufacturer recommends the belt be
replaced every 60,000 miles under severe driving conditions. For
1998-04 model years, the manufacturer recommends the belt be
replaced every 90,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (All Models) 1) Remove lower engine cover (if equipped).
Drain cooling system. Disconnect upper radiator hose. Remove accessory drive belts. Disconnect 2 power steering hoses from the air intake
chamber and resonator. Remove power steering pump drive belt.
Remove power steering pump with hoses attached, and hang out of
way. Remove A/C compressor with hoses attached, and hang out of
way.
2) Loosen cooling fan with fluid coupling and fan pulleys. Remove lower
fan shroud. Remove fan and fan pulleys.
3) Remove A/C compressor bracket from engine. On Tacoma and
4Runner, remove engine oil dipstick and tube. On all models, disconnect
electrical connectors and clamps from upper timing belt cover. Remove
upper timing belt cover. See Fig. 1. Remove power steering pump
adjusting strut. Remove fan bracket.
NOTE: Always turn crankshaft CLOCKWISE as viewed from timing
belt end of engine.
4) Ensure No. 1 cylinder is set at TDC of compression stroke (crankshaft
pulley groove aligned with zero mark on lower timing belt cover, and
camshaft sprocket timing marks are aligned with marks on back cover).
Use Pulley Holder (09213-54015) or equivalent to hold crankshaft
pulley. Remove crankshaft pulley bolt. Use gear puller to remove
crankshaft pulley.
5) Remove starter wire bracket and lower timing belt cover. Noting
installed position for reassembly reference, remove timing belt guide.
6) 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. 2.
7) If marks are not aligned, temporarily install crankshaft pulley bolt.
Turn crankshaft CLOCKWISE one revolution (360 degrees). Recheck
alignment of timing marks. Remove crankshaft pulley bolt.

8) 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.
9) Alternately loosening the bolts, remove timing belt tensioner and dust
boot. DO NOT hold tensioner with push rod facing DOWN. Remove
timing belt.
10) On Tundra and T100, loosen right camshaft timing pulley bolt using
Pulley Holder (09960-10010) or equivalent to hold pulley. Remove bolt,
knock pin and camshaft timing pulley.
Inspection (All Models) 1) Inspect idler pulleys for oil leakage at seal
area. Inspect idler pulley bearings for smoothness. Replace if defective.
CAUTION: DO NOT hold tensioner with push rod facing DOWN.
2) Inspect timing belt tensioner for oil leakage. Hold tensioner (push rod
facing upward) with both hands and push the push rod against a hard
surface. If push rod moves, replace tensioner. Measure protrusion of
push rod. If protrusion 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.
NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or
equivalent to 2 or 3 threads of pivot bolt.
Installation (Tacoma & 4Runner) 1) 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.
2) Install timing belt in following order:
a) Left (drivers side) camshaft pulley
b) No. 2 idler pulley
c) Right (passengers side) camshaft pulley
d) Water pump pulley
e) Crankshaft pulley
f) No. 1 idler pulley
If reusing old belt, ensure all reference marks are aligned.
3) Using a press, SLOWLY press in tensioner push rod with pressure of
200-2205 lbs. (100-1000 kg). Align holes of push rod and housing, and
insert a 1.27 mm hexagon wrench. Release pressure on push rod. See
Fig. 7.
4) Install dust boot on tensioner. Install tensioner and alternately tighten
2 bolts to specification. See TORQUE SPECIFICATIONS. Remove
hexagon wrench from tensioner.
5) Ensure timing marks of crankshaft timing pulley and oil pump body
are aligned, and check camshaft timing marks. See Fig. 2. If timing
marks do not align, remove timing belt and reinstall it. Remove crankshaft pulley bolt, if necessary.
6) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side toward timing belt. Install starter wire bracket and
lower timing belt cover with NEW gaskets. Install crankshaft pulley.
Install crankshaft pulley bolt and tighten to specification.
7) 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.
8) Install fan bracket. Install power steering adjusting strut. Install upper
timing belt cover with NEW gasket. Connect electrical connectors and
install clamps on timing belt cover. Using a NEW O ring with an
application of soapy water, install oil dipstick tube. Install A/C compressor bracket and A/C compressor. Install power steering pump. Connect
2 power steering hoses to air intake chamber and resonator. Install fan
and lower fan shroud. Install accessory drive belts. Install engine
undercover.
9) To complete installation, reverse removal procedure. Tighten all nuts
and bolts to specification. See TORQUE SPECIFICATIONS. Fill cooling
system and bleed air from system. Adjust drive belts to proper tension.

706

TOYOTA
3.4L V6 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA

707

3.4L V6 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 6: Aligning Camshaft Sprocket Timing Marks

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 7: Retracting Timing Belt Tensioner Rod

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 3: Locating Timing Belt Installation Marks

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 5: Aligning Crankshaft Sprocket Timing Mark

NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or

equivalent to 2 or 3 threads of pivot bolt.
Installation (Tundra & T100) 1) Ensure No. 1 cylinder is at TDC of
compression stroke by aligning crankshaft sprocket with mark on oil
pump body. See Fig. 5. Wipe any oil or water from timing pulleys. DO
NOT use any cleansing agent.
2) Align installation mark on timing belt with drilled mark on crankshaft
timing pulley. See Fig. 8. Install timing belt on crankshaft timing pulley,
No. 1 idler pulley and water pump pulley. Install timing belt guide with
cupped side away from crankshaft sprocket and flat side toward timing
belt.
3) Install lower timing belt cover and starter wire bracket, and tighten
bolts to specification. See TORQUE SPECIFICATIONS. Install crankshaft pulley. Install crankshaft pulley bolt and tighten to specification.
Ensure V notch (TDC mark) on crankshaft pulley aligns with 0 mark
on lower timing belt cover.
4) Ensure left camshaft sprocket timing mark is aligned with timing mark
on back cover, and right camshaft knock pin hole is aligned with timing
mark on back cover. See Fig. 9.
5) Using Pulley Holder (09960-10010), slightly rotate left camshaft
pulley CLOCKWISE. Align installation mark on timing belt with timing
mark on left camshaft pulley, and install timing belt on left camshaft
pulley. See Fig. 10.
6) Rotate left camshaft COUNTERCLOCKWISE to align timing mark
with timing mark on back cover. Ensure timing belt has tension between
crankshaft pulley and left camshaft pulley. Align installation mark on
timing belt with timing mark on right camshaft pulley, and install timing
belt on right camshaft pulley. See Fig. 11.
7) Slide right camshaft pulley onto camshaft. Align camshaft knock pin
hole with camshaft pulley knock pin groove marked R. Install knock
pin. See Fig. 12. Install camshaft pulley bolt, and tighten to specification.
See TORQUE SPECIFICATIONS.

TOYOTA

708

3.4L V6 (Cont.)
8) Using a press, SLOWLY press in tensioner push rod with pressure of
200-2205 lbs. (100-1000 kg). Align holes of push rod and housing, and
insert a 1.5 mm hexagon wrench. Release pressure on push rod. See
Fig. 7.
9) Install dust boot on tensioner. Install tensioner and alternately tighten
2 bolts to specification. See TORQUE SPECIFICATIONS. Remove 1.5
mm hexagon wrench from tensioner.
10) 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.
11) Install fan bracket. Install power steering adjusting strut. Install upper
timing belt cover with NEW gasket. Install A/C compressor bracket and
A/C compressor. Install power steering pump. Connect 2 power steering
hoses to air intake chamber and resonator. Install fan and lower fan
shroud. Install accessory drive belts. Install engine undercover.
12) To complete installation, reverse removal procedure. Tighten all nuts
and bolts to specification. See TORQUE SPECIFICATIONS. Fill cooling
system and bleed air from system. See COOLING SYSTEM BLEEDING. Check for leaks. Adjust drive belts to proper tension.

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 11: Aligning Installation Mark On Timing Belt With Timing

Mark On Right Camshaft Pulley (Tundra & T100)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 8: Aligning Timing Belt Installation Mark With Drilled Mark

On Crankshaft Timing Pulley (Tundra & T100)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 12: Installing Camshaft Timing Pulley Knock Pin

(Tundra & T100)

COOLING SYSTEM BLEEDING

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 9: Aligning Camshafts For Timing Belt Installation

(Tundra & T100)

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 10: Aligning Installation Mark On Timing Belt With Timing

Mark On Left Camshaft Pulley (Tundra & T100)

1) Fill cooling system. Install radiator cap. Move heater control to

warmest position. Start engine. Maintain engine speed at 2000-2500
RPM until engine is at normal operating temperature.
2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
coolant level to FULL line on coolant reservoir if necessary.

TOYOTA
3.4L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Compressor Bracket-To-Engine ......................................................................... 35 (47)
A/C Compressor-To-Bracket ..................................................................................... 18 (25)
Camshaft Pulley Bolt ............................................................................................... 81 (110)
Crankshaft Pulley Bolt
T100 & 1995-98 Tacoma & 4Runner ................................................................. 184 (250)
1999-03 4Runner ................................................................................................ 217 (295)
1999-04 Tacoma .................................................................................................. 217 (295)
2000-04 Tundra ................................................................................................... 217 (295)
No. 1 Idler Pulley Pivot Bolt ................................................................................... 1 25 (35)
No. 2 Idler Pulley Bolt .............................................................................................. 30 (40)
Power Steering Pump Bolt/Nut ................................................................................. 31 (43)
Spark Plug ................................................................................................................. 13 (18)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 14 (20)
INCH Lbs. (N.m)
Fan Retaining Nut .................................................................................................... 48 (5.4)
Lower Timing Belt Cover Bolt ..................................................................................... 80 (9)
Oil Dipstick Tube ......................................................................................................... 71 (8)
Upper Timing Belt Cover Bolt ..................................................................................... 80 (9)
1

Apply Loctite 242 or equivalent to 2 or 3 threads of pivot bolt

709

VOLKSWAGEN

710

1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel

TIMING BELT APPLICATION
Application
1.5L 4-Cyl. Diesel
Dasher
1979-80 .....................................................
Rabbit
1977-80 .....................................................
Rabbit Pickup
1980 ...........................................................
1.6L 4-Cyl. Diesel & Turbo Diesel
Dasher
1981 ...........................................................
Golf
1985-87 .....................................................
1988-92 (Canadian) ..................................
Jetta
1981-86 .....................................................
1986 (Canadian) .......................................
1989-92 .....................................................
1988-92 (Canadian) ..................................
Quantum
1982-85 .....................................................
Rabbit
1981-84 .....................................................
Rabbit Pickup
1981-83 .....................................................
Vanagon
1982 ...........................................................

Labor Time

Belt
Part No.

2.8 Hours ... ..... T043

1.5 Hours ... ..... T043
2.8 Hours ... ..... T043

2.8 Hours ... ..... T043

2.8 Hours ... ..... T043
2.2 Hours ... ..... T043
2.8
2.8
2.2
2.2

Hours
Hours
Hours
Hours

... .....
... .....
... .....
... .....

T043
T043
T043
T043

2.8 Hours ... ..... T043

1.5 Hours ... ..... T043
2.8 Hours ... ..... T043
2.8 Hours ... ..... T043

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Installing Camshaft Setting Bar

belt so there is no slack between camshaft sprocket and injection pump,
and between injection pump and crankshaft sprocket.
2) 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.
3) Turn crankshaft 2 revolutions in direction of engine rotation. Using a
rubber hammer, strike belt once between camshaft sprocket and
injection pump sprocket. Recheck belt tension and install remaining
components in reverse order of removal. Check injection pump timing.
Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Sprockets do not have to be removed to replace drive belt.
Removal 1) Disconnect negative battery cable. Loosen alternator and
remove drive belt. Remove crankshaft drive belt pulley. Remove air
cleaner and ducting. Remove timing belt and cylinder head cover.
Remove timing plug on top of bellhousing. Rotate engine to bring No. 1
cylinder to TDC. Check that TDC mark on flywheel is aligned with
reference.
2) Using Setting Bar (2065A for Vanagon, 2065 for other models) 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.
3) 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 1) Ensure that flywheel is still aligned with TDC mark. With
camshaft and injection pump locked in place, loosen camshaft sprocket
bolt 1/2 turn. Lightly tap camshaft gear loose from camshaft. Install drive

Courtesy of Volkswagen United States, Inc.

Fig. 2: Installing Timing Belt Tension Gauge

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley Bolts ............................................................................................. 15 (20)
Crankshaft Sprocket Bolt
Except Vanagon .................................................................................................... 81 (110)
Vanagon ............................................................................................................... 110 (150)
Intermediate Sprocket Bolt ........................................................................................ 33 (45)
Timing Belt Tensioner Lock Nut ............................................................................... 33 (45)
Water Pump Pulley Bolt ............................................................................................ 15 (20)

VOLKSWAGEN

711

1.5L, 1.6L & 1.7L 4-Cylinder Gasoline

TIMING BELT APPLICATION
Application

Labor Time

1.5L 4-Cyl.
Dasher
1974-75 ............................ .... 1.3 Hrs.
Rabbit
1975-79 ............................ .... 1.5 Hrs.
Scirocco
1978 ................................. .... 1.8 Hrs.
1.6L 4-Cyl.
Dasher
1976-80 ............................ .... 1.5 Hrs.
Jetta
1980 ................................. .... 1.8 Hrs.
Pickup
1980 ................................. .... 1.8 Hrs.
Rabbit
1980 ................................. .... 1.5 Hrs.
Scirocco
1976-80 ............................ .... 1.8 Hrs.
1.7L 4-Cyl.
Jetta
1981-84 ............................ .... 1.8 Hrs.
Quantum
1982-83 ............................ ... 1 1.8 Hrs.
Rabbit
1981 ................................. .... 1.5 Hrs.
1982-84 ............................ .... 1.8 Hrs.
Rabbit Pickup
1981-83 ............................ .... 1.8 Hrs.
Scirocco
1981-83 ............................ .... 1.8 Hrs.
1

Component
Belt
Kit No.
Part No.

3) Reverse removal procedure for remaining components. Adjust drive

belts to proper tension.

.... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017

... .. TCK017 .. ..... T017

Courtesy of Volkswagen United States, Inc.

Fig. 1: Aligning Crankshaft & Intermediate Sprockets

.... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017
.... .. TCK017 .. ..... T017

With Air Conditioning, Without Factory Air Conditioning,

With Radiator removal, labor time is 3.9 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

Fig. 2: Aligning Camshaft With Cylinder Head Flange

REMOVAL & INSTALLATION

TORQUE SPECIFICATIONS

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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 engine.
Installation 1) Rotate camshaft sprocket until index punch mark on
camshaft sprocket is lined up with top surface of valve cover mounting
flange on spark plug side of head. Rotate crankshaft and intermediate
shaft until index punch mark on intermediate shaft sprocket aligns with
V notch on crankshaft pulley. See Figs. 1 and 2.
2) Use care not to move any sprocket. Fit belt on bottom first, and then
at top. There should be no slack between sprockets. Tighten tensioner
so belt can just be twisted 90 degrees halfway between camshaft and
intermediate sprockets. Tighten adjuster lock nut.

Courtesy of Volkswagen United States, Inc.

TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Bolts ............................................................................................. 15 (20)
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.

VOLKSWAGEN

712

1.8L 4-Cylinder
Golf, GTI & Jetta AWD, AWP & AWW Engines
REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder Turbo (AWD, AWP & AWW Engines)

Golf
2000-01 ..................................................... 2.9 Hours ... ..... T306
GTI & Jetta
2000-04 ..................................................... 2.9 Hours ... ..... T306
NOTE: Engine code is located on machined pad on bellhousing
flange, where engine connects to transaxle.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: To identify engine, check engine code located on a pad on
engine block near bellhousing of transmission.
Removal 1) Working under hood, remove engine cover. Working
under vehicle, remove insulation tray.
2) On Golf and GTI, remove mounting screws and pull right headlight
housing out slightly forward. Disconnect electrical connection and pull
right headlight housing out from vehicle.

The manufacturer suggests the belt be replaced at 120,000 mile

intervals.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Identifying Turbocharger Charge Air Cooling System Components

VOLKSWAGEN

713

1.8L 4-Cylinder
Golf, GTI & Jetta AWD, AWP & AWW Engines (Cont.)
3) On Jetta, Remove screws and pull right headlight access cover
upward. Disconnect harness connector and remove securing screws at
top of right headlight. Remove securing screws at bottom of right
headlight and pull headlight housing out forward to remove from vehicle.
4) Remove charge air cooler duct at bottom of right-hand crossmember.
See Fig. 1. Rotate serpentine drive belt tensioner clockwise (as viewed
from front of engine) to relieve belt tension using a 16 mm wrench. See
Fig. 2. Lock tensioner in place using Mandrel (T10060). Remove
serpentine drive belt and tensioner.
5) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Ensure that TDC marks on flywheel and bellhousing are aligned.
See Fig. 3 or 4.
6) Remove cooling system expansion tank and power steering reservoir
bolts. Leaving hoses attached, secure expansion tank and reservoir out
of way.
7) Remove vacuum hose connecting fuel evaporative canister to throttle
body. Unplug coolant expansion tank and fuel evaporative canister
harness connectors. Remove upper timing belt cover. See Fig. 5.
8) Attach Engine Support Bridge (10-222A) with Bracket (10222A/1),
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 supported from below with a floor jack. Use care not to damage
components.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Setting Crankshaft To TDC (Automatic Transmission)

CAUTION: Engine mount assembly is secured by torque-to-yield

bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt.
These bolts MUST be replaced if they are loosened or removed.
9) Remove bolts from engine mount assembly at timing belt end of
engine. Remove engine mount.
10) Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft
pulley. It is NOT necessary to remove crankshaft pulley center bolt.
11) Remove lower and middle timing belt covers. See Fig. 5. Remove
engine bracket from engine block. See Fig. 6. If reusing old timing belt,
mark timing belt with arrow to indicate original direction of rotation.
12) Screw Tensioning Bolt (T10092) or a M5 x 55 stud into the timing belt
tensioner bracket. See Fig. 7. Install hex nut and washer onto stud.
13) SLOWLY turn hex nut on stud to compress timing belt tensioner.
Compress tensioner just enough so that Locking Pin (T40011) or drill bit
can be inserted through the tensioner body, locking the tensioner in
place.

Courtesy of Volkswagen United States, Inc.

Fig. 4: Setting Crankshaft To TDC (Manual Transmission)

CAUTION: 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.
14) Remove timing belt. Turn crankshaft back just slightly to ensure that
crankshaft is not at TDC for any cylinder in case camshaft moves.

Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Components

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Belt Tensioner

Installation 1) Ensure camshaft 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. 8. Install timing belt on water pump,
tensioner pulley and camshaft sprocket.

VOLKSWAGEN

714

1.8L 4-Cylinder
Golf, GTI & Jetta AWD, AWP & AWW Engines (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 8: Aligning Timing Marks

Fig. 6: Locating Engine Bracket-To-Block Bolts

Courtesy of Audi of America, Inc.

Fig. 7: Compressing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

NOTE: Before installing engine mount, insert bolts into engine

mount.
2) Install timing belt around crankshaft sprocket. If installing used belt,
ensure it is installed in original direction of rotation. Install engine mount
bracket to block. Install lower timing belt guard. Use Locking Fluid (D
000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley,
and tighten bolt to specification. See TORQUE SPECIFICATIONS.
3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 8. Place timing belt
on water pump, tensioner pulley and camshaft sprocket.
4) Compress tensioner and remove locking pin or drill bit from timing belt
tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft
2 complete revolutions in normal direction of rotation. Align camshaft
and crankshaft timing marks. Install crankshaft pulley.
5) Install center and upper timing belt covers. 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. 9.
6) Remove Engine Support Bracket (10-222) or floor jack from under
vehicle. Install serpentine belt tensioner and serpentine belt.
7) Install coolant expansion tank and power steering reservoir. Install
vacuum line between fuel evaporative canister and throttle body. To
install remaining components, reverse removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS.

Fig. 9: Locating Right-Hand Engine Support Arm

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft Sprocket ............................................................... 18 (25)
Engine Mount-To-Body 1
Step 1 ...................................................................................................................... 30 (40)
Step 2 ................................................................................................... Additional 1/4 Turn
Engine Mount-To-Engine Bracket 1
Step 1 ...................................................................................................................... 44 (60)
Step 2 ................................................................................................... Additional 1/4 Turn
Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
Timing Belt Tensioner
Bottom Bolt .............................................................................................................. 11 (15)
Top Bolt ................................................................................................................... 15 (20)
Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
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.

VOLKSWAGEN

715

1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder DOHC (APH, AWP & AWV Engines)

New Beetle
1999-04 ..................................................... 2.9 Hours ... ..... T306
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the timing belt AND tensioner be replaced at
105,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

CAUTION: Engine mount assembly is secured by torque-to-yield

bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt.
These bolts MUST be replaced if they are loosened or removed.
8) Remove bolts from engine mount assembly at timing belt end of
engine. Remove engine mount.
9) Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft
pulley. It is NOT necessary to remove crankshaft pulley center bolt.
10) Remove lower and middle timing belt covers. Remove engine
bracket from engine block. See Fig. 7. If reusing old timing belt, mark
timing belt with arrow to indicate original direction of rotation.
11) Screw Tensioning Bolt (T10092) or M5 x 55 x 1 stud into timing belt
tensioner bracket. See Fig. 8. Install hex nut and washer onto stud.
12) SLOWLY turn hex nut on stud to compress timing belt tensioner.
Compress tensioner just enough so that Locking Pin (T40011) or drill bit
can be inserted through the tensioner body, locking the tensioner in
place.
CAUTION: 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.
13) Remove timing belt. Turn crankshaft back just slightly to ensure that
crankshaft is not at TDC for any cylinder in case camshaft moves.

TIMING BELT
Removal 1) Remove engine cover. Remove noise insulation pan from
under engine compartment.
2) Remove air duct pipe between turbocharger and charge air cooler.
See Fig. 1. Air duct pipe is located along bottom right of cross member.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Serpentine Drive Belt Tension (1 Of 2)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Identifying Air Duct

3) Mark rotation direction of serpentine drive belt. Move serpentine drive
belt tensioner as shown to release tension on belt. See Fig. 2. Secure
tensioner using a drift, about .18 (4.5 mm) x 2.2 (55 mm). See Fig. 3.
Remove serpentine 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.
4) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Ensure that TDC marks on flywheel and bellhousing are aligned.
See Fig. 4 or 5.
5) 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.
6) Remove upper timing belt cover. See Fig. 6.
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 supported from below with a floor jack.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Releasing Serpentine Drive Belt Tension (2 Of 2)

Installation 1) Ensure camshaft 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. 9.

716

VOLKSWAGEN

1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Setting Crankshaft to TDC (Automatic Transmission)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Locating Engine Bracket-To-Block Bolts

Courtesy of Volkswagen United States, Inc.

Fig. 5: Setting Crankshaft to TDC (Manual Transmission)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Installing Timing Belt Tensioner Locking Pin

Courtesy of Volkswagen United States, Inc.

Fig. 6: Exploded View of Timing Belt & Components

NOTE: Before installing engine mount, insert bolts into engine
mount.
2) Install timing belt around crankshaft sprocket. If installing used belt,
ensure it is installed in original direction of rotation. Install engine mount
bracket to block. Install lower timing belt guard. Use Locking Fluid (D
000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley,
and tighten bolts to specification. See TORQUE SPECIFICATIONS.
3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 9. Place timing belt
on water pump, tensioner pulley and camshaft sprocket.

4) Remove Locking Pin (T40011) or drill bit and unscrew Tensioning Bolt
(T10092). See Fig. 8.
5) Turn crankshaft 2 revolutions, and check that camshaft and crankshaft marks align properly. See Fig. 9.
6) Install middle and upper timing belt covers. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
7) Install engine mount to engine bracket and body using NEW bolts.
Adjust engine mount clearance. See Fig. 10.
8) Remove engine support bridge or floor jack. 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.
9) To complete installation, reverse remaining removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.

VOLKSWAGEN

717

1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Audi of America, Inc.

Fig. 9: Aligning Camshaft & Crankshaft Timing Marks

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Center Bolt 1
Step 1 ...................................................................................................................... 66 (90)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
Engine Mount Bracket-To-Engine ............................................................................. 33 (45)
Engine Mount-To-Body 1
Step 1 ...................................................................................................................... 30 (40)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
Engine Mount-To-Engine Bracket 1
Step 1 ...................................................................................................................... 44 (60)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
Serpentine Drive Belt Tensioner Bolt ....................................................................... 18 (25)
Timing Belt Cover Bolt .............................................................................................. 15 (20)
Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20)
Timing Belt Tensioner Mount Bolt ................................................ ............................ 11 (15)
Timing Belt Tensioner Pulley Bolt ............................................................................. 18 (25)
Water Pump Bolt ....................................................................................................... 11 (15)
1

Courtesy of Volkswagen United States, Inc.

Fig. 10: Adjusting Engine Mount Clearance

Replace bolts if loosened or removed.

VOLKSWAGEN

718

1.8L 4-Cylinder Passat AEB & ATW Engines

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.8L 4-Cylinder DOHC (AEB & ATW Engines)

Passat
1998-00
152 Tooth Belt ........................................ 3.6 Hours ... ..... T291
153 Tooth Belt ........................................ 3.6 Hours ... ..... T317
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1998-99 model years, the manufacturer suggests the belt be
replaced at 90,000 mile intervals. For 2000 model year, the manufacturer suggests the belt AND tensioner be replaced at 105,000 mile
intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Exploded View Of Front Bumper Assembly

TIMING BELT
NOTE: ATW engines use T317 (153 tooth belt). AEB engines are
originally equipped with T291 (152 tooth belt), but may have had
tensioner and belt upgraded to T317 (153 tooth belt).
NOTE: Front lock carrier (radiator support) must be moved forward
to remove timing belt.
Removal 1) Raise and support vehicle. Remove front, lower engine
cover. Lower vehicle. Separate release lever from hood lock. Remove
front bumper cover. See Fig. 1. Remove bumper carrier from impact
damper.
2) 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. 2.
3) Remove lock carrier front support bolts. Remove lock carrier-to-side
panel bolts. Insert Lock Carrier Guide (3369) into hole on drivers side of
vehicle. Slide lock carrier forward on lock carrier guides.
4) 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. 3.
5) Remove accessory drive belt tensioner pulley and lever. Turn
crankshaft to TDC of compression stroke on No. 1 cylinder. See Fig. 4.
6) 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.
7) If reusing timing belt, mark belt with arrow to indicate direction of
rotation. Remove timing belt.
CAUTION: 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 1) Align timing marks on camshaft sprocket with mark on
cylinder head cover. See Fig. 4. 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.
2) 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 piston No. 2 lifts about .040 (1 mm). See Fig. 5.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Exploded View Of Lock Carrier Assembly

3) Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions. Make sure camshaft and
crankshaft timing marks are aligned.
4) 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. 6. Check for wear in Areas B and C if
dimension is not correct.
5) Remove crankshaft pulley. Install lower and upper timing belt covers.
Install crankshaft pulley. Tighten bolts to specification. 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.
6) Install lock carrier in original location. Install bumper and bumper
cover.

VOLKSWAGEN

719

1.8L 4-Cylinder Passat AEB & ATW Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Checking Timing Belt Tension

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Accessory Drive Belt Tensioner Bolt ........................................................................ 18 (25)
A/C Drive Belt Tensioner Bolt ................................................................................... 22 (30)
Bumper Carrier-To-Impact Damper Vertical Bolt ...................................................... 15 (20)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Impact Damper-To-Lock Carrier Bolt ........................................................................ 68 (50)
Lock Carrier
Front Support Bolt ................................................................................................... 37 (50)
Timing Belt Tensioner Pulley Bolt ............................................................................. 18 (25)
INCH Lbs. (N.m)
Bumper Guide-To-Side Panel Bolt .............................................................................. 18 (2)
Lock Carrier-To-Side Panel Bolt ................................................................................. 71 (8)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Timing Belt Tensioner Bolt ........................................................................................ 89 (10)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Volkswagen United States, Inc.

Fig. 5: Adjusting Timing Belt Tension

VOLKSWAGEN

720

1.8L 4-Cylinder Passat AUG & AWM Engines

TIMING BELT APPLICATION
Belt
Part No.

NOTE: If necessary, align pressure piston using needle nose pliers

or a thin wire (hole in piston and hole in housing must align).

1.8L 4-Cylinder DOHC (AUG & AWM Engines)

Passat
2000-04 ..................................................... 3.6 Hours ... ..... T306

6) On vehicles built through July 2000, align holes in timing belt

tensioner piston rod and housing. 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.

Application

Labor Time

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the timing belt AND tensioner be replaced at
105,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools. This will
allow servicing of front engine components. Lock carrier can be
removed at technicians discretion.
Removal 1) For vehicles manufactured up to September, 2000,
disconnect front turn signal light assembly wiring harnesses. Separate
hood release lever from bumper cover. Remove front bumper cover. See
Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner
housing. Remove support bolts from lock carrier assembly. See Fig. 2.
Install Support Tool (3369) through lock carrier to body. Remove oil
cooler from lock carrier assembly. Move lock carrier forward on support
tools.
2) For vehicles manufactured from October, 2000, remove bumper
cover from bumper carrier. See Fig. 3. 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.
3) On all vehicles, loosen bolts for air conditioning drive belt and remove
belt. Remove serpentine drive belt. Remove serpentine drive belt
tensioner.
NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior
to removal. Running a used belt in the opposite direction could
destroy it.
4) Remove upper timing belt cover. See Fig. 5. Rotate crankshaft to TDC
No. 1 cylinder. See Fig. 6.
CAUTION: Vibration damper outer bolts and center bolt are torqueto-yield type. If loosened or removed, bolts must be replaced.
5) Remove vibration damper. It is NOT necessary to remove center bolt
from vibration damper. Remove lower and middle timing belt covers.
See Fig. 5. For vehicles built through July 2000, go to next step. For
vehicles built after July 2000, go to step 7).

CAUTION: Tensioners on vehicles built after July 2000 are oil-filled.

Excessive force during compression can damage tensioner.
7) On vehicles built after July 2000, insert a hex wrench into hex socket
on tensioner and push pulley counter-clockwise in direction of arrow with
a socket head wrench using even but not excessive application of force
until tensioner piston can be locked with Locking Plate (T10008). See
Fig. 8.
8) To loosen tensioner on models built after July 2000, install Pin
Wrench (3387). Ensure tab on Pin Wrench is not bent. Loosen nut in
center of tensioner, and rotate clockwise using Pin Wrench.
9) On all models, remove timing belt. Turn crankshaft back just slightly
to ensure that crankshaft is not at TDC for any cylinder.
CAUTION: 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 1) Align timing marks on camshaft sprocket with mark on
cylinder head cover. Ensure crankshaft sprocket is still aligned with
timing mark. See Fig. 6.
2) Install timing belt around crankshaft sprocket. Install lower timing belt
cover. Install NEW vibration damper bolts, and tighten to specification.
See TORQUE SPECIFICATIONS.
3) Set crankshaft pulley to TDC No. 1 cylinder. Place timing belt on water
pump, tensioner pulley and camshaft sprocket. For models built through
July 2000, go to next step. For models built after July 2000, go to step 5).
NOTE: Engine must be cool (not more than lukewarm) when
tensioning timing belt.
4) On models built through July 2000, remove Locking Pin (T40011) and
unscrew Tensioning Bolt (T10092). See Fig. 7.
CAUTION: If tensioner is fully extended at any time, it must be
pressed back into compressed position using tensioner assembly
and Pin Wrench. Excessive force during this compression procedure can damage tensioner assembly.
5) On models built after July 2000, rotate tensioner counterclockwise
using Pin Wrench (3387), removing all tension until Locking Plate
(T10008) can be removed without force. After removing Locking Plate,
rotate tensioner clockwise using Pin Wrench until a 5/16 (8 mm) drill bit
can be inserted between tensioner lever and housing through underside
of tensioner. While holding tensioner in this position, tighten tensioner
retaining bolt to specification. See TORQUE SPECIFICATIONS.
6) On all models, turn crankshaft 2 revolutions in normal direction of
rotation. Check that camshaft and crankshaft timing marks align properly. See Fig. 6.
7) On models built after July 2000, using a drill bit check dimension
between tightening lever and housing of tightening device. Specified
value .236-.393 (6-10 mm). If dimension is not as specified, repeat
timing belt tensioning procedure.
8) To finish installation, reverse remaining removal procedure. Tighten
all fasteners to specification. See TORQUE SPECIFICATIONS.

VOLKSWAGEN

721

1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Front Bumper Cover (Up To September, 2000)

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing Front Bumper Cover (From October, 2000)

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Moving Lock Carrier To Service Position

(Up To September, 2000)

Fig. 4: Moving Lock Carrier To Service Position

(From October, 2000)

722

VOLKSWAGEN
1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Exploded View Of Timing Belt Components

Courtesy of Volkswagen United States, Inc.

Fig. 7: Compressing Timing Belt Tensioner (Up To July, 2000)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Aligning Camshaft & Crankshaft Timing Marks

VOLKSWAGEN

723

1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Audi of America, Inc.

Application
Ft. Lbs. (N.m)
Bumper Carrier-To-Impact Absorber Vertical Bolt .................................................... 15 (20)
Camshaft Sprocket Bolt ............................................................................................ 50 (65)
Crankshaft Pulley Center Bolt 1
Step 1 ...................................................................................................................... 66 (90)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
Idler Pulley Bolt ......................................................................................................... 18 (25)
Impact Damper-To-Lock Carrier Bolt (From Oct. 2000) .......................................... 68 (50)
Lock Carrier
Front Support Bolt ................................................................................................... 37 (50)
Timing Belt Tensioner Bolt ........................................................................................ 11 (15)
Serpentine Drive Belt Tensioner Bolt ....................................................................... 18 (25)
Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
Water Pump Bolt ....................................................................................................... 11 (15)
INCH Lbs. (N.m)

Fig. 8: Compressing Timing Belt Tensioner (From July, 2000)

Bumper Guide-To-Side Panel Bolt .............................................................................. 18 (2)

Lock Carrier-To-Side Panel Bolt ................................................................................. 71 (8)
Timing Belt Cover Bolt 1 ............................................................................................ 89 (10)
Vibration Damper Bolt 1
Step 1 ...................................................................................................................... 89 (10)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
1

Replace bolt if loosened or removed.

VOLKSWAGEN

724

1.8L 4-Cylinder SOHC, 1983-93

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

1.8L 4-Cyl. SOHC

Cabriolet
1985-93 ............................ 1, 2 1.8 Hours . ..
Corrado
1990-92 ........................... ... 1.8 Hours ... ..
Fox
1987-93 ............................ 1, 2 1.8 Hours . ..
Golf
1985-92 ............................ 1, 2 1.8 Hours . ..
Golf (Canadian)
1993-95 ........................... ... 1.8 Hours ... ..
GTI
1984-87 ............................ 1, 2 1.8 Hours . ..
1988-89 ........................... ... 1.9 Hours ... ..
1990-92 ............................ 1, 2 1.8 Hours . ..
Jetta
1984-92 ........................... ... 1.8 Hours ... ..
Jetta (Canadian)
1993-95 ........................... ... 1.8 Hours ... ..
Passat (Canadian)
1992-94 ........................... ... 1.8 Hours ... ..
Quantum
1985 ................................ .. 1 1.8 Hours .. ..
Rabbit
1983-84 ............................ 1, 2 1.8 Hours . ..
Scirocco
1983-88 ............................ 1, 2 1.8 Hours . ..
1

TCK017 .. ..... T017

TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017
TCK017 .. ..... T017

With Air Conditioning, Without Factory Air Conditioning,

With Radiator removal, labor time is 3.9 hours.
With Air Conditioning, Without Factory Air Conditioning,
Without Radiator removal, labor time is 3.6 hours.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Timing Belt

3) 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.
4) By hand, rotate crankshaft 2 turns and check timing mark alignment.
To complete installation, reverse removal procedure. Adjust drive belts
to proper tension.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Audi of America, Inc.

Fig. 2: Aligning Ignition Rotor

Although the manufacturer does not recommend a specific scheduled

maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
Removal Disconnect negative battery cable. Match mark all components to ensure reassembly in original position. See Fig. 1. DO NOT turn
crankshaft with belt removed. Valve damage 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 1) 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.
2) With intermediate shaft/ignition rotor positioned, rotate crankshaft 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 timing belt.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Aligning 1.8L Timing Marks (8-Valve)

VOLKSWAGEN

725

1.8L 4-Cylinder SOHC, 1983-93 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
A/C Bracket-To-Engine Bolt ...................................................................................... 22 (30)
Crankshaft Timing Sprocket Bolt .............................................................................. 66 (90)
Intermediate Shaft Sprocket Bolt .............................................................................. 59 (80)
Lower Pulley Bolt ...................................................................................................... 15 (20)
Timing Belt Tensioner Nut ........................................................................................ 33 (45)
Water Pump Pulley Bolt ............................................................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Retaining Nut ....................................................................................... 89 (10)
Water Pump-To-Housing ........................................................................................... 89 (10)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Checking 1.8L Timing Belt Tension (8-Valve)

VOLKSWAGEN

726

1.8L & 2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION
Application

Labor Time

1.8L 4-Cyl. DOHC

GTI
1987-89 .....................................................
Jetta
1987-89 .....................................................
Scirocco (Canadian)
1988-89 .....................................................
Scirocco
1987-88 .....................................................
2.0L 4-Cyl. DOHC
GTI
1990-92 .....................................................
Jetta
1990-92 .....................................................
Passat
1990-92 .....................................................

Belt
Part No.

1.9 Hours ... ..... T292

1.9 Hours ... ..... T292
1.8 Hours ... ..... T292

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.
2) 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 Tension Scale (VW 210), or equivalent, reads 13-14.
3) Rotate crankshaft 2 revolutions and check timing mark alignment. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

1.9 Hours ... ..... T292

1.9 Hours ... ..... T292

1.9 Hours ... ..... T292
1.9 Hours ... ..... T292

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Aligning Ignition Rotor

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Match mark all
components to ensure reassembly to original position. Remove accessory drive belts.
2) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Remove fan belt and water pump pulleys. See Fig. 1. Remove
timing belt covers. Remove tensioner pulley. Remove timing belt.
Courtesy of Volkswagen United States, Inc.

Fig. 3: Timing Mark Alignment

Courtesy of Volkswagen United States, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Installation 1) Install timing belt around crankshaft and intermediate
shaft sprockets. Install lower timing belt cover. Install vibration damper,

Courtesy of Volkswagen United States, Inc.

Fig. 4: Proper Timing Belt Tension

VOLKSWAGEN
1.8L & 2.0L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Crankshaft Pulley Nut ............................................................................................... 15 (20)
Crankshaft Sprocket Bolt
16-Valve ............................................................................................................... 148 (200)
Intermediate Shaft Sprocket Bolt
16-Valve ................................................................................................................... 48 (65)
Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45)
Water Pump Pulley ................................................................................................... 15 (20)
INCH Lbs. (N.m)
Upper & Lower Timing Belt Cover Bolt ..................................................................... 53 (6)
Water Pump-To-Housing ........................................................................................... 84 (10)

727

VOLKSWAGEN

728

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cylinder Turbo Diesel (AAZ, AHU & 1Z Engines)

Golf & Golf III 1
1993-95 ..................................................... 2.8 Hours ... .....
1996-97 ..................................................... 2.8 Hours ... .....
Jetta & Jetta III 1
1993-95 ..................................................... 2.8 Hours ... .....
1996-98 ..................................................... 2.8 Hours ... .....
Passat (USA) 1
1996-97 ..................................................... 2.8 Hours ... .....
Passat (Canada) 1
1993-98 ..................................................... 2.2 Hours ... .....
1

T242
T242
T242
T242
T242
T242

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.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Serpentine Belt

The manufacturer recommends the belt AND tensioner be replaced at

60,000 mile intervals.

CAUTION: Use spanner wrench to hold camshaft sprocket while

loosening center bolt. Do not use camshaft setting bar to hold
camshaft sprocket.

REMOVAL & INSTALLATION

2) Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch
through hole in rear of timing belt cover until it contacts rear of camshaft
sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft
sprocket on camshaft taper.
3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and
crankshaft at TDC, install timing belt on engine. If reusing old belt,
ensure belt is installed in original direction of rotation. Remove Lock Pin
(2064) from injection pump sprocket.
4) 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 tension belt. Install Tension Tool (VW210) set to
12 to 13. Measure tension midway between camshaft sprocket and
injection pump sprocket. Tighten lock nut on timing belt tensioner to 33
ft. lbs. (45 N.m).
5) On models with semiautomatic timing belt tensioner, install 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).
6) On all models, tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Remove setting bar from camshaft.
7) Turn crankshaft 2 revolutions in normal direction of rotation. Recheck
timing belt tension.
8) On models with semiautomatic tensioner, 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
original position (raised and notched portions aligned). If not, replace
tensioner.
9) 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 original direction of rotation.
10) Install valve cover. On engine code AAZ, check fuel injection
delivery. Consult service information for procedure.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Golf, Jetta & Passat w/AAZ Engine, Up To Sept., 1994)
1) 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. Remove tensioner pulley. On models
without serpentine belts, remove accessory drive belts.
2) On all models, remove upper timing belt cover. See Fig. 2. Remove
valve cover.
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Flywheel TDC mark must be aligned to mark on transmission
mating flange. See Fig. 3.
4) Lock camshaft in place with Setting Bar (2065A) installed on rear of
camshaft. See Fig. 4. Center setting bar by turning camshaft so one side
of setting bar contacts cylinder head. Using feeler gauge, measure
distance between other end of setting bar and cylinder head.
5) Divide this feeler gauge dimension in half. Place a feeler gauge
corresponding to half the bar-to-cylinder head dimension between
setting bar and one side of cylinder head.
6) Turn camshaft until setting bar contacts feeler gauge. Place second
feeler gauge of same dimension between other end of bar and cylinder
head.
7) 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.
8) If reusing old timing belt, mark belt with arrow to indication original
direction of rotation. Move timing belt tensioner, and remove timing belt.
Installation (Golf & Jetta w/AAZ Engine, Up To Sept., 1994) 1)
Ensure TDC mark on flywheel and transmission mating flange are still
aligned. See Fig. 3.

VOLKSWAGEN

729

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

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 October 1994) 1) 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. Remove
tensioner pulley. On models without serpentine belts, remove accessory
drive belts.
2) On all models, remove upper timing belt cover. See Fig. 2. Remove
valve cover.
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. Flywheel TDC mark must be aligned to mark on transmission
mating flange.
4) Lock camshaft in place with Setting Bar (2065A) installed on rear of
camshaft. See Fig. 4. Center setting bar by turning camshaft so one side
of setting bar contacts cylinder head. Using feeler gauge, measure
distance between other end of setting bar and cylinder head.
5) Divide this feeler gauge dimension in half. Place a feeler gauge
corresponding to half the bar-to-cylinder head dimension between
setting bar and one side of cylinder head.
6) Lock injection pump in place using lock pin. See Figs. 5and 8. Loosen
injection pump sprocket mounting bolt(s).
7) Loosen timing belt tensioner. On Passat with 1Z engine, remove
water pump pulley and power steering pump pulley.
8) On all models, remove crankshaft vibration damper. Remove the
lower timing belt cover. See Fig. 2.
9) If reusing old timing belt, mark belt with arrow to indication original
direction of rotation. Move timing belt tensioner, and remove timing belt.
Installation (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ
Engine, From Oct., 1994) 1) Ensure TDC mark on flywheel and
transmission mating flange are still aligned. See Fig. 3.
CAUTION: Use spanner wrench to hold camshaft sprocket while
loosening center bolt. Do not use camshaft setting bar to hold
camshaft sprocket.
2) Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch
through hole in rear of timing belt cover until it contacts rear of camshaft
sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft
sprocket on camshaft taper.
3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and
crankshaft at TDC, install timing belt on engine. If reusing old belt,
ensure belt is installed in original direction of rotation.
4) Install 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).
5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS.
Tighten injection pump sprocket mounting bolt(s).
6) Remove setting bar from camshaft. Remove lock pin from injection
pump
7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set
No. 1 cylinder to TDC of compression stroke.
8) On models with semiautomatic tensioner, 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
original position (raised and notched portions aligned). If not, replace
tensioner.
9) 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
injection pump sprocket mounting bolt(s), and turn sprocket until lock pin
can be inserted in place. Tighten mounting bolt(s).
10) 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 original direction of rotation.

11) 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) 1) Disconnect front turn
signal light assembly wiring harnesses. Separate hood release lever
from bumper cover. Remove front bumper cover. See Fig. 9. Remove
bumper beam.
2) Remove air intake duct from air cleaner housing. Remove support
bolts from lock carrier assembly. See Fig. 10. Install Support Tool (3369)
through lock carrier to body. Remove oil cooler from lock carrier
assembly. Move lock carrier forward on support tools.
3) 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. 3.
4) Lock camshaft in place with Setting Bar (2065A) installed on rear of
camshaft. See Fig. 4. Center setting bar by turning camshaft so one side
of setting bar contacts cylinder head. Using feeler gauge, measure
distance between other end of setting bar and cylinder head.
5) Divide this feeler gauge dimension in half. Place a feeler gauge
corresponding to half the bar-to-cylinder head dimension between
setting bar and one side of cylinder head.
6) Remove timing belt tensioner. Lock injection pump in place using lock
pin. See Fig. 8. Loosen injection pump sprocket mounting bolts.
7) Remove crankshaft vibration damper. Remove lower timing belt
cover. See Fig. 2.
8) If reusing old timing belt, mark belt with arrow to indication original
direction of rotation. Move timing belt tensioner, and remove timing belt.
Installation (1998 Passat w/AHH Engine) 1) Ensure TDC mark on
flywheel and transmission mating flange are still aligned. See Fig. 3.
CAUTION: Use spanner wrench to hold camshaft sprocket while
loosening center bolt. Do not use camshaft setting bar to hold
camshaft sprocket.
2) 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.
3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and
crankshaft at TDC, install timing belt on engine. If reusing old belt,
ensure belt is installed in original direction of rotation.
4) Install 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).
5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS.
Tighten injection pump sprocket mounting bolts.
6) Remove setting bar from camshaft. Remove lock pin from injection
pump.
7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set
No. 1 cylinder to TDC of compression stroke.
8) 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 original position (raised and notched portions
aligned). If not, replace tensioner.
9) 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.
10) Install timing belt covers. Install vibration damper. Install valve cover.
To prevent damage to serpentine belt, install in original direction of
rotation.
11) Place lock carrier in original position on body. Install front bumper
assembly.
12) Check injection pump start of delivery. Consult service information
for procedure using VAG 1551/1552 factory scan tool.

730

VOLKSWAGEN

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 2: Exploded View of Timing Belt & Components

Courtesy of Volkswagen United States, Inc.

Fig. 4: Locking Camshaft With Setting Bar (2065A)

Courtesy of Volkswagen United States, Inc.

Fig. 3: Locating TDC Mark on Flywheel/Flexplate

Courtesy of Volkswagen United States, Inc.

Fig. 5: Locking Diesel Fuel Injection Pump Sprocket (AHU & 1Z

Engines; AAZ Engines Up To September 1994)

VOLKSWAGEN

731

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Tensioning Timing Belt (AAZ Engines Up To October

1994, Without Semi-Automatic Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Exploded View of Bumper Assembly (1998 Passat)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Adjusting Timing Belt Tension (Semi-Automatic

Timing Belt Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 10: Exploded View Of Lock Carrier Assembly (1998 Passat)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Locking Diesel Fuel Injection Pump Sprocket

(AHH Engine & AAZ Engines From October 1994)

732

VOLKSWAGEN

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

TORQUE SPECIFICATIONS

TECHNICAL SERVICE BULLETIN

TORQUE SPECIFICATIONS (GOLF & JETTA)

TIMING BELT RUNS TOWARD OUTSIDE, WEARS OUT,

JUMPS OFF SPROCKET OR CRACKS

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Center Bolt
Step 1 ...................................................................................................................... 66 (90)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (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

1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines) 1) If this condition
exists, replace timing belt and semiautomatic tensioner (Part No. 028
109 243F).
2) 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.
3) 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.
4) 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.

ALWAYS replace if loosened or removed.

TORQUE SPECIFICATIONS (PASSAT)

Application
Ft. Lbs. (N.m)
Bumper Beam-To-Impact Absorber Bolt (1998) ....................................................... 15 (20)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Center Bolt
Step 1 ...................................................................................................................... 66 (90)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
Injection Pump Sprocket Mounting Bolts
Step 1 ...................................................................................................................... 15 (20)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90)
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 if loosened or removed.

Courtesy of Volkswagen United States, Inc.

Fig. 11: Injection Pump Mounting Bracket (1994-97 Golf, Jetta &
Passat w/AAZ & 1Z Engines)

VOLKSWAGEN

733

1.9L 4-Cylinder Turbo Diesel ALH Engine

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cylinder Turbo Diesel (ALH Engine)

Golf 1
1999 ........................................................... 4.0 Hours ... .....
Or
2000-01
Before Eng. No. 500,000 ....................... 4.4 Hours ... .....
After Eng. No. 500,001 .......................... 4.4 Hours ... .....
2002-04 ..................................................... 4.4 Hours ... .....
Jetta 1
1999 ........................................................... 4.0 Hours ... .....
Or
2001-00
Before Eng. No. 500,000 ....................... 4.4 Hours ... .....
After Eng. No. 500,001 .......................... 4.4 Hours ... .....
2002-04 ..................................................... 4.4 Hours ... .....
New Beetle 1
1998 ........................................................... 4.4 Hours ... .....
1999 ........................................................... 4.4 Hours ... .....
Or
2000-01
Before Eng. No. 500,000 ....................... 4.4 Hours ... .....
After Eng. No. 500,001 .......................... 4.4 Hours ... .....
2002-04 ..................................................... 4.4 Hours ... .....
1

3) If serpentine belt is to be reused, mark rotational direction of belt.

Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise
to relieve belt tension, and remove serpentine belt. Remove serpentine
belt tensioner.

T301
T321

CAUTION: The valve cover has an integrated, vulcanized gasket. If

gasket is damaged or leaking, replace the valve cover.

T301
T321
T321

4) Remove brake booster vacuum pump. Remove upper timing belt

cover. Remove engine valve cover using care not to damage gasket.
5) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. TDC mark can be viewed through access hole in engine-totransmission mating flange. See Fig. 1.
6) 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 between other end of setting bar and cylinder head.
Divide this dimension in half. Place a feeler gauge corresponding to half
the bar-to-cylinder head dimension between 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.

T301
T321
T301
T321
T321
T301
T301
T321
T301
T321
T321

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.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
SCHEDULED MAINTENANCE INTERVAL
1
Interval
Model Year
1998-99 .......................................................... ............................................................ 60,000
2000 ............................................................... ............................................................ 40,000
2001 2 ............................................................. ............................................................ 40,000
2001 3 ............................................................. ............................................................ 60,000
2002 ............................................................... ............................................................ 80,000
2003-04 .......................................................... .......................................................... 100,000
1
2
3

Replace timing belt and tensioner together.

Models equipped with automatic transmissions.
Models equipped with manual transmission.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating TDC Mark on Flywheel/Flexplate

NOTE: Timing belt installation procedure requires using a factory
scan tester (VAG 1551/1552) to adjust injection pump timing.
Removal (Golf & Jetta) 1) Working under hood, remove fuel supply
and return lines from fuel filter. Seal fuel lines to prevent contamination
of fuel system. Remove upper and lower right headlight assembly
mounting screws. Disconnect harness connectors and remove right
headlight assembly.
2) Remove pipe between charge air cooler (intercooler) and intake
manifold. Remove upper engine cover. Remove right sound damper
cover.

7) 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.
8) Loosen, but do not remove, the 3 diesel injection pump sprocket
mounting bolts. Replace these bolts with NEW bolts during installation.
Attach Engine Support (10-222A) with legs (10-222A/1) or equivalent.
Remove coolant reservoir bottle and power steering reservoir, and
leaving hoses attached set aside.

VOLKSWAGEN

734

1.9L 4-Cylinder Turbo Diesel ALH Engine (Cont.)

5) 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 between other end of setting bar and cylinder head.
6) Divide this dimension in half. Place a feeler gauge corresponding to
half the bar-to-cylinder head dimension between 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.
7) 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.
Courtesy of Volkswagen United States, Inc.

Fig. 2: Locking Camshaft With Setting Bar

CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt.
This bolt MUST be replaced if loosened or removed.
9) Remove engine mount from timing belt end of engine. Remove 4
crankshaft pulley socket-head bolts and remove crankshaft pulley (it is
not necessary to remove center bolt). Remove middle and lower timing
belt covers. Remove engine mount bracket.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt
removed.
10) If reusing old timing belt, mark belt with arrow to indicate original
direction of rotation. Loosen timing belt tensioner lock nut. Turn tensioner to release belt and remove timing belt.

NOTE: The 3 diesel injection pump bolts are torque-to-yield type.

Manufacturer recommends replacing bolts during final assembly.
8) Loosen, but do not remove, the 3 diesel injection pump sprocket
mounting bolts. Manufacturer recommends replacing these torque-toyield bolts during final assembly. Support engine weight from above or
below with floor jack.
NOTE: On New Beetle, engine mount bolts are torque-to-yield type.
Manufacturer recommends replacing bolts if they are loosened or
removed.
9) Remove engine mount from timing belt end of engine.
CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt.
This bolt MUST be replaced if loosened or removed.
10) Remove 4 crankshaft pulley socket-head bolts, and remove crankshaft pulley (it is not necessary to remove center bolt). Remove timing
belt covers.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt
removed.
11) If reusing old timing belt, mark belt with arrow to indicate original
direction of rotation. Loosen timing belt tensioner lock nut. Turn tensioner to release belt and remove timing belt.
NOTE: Timing belt installation procedure requires using a factory
scan tester (VAG 1551/1552) to adjust injection pump timing.
Installation (All Models) 1) Ensure cylinder No. 1 is at TDC. Check
reference mark on flywheel and bellhousing. See Fig. 1.
CAUTION: Use Spanner Wrench (3036) to hold camshaft sprocket
while loosening and tightening camshaft sprocket bolt. DO NOT
use Camshaft Setting Bar (3418) to hold camshaft sprocket.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Locking Diesel Fuel Injection Pump Sprocket

Removal (New Beetle) 1) 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.
CAUTION: The valve cover has an integrated, vulcanized gasket. If
gasket is damaged or leaking, replace the valve cover.
2) Remove upper timing belt cover. Remove valve cover. Remove brake
booster vacuum pump. Remove pipe between charge air cooler and
turbocharger.
3) If serpentine belt is to be reused, mark rotational direction of belt.
Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise
to relieve belt tension, and remove serpentine belt. Remove serpentine
belt tensioner.
4) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
stroke. TDC mark can be viewed through access hole in engine-totransmission mating flange. See Fig. 1.

2) Using Spanner Wrench (3036) counter-hold camshaft and loosen

camshaft sprocket bolt 1/2 turn. See Fig. 4. On New Beetle, place drift
punch through rear timing belt cover and LIGHTLY tap camshaft
sprocket loose from tapered end of camshaft. On Golf and Jetta, use a
Two Arm Puller (T40001) to remove sprocket. Remove camshaft
sprocket.
3) Install timing belt onto crankshaft sprocket, idler pulley, water pump,
injection pump sprocket, and tensioner pulley. Adjust injection pump
sprocket on mount so mounting slots are centered. If installing old belt,
note direction of rotation mark.
4) Install camshaft sprocket together with timing belt. Install camshaft
sprocket bolt finger tight. Camshaft sprocket should still be free to turn.
5) On Golf and Jetta with automatic transaxle, use an Allen wrench to
turn timing belt tensioner clockwise until notch and pointer align. See
Fig. 5. If tensioner is turned too far and correct tension is exceeded,
tension must be fully released, and then readjusted. Tighten center lock
nut on tensioner pulley to specification. See TORQUE SPECIFICATIONS.

VOLKSWAGEN

735

1.9L 4-Cylinder Turbo Diesel ALH Engine (Cont.)

6) On Golf and Jetta with manual transaxle and New Beetle, install
Tension Pin Wrench (MATRA V159) on timing belt tensioner pulley. See
Fig. 6. Turn wrench clockwise until notch and raised mark are aligned.
Tighten tensioner pulley center nut to specification. See TORQUE
SPECIFICATIONS.
7) On all models, ensure tensioner is correctly installed in rear timing
belt cover. See Fig. 7. Ensure TDC marks on flywheel are still aligned.
Using Spanner Wrench (3036) counter-hold camshaft and tighten
camshaft sprocket center bolt to specification. See TORQUE SPECIFICATIONS.
8) Install NEW torque-to-yield mounting bolts in diesel injection pump
sprocket. Tighten injection pump bolts to 15 ft. lbs. (20 N.m). Before final
tightening of injection pump mounting bolts, perform start of injection
procedure (dynamic timing) using factory scan tester (VAG 1551/1552).
After performing start of injection procedure, tighten injection pump
sprocket mounting bolts an additional 90 degrees (1/4 turn).
9) Remove camshaft setting bar from rear of camshaft. Remove lock pin
from injection pump.
10) Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC
and ensure belt timing is correct. Ensure timing belt tensioner pulley
marks are still aligned.
11) To complete installation, reverse removal procedure. When installing
engine mount, install mounting bolts in holes on bracket before attempting to fit bracket to engine block. Tighten nuts and bolts to specification.
See TORQUE SPECIFICATIONS. Check fuel lines for leaks. Adjust
drive belts to proper tension.
12) Using scan tester (VAG 1551/1552), check Diesel injection pump
start of delivery.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Adjusting Timing Belt Tension (Golf & Jetta With

Manual Transaxle, & New Beetle)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Installing Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (GOLF & JETTA)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Diesel Injection Pump Sprocket Bolts 1 ......................................................... 15 (20) + 90
Engine Mount Bracket-To-Engine Bolt ...................................................................... 33 (45)
Idler Pulley Bolt ......................................................................................................... 15 (20)
Serpentine Drive Belt Tensioner ............................................................................... 18 (25)
Timing Belt Tensioner Pulley Nut ............................................................................. 15 (20)
Vacuum Pump Bolt ................................................................................................... 15 (20)
Water Pump Bolts ..................................................................................................... 16 (22)
INCH. Lbs. (N.m)
Courtesy of Volkswagen United States, Inc.

Fig. 4: Securing Camshaft Sprocket

Timing Belt Cover Bolt .............................................................................................. 89 (10)

Valve Cover Nut ........................................................................................................ 89 (10)
1

Replace with new torque-to-yield bolts on installation.

TORQUE SPECIFICATIONS (NEW BEETLE)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 33 (45)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Diesel Injection Pump Sprocket Bolts 1 ......................................................... 15 (20) + 90
Engine Mount Bracket-To-Engine Bolt 1 ........................................................ 30 (40) + 90
Engine Mount-To-Bracket Bolt 1 ..................................................................... 44 (60) + 90
Idler Pulley Bolt ......................................................................................................... 15 (20)
Timing Belt Tensioner Pulley Nut ............................................................................. 15 (20)
Water Pump Bolts ..................................................................................................... 11 (15)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
1

Courtesy of Volkswagen United States, Inc.

Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With

Automatic Transaxle)

Replace with new torque-to-yield bolts on installation.

VOLKSWAGEN

736

1.9L 4-Cylinder Turbo Diesel, BEW Engine

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cylinder Turbo Diesel (BEW Engine)

Golf 1
2004 ........................................................... 3.9 Hours ... ..... T321
Jetta 1
2004 ........................................................... 3.9 Hours ... ..... T321
New Beetle 1
2004 ........................................................... 3.9 Hours ... ..... T321
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.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer suggests the belt be replaced at 90,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (Golf & Jetta) 1) Remove right sound damper cover. If poly
V-belt is to be reused, mark rotational direction of belt. Using appropriate
wrench, rotate poly V-belt tensioner clockwise to relieve belt tension,
and remove belt. Lock tensioner using Locking Pin (T10060) or appropriate sized drift pushed through hole in tensioner. Remove poly V-belt
tensioner.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Attaching Engine Support & Removing Engine Mount

NOTE: It may be necessary to reposition bumper cover to remove

right headlight assembly.
2) Remove right headlight assembly. Remove charge air pipe between
charge air cooler (intercooler) and turbocharger.
3) Remove coolant expansion tank (leave coolant hoses connected).
Unbolt power steering reservoir and fuel filter and set aside (leave hoses
connected). Disconnect fuel lines from cylinder head cover.
4) Attach Engine Support Bridge (10-222A) with Bracket (10-222A/1),
and engage retainer in right lifting eye bolt located at cylinder head. See
Fig. 1. Lift engine slightly to remove weight from engine mounts. Engine
may also be supported from below with a floor jack. Use care not to
damage components.
5) Remove engine bracket-to-body mounting bolts, and remove complete mounting assembly.
6) Raise engine slightly with the support device, and unbolt engine
mounting bracket-to-cylinder block bolts (arrows) and remove. See
Fig. 2.
CAUTION: Engine mount assembly is secured by torque-to-yield
bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These
bolts MUST be replaced if they are loosened or removed.
7) Remove 4 crankshaft/vibration damper pulley socket-head bolts, and
crankshaft/vibration damper pulley. It is NOT necessary to remove
crankshaft pulley center bolt.
8) Remove timing belt covers. Turn crankshaft to TDC No. 1 cylinder.
Turn the crankshaft so far that the marking on the crankshaft sprocket is
at the top and the arrow on the rear timing belt guard aligns with the lugs
on the sender wheel of the hub. See Fig. 3.
9) Lock camshaft pulley with Locking Pin (3359). See Fig. 3. To do this,
slide locking pin through free elongated hole on left side of cylinder
head. Lock crankshaft pulley with Crankshaft Stop (T10050). To do this,

Courtesy of Volkswagen United States, Inc.

Fig. 2: Removing Engine Mount From Engine Block

push Crankshaft Stop from face side of timing belt pulley into pulley
teeth. The marks on the crankshaft pulley and the Crankshaft Stop must
align. At the same time, the pin of the Crankshaft Stop must engage in
hole in the sealing flange.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt
removed.
10) If reusing old timing belt, mark belt with arrow to indicate original
direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but
do not remove, camshaft pulley securing bolts (1) until camshaft pulley
can be moved within elongated holes. See Fig. 4.

VOLKSWAGEN

737

1.9L 4-Cylinder Turbo Diesel, BEW Engine (Cont.)

11) Turn Pin Wrench (3387) counterclockwise (opposite direction of
arrow on tensioner) until timing belt tensioner can be locked in position
using Locking Pin (T10115). See Fig. 5. Turn pin wrench clockwise (in
direction of arrow on tensioner) until stop and tighten tensioner securing
nut hand-tight. Remove timing belt first from coolant pump and then from
remaining pulleys.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Removing Timing Belt

tensioner clockwise to relieve belt tension. Lock tensioner using Locking
Pin (T10060) or appropriate sized drift pushed through hole in tensioner,
and remove belt. Remove poly V-belt tensioner.
3) Remove coolant expansion tank (leave coolant hoses connected).
Remove fuel filter retaining plate.
4) Attach Engine Support Bridge (10-222A) with Bracket (10-22A/8), and
engage retainer in right lifting eye bolt located at cylinder head. See
Fig. 1. Lift engine slightly to remove weight from engine mounts. Engine
may also be supported from below with a floor jack. Use care not to
damage components.
5) Remove engine bracket-to-body mounting bolts, and remove complete mounting assembly. See Fig. 1.
6) Remove upper timing belt guard. Remove lower charge air pipe (1).
See Fig. 6. Remove bolt/screw (2) and release connector (arrow).
Carefully cover or close open ends of charge air pipe. Remove center
and right side sound insulation.
7) Raise engine slightly with the support device, and unbolt engine
mounting bracket-to-cylinder block bolts (arrows) and remove mount.
See Fig. 2.
Courtesy of Volkswagen United States, Inc.

Fig. 3: Locating TDC Position; Locking Cam & Crankshafts Into

Position

CAUTION: Engine mount assembly is secured by torque-to-yield

bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These
bolts MUST be replaced if they are loosened or removed.
8) Remove 4 crankshaft/vibration damper pulley socket-head bolts.
Remove crankshaft/vibration damper pulley. It is NOT necessary to
remove crankshaft pulley center bolt.
9) Remove timing belt covers. Turn crankshaft to TDC No. 1 cylinder.
Turn the crankshaft so far that the marking on the crankshaft sprocket is
at the top and the arrow on the rear timing belt guard aligns with the lugs
on the sender wheel of the hub. See Fig. 3.
10) Lock camshaft pulley with Locking Pin (3359). See Fig. 3. To do this,
slide locking pin through free elongated hole on left side of cylinder
head. Lock crankshaft pulley with Crankshaft Stop (T10050). To do this,
push Crankshaft Stop from face side of timing belt pulley into pulley
teeth. The marks on the crankshaft pulley and the Crankshaft Stop must
align. At the same time, the pin of the Crankshaft Stop must engage in
the hole in the sealing flange.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt
removed.

Courtesy of Volkswagen United States, Inc.

Fig. 4: Loosening Camshaft Pulley Securing Bolts

Removal (New Beetle) 1) Working under hood, remove engine cover.
Pull front of engine cover abruptly upward and then pull forward out of
rear securing elements.
2) Remove upper charge air line and connecting hose. Carefully cover
or close open ends of charge air line. If poly V-belt is to be reused, mark
rotational direction of belt. Using appropriate wrench, rotatep poly V-belt

11) If reusing old timing belt, mark belt with arrow to indicate original
direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but
do not remove, camshaft pulley securing bolts (1) until camshaft pulley
can be moved within elongated holes. See Fig. 4.
12) Turn Pin Wrench (3387) counterclockwise (opposite direction of
arrow on tensioner) until timing belt tensioner can be locked in position
using Locking Pin (T10115). See Fig. 5. Turn pin wrench clockwise (in
direction of arrow on tensioner) until stop and tighten securing nut
hand-tight. Remove timing belt first from coolant pump and then from
remaining pulleys.

VOLKSWAGEN

738

1.9L 4-Cylinder Turbo Diesel, BEW Engine (Cont.)

engaged, check whether camshaft pulley hub can be fixed in place using
Locking Pin. If the hub cannot be locked; pull Crankshaft Stop pin out of
hole in sealing flange and turn crankshaft until hub can be locked with
locking pin.
6) Loosen, but do not remove, camshaft pulley securing bolts. See
Fig. 4. Turn crankshaft slightly against direction of engine rotation until
Crankshaft Stop pin is positioned just before hole in sealing flange
(arrow). See Fig. 8. Turn crankshaft in engine direction of rotation until
Crankshaft Stop pin engages in sealing flange while turning. Tighten
camshaft pulley securing bolts to 18 ft. lbs. (25 N.m). Remove Locking
Pin and Crankshaft Stop.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing Lower Charge Air Pipe (New Beetle)

Installation (All Models) 1) Adjustment work on timing belts must
only be performed on cold engines as the indicator on the tensioner
changes depending on the engine temperature. The tensioning roller
must be locked with Locking Pin (T10115) and secured to the right limit
stop before proceeding.
2) Turn camshaft pulley in elongated holes counterclockwise onto
centered position. See Fig. 4. Install timing belt to crankshaft pulley, belt
tensioner and camshaft pulley. Install timing belt onto coolant pump
timing belt pulley. If installing old belt, note direction of rotation mark.
3) Ensure that tab on tensioning roller seats correctly in rear timing belt
guard. Loosen tensioning roller securing nut. Relieve tension on tensioning roller by turning pin wrench and remove locking pin from
tensioning roller.
4) Carefully turn tensioning roller with Pin Wrench (3387) in direction of
arrow (on tensioner) until indicator is in middle of gap in base plate
(arrow). See Fig. 7. Hold tensioning roller in this position, and tighten
tensioning roller securing nut to 15 ft. lbs. (20 N.m) plus an additional 45
(1/8 turn). Counter-hold camshaft pulley, and tighten securing bolts to 18
ft. lbs. (25 N.m). Remove Locking Pin and Crankshaft Stop. Turn
crankshaft two rotations in direction of engine rotation and set again to
TDC No. 1 cylinder.

Courtesy of Volkswagen United States, Inc.

Fig. 8: Positioning Crankshaft Gear With Crankshaft Stop Pin

(T10050)
7) Turn crankshaft two rotations in engine direction of rotation until
crankshaft is set to TDC No. 1 cylinder again. With engine at TDC No. 1
cylinder, the shaft of the Crankshaft Stop (T10050) must be able to
engage in the sealing flange from direction of engine rotation. If the
crankshaft is turned past TDC No. 1 cylinder and the Crankshaft Stop
could not engage in the sealing flange, turn the crankshaft back 1/4 turn
to be able to turn the crankshaft in the direction of engine rotation again
to set it to TDC No. 1 cylinder. DO NOT turn the engine opposite to the
normal direction of rotation when turning to ensure the Crankshaft Stop
will engage.
8) Once Crankshaft Stop has engaged, check whether camshaft pulley
hub can be fixed in place using Locking Pin. Repeat timing mark
alignment check.
CAUTION: Engine mount assembly is secured by torque-to-yield
bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt.
These bolts MUST be replaced if they are loosened or removed.
9) Install lower timing belt guard and vibration damper/belt pulley. Install
center timing belt guard. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATIONS.
10) To complete installation, reverse removal procedure. When installing
engine mount, install mounting bolts in holes on bracket before attempting to fit bracket to engine block. Tighten nuts and bolts to specification.
See TORQUE SPECIFICATIONS.

Courtesy of Volkswagen United States, Inc.

Fig. 7: Tensioning Timing Belt

5) With engine at TDC No. 1 cylinder, the shaft of the Crankshaft Stop
(T10050) must be able to engage in the sealing flange from direction of
engine rotation. If the crankshaft is turned past TDC of No. 1 cylinder,
and the Crankshaft Stop could not engage in the sealing flange, turn the
crankshaft back 1/4 turn. Turn the crankshaft in the direction of engine
rotation again to set it to TDC No. 1 cylinder. DO NOT turn the engine
opposite to the normal direction of rotation when turning to ensure the
Crankshaft Stop will engage. Once Crankshaft Stop (T10050) has

VOLKSWAGEN

739

1.9L 4-Cylinder Turbo Diesel, BEW Engine (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (GOLF & JETTA)

TORQUE SPECIFICATIONS (NEW BEETLE)

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 74 (100)
Crankshaft Gear Bolt 1 .................................................................. ..................................... 2
Engine Mount-To-Engine Bolts ................................................................................. 33 (45)
Engine Mounting Bracket-To-Engine Bolt ............................................................... 74 (100)
Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3
Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25)
Poly V-Belt Tensioner ................................................................................................ 18 (25)
Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 74 (100)
Crankshaft Gear Bolt 1 .................................................................. ..................................... 2
Engine Mount-To-Engine Bolts ................................................................................. 33 (45)
Engine Mount-To-Engine Bracket Bolt .................................................................... 74 (100)
Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3
Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25)
Poly V-Belt Tensioner ................................................................................................ 18 (25)
Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4

INCH. Lbs. (N.m)

1

INCH. Lbs. (N.m)

Crankshaft Pulley Bolts ............................................................... .....................................

Timing Belt Cover Bolts ............................................................................................ 89 (10)

Crankshaft Pulley Bolts ............................................................... ..................................... 5

Timing Belt Cover Bolts ............................................................................................ 89 (10)

2
3
4
5

Replace with new torque-to-yield bolts on installation.

Tighten to 89 ft. lbs. (120 N.m) plus an additional 90 (1/4 turn).
Tighten to 30 ft. lbs. (40 N.m) plus an additional 90 (1/4 turn).
Tighten to 15 ft. lbs. (20 N.m) plus an additional 45 (1/8 turn).
Tighten to 89 INCH lbs. (10 N.m) plus an additional 90 (1/4 turn).

2
3
4
5

Replace with new torque-to-yield bolts on installation.

Tighten to 89 ft. lbs. (120 N.m) plus an additional 90 (1/4 turn).
Tighten to 30 ft. lbs. (40 N.m) plus an additional 90 (1/4 turn).
Tighten to 15 ft. lbs. (20 N.m) plus an additional 45 (1/8 turn).
Tighten to 89 INCH lbs. (10 N.m) plus an additional 90 (1/4 turn).

VOLKSWAGEN

740

2.0L 4-Cylinder ABA Engine

TIMING BELT APPLICATION
Application

Labor Time

2.0L 4-Cyl. (ABA Engine)

Cabrio
1995-02 ........................... ...
Golf
1993-99 ........................... ...
Golf (Canadian)
1995 ................................ ...
GTI
1996-99 ........................... ...
GTI (Canadian)
1993-95 ........................... ...
Jetta
1993-99 ........................... ...
Passat
1993-96 ........................... ...

Component
Belt
Kit No.
Part No.

1.9 Hours ... .. TCK262 .. ..... T262

1.9 Hours ... .. TCK262 .. ..... T262
1.9 Hours ... .. TCK262 .. ..... T262

CAUTION: To prevent valves from contacting piston, DO NOT

rotate camshaft or crankshaft with timing belt removed. Valve
damage may result.
4) If reusing timing belt, mark belt with arrow to indicate original direction
of rotation.
5) Place crankshaft at TDC by aligning flywheel (M/T) or drive plate (A/T)
TDC marks. See Fig. 5. Ensure camshaft timing mark is aligned with
mark on belt guard. See Fig. 6. Loosen belt tensioner. Remove timing
belt.

1.9 Hours ... .. TCK262 .. ..... T262

1.9 Hours ... .. TCK262 .. ..... T262
1.9 Hours ... .. TCK262 .. ..... T262
1.9 Hours ... .. TCK262 .. ..... T262

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals.
NOTE: Engine code (ABA) is stamped into machined pad on front
of cylinder block above crankcase breather, near cylinder head
mating surface. See Fig. 1.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Removing & Installing Ribbed (Accessory) Drive Belts

(Without A/C)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating Engine Identification Code (2.0L ABA)

REMOVAL & INSTALLATION

Courtesy of Volkswagen United States, Inc.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Fig. 3: Removing & Installing Ribbed (Accessory) Drive Belts

(With A/C)

TIMING BELT

NOTE: Disregard marking on intermediate shaft drive belt

sprocket.

Removal (Standard Tensioner Up To 1997) 1) Remove accessory

drive belts. See Fig. 2 or 3. Remove accessory drive belt tensioner
bracket. See Fig. 4.
2) Remove crankshaft pulley bolts and pulley (it is NOT necessary to
remove center bolt).
3) Remove water pump pulley. Remove upper and lower timing belt
covers.

Installation (Standard Tensioner Up To 1997) 1) Ensure crankshaft is still at TDC position. See Fig. 5. Remove distributor cap. Rotate
intermediate shaft counterclockwise until rotor is pointed at No. 1
cylinder mark. See Fig. 5. Ensure camshaft timing mark is still aligned
with mark on belt guard. See Fig. 6.
2) Install timing belt around crankshaft, intermediate shaft, tensioner,
and camshaft sprockets.

VOLKSWAGEN

741

2.0L 4-Cylinder ABA Engine (Cont.)

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Aligning Camshaft Timing Marks

Fig. 4: Exploded View Of Timing Belt & Components (With

Standard Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Adjusting Timing Belt Tension

CAUTION: To prevent valves from contacting piston, DO NOT
rotate camshaft or crankshaft with timing belt removed. Valve
damage may result.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Aligning Crankshaft & Distributor Timing Marks

3) 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 camshaft and intermediate shaft sprockets. See Fig. 7.
4) While holding tensioner pulley stationary, tighten tensioner pulley
center nut to specification. Rotate crankshaft 2 revolutions and recheck
check belt tension. Adjust tension as necessary. Recheck all timing
marks again.
5) Install timing belt covers. Install drive belt tensioner bracket. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.

Removal (Thermo Tensioner Roller 1997 & Up) 1) Remove air

cleaner with hot air intake and intake air duct.
2) Remove accessory drive belts. Release tension on ribbed (accessory) belt tensioner using Ribbed Belt Installation Tool (3299) and
remove ribbed belt at generator. Remove ribbed belt tension roller and
upper timing belt guard. Remove lower V-belt cover. Hold hydraulic
(P/S) pump pulley using (VAG1590) or mandrel, and remove fasteners
for coolant pump pulley. Remove coolant pump pulley and V-belt.
Remove vibration damper/pulley. See Figs. 2 and 3.
3) Turn drive plate (A/T) or flywheel (M/T) to align mark (arrows in
illustration) and place No. 1 cylinder at TDC. See Fig. 5. Remove lower
timing belt guard.
4) Mark the running direction on the timing belt. Remove fastener for
timing belt thermo tension roller. Remove belt and roller. Remove timing
belt thermo tensioner. See Fig. 8.
CAUTION: DO NOT turn the camshaft while any piston is at TDC
position. There is risk of damage to valves and piston crowns.
Installation (Thermo Tensioner Roller 1997 & Up) Assemble NEW
thermo tension roller and install on engine block. See Fig. 9. Tighten
bolt/washer assembly (2), Collar screw and 6-mm fastening nut to
specification. See TORQUE SPECIFICATIONS.

742

VOLKSWAGEN
2.0L 4-Cylinder ABA Engine (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Exploded View Of Timing Belt & Components

(With Thermo Tensioner Roller)
1) Place timing belt on crankshaft gear (note running direction of belt).
Ensure crankshaft timing is correct. See Fig. 5. Align mark on camshaft
drive sprocket with mark on cylinder head cover and/or timing belt
guard. See Fig. 6.
2) Turn tension roller to the right using two-pin spanner wrench, with one
pin inserted in hole in roller and other pin in slot at bottom of roller pivot
bracket (arrows in illustration) until tensioner piston No. 1 is driven all the
way out, and piston No. 2 lifts up about 0.040 (1.0 mm). See Fig. 10.
3) Tighten mounting bolt by hand. See Fig. 10. Rotate engine 2
revolutions in running direction. Counter-hold thermo tension roller with
two-pin spanner, and tighten mounting bolt to specification. See
TORQUE SPECIFICATIONS. Install lower timing belt guard. Install
vibration damper/pulley.
4) Install ribbed belt tension roller. Using Ribbed Belt Installation Tool
(3299), adjust tension on ribbed belt tensioner and position belt. Position
V-belt, and bolt coolant pump pulley to coolant pump. Install upper
timing belt guard. Install air cleaner with pre-heated air hose and intake
air duct.

Courtesy of Volkswagen United States, Inc.

Fig. 10: Installing & Adjusting Thermo Tensioner Roller

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (STANDARD TENSIONER UP TO 1997)
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 59 (80)
Crankshaft Pulley Bolt ............................................................................................... 18 (25)
Crankshaft Sprocket Center Bolt ................................................................. 1 66 (90) + 90
Drive Belt Tensioner Bracket Bolt ............................................................................. 15 (20)
Intermediate Shaft Sprocket Bolt .............................................................................. 59 (80)
Timing Belt Tensioner Center Nut ............................................................................ 33 (45)
Water Pump Pulley Bolt ............................................................................................ 18 (25)
INCH Lbs. (N.m)
Timing Belt Cover Nut .............................................................................................. 89 (10)
Valve Cover Retaining Nut ....................................................................................... 89 (10)
1

Replace torque-to-yield bolt on installation.

TORQUE SPECIFICATIONS (THERMO TENSIONER 1997 & UP)

Application
Ft. Lbs. (N.m)
Collar Screw Bolt ............................................................................................ 11-15 (15-20)
Torx Bolt .................................................................................................................. 18 (25)
INCH Lbs. (N.m)
Bolt & Washer Assembly (2) ............................................................................ 62-97 (7-11)
Nut ..................................................................................................................... 62-97 (7-11)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Thermo Tensioner Roller Assembly

VOLKSWAGEN

743

2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.
2.0L 4-Cyl. (AEG, AVH, AZG, BDC & BEV Engines)
Golf
1999-2004 ........................... 2.9 Hours ... .. TCK296 .. ..... T296
GTI
1999-00 ............................... 2.9 Hours ... ...... ..... ...... ..... T296
Jetta
1999-2004 ........................... 2.9 Hours ... .. TCK296 .. ..... T296
New Beetle
1998-04 ............................... 2.9 Hours ... .. TCK296 .. ..... T296
NOTE: A timing belt component kit is available for this application.
See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1998-00 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. For 2001-03 model
years, the manufacturer recommends the belt be replaced at 105,000
mile intervals.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Locating Engine Identification Code

(AVH, AZG, BDC & BEV)

NOTE: For 2004, manufacturer does not provide a timing belt

replacement interval.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: Engine code AEG is stamped into machined pad on front of
cylinder block above crankcase breather, near cylinder head mating surface. See Fig. 1. For all other 2.0L engines, engine code is
stamped on transmission mating flange at the rear of the engine.
See Fig. 2. For all engines, code can also be found on the vehicle
data plate and on a sticker on the timing belt cover.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Releasing Serpentine Belt Tensioner

Fig. 1: Locating Engine Identification Code (AEG)

2) Remove serpentine belt tensioner assembly. See Fig. 4. Turn

crankshaft to TDC position. See Fig. 5. Align TDC marks visible in
bellhousing access hole. See Fig. 6. Remove upper timing belt cover.
Ensure camshaft sprocket timing mark aligns with mark on rear cover.
See Fig. 5.
3) 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 reservoir (hoses attached), and set
aside. On Beetle, pull off EVAP hoses at EVAP canister and throttle
valve housing.
4) On all models, remove engine mount from timing belt end of engine.
See Fig. 7. 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).
5) Remove timing belt covers. Remove engine support from front of
engine. See Fig. 4.

TIMING BELT

CAUTION: To prevent valves from contacting piston, DO NOT

rotate camshaft or crankshaft with timing belt removed.

Removal (AEG, AVH, AZG, BEV & BDC Engine Codes) 1) Remove
right hand insulation tray from engine compartment. Remove engine
cover. Rotate serpentine belt tensioner clockwise to relieve belt tension.
Remove serpentine belt. See Fig. 3. Lock in place using Mandrel
(T10060) or a drift.

6) If reusing old belt, mark belt with arrow to indicate original direction of
rotation. Loosen timing belt tensioner nut and rotate timing belt tensioner
away from belt to remove timing belt. See Fig. 8.

Courtesy of Volkswagen United States, Inc.

744

VOLKSWAGEN
2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Exploded View Of Timing Belt & Components

(AEG, AVH, AZG, BDC & BEV Engine Codes)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Locating TDC Mark on Transaxle

Courtesy of Volkswagen United States, Inc.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Volkswagen United States, Inc.

Fig. 7: Identifying Right-Hand Engine Mount

VOLKSWAGEN

745

2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Volkswagen United States, Inc.

Fig. 8: Releasing/Adjusting Timing Belt Tension

Installation (AEG, AVH, AZG, BDC & BEV Engine Codes) 1) Ensure
crankshaft and camshaft timing marks are still aligned. See Figs. 5
and 6.
2) 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.
3) Install timing belt lower and center covers. Install crankshaft pulley
and tighten bolts to specification. Install engine mount-to-body and
engine support. Remove floor jack or engine support bar from engine.
4) Install timing belt on camshaft sprocket and timing belt tensioner.
Make sure there is no slack in timing belt.
5) 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. 8.
6) 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.
7) Install upper timing belt cover. Install serpentine belt tensioner and
serpentine belt. To complete installation, reverse removal procedure.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.

Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 74 (100)
Camshaft Sprocket Sealing Plug .............................................................................. 18 (25)
Crankshaft Pulley Socket-Head Bolts
Golf, GTI & Jetta ..................................................................................................... 30 (40)
New Beetle .............................................................................................................. 18 (25)
Crankshaft Sprocket Center Bolt ......................................................................... 1, 2 66 (90)
Engine Mounting Bolts
Engine Support-To-Engine Block ............................................................................ 33 (45)
Mounting Bracket-To-Body (Small Bolt) .................................................................. 18 (25)
Mounting Bracket-To-Body Bolts (Large Bolts) 1 ........................ ..................................... 2
Mount-To-Body ....................................................................................................... 74 (100)
Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
Timing Belt Tensioner Center Nut ............................................................................ 15 (20)
Water Pump Bolt ....................................................................................................... 11 (15)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Retaining Nut ....................................................................................... 89 (10)
1
2

Replace torque-to-yield bolt on installation.

First tighten to (40 N.m), then tighten bolts an additional 90 (1/4 turn).

VOLKSWAGEN

746

2.0L 4-Cylinder BBW Engines

TIMING BELT APPLICATION
Application

Labor Time

Component
Belt
Kit No.
Part No.

2.0L 4-Cyl. (BBW Engine)

Golf
2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296
Jetta
2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296

2) Remove upper intake manifold as follows. Turn ignition off. Check

whether a coded radio is installed, and obtain radio code as necessary.
Disconnect battery ground strap.
3) Open cap on coolant expansion tank. Clamp off hose (3). See Fig. 3.
Disconnect hoses (1), (2) and (3). Disconnect harness connector (1) and
pull off hoses (4), (5), (6) and (7). See Fig. 4.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
NOTE: For 2004, manufacturer does not provide a timing belt
replacement interval.

REMOVAL & INSTALLATION

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Serpentine Belt Tensioner

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.
NOTE: For 2.0L engines, engine code is stamped on transmission
mating flange at the rear of the engine. See Fig. 1. For all engines,
code can also be found on the vehicle data plate and on a sticker
on the timing belt cover.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing & Installing Upper Intake Manifold (1 Of 2)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating Engine Identification Code

TIMING BELT
NOTE: 2004 Golf and Jetta models equipped with engine code BEV
engine are fitted with variable valve timing.
Removal (2004 Golf & Jetta W/BBW Engine Code) 1) Remove
engine cover. Remove right hand insulation tray from engine compartment. Rotate serpentine belt tensioner clockwise to relieve belt tension.
Remove serpentine belt. See Fig. 2. Lock tensioner in place using
Mandrel (T10060) or a appropriate sized drift. Remove serpentine belt
tensioner.

Courtesy of Volkswagen United States, Inc.

Fig. 4: Removing & Installing Upper Intake Manifold (2 Of 2)

VOLKSWAGEN

747

2.0L 4-Cylinder BBW Engines (Cont.)

4) Release clamps (3) and (8) and remove intake hose (2). Disconnect
throttle valve control module harness connector. Remove rear bolts from
warm air deflector plate and front bolts from lower intake manifold.
Remove lower intake manifold, leave coolant hoses connected to
throttle valve control module and vacuum hose to brake booster, and lay
to side. Seal intake ports in lower intake manifold with clean cloths. To
remove upper intake manifold, remove the throttle valve control module
and vacuum hose from the brake booster.
5) Remove upper timing belt guard. Remove coolant expansion tank
(supply hose remains connected, close union for return supply hose).
Remove power steering reservoir (hoses remain connected).
6) Disconnect camshaft timing adjustment valve harness connector.
Remove cylinder head (valve) cover. Attach Engine Mount Support
(10-222A) with Legs (10-222A/1) or equivalent. Remove securing bolts
from assembly mounting/engine mounting, assembly mounting/body,
and assembly mounting bracket/body (arrows) and remove assembly
mounting complete. See Fig. 5. Only remove engine mounting when
engine is secured with Engine Mount Support.
7) Remove 4 socket-head bolts and remove vibration damper/belt
pulley. See Fig. 6. Remove engine bracket from cylinder block. When
loosening the front engine mounting bolt the engine must be raised
slightly with the support device.
8) Remove center and lower timing belt guards. If timing belt is to be
reused, mark direction of rotation belt. Turn crankshaft until camshaft is
set to TDC No. 1 cylinder.
9) With crankshaft and camshafts set at TDC No. 1 cylinder Adjustment
Bar (2065A) must be able to be pushed into slot of camshaft. See Fig. 7.
Remove Adjustment Bar. Release tensioner and remove toothed belt.
Turn crankshaft 45 against direction of engine rotation.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing Vibration Damper & Engine Mount Bracket

Courtesy of Volkswagen United States, Inc.

Fig. 7: Identifying Adjustment Bar (2065A)

NOTE: When starting installation of timing belt pistons must not be
positioned at TDC.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Attaching Engine Support & Removing Engine Mount

Installation (2004 Golf & Jetta W/BBW Engine Code) 1) Place a flat
container under camshaft sprocket to collect oil which will leak out when
camshaft sealing plug (1) is loosened. See Fig. 8. Unscrew sealing plug
(1) carefully and collect leaking oil.
2) Clean oil from camshaft sprocket with a cloth. Counter-holding
camshaft with Counter Bracket (T10172) with Pins (T10172/3) or
equivalent, remove camshaft pulley bolt. See Fig. 9. DO NOT rotate
camshaft, if possible. Remove camshaft sprocket from camshaft and
clean it.

VOLKSWAGEN

748

2.0L 4-Cylinder BBW Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Removing & Installing Camshaft Sealing Plug

Courtesy of Volkswagen United States, Inc.

Fig. 10: Identifying Crankshaft Alignment Marks

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 11: Tensioning Timing Belt

Fig. 9: Removing & Installing Camshaft Pulley

NOTE: At this point, manufacturer recommends replacing camshaft seal as a preventative and inexpensive measure.
3) Install camshaft sprocket and camshaft bolt. Set camshaft to TDC
No. 1 cylinder and insert Adjustment Bar. See Fig. 7. Loosen camshaft
bolt until using Counter Bracket (T10172), camshaft sprocket can be
turned easily. Place toothed belt on crankshaft pulley and coolant pump
(observe direction of rotation). Install center and lower timing belt
guards. Install vibration damper/belt pulley. See Fig. 6.
4) Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder
notch (2) on vibration damper/belt pulley must align with notch (1) on
timing belt guard. See Fig. 10.
5) Turn camshaft sprocket so that Counter Bracket can be inserted.
Place timing belt on tensioning roller and camshaft sprocket. Turn
tensioning roller on eccentric with two hole Pin Wrench (T10004) five
times to limit stop in both directions. See Fig. 11. Tension toothed belt by
turning eccentric to left (direction of arrow) with two hole Pin Wrench
(T10004) onto limit stop. Release tension on toothed belt until notch (1)
and indicator (2) align (use mirror). Tighten tensioner securing nut to 15
ft. lbs. (20 N.m). Verify that crankshaft is at TDC, correcting if necessary.
6) Using Counter Bracket hold camshaft sprocket and tighten camshaft
bolt to 30 ft. lbs. (40 N.m). See Fig. 12. Remove Adjustment Bar from
rear of camshaft. Counter-hold camshaft sprocket and tighten camshaft
bolt to 96 ft. lbs. (130 N.m).

Courtesy of Volkswagen United States, Inc.

Fig. 12: Counter-Holding & Torquing Camshaft Sprocket Bolt

7) Turn crankshaft two rotations in direction of engine rotation until
Adjustment Bar can be inserted. It is essential that the last 45 (1/8 turn)
is performed without stopping. If the crankshaft has been turned to far,
turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1
cylinder again (insert the Adjustment Bar).
8) Check that crankshaft is at TDC. Notch (2) on vibration damper/belt
pulley must be at positioned a (maximum 5 mm) after TDC marking on
lower timing belt guard. See Fig. 10. If the crankshaft is not positioned
as specified repeat adjustment.

VOLKSWAGEN

749

2.0L 4-Cylinder BBW Engines (Cont.)

9) If the crankshaft positioned as specified, verify timing belt tension,
indicator and notch align, adjusting as necessary.
10) Install sealing plug (1) with NEW O-ring to camshaft pulley. See
Fig. 8. Tightening sealing plug to 18 ft. lbs. (25 N.m). Install engine
mounting to cylinder block. Tighten to bolts specification. See TORQUE
SPECIFICATIONS. Insert bolts into engine bracket before installing
engine bracket. Tighten all bolts of the engine bracket to specification,
before installing the engine mounting.
11) Remaining installation is performed in reverse order to removal.
Replace all O ring seals or gaskets that were disturbed during removal.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
Check and top off engine oil level as necessary. Note the following
concerning intake manifold installation:
Considering installed position, replace intake manifold lower part
seal.
After connecting battery cables, turn ignition on engine off, for 10
seconds before starting engine.
Adapt (match) ECM to throttle valve control module. Generate
readiness code again if DTC memory has been erased or ECM was
disconnected from battery voltage. See appropriate service information.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt .......................................................................................... 74 (100)
Camshaft Sprocket Bolt
Step 1 1 .................................................................................................................... 30 (40)
Step 2 1 .................................................................................................................. 96 (130)
Camshaft Sprocket Sealing Plug .............................................................................. 18 (25)
Crankshaft Pulley Socket-Head Bolts ....................................................................... 18 (25)
Crankshaft Sprocket Center Bolt ......................................................................... 2, 3 66 (90)
Engine Mounting Bolts
Engine Support-To-Engine Block ............................................................................ 33 (45)
Mounting Bracket-To-Body (Small Bolt) .................................................................. 18 (25)
Mounting Bracket-To-Body Bolts (Large Bolts) 2 ........................ ..................................... 3
Mount-To-Body ....................................................................................................... 74 (100)
Intake Manifold
Lower Part ............................................................................................................... 15 (20)
Upper Part-To-Lower Part ........................................................... ..................................... 4
Upper Part-To-Bracket Bolt ..................................................................................... 18 (25)
Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
Timing Belt Tensioner Center Nut ............................................................................ 15 (20)
Water Pump Bolt ....................................................................................................... 11 (15)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Retaining Nut ....................................................................................... 89 (10)
1

2
3
4

For step 1, with Adjustment Bar installed, use Counter Bracket tool to hold camshaft
sprocket and tighten camshaft bolt to specification. See Fig. 12. Step 2, remove
Adjustment Bar from rear of camshaft. Counter-hold camshaft sprocket and tighten
camshaft bolt to final specification.
Replace torque-to-yield bolt on installation.
First tighten to (40 N.m), then tighten bolts an additional 90 (1/4 turn).
Tighten to 89 INCH lbs. (10 N.m).

VOLKSWAGEN

750

2.5L 5-Cylinder
TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.5L 5-Cylinder
Eurovan
1992-96 ..................................................... 2.3 Hours ... ....... N/A
Transporter (Canadian)
1992-96 ..................................................... 2.3 Hours ... ....... N/A
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific scheduled
maintenance interval, aftermarket belt manufacturers suggest the belt
be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal Remove lower sound dampening pan.
1) Removing V-belt or serpentine belt.
2) Remove timing belt upper cover.
3) Fit counter Hold Tool (3419) and loosen vibration damper and
crankshaft sprocket. See Fig. 1.

2) For ALL engines, place timing belt on crankshaft sprocket, relay roller
or tensioning roller and coolant pump (note direction of rotation).
3) For vehicles build up to July, 1995, install lower timing belt cover
and install mounting bolt M8 for coolant pump. If tensioning roller is
installed, tighten to 15 ft. lbs. (20 N.m).
4) For ALL engines, torque vibration damper to crankshaft timing belt
sprocket (4 M8 bolts):
V- Belt Pulley 15 ft. lbs. (20 N.m).
Serpentine Belt Pulley 15 ft. lbs. (20 N.m), pull another 1/4 turn (90
degrees further).
5) Install vibration damper center bolt.
Vehicles With Long Center Bolt (110 mm) Insert Counter-Hold Tool
(3419). See Fig. 6. Tighten crankshaft vibration damper and crankshaft
timing belt sprocket center bolt to 118 ft. lbs. (160 N.m), plus 180 degree
(1/2) additional turn. The additional 1/2 turn can be completed in several
stages.
Vehicles With Short Center Bolt (65 mm) Coat threads and bolt
head contact surface of center bolt with (AMV 188 001 02), or equivalent. Insert Counter-Hold Tool (3419). See Fig. 6. Tighten center bolt to
340 ft. lbs. (460 N.m).
6) For ALL engines, Set camshaft sprocket to marking TDC Cyl. 1. The
marking on the camshaft sprocket must align with the mark on the rear
timing belt cover. See Fig. 7.
NOTE: Adjust timing belt tension with engine cold.
8) For vehicles WITH tensioning roller built up to July, 1995, loosen
nut (1) and check that tensioning roller moves freely, then place timing
belt on camshaft sprocket (note direction of rotation). See Fig. 9. Tighten
tensioning roller mounting bolt hand tight. Turn engine about 2 turns until
just before TDC. To tension timing belt, turn crankshaft slowly to TDC
position (crankshaft must not jump back). Tighten tensioning roller nut to
11 ft. lbs. (15 N.m). Go to step 11).
7) If the engine is installed in the vehicle, set flywheel (A) or drive plate
(B) to TDC No. 1 cylinder. See Fig. 8. If the engine is removed from the
vehicle, bring mark on vibration damper (C) and mark on lower timing
belt cover into alignment. See Fig. 8.
9) For vehicles WITH tensioning roller built from August, 1995 and
up, place timing belt on crankshaft sprocket. For used belts note
direction of rotation. Tighten tensioning roller mounting bolt hand tight.
Turn tensioning roller clockwise onto the tensioning roller internal stop
using box wrench. Then turn tensioning roller back until both pointers
are aligned (arrow B). See Fig. 10. Tighten tensioning roller mounting
bolt to 15 ft. lbs. (20 N.m). Go to step 11).
NOTE: On older engines, VW recommends that sealing surfaces be
cleaned and the O-ring replaced when loosening the coolant pump.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing/Installing Crankshaft Vibration Damper

4) Remove vibration damper center bolt.
5) Remove the 4 x M8 crankshaft vibration damper/timing belt pulley
mounting bolts.
6) Remove vibration damper.
7) Remove timing belt lower cover.
8) If reusing old timing belt, mark direction of rotation on timing belt.
9) Loosen tensioning roller or coolant pump and remove timing belt.
CAUTION: Pistons should not be positioned at TDC. Danger of
damage to valve train and/or piston crowns exist.
NOTE: When turning the camshaft the crankshaft must not be at
TDC.
Installation 1) For vehicles built from August, 1995 and up, install
tensioning roller (1) so that the tensioning roller tab seats in the timing
belt cover lower section moving pin (arrow A). See Fig. 5. Tighten
tensioning roller mounting bolt hand tight.

10) For vehicles WITHOUT tensioning roller, place timing belt on

camshaft sprocket. Loosen coolant pump fasteners. Tension timing belt
by turning loosened coolant pump to left and upward. See Fig. 11. It
must be possible to turn the timing belt 90 with the thumb and forefinger
between camshaft and intermediate shaft sprockets. See Fig. 12.
Tighten coolant pump mounting bolts to 15 ft. lbs. (20 N.m). See Fig. 11.
Go to step 11).
11) On ALL engines, rotate crankshaft two full turns and check adjustment. Install upper timing belt cover
12) Install serpentine belt. See Figs. 13-15. Check ignition timing and
adjust, if necessary.

VOLKSWAGEN

751

2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 2: Identifying Timing Belt & Components (2.5L, Up To July, 1995)

Courtesy of Volkswagen United States, Inc.

Fig. 3: Identifying Timing Belt & Components (2.5L, From August, 1995 & Up)

752

VOLKSWAGEN
2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Identifying Crankshaft Vibration Damper & Components (2.5L)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Setting Up & Installing Tensioning Roller (Vehicles Built

From August, 1995 & Up)

VOLKSWAGEN

753

2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing/Installing Crankshaft Vibration Damper

Courtesy of Volkswagen United States, Inc.

Fig. 7: Setting Camshaft Sprocket To TDC Cylinder No. 1.

Courtesy of Volkswagen United States, Inc.

Fig. 8: Setting Crankshaft To TDC Cylinder No. 1.

Courtesy of Volkswagen United States, Inc.

Fig. 9: Tensioning Timing Belt (Vehicles Built Up To July, 1995)

Courtesy of Volkswagen United States, Inc.

Fig. 10: Tensioning Timing Belt (Vehicles Built From

August, 1995 & Up)

Courtesy of Volkswagen United States, Inc.

Fig. 11: Tensioning Timing Belt Vehicles Without

Tensioning Roller

VOLKSWAGEN

754

2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 15: Serpentine Drive Belt Routing (2.5L Without A/C)

Courtesy of Volkswagen United States, Inc.

Fig. 12: Adjustment Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Component
Ft. Lbs. (N.m)
A/C Bracket-To-Engine Bolt ...................................................................................... 22 (30)
Center Engine Mounting Bolt (M10 x 60) ................................................................ 48 (65)
Coolant Fan Thermo Switch ..................................................................................... 18 (25)
Coolant (Water) Pump-To-Cylinder Block ................................................................. 15 (20)
Coolant (Water) Pump Pulley ................................................................................... 15 (20)
Drive Axle-To-Flange Shaft ....................................................................................... 41 (55)
Idler Roller-To-Tensioner Bracket .............................................................................. 15 (20)
Serpentine Belt Tensioner Bracket-To-Engine Block ................................................ 30 (40)
Timing Belt Tensioner Nut ........................................................................................ 15 (20)
Transmission Mount-To-Sub Frame .......................................................................... 33 (45)
Vibration Damper Center Bolt ....................................................... ..................................... 1
INCH Lbs. (N.m)

Courtesy of Volkswagen United States, Inc.

Fig. 13: Serpentine Drive Belt Routing (2.5L Basic)

Radiator Mounting Bolt ............................................................................................. 89 (10)

Sound Dampening Pan Hex Nut ................................................................................ 80 (9)
Timing Belt Covers (M6 Short) ............................................................................... 2 89 (10)
Timing Belt Covers (M8 Long) ............................................................................. 2 177 (20)
Timing Belt Inner Covers .............................................................. ..................................... 2
Thermostat Housing .................................................................................................. 89 (10)
Valve Cover ............................................................................................................... 89 (10)
1
2

Courtesy of Volkswagen United States, Inc.

Fig. 14: Serpentine Drive Belt Routing (2.5L With A/C)

For torque specifications, see Fig. 4.

For torque specifications related to timing belt components, refer to appropriate
illustration. See Figs. 2 and 3.

VOLKSWAGEN

755

2.8L V6 Passat AHA & ATQ Engines

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.8L V6 (AHA & ATQ Engines)

Passat
1998-04 ..................................................... 4.4 Hours ... ..... T297
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
SCHEDULED REPLACEMENT INTERVAL
Model Year
Interval
1998 ............................................................... ............................................................ 90,000
1999 ............................................................... ............................................................ 75,000
2000-04 .......................................................... .......................................................... 105,000

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: Obtain the radio anti-theft code before disconnecting
the battery.
NOTE: Lock carrier is slid forward onto alignment tools. This will
allow servicing of front engine components. Lock carrier can be
removed at technicians discretion.
Removal 1) Disconnect negative battery cable. Remove engine top
cover. Remove noise insulation panel from under front of vehicle.
2) For vehicles manufactured up to September, 2000, disconnect front
turn signal light assembly wiring harnesses. Separate hood release
lever from bumper cover. Remove front bumper cover. See Fig. 1.
Remove bumper beam. Remove air intake duct from air cleaner
housing. Remove support bolts from lock carrier assembly. See Fig. 2.
Install Support Tool (3369) through lock carrier to body. Remove oil
cooler from lock carrier assembly. Move lock carrier forward on support
tools.
3) For vehicles manufactured from October, 2000, remove bumper
cover from bumper carrier. See Fig. 3. 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.
4) Hold cooling fan pulley with spanner wrench (3312). See Fig. 5.
Unscrew and remove viscous cooling fan clutch from pulley. Viscous
cooling fan is LEFT-HAND threaded.
5) Use a long 17-mm box wrench to turn serpentine belt tensioner
counterclockwise and relieve belt tension. Secure tensioning roller with
pin 3204 when both holes are positioned over one another. Remove
serpentine belt. If reusing belt, mark belt rotation direction with arrow for
reassembly reference.
6) Unclip timing belt guard on front of both camshafts and remove.
Position crankshaft to top dead center No. 3 cylinder. Mark on toothed
belt guard must align with notch on belt pulley. See Fig. 6.
7) 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. See Fig. 6.
8) Remove sealing plug from left side of engine block. See Fig. 8. TDC
mark on crankshaft must be visible or be felt through sealing hole. Install
Crankshaft Holding Tool (Audi 3242) into sealing plug hole.

9) Remove serpentine belt tensioner. Remove center and left timing belt
covers.
10) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner
pulley clockwise to compress timing belt tensioner. See Fig. 9. 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
may result if belts are installed in opposite direction of rotation.
11) Remove crankshaft vibration damper from crankshaft. It is NOT
necessary to remove center bolt. If center bolt is removed, manufacturer
recommends using NEW bolt on reassembly. Remove serpentine belt
idler pulley.
12) Remove fan retainer and belt pulley toothed belt protection. Remove
timing belt.
Installation 1) Install Camshaft Locator Bar (3391) into locking plates
of camshafts. See Fig. 10. Loosen camshaft sprocket bolts about 5
turns. Remove locator bar.
2) 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.
3) 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.
4) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner
so that 2-mm pin can be removed from tensioner.
5) Pre-load timing belt tension, using 8-mm hex socket and torque
wrench on timing belt tensioner pulley, apply 11 ft. lbs. (15 N.m) to
tensioner in direction of tension (clockwise).
6) Tighten camshaft sprocket bolts to specification. See TORQUE
SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft
holder. Install sealing plug.
7) Install timing belt cover. Install crankshaft pulley. Install serpentine
drive belt.
8) To complete installation, reverse remaining removal procedure. When
installing crankshaft pulley, ensure notches in pulley are aligned with
locating lugs in crankshaft. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Front Bumper Cover (Up To September, 2000)

VOLKSWAGEN

756

2.8L V6 Passat AHA & ATQ Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Moving Lock Carrier To Service Position

(From October, 2000)
Courtesy of Volkswagen United States, Inc.

Fig. 2: Moving Lock Carrier To Service Position

(Up To September, 2000)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Removing & Installing Viscous Fan

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing Front Bumper Cover (From October, 2000)

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Crankshaft Timing Marks

VOLKSWAGEN

757

2.8L V6 Passat AHA & ATQ Engines (Cont.)

Courtesy of Audi of America, Inc.

Fig. 7: Aligning Camshaft Sprocket Holes

Courtesy of Audi of America, Inc.

Fig. 10: Installing Camshaft Locator Bar

Courtesy of Audi of America, Inc.

Fig. 8: Installing Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 11: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 40 (55)
Crankshaft Pulley Center Bolt ......................................................................... 1, 2 148 (200)
Crankshaft Pulley-To-Crankshaft Hex Bolt ............................................................... 18 (25)
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)
Lock Carrier-To-Body Torx Bolts ............................................................................... 89 (10)
Timing Belt Tensioner Bolt/Nut ................................................................................. 89 (10)
Water Pump Bolt ....................................................................................................... 89 (10)
1
2

Courtesy of Audi of America, Inc.

Fig. 9: Compressing Timing Belt Tensioner

If removed, manufacturer recommends using NEW bolt.

Tighten to initial specification than an additional 180 (1/2 turn).

VOLVO

758

1.9L 4-Cylinder Turbo 2000-01

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cyl. Turbo

S40 & V40
2000-01
Up To VIN 1219110 ................................ 3.1 Hours ... ..... T252
From Engine Vin 1219111 ..................... 3.1 Hours ......... T311
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 2000-01 model years, the manufacturer recommends the timing belt
and belt tensioner be replaced every 105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT

5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn

tensioner counterclockwise until tensioner indicator passes marked
position. See Fig. 8.
6) Turn tensioner eccentric back so that indicators position is in center
of window. See Fig. 8. Holding eccentric in this position, tighten bolt B
to 15 ft. lbs (20 N.m) without moving tensioner.
7) Recheck adjustment by pressing pin A clockwise and counterclockwise to check. Rotate crankshaft two complete revolutions, 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
complete 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.
8) Install engine bracket (if removed), timing belt covers, and snow cap.
NOTE: Close lid in side cover and move wheels to straight-ahead
position.
9) 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.

CAUTION: DO NOT turn crankshaft or camshafts while belt is

removed.
Removal 1) Remove right engine compartment cover and cover
above right headlight unit. Release serpentine drive belt by turning
tensioner clockwise. Remove serpentine drive belt. See Fig. 1.
2) Remove two screws securing upper timing belt covers. Remove
upper cover by releasing the two clips then remove the screw and the
cover. See Fig. 2.
3) Use an appropriate engine lifting tool to support the weight of the
engine at timing belt end of engine.
4) Remove engine mount bolts and nuts on timing end of engine.
Remove engine mount. See Fig. 3 or 4.
5) Remove lower timing gear cover by releasing the bottom cover and
moving it backwards. See Fig. 5. On 2000 models, engine bracket may
have to be removed for clearance to remove belt. See Fig. 6.
6) 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. 7.
7) Loosen timing belt tensioner pulley bolt. See Fig. 8. Holding 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.
8) Remove splashguards from under engine compartment. Remove
bolts and snow cap. See Fig. 9. 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 1) 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 engine compartment.
2) Ensure camshaft and crankshaft timing marks are still aligned.
Position new timing belt tensioner, and finger tighten bolt A. See
Fig. 10. Turn eccentric from tensioner in lowest position.
3) Install timing belt in correct sequence. See Fig. 11. Install upper rear
timing cover on engine (do not tighten).
CAUTION: Timing belt tension MUST be adjusted when the engine
is cold. Around 68F (20C) is the best temperature.
4) With timing belt installed, turn crankshaft clockwise until timing belt is
tensioned. Belt must be tensioned between intake camshaft sprocket,
idler pulley and crankshaft.

Courtesy of Volvo Cars of North America.

Fig. 1: Removing Accessory Drive Belt

VOLVO

759

1.9L 4-Cylinder Turbo 2000-01 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 2: Removing Timing Gear Covers

Courtesy of Volvo Cars of North America.

Fig. 5: Removing Lower Timing Gear Cover

Courtesy of Volvo Cars of North America.

Fig. 3: Locating Engine Mount (2000)

Courtesy of Volvo Cars of North America.

Fig. 6: Locating Engine Bracket Bolts

Courtesy of Volvo Cars of North America.

Fig. 4: Locating Engine Mount (2001)

Courtesy of Volvo Cars of North America.

Fig. 7: Locating Upper Rear Timing Belt Cover

VOLVO

760

1.9L 4-Cylinder Turbo 2000-01 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 8: Adjusting Timing Belt Tension

Courtesy of Volvo Cars of North America.

Fig. 10: Installing New Tensioner

Courtesy of Volvo Cars of North America.

Fig. 9: Locating Snow Cap & Bolts

VOLVO

761

1.9L 4-Cylinder Turbo 2000-01 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Engine Bracket-To-Engine Block Bolt
Step 1 ...................................................................................................................... 26 (35)
Step 2 ........................................................................................................... Plus 75 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)
Idler Pulley Bolt ......................................................................................................... 18 (24)
Timing Belt Tensioner Pulley Bolt ............................................................................. 15 (20)
Water Pump Bolt ....................................................................................................... 13 (17)
Wheel Lug Nut ........................................................................................................ 81 (110)
INCH Lbs. (N.m)
Power Steering Hose Bolt ........................................................................................ 89
Snow Cap Bolt .......................................................................................................... 89
Timing Belt Cover
Front ....................................................................................................................... 106
Upper ....................................................................................................................... 89

Courtesy of Volvo Cars of North America.

Fig. 11: Installing New Timing Belt

Courtesy of Volvo Cars of North America.

Fig. 12: Aligning Timing Marks

Courtesy of Volvo Cars of North America.

Fig. 13: Identifying Timing Belt Tension Positions

(10)
(10)
(12)
(10)

VOLVO

762

1.9L 4-Cylinder Turbo 2002-04

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.9L 4-Cyl. Turbo

S40 & V40
2002-04 ..................................................... 3.1 Hours ......... T311
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the timing belt and belt tensioner be
replaced every 105,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while belt is
removed.
Removal 1) Remove right engine compartment cover and cover
above right headlight unit. Release serpentine drive belt by turning
tensioner clockwise. Remove serpentine drive belt. See Fig. 1.
2) Remove 2 screws securing upper timing belt covers. Remove upper
cover by releasing 2 clips, then remove screw and cover. See Fig. 2.
3) Remove metal bracket for power steering hose from rotation protection for serpentine drive belt. See Fig. 3. Install Lifting Beam (999-5006),
Lifting Arm (999-5383) and Lifting Hook (999-5460) to support weight of
engine at timing belt end of engine. See .
4) Remove screws for power steering holder. Remove engine mount
bolts and nuts on timing belt end of engine. Remove engine mount. See
Fig. 4. Remove lower timing cover.
5) Remove right front wheel. Position upper timing cover. Turn crankshaft until camshaft sprocket timing marks align with inner timing gear
cover, and crankshaft sprocket aligns with oil pump housing. See Fig. 2.
Turn crankshaft further a 1/4 turn clockwise and then back again until
marks correspond. Remove upper timing cover.
6) Loosen timing belt tensioner pulley bolt. See Fig. 5. Holding tensioner
pulley bolt stationary, rotate pulley eccentric clockwise with a 6-mm Allen
wrench to 10 oclock position. Remove timing belt from tensioner pulley,
camshaft sprockets and water pump.
7) Remove splash guards from under engine compartment. See Fig. 6.
Remove bolts and snow cap. See Fig. 7. Remove timing belt with a
turning motion. Clean surrounding area.
Inspection Spin idler pulley and tensioner pulley, and listen for noise.
Ensure pulley surfaces in contact with belt are clean and smooth.
Installation 1) Install timing belt over pulley on the crankshaft and
route belt upwards. Install lower snow cap and bolts. Install splash
guards under engine compartment.
2) Ensure camshaft and crankshaft timing marks are still aligned. See
Fig. 2. When installing a new idler pulley, tighten bolt to specified torque.
See TORQUE SPECIFICATIONS. When installing a new timing belt
tensioner, screw tension pulley into place using center screw. Screw in
center screw by hand. Ensure that tensioner fork is centered over
cylinder block rib. Ensure that Allen hole on eccentric is at 10 oclock.
3) Install timing belt in correct sequence shown in Fig. 8.
CAUTION: Timing belt tension MUST be adjusted when the engine
is cold. Around 68F (20C) is the best temperature. See Fig. 9.
4) With timing belt installed, turn crankshaft clockwise until timing belt
tensions. Belt must have tension between intake camshaft sprocket,
idler pulley and crankshaft.

5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn

tensioner counterclockwise until tensioner indicator passes marked
position. See Fig. 5.
6) Turn tensioner eccentric back so that indicators position is in center
of window. See Fig. 5. Holding eccentric in this position, tighten bolt B
to 15 ft. lbs (20 N.m) without moving tensioner.
7) Recheck adjustment by pressing pin A clockwise and counterclockwise to check. See Fig. 10. Install upper timing cover. Rotate crankshaft
2 complete revolutions, 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. After readjustment, always
turn crankshaft 2 complete 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 left or right of center. See Fig. 9.
8) Install timing covers. Install engine mount. Tighten bolts on engine
side to specification. See TORQUE SPECIFICATIONS. Tighten bolts on
body side to specification. Install power steering reservoir.
NOTE: Close lid in side cover and move wheels to straight-ahead
position.
9) Remove engine lifting tool. Install metal bracket for power steering
hose on rotation protection for serpentine drive belt. Install right front
wheel. Install serpentine drive belt. Install right hand engine cover and
cover over right headlight unit. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS.

Courtesy of Volvo Cars of North America.

Fig. 1: Removing Accessory Drive Belt

VOLVO

763

1.9L 4-Cylinder Turbo 2002-04 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Volvo Cars of North America.

Fig. 5: Adjusting Timing Belt Tension

Courtesy of Volvo Cars of North America.

Courtesy of Volvo Cars of North America.

Fig. 6: Removing Splash Guards

Fig. 3: Removing Power Steering Hose Metal Bracket

Courtesy of Volvo Cars of North America.

Fig. 7: Removing Snow Cap & Bolts

Courtesy of Volvo Cars of North America.

Fig. 4: Removing Engine Mount

VOLVO

764

1.9L 4-Cylinder Turbo 2002-04 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 10: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Engine Mount
To-Body Nut ............................................................................................................. 37 (50)
To-Engine Bolt ......................................................................................................... 50 (67)
Idler Pulley Bolt ......................................................................................................... 18 (24)
Timing Belt Tensioner Pulley Bolt ............................................................................. 15 (20)
Wheel Lug Nut 1 ...................................................................................................... 81 (110)

Courtesy of Volvo Cars of North America.

Fig. 8: Installing Timing Belt

INCH Lbs. (N.m)

Timing Belt Cover
Front ....................................................................................................................... 106 (12)
Upper ......................................................................................................................... 71 (8)
1

Courtesy of Volvo Cars of North America.

Fig. 9: Identifying Timing Belt Tension Positions

Use anti-corrosion agent (Volvo P/N 1161038-3 or equivalent).

VOLVO

765

2.1L & 2.3L 4-Cylinder B21 & B23

REMOVAL & INSTALLATION

TIMING BELT APPLICATION

Application

2.1L 4-Cyl. B21

242, 244 & 245
1976-79 ............................ ....
DL & GL
1980-83 ............................ ....
DL (Canadian)
1983 ................................. ....
GLT
1981-83 ............................ ....
GT Turbo
1984-85 ............................ ....
2.3L 4-Cyl. B23
DL & GL
1982-85 ............................ ....
GLE (Canadian)
1984 ................................. ....
GLT (Canadian)
1983 ................................. ....
760 GLE
1984 ................................. ....
1

Labor Time Component

Belt
Kit No.
Part No.

CAUTION: This application is an interference engine. Do not rotate

camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

1.3 Hrs. .... .. TCK032 .. ..... T032

1.3 Hrs. .... .. TCK032 .. ..... T032
1.3 Hrs. .... .. TCK032 .. ..... T032
1.3 Hrs. .... .. TCK032 .. ..... T032
1.3 Hrs. .... .. TCK032 .. ..... T032

1.3 Hrs. .... .. TCK032 .. ..... T032

1.3 Hrs. .... .. TCK032 .. ..... T032
1.3 Hrs. .... .. TCK032 .. ..... T032

TIMING BELT
Removal Disconnect negative battery cable. Remove fan shroud and
accessory drive belts. Remove timing belt cover. Rotate crankshaft until
timing marks are aligned. See Fig. 1. Loosen belt tensioner and pull belt
outward until tensioner spring is compressed. Tighten tensioner nut.
Remove timing belt.
Installation 1) Ensure that timing marks are still aligned. See Fig. 1.
Install 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.
2) To complete installation, reverse removal procedure. Adjust drive
belts to proper tension.

1.3 Hrs. .... .. TCK032 .. ..... T032

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1976-85 engines, the manufacturer recommends the belt be
replaced every 40,000 miles. On 1986-88 engines, the manufacturer
recommends the belt be replaced every 50,000 miles.

Fig. 1: Locating Timing Marks for Crankshaft, Intermediate Shaft

& Camshaft

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket .................................................................................................... 37 (50)
Crankshaft Sprocket ................................................................................................ 22 (166)
Drive Belt Tensioner Nut ........................................................................................... 37 (50)
Fan Bolt ..................................................................................................................... 33 (45)
Intermediate Shaft Sprocket ..................................................................................... 37 (50)

VOLVO

766

2.3L & 2.4L 5-Cylinder 1998-01

TIMING BELT APPLICATION
Application

Labor Time

2.3L 5-Cyl. Turbo

C70, S70 & V70
1998-01, Up To VIN 1266127 ...................
1998-01, From VIN 1266128 ....................
S60
2001, Up To VIN 1266127 ........................
2001, From VIN 1266128 .........................
2.4L 5-Cyl.
C70, S70 & V70
1998-01, Up To VIN 1266127 ...................
1998-01, From VIN 1266128 ....................
S60
2001, Up To VIN 1266127 ........................
2001, From VIN 1266128 .........................

Belt
Part No.

2.4 Hours ... ..... T252

1.8 Hours ......... T311
2.2 Hours ... ..... T252
2.2 Hours ......... T311

2.4 Hours ... ..... T252

1.8 Hours ......... T311
2.2 Hours ... ..... T252
2.2 Hours ......... T311

4) Turn crankshaft clockwise (as viewed from timing belt end of engine)
to align the timing marks on the crankshaft pulley and camshaft
sprockets. See Fig. 2. Turn crankshaft an additional 1/4 turn clockwise,
and then back again until the timing marks align.
5) 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.
6) Raise and support vehicle. Holding vibration damper stationary with
Counterhold (999 5433) or equivalent, remove vibration damper center
bolt. Remove vibration damper. Lower vehicle. Remove timing belt.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For 1998 model year, the manufacturer recommends the belt be
replaced every 70,000 miles. For 1999-01 model years, the manufacturer recommends the belt be replaced every 105,000 miles. In addition,
manufacturer recommends replacing timing belt tensioner on 2001 C70.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Courtesy of Volvo Cars of North America.

CAUTION: DO NOT turn crankshaft or camshafts while belt is

removed.
Removal 1) Remove key from ignition switch. Remove accessory
drive (serpentine) belt. See Fig. 1. On S60 models, remove the cross
brace between the front shock towers.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Inspection Spin tensioner and idler pulleys and listen for bearing
noise. Ensure pulley surfaces in contact with belt are clean and smooth.
Installation 1) If timing belt tensioner was removed, ensure tensioner
fork is installed with fork centered over rib on engine block.
2) Place timing belt around crankshaft pulley. Install vibration damper.
Install vibration damper center bolt. Hold vibration damper stationary
with Counterhold (999 5433) or equivalent, and tighten center bolt to
specification. See TORQUE SPECIFICATIONS. Install NEW vibration
damper pulley bolts (if removed).
3) Place timing belt around idler pulley, intake camshaft pulley, exhaust
camshaft pulley, water pump and timing belt tensioner. See Fig. 3.
NOTE: Timing belt tension MUST be adjusted when the engine is
cold. Around 68F (20C) is the best temperature.

Courtesy of Volvo Cars of North America.

Fig. 1: Removing Accessory Drive (Serpentine) Belt &

Drive Belt Routing
2) 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. Remove accessory drive belt.
3) Remove front timing belt cover. Raise and support vehicle. Remove
right front wheel. Remove nut from fender liner cover. Remove upper
timing belt cover.

4) 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.
5) 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. 4.
6) 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.
7) 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.
8) Turn crankshaft clockwise 2 turns. Align camshaft and crankshaft
timing marks. Ensure the timing belt tensioner indicator is within the
correct area.

VOLVO

767

2.3L & 2.4L 5-Cylinder 1998-01 (Cont.)

9) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure
camshaft and crankshaft sprocket timing marks are still aligned. Ensure
timing belt tensioner indicator is in the correct position for engine
temperature.
10) Install front and upper timing belt covers. Install accessory drive belt.
Install power steering reservoir. Check power steering fluid level. Refill,
if necessary.
11) Install coolant reservoir. Install fender liner cover. Install front wheel.
On S60, install shock tower brace.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Shock Tower Brace (S60)
Engine Bracket Bolt ................................................................................................ 37 (50)
Shock Tower Bolt .................................................................................................... 59 (80)
Timing Belt Idler Pulley Bolt ......................................................... ................. 17-18 (24-25)
Timing Belt Tensioner Bolt ........................................................................................ 15 (20)
Vibration Damper Center Bolt ............................................................................... 133 (180)
Vibration Damper Pulley Bolts 1
Step 1 ...................................................................................................................... 18 (25)
Step 2 .................................................................................................................... Plus 30
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

Courtesy of Volvo Cars of North America.

Fig. 3: Identifying Timing Belt Routing

Courtesy of Volvo Cars of North America.

Fig. 4: Adjusting Timing Belt Tension

Always replace bolts if loosened or removed.

VOLVO

768

2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder 1992-98

TIMING BELT APPLICATION
Application
2.3L 5-Cyl. Turbo
850
1994 ..........................................................
1994 ..........................................................
1995-97 ....................................................
850 (Canadian)
1996 ..........................................................
2.4L 5-Cyl.
850
1993 ..........................................................
1993 ..........................................................
1994-97 ....................................................
850 (Canadian)
1995 ..........................................................
1995 ..........................................................
2.9L 6-Cyl.
S90 & V90
1997-98 ....................................................
960
1992-93 ....................................................
1994 ..........................................................
1995-97 ....................................................
1

2
3

Labor Time

Belt
Part No.

2.4 Hours .. ... 2 T217

2.4 Hours .. ... 3 T252
1
2.4 Hours .. ..... T252
1

2.4 Hours .. ..... T252

2.4 Hours .. ... 2 T217

1
2.4 Hours .. ... 3 T252
1
2.4 Hours .. ..... T252
1

2.4 Hours .. ...

2.4 Hours .. ...

2.2 Hours .. ..... T270

T217
T269

2.2 Hours .. ..... T217

2.2 Hours .. ..... T252
1
2.2 Hours .. ..... T270
1

With Air Conditioning, add .5 hours.

With shimmed Air Conditioning belt, add .5 hours.
Through engine number 131034.
From engine number 131035.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

Removal (6-Cylinder) 1) Remove auxiliary drive belt, front transmission cover splash guard under engine, vibration damper guard, and
ignition coil cover.
2) Turn crankshaft clockwise until timing marks on camshaft pulleys/
transmission plate and crankshaft pulley/oil pump housing are aligned.
See Fig. 1. Remove upper transmission cover.
3) Remove tensioner upper mounting bolt, and loosen lower mounting
bolt. Twist tensioner to free plunger/pulley. If reusing old timing belt,
mark belt with arrow to indicate rotation direction. Remove lower bolt,
tensioner, and timing belt.
CAUTION: DO NOT turn crankshaft or camshafts while belt is
removed.
Inspection Spin tensioner and idler pulleys and listen for bearing
noise. 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.
Installation 1) Compress tensioner and tighten center nut. Wait until
compression has taken place and insert a 2-mm locking pin in plunger.
Install tensioner and tighten mounting bolts to specification. See
TORQUE SPECIFICATIONS.
2) Place timing belt around crankshaft pulley and right idler. Place belt
over camshaft pulleys. Position belt around water pump and press over
tensioner pulley.
3) Remove tensioner locking pin. To complete installation, reverse
removal procedure. Turn crankshaft 2 revolutions to ensure timing
marks on crankshaft and camshaft pulleys are aligned. See Fig. 1.
Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
On 1992 960 models, the manufacturer recommends the belt be
replaced every 30,000 mile intervals, starting at the first 40,000 mile
service. On 1993 960 models, the manufacturer recommends the belt
be replaced at 30,000 mile intervals, starting at the first 30,000 mile
service. On 1994 960 models, the manufacturer recommends the belt
be replaced every 50,000 miles. On 1993 850 models, with engine
number 131034 and earlier, 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 the
belt be replaced every 70,000 miles. On ALL 1995-98 models, the
manufacturer recommends the belt be replaced every 70,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal (5-Cylinder) 1) 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 auxiliary drive
belt.
2) 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 aligned. See Fig. 1.
3) Remove tensioner upper mounting bolt, and loosen tensioner lower
bolt. Twist tensioner to free pulley. Remove lower bolt, tensioner, and
upper timing belt cover. If reusing old timing belt, mark belt with arrow to
indicate rotation direction. Remove timing belt.

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

VOLVO

769

2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder 1992-98 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Volvo Cars of North America.

Fig. 2: Checking Tensioner & Idler Pulleys

Application
Ft. Lbs. (N.m)
Camshaft Cover Bolt ................................................................................................. 13 (17)
Camshaft Pulley Bolt ................................................................................................. 15 (20)
Spark Plug ................................................................................................................. 18 (25)
Timing Belt Pulley Bolt .............................................................................................. 30 (40)
Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
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 Turn
6-Cylinder
Step 1 .................................................................................................................... 26 (35)
Step 2 ......................................................................................................... Plus 50 Turn
Water Pump Bolt ....................................................................................................... 13 (17)
Wheel Lug Nut ........................................................................................................ 81 (110)

VOLVO

770

2.3L 4-Cylinder B230, B230F & B230FT

TIMING BELT APPLICATION
Application

Labor Time Component

Belt
Kit No.
Part No.

2.3L 4-Cyl. SOHC

Coupe
1991 ................................. .... 2.7 Hrs. .... ..
240 Series
1986 ................................... 2, 3 2.0 Hrs. .. ..
1987-92 ............................ ... 3 2.0 Hrs. ... ..
1993 ................................. ... 3 2.0 Hrs. ... ..
740 Series
1986-92 ............................ .... 2.2 Hrs. .... ..
760 Series
1985-90 ............................ .... 2.2 Hrs. .... ..
780 Series
1989-90 ............................ .... 2.7 Hrs. .... ..
940 Series
1991-92 ............................ .... 2.2 Hrs. .... ..
1993-95 ............................ .... 2.2 Hrs. .... ..
1
2

TCK032 .. ..... T032

TCK032 .. ..... T032
TCK032 .. ..... T032
TCK234 .. ..... T234

NOTE: If reusing timing belt, mark direction of rotation for installation reference.
4) Place mark on timing belt to indicate direction of belt rotation. Loosen
belt tensioner nut one turn. Pull on timing belt to compress belt tensioner
spring. Tighten belt tensioner nut.
5) 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.

TCK032 .. ..... T032

TCK032 .. ..... T032
TCK032 .. ..... T032
TCK032 .. ..... T032
TCK234 .. ..... T234

With Air Conditioning, add .5 hours.

On Diesel engines, Front Belt labor time is 3.6 hours. On Diesel
engines, Rear Belt labor time is 1.9 hours.
On 240 model, with Shimmed Air Conditioning Belt, add, .5
hours.

NOTE: A timing belt component kit is available for this application.

See page A1 for information on component kits.
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Timing Marks

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 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.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
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 1) 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.
2) 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.
3) Remove nut and washer from belt tensioner. Install Crankshaft 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.

Inspection Check belt teeth for cracks, damage or oil contamination.

Inspect all sprockets for damage. Check belt tensioner for roughness in
rotation. Replace components if damaged.
Installation 1) Install belt tensioner if previously removed. Ensure all
timing marks align. See Fig. 1Fig. 1.
2) Outer side of timing belt has 2 lines, which should fit toward
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.
3) Loosen bolt on belt tensioner to apply spring tension against drive
belt. Tighten belt tensioner nut. Ensure timing marks align. To install
remaining components, reverse removal procedure.
CAUTION: Readjust timing belt when engine reaches normal operating temperature.
4) 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 pressure on timing belt. This readjusts
timing belt to allow for belt stretch. Tighten belt tensioner nut. Install
rubber plug. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ............................................................................................ 37 (50)
Crankshaft Pulley Bolt 1
Step 1 ...................................................................................................................... 44 (60)
Step 2 ........................................................................................................... Additional 60
Intermediate Shaft Sprocket Bolt .............................................................................. 38 (51)
1

Apply light coat of oil to bolts before installation.

VOLVO

771

2.3L 4-Cylinder B234

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.3L 4-Cyl. B234

740 Series (Canadian)
1986-88
Balance Shaft ...................................... .......... 2 .......... .....
Camshaft ................................................ 2.8 Hours ... .....
1989 (With Automatic Tensioner)
Balance Shaft ...................................... .......... 2 .......... .....
Camshaft ................................................ 2.8 Hours ... .....
1989 (With Manual Tensioner)
Balance Shaft ...................................... .......... 2 .......... .....
Camshaft ................................................ 2.8 Hours ... .....
1990
Balance Shaft ...................................... .......... 2 .......... .....
Camshaft ................................................ 2.8 Hours ... .....
940 Series (Canadian)
1991-92
Balance Shaft ...................................... .......... 2 .......... .....
Camshaft ................................................ 2.8 Hours ... .....
1
2

T174
T173
T174
T198
T174
T173
T174
T173

T174
T198

With Air Conditioning, add .5 hours.

Balance shaft belt labor time is included in
camshaft belt labor time.

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Camshaft & Crankshaft Markings

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 50,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

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 1) 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.
2) 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.
3) Loosen tensioner lock nut, then compress tensioner spring. Tighten
tensioner lock nut and remove camshaft timing belt.
4) Do not turn crankshaft and camshafts while timing belt is removed.
Remove balance shaft belt idler pulley. Loosen lock nut and remove
balance shaft belt. See Fig. 2.
Installation 1) Check that balance shaft marking aligns with markings
on transmission mounting plate. See Fig. 3. Ensure that crankshaft
marking is opposite TDC marking on cylinder head. Install balance shaft
belt under crankshaft pulley assembly. Ensure that blue dot (marking B)
is opposite bottom TDC marking on belt guide plate at bottom of
crankshaft. See Fig. 4.
2) 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.

Courtesy of Volvo Cars of North America.

Fig. 2: Removing Balance Shaft Belt

3) 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 position to ensure that balance shaft belt
engages properly in pulleys. Return crankshaft to TDC position.
4) 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. lbs. (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.

VOLVO

772

2.3L 4-Cylinder B234 (Cont.)

5) Position gauge above idler. See Fig. 6. 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. 7. Ensure that
single line markings align with pulley markings.
6) 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.
7) 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 normal operating temperature, then shut
engine off.
8) To check balance timing belt tension, start engine and allow 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.
9) If belt tension is low, rotate tensioner slightly clockwise, then rotate
crankshaft clockwise one revolution. Belt tension should be within 4.7 to
5.1 unit range. If belt tension is high, repeat procedure. Install idler pulley
and timing covers.
10) 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 camshaft 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. lbs. (51 N.m). Replace protective cap in measuring zone.
See Fig. 10.
11) 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 lock nut. Position 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.
12) If belt tension is high, adjust to obtain a reading of 4.8 to 5.2 units.
Torque tensioner lock nut to 37 ft. lbs. (51 N.m), and rotate crankshaft
clockwise. Measure belt tension. Belt tension should be 5.3 to 5.7 unit
range.
13) Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Remove protective
cap, then loosen tensioner. To complete installation, reverse removal
procedure. Adjust drive belts to proper tension.

Courtesy of Volvo Cars of North America.

Fig. 4: Installing Balance Shaft Belt

Courtesy of Volvo Cars of North America.

Fig. 5: Adjusting Tensioner

Courtesy of Volvo Cars of North America.

Fig. 3: Aligning Balance Shaft & Crankshaft Markings

VOLVO

773

2.3L 4-Cylinder B234 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 6: Checking Balance Shaft Belt Tension

Courtesy of Volvo Cars of North America.

Fig. 8: Rotating Crankshaft

Courtesy of Volvo Cars of North America.

Fig. 9: Checking Belt Tension

Courtesy of Volvo Cars of North America.

Fig. 7: Installing Timing Belt

VOLVO

774

2.3L 4-Cylinder B234 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Tensioner Locking Bolt ........................................................................................... 29.5 (40)
Tensioner Lock Nut ................................................................................................ 37.0 (49)

Courtesy of Volvo Cars of North America.

Fig. 10: Adjusting Belt Tension

VOLVO

775

2.3L, 2.4L & 2.5L 5-Cylinder 2002-04

TIMING BELT APPLICATION
Application
2.3L 5-Cyl. Turbo
C70, S60 & V70
2002-04 .....................................................
2.4L 5-Cyl. Non-Turbo
S60 & V70
2002-04 .....................................................
2.4L 5-Cyl. Turbo
C70, S60 & V70
2002-04 .....................................................
2.5L 5-Cyl. Turbo
XC90
2003-04 .....................................................

Labor Time

Belt
Part No.

2.2 Hours ... ..... T252

2.2 Hours ... ..... T252

2.2 Hours ... ..... T331

2.3 Hours ... ..... T331

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

For 2002-03 models, manufacturer recommends timing belt be replaced

every 120,000 miles for XC90, and 105,000 miles for all other vehicles.
For 2004 models, manufacturer recommends timing belt be replaced
every 120,000 miles for AWD models equipped with 2.5L Turbo engines,
and 105,000 miles for all other vehicles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while timing belt
is removed.
Removal 1) Remove key from ignition switch. On all models except
C70, remove cross brace between front shock towers.
WARNING: DO NOT spill power steering fluid. It is extremely
flammable.
2) 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. If necessary, use a small screwdriver
and remove plastic cover on accessory belt tensioner. Use a wrench and
turn accessory belt tensioner clockwise to release tension and remove
accessory drive belt.
3) Remove front timing belt cover. Raise and support vehicle. Remove
right front wheel. Remove nut from fender liner cover.
4) Install upper timing belt cover. Turn crankshaft clockwise (as viewed
from timing belt end of engine) to align timing marks on timing belt cover,
crankshaft pulley and camshaft sprockets. See Fig. 1. Turn crankshaft
an additional 1/4 turn clockwise, and then back again until timing marks
align.
5) Remove upper timing belt cover. Loosen timing belt tensioner pulley
center bolt slightly. Holding center bolt, turn tensioner eccentric clockwise with a 6-mm Allen wrench. Turn eccentric until hole for Allen wrench
is at 10 oclock position. See Fig. 2.
6) Remove timing belt from tension pulley, camshaft pulley and water
pump.
7) Holding vibration damper stationary with Counterhold (999 5433) or
equivalent, work vibration damper loose. Remove timing belt.
Inspection Spin tensioner and idler pulleys, and listen for bearing
noise. Ensure pulley surfaces in contact with belt are clean and smooth.
Installation 1) If timing belt tensioner was removed, ensure tensioner
fork is installed with fork centered over rib on engine block.

Courtesy of Volvo Cars of North America.

Fig. 2: Identifying Timing Belt Tensioner

2) Place timing belt around crankshaft pulley. Install vibration damper.
Install vibration damper center bolt. Hold vibration damper stationary
with Counterhold (999 5433) or equivalent, and tighten center bolt to
specification. See TORQUE SPECIFICATIONS. Remove Counterhold
and install NEW screws. Tighten to specification. See TORQUE SPECIFICATIONS.
3) Place timing belt around idler pulley, intake camshaft pulley, exhaust
camshaft pulley, water pump and timing belt tensioner. See Fig. 3.
NOTE: Timing belt tension MUST be adjusted when engine is cold.
Around 68F (20C) is best temperature.
4) Slowly turn crankshaft clockwise (as viewed from timing belt end of
engine) until timing belt is tensioned. Belt should be tight between intake
camshaft sprocket, idler pulley and crankshaft sprocket.
5) Hold timing belt tensioner pulley bolt secure, and turn tensioner
eccentric counterclockwise until tensioner needle passes to right of
center position. See Fig. 4.
6) Turn tensioner eccentric back until needle reaches marked position
corresponding to engine temperature. At 68F (20C), needle must be
centered in window.
7) Holding timing belt tensioner eccentric steady, tighten center bolt to
15 ft. lbs. (20 N.m). Ensure tensioner needle is still in correct position.
Press timing belt to see if indicator on tensioner moves easily.
8) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure
camshaft and crankshaft sprocket timing marks are still aligned. Ensure
timing belt tensioner indicator is in correct position for engine temperature.

VOLVO

776

2.3L, 2.4L & 2.5L 5-Cylinder 2002-04 (Cont.)

9) Install front timing belt cover. Install upper timing belt cover. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. Install accessory drive belt. Install power steering reservoir. Check power steering
fluid level. Refill, if necessary.
10) Install coolant reservoir. Install fender liner cover. Install front wheel.
On all models except C70, install cross brace between shock towers.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Idler Pulley ................................................................................................................. 17 (24)
Shock Tower Brace
Brace-To-Bracket Bolt ............................................................................................. 37 (50)
Bracket-To-Shock Tower Bolt .................................................................................. 59 (80)
Timing Belt Tensioner Bolt ........................................................................................ 15 (20)
Vibration Damper Center Bolt ............................................................................... 133 (180)
Vibration Damper Pulley-To-Cranshaft Sprocket Screw 1
Step 1 ...................................................................................................................... 18 (25)
Step 2 .................................................................................................................... Plus 30
Wheel Lug Nut
C70 ........................................................................................................................ 81 (110)
S60, V70, XC70 & XC90 .................................................................................... 103 (140)
INCH Lbs. (N.m)
Front Timing Belt Cover Bolt .................................................................................. 106 (12)
Upper Timing Belt Cover Bolt ..................................................................................... 71 (8)
1

Courtesy of Volvo Cars of North America.

Fig. 3: Identifying Timing Belt Routing

Courtesy of Volvo Cars of North America.

Fig. 4: Adjusting Timing Belt Tension

Always replace bolts if loosened or removed.

VOLVO

777

2.4L & 2.5L 5-Cylinder Turbo 2004 1/2

TIMING BELT APPLICATION
Application
2.4L 5-Cyl.
S40
2004 1/2
2.5L 5-Cyl.
S40
2004 1/2

Labor Time

Belt
Part No.

Turbo
................................................. ........ N/A ........ ..... T331
Turbo
................................................. ........ N/A ........ ..... T331

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Manufacturer recommends timing belt, tensioner and idler pulley
replacement every 120,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

Courtesy of Volvo Cars of North America.

Fig. 2: Removing Engine Mount & Limiter

TIMING BELT
Removal 1) Lift coolant expansion tank out of holder and place on top
of engine. Fit Lifting Beam (999-7103). See Fig. 1.

Courtesy of Volvo Cars of North America.

Fig. 3: Disconnecting Power Steering Pressure Line From Pump

Courtesy of Volvo Cars of North America.

Fig. 1: Installing Lifting Beam

2) Remove bolts for engine mount limiter. Remove limiter. Remove bolts
holding engine mount to cylinder head. See Fig. 2. Remove engine
mount.
3) Remove front transmission cover bolts and covers.
4) Raise and support vehicle. Remove right front wheel. Remove fender
liner. Lower vehicle so that timing belt pulley is visible and Lifting Beam
is accessible.
5) Disconnect power steering pressure line from pump. See Fig. 3.
Clean any spilled fluid immediately. Seal line and pump opening.
6) Remove outer accessory drive belt. Rotate outer tensioner clockwise
and remove belt.
7) Remove vibration damper. Remove 4 outer damper bolts first using
crankshaft center nut to counter. Use Counterhold (999-5433) to hold
damper and remove crankshaft center nut. See Fig. 4. Remove Counterhold and work vibration damper loose.
8) Turn crankshaft clockwise until crankshaft and camshaft timing marks
align. See Fig. 5. Lower engine so that belt tensioner bolts are
accessible from underneath.

Courtesy of Volvo Cars of North America.

Fig. 4: Using Counterhold To Remove Vibration Damper

9) Loosen belt tensioner center bolt slightly. Hold center bolt and turn
eccentric clockwise using a 6mm Allen key. Turn to 10 oclock position
and remove timing belt from pulleys.

VOLVO

778

2.4L & 2.5L 5-Cylinder Turbo 2004 1/2 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

NOTE: Tensioner and idler pulley will not be reused.
10) Remove belt tensioner and idler pulley. Discard both.
NOTE: Timing belt tensioner and idler pulley MUST be replaced
with timing belt.
Installation 1) Fit new tensioner with center bolt. Ensure tensioner
fork is centered over rib in engine block. Ensure Allen key hole on
eccentric is at 10 oclock position. Install new idler pulley and tighten
bolts to specification. See TORQUE SPECIFICATIONS.
2) Ensure timing marks are aligned. Install timing belt in the following
order:
Crankshaft.
Idler pulley.
Intake camshaft.
Exhaust camshaft.
Water pump.
Tensioner.

Courtesy of Volvo Cars of North America.

Fig. 7: Adjusting Timing Belt Tensioner

6) Ensure tensioner indicator is within marked area. If not, adjust belt
tension again. If so, go to next step.
7) Install vibration damper. Use Counterhold (999-5433) to tighten
crankshaft center nut. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
8) Install outer accessory drive belt. Connect pressure hose to power
steering pump. Do not forget to remove seals from pipe and pump
openings.
9) Install fender liner and front wheel. Tighten wheel lugs to specification. See TORQUE SPECIFICATIONS.
10) Lower vehicle. Install front transmission covers. Install engine mount
and limiter. Remove Lifting Beam. Fit coolant expansion tank.
11) Fit all remaining components. Start engine and check function.

NOTE: Engine MUST be cold to accurately adjust timing belt

tension. Approximately 20C (68F) is a suitable temperature. At
higher temperatures (engine at operating temperature or a high
outside temperature, for example) the indicator is further to the
right. See Fig. 6.

Courtesy of Volvo Cars of North America.

Courtesy of Volvo Cars of North America.

Fig. 6: Adjusting Timing Belt Tension

3) Install crankshaft center nut. Turn crankshaft slowly clockwise until
timing belt tension is correct. Belt must be in tension between intake
camshaft pulley, idler pulley and crankshaft pulley.
4) Hold tensioner center bolt still and turn eccentric clockwise until
tensioner indicator passes marked position. Then turn eccentric back so
indicator reaches marked position in center of window. Hold eccentric
still and tighten center bolt to specification. See Fig. 7 and TORQUE
SPECIFICATIONS. Ensure indicator is still in correct position.
5) Press on timing belt between pulleys and ensure tensioner moves
easily. Install upper timing cover. Turn crankshaft clockwise 2 revolutions and ensure crankshaft and camshaft timing marks align.

Fig. 8: Identifying Timing Belt Routing

VOLVO
2.4L & 2.5L 5-Cylinder Turbo 2004 1/2 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Engine Mount-To-Engine Bolts
Step 1 ...................................................................................................................... 26 (35)
Step 2 .................................................................................................................... Plus 75
Engine Mount Limiter-To-Chassis ............................................................................. 59 (80)
Idler Pulley Bolts ....................................................................................................... 17 (24)
Power Steering Pressure Line Connection .............................................................. 13 (18)
Timing Belt Tensioner Center Bolt ............................................................................ 15 (20)
Vibration Damper Center Bolt ............................................................................... 133 (180)
Vibration Damper Pulley Screw 1
Step 1 ...................................................................................................................... 18 (25)
Step 2 .................................................................................................................... Plus 60
Wheel Bolts
Step 1 ...................................................................................................................... 15 (20)
Step 2 ...................................................................................................................... 70 (95)
INCH Lbs. (N.m)
Upper Timing Belt Cover Bolt ................................................................................... 89 (10)
Front Timing Belt Cover Bolt ...................................................................................... 71 (8)
1

Always replace bolts if loosened or removed.

779

VOLVO

780

2.4L 6-Cylinder Diesel

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

2.4L 6-Cyl. Diesel

DL
1982
Camshaft ............................................... 1 3.6 Hours .. .....
Injection Pump ....................................... 1.9 Hours ... .....
GL
1982-84
Camshaft ............................................... 1 3.6 Hours .. .....
Injection Pump ....................................... 1.9 Hours ... .....
740 Series
1985-86
Camshaft ............................................... 1 3.6 Hours .. .....
Injection Pump ....................................... 1.9 Hours ... .....
760 GLE
1983-84
Camshaft ............................................... 1 3.9 Hours .. .....
Injection Pump ....................................... 1.9 Hours ... .....
760 Series
1985
Camshaft ............................................... 1 3.9 Hours .. .....
Injection Pump ....................................... 1.9 Hours ... .....
1

T083
T082

T083
T082

T083
T082
Courtesy of Volvo Cars of North America.

T083
T082

Fig. 1: Camshaft Timing & Injection Timing At TDC

T083
T082

With Air Conditioning, add .5 hours.

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends the belt be replaced every 75,000 miles.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) 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.
3) 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.
4) Remove center bolt from idler pulley. Using Idler Pulley Removal Tool
(5202) or equivalent, remove idler pulley. Replace 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.
CAUTION: Idler pulley must be replaced when replacing timing
gear belt. Use Puller (5202) to remove pulley.
CAUTION: Camshaft MUST NOT rotate, or damage to valves and
pistons may result.
5) Tap gear loose from camshaft tapered end. Remove injection 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 camshaft sprocket, and Wrench (5201) or equivalent to
remove center retaining bolt. Tap gear loose from camshaft. See Fig. 2.

Courtesy of Volvo Cars of North America.

Fig. 2: Using Camshaft Gear Retaining Wrench

Installation 1) Check that No. 1 cylinder is at TDC, timing mark on
flywheel is at 0, and camshaft lobes for No. 1 cylinder are facing up
with equally large angles in comparison with cylinder head. See Fig. 1.
Place Camshaft Lock Gauge Tool (5190) or equivalent in camshaft
groove at rear of cylinder head.
NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool
(5190) or equivalent is to compensate for timing gear clearance.
2) Place a .008 (.2 mm) feeler gauge under left side of Camshaft
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).
3) 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.
4) 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.
5) 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.

VOLVO

781

2.4L 6-Cylinder Diesel (Cont.)

6) 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. Reverse removal procedure to complete installation.
Adjust drive belts to proper tension.

Courtesy of Volvo Cars of North America.

Fig. 4: Locating Injection Pump Alignment Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Volvo Cars of North America.

Fig. 3: Setting Timing Using Camshaft Locking Gauge

Application
Ft. Lbs. (N.m)
Camshaft Gear Bolt
Front ......................................................................................................................... 33 (45)
Rear ....................................................................................................................... 74 (100)
Crankshaft Pulley Nut ........................................................................................... 258 (350)
Injector Pump Gear ................................................................................................... 33 (45)

VOLVO

782

2.8L & 2.9L 6-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

2.8L 6-Cyl. Turbo

S80
1999 ...........................................................
2000-01 .....................................................
2.9L 6-Cyl. Turbo
S80
2002-03 .....................................................
XC90
2003-04 .....................................................
2.9L 6-Cyl. Non-Turbo
S80
1999 .........................................................
2000-03 ...................................................

Belt
Part No.

4.4 Hours ... ..... T270

3.5 Hours ... ..... T319

3.5 Hours ... ..... T319

3.5 Hours ... ..... T319

2.7 Hours ... ..... T270

3.6 Hours ... ..... T319

NOTE: For information about tensioners and/or pulleys (when

available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
For S80 models, manufacturer recommends the timing belt and belt
tensioner be replaced every 105,000 miles.
For 2003-04 XC90 models, manufacturer recommends the timing belt
and belt tensioner be replaced every 120,000 miles.

4) Remove air duct, cover, surround and control module box. Remove
hose between thermostat housing and expansion tank. Remove front
timing belt cover.
5) Seal hose between expansion tank and radiator. Disconnect hose at
expansion tank. Lift expansion tank and place on top of engine.
6) Raise and support vehicle. Remove right front wheel. Remove plastic
nuts from cover in fender liner. Install upper timing belt cover.
7) Rotate crankshaft clockwise until timing marks are aligned. See
Fig. 2. Rotate crankshaft further 1/4 turn clockwise, then rotate counterclockwise until marks are aligned.
8) Remove upper timing belt cover. Remove 4 vibration damper screws.
Remove vibration damper. Remove accessory drive belt. On models
with hydraulic timing belt tensioner, go to next step. On models without
hydraulic timing belt tensioner, go to step 11).
9) Install Counterhold (999 5433), and remove crankshaft center nut.
See Fig. 3. Remove counterhold and accessory drive belt pulley.
10) Remove timing belt tensioner/hydraulic unit upper screw, then
loosen lower screw. Turn tensioner/hydraulic unit so that cylinder comes
free. Remove lower screw. Remove tensioner/hydraulic unit. Remove
timing belt.
11) Remove belt cover behind crankshaft pulley for accessory drive belt.
Spray universal oil around rubber sleeve on underside of oil pump.
Remove rubber sleeve.
12) Slightly loosen timing belt tensioner center screw. Hold screw from
turning. Using a 6-mm hex wrench in eccentric, turn tensioner counterclockwise until eccentric is at 10 oclock position. See Fig. 4. Remove
timing belt.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) Remove ignition key. Remove engine stabilizer brace. On
turbo models, remove plastic pipes between turbocharger and charge
air cooler, and between turbocharger and air cleaner. Set them aside.
2) Remove clamp from intake manifold for turbocharger for cylinders
Nos. 1, 2 and 3. Turn upper section of pipe toward firewall. On all
models, lift power steering fluid reservoir, and place on top of engine.
NOTE: Ensure power steering fluid does not leak out of ventilation
hole.
3) Using a 15-mm wrench, rotate accessory drive belt tensioner
clockwise to relieve tension on belt. See Fig. 1. Lift off accessory drive
belt. Remove upper timing belt cover.

Courtesy of Volvo Cars of North America.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Volvo Cars of North America.

Courtesy of Volvo Cars of North America.

Fig. 1: Identifying Accessory Drive (Serpentine) Belt Routing

Fig. 3: Removing Crankshaft Center Nut

VOLVO

783

2.8L & 2.9L 6-Cylinder (Cont.)

11) To complete installation, reverse removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Fill coolant
and power steering fluid.

Courtesy of Volvo Cars of North America.

Fig. 4: Identifying 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.
On models with hydraulic timing belt tensioner, ensure tensioner/
hydraulic unit shows no visible signs of leakage.
NOTE: The variable valve timing unit on B6304S engine does not
have a return spring. The unit is easily dislodged when installing
timing belt.

Courtesy of Volvo Cars of North America.

Fig. 5: Compressing Timing Belt Tensioner/Hydraulic Unit Piston

(Hydraulic Tensioner)

Installation 1) On models without hydraulic timing belt tensioner, go to

step 3). On models with hydraulic timing belt tensioner, position
tensioner/hydraulic unit in Tool (999 5456). See Fig. 5.
2) Screw center nut on Tool (999 5456) to the bottom. Wait until piston
is compressed, then install a lock pin into the piston. Install tensioner/
hydraulic unit. Tighten screws to specification. See TORQUE SPECIFICATIONS.
NOTE: Tensioner/hydraulic unit must be replaced if there is no
resistance when pushing piston in or if piston cannot be pushed in.
3) On all models, ensure timing marks are aligned. See Fig. 2. Install
timing belt in order shown in illustration. See Fig. 6.
4) On models with hydraulic timing belt tensioner, go to next step. On
models without hydraulic timing belt tensioner, go to step 6).
5) Pull lock pin out of tensioner/hydraulic unit. Install accessory drive belt
pulley. Install crankshaft center nut. Rotate crankshaft clockwise 2
revolutions, and ensure timing marks are aligned. Install Counterhold
(999 5433), and tighten crankshaft center nut to specification. See
TORQUE SPECIFICATIONS. Go to step 10).
6) Carefully rotate crankshaft clockwise until timing belt is tensioned.
Timing belt must be tight between intake camshaft pulley, idler pulley
and crankshaft.
CAUTION: Timing belt tension MUST be adjusted when the engine
is cold. Around 68F (20C) is the best temperature.
7) Hold tensioner center screw from turning. Using 6-mm hex wrench,
turn tensioner eccentric clockwise until tensioner indicator passes
marked position. See Fig. 7.
8) Turn tensioner eccentric back so that indicators position is in center
of window. See Fig. 7. Holding eccentric in this position, tighten center
screw to specification. See TORQUE SPECIFICATIONS.
9) Ensure indicator is in correct position. Press belt to ensure that
tensioner indicator moves easily. Install upper timing belt cover. Rotate
crankshaft clockwise 2 revolutions, and ensure timing marks are aligned
and tensioner indicator is in correct position.
10) On all models, install accessory drive belt around crankshaft pulley.
Install vibration damper with NEW screws. Tighten screws to 26 ft. lbs.
(35 N.m), then angle tighten 50 degrees. Use crankshaft center nut as
a counterhold.

Courtesy of Volvo Cars of North America.

Fig. 6: Identifying Timing Belt Installation Order

VOLVO

784

2.8L & 2.9L 6-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

Courtesy of Volvo Cars of North America.

Fig. 7: Identifying Timing Belt Tension Positions

(Mechanical Tensioner)

Application
Ft. Lbs. (N.m)
Crankshaft Center Nut .......................................................................................... 221 (300)
Engine Stabilizer Brace
To-Body Bolt ............................................................................................................ 37 (50)
To-Engine Bracket Bolt ........................................................................................... 59 (80)
Idler Pulley Bolt ......................................................................................................... 18 (24)
Timing Belt Tensioner
Center Screw (Except Hydraulic Tensioner) .......................................................... 18 (24)
Tensioner Pulley Screw (Hydraulic Tensioner) ....................................................... 22 (30)
Hydraulic Unit Screw ............................................................................................... 18 (24)
Vibration Damper-To-Crankshaft Sprocket Screw 1
Step 1 ...................................................................................................................... 26 (35)
Step 2 .......................................................................................... ......................... Turn 50
Wheel Lug Nut ........................................................................................................ 81 (110)
INCH Lbs. (N.m)
Timing Belt Cover
Front ....................................................................................................................... 106 (12)
Upper ......................................................................................................................... 71 (8)
1

Use NEW screws.

YUGO

785

1.1L & 1.3L 4-Cylinder

TIMING BELT APPLICATION
Application

Labor Time

Belt
Part No.

1.1L 4-Cyl.
GV Series
1986-89 ..................................................... 2.5 Hours ... ..... T018
1.3L 4-Cyl.
GV Series
1987 ........................................................... 2.5 Hours ... ..... T018
NOTE: For information about tensioners and/or pulleys (when
available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
The manufacturer recommends inspection of the timing belt every
15,000 miles. Although the manufacturer does not recommend a
specific scheduled replacement interval, belt manufacturers suggest the
belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION

CAUTION: This application is an interference engine. Do not rotate
camshaft or crankshaft when timing belt is removed, or engine
damage may occur.

TIMING BELT
Removal 1) 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.
2) Align camshaft sprocket with timing mark. See Fig. 1. Loosen
tensioner lock nut and move tensioner pulley toward engine mount.
Tighten nut to secure tensioner in slack position. Remove and discard
timing belt.

Courtesy of Yugo America, Inc.

Fig. 1: Identifying Camshaft-To-Crankshaft Alignment

CAUTION: Timing belts cannot be reused. DO NOT readjust belt

tension following initial installation of a new belt.
Installation 1) Align camshaft sprocket with timing mark. Align
crankshaft sprocket with reference index. See Fig. 2. Position timing belt
tensioner to its limit 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 tension. Tighten tensioner lock nut to 33 ft.
lbs. (45 N.m).
2) 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 installation. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Camshaft Housing Bolts ........................................................................................... 14 (19)
Camshaft Sprocket Bolt ............................................................................................ 61 (83)
Camshaft Pulley Nut ............................................................................................. 101 (137)
Tensioner Pulley Support Nut ................................................................................... 33 (45)

Courtesy of Yugo America, Inc.

Fig. 2: Exploded View Of Timing Belt &

Related Components

786

Changeover Listing
PowerGrip Timing System Products
Showing Competitive Numbers with Our Corresponding PowerGrip Numbers

The Gates 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 Gates numbers, and does not mean that the competitive number shown will fit all applications recommended for the Gates 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
No.

Gates
No.

ACDELCO
Timing Belts
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB020.................
T020
TB028.................
T028
TB032.................
T032
TB036.................
T036
TB037.................
T037
TB039.................
T039
TB041.................
T041
TB043.................
T043
TB061.................
T061
TB062.................
T062
TB064.................
T064
TB065.................
T065
TB067.................
T067
TB068.................
T068
TB069.................
T069
TB070.................
T070
TB071.................
T071
TB073.................
T073
TB074.................
T074
TB075.................
T075
TB076.................
T076
TB077.................
T077
TB078.................
T078
TB079.................
T079
TB081.................
T081
TB082.................
T082
TB083.................
T083
TB084.................
T084
TB087.................
T087
TB088.................
T088
TB089.................
T089
TB090.................
T090
TB091.................
T091
TB092.................
T092
TB093.................
T093
TB094.................
T094
TB095.................
T095
TB096.................
T096
TB097.................
T097
TB098.................
T098
TB099.................
T099
TB100.................
T100
TB101.................
T101
TB102.................
T102
TB103.................
T103
TB104.................
T104
TB106.................
T106
TB107.................
T107
TB112.................
T112
TB113.................
T113
TB114.................
T114
TB117.................
T117
TB118.................
T118
TB119.................
T119
TB120.................
T120
TB121.................
T121
TB122.................
T122
TB123.................
T123
TB124.................
T124
TB125.................
T125
TB126.................
T126
TB127.................
T127
TB128.................
T128
TB129.................
T129
TB130.................
T130
TB131.................
T131
TB132.................
T132
TB134.................
T134
TB135.................
T135
TB136.................
T136
TB137.................
T137

Competitive
No.

Gates
No.

ACDELCO - Cont.
Timing Belts - Cont.
TB138.................
TB139.................
TB140.................
TB141.................
TB142.................
TB143.................
TB144.................
TB145.................
TB146.................
TB147.................
TB148.................
TB149.................
TB150.................
TB151.................
TB152.................
TB153.................
TB154.................
TB155.................
TB157.................
TB158.................
TB159.................
TB160.................
TB161.................
TB162.................
TB163.................
TB164.................
TB165.................
TB166.................
TB167.................
TB168.................
TB169.................
TB170.................
TB171.................
TB172.................
TB173.................
TB174.................
TB176.................
TB177.................
TB178.................
TB179.................
TB180.................
TB181.................
TB182.................
TB183.................
TB184.................
TB185.................
TB186.................
TB187.................
TB188.................
TB189.................
TB190.................
TB191.................
TB192.................
TB193.................
TB194.................
TB195.................
TB196.................
TB197.................
TB198.................
TB199.................
TB200.................
TB201.................
TB203.................
TB204.................
TB205.................
TB206.................
TB207.................
TB208.................
TB209.................
TB210.................
TB211.................
TB212.................
TB213.................
TB214.................
TB215.................

T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T203
T204
T205
T206
T207
T208
T209
T210
T211
T212
T213
T214
T215

Competitive
No.

Gates
No.

ACDELCO - Cont.
Timing Belts - Cont.
TB216.................
TB217.................
TB218.................
TB219.................
TB220.................
TB221.................
TB222.................
TB223.................
TB224.................
TB225.................
TB226.................
TB227.................
TB228.................
TB229.................
TB230.................
TB232.................
TB233.................
TB234.................
TB235.................
TB236.................
TB237.................
TB239.................
TB240.................
TB241.................
TB242.................
TB243.................
TB244.................
TB245.................
TB246.................
TB247.................
TB248.................
TB249.................
TB251.................
TB252.................
TB253.................
TB254.................
TB255.................
TB256.................
TB257.................
TB258.................
TB259.................
TB260.................
TB262.................
TB263.................
TB264.................
TB265.................
TB266.................
TB267.................
TB269.................
TB270.................
TB271.................
TB272.................
TB273.................
TB276.................
TB277.................
TB278.................
TB279.................
TB280.................
TB281.................
TB282.................
TB283.................
TB284.................
TB285.................
TB286.................
TB287.................
TB288.................
TB289.................
TB290.................
TB291.................
TB292.................
TB293.................
TB294.................
TB295.................
TB296.................
TB297.................

T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T260
T262
T263
T264
T265
T266
T267
T269
T270
T271
T272
T273
T276
T277
T278
T279
T280
T281
T282
T283
T284
T285
T286
T287
T288
T289
T290
T291
T292
T293
T294
T295
T296
T297

Competitive
No.

Gates
No.

ACDELCO - Cont.
Timing Belts - Cont.
TB298.................
T298
TB299.................
T299
TB300.................
T300
TB301.................
T301
TB302.................
T302
TB303.................
T303
TB304.................
T304
TB305.................
T305
TB306.................
T306
TB307.................
T307
TB308.................
T308
TB309.................
T309
TB310.................
T310
TB311.................
T311
TB312.................
T312
TB313.................
T313
TB314.................
T314
TB315.................
T315
TB316.................
T316
TB317.................
T317
TB318.................
T318
TB319.................
T319
TB320.................
T320
TB321.................
T321
TB322.................
T322
TB323.................
T323
TB324.................
T324
TB326.................
T326
TB327.................
T327
TB329.................
T329
Timing Belt Tensioners
T41000...............
T41000
T41001...............
T41001
T41002...............
T41002
T41003...............
T41003
T41004...............
T41004
T41005...............
T41005
T41006...............
T41006
T41007...............
T41007
T41008...............
T41008
T41009...............
T41009
T41010...............
T41010
T41011...............
T41011
T41012...............
T41012
T41013...............
T41013
T41014...............
T41014
T41015...............
T41015
T41016...............
T41016
T41017...............
T41017
T41018...............
T41018
T41019...............
T41019
T41020...............
T41020
T41021...............
T41021
T41022...............
T41022
T41023...............
T41023
T41024...............
T41024
T41025...............
T41025
T41026...............
T41026
T41027...............
T41027
T41028...............
T41028
T41029...............
T41029
T41030...............
T41030
T41031...............
T41031
T41032...............
T41032
T41033...............
T41033
T41034...............
T41034
T41035...............
T41035
T41036...............
T41036
T41037...............
T41037
T41038...............
T41038
T41039...............
T41039
T41040...............
T41040
T41041...............
T41041
T41042...............
T41042

Competitive
No.

Gates
No.

ACDELCO - Cont.
Timing Belt Tensioners
- Cont.
T41043...............
T41043
T41044...............
T41044
T41045...............
T41045
T41046...............
T41046
T41047...............
T41047
T41048...............
T41048
T41049...............
T41049
T41050...............
T41050
T41051...............
T41051
T41052...............
T41052
T41053...............
T41053
T41054...............
T41054
T41055...............
T41055
T41056...............
T41056
T41057...............
T41057
T41058...............
T41058
T41059...............
T41059
T41060...............
T41060
T41061...............
T41061
T41062...............
T41062
T41063...............
T41063
T41064...............
T41064
T41065...............
T41065
T41066...............
T41066
T41067...............
T41067
T41068...............
T41068
T41069...............
T41069
T41070...............
T41070
T41071...............
T41071
T41072...............
T41072
T41073...............
T41073
T41074...............
T41074
T41075...............
T41075
T41076...............
T41076
T41077...............
T41077
T41078...............
T41078
T41079...............
T41079
T41080...............
T41080
T41081...............
T41081
T41083...............
T41083
T41084...............
T41084
T41085...............
T41085
T41087...............
T41087
T41088...............
T41088
T41089...............
T41089
T41090...............
T41090
T41091...............
T41091
T41092...............
T41092
T43001...............
T43001
T43002...............
T43002
T43003...............
T43003
T43004...............
T43004
T43005...............
T43005
T43006...............
T43006
T43007...............
T43007
T43008...............
T43008
T43010...............
T43010
Timing Belt Pulleys
T42001...............
T42001
T42002...............
T42002
T42003...............
T42003
T42004...............
T42004
T42005...............
T42005
T42006...............
T42006
T42007...............
T42007
T42008...............
T42008
T42009...............
T42009
T42010...............
T42010
T42011...............
T42011
T42012...............
T42012
T42013...............
T42013
T42014...............
T42014
T42015...............
T42015

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

ACDELCO - Cont.
Timing Belt Pulleys - Cont.
T42016...............
T42016
T42017...............
T42017
T42018...............
T42018
T42020...............
T42020
T42021...............
T42021
T42022...............
T42022
T42023...............
T42023
T42024...............
T42024
T42025...............
T42025
T42026...............
T42026
T42027...............
T42027
T42028...............
T42028
T42029...............
T42029
T42030...............
T42030
T42031...............
T42031
T42032...............
T42032
T42033...............
T42033
T42034...............
T42034
T42035...............
T42035
T42036...............
T42036
T42037...............
T42037
T42038...............
T42038
AQUA POWER
Timing Belts
1221 ...................
T032
ATLAS
Timing Belts
689900 ...............
T067
689901 ...............
T071
689902 ...............
T014
689903 ...............
T061
689904 ...............
T017
689905 ...............
T081
689906 ...............
T070
689907 ...............
T089
689908 ...............
T077
689909 ...............
T094
ATLAS (CANADA)
Timing Belts
TB1001...............
T121
TB1002...............
T127
TB1003...............
T128
TB1004...............
T101
TB1005...............
T125
TB1006...............
T126
TB1007...............
T130
TB1008...............
T129
TB1010...............
T114
TB1011...............
T300
TB1012...............
T299
TB1013...............
T091
TB1014...............
T092
TB1015...............
T117
TB1016...............
T119
TB1017...............
T292
TB1018...............
T134
TB1020...............
T136
TB1021...............
T137
TB1022...............
T138
TB1023...............
T139
TB1024...............
T140
TB1026...............
T141
TB1027...............
T123
TB1028...............
T090
TB1031...............
T113
TB1032...............
T132
TB1033...............
T142
TB1034...............
T143
TB1035...............
T144
TB1036...............
T145
TB1037...............
T146
TB1038...............
T147
TB1039...............
T148
TB1040...............
T149
TB1041...............
T150
TB1042...............
T151
TB1044...............
T102
TB1045...............
T103
TB1047...............
T124
TB1048...............
T154
TB1049...............
T155
TB1051...............
T157
TB1052...............
T158
TB1053...............
T159
TB1054...............
T160
TB1055...............
T161
TB1056...............
T162
TB1057...............
T153

Competitive
No.

Gates
No.

ATLAS (CANADA) - Cont.

Timing Belts - Cont.
TB1058...............
T163
TB1059...............
T164
TB1060...............
T165
TB1061...............
T166
TB1062...............
T169
TB1063...............
T167
TB1064...............
T168
TB6401...............
T014
TB6402...............
T013
TB6403...............
T037
TB6404...............
T017
TB6406...............
T018
TB6408...............
T020
TB6409...............
T039
TB6410...............
T032
TB6411...............
T041
TB6412...............
T062
TB6415...............
T028
TB6416...............
T064
TB6417...............
T065
TB6418...............
T061
TB6419...............
T073
TB6424...............
T069
TB6425...............
T070
TB6426...............
T068
TB6427...............
T071
TB6428...............
T067
TB6429...............
T076
TB6430...............
T075
TB6431...............
T078
TB6432...............
T077
TB6433...............
T043
TB6434...............
T074
TB6435...............
T081
TB6436...............
T088
TB6437...............
T087
TB6438...............
T093
TB6439...............
T094
TB6440...............
T104
TB6442...............
T100
TB6443...............
T084
TB6444...............
T099
TB6446...............
T082
TB6447...............
T083
TB6448...............
T095
TB6450...............
T176
TB6451...............
T089
TB6452...............
T118
TB6453...............
T079
TB6454...............
T122
AUTO VALUE
Timing Belts
R0100.................
T100
R0101.................
T101
R0102.................
T102
R0103.................
T103
R0104.................
T104
R013...................
T013
R014...................
T014
R017...................
T017
R018...................
T018
R020...................
T020
R028...................
T028
R032...................
T032
R036...................
T036
R037...................
T037
R039...................
T039
R041...................
T041
R042...................
T068
R043...................
T043
R061...................
T061
R062...................
T062
R063...................
T073
R064...................
T064
R065...................
T065
R067...................
T067
R069...................
T069
R070...................
T070
R071...................
T071
R073...................
T073
R074...................
T074
R075...................
T075
R076...................
T076
R077...................
T077
R078...................
T078
R079...................
T079
R081...................
T081
R084...................
T084
R087...................
T087
R088...................
T088

Competitive
No.

Gates
No.

AUTO VALUE - Cont.

Timing Belts - Cont.
R089...................
T089
R090...................
T090
R091...................
T091
R092...................
T092
R093...................
T093
R094...................
T094
R095...................
T095
R096...................
T096
R098...................
T098
R099...................
T099
AUTOZONE (See GOODYEAR)
AVON AUTO
Timing Belts
B0100.................
T100
B0101.................
T101
B0102.................
T102
B0103.................
T103
B0104.................
T104
B0114.................
T114
B0118.................
T162
B013...................
T013
B014...................
T014
B017...................
T017
B018...................
T018
B020...................
T020
B028...................
T028
B032...................
T032
B036...................
T036
B037...................
T037
B039...................
T039
B041...................
T041
B043...................
T043
B061...................
T061
B062...................
T062
B063...................
T073
B064...................
T064
B065...................
T065
B067...................
T067
B068...................
T068
B069...................
T069
B070...................
T070
B071...................
T071
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B079...................
T079
B081...................
T081
B082...................
T082
B083...................
T083
B084...................
T084
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B091...................
T091
B092...................
T092
B093...................
T093
B094...................
T094
B095...................
T095
B096...................
T096
B099...................
T099
BALKAMP
Timing Belts
9-013..................
T013
9-014..................
T014
9-017..................
T017
9-018..................
T018
9-020..................
T020
9-028..................
T028
9-032..................
T032
9-036..................
T036
9-037..................
T037
9-039..................
T039
9-041..................
T041
9-043..................
T043
9-061..................
T061
9-062..................
T062
9-063..................
T073
9-064..................
T064
9-065..................
T065
9-067..................
T067
9-068..................
T068
9-069..................
T069
9-070..................
T070
9-071..................
T071
9-073..................
T073

Competitive
No.

Gates
No.

BALKAMP - Cont.
Timing Belts - Cont.
9-074..................
T074
9-075..................
T075
9-076..................
T076
9-077..................
T077
9-078..................
T078
9-079..................
T079
9-081..................
T081
9-082..................
T082
9-083..................
T083
9-084..................
T084
9-087..................
T087
9-088..................
T088
9-089..................
T089
9-090..................
T090
9-091..................
T091
9-092..................
T092
9-093..................
T093
9-094..................
T094
9-095..................
T095
9-096..................
T096
9-098..................
T098
9-099..................
T099
9-100..................
T100
9-101..................
T101
BANDO
Timing Belts
100ZA19.............
T061
109ZA19.............
T088
111ZA19.............
T121
113ZA19.............
T065
118ZA19.............
T069
121ZA19.............
T017
124ZA25.............
T071
135ZA25.............
T043
142ZA25.............
T074
206AL050...........
T062
315AL075...........
T028
326AHL125 ........
T075
330AL075...........
T070
345AL075...........
T073
398AL075...........
T077
458AL075...........
T013
89ZA19...............
T095
94ZA19...............
T036
97ZA25...............
T067
99ZA15...............
T037
99ZA19...............
T039
BAP-GEON
Timing Belts
54-70301............
T062
54-70302............
T073
54-70303............
T064
54-70901............
T041
54-70902............
T028
54-70904............
T073
54-71501............
T070
54-72001............
T017
54-72100............
T065
54-76000............
T020
54-76300............
T069
54-76301............
T018
54-77801............
T014
54-77802............
T067
54-79800............
T013
BECK ARNLEY
Timing Belts
026-0018............
T028
026-0026............
T020
026-0034............
T020
026-0042............
T018
026-0067............
T036
026-0075............
T041
026-0083............
T013
026-0091............
T014
026-0109............
T032
026-0117............
T065
026-0125............
T068
026-0133............
T062
026-0158............
T064
026-0174............
T069
026-0175............
T070
026-0176............
T017
026-0177............
T043
026-0178............
T083
026-0179............
T073
026-0180............
T082
026-0182............
T088
026-0183............
T078

Competitive
No.

787
Gates
No.

BECK ARNLEY - Cont.

Timing Belts - Cont.
026-0184............
026-0185............
026-0186............
026-0187............
026-0188............
026-0189............
026-0190............
026-0191............
026-0192............
026-0193............
026-0194............
026-0195............
026-0196............
026-0197............
026-0198............
026-0199............
026-0201............
026-0202............
026-0205............
026-0206............
026-0207............
026-0208............
026-0209............
026-0210............
026-0212............
026-0213............
026-0215............
026-0216............
026-0217............
026-0218............
026-0219............
026-0220............
026-0221............
026-0222............
026-0223............
026-0224............
026-0225............
026-0226............
026-0228............
026-0229............
026-0230............
026-0231............
026-0232............
026-0233............
026-0234............
026-0235............
026-0236............
026-0237............
026-0238............
026-0239............
026-0240............
026-0242............
026-0243............
026-0244............
026-0245............
026-0246............
026-0247............
026-0248............
026-0249............
026-0250............
026-0251............
026-0252............
026-0253............
026-0255............
026-0256............
026-0258............
026-0259............
026-0260............
026-0261............
026-0262............
026-0263............
026-0264............
026-0265............
026-0266............
026-0267............
026-0268............
026-0269............
026-0270............
026-0271............
026-0272............
026-0273............
026-0274............
026-0275............
026-0276............
026-0277............
026-0278............
026-0279............
026-0280............
026-0281............
026-0282............
026-0283............
026-0284............

T077
T089
T090
T092
T091
T084
T074
T087
T079
T076
T075
T107
T093
T096
T106
T140
T196
T100
T097
T101
T095
T161
T160
T120
T300
T299
T158
T104
T112
T293
T119
T138
T071
T162
T113
T117
T149
T141
T122
T124
T128
T134
T129
T139
T146
T148
T292
T170
T143
T131
T144
T142
T135
T179
T147
T126
T136
T125
T164
T166
T165
T130
T121
T167
T043
T197
T137
T171
T177
T179
T103
T102
T157
T159
T151
T182
T184
T181
T155
T144
T178
T104
T150
T187
T180
T186
T176
T191
T174
T183
T154
T168

Changeover Listing - PowerGrip Timing System Products

788
Competitive
No.

Gates
No.

BECK ARNLEY - Cont.

Timing Belts - Cont.
026-0285............
026-0286............
026-0287............
026-0288............
026-0289............
026-0290............
026-0293............
026-0294............
026-0295............
026-0296............
026-0297............
026-0298............
026-0299............
026-0300............
026-0301............
026-0302............
026-0303............
026-0304............
026-0305............
026-0306............
026-0307............
026-0308............
026-0309............
026-0310............
026-0311............
026-0312............
026-0314............
026-0316............
026-0317............
026-0318............
026-0319............
026-0320............
026-0322............
026-0323............
026-0324............
026-0325............
026-0326............
026-0327............
026-0329............
026-0330............
026-0331............
026-0332............
026-0334............
026-0335............
026-0336............
026-0338............
026-0339............
026-0340............
026-0341............
026-0344............
026-0345............
026-1000............
026-1001............
026-1002............
026-1003............
026-1004............
026-1005............
026-1006............
026-1007............
026-1008............
026-1009............
026-1010............
026-1011............
026-1012............
026-1013............
026-1014............
026-1015............
026-1016............
026-1017............
026-1018............
026-1021............
026-1022............
026-1023............
026-1024............
026-1025............
026-1026............
026-1027............
026-1028............
026-1029............
026-1030............
026-1031............
026-1033............
026-1034............
026-1035............
026-1037............
026-1038............
026-1039............
026-1040............
026-1042............
026-1043............
026-1044............
026-1045............

T173
T172
T207
T152
T189
T188
T198
T208
T211
T201
T204
T218
T216
T203
T212
T193
T185
T221
T220
T194
T224
T226
T223
T227
T214
T209
T229
T230
T232
T217
T195
T234
T235
T252
T241
T236
T262
T228
T252
T281
T253
T247
T249
T263
T259
T120
T244
T243
T264
T271
T316
T158
T196
T161
T160
T199
T159
T254
T242
T262
T276
T272
T200
T266
T190
T240
T267
T215
T126
T257
T246
T287
T284
T286
T277
T278
T282
T279
T270
T205
T207
T297
T296
T302
T298
T288
T303
T308
T310
T309
T305
T311

Competitive
No.

Gates
No.

BECK ARNLEY - Cont.

Timing Belt Tensioners
LER80038 ..........
T41037
LER88893 ..........
T41041
024-0953............
T41055
024-0954............
T41042
024-0955............
T41057
024-0963............
T41079
024-0964............
T41045
024-0966............
T41043
024-0976............
T41035
024-0981............
T41058
024-0982............
T41088
024-0985............
T41080
024-0986............
T41081
024-0987............
T41083
024-0991............
T41012
024-0992............
T41017
024-1008............
T41062
024-1012............
T41005
024-1028............
T41069
024-1046............
T41061
024-1050............
T41064
024-1074............
T41059
024-1076............
T41011
024-1077............
T41003
024-1079............
T41076
024-1081............
T41067
024-1083............
T41073
024-1086............
T41074
024-1087............
T41066
024-1088............
T41025
024-1089............
T41029
024-1090............
T41056
024-1091............
T41060
024-1106............
T41026
024-1118............
T41075
024-1119............
T41015
024-1144............
T41013
024-1145............
T41014
024-1147............
T41052
024-1151............
T41018
024-1152............
T41053
024-1153............
T41016
024-1154............
T41020
024-1155............
T41021
024-1156............
T41030
024-1160............
T41044
024-1162............
T41031
024-1164............
T41051
024-1165............
T41034
024-1166............
T41009
024-1167............
T41033
024-1168............
T41039
024-1172............
T41072
024-1177............
T41078
024-1187............
T41071
024-1193............
T41048
024-1195............
T41063
024-1197............
T41027
024-1199............
T41023
024-1204............
T41065
024-1206............
T41054
Timing Belt Pulleys
024-1006............
T42025
024-1082............
T42028
024-1092............
T42011
024-1148............
T42009
024-1149............
T42010
024-1150............
T42001
024-1157............
T42013
024-1163............
T42005
024-1174............
T42008
024-1176............
T42030
024-1178............
T42031
024-1180............
T42021
024-1184............
T42020
024-1190............
T42029
024-1203............
T42012
BORG WARNER
Timing Belts
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB020.................
T020
TB028.................
T028
TB029.................
T104
TB032.................
T032
TB036.................
T036
TB037.................
T037
TB039.................
T039

Competitive
No.

Gates
No.

BORG WARNER - Cont.

Timing Belts - Cont.
TB041.................
TB042.................
TB043.................
TB061.................
TB062.................
TB063.................
TB064.................
TB065.................
TB067.................
TB068.................
TB069.................
TB070.................
TB071.................
TB073.................
TB074.................
TB075.................
TB076.................
TB077.................
TB078.................
TB079.................
TB081.................
TB082.................
TB083.................
TB084.................
TB087.................
TB088.................
TB089.................
TB090.................
TB091.................
TB092.................
TB093.................
TB094.................
TB095.................
TB096.................
TB098.................
TB099.................
TB100.................
TB101.................
TB102.................
TB103.................
TB104.................
TB106.................
TB107.................
TB110.................
TB112.................
TB113.................
TB114.................
TB115.................
TB116.................
TB117.................
TB118.................
TB119.................
TB121.................
TB122.................
TB123.................
TB124.................
TB125.................
TB126.................
TB127.................
TB128.................
TB129.................
TB130.................
TB131.................
TB132.................
TB133.................
TB134.................
TB135.................
TB136.................
TB137.................
TB138.................
TB139.................
TB140.................
TB141.................
TB142.................
TB143.................
TB144.................
TB145.................
TB146.................
TB147.................
TB148.................
TB153.................
TB154.................
TB155.................
TB157.................
TB158.................
TB159.................
TB160.................
TB161.................
TB162.................
TB163.................
TB164.................
TB165.................

T041
T068
T043
T061
T062
T073
T064
T065
T067
T068
T069
T070
T071
T073
T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T098
T099
T100
T101
T102
T103
T104
T106
T107
T196
T112
T113
T114
T299
T300
T117
T118
T119
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165

Competitive
No.

Gates
No.

BORG WARNER - Cont.

Timing Belts - Cont.
TB166.................
T166
TB167.................
T167
TB168.................
T168
TB169.................
T169
TB170.................
T170
TB171.................
T171
TB172.................
T172
TB177.................
T177
TB178.................
T178
TB179.................
T179
TB183.................
T183
TB184.................
T184
TB185.................
T185
TB186.................
T186
TB187.................
T187
TB191.................
T191
TB192.................
T192
TB194.................
T194
TB195.................
T195
TB199.................
T199
TB200.................
T200
TB201.................
T201
TB202.................
T248
TB204.................
T204
TB206.................
T206
TB208.................
T208
TB210.................
T210
TB214.................
T214
TB228.................
T228
TB233.................
T233
TB235.................
T235
TB236.................
T236
TB237.................
T237
T219...................
T219
BOSCH
Timing Belts
914416094 .........
T036
9144161055 .......
T062
9144161084 .......
T088
9144161092 .......
T073
9144161095 .......
T041
9144161113 .......
T065
9144161116 .......
T018
9144161118 .......
T069
9144161121 .......
T017
9144161122 .......
T013
9144161146 .......
T020
9144161148 .......
T068
9144165075 .......
T082
9144165119 .......
T083
9144165135 .......
T043
BRYCO
Timing Belts
B013...................
T013
B014...................
T014
B017...................
T017
B028...................
T028
B036...................
T036
B041...................
T041
B043...................
T043
B062...................
T062
B064...................
T064
B067...................
T067
B070...................
T070
B071...................
T071
B073...................
T073
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B079...................
T079
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B091...................
T091
B092...................
T092
B093...................
T093
B094...................
T094
B095...................
T095
B096...................
T096
B099...................
T099
B100...................
T100
B101...................
T101
B102...................
T102
B103...................
T103
B104...................
T104
B112...................
T112

Competitive
No.

Gates
No.

BRYCO - Cont.
Timing Belts - Cont.
B113...................
T113
B114...................
T114
B115...................
T299
B116...................
T300
B117...................
T117
B118...................
T118
B121...................
T121
B122...................
T122
B123...................
T123
B124...................
T124
B126...................
T126
B127...................
T127
B128...................
T128
B130...................
T130
B132...................
T132
B133...................
T292
B134...................
T134
B136...................
T136
B137...................
T137
B138...................
T138
B139...................
T139
B141...................
T141
B142...................
T142
B143...................
T143
B144...................
T144
B145...................
T145
B146...................
T146
B147...................
T147
B149...................
T149
B153...................
T153
B154...................
T154
B155...................
T155
B157...................
T157
B158...................
T158
B159...................
T159
B160...................
T160
B161...................
T161
B162...................
T162
B164...................
T164
B165...................
T165
B167...................
T167
B168...................
T168
B169...................
T169
B176...................
T176
B177...................
T177
B179...................
T179
B182...................
T182
B184...................
T184
B185...................
T185
B186...................
T186
B187...................
T187
B191...................
T191
B194...................
T194
B195...................
T195
B199...................
T199
B201...................
T201
B204...................
T204
B208...................
T208
B210...................
T210
B223...................
T223
B224...................
T224
B227...................
T227
B228...................
T228
B229...................
T229
B230...................
T230
B235...................
T235
B236...................
T236
B237...................
T237
B258...................
T258
T115...................
T299
54700 .................
T095
54742 .................
T075
54754 .................
T112
54755 .................
T176
54788 .................
T076
CARQUEST
Timing Belts
T013...................
T013
T014...................
T014
T096...................
T096
T097...................
T097
T098...................
T098
T099...................
T099
T100...................
T100
T101...................
T101
T102...................
T102
T103...................
T103
T104...................
T104
T106...................
T106
T107...................
T107

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

CARQUEST - Cont.
Timing Belts - Cont.
T112...................
T113...................
T114...................
T117...................
T118...................
T119...................
T120...................
T121...................
T122...................
T123...................
T124...................
T125...................
T126...................
T127...................
T128...................
T129...................
T130...................
T131...................
T132...................
T134...................
T135...................
T136...................
T137...................
T138...................
T139...................
T140...................
T141...................
T142...................
T143...................
T144...................
T145...................
T146...................
T147...................
T148...................
T149...................
T150...................
T151...................
T152...................
T153...................
T154...................
T155...................
T157...................
T158...................
T159...................
T160...................
T161...................
T162...................
T163...................
T164...................
T165...................
T166...................
T167...................
T168...................
T169...................
T170...................
T171...................
T172...................
T173...................
T174...................
T176...................
T177...................
T178...................
T179...................
T180...................
T181...................
T182...................
T183...................
T184...................
T185...................
T186...................
T187...................
T188...................
T189...................
T190...................
T191...................
T192...................
T193...................
T194...................
T195...................
T196...................
T197...................
T198...................
T199...................
T200...................
T201...................
T203...................
T204...................
T205...................
T206...................
T207...................
T208...................
T209...................

T112
T113
T114
T117
T118
T119
T120
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T203
T204
T205
T206
T207
T208
T209

Competitive
No.

Gates
No.

CARQUEST - Cont.
Timing Belts - Cont.
T210...................
T211...................
T212...................
T213...................
T214...................
T215...................
T216...................
T217...................
T218...................
T219...................
T220...................
T221...................
T222...................
T223...................
T224...................
T225...................
T226...................
T227...................
T228...................
T229...................
T230...................
T232...................
T233...................
T234...................
T235...................
T236...................
T237...................
T239...................
T240...................
T241...................
T242...................
T243...................
T244...................
T245...................
T246...................
T247...................
T248...................
T249...................
T251...................
T252...................
T253...................
T254...................
T255...................
T256...................
T257...................
T258...................
T259...................
T260...................
T262...................
T263...................
T264...................
T265...................
T266...................
T267...................
T269...................
T271...................
T272...................
T273...................
T276...................
T277...................
T278...................
T279...................
T280...................
T281...................
T282...................
T283...................
T284...................
T285...................
T286...................
T287...................
T288...................
T289...................
T290...................
T291...................
T292...................
T293...................
T294...................
T295...................
T296...................
T297...................
T298...................
T299...................
T300...................
T301...................
T302...................
T303...................
T304...................
T305...................
T306...................

T210
T211
T212
T213
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T260
T262
T263
T264
T265
T266
T267
T269
T271
T272
T273
T276
T277
T278
T279
T280
T281
T282
T283
T284
T285
T286
T287
T288
T289
T290
T291
T292
T293
T294
T295
T296
T297
T298
T299
T300
T301
T302
T303
T304
T305
T306

Competitive
No.

Gates
No.

CLEVELAND MOTIVE
Timing Belts
B013...................
T013
B014...................
T014
B037...................
T037
B043...................
T043
B068...................
T068
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B081...................
T081
CLEVITE ENGINE PARTS
Timing Belts
TB-100 ...............
T100
TB-101 ...............
T101
TB-102 ...............
T102
TB-103 ...............
T103
TB-104 ...............
T104
TB-106 ...............
T106
TB-107 ...............
T107
TB-112 ...............
T112
TB-113 ...............
T113
TB-114 ...............
T114
TB-117 ...............
T117
TB-118 ...............
T118
TB-119 ...............
T119
TB-120 ...............
T120
TB-121 ...............
T121
TB-122 ...............
T122
TB-123 ...............
T123
TB-124 ...............
T124
TB-125 ...............
T125
TB-126 ...............
T126
TB-127 ...............
T127
TB-128 ...............
T128
TB-129 ...............
T129
TB-13 .................
T013
TB-130 ...............
T130
TB-131 ...............
T131
TB-132 ...............
T132
TB-134 ...............
T134
TB-135 ...............
T135
TB-136 ...............
T136
TB-137 ...............
T137
TB-138 ...............
T138
TB-139 ...............
T139
TB-14 .................
T014
TB-140 ...............
T140
TB-141 ...............
T141
TB-142 ...............
T142
TB-143 ...............
T143
TB-144 ...............
T144
TB-145 ...............
T145
TB-146 ...............
T146
TB-147 ...............
T147
TB-148 ...............
T148
TB-149 ...............
T149
TB-150 ...............
T150
TB-151 ...............
T151
TB-152 ...............
T152
TB-153 ...............
T153
TB-154 ...............
T154
TB-155 ...............
T155
TB-157 ...............
T157
TB-158 ...............
T158
TB-159 ...............
T159
TB-160 ...............
T160
TB-161 ...............
T161
TB-162 ...............
T162
TB-163 ...............
T163
TB-164 ...............
T164
TB-165 ...............
T165
TB-166 ...............
T166
TB-167 ...............
T167
TB-168 ...............
T168
TB-169 ...............
T169
TB-17 .................
T017
TB-170 ...............
T170
TB-171 ...............
T171
TB-172 ...............
T172
TB-173 ...............
T173
TB-174 ...............
T174
TB-176 ...............
T176
TB-177 ...............
T177
TB-178 ...............
T178
TB-179 ...............
T179
TB-18 .................
T018
TB-180 ...............
T180
TB-181 ...............
T181
TB-182 ...............
T182
TB-183 ...............
T183

Competitive
No.

Gates
No.

CLEVITE ENGINE PARTS

- Cont.
Timing Belts - Cont.
TB-184 ...............
TB-185 ...............
TB-186 ...............
TB-187 ...............
TB-188 ...............
TB-189 ...............
TB-190 ...............
TB-191 ...............
TB-192 ...............
TB-193 ...............
TB-194 ...............
TB-195 ...............
TB-196 ...............
TB-197 ...............
TB-198 ...............
TB-199 ...............
TB-20 .................
TB-200 ...............
TB-201 ...............
TB-203 ...............
TB-204 ...............
TB-205 ...............
TB-206 ...............
TB-208 ...............
TB-209 ...............
TB-210 ...............
TB-211 ...............
TB-212 ...............
TB-214 ...............
TB-215 ...............
TB-216 ...............
TB-217 ...............
TB-218 ...............
TB-219 ...............
TB-220 ...............
TB-221 ...............
TB-222 ...............
TB-223 ...............
TB-224 ...............
TB-226 ...............
TB-227 ...............
TB-228 ...............
TB-229 ...............
TB-230 ...............
TB-232 ...............
TB-233 ...............
TB-234 ...............
TB-235 ...............
TB-236 ...............
TB-237 ...............
TB-239 ...............
TB-240 ...............
TB-241 ...............
TB-242 ...............
TB-243 ...............
TB-244 ...............
TB-245 ...............
TB-246 ...............
TB-247 ...............
TB-248 ...............
TB-249 ...............
TB-251 ...............
TB-252 ...............
TB-253 ...............
TB-254 ...............
TB-255 ...............
TB-256 ...............
TB-257 ...............
TB-258 ...............
TB-259 ...............
TB-262 ...............
TB-263 ...............
TB-264 ...............
TB-265 ...............
TB-266 ...............
TB-267 ...............
TB-271 ...............
TB-273 ...............
TB-276 ...............
TB-277 ...............
TB-278 ...............
TB-279 ...............
TB-28 .................
TB-281 ...............
TB-282 ...............
TB-284 ...............
TB-285 ...............
TB-286 ...............
TB-287 ...............
TB-288 ...............
TB-291 ...............

T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T020
T200
T201
T203
T204
T205
T206
T208
T209
T210
T211
T212
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T262
T263
T264
T265
T266
T267
T271
T273
T276
T277
T278
T279
T028
T281
T282
T284
T285
T286
T287
T288
T291

Competitive
No.

789
Gates
No.

CLEVITE ENGINE PARTS

- Cont.
Timing Belts - Cont.
TB-292 ...............
T292
TB-296 ...............
T296
TB-297 ...............
T297
TB-298 ...............
T298
TB-300 ...............
T300
TB-302 ...............
T302
TB-303 ...............
T303
TB-308 ...............
T308
TB-309 ...............
T309
TB-310 ...............
T310
TB-32 .................
T032
TB-36 .................
T036
TB-37 .................
T037
TB-39 .................
T039
TB-41 .................
T041
TB-43 .................
T043
TB-61 .................
T061
TB-62 .................
T062
TB-64 .................
T064
TB-65 .................
T065
TB-67 .................
T067
TB-69 .................
T069
TB-70 .................
T070
TB-71 .................
T071
TB-73 .................
T073
TB-74 .................
T074
TB-75 .................
T075
TB-76 .................
T076
TB-77 .................
T077
TB-78 .................
T078
TB-79 .................
T079
TB-81 .................
T081
TB-82 .................
T082
TB-83 .................
T083
TB-84 .................
T084
TB-87 .................
T087
TB-88 .................
T088
TB-89 .................
T089
TB-90 .................
T090
TB-91 .................
T091
TB-92 .................
T092
TB-93 .................
T093
TB-94 .................
T094
TB-95 .................
T095
TB-96 .................
T096
TB-97 .................
T097
TB-98 .................
T098
TB-99 .................
T099
CLOYES GEAR
Timing Belts
B013...................
T013
B014...................
T014
B017...................
T017
B018...................
T018
B020...................
T020
B028...................
T028
B032...................
T032
B036...................
T036
B037...................
T037
B039...................
T039
B041...................
T041
B043...................
T043
B061...................
T061
B062...................
T062
B063...................
T073
B064...................
T064
B065...................
T065
B067...................
T067
B068...................
T068
B069...................
T069
B070...................
T070
B071...................
T071
B073...................
T073
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B079...................
T079
B081...................
T081
B082...................
T082
B083...................
T083
B084...................
T084
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B091...................
T091
B092...................
T092

Changeover Listing - PowerGrip Timing System Products

790
Competitive
No.

Gates
No.

CLOYES GEAR - Cont.

Timing Belts - Cont.
B093...................
B094...................
B095...................
B096...................
B097...................
B098...................
B099...................
B100...................
B101...................
B102...................
B103...................
B104...................
B106...................
B107...................
B108...................
B112...................
B113...................
B114...................
B115...................
B116...................
B117...................
B118...................
B119...................
B121...................
B122...................
B123...................
B124...................
B125...................
B126...................
B127...................
B128...................
B129...................
B130...................
B131...................
B132...................
B133...................
B134...................
B135...................
B136...................
B137...................
B138...................
B139...................
B140...................
B141...................
B142...................
B143...................
B144...................
B145...................
B146...................
B147...................
B148...................
B149...................
B150...................
B151...................
B152...................
B153...................
B154...................
B155...................
B157...................
B158...................
B159...................
B160...................
B161...................
B162...................
B163...................
B164...................
B165...................
B166...................
B167...................
B168...................
B169...................
B170...................
B171...................
B172...................
B174...................
B176...................
B177...................
B178...................
B179...................
B180...................
B181...................
B182...................
B183...................
B184...................
B185...................
B186...................
B187...................
B189...................
B190...................
B191...................
B192...................
B193...................

T093
T094
T095
T096
T097
T098
T099
T100
T101
T102
T103
T104
T106
T107
T293
T112
T113
T114
T299
T300
T117
T118
T119
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T189
T190
T191
T192
T193

Competitive
No.

Gates
No.

CLOYES GEAR - Cont.

Timing Belts - Cont.
B194...................
B195...................
B196...................
B199...................
B200...................
B201...................
B203...................
B204...................
B205...................
B206...................
B208...................
B209...................
B210...................
B211...................
B212...................
B214...................
B216...................
B219...................
B220...................
B221...................
B223...................
B224...................
B225...................
B226...................
B227...................
B228...................
B229...................
B230...................
B232...................
B233...................
B234...................
B235...................
B236...................
B237...................
B239...................
B240...................
B241...................
B243...................
B244...................
B245...................
B246...................
B247...................
B248...................
B249...................
B251...................
B252...................
B253...................
B254...................
B255...................
B256...................
B257...................
B258...................
B259...................
B262...................
B263...................
B264...................
B265...................
B266...................
B267...................
B271...................
B272...................
B273...................
B276...................
B277...................
B278...................
B279...................
B280...................
B281...................
B282...................
B283...................
B284...................
B285...................
B286...................
B287...................
B288...................
B289...................
B291...................
B292...................
B294...................
B295...................
B296...................
B297...................
B298...................
B299...................
B300...................
B301...................
B302...................
B303...................
B304...................
B305...................
B308...................

T194
T195
T196
T199
T200
T201
T203
T204
T205
T206
T208
T209
T210
T211
T212
T214
T216
T219
T220
T221
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T262
T263
T264
T265
T266
T267
T271
T272
T273
T276
T277
T278
T279
T280
T281
T282
T283
T284
T285
T286
T287
T288
T289
T291
T292
T294
T295
T296
T297
T298
T299
T300
T301
T302
T303
T304
T305
T308

Competitive
No.

Gates
No.

CLOYES GEAR - Cont.

Timing Belt Tensioners
9-5011................
T41005
9-5032................
T41055
9-5033................
T41042
9-5038................
T41057
9-5066................
T41066
9-5075................
T41058
9-5089................
T41080
9-5091................
T41000
9-5096................
T41069
9-5097................
T41068
9-5104................
T41070
9-5105................
T41043
9-5106................
T41053
9-5107................
T41050
9-5108................
T41049
9-5114................
T41006
9-5117................
T41077
9-5124................
T41059
9-5126................
T41017
9-5135................
T41074
9-5148................
T41079
9-5154................
T41061
9-5155................
T41062
9-5156................
T41081
9-5160................
T41056
9-5161................
T41045
9-5162................
T41011
9-5163................
T41012
9-5164................
T41030
9-5165................
T41035
9-5166................
T41029
9-5182................
T41064
9-5183................
T41026
9-5192................
T41001
9-5194................
T41046
9-5195................
T41048
9-5196................
T41044
9-5197................
T41047
9-5198................
T41015
9-5202................
T41019
9-5203................
T41014
9-5204................
T41013
9-5206................
T41076
9-5209................
T41073
9-5213................
T41031
9-5221................
T41010
9-5224................
T41051
9-5226................
T41020
9-5262................
T41016
9-5263................
T41025
9-5269................
T41003
9-5270................
T41004
9-5271................
T41039
9-5272................
T41052
9-5275................
T41060
9-5282................
T41065
9-5292................
T41036
9-5293................
T41033
9-5299................
T41071
9-5301................
T41067
9-5342................
T41072
9-5343................
T41009
9-5350................
T41007
9-5354................
T41018
9-5357................
T41002
9-5390................
T41008
9-9228................
T41021
Timing Belt Pulleys
S675...................
T42022
9-5110................
T42026
9-5118................
T42027
9-5184................
T42001
9-5207................
T42028
9-5214................
T42005
9-5215................
T42003
9-5216................
T42011
9-5222................
T42006
9-5223................
T42007
9-5225................
T42017
9-5244................
T42020
9-5283................
T42021
9-5300................
T42029
9-5302................
T42025
9-5303................
T42030
9-5325................
T42010
9-5326................
T42009
CONTINENTAL
Timing Belts
6585901 .............
T065
6585902 .............
T017

Competitive
No.

Gates
No.

CONTINENTAL - Cont.
Timing Belts - Cont.
6585910 .............
T013
6585911 .............
T082
6585912 .............
T083
6585913 .............
T032
6585914 .............
T043
6585916 .............
T018
6585918 .............
T020
6585921 .............
T068
6585924 .............
T078
6585929 .............
T064
6585933 .............
T062
6585934 .............
T073
6585935 .............
T077
6585939 .............
T028
6585943 .............
T041
6585945 .............
T069
6585949 .............
T070
6589089 .............
T131
6589092 .............
T084
6589095 .............
T107
6589100 .............
T081
6589103 .............
T106
6598500 .............
T062
6598506 .............
T028
6598512 .............
T073
6598513 .............
T041
6598519 .............
T077
6598521 .............
T088
6598523 .............
T069
6598530 .............
T087
6598534 .............
T075
6598550 .............
T094
6598551 .............
T293
6598554 .............
T196
CONTITECH
Timing Belts
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB032.................
T032
TB036.................
T036
TB041.................
T041
TB043.................
T043
TB061.................
T061
TB063.................
T073
TB064.................
T064
TB065.................
T065
TB068.................
T068
TB069.................
T069
TB070.................
T070
TB074.................
T074
TB075.................
T075
TB076.................
T076
TB077.................
T077
TB078.................
T078
TB079.................
T079
TB081.................
T081
TB082.................
T082
TB083.................
T083
TB084.................
T084
TB087.................
T087
TB088.................
T088
TB089.................
T089
TB090.................
T090
TB091.................
T091
TB092.................
T092
TB093.................
T093
TB094.................
T094
TB095.................
T095
TB096.................
T096
TB097.................
T097
TB098.................
T098
TB099.................
T099
TB100.................
T100
TB101.................
T101
TB102.................
T102
TB103.................
T103
TB104.................
T104
TB106.................
T106
TB107.................
T107
TB108.................
T293
TB110.................
T196
TB112.................
T112
TB113.................
T113
TB115.................
T299
TB116.................
T300
TB117.................
T117
TB118.................
T118
TB119.................
T119
TB121.................
T121

Competitive
No.

Gates
No.

CONTITECH - Cont.
Timing Belts - Cont.
TB122.................
TB123.................
TB124.................
TB125.................
TB126.................
TB127.................
TB128.................
TB129.................
TB130.................
TB131.................
TB133.................
TB134.................
TB135.................
TB136.................
TB137.................
TB138.................
TB139.................
TB140.................
TB141.................
TB142.................
TB143.................
TB144.................
TB145.................
TB146.................
TB147.................
TB148.................
TB150.................
TB151.................
TB152.................
TB154.................
TB155.................
TB157.................
TB158.................
TB159.................
TB160.................
TB162.................
TB163.................
TB164.................
TB165.................
TB166.................
TB167.................
TB168.................
TB169.................
TB170.................
TB171.................
TB172.................
TB173.................
TB174.................
TB176.................
TB177.................
TB178.................
TB179.................
TB180.................
TB181.................
TB182.................
TB183.................
TB184.................
TB185.................
TB186.................
TB187.................
TB188.................
TB189.................
TB190.................
TB191.................
TB193.................
TB195.................
TB196.................
TB197.................
TB198.................
TB199.................
TB200.................
TB201.................
TB203.................
TB204.................
TB205.................
TB208.................
TB209.................
TB210.................
TB211.................
TB212.................
TB213.................
TB214.................
TB215.................
TB216.................
TB217.................
TB218.................
TB220.................
TB221.................
TB222.................
TB224.................
TB225.................
TB227.................

T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T150
T151
T152
T154
T155
T157
T158
T159
T160
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T193
T195
T196
T197
T198
T199
T200
T201
T203
T204
T205
T208
T209
T210
T211
T212
T213
T214
T215
T216
T217
T218
T220
T221
T222
T224
T225
T227

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

CONTITECH - Cont.
Timing Belts - Cont.
TB228.................
T228
TB229.................
T229
TB230.................
T230
TB232.................
T232
TB233.................
T233
TB235.................
T235
TB236.................
T236
TB239.................
T239
TB240.................
T240
TB241.................
T241
TB252.................
T252
CY-LENT
Timing Belts
C013...................
T013
C014...................
T014
C017...................
T017
C018...................
T018
C020...................
T020
C028...................
T028
C032...................
T032
C037...................
T037
C039...................
T039
C041...................
T041
C043...................
T043
C061...................
T061
C062...................
T062
C063...................
T073
C064...................
T064
C065...................
T065
C067...................
T067
C069...................
T069
C070...................
T070
C071...................
T071
C073...................
T073
C075...................
T075
C076...................
T076
C077...................
T077
C078...................
T078
C081...................
T081
DAYCO
Timing Belts
A206L050...........
T062
A234L075...........
T073
A315L075...........
T028
A356L075...........
T041
A371L059...........
T037
A375L075...........
T061
A450L075...........
T064
A453L075...........
T017
A457L075...........
T013
A484L088...........
T014
A547L075...........
T020
94011 .................
T092
94075 .................
T070
94078 .................
T203
94080 .................
T203
94098 .................
T089
94100 .................
T090
94123 .................
T117
94133 .................
T128
94165 .................
T146
94169 .................
T148
94185 .................
T163
94266 .................
T091
94283 .................
T124
94284 .................
T185
94293 .................
T165
94294 .................
T179
94340 .................
T155
94341 .................
T139
94350 .................
T167
94351 .................
T168
94430 .................
T155
95013 .................
T013
95014 .................
T014
95017 .................
T017
95018 .................
T018
95020 .................
T020
95028 .................
T028
95032 .................
T032
95036 .................
T036
95037 .................
T037
95039 .................
T039
95041 .................
T041
95042 .................
T068
95043 .................
T043
95061 .................
T061
95062 .................
T062
95063 .................
T073

Competitive
No.

Gates
No.

DAYCO - Cont.
Timing Belts - Cont.
95064 .................
95065 .................
95067 .................
95068 .................
95069 .................
95070 .................
95071 .................
95073 .................
95074 .................
95075 .................
95076 .................
95077 .................
95078 .................
95079 .................
95081 .................
95082 .................
95083 .................
95084 .................
95087 .................
95088 .................
95089 .................
95090 .................
95091 .................
95092 .................
95093 .................
95094 .................
95095 .................
95096 .................
95097 .................
95098 .................
95099 .................
95100 .................
95101 .................
95102 .................
95103 .................
95104 .................
95106 .................
95107 .................
95108 .................
95110 .................
95112 .................
95113 .................
95114 .................
95115 .................
95116 .................
95117 .................
95118 .................
95119 .................
95120 .................
95121 .................
95122 .................
95123 .................
95124 .................
95125 .................
95126 .................
95127 .................
95128 .................
95129 .................
95130 .................
95131 .................
95132 .................
95133 .................
95134 .................
95135 .................
95136 .................
95137 .................
95138 .................
95139 .................
95140 .................
95141 .................
95142 .................
95143 .................
95144 .................
95145 .................
95146 .................
95147 .................
95148 .................
95150 .................
95151 .................
95152 .................
95153 .................
95154 .................
95155 .................
95157 .................
95158 .................
95159 .................
95160 .................
95161 .................
95162 .................
95163 .................
95164 .................
95165 .................

T064
T065
T067
T068
T069
T070
T071
T073
T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T097
T098
T099
T100
T101
T102
T103
T104
T106
T107
T293
T196
T112
T113
T114
T299
T300
T117
T118
T119
T120
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165

Competitive
No.

Gates
No.

DAYCO - Cont.
Timing Belts - Cont.
95166 .................
95167 .................
95168 .................
95169 .................
95170 .................
95171 .................
95172 .................
95173 .................
95174 .................
95176 .................
95177 .................
95178 .................
95179 .................
95180 .................
95181 .................
95182 .................
95183 .................
95184 .................
95185 .................
95186 .................
95187 .................
95188 .................
95190 .................
95191 .................
95192 .................
95193 .................
95194 .................
95195 .................
95196 .................
95197 .................
95198 .................
95199 .................
95200 .................
95201 .................
95202 .................
95203 .................
95204 .................
95205 .................
95206 .................
95207 .................
95208 .................
95210 .................
95211 .................
95212 .................
95214 .................
95215 .................
95216 .................
95217 .................
95218 .................
95219 .................
95220 .................
95221 .................
95223 .................
95224 .................
95225 .................
95226 .................
95227 .................
95228 .................
95229 .................
95230 .................
95232 .................
95233 .................
95234 .................
95235 .................
95236 .................
95237 .................
95240 .................
95241 .................
95244 .................
95245 .................
95246 .................
95247 .................
95248 .................
95249 .................
95251 .................
95252 .................
95253 .................
95254 .................
95255 .................
95257 .................
95258 .................
95259 .................
95262 .................
95263 .................
95264 .................
95265 .................
95266 .................
95269 .................
95271 .................
95272 .................
95273 .................
95276 .................

T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T248
T203
T204
T205
T206
T207
T208
T210
T211
T212
T214
T215
T216
T217
T218
T219
T220
T221
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T240
T241
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T257
T258
T259
T262
T263
T264
T265
T266
T269
T271
T272
T273
T276

Competitive
No.

Gates
No.

Competitive
No.

791
Gates
No.

DAYCO - Cont.
Timing Belts - Cont.

DURKEE-ATWOOD - Cont.
Timing Belts - Cont.

95277 .................
T277
95278 .................
T278
95281 .................
T281
95283 .................
T283
95284 .................
T284
95286 .................
T286
95287 .................
T287
95288 .................
T288
95289 .................
T289
95291 .................
T291
95292 .................
T292
95293 .................
T293
95294 .................
T294
95295 .................
T295
95296 .................
T296
95298 .................
T298
95299 .................
T299
95300 .................
T300
95302 .................
T302
95303 .................
T303
95304 .................
T304
95308 .................
T308
95311 .................
T311
DAYCO EUROPE
Timing Belts
19084 .................
T028
19113 .................
T065
19116 .................
T018
19121 .................
T017
19122 .................
T013
19123 .................
T032
19146 .................
T020
DURKEE-ATWOOD
Timing Belts
24-436PD...........
T018
24-457PD...........
T017
24-542PD...........
T020
28-457PD...........
T013
28-487PD...........
T014
88013 .................
T013
88014 .................
T014
88017 .................
T017
88018 .................
T018
88020 .................
T020
88028 .................
T028
88032 .................
T032
88037 .................
T037
88039 .................
T039
88041 .................
T041
88042 .................
T068
88043 .................
T043
88046 .................
T013
88047 .................
T014
88050 .................
T018
88052 .................
T020
88057 .................
T037
88058 .................
T039
88060 .................
T017
88061 .................
T061
88062 .................
T062
88063 .................
T073
88064 .................
T064
88065 .................
T065
88067 .................
T067
88069 .................
T069
88070 .................
T070
88071 .................
T071
88074 .................
T074
88075 .................
T075
88076 .................
T076
88077 .................
T077
88078 .................
T078
88079 .................
T079
88081 .................
T081
88082 .................
T082
88083 .................
T083
88084 .................
T084
88087 .................
T087
88088 .................
T088
88089 .................
T089
88090 .................
T090
88091 .................
T091
88092 .................
T092
88093 .................
T093
88094 .................
T094
88095 .................
T095
88099 .................
T099
88100 .................
T100
88101 .................
T101

88102 .................
T102
88104 .................
T104
88106 .................
T106
88107 .................
T107
88112 .................
T112
88113 .................
T113
88114 .................
T114
88115 .................
T299
88116 .................
T300
88117 .................
T117
88118 .................
T118
88121 .................
T121
88122 .................
T122
88124 .................
T124
88125 .................
T125
88126 .................
T126
88127 .................
T127
88130 .................
T130
88131 .................
T131
88132 .................
T132
88133 .................
T292
88134 .................
T134
88136 .................
T136
88138 .................
T138
88141 .................
T141
88143 .................
T143
88144 .................
T144
88146 .................
T146
88153 .................
T153
88157 .................
T157
88158 .................
T158
88159 .................
T159
88160 .................
T160
88161 .................
T161
88162 .................
T162
88163 .................
T163
88165 .................
T165
88170 .................
T170
DYNAFLEX (See DAYCO)
DYNAGEAR
Timing Belts
B013...................
T013
B014...................
T014
B017...................
T017
B018...................
T018
B020...................
T020
B028...................
T028
B032...................
T032
B037...................
T037
B039...................
T039
B041...................
T041
B043...................
T043
B061...................
T061
B062...................
T062
B063...................
T073
B064...................
T064
B065...................
T065
B067...................
T067
B068...................
T068
B069...................
T069
B070...................
T070
B071...................
T071
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B081...................
T081
B087...................
T087
B088...................
T088
B093...................
T093
B094...................
T094
B095...................
T095
B099...................
T099
B104...................
T104
B112...................
T112
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB020.................
T020
TB028.................
T028
TB029.................
T104
TB032.................
T032
TB036.................
T036
TB037.................
T037
TB039.................
T039
TB041.................
T041
TB043.................
T043
TB061.................
T061

Changeover Listing - PowerGrip Timing System Products

792
Competitive
No.

Gates
No.

DYNAGEAR - Cont.
Timing Belts - Cont.
TB062.................
TB063.................
TB064.................
TB065.................
TB067.................
TB068.................
TB069.................
TB070.................
TB071.................
TB073.................
TB074.................
TB075.................
TB076.................
TB077.................
TB078.................
TB079.................
TB081.................
TB082.................
TB083.................
TB084.................
TB087.................
TB088.................
TB089.................
TB090.................
TB091.................
TB092.................
TB093.................
TB094.................
TB095.................
TB096.................
TB098.................
TB099.................
TB100.................
TB101.................
TB102.................
TB103.................
TB104.................
TB106.................
TB107.................
TB108.................
TB110.................
TB112.................
TB113.................
TB114.................
TB115.................
TB116.................
TB117.................
TB118.................
TB119.................
TB121.................
TB122.................
TB123.................
TB124.................
TB125.................
TB126.................
TB127.................
TB128.................
TB129.................
TB130.................
TB131.................
TB132.................
TB133.................
TB134.................
TB135.................
TB136.................
TB137.................
TB138.................
TB139.................
TB140.................
TB141.................
TB142.................
TB143.................
TB144.................
TB145.................
TB146.................
TB147.................
TB148.................
TB149.................
TB150.................
TB151.................
TB152.................
TB153.................
TB154.................
TB155.................
TB157.................
TB158.................
TB159.................
TB160.................
TB161.................
TB162.................
TB163.................
TB164.................

T062
T073
T064
T065
T067
T068
T069
T070
T071
T073
T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T098
T099
T100
T101
T102
T103
T104
T106
T107
T293
T196
T112
T113
T114
T299
T300
T117
T118
T119
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164

Competitive
No.

Gates
No.

DYNAGEAR - Cont.
Timing Belts - Cont.
TB165.................
T165
TB166.................
T166
TB167.................
T167
TB168.................
T168
TB169.................
T169
Timing Belt Tensioners
7206 ...................
T41076
7209 ...................
T41073
9011 ...................
T41005
9032 ...................
T41055
9033 ...................
T41042
9038 ...................
T41057
9066 ...................
T41066
9075 ...................
T41058
9089 ...................
T41080
9091 ...................
T41000
9096 ...................
T41069
9097 ...................
T41068
9104 ...................
T41070
9105 ...................
T41043
9106 ...................
T41053
9107 ...................
T41050
9108 ...................
T41049
9114 ...................
T41006
9117 ...................
T41077
9124 ...................
T41059
9126 ...................
T41017
9135 ...................
T41074
9148 ...................
T41079
9154 ...................
T41061
9155 ...................
T41062
9156 ...................
T41081
9160 ...................
T41056
9161 ...................
T41045
9162 ...................
T41011
9163 ...................
T41012
9164 ...................
T41030
9165 ...................
T41035
9166 ...................
T41029
9182 ...................
T41064
9183 ...................
T41026
9192 ...................
T41001
9194 ...................
T41046
9195 ...................
T41048
9196 ...................
T41044
9197 ...................
T41047
9198 ...................
T41015
9202 ...................
T41019
9203 ...................
T41014
9204 ...................
T41013
9213 ...................
T41031
9221 ...................
T41010
9224 ...................
T41051
9226 ...................
T41020
9262 ...................
T41016
9263 ...................
T41025
9268 ...................
T41021
9269 ...................
T41003
9270 ...................
T41004
9271 ...................
T41039
9272 ...................
T41052
9275 ...................
T41060
9276 ...................
T41027
9282 ...................
T41065
9292 ...................
T41036
9293 ...................
T41033
9299 ...................
T41071
9301 ...................
T41067
9343 ...................
T41009
9900 ...................
T41007
9903 ...................
T41018
9904 ...................
T41072
Timing Belt Pulleys
S675...................
T42022
7184 ...................
T42001
7207 ...................
T42028
7214 ...................
T42005
7215 ...................
T42003
7216 ...................
T42011
7222 ...................
T42006
7223 ...................
T42007
7227 ...................
T42018
7244 ...................
T42020
7274 ...................
T42017
7283 ...................
T42021
7300 ...................
T42029
7302 ...................
T42025
7303 ...................
T42030
9110 ...................
T42026
9118 ...................
T42027

Competitive
No.

Gates
No.

DYNAGEAR - Cont.
Timing Belt Pulleys - Cont.
9325 ...................
T42010
9326 ...................
T42009
ELGIN MACH.
Timing Belts
LB-013................
T013
LB-014................
T014
LB-017................
T017
LB-018................
T018
LB-020................
T020
LB-028................
T028
LB-032................
T032
LB-036................
T036
LB-037................
T037
LB-039................
T039
LB-041................
T041
LB-043................
T043
LB-061................
T061
LB-062................
T062
LB-063................
T073
LB-064................
T064
LB-065................
T065
LB-067................
T067
LB-068................
T068
LB-069................
T069
LB-070................
T070
LB-071................
T071
LB-073................
T073
LB-074................
T074
LB-075................
T075
LB-076................
T076
LB-077................
T077
LB-078................
T078
LB-081................
T081
LB-088................
T088
LB-093................
T093
FEDERAL MOGUL
Timing Belts
LB013.................
T013
LB014.................
T014
LB020.................
T020
LB028.................
T028
LB032.................
T032
LB036.................
T036
LB037.................
T037
LB039.................
T039
LB041.................
T041
LB043.................
T043
LB061.................
T061
LB062.................
T062
LB064.................
T064
LB065.................
T065
LB067.................
T067
LB069.................
T069
LB070.................
T070
LB071.................
T071
LB073.................
T073
LB074.................
T074
LB075.................
T075
LB076.................
T076
LB077.................
T077
LB078.................
T078
LB081.................
T081
LB082.................
T082
LB083.................
T083
LB087.................
T087
LB088.................
T088
LB089.................
T089
LB090.................
T090
LB093.................
T093
LB094.................
T094
LB095.................
T095
LB099.................
T099
LB101.................
T101
LB102.................
T102
LB103.................
T103
LB104.................
T104
LB107.................
T107
LB108.................
T293
LB110.................
T196
LB112.................
T112
LB113.................
T113
LB114.................
T114
LB115.................
T299
LB116.................
T300
LB117.................
T117
LB118.................
T162
LB119.................
T119
LB122.................
T122
LB124.................
T124

Competitive
No.

Gates
No.

FEDERAL MOGUL - Cont.

Timing Belts - Cont.
LB125.................
T125
LB126.................
T237
LB128.................
T128
LB129.................
T129
LB130.................
T130
LB131.................
T131
LB132.................
T132
LB133.................
T292
LB134.................
T134
LB135.................
T135
LB136.................
T233
LB138.................
T199
LB139.................
T139
LB141.................
T141
LB142.................
T142
LB143.................
T143
LB144.................
T144
LB145.................
T145
LB146.................
T146
LB147.................
T147
LB148.................
T148
LB149.................
T149
LB152.................
T152
LB153.................
T153
LB154.................
T154
LB155.................
T155
LB157.................
T157
LB158.................
T158
LB159.................
T159
LB160.................
T160
LB161.................
T161
LB162.................
T162
LB163.................
T163
LB164.................
T164
LB165.................
T165
LB166.................
T166
LB167.................
T167
LB168.................
T168
LB169.................
T169
LB170.................
T170
LB172.................
T254
LB176.................
T176
LB177.................
T177
LB179.................
T179
LB180.................
T180
LB183.................
T183
LB184.................
T184
LB185.................
T185
LB186.................
T186
LB187.................
T187
LB193.................
T193
LB194.................
T194
LB202.................
T248
LB210.................
T210
FIRESTONE
Timing Belts
51309510 ...........
T017
51309618 ...........
T061
51309677 ...........
T067
51309693 ...........
T071
51309766 ...........
T081
FRESHSTART (See GOODYEAR)
GENERAL CHAIN
Timing Belts
B4013.................
T013
B4014.................
T014
B4017.................
T017
B4018.................
T018
B4020.................
T020
B4028.................
T028
B4032.................
T032
B4036.................
T036
B4037.................
T037
B4039.................
T039
B4041.................
T041
B4042.................
T068
B4043.................
T043
B4061.................
T061
B4065.................
T065
B4067.................
T067
B4070.................
T070
B4071.................
T071
B4073.................
T073
B4075.................
T075
B4076.................
T076
B4501.................
T196
B4507.................
T100
B4510.................
T077

Competitive
No.

Gates
No.

GENERAL CHAIN - Cont.

Timing Belts - Cont.
B4511.................
T078
B4512.................
T079
B4513.................
T087
B4514.................
T084
B4515.................
T101
B4516.................
T070
B4518.................
T112
B4519.................
T084
B4540.................
T127
B4550.................
T089
B4551.................
T090
B4580.................
T094
B4590.................
T082
GMB
Timing Belt Tensioners
GT10010 ............
T41042
GT10022 ............
T41037
GT10031 ............
T41043
GT10032 ............
T41044
GT10040 ............
T41045
GT10060 ............
T41046
GT10070 ............
T41047
GT10072 ............
T41038
GT10080 ............
T41048
GT10100 ............
T41039
GT10130 ............
T41049
GT10140 ............
T41050
GT10150 ............
T41041
GT20010 ............
T41029
GT20040 ............
T41030
GT20050 ............
T41031
GT40010 ............
T41003
GT80010 ............
T41066
GT80020 ............
T41067
GT80050 ............
T41060
GT80070 ............
T41079
GT80090 ............
T41051
GT80100 ............
T41011
GT80110 ............
T41058
GT80140 ............
T41068
GT80170 ............
T41012
GT80250 ............
T41025
GT80280 ............
T41080
GT80310 ............
T41009
GT80320 ............
T41064
GT80340 ............
T41059
GT80360 ............
T41069
GT80370 ............
T41070
GT80390 ............
T41013
GT80400 ............
T41052
GT80410 ............
T41004
GT80420 ............
T41071
GT80430 ............
T41072
GT80440 ............
T41014
GT80480 ............
T41053
GT80490 ............
T41005
GT80500 ............
T41006
GT80550 ............
T41015
GT80560 ............
T41061
GT80570 ............
T41062
GT80580 ............
T41016
GT80590 ............
T41017
GT80600 ............
T41073
GT80610 ............
T41018
GT80620 ............
T41026
GT80630 ............
T41074
GT80640 ............
T41065
GT80650 ............
T41019
GT80660 ............
T41033
GT80670 ............
T41034
GT80680 ............
T41075
GT80700 ............
T41076
GT80710 ............
T41077
GT80800 ............
T41054
GT80820 ............
T41000
GT80830 ............
T41001
GT80860 ............
T41021
GT80890 ............
T41055
GT80900 ............
T41056
GT80940 ............
T41010
GT80950 ............
T41057
GT80970 ............
T41035
420-8820............
T41000
420-8830............
T41001
420-9010............
T41002
422-4010............
T41003
422-8410............
T41004
425-8490............
T41005
425-8500............
T41006
425-8960............
T41007

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

GMB - Cont.
Timing Belt Tensioners
- Cont.
425-9000............
T41008
430-8310............
T41009
430-8940............
T41010
435-8100............
T41011
435-8170............
T41012
435-8390............
T41013
435-8440............
T41014
435-8550............
T41015
435-8580............
T41016
435-8590............
T41017
435-8610............
T41018
435-8650............
T41019
435-8850............
T41020
435-8860............
T41021
435-9030............
T41022
435-9040............
T41023
435-9120............
T41024
440-8250............
T41025
440-8620............
T41026
440-9070............
T41027
440-9110............
T41028
445-2010............
T41029
445-2040............
T41030
445-2050............
T41031
445-2140............
T41032
445-8660............
T41033
445-8670............
T41034
445-8970............
T41035
445-9100............
T41036
446-1022............
T41037
446-1061............
T41087
446-1072............
T41038
446-1100............
T41039
446-1101............
T41040
446-1150............
T41041
448-1010............
T41042
448-1031............
T41043
448-1032............
T41044
448-1040............
T41045
448-1060............
T41046
448-1070............
T41047
448-1080............
T41048
448-1130............
T41049
448-1140............
T41050
448-8090............
T41051
448-8400............
T41052
448-8480............
T41053
448-8800............
T41054
448-8890............
T41055
448-8900............
T41056
448-8950............
T41057
450-8110............
T41058
450-8340............
T41059
450-8910............
T41085
460-8050............
T41060
460-8560............
T41061
460-8570............
T41062
460-9080............
T41063
465-8320............
T41064
465-8640............
T41065
470-8010............
T41066
470-8020............
T41067
470-8140............
T41068
470-8360............
T41069
470-8370............
T41070
470-8420............
T41071
470-8430............
T41072
470-8600............
T41073
470-8630............
T41074
470-8680............
T41075
470-8700............
T41076
470-8710............
T41077
470-9090............
T41078
480-8070............
T41079
480-8280............
T41080
490-9143............
T41081
Timing Belt Pulleys
GT10050 ............
T42017
GT10110 ............
T42018
GT10160 ............
T42015
GT10170 ............
T42016
GT20020 ............
T42003
GT20030 ............
T42004
GT20060 ............
T42005
GT20090 ............
T42006
GT20100 ............
T42007
GT80030 ............
T42025
GT80040 ............
T42008
GT80150 ............
T42026
GT80330 ............
T42027

Competitive
No.

Gates
No.

GMB - Cont.
Timing Belt Pulleys - Cont.
GT80350 ............
T42028
GT80380 ............
T42029
GT80510 ............
T42009
GT80520 ............
T42010
GT80530 ............
T42011
GT80540 ............
T42030
GT80690 ............
T42022
GT80870 ............
T42012
GT80880 ............
T42013
GT80910 ............
T42021
GT80930 ............
T42020
425-9350............
T42033
425-9360............
T42032
425-9390............
T42034
425-9400............
T42035
440-8840............
T42001
440-9060............
T42002
445-2020............
T42003
445-2030............
T42004
445-2060............
T42005
445-2090............
T42006
445-2100............
T42007
445-8040............
T42008
445-8510............
T42009
445-8520............
T42010
445-8530............
T42011
445-8870............
T42012
445-8880............
T42013
446-1111............
T42014
446-1160............
T42015
446-1170............
T42016
448-1050............
T42017
448-1110............
T42018
450-8920............
T42020
450-8930............
T42021
460-8690............
T42022
460-9020............
T42023
460-9130............
T42024
470-8030............
T42025
470-8150............
T42026
470-8330............
T42027
470-8350............
T42028
470-8380............
T42029
470-8540............
T42030
470-9050............
T42031
GOODYEAR
Timing Belts
CD-100...............
T100
CD-101...............
T101
CD-104...............
T104
CD-106...............
T106
CD-112...............
T112
CD-113...............
T113
CD-114...............
T114
CD-115...............
T299
CD-116...............
T300
CD-117...............
T117
CD-118...............
T118
CD-122...............
T122
CD-124...............
T124
CD-125...............
T125
CD-126...............
T126
CD-127...............
T127
CD-128...............
T128
CD-129...............
T129
CD-13.................
T013
CD-130...............
T130
CD-131...............
T131
CD-132...............
T132
CD-133...............
T292
CD-134...............
T134
CD-136...............
T136
CD-137...............
T137
CD-138...............
T138
CD-139...............
T139
CD-14.................
T014
CD-140...............
T140
CD-141...............
T141
CD-142...............
T142
CD-143...............
T143
CD-144...............
T144
CD-145...............
T145
CD-146...............
T146
CD-147...............
T147
CD-148...............
T148
CD-149...............
T149
CD-150...............
T150
CD-151...............
T151
CD-152...............
T152
CD-153...............
T153

Competitive
No.

Gates
No.

GOODYEAR - Cont.
Timing Belts - Cont.
CD-154...............
CD-155...............
CD-157...............
CD-158...............
CD-159...............
CD-160...............
CD-161...............
CD-162...............
CD-163...............
CD-164...............
CD-165...............
CD-166...............
CD-167...............
CD-168...............
CD-169...............
CD-17.................
CD-170...............
CD-171...............
CD-172...............
CD-173...............
CD-174...............
CD-176...............
CD-177...............
CD-178...............
CD-179...............
CD-18.................
CD-180...............
CD-181...............
CD-182...............
CD-183...............
CD-184...............
CD-185...............
CD-186...............
CD-187...............
CD-188...............
CD-189...............
CD-190...............
CD-191...............
CD-192...............
CD-193...............
CD-194...............
CD-195...............
CD-196...............
CD-197...............
CD-198...............
CD-199...............
CD-20.................
CD-200...............
CD-201...............
CD-202...............
CD-203...............
CD-204...............
CD-205...............
CD-206...............
CD-207...............
CD-208...............
CD-209...............
CD-210...............
CD-211...............
CD-212...............
CD-213...............
CD-214...............
CD-215...............
CD-216...............
CD-217...............
CD-218...............
CD-219...............
CD-220...............
CD-221...............
CD-222...............
CD-223...............
CD-224...............
CD-225...............
CD-226...............
CD-227...............
CD-228...............
CD-229...............
CD-230...............
CD-232...............
CD-233...............
CD-234...............
CD-235...............
CD-236...............
CD-237...............
CD-239...............
CD-240...............
CD-241...............
CD-242...............
CD-243...............
CD-244...............
CD-245...............
CD-246...............

T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T017
T170
T171
T172
T173
T174
T176
T177
T178
T179
T018
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T020
T200
T201
T248
T203
T204
T205
T206
T207
T208
T209
T210
T211
T212
T213
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246

Competitive
No.

Gates
No.

GOODYEAR - Cont.
Timing Belts - Cont.
CD-247...............
CD-248...............
CD-249...............
CD-251...............
CD-252...............
CD-253...............
CD-254...............
CD-255...............
CD-256...............
CD-257...............
CD-258...............
CD-259...............
CD-260...............
CD-262...............
CD-263...............
CD-264...............
CD-265...............
CD-266...............
CD-267...............
CD-269...............
CD-271...............
CD-272...............
CD-273...............
CD-276...............
CD-277...............
CD-278...............
CD-279...............
CD-28.................
CD-280...............
CD-281...............
CD-282...............
CD-283...............
CD-284...............
CD-285...............
CD-286...............
CD-287...............
CD-288...............
CD-289...............
CD-290...............
CD-291...............
CD-292...............
CD-293...............
CD-294...............
CD-295...............
CD-296...............
CD-297...............
CD-298...............
CD-299...............
CD-300...............
CD-301...............
CD-302...............
CD-303...............
CD-304...............
CD-305...............
CD-306...............
CD-32.................
CD-36.................
CD-37.................
CD-39.................
CD-41.................
CD-42.................
CD-43.................
CD-61.................
CD-62.................
CD-63.................
CD-64.................
CD-65.................
CD-67.................
CD-69.................
CD-70.................
CD-71.................
CD-74.................
CD-77.................
CD-78.................
CD-81.................
CD-87.................
CD-88.................
CD-89.................
CD-90.................
CD-91.................
CD-92.................
CD-93.................
CD-94.................
CD-95.................
CD-99.................
40013 .................
40014 .................
40017 .................
40018 .................
40020 .................
40028 .................
40032 .................

T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T260
T262
T263
T264
T265
T266
T267
T269
T271
T272
T273
T276
T277
T278
T279
T028
T280
T281
T282
T283
T284
T285
T286
T287
T288
T289
T290
T291
T292
T293
T294
T295
T296
T297
T298
T299
T300
T301
T302
T303
T304
T305
T306
T032
T036
T037
T039
T041
T068
T043
T061
T062
T073
T064
T065
T067
T069
T070
T071
T074
T077
T078
T081
T087
T088
T089
T090
T091
T092
T093
T094
T095
T099
T013
T014
T017
T018
T020
T028
T032

Competitive
No.

793
Gates
No.

GOODYEAR - Cont.
Timing Belts - Cont.
40036 .................
40037 .................
40039 .................
40041 .................
40042 .................
40043 .................
40046 .................
40047 .................
40050 .................
40052 .................
40057 .................
40058 .................
40060 .................
40061 .................
40062 .................
40063 .................
40064 .................
40065 .................
40067 .................
40068 .................
40069 .................
40070 .................
40071 .................
40073 .................
40074 .................
40075 .................
40076 .................
40077 .................
40078 .................
40079 .................
40081 .................
40082 .................
40083 .................
40084 .................
40087 .................
40088 .................
40089 .................
40090 .................
40091 .................
40092 .................
40093 .................
40094 .................
40095 .................
40096 .................
40097 .................
40098 .................
40099 .................
40100 .................
40101 .................
40102 .................
40103 .................
40104 .................
40106 .................
40107 .................
40112 .................
40113 .................
40114 .................
40115 .................
40116 .................
40117 .................
40118 .................
40119 .................
40121 .................
40122 .................
40123 .................
40124 .................
40125 .................
40126 .................
40127 .................
40128 .................
40129 .................
40130 .................
40131 .................
40132 .................
40133 .................
40134 .................
40135 .................
40136 .................
40137 .................
40138 .................
40139 .................
40140 .................
40141 .................
40142 .................
40143 .................
40144 .................
40145 .................
40146 .................
40147 .................
40148 .................
40149 .................
40151 .................

T036
T037
T039
T041
T068
T043
T013
T014
T018
T020
T037
T039
T017
T061
T062
T073
T064
T065
T067
T068
T069
T070
T071
T073
T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T097
T098
T099
T100
T101
T102
T103
T104
T106
T107
T176
T113
T114
T299
T300
T117
T118
T119
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T151

Changeover Listing - PowerGrip Timing System Products

794
Competitive
No.

Gates
No.

GOODYEAR - Cont.
Timing Belts - Cont.
40152 .................
40153 .................
40154 .................
40155 .................
40157 .................
40158 .................
40159 .................
40160 .................
40161 .................
40162 .................
40163 .................
40164 .................
40165 .................
40166 .................
40167 .................
40168 .................
40169 .................
40170 .................
40171 .................
40172 .................
40173 .................
40174 .................
40176 .................
40177 .................
40178 .................
40179 .................
40180 .................
40181 .................
40182 .................
40183 .................
40184 .................
40185 .................
40186 .................
40187 .................
40188 .................
40189 .................
40190 .................
40191 .................
40192 .................
40193 .................
40194 .................
40195 .................
40196 .................
40197 .................
40198 .................
40199 .................
40200 .................
40201 .................
40202 .................
40203 .................
40204 .................
40205 .................
40206 .................
40207 .................
40208 .................
40209 .................
40210 .................
40211 .................
40212 .................
40213 .................
40214 .................
40215 .................
40216 .................
40217 .................
40218 .................
40219 .................
40220 .................
40221 .................
40222 .................
40223 .................
40224 .................
40225 .................
40226 .................
40227 .................
40228 .................
40229 .................
40230 .................
40232 .................
40233 .................
40234 .................
40235 .................
40236 .................
40237 .................
40239 .................
40240 .................
40241 .................
40242 .................
40243 .................
40244 .................
40245 .................
40246 .................
40247 .................

T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T248
T203
T204
T205
T206
T207
T208
T209
T210
T211
T212
T213
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247

Competitive
No.

Gates
No.

GOODYEAR - Cont.
Timing Belts - Cont.
40248 .................
T248
40249 .................
T249
40251 .................
T251
40252 .................
T252
40253 .................
T253
40254 .................
T254
40255 .................
T255
40256 .................
T256
40257 .................
T257
40258 .................
T258
40259 .................
T259
40260 .................
T260
40262 .................
T262
40263 .................
T263
40264 .................
T264
40265 .................
T265
40266 .................
T266
40267 .................
T267
40269 .................
T269
40271 .................
T271
40272 .................
T272
40273 .................
T273
40274 .................
T274
40275 .................
T275
40276 .................
T276
40277 .................
T277
40278 .................
T278
40279 .................
T279
40280 .................
T280
40281 .................
T281
40282 .................
T282
40283 .................
T283
40284 .................
T284
40285 .................
T285
40286 .................
T286
40287 .................
T287
40288 .................
T288
40289 .................
T289
40290 .................
T290
40291 .................
T291
40292 .................
T292
40293 .................
T293
40294 .................
T294
40295 .................
T295
40296 .................
T296
40297 .................
T297
40298 .................
T298
40299 .................
T299
40300 .................
T300
40301 .................
T301
40302 .................
T302
40303 .................
T303
40304 .................
T304
40305 .................
T305
40306 .................
T306
40307 .................
T307
40308 .................
T308
40309 .................
T309
40310 .................
T310
40311 .................
T311
40312 .................
T312
40313 .................
T313
40314 .................
T314
40315 .................
T315
40316 .................
T316
40317 .................
T317
40318 .................
T318
40319 .................
T319
40320 .................
T320
40321 .................
T321
40322 .................
T322
40323 .................
T323
40324 .................
T324
40325 .................
T325
Timing Belt Tensioners
48001 .................
T43005
48002 .................
T43002
48003 .................
T43003
48004 .................
T43008
48005 .................
T43004
48007 .................
T43001
48008 .................
T43007
HOOF PRODUCTS
Timing Belts
HB013 ................
T013
HB014 ................
T014
HB017 ................
T017
HB018 ................
T018
HB020 ................
T020
HB028 ................
T028

Competitive
No.

Gates
No.

HOOF PRODUCTS - Cont.

Timing Belts - Cont.
HB032 ................
T032
HB036 ................
T036
HB037 ................
T037
HB039 ................
T039
HB041 ................
T041
HB042 ................
T068
HB043 ................
T043
HB061 ................
T061
HB062 ................
T062
HB063 ................
T073
HB064 ................
T064
HB065 ................
T065
HB067 ................
T067
HB069 ................
T069
HB070 ................
T070
HB071 ................
T071
HB073 ................
T073
HB074 ................
T074
HB075 ................
T075
HB076 ................
T076
HB077 ................
T077
HB078 ................
T078
HB079 ................
T079
HB081 ................
T081
HB082 ................
T082
HB083 ................
T083
HB084 ................
T084
HB087 ................
T087
HB088 ................
T088
HB089 ................
T089
HB090 ................
T090
HB091 ................
T091
HB092 ................
T092
HB093 ................
T093
HB094 ................
T094
HB095 ................
T095
HB096 ................
T096
HB099 ................
T099
HB100 ................
T100
HB102 ................
T102
HB103 ................
T103
HB104 ................
T104
HB114 ................
T114
HB115 ................
T299
HB116 ................
T300
HB118 ................
T118
HB121 ................
T121
HB122 ................
T122
HB127 ................
T127
HB128 ................
T128
LAZORLITE
Timing Belts
L55-4014............
T013
L55-4022............
T062
L55-4030............
T064
L55-4049............
T028
L55-4057............
T041
L55-4065............
T041
L55-4081............
T073
L55-4103............
T078
L55-4111............
T077
L55-4120............
T074
L55-4138............
T079
L55-4154............
T088
L55-4162............
T089
L55-4170............
T090
L55-4189............
T092
L55-4200............
T070
L55-4219............
T075
L55-4227............
T076
L55-4235............
T117
L55-4243............
T093
L55-4251............
T091
L55-4260............
T095
L55-4286............
T104
L55-4294............
T101
L55-4308............
T084
L55-4316............
T087
L55-4324............
T094
L55-4332............
T099
L55-4405............
T017
L55-4472............
T300
L55-4480............
T299
L55-4499............
T112
L55-4502............
T161
L55-4510............
T118
L55-4529............
T104
L55-4537............
T137
L55-4596............
T149
L55-4600............
T141

Competitive
No.

Gates
No.

LAZORLITE - Cont.
Timing Belts - Cont.
L55-4618............
T141
L55-4626............
T117
L55-4634............
T134
L55-4642............
T128
L55-4650............
T124
L55-4669............
T139
L55-4677............
T103
L55-4685............
T135
L55-4693............
T136
L55-4707............
T126
L55-4715............
T098
L55-4723............
T138
L55-4731............
T130
L55-4740............
T129
L55-4758............
T145
L55-4766............
T122
L55-4774............
T121
L55-4782............
T148
L55-4790............
T138
L55-4812............
T146
L55-4820............
T159
L55-4839............
T168
L55-4847............
T144
L55-4855............
T142
L55-4863............
T143
L55-4880............
T167
L55-4898............
T165
L55-4901............
T164
L55-4910............
T150
L55-4928............
T151
L55-4936............
T166
L55-4944............
T113
L55-4952............
T157
L55-4960............
T154
L55-4979............
T125
U55-4359 ...........
T069
U55-4367 ...........
T018
U55-4375 ...........
T068
U55-4383 ...........
T020
U55-4405 ...........
T017
U55-4413 ...........
T065
U55-4421 ...........
T127
U55-4430 ...........
T083
U55-4448 ...........
T032
U55-4456 ...........
T082
U55-4464 ...........
T043
U55-4545 ...........
T082
U55-4553 ...........
T083
U55-4561 ...........
T293
U55-4570 ...........
T107
U55-4588 ...........
T119
U55-4871 ...........
T292
LEMPCO
Timing Belts
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB028.................
T028
TB037.................
T037
TB039.................
T039
TB041.................
T041
TB063.................
T073
TB064.................
T064
TB071.................
T071
TB112.................
T112
LINK-BELT
Timing Belts
B013...................
T013
B014...................
T014
B037...................
T037
LITENS AUTOMOTIVE
Timing Belt Tensioners
979002 ...............
T43004
MBL THREE STARS
Timing Belts
100ZA19.............
T061
106ZA19.............
T077
109ZA19.............
T088
113ZA19.............
T065
116ZA19.............
T018
118ZA19.............
T069
120ZA19.............
T064
121ZA19.............
T017
122ZA19.............
T013
123ZA19.............
T032
124ZA25.............
T071

Competitive
No.

Gates
No.

MBL THREE STARS - Cont.

Timing Belts - Cont.
129ZA22.............
T014
134ZA30.............
T076
134ZB301...........
T076
135ZB25.............
T043
139ZA25.............
T087
142ZA25.............
T074
146ZA19.............
T020
148ZA19.............
T068
55ZA13...............
T062
84ZA19...............
T028
87ZA34...............
T075
87ZB34...............
T075
88ZA19...............
T070
92ZA19...............
T073
95ZA19...............
T041
97ZA25...............
T067
98ZA19...............
T078
99ZA15...............
T037
99ZA19...............
T039
MCQUAY-NORRIS
Timing Belts
TC013 ................
T013
TC014 ................
T014
TC017 ................
T017
TC018 ................
T018
TC020 ................
T020
TC028 ................
T028
TC032 ................
T032
TC036 ................
T036
TC037 ................
T037
TC039 ................
T039
TC041 ................
T041
TC042 ................
T068
TC043 ................
T043
TC061 ................
T061
TC062 ................
T062
TC063 ................
T073
TC064 ................
T064
TC065 ................
T065
TC067 ................
T067
TC068 ................
T068
TC069 ................
T069
TC070 ................
T070
TC071 ................
T071
TC074 ................
T074
TC075 ................
T075
TC076 ................
T076
TC077 ................
T077
TC078 ................
T078
TC081 ................
T081
TC087 ................
T087
TC088 ................
T088
TC089 ................
T089
MELLING AUTOMOTIVE
Timing Belts
B0100.................
T100
B0101.................
T101
B0102.................
T102
B0103.................
T103
B0104.................
T104
B0106.................
T106
B0107.................
T107
B0108.................
T293
B0112.................
T176
B0113.................
T113
B0114.................
T114
B0115.................
T299
B0116.................
T300
B0117.................
T117
B0118.................
T162
B0119.................
T119
B0121.................
T121
B0122.................
T122
B0123.................
T123
B0124.................
T124
B0125.................
T125
B0126.................
T126
B0127.................
T127
B0128.................
T128
B0129.................
T129
B013...................
T013
B0130.................
T130
B0131.................
T131
B0132.................
T132
B0133.................
T292
B0134.................
T134
B0135.................
T135
B0136.................
T136
B0137.................
T137

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

MELLING AUTOMOTIVE
- Cont.
Timing Belts - Cont.
B0138.................
B0139.................
B014...................
B0140.................
B0141.................
B0142.................
B0143.................
B0144.................
B0145.................
B0146.................
B0147.................
B0148.................
B0149.................
B0150.................
B0151.................
B0152.................
B0153.................
B0154.................
B0155.................
B0157.................
B0158.................
B0159.................
B0160.................
B0161.................
B0162.................
B0163.................
B0164.................
B0165.................
B0166.................
B0167.................
B0168.................
B0169.................
B017...................
B0170.................
B0171.................
B0172.................
B0174.................
B0176.................
B0177.................
B0178.................
B0179.................
B018...................
B0180.................
B0181.................
B0182.................
B0183.................
B0184.................
B0185.................
B0186.................
B0187.................
B0189.................
B0191.................
B0192.................
B0193.................
B0194.................
B0195.................
B0199.................
B020...................
B0202.................
B0203.................
B0204.................
B0205.................
B0208.................
B0210.................
B0216.................
B0219.................
B0223.................
B0224.................
B0226.................
B0228.................
B0229.................
B0230.................
B0232.................
B0233.................
B0237.................
B0239.................
B028...................
B029...................
B032...................
B036...................
B037...................
B039...................
B041...................
B042...................
B043...................
B061...................
B062...................
B063...................
B064...................
B065...................
B067...................

T138
T139
T014
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T017
T170
T171
T172
T174
T176
T177
T178
T179
T018
T180
T181
T182
T183
T184
T185
T186
T187
T189
T191
T192
T193
T194
T195
T199
T020
T248
T203
T204
T205
T208
T210
T216
T219
T223
T224
T226
T228
T229
T230
T232
T233
T237
T239
T028
T104
T032
T036
T037
T039
T041
T068
T043
T061
T062
T073
T064
T065
T067

Competitive
No.

Gates
No.

MELLING AUTOMOTIVE
- Cont.
Timing Belts - Cont.
B069...................
T069
B070...................
T070
B071...................
T071
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077
B078...................
T078
B079...................
T079
B081...................
T081
B082...................
T082
B083...................
T083
B084...................
T084
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B091...................
T091
B092...................
T092
B093...................
T093
B094...................
T094
B095...................
T095
B096...................
T096
B097...................
T097
B098...................
T098
B099...................
T099
MIGHTY
Timing Belts
CD100................
T100
CD101................
T101
CD102................
T102
CD103................
T103
CD104................
T104
CD111................
T140
CD112................
T176
CD113................
T113
CD114................
T114
CD115................
T299
CD116................
T300
CD117................
T117
CD118................
T118
CD119................
T119
CD121................
T121
CD122................
T122
CD123................
T123
CD124................
T124
CD125................
T125
CD126................
T126
CD127................
T127
CD128................
T128
CD129................
T129
CD13..................
T013
CD130................
T130
CD131................
T131
CD132................
T132
CD133................
T292
CD134................
T134
CD135................
T135
CD136................
T136
CD137................
T137
CD138................
T138
CD139................
T139
CD14..................
T014
CD141................
T141
CD142................
T142
CD143................
T143
CD144................
T144
CD145................
T145
CD146................
T146
CD147................
T147
CD148................
T148
CD153................
T153
CD154................
T154
CD155................
T155
CD157................
T157
CD158................
T158
CD159................
T159
CD160................
T160
CD161................
T161
CD162................
T162
CD163................
T163
CD164................
T164
CD165................
T165
CD166................
T166
CD167................
T167
CD17..................
T017
CD176................
T176
CD18..................
T018
CD185................
T185

Competitive
No.

Gates
No.

MIGHTY - Cont.
Timing Belts - Cont.
CD186................
T186
CD187................
T187
CD191................
T191
CD20..................
T020
CD208................
T208
CD210................
T210
CD28..................
T028
CD32..................
T032
CD36..................
T036
CD37..................
T037
CD39..................
T039
CD41..................
T041
CD42..................
T068
CD43..................
T043
CD61..................
T061
CD62..................
T062
CD63..................
T073
CD64..................
T064
CD65..................
T065
CD67..................
T067
CD69..................
T069
CD70..................
T070
CD71..................
T071
CD74..................
T074
CD75..................
T075
CD76..................
T076
CD77..................
T077
CD78..................
T078
CD79..................
T079
CD81..................
T081
CD82..................
T082
CD83..................
T083
CD84..................
T084
CD87..................
T087
CD88..................
T088
CD89..................
T089
CD90..................
T090
CD91..................
T091
CD92..................
T092
CD93..................
T093
CD94..................
T094
CD95..................
T095
CD99..................
T099
MITSUBOSHI
Timing Belts
106ZA19.............
T077
111ZA19.............
T121
116ZA19.............
T018
120ZA19.............
T064
122ZA19.............
T013
123ZA19.............
T032
127ZA25.............
T079
129ZA22.............
T014
134ZB30.............
T076
139ZA25.............
T087
146ZA19.............
T020
148ZA19.............
T068
55ZA13...............
T062
55ZB13...............
T090
83ZB19...............
T092
84ZA19...............
T028
87ZB34...............
T075
88ZA19...............
T070
89ZA19...............
T095
92ZA19...............
T073
94ZA19...............
T036
95ZA19...............
T041
98ZA19...............
T078
MOPAR
Timing Belts
BTC-13...............
T013
BTC-14...............
T014
BTC-37...............
T037
BTC-39...............
T020
B0040013...........
T013
B0040017...........
T017
B0040062...........
T062
B0040063...........
T073
B0040064...........
T064
B0040071...........
T071
MOTORCRAFT
Timing Belts
CET13................
T013
CET135..............
T135
CET14................
T014
CET17................
T017
CET207..............
T207
CET230..............
T230

Competitive
No.

Gates
No.

MOTORCRAFT - Cont.
Timing Belts - Cont.
CET257..............
T257
CET262..............
T262
CET263..............
T263
CET264..............
T264
CET265..............
T265
CET271..............
T271
CET272..............
T272
CET273..............
T273
CET277..............
T277
CET278..............
T278
CET279..............
T279
CET28................
T028
CET280..............
T280
CET281..............
T281
CET282..............
T282
CET284..............
T284
CET285..............
T285
CET286..............
T286
CET287..............
T287
CET288..............
T288
CET289..............
T289
CET290..............
T290
CET291..............
T291
CET37................
T037
CET39................
T039
CET41................
T041
CET61................
T061
CET67................
T067
CET70................
T070
CET71................
T071
CET94................
T094
MOTORCRAFT CANADA
Timing Belts
CET13................
T013
CET135..............
T135
CET14................
T014
CET17................
T017
CET207..............
T207
CET230..............
T230
CET257..............
T257
CET262..............
T262
CET263..............
T263
CET264..............
T264
CET265..............
T265
CET271..............
T271
CET272..............
T272
CET273..............
T273
CET277..............
T277
CET278..............
T278
CET279..............
T279
CET28................
T028
CET280..............
T280
CET281..............
T281
CET282..............
T282
CET284..............
T284
CET285..............
T285
CET286..............
T286
CET287..............
T287
CET288..............
T288
CET289..............
T289
CET290..............
T290
CET291..............
T291
CET37................
T037
CET39................
T039
CET41................
T041
CET61................
T061
CET67................
T067
CET70................
T070
CET71................
T071
CET94................
T094
NAPA
Timing Belts
25-90073............
T073
25-90096............
T096
25-90097............
T097
25-90130............
T013
25-90140............
T014
25-90150............
T032
25-90160............
T041
25-90166............
T166
25-90167............
T167
25-90168............
T168
25-90169............
T169
25-90170............
T017
25-90171............
T171
25-90172............
T172
25-90173............
T173
25-90174............
T174
25-90176............
T176

Competitive
No.

795
Gates
No.

NAPA - Cont.
Timing Belts - Cont.
25-90177............
25-90178............
25-90179............
25-90180............
25-90181............
25-90182............
25-90183............
25-90184............
25-90185............
25-90186............
25-90187............
25-90188............
25-90189............
25-90191............
25-90192............
25-90193............
25-90194............
25-90195............
25-90196............
25-90197............
25-90198............
25-90199............
25-90200............
25-90201............
25-90202............
25-90203............
25-90204............
25-90205............
25-90206............
25-90207............
25-90208............
25-90209............
25-90210............
25-90211............
25-90212............
25-90213............
25-90214............
25-90215............
25-90216............
25-90217............
25-90218............
25-90219............
25-90220............
25-90221............
25-90222............
25-90223............
25-90224............
25-90225............
25-90226............
25-90227............
25-90228............
25-90229............
25-90232............
25-90233............
25-90234............
25-90235............
25-90236............
25-90237............
25-90239............
25-90250............
25-90260............
25-90270............
25-90280............
25-90290............
25-90310............
25-90320............
25-90330............
25-90340............
25-90350............
25-90360............
25-90370............
25-90380............
25-90390............
25-90400............
25-90410............
25-90420............
25-90430............
25-90440............
25-90450............
25-90460............
25-90470............
25-90480............
25-90490............
25-90510............
25-90520............
25-90530............
25-90540............
25-90550............
25-90560............
25-90570............
25-90590............
25-90600............

T177
T178
T179
T018
T181
T182
T183
T184
T185
T186
T187
T188
T189
T191
T192
T193
T194
T195
T196
T197
T198
T199
T020
T201
T248
T203
T204
T205
T206
T207
T208
T209
T039
T211
T212
T213
T214
T215
T216
T217
T218
T219
T062
T221
T222
T223
T224
T225
T226
T227
T228
T229
T232
T233
T234
T235
T236
T237
T239
T028
T061
T064
T065
T073
T069
T036
T070
T068
T071
T067
T037
T076
T075
T078
T077
T043
T074
T081
T088
T087
T093
T094
T104
T100
T084
T099
T098
T082
T083
T095
T112
T089

Changeover Listing - PowerGrip Timing System Products

796
Competitive
No.

Gates
No.

NAPA - Cont.
Timing Belts - Cont.
25-90610............
25-90620............
25-90630............
25-90640............
25-90650............
25-90670............
25-90680............
25-90690............
25-90700............
25-90710............
25-90720............
25-90730............
25-90740............
25-90750............
25-90760............
25-90770............
25-90780............
25-90790............
25-90800............
25-90810............
25-90820............
25-90830............
25-90840............
25-90850............
25-90860............
25-90870............
25-90880............
25-90890............
25-90900............
25-90910............
25-90920............
25-90930............
25-90940............
25-90950............
25-90960............
25-90970............
25-90980............
25-90990............
25-91000............
25-91001............
25-91002............
25-91003............
25-91004............
25-91005............
25-91006............
25-91007............
25-91008............
25-91009............
25-91010............
25-91011............
25-91012............
25-91014............
25-91015............
25-91016............
25-91017............
25-91018............
25-91019............
25-91020............
25-91021............
25-91022............
25-91023............
25-91120............
25-91170............
25-91180............
25-91190............
25-91200............
25-91210............
25-91220............
25-91230............
25-91240............
250013 ...............
250014 ...............
250017 ...............
250018 ...............
250020 ...............
250028 ...............
250032 ...............
250036 ...............
250037 ...............
250039 ...............
250041 ...............
250043 ...............
250061 ...............
250062 ...............
250064 ...............
250065 ...............
250067 ...............
250068 ...............
250069 ...............
250070 ...............
250071 ...............
250073 ...............

T118
T079
T122
T121
T127
T101
T125
T126
T130
T129
T106
T114
T300
T299
T091
T092
T117
T119
T292
T134
T135
T136
T137
T138
T139
T140
T131
T141
T123
T090
T293
T196
T113
T132
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T102
T103
T107
T124
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T153
T120
T170
T180
T190
T200
T210
T220
T230
T240
T013
T014
T017
T018
T020
T028
T032
T036
T037
T039
T041
T043
T061
T062
T064
T065
T067
T068
T069
T070
T071
T073

Competitive
No.

Gates
No.

NAPA - Cont.
Timing Belts - Cont.
250074 ...............
250075 ...............
250076 ...............
250077 ...............
250078 ...............
250079 ...............
250081 ...............
250082 ...............
250083 ...............
250084 ...............
250087 ...............
250088 ...............
250089 ...............
250090 ...............
250091 ...............
250092 ...............
250093 ...............
250094 ...............
250095 ...............
250096 ...............
250097 ...............
250098 ...............
250099 ...............
250100 ...............
250101 ...............
250102 ...............
250103 ...............
250104 ...............
250106 ...............
250107 ...............
250108 ...............
250112 ...............
250113 ...............
250114 ...............
250115 ...............
250116 ...............
250117 ...............
250118 ...............
250119 ...............
250120 ...............
250121 ...............
250122 ...............
250123 ...............
250124 ...............
250125 ...............
250126 ...............
250127 ...............
250128 ...............
250129 ...............
250130 ...............
250131 ...............
250132 ...............
250133 ...............
250134 ...............
250135 ...............
250136 ...............
250137 ...............
250138 ...............
250139 ...............
250140 ...............
250141 ...............
250142 ...............
250143 ...............
250144 ...............
250145 ...............
250146 ...............
250147 ...............
250148 ...............
250149 ...............
250150 ...............
250151 ...............
250152 ...............
250153 ...............
250154 ...............
250155 ...............
250157 ...............
250158 ...............
250159 ...............
250160 ...............
250161 ...............
250162 ...............
250163 ...............
250164 ...............
250165 ...............
250166 ...............
250167 ...............
250168 ...............
250169 ...............
250170 ...............
250171 ...............
250172 ...............
250173 ...............

T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T097
T098
T099
T100
T101
T102
T103
T104
T106
T107
T293
T112
T113
T114
T299
T300
T117
T118
T119
T120
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T292
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173

Competitive
No.

Gates
No.

NAPA - Cont.
Timing Belts - Cont.
250174 ...............
250176 ...............
250177 ...............
250178 ...............
250179 ...............
250180 ...............
250181 ...............
250182 ...............
250183 ...............
250184 ...............
250185 ...............
250186 ...............
250187 ...............
250188 ...............
250189 ...............
250190 ...............
250191 ...............
250192 ...............
250193 ...............
250194 ...............
250195 ...............
250196 ...............
250197 ...............
250198 ...............
250199 ...............
250200 ...............
250201 ...............
250202 ...............
250203 ...............
250204 ...............
250205 ...............
250206 ...............
250207 ...............
250208 ...............
250209 ...............
250210 ...............
250211 ...............
250212 ...............
250213 ...............
250214 ...............
250215 ...............
250216 ...............
250217 ...............
250218 ...............
250219 ...............
250220 ...............
250221 ...............
250222 ...............
250223 ...............
250224 ...............
250225 ...............
250226 ...............
250227 ...............
250228 ...............
250229 ...............
250230 ...............
250232 ...............
250233 ...............
250234 ...............
250235 ...............
250236 ...............
250237 ...............
250239 ...............
250240 ...............
250241 ...............
250242 ...............
250243 ...............
250244 ...............
250245 ...............
250246 ...............
250247 ...............
250248 ...............
250249 ...............
250251 ...............
250252 ...............
250253 ...............
250254 ...............
250255 ...............
250256 ...............
250257 ...............
250258 ...............
250259 ...............
250260 ...............
250262 ...............
250263 ...............
250264 ...............
250265 ...............
250266 ...............
250267 ...............
250269 ...............
250270 ...............
250271 ...............

T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T248
T203
T204
T205
T206
T207
T208
T209
T210
T211
T212
T213
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T260
T262
T263
T264
T265
T266
T267
T269
T270
T271

Competitive
No.

Gates
No.

NAPA - Cont.
Timing Belts - Cont.
250272 ...............
T272
250273 ...............
T273
250274 ...............
T274
250275 ...............
T275
250276 ...............
T276
250277 ...............
T277
250278 ...............
T278
250279 ...............
T279
250280 ...............
T280
250281 ...............
T281
250282 ...............
T282
250283 ...............
T283
250284 ...............
T284
250285 ...............
T285
250286 ...............
T286
250287 ...............
T287
250288 ...............
T288
250289 ...............
T289
250290 ...............
T290
250291 ...............
T291
250292 ...............
T292
250293 ...............
T293
250294 ...............
T294
250295 ...............
T295
250296 ...............
T296
250297 ...............
T297
250298 ...............
T298
250299 ...............
T299
250300 ...............
T300
250301 ...............
T301
250302 ...............
T302
250303 ...............
T303
250304 ...............
T304
250305 ...............
T305
250306 ...............
T306
250307 ...............
T307
250308 ...............
T308
250309 ...............
T309
250310 ...............
T310
250311 ...............
T311
250312 ...............
T312
250313 ...............
T313
250314 ...............
T314
250315 ...............
T315
250316 ...............
T316
250317 ...............
T317
250318 ...............
T318
250319 ...............
T319
250320 ...............
T320
250321 ...............
T321
250322 ...............
T322
250323 ...............
T323
250324 ...............
T324
250325 ...............
T325
250326 ...............
T326
250327 ...............
T327
250329 ...............
T329
Timing Belt Tensioners
T43001...............
T43001
T43002...............
T43002
T43003...............
T43003
T43004...............
T43004
T43005...............
T43005
T43006...............
T43006
T43007...............
T43007
T43008...............
T43008
T43010...............
T43010
PAREX TRANS. PARTS
Timing Belts
013 .....................
T013
018 .....................
T018
020 .....................
T020
028 .....................
T028
032 .....................
T032
037 .....................
T037
041 .....................
T041
043 .....................
T043
062 .....................
T062
065 .....................
T065
067 .....................
T067
068 .....................
T068
069 .....................
T069
070 .....................
T070
071 .....................
T071
074 .....................
T074
075 .....................
T075
076 .....................
T076
077 .....................
T077
078 .....................
T078
081 .....................
T081

Competitive
No.

Gates
No.

PAREX TRANS. PARTS

- Cont.
Timing Belts - Cont.
087 .....................
T087
088 .....................
T088
093 .....................
T093
094 .....................
T094
095 .....................
T095
099 .....................
T099
104 .....................
T104
PEP BOYS (See DAYCO)
PERFECT CIRCLE
Timing Belts
9-100..................
T100
9-101..................
T101
9-102..................
T102
9-103..................
T103
9-104..................
T104
9-13....................
T013
9-14....................
T014
9-17....................
T017
9-18....................
T018
9-20....................
T020
9-28....................
T028
9-32....................
T032
9-36....................
T036
9-37....................
T037
9-39....................
T039
9-41....................
T041
9-43....................
T043
9-61....................
T061
9-62....................
T062
9-63....................
T073
9-64....................
T064
9-65....................
T065
9-67....................
T067
9-69....................
T069
9-70....................
T070
9-71....................
T071
9-74....................
T074
9-75....................
T075
9-76....................
T076
9-77....................
T077
9-78....................
T078
9-79....................
T079
9-81....................
T081
9-84....................
T084
9-87....................
T087
9-88....................
T088
9-89....................
T089
9-90....................
T090
9-91....................
T091
9-92....................
T092
9-93....................
T093
9-94....................
T094
9-96....................
T096
9-98....................
T098
9-99....................
T099
PERFECTION AM
Timing Belts
B0101.................
T101
B0102.................
T102
B0103.................
T103
B0104.................
T104
B0114.................
T114
B0118.................
T162
B013...................
T013
B014...................
T014
B017...................
T017
B018...................
T018
B020...................
T020
B028...................
T028
B032...................
T032
B036...................
T036
B037...................
T037
B039...................
T039
B041...................
T041
B043...................
T043
B061...................
T061
B062...................
T062
B063...................
T073
B064...................
T064
B065...................
T065
B067...................
T067
B069...................
T069
B070...................
T070
B071...................
T071
B074...................
T074
B075...................
T075
B076...................
T076
B077...................
T077

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

PERFECTION AM - Cont.
Timing Belts - Cont.
B078...................
T078
B081...................
T081
B082...................
T082
B083...................
T083
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B093...................
T093
B094...................
T094
B095...................
T095
B099...................
T099
013 .....................
T013
014 .....................
T014
017 .....................
T017
018 .....................
T020
037 .....................
T037
039 .....................
T039
PETRO-CANADA
Timing Belts
742-P014............
T014
742-P017............
T017
742-P028............
T028
742-P061............
T061
742-P067............
T067
742-P071............
T071
PIRELLI
Timing Belts
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB020.................
T020
TB028.................
T028
TB032.................
T032
TB036.................
T036
TB037.................
T037
TB039.................
T039
TB041.................
T041
TB042.................
T068
TB043.................
T043
TB061.................
T061
TB062.................
T062
TB063.................
T073
TB064.................
T064
TB065.................
T065
TB067.................
T067
TB069.................
T069
TB070.................
T070
TB071.................
T071
TB074.................
T074
TB075.................
T075
TB076.................
T076
TB077.................
T077
TB078.................
T078
TB081.................
T081
TB082.................
T082
TB083.................
T083
TB087.................
T087
TB088.................
T088
TB089.................
T158
TB090.................
T159
TB093.................
T093
TB094.................
T160
TB095.................
T095
TB099.................
T161
TB101.................
T101
TB102.................
T102
TB103.................
T103
TB104.................
T104
TB112.................
T176
TB113.................
T113
TB114.................
T114
TB115.................
T299
TB116.................
T300
TB117.................
T117
TB118.................
T162
TB119.................
T119
TB122.................
T122
TB124.................
T124
TB125.................
T125
TB126.................
T237
TB127.................
T127
TB128.................
T128
TB129.................
T129
TB130.................
T130
TB131.................
T131
TB132.................
T132
TB133.................
T292

Competitive
No.

Gates
No.

PIRELLI - Cont.
Timing Belts - Cont.
TB134.................
TB135.................
TB136.................
TB138.................
TB139.................
TB141.................
TB142.................
TB143.................
TB144.................
TB145.................
TB146.................
TB147.................
TB148.................
TB153.................
TB154.................
TB155.................
TB157.................
TB158.................
TB159.................
TB160.................
TB161.................
TB162.................
TB163.................
TB164.................
TB165.................
TB166.................
TB167.................
TB168.................
TB169.................
TB170.................
TB172.................
TB176.................
TB177.................
TB179.................
TB180.................
TB183.................
TB184.................
TB185.................
TB186.................
TB187.................
TB190.................
TB191.................
TB192.................
TB193.................
TB194.................
TB199.................
TB201.................
TB202.................
TB205.................
TB210.................
80013 .................
80014 .................
80017 .................
80018 .................
80020 .................
80028 .................
80032 .................
80037 .................
80039 .................
80041 .................
80042 .................
80043 .................
80061 .................
80062 .................
80064 .................
80065 .................
80067 .................
80069 .................
80070 .................
80071 .................
88013 .................
88014 .................
88017 .................
88018 .................
88020 .................
88028 .................
88032 .................
88037 .................
88039 .................
88041 .................
88042 .................
88043 .................
88061 .................
88062 .................
88063 .................
88064 .................
88065 .................
88067 .................
88069 .................
88070 .................
88071 .................
88074 .................

T134
T135
T233
T199
T139
T141
T142
T143
T144
T145
T146
T147
T148
T153
T154
T155
T157
T158
T159
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T254
T176
T177
T179
T180
T183
T184
T185
T186
T187
T190
T191
T192
T193
T194
T199
T201
T248
T205
T210
T013
T014
T017
T018
T020
T028
T032
T037
T039
T041
T068
T043
T061
T062
T064
T065
T067
T069
T070
T071
T013
T014
T017
T018
T020
T028
T032
T037
T039
T041
T068
T043
T061
T062
T073
T064
T065
T067
T069
T070
T071
T074

Competitive
No.

Gates
No.

PIRELLI - Cont.
Timing Belts - Cont.
88075 .................
T075
88076 .................
T076
88077 .................
T077
88078 .................
T078
88081 .................
T081
88082 .................
T082
88083 .................
T083
88087 .................
T087
88088 .................
T088
88089 .................
T158
88090 .................
T159
88093 .................
T093
88094 .................
T160
88095 .................
T095
88099 .................
T161
88101 .................
T101
88102 .................
T102
88104 .................
T104
88112 .................
T176
88113 .................
T113
88114 .................
T114
88115 .................
T299
88116 .................
T300
88117 .................
T117
88118 .................
T162
88122 .................
T122
88124 .................
T124
88125 .................
T125
88126 .................
T237
88130 .................
T130
88131 .................
T131
88132 .................
T132
88134 .................
T134
88136 .................
T233
88138 .................
T199
88141 .................
T141
88143 .................
T143
88144 .................
T144
88146 .................
T146
88153 .................
T153
88157 .................
T157
88158 .................
T158
88159 .................
T159
88160 .................
T160
88161 .................
T161
88162 .................
T162
88163 .................
T163
88165 .................
T165
88170 .................
T170
PRO-1
Timing Belts
013 .....................
T013
014 .....................
T014
017 .....................
T017
037 .....................
T037
039 .....................
T039
061 .....................
T061
067 .....................
T067
081 .....................
T081
PROVEN VALU
Timing Belts
TB-013 ...............
T013
TB-014 ...............
T014
TB-017 ...............
T017
TB-018 ...............
T018
TB-020 ...............
T020
TB-028 ...............
T028
TB-032 ...............
T032
TB-036 ...............
T036
TB-037 ...............
T037
TB-039 ...............
T039
TB-041 ...............
T041
TB-043 ...............
T043
TB-061 ...............
T061
TB-062 ...............
T062
TB-063 ...............
T073
TB-064 ...............
T064
TB-065 ...............
T065
TB-067 ...............
T067
TB-068 ...............
T068
TB-069 ...............
T069
TB-070 ...............
T070
TB-071 ...............
T071
TB-073 ...............
T073
TB-074 ...............
T074
TB-075 ...............
T075
TB-076 ...............
T076
TB-077 ...............
T077
TB-078 ...............
T078

Competitive
No.

Gates
No.

PROVEN VALU - Cont.

Timing Belts - Cont.
TB-079 ...............
T079
TB-081 ...............
T081
TB-082 ...............
T082
TB-083 ...............
T083
TB-084 ...............
T084
TB-087 ...............
T087
TB-088 ...............
T088
TB-089 ...............
T089
TB-090 ...............
T090
TB-091 ...............
T091
TB-092 ...............
T092
TB-093 ...............
T093
TB-094 ...............
T094
TB-095 ...............
T095
TB-096 ...............
T096
TB-098 ...............
T098
TB-099 ...............
T099
TB-100 ...............
T100
TB-101 ...............
T101
TB-102 ...............
T102
TB-103 ...............
T103
TB-104 ...............
T104
TB-112 ...............
T112
TB-113 ...............
T113
TB-114 ...............
T114
TB-115 ...............
T299
TB-116 ...............
T300
TB-117 ...............
T117
TB-118 ...............
T118
TB-119 ...............
T119
TB-121 ...............
T121
TB-122 ...............
T122
TB-123 ...............
T123
TB-125 ...............
T125
TB-126 ...............
T126
TB-127 ...............
T127
TB-128 ...............
T128
TB-129 ...............
T129
TB-130 ...............
T130
TB-134 ...............
T134
TB-139 ...............
T139
REPCOPARTS
Timing Belts
4013 ...................
T013
4014 ...................
T014
4017 ...................
T017
4018 ...................
T018
4020 ...................
T020
4028 ...................
T028
4029 ...................
T104
4032 ...................
T032
4036 ...................
T036
4037 ...................
T037
4039 ...................
T039
4041 ...................
T041
4042 ...................
T068
4043 ...................
T043
4061 ...................
T061
4065 ...................
T065
4070 ...................
T070
4071 ...................
T071
4073 ...................
T073
4074 ...................
T074
4077 ...................
T077
4078 ...................
T078
4079 ...................
T079
4081 ...................
T081
4082 ...................
T082
4083 ...................
T083
4084 ...................
T084
4089 ...................
T089
4091 ...................
T091
4092 ...................
T092
4093 ...................
T093
4094 ...................
T094
4095 ...................
T095
4096 ...................
T096
4097 ...................
T097
4098 ...................
T098
4099 ...................
T099
4100 ...................
T100
4101 ...................
T101
4102 ...................
T102
4103 ...................
T103
4104 ...................
T104
4106 ...................
T106

Competitive
No.

797
Gates
No.

REPUBLIC
Timing Belts
R0112.................
T176
R0113.................
T113
R0114.................
T114
R0115.................
T299
R0116.................
T300
R0117.................
T117
R0118.................
T162
R0119.................
T119
R0122.................
T122
R0124.................
T124
R0125.................
T125
R0126.................
T126
R0127.................
T127
R0128.................
T128
R0129.................
T129
R0130.................
T130
R0132.................
T132
R0133.................
T292
R0134.................
T134
R0135.................
T135
R0136.................
T233
R0138.................
T138
R0139.................
T139
R0141.................
T141
R0142.................
T142
R0143.................
T143
R0144.................
T144
R0145.................
T145
R0146.................
T146
R0147.................
T147
R0148.................
T148
R0153.................
T153
R0154.................
T154
R0157.................
T157
R0158.................
T158
R0159.................
T159
R0160.................
T160
R0161.................
T161
R0162.................
T162
R0163.................
T163
R0164.................
T164
R0166.................
T166
R0167.................
T167
R0168.................
T168
R0169.................
T169
R0170.................
T170
R0176.................
T176
R0177.................
T177
R0179.................
T179
R0184.................
T184
R0185.................
T185
R0186.................
T186
R0187.................
T187
R082...................
T082
R083...................
T083
REPUBLIC PARTS
Timing Belts
R-0100 ...............
T100
R-0101 ...............
T101
R-0102 ...............
T102
R-0103 ...............
T103
R-0104 ...............
T104
R-0112 ...............
T112
R-013 .................
T013
R-014 .................
T014
R-017 .................
T017
R-018 .................
T018
R-020 .................
T020
R-028 .................
T028
R-032 .................
T032
R-036 .................
T036
R-037 .................
T037
R-039 .................
T039
R-041 .................
T041
R-042 .................
T068
R-043 .................
T043
R-061 .................
T061
R-062 .................
T062
R-063 .................
T073
R-064 .................
T064
R-065 .................
T065
R-067 .................
T067
R-068 .................
T068
R-069 .................
T069
R-070 .................
T070
R-071 .................
T071
R-073 .................
T073
R-074 .................
T074
R-075 .................
T075
R-076 .................
T075
R-077 .................
T077

798
Competitive
No.

Changeover Listing - PowerGrip Timing System Products

Gates
No.

REPUBLIC PARTS - Cont.

Timing Belts - Cont.
R-078 .................
T078
R-079 .................
T079
R-081 .................
T081
R-084 .................
T084
R-087 .................
T087
R-088 .................
T088
R-089 .................
T089
R-090 .................
T090
R-091 .................
T091
R-092 .................
T092
R-093 .................
T093
R-094 .................
T094
R-095 .................
T095
R-096 .................
T096
R-098 .................
T098
R-099 .................
T099
ROCKHILL
Timing Belts
TB-100 ...............
T100
TB-101 ...............
T101
TB-102 ...............
T102
TB-103 ...............
T103
TB-104 ...............
T104
TB-112 ...............
T176
TB-118 ...............
T118
TB-13 .................
T013
TB-14 .................
T014
TB-17 .................
T017
TB-18 .................
T018
TB-20 .................
T020
TB-28 .................
T028
TB-32 .................
T032
TB-36 .................
T036
TB-37 .................
T037
TB-39 .................
T039
TB-41 .................
T041
TB-43 .................
T043
TB-61 .................
T061
TB-62 .................
T062
TB-63 .................
T073
TB-64 .................
T064
TB-65 .................
T065
TB-67 .................
T067
TB-68 .................
T068
TB-69 .................
T069
TB-70 .................
T070
TB-71 .................
T071
TB-73 .................
T073
TB-74 .................
T074
TB-75 .................
T075
TB-76 .................
T076
TB-77 .................
T077
TB-78 .................
T078
TB-79 .................
T079
TB-81 .................
T081
TB-82 .................
T082
TB-83 .................
T083
TB-84 .................
T084
TB-87 .................
T087
TB-88 .................
T088
TB-89 .................
T158
TB-90 .................
T159
TB-91 .................
T091
TB-92 .................
T092
TB-93 .................
T093
TB-94 .................
T094
TB-95 .................
T095
TB-98 .................
T098
TB-99 .................
T161
SEALED POWER
Timing Belts
222-100..............
T100
222-13................
T013
222-14................
T014
222-17................
T017
222-18................
T018
222-20................
T020
222-28................
T028
222-32................
T032
222-36................
T036
222-37................
T037
222-39................
T039
222-41................
T041
222-42................
T068
222-43................
T043
222-61................
T061
222-62................
T062
222-63................
T073
222-64................
T064

Competitive
No.

Gates
No.

SEALED POWER - Cont.

Timing Belts - Cont.
222-65................
222-67................
222-69................
222-70................
222-71................
222-73................
222-74................
222-75................
222-76................
222-77................
222-78................
222-81................
222-87................
222-88................
222-89................
222-90................
222-91................
222-92................
222-93................
222-94................
222-95................
222-99................
222B160.............
222B161.............
222B162.............
222B163.............
222B164.............
222B165.............
222B166.............
222B167.............
222B168.............
222B169.............
222B170.............
222B172.............
222B177.............
222B179.............
222B180.............
222B183.............
222B184.............
222B185.............
222B186.............
222B187.............
222B193.............
222B194.............
222B202.............
222B210.............
222013 ...............
222014 ...............
222017 ...............
222018 ...............
222020 ...............
222028 ...............
222032 ...............
222036 ...............
222037 ...............
222039 ...............
222041 ...............
222043 ...............
222061 ...............
222062 ...............
222063 ...............
222064 ...............
222065 ...............
222067 ...............
222069 ...............
222070 ...............
222071 ...............
222074 ...............
222075 ...............
222076 ...............
222077 ...............
222078 ...............
222082 ...............
222083 ...............
222087 ...............
222088 ...............
222089 ...............
222090 ...............
222093 ...............
222094 ...............
222095 ...............
222099 ...............
222101 ...............
222102 ...............
222103 ...............
222104 ...............
222107 ...............
222108 ...............
222110 ...............
222112 ...............
222113 ...............
222114 ...............

T065
T067
T069
T070
T071
T073
T074
T075
T076
T077
T078
T081
T087
T088
T089
T090
T091
T092
T093
T094
T095
T161
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T254
T177
T179
T180
T183
T184
T185
T186
T187
T193
T194
T248
T210
T013
T014
T017
T018
T020
T028
T032
T036
T037
T039
T041
T043
T061
T062
T073
T064
T065
T067
T069
T070
T071
T074
T075
T076
T077
T078
T082
T083
T087
T088
T158
T159
T093
T160
T095
T161
T101
T102
T103
T104
T107
T293
T196
T176
T113
T114

Competitive
No.

Gates
No.

SEALED POWER - Cont.

Timing Belts - Cont.
222115 ...............
T299
222116 ...............
T300
222117 ...............
T117
222118 ...............
T162
222119 ...............
T119
222122 ...............
T122
222124 ...............
T124
222125 ...............
T125
222126 ...............
T237
222128 ...............
T128
222129 ...............
T129
222130 ...............
T130
222131 ...............
T131
222132 ...............
T132
222133 ...............
T292
222134 ...............
T134
222135 ...............
T135
222136 ...............
T233
222138 ...............
T199
222139 ...............
T139
222141 ...............
T141
222142 ...............
T142
222143 ...............
T143
222144 ...............
T144
222145 ...............
T145
222146 ...............
T146
222147 ...............
T147
222148 ...............
T148
222152 ...............
T152
222153 ...............
T153
222154 ...............
T154
222155 ...............
T155
222157 ...............
T157
222158 ...............
T158
222159 ...............
T159
SIERRA
Timing Belts
18-4029..............
T032
SKF
Timing Belt Tensioners
VKM11000 .........
T41079
VKM11010 .........
T41080
VKM11113 .........
T43010
VKM16300 .........
T41081
VKM18100 .........
T41083
VKM51001 .........
T41002
VKM51003 .........
T41084
VKM54000 .........
T41006
VKM54001 .........
T41005
VKM54002 .........
T41008
VKM54003 .........
T43003
VKM61000 .........
T41001
VKM61001 .........
T41000
VKM64000 .........
T41007
VKM70001 .........
T43002
VKM71001 .........
T41068
VKM71003 .........
T41067
VKM71004 .........
T41075
VKM71007 .........
T41072
VKM71008 .........
T41078
VKM71100 .........
T41077
VKM71101 .........
T41070
VKM71201 .........
T41076
VKM71202 .........
T41066
VKM71400 .........
T41071
VKM71401 .........
T41074
VKM71404 .........
T41069
VKM71800 .........
T41073
VKM72000 .........
T41058
VKM72004 .........
T41059
VKM72200 .........
T41088
VKM72300 .........
T41089
VKM73000 .........
T41011
VKM73001 .........
T41015
VKM73002 .........
T41019
VKM73003 .........
T41018
VKM73004 .........
T41021
VKM73005 .........
T41023
VKM73006 .........
T41024
VKM73007 .........
T41022
VKM73011 .........
T41013
VKM73101 .........
T41017
VKM73200 .........
T41012
VKM73201 .........
T41016
VKM73600 .........
T41014
VKM73605 .........
T41090
VKM74000 .........
T41034
VKM74001 .........
T41035
VKM74002 .........
T41091

Competitive
No.

Gates
No.

SKF - Cont.
Timing Belt Tensioners
- Cont.
VKM74005 .........
T41036
VKM74007 .........
T41033
VKM74200 .........
T41030
VKM74201 .........
T41031
VKM74600 .........
T41029
VKM75000 .........
T41039
VKM75001 .........
T41051
VKM75002 .........
T41052
VKM75004 .........
T41048
VKM75006 .........
T41037
VKM75008 .........
T41045
VKM75033 .........
T41044
VKM75044 .........
T41047
VKM75064 .........
T41054
VKM75100 .........
T41042
VKM75101 .........
T41055
VKM75108 .........
T41056
VKM75113 .........
T41053
VKM75119 .........
T41057
VKM75130 .........
T41043
VKM75144 .........
T41046
VKM75601 .........
T41050
VKM75612 .........
T41049
VKM75613 .........
T41038
VKM76001 .........
T41065
VKM76200 .........
T41010
VKM76202 .........
T41064
VKM76203 .........
T41009
VKM77300 .........
T41003
VKM77500 .........
T41004
VKM78000 .........
T41063
VKM78001 .........
T41062
VKM78002 .........
T41061
VKM78003 .........
T41092
VKM78105 .........
T41060
VKM79000 .........
T41026
VKM79001 .........
T41025
VKM79007 .........
T41028
Timing Belt Pulleys
VKM64001 .........
T42032
VKM64002 .........
T42033
VKM64003 .........
T42034
VKM64004 .........
T42035
VKM64005 .........
T42036
VKM81000 .........
T42030
VKM81001 .........
T42026
VKM81004 .........
T42025
VKM81005 .........
T42031
VKM81007 .........
T42037
VKM81100 .........
T42027
VKM81200 .........
T42028
VKM81400 .........
T42029
VKM82000 .........
T42021
VKM82001 .........
T41085
VKM82501 .........
T42020
VKM83003 .........
T42038
VKM84000 .........
T42008
VKM84001 .........
T42010
VKM84002 .........
T42009
VKM84003 .........
T42013
VKM84004 .........
T42012
VKM84005 .........
T42007
VKM84006 .........
T42006
VKM84007 .........
T42011
VKM84201 .........
T42005
VKM84600 .........
T42003
VKM84601 .........
T42004
VKM85000 .........
T42017
VKM85002 .........
T42018
VKM88000 .........
T42023
VKM88001 .........
T42024
VKM88002 .........
T42022
VKM89000 .........
T42002
SUNOCO
Timing Belts
TB063.................
T073
TB070.................
T070
TB077.................
T077
TB401.................
T014
TB402.................
T013
TB403.................
T037
TB404.................
T017
TB409.................
T039
TB411.................
T041
TB415.................
T028
TB418.................
T061
TB428.................
T067
T1043.................
T043
T1064.................
T064

Competitive
No.

Gates
No.

SUNOCO - Cont.
Timing Belts - Cont.
T1071.................
T071
T1081.................
T081
T.R.W.
Timing Belts
LB042.................
T068
LB074.................
T074
LB075.................
T075
LB077.................
T077
LB078.................
T078
LB079.................
T079
LB081.................
T081
LB082.................
T082
LB083.................
T083
LB084.................
T084
LB087.................
T087
LB088.................
T088
LB090.................
T090
LB091.................
T091
LB092.................
T092
LB093.................
T093
LB094.................
T094
LB095.................
T095
LB100.................
T100
LB101.................
T101
LB102.................
T102
LB103.................
T103
LB104.................
T104
LB112.................
T112
LB113.................
T113
LB114.................
T114
LB115.................
T299
LB116.................
T300
LB117.................
T117
LB118.................
T162
LB119.................
T119
LB121.................
T121
LB122.................
T122
LB123.................
T123
LB124.................
T124
LB125.................
T125
LB126.................
T237
LB128.................
T128
LB129.................
T129
LB13...................
T013
LB130.................
T130
LB132.................
T132
LB134.................
T134
LB136.................
T233
LB137.................
T137
LB138.................
T199
LB139.................
T139
LB14...................
T014
LB141.................
T141
LB142.................
T142
LB143.................
T143
LB144.................
T144
LB146.................
T146
LB148.................
T148
LB149.................
T149
LB150.................
T150
LB151.................
T151
LB153.................
T153
LB155.................
T155
LB157.................
T157
LB158.................
T158
LB159.................
T159
LB160.................
T160
LB161.................
T161
LB163.................
T163
LB164.................
T164
LB165.................
T165
LB166.................
T166
LB167.................
T167
LB168.................
T168
LB169.................
T169
LB17...................
T017
LB18...................
T018
LB20...................
T020
LB28...................
T028
LB32...................
T032
LB36...................
T036
LB37...................
T037
LB39...................
T039
LB41...................
T041
LB43...................
T043
LB61...................
T061
LB62...................
T062
LB63...................
T073
LB64...................
T064
LB65...................
T065

Changeover Listing - PowerGrip Timing System Products

Competitive
No.

Gates
No.

Competitive
No.

Gates
No.

Competitive
No.

Gates
No.

Competitive
No.

Gates
No.

Competitive
No.

799
Gates
No.

T.R.W. - Cont.
Timing Belts - Cont.

ULTRALAST - Cont.
Timing Belts - Cont.

UNIROYAL - Cont.
Timing Belts - Cont.

VERA - Cont.
Timing Belts - Cont.

WOLVERINE - Cont.
Timing Belts - Cont.

LB67...................
T067
LB68...................
T068
LB69...................
T069
LB70...................
T070
LB71...................
T071
LB73...................
T073
LB74...................
T074
LB75...................
T075
LB76...................
T076
LB77...................
T077
LB78...................
T078
LB79...................
T079
LB81...................
T081
LB82...................
T082
LB83...................
T083
LB84...................
T084
LB87...................
T087
LB88...................
T088
LB89...................
T158
LB90...................
T159
LB91...................
T091
LB92...................
T092
LB93...................
T093
LB94...................
T160
LB95...................
T095
LB96...................
T096
LB98...................
T098
LB99...................
T161
TEXACO
Timing Belts
TB401.................
T014
TB402.................
T013
TB403.................
T037
TB404.................
T017
TB409.................
T039
TB411.................
T041
TB415.................
T028
ULTRALAST
Timing Belts
B013...................
T013
B014...................
T014
B017...................
T017
B028...................
T028
B032...................
T032
B036...................
T036
B037...................
T037
B039...................
T039
B041...................
T041
B043...................
T043
B061...................
T061
B064...................
T064
B067...................
T067
B070...................
T070
B071...................
T071
B073...................
T073
B074...................
T074
B077...................
T077
B078...................
T078
B081...................
T081
B087...................
T087
B088...................
T088
B089...................
T089
B090...................
T090
B094...................
T094
B095...................
T095
B099...................
T099
B101...................
T101
B104...................
T104
B112...................
T112
B113...................
T113
B114...................
T114
B116...................
T300
B117...................
T117
B118...................
T118
B122...................
T122
B124...................
T124
B125...................
T125
B126...................
T126
B128...................
T128
B129...................
T129
B130...................
T130
B132...................
T132
B134...................
T134
B136...................
T136
B138...................
T138
B139...................
T139
B141...................
T141
B142...................
T142
B143...................
T143

B145...................
T145
B146...................
T146
B147...................
T147
B148...................
T148
B153...................
T153
B154...................
T154
B155...................
T155
B157...................
T157
B158...................
T158
B159...................
T159
B160...................
T160
B161...................
T161
B162...................
T162
B163...................
T163
B164...................
T164
B166...................
T166
B167...................
T167
B168...................
T168
B172...................
T172
B177...................
T177
B179...................
T179
B184...................
T184
B185...................
T185
B186...................
T186
B187...................
T187
B191...................
T191
B194...................
T194
B199...................
T199
B233...................
T233
B236...................
T236
B32.....................
T032
TB063.................
T073
TB070.................
T070
TB077.................
T077
TB401.................
T014
TB402.................
T013
TB403.................
T037
TB404.................
T017
TB409.................
T039
TB411.................
T041
TB415.................
T028
TB418.................
T061
TB428.................
T067
T013...................
T013
T014...................
T014
T017...................
T017
T028...................
T028
T032...................
T032
T037...................
T037
T039...................
T039
T041...................
T041
T043...................
T043
T061...................
T061
T063...................
T073
T064...................
T064
T067...................
T067
T070...................
T070
T071...................
T071
T073...................
T073
T077...................
T077
T081...................
T081
T087...................
T087
T089...................
T089
T092...................
T092
T094...................
T094
T099...................
T099
T1043.................
T043
T1064.................
T064
T1071.................
T071
T1081.................
T081
T115...................
T299
T203...................
T203
T210...................
T210
T228...................
T228
UNIROYAL
Timing Belts
A206L050...........
T062
A206L050S ........
T090
A315L075...........
T028
A326L134B ........
T075
A330L075...........
T070
A345L075...........
T073
A356L075...........
T041
A363L100...........
T067
A367L075...........
T078
A371L060...........
T037
A371L075...........
T039
A375L075...........
T061
A397L075...........
T077
A408L075...........
T088

A416L075R ........
T081
A423L075...........
T065
A435L075...........
T018
A442L075...........
T069
A443L075...........
T069
A450L075...........
T064
A450L075S ........
T093
A453L075...........
T017
A457L075...........
T013
A457L075S ........
T158
A461L075...........
T032
A465L100...........
T071
A483L087...........
T014
A484L088...........
T014
A502L118B ........
T076
A506L100B ........
T043
A521L100...........
T087
A532L100...........
T074
A547L075...........
T020
A555L075...........
T068
UNOCAL
Timing Belts
TB063.................
T073
TB070.................
T070
TB077.................
T077
TB401.................
T014
TB402.................
T013
TB403.................
T037
TB404.................
T017
TB409.................
T039
TB411.................
T041
TB415.................
T028
TB418.................
T061
TB428.................
T067
T013...................
T013
T014...................
T014
T017...................
T017
T028...................
T028
T032...................
T032
T037...................
T037
T039...................
T039
T041...................
T041
T043...................
T043
T061...................
T061
T063...................
T073
T064...................
T064
T067...................
T067
T070...................
T070
T071...................
T071
T073...................
T073
T077...................
T077
T081...................
T081
T094...................
T094
T1043.................
T043
T1064.................
T064
T1071.................
T071
T1081.................
T081
VERA
Timing Belts
A326L134B ........
T075
45-00070............
T062
45-00096............
T062
45-00724............
T028
45-00732............
T036
45-00740............
T020
45-00773............
T032
45-00781............
T018
45-00799............
T014
45-00807............
T013
45-00815............
T043
45-00823............
T017
45-00849............
T065
45-00856............
T069
45-00864............
T070
45-00930............
T073
45-00948............
T064
45-00955............
T041
45-01051............
T082
45-01069............
T083
45-01127............
T076
45-01135............
T075
45-01150............
T078
45-01168............
T077
45-01176............
T074
45-01200............
T107
45-01226............
T158
45-01234............
T091
45-01267............
T106
45-01275............
T196

45-01283............
T088
45-01291............
T087
45-01325............
T104
45-01341............
T099
45-01366............
T094
45-01382............
T093
45-01408............
T062
45-01424............
T100
45-01440............
T103
45-01481............
T090
45-01499............
T092
45-01580............
T127
45-01614............
T293
45-01622............
T292
45-01630............
T118
45-01648............
T095
45-01655............
T137
45-01663............
T300
45-01671............
T299
45-01689............
T131
45-01697............
T135
45-01705............
T136
45-01713............
T176
45-01721............
T126
45-01739............
T101
45-01754............
T138
45-01762............
T129
45-01770............
T071
45-01788............
T122
45-01796............
T141
45-01804............
T134
45-01812............
T113
45-01820............
T117
45-01838............
T124
45-01853............
T121
45-01861............
T140
45-01879............
T147
45-01887............
T102
45-01895............
T119
45-01911............
T152
45-01945............
T187
45-01952............
T186
45-01960............
T143
45-01978............
T145
45-01986............
T144
45-01994............
T142
45-02009............
T124
45-02017............
T169
45-02025............
T149
45-02033............
T146
45-02041............
T155
45-02066............
T167
45-02074............
T168
45-02082............
T139
45-02090............
T300
45-02108............
T299
45-02116............
T164
45-02124............
T157
45-02140............
T199
45-02157............
T154
45-02199............
T127
45-02215............
T128
45-05074............
T168
WESTERN AUTO
Timing Belts
74-2736-2...........
T067
74-2737-0...........
T061
74-2738-8...........
T039
74-2739-6...........
T037
74-2741-2...........
T013
74-2742-0...........
T014
74-2743-8...........
T017
74-2744-6...........
T071
WOLVERINE
Timing Belts
TB013.................
T013
TB014.................
T014
TB017.................
T017
TB018.................
T018
TB020.................
T020
TB028.................
T028
TB032.................
T032
TB036.................
T036
TB037.................
T037
TB039.................
T039
TB041.................
T041
TB043.................
T043
TB061.................
T061
TB062.................
T062

TB063.................
T073
TB064.................
T064
TB067.................
T067
TB069.................
T069
TB070.................
T070
TB071.................
T071
TB073.................
T073
TB077.................
T077
TB078.................
T078
TB081.................
T081
TB095.................
T095
WORLD PARTS
Timing Belts
W11-600.............
T018
W11-601.............
T020
W11-631.............
T075
W11-636.............
T013
W11-639.............
T013
W11-640.............
T076
W11-643.............
T017
W11-645.............
T020
W11-651.............
T028
W11-654.............
T041
W11-655.............
T014
W11-657.............
T036
W11-658.............
T032
W11-659.............
T043
W11-660.............
T064
W11-661.............
T062
W11-665.............
T070
W11-669.............
T073
W11-670.............
T065
W11-673.............
T068
W16-801.............
T079
W16-802.............
T084
W16-803.............
T078
W16-804.............
T087
W16-805.............
T101
W16-807.............
T090
W16-808.............
T158
W16-811.............
T083
W16-812.............
T082
W16-814.............
T299
W16-815.............
T094
W16-816.............
T300

800

Manufacturers Part Numbers

PowerGrip Timing System Products
Showing Factory Part Numbers for Timing Belts, Tensioners and Pulleys
With the Corresponding PowerGrip Replacement Numbers

Mfr.
Part No.
ADO41407 ..........
AD041407 ...........
A405RU100.........
BNP2955.............
BPY112205 .........
BP0112205 .........
BP0112205A .......
BP0112205B .......
BP0212205 .........
BP0212205A .......
B10112205A .......
B59712205..........
B6S712205A .......
B6S712205B .......
B6S712205C Kia
B6S712205C Ma
zda ....................
B6S712205D.......
B6Y212205 .........
B63012205..........
B63012205A .......
B63012205B .......
B63012205C .......
B63012205D .......
B63012205E .......
B63012700C .......
B63012700D .......
B63012700E .......
B63212205..........
B632122050........
B66012205..........
B66012205B .......
B66012205C .......
B66012700D .......
B66012700E .......
B66012730A .......
B66012730B .......
B66012730C .......
C3905942............
DBP4131.............
DBP9289.............
D1FZ 6268 A ......
D4FZ 6K 254A....
D4FZ 6268 A ......
D4ZE 6268 AE ...
D42E 6268 AB....
D8EE 6268 AA ...
D9EE 6268 AA ...
ECP244...............
E1EE 6268 DA ...
E1FZ 6268 D ......
E2CE 6268 AA ...
E2EE 6268 AA ...
E3EE 6268 AA ...
E3FZ 6268 A ......
E43Z 6268 B ......
E43Z 6268 C ......
E5EE 6K 254AA .
E5FZ 6K254 A....
E5FZ 6268 A ......
E5RE 6268 AA ...
E5RE 8286 AA ...
E5TZ 6268 A ......
E5TZ 6268 B ......
E5ZZ 6268 A ......
E7GZ 6268 A......
E7GZ 6268 B......
E7GZ 6268 C .....
E80112205..........
E9DZ 6268 A......
E9JY 6K 254A ....
E9JY 6268 A ......
E92Z 6K 254A ....
FC01201202 .......
FC01201203 .......
FDU1464.............
FEO1122050.......
FEY812205 .........
FEY8122050 .......
FEY912205 .........
FE0112205..........
FE01122050........

Gates
No.
T090
T090
T264
T028
T185
T185
T185
T185
T185
T185
T141
T179
T179
T179
T179
T179
T179
T141
T141
T123
T123
T123
T141
T141
T41030
T41030
T41030
T141
T141
T149
T149
T149
T41031
T41031
T42005
T42005
T42005
T165
T099
T099
T013
T41005
T014
T014
T014
T014
T014
T129
T067
T067
T194
T067
T067
T067
T103
T102
T41006
T41006
T067
T014
T142
T092
T091
T014
T141
T141
T141
T077
T248
T41031
T179
T41029
T020
T020
T142
T088
T113
T113
T113
T088
T088

Mfr.
Part No.
FE0212205..........
FE0312205..........
FE03122050........
FE0412205..........
FE04122050........
FE0612205..........
FE0812205..........
FE08122050........
FE0912205..........
FE09122050........
FE1H12205A.......
FE1H12700A.......
FE1H12730 .........
FE1H12730A.......
FE1J12205..........
FE3N12730 .........
FE7912205..........
FE7915205..........
FP0112205A .......
FSY112205 .........
FS0112205A .......
FS0112700A .......
FS0112700B .......
FS0112730A .......
FS0212205..........
F0BZ 6268 A ......
F0CZ 6K 254A....
F0EE 6K 254AA .
F1ZZ 6268 A ......
F17E 6268 AA ....
F2CE 6268 AA ...
F2Y112205..........
F20212205 ..........
F20312205 ..........
F21012205 ..........
F3BZ 6268 A ......
F3CZ 6268 A ......
F3DZ 6268 A ......
F3XY 6268 A ......
F32Z 6268 A.......
F32Z 6268 B.......
F37E 6268 AA ....
F4BZ 6268 A ......
F4XY 6268 A ......
F42Z 6268 A.......
F47E 6268 AA ....
F47Z 6268 B.......
F5CE 6268 AA ...
F5RZ 6K 254A....
F5RZ 6268 A ......
F50112700A........
F50112730A........
F50512700B........
F57E 6K 254AA..
F57E 6268 AA ....
F57E 6268 BB ....
F57Z 6K 254A ....
F57Z 6268 A.......
F7CZ 6268 AA....
F8CZ 6K 254AA .
F8CZ 6268 AA....
F80112205 ..........
F80212205 ..........
F80512700 ..........
F80512700A........
F80512700C .......
F9JY 6268 A.......
GC01201200.......
GC01201201.......
GTB1208.............
GTB1237.............
HM8268BA..........
JE1512730 ..........
JE1512730A........
JE1512730D .......
JE1512750 ..........
JE1512750A........
JE2612205 ..........
JE2612205A........
JE2612205B........
JE26122050 ........
JE2612730A........

Gates
No.
T088
T113
T113
T113
T113
T117
T117
T113
T117
T113
T264
T41029
T42003
T42003
T264
T42004
T113
T113
T316
T228
T228
T41091
T41091
T42008
T228
T185
T41007
T41007
T210
T210
T194
T134
T134
T134
T134
T185
T179
T248
T104
T228
T214
T210
T185
T249
T228
T210
T210
T283
T41008
T258
T41091
T42008
T41091
T41005
T276
T276
T41005
T276
T283
T43003
T294
T077
T077
T41035
T41035
T41035
T179
T068
T068
T129
T142
T013
T42011
T42011
T42011
T41033
T41033
T183
T183
T183
T183
T42006

Mfr.
Part No.
JE2612740 ..........
JE2612740A........
JE2612750 ..........
JE4812730 ..........
JE4812740 ..........
JF0112205 ..........
JF0112205A........
JF0112205D........
JF0112730 ..........
JF0112730A........
JF0112750 ..........
J0856351 ............
KJ0112205 ..........
KLY212SJ0 .........
KL0112205..........
KL0112730..........
KL0112730A .......
KL0112740..........
KL0112750..........
KL0212750..........
KL0212750A .......
K0AA352700 .......
K0BA352700 .......
LHN100420L .......
LNH100410L .......
MBP0112205B K
ia .......................
MBP0112205B M
itsubishi .............
MB6S712205C....
MD008960...........
MD008961...........
MD008965...........
MD008968...........
MD008969...........
MD009277...........
MD009352...........
MD009650...........
MD009651...........
MD009666...........
MD009667...........
MD011536...........
MD013805...........
MD015310...........
MD015311...........
MD015701...........
MD030599...........
MD030600...........
MD030605...........
MD030610...........
MD040754...........
MD040756...........
MD040797...........
MD041390...........
MD041407...........
MD050119...........
MD050125...........
MD050130...........
MD050135...........
MD050175...........
MD060461...........
MD068173...........
MD095866...........
MD098491...........
MD098492...........
MD098706...........
MD099706...........
MD099707...........
MD099708...........
MD100103...........
MD100619...........
MD100620...........
MD100632...........
MD100679...........
MD100814...........
MD102248...........
MD102249...........
MD104578...........
MD106103...........
MD109958...........
MD110029...........
MD110041...........

Gates
No.
T42007
T42007
T41036
T42012
T42013
T146
T146
T146
T42011
T42011
T41033
T140
T267
T41034
T214
T42010
T42010
T42009
T41034
T41034
T41034
T248
T248
T326
T327
T185

T185
T179
T013
T062
T41055
T013
T062
T064
T013
T41057
T062
T064
T064
T41043
T093
T093
T159
T089
T073
T073
T41042
T073
T41053
T062
T062
T158
T159
T092
T41049
T091
T41050
T092
T091
T124
T093
T089
T124
T073
T073
T091
T090
T090
T064
T013
T062
T139
T128
T093
T158
T41048
T159
T41056
T167
T165

Interference engine application.

Mfr.
Part No.
MD110709...........
MD111427...........
MD113561...........
MD113562...........
MD113563...........
MD113564...........
MD113790...........
MD115976...........
MD115977...........
MD120487...........
MD121993...........
MD128765...........
MD129033...........
MD129355...........
MD133115...........
MD133116...........
MD134377...........
MD13805.............
MD140070...........
MD140071...........
MD140227...........
MD140228...........
MD140229...........
MD145713...........
MD145714...........
MD145716...........
MD145813...........
MD146186...........
MD151447...........
MD152243...........
MD152622...........
MD154243...........
MD156604...........
MD160103...........
MD161427...........
MD171748...........
MD171749...........
MD175375...........
MD176387...........
MD182195...........
MD182201...........
MD182291...........
MD182292...........
MD182293...........
MD182294...........
MD182295 Chrys
ler ......................
MD182295 Mitsu
bishi...................
MD182537...........
MD183005...........
MD183006...........
MD185544...........
MD189522...........
MD191982...........
MD192068...........
MD193874...........
MD193875...........
MD199418...........
MD307487...........
MD315265...........
MD319022...........
MD322641...........
MD325854...........
MD326059...........
MD336149...........
MD340625...........
MO4667611 ........
OHC013 ..............
OHC014 ..............
OHC017 ..............
OHC018 ..............
OHC020 ..............
OHC028 ..............
OHC032 ..............
OHC036 ..............
OHC037 ..............
OHC039 ..............
OHC041 ..............
OHC043 ..............
OHC061 ..............
OHC062 ..............

Gates
No.
T124
T139
T064
T013
T073
T128
T158
T41047
T168
T155
T42017
T41045
T41044
T41046
T167
T165
T091
T093
T195
T41039
T155
T158
T124
T167
T165
T168
T191
T41051
T42018
T159
T092
T204
T42017
T090
T195
T167
T168
T41052
T201
T168
T165
T167
T256
T232
T230
T168
T168

T41054
T195
T253
T41038
T229
T288
T41038
T195
T253
T165
T259
T41052
T42018
T287
T289
T167
T232
T289
T246
T013
T014
T017
T018
T020
T028
T032
T036
T037
T039
T041
T043
T061
T062

Mfr.
Part No.
OHC064 ..............
OHC065 ..............
OHC067 ..............
OHC068 ..............
OHC069 ..............
OHC070 ..............
OHC071 ..............
OHC073 ..............
OHC074 ..............
OHC075 ..............
OHC076 ..............
OHC077 ..............
OHC078 ..............
OHC079 ..............
OHC081 ..............
OHC082 ..............
OHC083 ..............
OHC084 ..............
OHC087 ..............
OHC088 ..............
OHC089 ..............
OHC090 ..............
OHC091 ..............
OHC092 ..............
OHC093 ..............
OHC094 ..............
OHC095 ..............
OHC096 ..............
OHC097 ..............
OHC098 ..............
OHC099 ..............
OHC100 ..............
OHC101 ..............
OHC102 ..............
OHC103 ..............
OHC104 ..............
OHC106 ..............
OHC107 ..............
OHC112 ..............
OHC113 ..............
OHC114 ..............
OHC117 ..............
OHC118 ..............
OHC119 ..............
OHC120 ..............
OHC121 ..............
OHC122 ..............
OHC123 ..............
OHC124 ..............
OHC125 ..............
OHC126 ..............
OHC127 ..............
OHC128 ..............
OHC129 ..............
OHC130 ..............
OHC131 ..............
OHC132 ..............
OHC134 ..............
OHC135 ..............
OHC136 ..............
OHC137 ..............
OHC138 ..............
OHC139 ..............
OHC140 ..............
OHC141 ..............
OHC142 ..............
OHC143 ..............
OHC144 ..............
OHC145 ..............
OHC146 ..............
OHC147 ..............
OHC148 ..............
OHC149 ..............
OHC150 ..............
OHC151 ..............
OHC152 ..............
OHC153 ..............
OHC154 ..............
OHC155 ..............
OHC157 ..............
OHC158 ..............
OHC159 ..............

Gates
No.
T064
T065
T067
T068
T069
T070
T071
T073
T074
T075
T076
T077
T078
T079
T081
T082
T083
T084
T087
T088
T089
T090
T091
T092
T093
T094
T095
T096
T097
T098
T099
T100
T101
T102
T103
T104
T106
T107
T112
T113
T114
T117
T118
T119
T120
T121
T122
T123
T124
T125
T126
T127
T128
T129
T130
T131
T132
T134
T135
T136
T137
T138
T139
T140
T141
T142
T143
T144
T145
T146
T147
T148
T149
T150
T151
T152
T153
T154
T155
T157
T158
T159

801

Manufacturers Part Numbers - PowerGrip Timing System Products

Mfr.
Part No.
OHC160 ..............
OHC161 ..............
OHC162 ..............
OHC163 ..............
OHC164 ..............
OHC165 ..............
OHC166 ..............
OHC167 ..............
OHC168 ..............
OHC169 ..............
OHC170 ..............
OHC171 ..............
OHC172 ..............
OHC173 ..............
OHC174 ..............
OHC176 ..............
OHC177 ..............
OHC178 ..............
OHC179 ..............
OHC180 ..............
OHC181 ..............
OHC182 ..............
OHC183 ..............
OHC184 ..............
OHC185 ..............
OHC186 ..............
OHC187 ..............
OHC188 ..............
OHC189 ..............
OHC190 ..............
OHC191 ..............
OHC192 ..............
OHC193 ..............
OHC194 ..............
OHC195 ..............
OHC196 ..............
OHC197 ..............
OHC198 ..............
OHC199 ..............
OHC200 ..............
OHC201 ..............
OHC203 ..............
OHC204 ..............
OHC205 ..............
OHC206 ..............
OHC207 ..............
OHC208 ..............
OHC209 ..............
OHC210 ..............
OHC211 ..............
OHC212 ..............
OHC213 ..............
OHC214 ..............
OHC215 ..............
OHC216 ..............
OHC217 ..............
OHC218 ..............
OHC219 ..............
OHC220 ..............
OHC221 ..............
OHC222 ..............
OHC223 ..............
OHC224 ..............
OHC225 ..............
OHC226 ..............
OHC227 ..............
OHC228 ..............
OHC229 ..............
OHC230 ..............
OHC232 ..............
OHC233 ..............
OHC234 ..............
OHC235 ..............
OHC236 ..............
OHC237 ..............
OHC239 ..............
OHC240 ..............
OHC241 ..............
OHC242 ..............
OHC243 ..............
OHC244 ..............
OHC245 ..............
OHC246 ..............
OHC247 ..............
OHC248 ..............
OHC249 ..............
OHC251 ..............
OHC252 ..............
OHC253 ..............
OHC254 ..............
OHC255 ..............
OHC256 ..............
OHC257 ..............
OHC258 ..............
OHC259 ..............
OHC260 ..............

Gates
No.
T160
T161
T162
T163
T164
T165
T166
T167
T168
T169
T170
T171
T172
T173
T174
T176
T177
T178
T179
T180
T181
T182
T183
T184
T185
T186
T187
T188
T189
T190
T191
T192
T193
T194
T195
T196
T197
T198
T199
T200
T201
T203
T204
T205
T206
T207
T208
T209
T210
T211
T212
T213
T214
T215
T216
T217
T218
T219
T220
T221
T222
T223
T224
T225
T226
T227
T228
T229
T230
T232
T233
T234
T235
T236
T237
T239
T240
T241
T242
T243
T244
T245
T246
T247
T248
T249
T251
T252
T253
T254
T255
T256
T257
T258
T259
T260

Mfr.
Part No.
OHC262 ..............
OHC263 ..............
OHC264 ..............
OHC265 ..............
OHC266 ..............
OHC267 ..............
OHC269 ..............
OHC270 ..............
OHC271 ..............
OHC272 ..............
OHC273 ..............
OHC274 ..............
OHC275 ..............
OHC276 ..............
OHC277 ..............
OHC278 ..............
OHC279 ..............
OHC280 ..............
OHC281 ..............
OHC282 ..............
OHC283 ..............
OHC284 ..............
OHC285 ..............
OHC286 ..............
OHC287 ..............
OHC288 ..............
OHC289 ..............
OHC290 ..............
OHC291 ..............
OHC292 ..............
OHC293 ..............
OHC294 ..............
OHC295 ..............
OHC296 ..............
OHC297 ..............
OHC298 ..............
OHC299 ..............
OHC300 ..............
OHC301 ..............
OHC302 ..............
OHC303 ..............
OHC304 ..............
OHC305 ..............
OHC306 ..............
OHC307 ..............
OHC308 ..............
OHC309 ..............
OHC310 ..............
OHC311 ..............
OHC312 ..............
OHC313 ..............
OHC314 ..............
OHC315 ..............
OHC316 ..............
OHC317 ..............
OHC318 ..............
OHC319 ..............
OHC320 ..............
OHC321 ..............
OHC322 ..............
OHC323 ..............
OHC324 ..............
OHC325 ..............
OHC326 ..............
OHC327 ..............
OHC329 ..............
OJE2612730A Ki
a ........................
OJE2612730A M
azda ..................
OJE2612740A.....
OJE2612750 Kia.
OJE2612750 Ma
zda ....................
OK24712700 .......
OK90012700 .......
OK93712700A.....
OK93712730 .......
OK95412730 .......
OK95512730A.....
OK97212205 .......
OK97212700 .......
OK97212700A.....
OK97212730 .......
OK97312700 .......
RF0312205 .........
RF03122050 .......
RF0312206A .......
RF4312205 .........
RF7112205 .........
RF7912205 .........
R1463635109......
T0718752 ............
T0718836 ............
T0729581 ............
T830 ....................

Gates
No.
T262
T263
T264
T265
T266
T267
T269
T270
T271
T272
T273
T274
T275
T276
T277
T278
T279
T280
T281
T282
T283
T284
T285
T286
T287
T288
T289
T290
T291
T292
T293
T294
T295
T296
T297
T298
T299
T300
T301
T302
T303
T304
T305
T306
T307
T308
T309
T310
T311
T312
T313
T314
T315
T316
T317
T318
T319
T320
T321
T322
T323
T324
T325
T326
T327
T329
T42006
T42006
T42007
T41036
T41036
T41032
T41035
T41031
T42005
T42004
T42004
T264
T41029
T41029
T42004
T41029
T103
T103
T102
T103
T103
T103
T140
T119
T140
T140
T264

Mfr.
Part No.
XHM460 ..............
XS4Z 6M 250AA.
XS4Z 6M 250BA.
YF0912205..........
ZZM112205.........
ZZM312205.........
Z50112205 ..........
Z50212205 ..........
0B59712205........
0K24712205........
0K24712700........
0K30E12205 .......
0K95412205........
0K97212205........
0060562106 ........
026109243 ..........
026109243E........
026109243L ........
027109119A........
027109119C........
028109119D........
028109119K........
028109119M .......
028109119P........
028109243E........
028109243F ........
034109119 ..........
034109119A........
03510911 ............
035109119 ..........
037109119C........
038109119 ..........
038109119B........
038109119D........
038109119M .......
038109243N........
048109119D........
054109119A........
054109119E........
054109119G .......
054109119H........
056109119A........
056109243D........
058109119A........
058109119B........
058109119C........
058109119D........
06A109119C .......
06A109479A .......
06A109479B .......
06A109479C .......
06B109119A .......
06B109119B .......
06B109119F........
06141PH9305 .....
06141679305 ......
068109119 ..........
068109119A........
068109119E........
068109243F ........
069109119A........
069130113A........
074109119 ..........
075RH200 ...........
075109119B........
077109119B........
077109119C........
077109119D........
077109119E........
078109119A........
078109119C........
078109119D........
078109119G .......
078109119H........
081616 ................
081619 ................
081629 ................
081632 ................
081640 ................
088AG19 .............
09128500 ............
10068553 ............
101R24................
10162006 ............
102500 ................
108R24................
1125360160 ........
113R190..............
11311272384 ......
11311286168 ......
11311711082 ......
11311711153 ......
11311713361 ......
119RH250 ...........
1191303105 ........
119130310500 ....

Gates
No.
T129
T42036
T42034
T294
T210
T276
T266
T308
T179
T302
T42032
T318
T281
T264
T120
T41079
T41079
T41079
T292
T292
T242
T242
T242
T242
T43006
T43006
T127
T197
T065
T065
T262
T301
T301
T301
T321
T43007
T262
T197
T225
T197
T225
T017
T41079
T291
T317
T317
T291
T296
T43010
T43010
T43010
T306
T306
T306
T070
T274
T043
T043
T043
T41080
T083
T082
T170
T082
T083
T207
T297
T207
T207
T218
T297
T218
T297
T297
T018
T069
T189
T140
T188
T070
T285
T163
T099
T192
T078
T094
T075
T065
T106
T106
T131
T41083
T131
T083
T120
T120

Interference engine application.

Mfr.
Part No.
1257223 ..............
1257237 ..............
12581899 ............
12612650017 ......
12612650044 ......
1272382 ..............
1272384 ..............
12723842 ............
1276150G00 .......
1276153B00........
1276153B01........
1276160A00........
1276160B10........
1276160E00........
1276163B00........
1276163E00........
1276170C00........
1276171C00........
1276172F00 ........
1276173000 ........
1276173001 ........
1276178400 ........
1276180C00........
1276182000 ........
1276185Z00 ........
1281053B00........
1281053B01........
1281071C00........
1281071C01........
1281082001 ........
1281082002 ........
1281082003 ........
1281086500 ........
1281086501 ........
1286168 ..............
12861684 ............
130RG25.............
13028AA010 .......
13028AA040 .......
13028AA072 .......
13028AA101 .......
13028AA102 .......
13028AA120 .......
13028AA150 .......
13028AA170 .......
13028AA181 .......
13028AA21A .......
13028D0100........
13028D1700........
13028D4200........
13028D4210........
13028D4211........
13028KA021 .......
13028V4000........
13028V4310........
13028V5100........
13028V5200........
13028V5201........
13028V5210........
13028V5220........
13028V5221........
130280B700........
130280B785........
1302810M00 .......
1302811M00 .......
1302811M10 .......
1302812C00........
1302812G00 .......
1302816A01........
1302816A10........
1302816E00........
1302816E10........
1302816E85........
1302816V00........
1302820R00........
1302845P00........
1302851E00........
1302851E10........
1302861A00........
1302885 ..............
1302885E00........
13029AA010 .......
13029AA011 .......
13029AA040 .......
13029AA070 .......
13029AA080 .......
13029AA11 .........
13069AA034 .......
13069AA035 .......
13069AA036 .......
13069AA037 .......
13069AA063 .......
13070AA00 .........
13070AA000 .......
13070AA001 .......
13070D0100........

Gates
No.
T083
T082
T329
T41015
T129
T106
T106
T106
T194
T171
T171
T164
T166
T241
T095
T243
T194
T212
T272
T028
T028
T070
T243
T095
T309
T41010
T41010
T41065
T41065
T41064
T41064
T41064
T41009
T41009
T106
T106
T084
T300
T150
T277
T172
T172
T209
T254
T300
T304
T307
T100
T078
T137
T137
T137
T135
T017
T093
T104
T104
T104
T104
T104
T104
T249
T249
T077
T077
T077
T100
T104
T096
T096
T104
T104
T104
T180
T078
T251
T137
T137
T077
T104
T104
T299
T299
T151
T299
T299
T299
T41063
T41063
T41063
T41063
T41092
T41062
T41061
T41062
T41088

Mfr.
Part No.
13070KA020 .......
13070V5001........
1307001M00 .......
1307016A00........
1307016A02 Nis
san ....................
1307016A02 Sub
aru.....................
1307016A03........
1307042L00 ........
13071AA001 .......
13071AA002 .......
13073AA000 .......
13073AA080 .......
13073AA081 .......
13073AA140 .......
13073AA142 .......
13077F6200 ........
13077F6510 ........
13077F6512 ........
1307745V00........
13085AA010 .......
1320811M00 .......
1326288 ..............
13404PT0003......
13404PT0004......
13404P13003......
13405PAAA01.....
13405PAAA02.....
13405PAAA03.....
13405PTO004.....
13405PT0004......
13440P5A004 .....
1350311010 ........
1350311011 ........
1350311020 ........
1350311030 ........
1350311040 ........
1350350010 ........
1350350011 ........
1350354010 ........
1350354020 ........
1350362010 ........
1350362030 ........
1350363010 ........
1350363011 ........
1350363020 ........
1350363021 ........
1350364010 ........
1350364020 ........
1350365010 ........
1350388360 ........
1350388380 ........
1350501010 ........
1350502020 ........
1350511010 ........
1350511011 ........
1350511020 ........
1350511040 ........
1350511050 ........
1350515031 ........
1350515040 ........
1350515041 ........
1350515050 ........
1350516020 ........
1350516021 ........
1350520010 ........
1350520020 ........
1350543010 ........
1350550010 ........
1350550011 ........
1350550021 ........
1350550022 ........
1350562031 ........
1350562050 ........
1350562060 ........
1350563011 ........
1350563021 ........
1350564010 ........
1350564011 ........
1350564020 ........
1350564021 ........
1350565020 ........
1350565040 ........
1350574010 ........
1350574011 ........
1350587102 ........
1350587702 ........
1351415010 ........
1351487711 ........
135148771100 ....
1351487711000 ..
1356422021 ........
135680A010........
1356803010 ........
1356803020 ........

Gates
No.
T41060
T41059
T41058
T41089
T41089
T41089
T41089
T41059
T41062
T41062
T42022
T42023
T42023
T42023
T42023
T42021
T42020
T42021
T42021
T42024
T077
T174
T41013
T41013
T41022
T186
T186
T186
T186
T186
T280
T42028
T42028
T42028
T42029
T42029
T42031
T42031
T42026
T42026
T42030
T42030
T42025
T42025
T42025
T42025
T42027
T42027
T42037
T42025
T42025
T41066
T41074
T41076
T41076
T41076
T41071
T41071
T41066
T41066
T41066
T41072
T41074
T41074
T41075
T41075
T41069
T41078
T41078
T41078
T41078
T41075
T41075
T41075
T41070
T41070
T41077
T41077
T41077
T41077
T41073
T41073
T41067
T41067
T41004
T41003
T070
T178
T178
T178
T126
T257
T138
T199

802

Manufacturers Part Numbers - PowerGrip Timing System Products

Mfr.
Part No.
1356803021 ........
1356809040 ........
1356809041 ........
1356809050 ........
1356809080 ........
1356811030 ........
1356811031 ........
1356811032 ........
1356811033 ........
1356811100 ........
1356811101 ........
1356811111 ........
1356815010 ........
1356815011 ........
1356815020 ........
1356815030 ........
1356815040 ........
1356815041 ........
1356815042 ........
1356815050 ........
1356816010 ........
1356816020 ........
1356816040 ........
1356816041 ........
1356816050 ........
1356816051 ........
1356816060 ........
1356816061 ........
1356816070 ........
1356816071 ........
1356819045 ........
1356819046 ........
1356819055 ........
1356819056 ........
1356819085 ........
1356819086 ........
1356819115 ........
1356819116 ........
1356819125 ........
1356819135 ........
1356819145 ........
1356820010 ........
1356820020 ........
1356829015 ........
1356829025 ........
1356842010 ........
1356842011 ........
1356842012 ........
1356842020 ........
1356842021 ........
1356843010 ........
1356843020 ........
1356843030 ........
1356843040 ........
1356846020 ........
1356849015 ........
1356849035 ........
1356849036 ........
1356849046 ........
1356849055 ........
1356850010 ........
1356850020 ........
1356854010 ........
1356854020 ........
1356854030 ........
1356854031 ........
1356854038 ........
1356854050 ........
1356854051 ........
1356859015 ........
1356859016 ........
1356859017 ........
1356859025 ........
1356859026 ........
1356859027 ........
1356859045 ........
1356859095 ........
1356862020 ........
1356862030 ........
1356862030A......
1356862040 ........
1356862050 ........
1356863010 ........
1356863020 ........
1356863022 ........
1356864010 ........
1356864011 ........
1356865010 ........
1356865010A......
1356865020 ........
1356869025 ........
1356869035 ........
1356869045 ........
1356869055 ........
1356869065 ........
1356869066 ........

Gates
No.
T199
T199
T199
T257
T257
T136
T233
T233
T233
T208
T208
T208
T070
T070
T070
T070
T036
T036
T239
T036
T112
T176
T236
T236
T236
T236
T235
T235
T235
T235
T236
T236
T235
T235
T233
T233
T208
T208
T070
T239
T112
T257
T257
T257
T257
T126
T237
T126
T126
T237
T074
T074
T101
T101
T215
T237
T215
T215
T074
T101
T190
T298
T079
T079
T079
T079
T079
T084
T084
T079
T079
T079
T084
T084
T084
T190
T298
T157
T200
T200
T157
T271
T087
T087
T087
T098
T098
T154
T154
T240
T200
T157
T087
T154
T098
T098

Mfr.
Part No.
1356869075 ........
1356869095 ........
1356874010 ........
1356874011 ........
1356874012 ........
1356874012B......
1356874013 ........
1356874020 ........
1356874021 ........
1356879025 ........
1356879045 ........
1356879095 ........
1356887101 ........
1356887101000 ..
1356887102 ........
1356887102000 ..
1356887103 ........
1356887103000 ..
1356887104 ........
1356887104000 ..
1356887708 ........
1356888360 ........
1356888361 ........
1356888380 ........
1356888381 ........
1356888382 ........
139AG25 .............
14001168 ............
14400MG9000 ....
14400MG90000 ..
14400PAAA01.....
14400PAAA02.....
14400PC6004 .....
14400PC60040 ...
14400PC60042 ...
14400PD2004 .....
14400PD6004 .....
14400PE0004 .....
14400PE00040 ...
14400PE3004 .....
14400PE30040 ...
14400PG6004 .....
14400PG60040 ...
14400PG6014 .....
14400PG6040 .....
14400PH7004 .....
14400PH70040 ...
14400PH7014 .....
14400PH70140 ...
14400PH90040 ...
14400PH90040P.
14400PK1004 .....
14400PK10040 ...
14400PK2004 .....
14400PK20040 ...
14400PK3004 .....
14400PLM004.....
14400PMMA01 ...
14400PM3004.....
14400PM30040...
14400PM6004.....
14400PM70040...
14400PR3004 .....
14400PR4A01.....
14400PR4A01M1
14400PT0004......
14400PV1004 .....
14400PY3A010 ...
14400PY3004 .....
14400P0A004 .....
14400P0GA01.....
14400P0GA010M
1 ........................
14400P08004......
14400P13004......
14400P14004......
14400P2E004 .....
14400P2FA01 .....
14400P2T004......
14400P28004......
14400P5A004 .....
14400P7J004 ......
14400P72004......
14400P72014......
14400P8AA01 .....
14400P8AA02 .....
14400RCAA01 ....
14400TG6004 .....
14400634003 ......
14400634004 ......
14400634005 ......
144006340050 ....
144006340051 ....
14400634014 ......
144006340141 ....
14400657004 ......

Gates
No.
T240
T271
T138
T138
T199
T199
T199
T138
T199
T199
T125
T199
T181
T181
T181
T181
T182
T182
T182
T182
T178
T125
T125
T125
T125
T125
T087
T061
T070
T070
T244
T244
T160
T094
T160
T160
T160
T099
T099
T099
T161
T130
T130
T130
T130
T129
T129
T129
T129
T070
T070
T144
T144
T142
T142
T142
T312
T312
T143
T143
T145
T142
T227
T184
T184
T187
T211
T193
T193
T244
T263
T263
T223
T226
T216
T224
T224
T227
T224
T279
T184
T247
T247
T286
T286
T329
T130
T028
T028
T028
T028
T028
T028
T028
T036

Mfr.
Part No.
144006570040 ....
144006570042 ....
14400657014 ......
144006570140 ....
14400657024 ......
144006570240 ....
144006570241 ....
144006570242 ....
1440065704 ........
14400673004 ......
144006730040 ....
144006730041 ....
144006730042 ....
14400679003 ......
144006790040 ....
144006790041 ....
14400679014X....
14401MN5004.....
14401MN50040...
14401MT3004 .....
14401MT30041 ...
14450P8AA01 .....
14510PC6004 .....
14510PE0003 .....
14510PE0005 .....
14510PG6013 .....
14510PH1003 .....
14510PH1004 .....
14510PH3003 .....
14510PH7003 .....
14510PH7004 .....
14510PK1014 .....
14510PM3003.....
14510PM7003.....
14510PM7004.....
14510PR3003 .....
14510PR3004 .....
14510PT0003......
14510PT0004......
14510PV0003 .....
14510PY3003 .....
14510PY3004 .....
14510P08003......
14510P08004......
14510P13003......
14510P30003......
14510P8AA01 .....
146R190..............
1649170 ..............
1649171 ..............
1680616A00........
1680616A10........
1711082 ..............
1713361 ..............
177RG25.............
2335238010 ........
2335632010 ........
2335632020 ........
2335632030 ........
2335633110 ........
2335633120 ........
2335633130 ........
2335633140 ........
2335633150 ........
2335633160 ........
2335638000 ........
2335638010 ........
2335638020 ........
2335732000 ........
2335732010 ........
2335732020 ........
2335733120 ........
2335742000 ........
2335742010 ........
2413232010 ........
2431032010 ........
243122Y000........
2431221040 ........
2431222010 ........
2431222611 ........
2431222612 ........
2431223001 ........
2431223201 ........
2431223202 Hyu
ndai ...................
2431223202 Kia..
2431223400 ........
2431224000 ........
2431224010 ........
2431224050 ........
2431226000 ........
2431226001 ........
2431232610 ........
2431232620 ........
2431232820 ........
2431233010 ........

Gates
No.
T036
T041
T036
T036
T041
T041
T041
T041
T036
T073
T073
T073
T073
T274
T274
T274
T274
T275
T275
T325
T325
T42038
T41012
T41017
T41017
T41018
T41012
T41012
T41019
T41015
T41015
T41019
T41011
T41011
T41011
T41016
T41016
T41014
T41014
T41020
T41021
T41021
T41023
T41023
T41024
T41016
T41090
T020
T067
T067
T097
T097
T131
T131
T098
T314
T159
T159
T159
T168
T168
T168
T168
T168
T168
T314
T314
T314
T41053
T41053
T41053
T41047
T41050
T41050
T089
T41044
T302
T073
T191
T324
T324
T278
T284
T284
T284
T284
T128
T128
T128
T282
T282
T124
T124
T089
T165

Interference engine application.

Mfr.
Part No.
2431233020 ........
2431233030 ........
2431233040 ........
2431233050 ........
2431233060 ........
2431233110 ........
2431233120 ........
2431233130 ........
2431233140 ........
2431233150 ........
2431233160 ........
2431235000 ........
2431235010 ........
2431235040 ........
2431237100 ........
2431237400 ........
2431237500 Hyu
ndai ...................
2431237500 Kia..
2431238210 Hyu
ndai ...................
2431238210 Kia..
2431238220 ........
2431239400 ........
2431239800 Hyu
ndai ...................
2431239800 Kia..
24410-38001 .......
2441021010 ........
2441022000 ........
2441022020 ........
2441023011 ........
2441023500 Hyu
ndai ...................
2441023500 Kia..
2441026000 ........
2441032000 ........
2441032010 ........
2441032553 ........
2441035010 ........
2441035020 ........
2441039001 Hyu
ndai ...................
2441039001 Kia..
2445033010 ........
2445033020 ........
2445037100 Hyu
ndai ...................
2445037100 Kia..
2445038010 ........
24502982 ............
24503363 ............
248102X700........
2481023011 ........
2481023500 ........
2481026020 ........
2481033021 ........
2481033024 ........
2481035530 Hyu
ndai ...................
2481035530 Kia..
2481037100 Hyu
ndai ...................
2481037100 Kia..
2481037120 ........
271705 ................
2717056 ..............
271713 ................
271714 ................
2717148 ..............
271720 ................
271747 ................
2717478 ..............
271834 ................
2718344 ..............
271835 ................
2718351 ..............
271856 ................
2718567 ..............
271876 ................
2718765 ..............
271952 ................
2719524 ..............
272327 ................
272329 ................
2723294 ..............
272386 ................
274184 ................
2900009150 ........
3250141 ..............
3342103 ..............
3507227 ..............
3507651 ..............
3507704 ..............
3514323 ..............
3531358 ..............

Gates
No.
T165
T165
T165
T165
T165
T167
T167
T167
T167
T167
T167
T139
T139
T139
T315
T315
T315
T315
T313
T313
T313
T322
T323
T323
T41087
T41042
T41037
T41037
T41041
T41041
T41041
T41037
T41044
T41044
T41046
T41048
T41048
T41040
T41039
T41046
T41046
T41040
T41040
T41087
T192
T273
T42005
T42015
T42015
T42016
T42017
T42017
T42014
T42018
T42014
T42014
T42014
T217
T217
T032
T198
T198
T173
T234
T234
T252
T252
T252
T269
T252
T252
T270
T270
T217
T217
T252
T311
T311
T270
T319
T305
T017
T119
T083
T217
T234
T173
T198

Mfr.
Part No.
3547459 ..............
35474592 ............
360525 ................
376388 ................
376401 ................
414701001 ..........
414705601 ..........
4164869 ..............
4176840 ..............
4182426 ..............
4201379 ..............
4201738 ..............
4201739 ..............
4242396 ..............
4300516 ..............
4302971 ..............
4304099 ..............
4315705 ..............
4343824 ..............
4343946 ..............
43439469 ............
4387534 ..............
4387549 ..............
4401261 ..............
4401269 ..............
4406634 ..............
4420507 ..............
4484494 ..............
4504163 ..............
4573347 ..............
4573348 ..............
4573944 ..............
460165 ................
4621348 ..............
4621844 ..............
46337 ..................
463377 ................
4633772 ..............
463633 ................
4636338 ..............
4663515 ..............
4663598 ..............
4667530 ..............
4667606 ..............
4667611 ..............
4667625 ..............
4770491 ..............
477393 ................
4781570AB .........
4792353 ..............
484981001 ..........
4884320AA .........
5010371AA .........
512430160 ..........
512536016 ..........
5125360160 ........
5203401 ..............
52267904 ............
52289664 ............
524034 ................
5240346 ..............
5862021480 ........
5862021620 ........
5862059260 ........
5862059340 ........
5985163 ..............
60507464 ............
60562106 ............
636350 ................
636359 ................
636363 ................
636365 ................
636368 ................
636370 ................
636560 ................
636562 ................
636565 ................
6842469 ..............
70HM 6268 AB ...
70HM 6268 BA ...
7533266 ..............
7533267 ..............
7700618657 ........
7700663550 ........
7700666593 ........
7700717284 ........
7700718725 ........
7700718726 ........
7700718752 ........
7700718836 ........
7700729581 ........
7700853660 ........
7701348801 ........
8091287220 ........
82317934 ............
85867058 ............

Gates
No.
T174
T174
T037
T037
T037
T028
T079
T020
T018
T020
T068
T068
T068
T069
T122
T122
T075
T41001
T114
T071
T071
T132
T153
T069
T069
T032
T018
T206
T285
T41084
T41084
T219
T039
T285
T265
T032
T032
T032
T41081
T41081
T41002
T255
T206
T245
T246
T265
T285
T41002
T43008
T295
T028
T43001
T43005
T075
T075
T075
T071
T163
T163
T017
T017
T186
T187
T186
T244
T087
T120
T120
T081
T081
T081
T148
T148
T081
T081
T148
T081
T198
T013
T013
T013
T013
T018
T018
T069
T140
T140
T140
T119
T140
T140
T140
T018
T305
T065
T096

Manufacturers Part Numbers - PowerGrip Timing System Products

Mfr.
Part No.
8920639440 ........
894109626 ..........
8941096260 ........
8941583270 ........
8941606560 ........
8941743060 ........
894200372A........
8942151970 ........
8942151971 ........
8942152540 ........
8942187820 ........
894220372A........
8942209220 ........
8942220922 ........
8942353620 ........
8942372420 ........
894337708 ..........
8943377080 ........
8943624350 ........
8943648160 ........
8943648161 ........
8943864881 ........
8943864882 ........
8943864883 ........
8943864970 ........
8944161450 ........
8944233311 ........
8944294860 ........
8944520940 ........

Gates
No.
T305
T162
T118
T121
T122
T147
T122
T41025
T41025
T121
T088
T122
T076
T076
T088
T121
T177
T177
T41027
T41028
T41028
T42002
T42002
T42002
T220
T088
T42001
T169
T162

Mfr.
Part No.
8944723490 ........
8944723491 ........
8944795230 ........
8970163260 ........
8970270620 ........
8970417840 ........
8970422680 ........
8971160020 ........
8971363210 Hon
da ......................
8971363210 Isuz
u ........................
90122429 ............
90231883 ............
90234902 ............
90324698 ............
90324699 ............
90325576 ............
90325578 ............
90353179 ............
90353211 ............
90354783 ............
90409900 ............
90410014 ............
90410223 ............
90410768 ............
90410771 ............
90500360 ............
90530599 ............

Gates
No.
T41026
T41026
T162
T221
T205
T122
T147
T41028
T303
T303
T081
T148
T081
T148
T148
T081
T081
T203
T081
T148
T081
T081
T203
T285
T285
T285
T285

Mfr.
Part No.
91112009 ............
91171175 ............
91172367 ............
91172368 ............
91173157 ............
912761 ................
9128500 ..............
9128722 ..............
9135031 ..............
9135450 ..............
9135733 ..............
9151772280 ........
91540557 ............
9154055780 ........
91541318 ............
9180954 ..............
92029834 ............
92063917 ............
92066312 ............
928M 6K254 AC .
928M 6M250 BC
928M 6M250 DC
928M 6268 AB....
92810515710 ......
92810515730 ......
92810515740 ......
92810515750 ......
93202400 ............
94029834 ............

Gates
No.
T070
T272
T194
T41010
T194
T014
T285
T305
T252
T173
T252
T189
T188
T188
T188
T252
T075
T309
T309
T41008
T42036
T42032
T258
T196
T196
T196
T196
T43002
T075

Interference engine application.

Mfr.
Part No.
94109626 ............
94158327 ............
94160656 ............
94215197 ............
94215254 ............
94220922 ............
94337708 ............
94386497 ............
9440383 ..............
94410221902 ......
94410221904 ......
94410513703 ......
94410515703 ......
94410515704 ......
94410515706 ......
94410532300 ......
94410532301 ......
94410532302 ......
94429486 ............
94452094 ............
94479523 ............
94840054 ............
94844702 ............
94846144 ............
94847323 ............
94848472 ............
94849175 ............
94849597 ............
94854403 ............

Gates
No.
T118
T121
T122
T41025
T121
T076
T177
T220
T311
T293
T293
T107
T107
T107
T152
T152
T152
T152
T169
T118
T162
T070
T112
T036
T41066
T176
T036
T036
T236

Mfr.
Part No.
94854404 ............
94856081 ............
94856082 ............
95ZA19................
95951646 ............
96051646 ............
96057945 ............
96060050 ............
96065049 ............
96067809 ............
96068423 ............
96068424 ............
96068591 ............
96144976 ............
96183352 Daewo
o Int...................
96183352 Gener
al Motors...........
96414718702 ......
97016326 ............
97027062 ............
97041784 ............
97042268 ............
978M 6M250 AA.
978M 6M250 BA.
978M 6268 AA....
99314718701 ......
99919213150 ......

803
Gates
No.
T235
T236
T235
T100
T095
T095
T164
T166
T41009
T095
T241
T243
T212
T148
T310
T309
T222
T221
T205
T122
T147
T42035
T42036
T294
T290
T213