Bandas de Tiempo 2005 - Full Motores Check PDF

FMC
Table of Contents WARNING

Be Safe! Do not use Gates belts, pulleys or
sprockets on any aircraft propeller or rotor drive
Introduction & Technical Information . . . . . . . . . . A1 systems or in-flight accessory drives. Those
Gates products are not designed or intended for
aircraft use.
Alphabetical Model Listing . . . . . . . . . . . . . . . . A15
CAUTION
Use Gates products only on applications specified
Replacement Instructions . . . . . . . . . . . . . . . . . . . 1 in Gates literature. Install and maintain products
according to the vehicle manufacturer’s recom-
mended procedures and with the recommended
Changeover Listing . . . . . . . . . . . . . . . . . . . . . 786 tools. Failure to follow these instructions could
result in injury or property damage. Gates
Manufacturers’ Part Numbers . . . . . . . . . . . . . . 800 Corporation disclaims all liability due to failure to
follow these instructions.
PARA MAS MANUALES VISÍTENOS EN

YOUTUBE Y FACEBOOK COMO: FULL
MOTORES CHECK
Gates PowerGrip™
Timing Component Kits
and
Individual Timing Components
Now you can have it either way!
PowerGrip™Timing PowerGrip™
Component Kits Timing Components!
PowerGrip™ Timing Component Kits give you the best Gates is the largest producer of automotive timing
and most complete repair solution for your customers. belts in the world. Because we are the leader, we are
Save time and money by preventing costly comebacks the experts in the timing system. Our expertise is used
and warranties. Ideal for the consumer because the job globally to help OEMs design the most durable and
is done right the first time; saving them from returning efficient timing systems available.
when other components fail and accrue additional
labor costs. Now Gates brings this expertise to you with
PowerGrip™ Timing tensioners and idlers!
A broken belt can cause severe and expensive engine
damage. A failing or failed tensioner or idler pulley Although Gates recommends a PowerGrip™ Timing
bearing often causes timing belt failure. That’s why Component Kit whenever changing a timing belt,
each kit comes with the right components, plus detailed there are those who will only want to replace a single
installation instructions specific to each application. part. PowerGrip™ Timing Components provide the
solution. The broad Gates line covers passenger car
With PowerGrip™ kits, it’s not necessary to multi-source and light truck applications and includes automatic
components, look up several different manufacturers, timing tensioners that, until now, were only available
or present your customer with several cartons contain- through an OEM dealership.
ing different parts. Deliver in one carton with all the
components required to do a thorough job. So, whether it’s the complete job or just what's neces-
sary, Gates PowerGrip™ Timing Component System
(Kits can contain multiple belts, tensioners, idler and ten- products are the solution!
sioner pulleys, depending on the application. Kits do not
Note: Beware of low cost timing belts with little or no war-
contain hydraulic tensioning cylinders or tensioning springs.)
ranty. 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 sys-
tem 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, result-
ing 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
Today’s 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 today’s 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 Aren’t 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 won’t 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 com-
pressed, 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 today’s high rev’ing 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 hex-
head 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 vehicle’s
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 pro-
viding 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-8’s, use a timing belt. The timing belt is critical to the engine because it sets
the engine’s 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 customer’s 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 belt’s 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 manufacturer’s 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, it’s a good time to
replace the belt.
A8
Timing Belt Troubleshooting Guide
Symptom Probable Cause Concern/Corrective Action
1. Excessive shock load. 1. Excessive RPMs; Modified engine.
2. Improper belt handling and storage prior 2. Follow proper storage and handling procedures.
Tensile Failure to installation.
3. Debris or foreign object in drive. 3. Remove objects; Replace pulleys.
4. Extreme pulley/sprocket run-out. 4. Replace pulley/sprocket.
5. Extreme Over-tension. 5. Adjust tension to recommended value.
1. Seized Drive Component 1. Replace Component (Tensioner/Idler pulley, W.P.,

camshaft, Oil pump).
2. Excessive shock loads. 2. Excessive RPMs; Modified engine.
Tooth Shear 3. Extreme sprocket run-out. 3. Check camshaft/crankshaft journals.
4. Worn sprocket. 4. Replace sprocket.
5. Misaligned drive. 5. Worn sprocket bearing, replace sprocket; Bent bracket;
Improper sprocket installation.
6. Belt under tensioned. 6. Adjust tension to recommended value.
1. Too low or high belt tension. 1. Adjust tension to recommended value.

2. Belt running partly off unflanged sprocket. 2. Correct alignment.
Tooth Wear 3. Misaligned drive. 3. Worn sprocket bearing, replace sprocket; Bent bracket;
4. Worn sprocket. 4. Replace sprocket.
1. Extreme high temperature 1. Overheated engine; Seized or partially seized pulley

2. Extreme low temperature at start-up. 2. Install engine heater
Backside Cracks
3. Cocked sprocket. 3. Replace Sprocket.
4. Excessive tension 4. Adjust tension to recommended value.
Land Wear 1. Excessive tension 1. Adjust tension to recommended value.

(wear between teeth) 2. Worn Sprocket 2. Replace Sprocket
1. Oil, fuel, coolant leak. 1. Replace faulty seals and/or gaskets; Check timing cover
Contamination for improper installation, replace if cracked or worn.
1. Damage due to handling. 1. Follow proper handling instructions.

2. Flange damage. 2. Replace sprocket.
3. Belt tension too low. 3. Adjust tension to recommended value.
Edge Wear 4. Rough belt pulley flange. 4. Replace sprocket.
5. Improper tracking. 5. Correct alignment.
6. Belt contacting engine, timing cover or 6. Remove obstruction or correct alignment.
other engine component.
1. High tension. 1. Adjust tension to recommended value.

2. Low tension. 2. Adjust tension to recommended value.
Unusual Noise 3. Misalignment. 3. Worn sprocket bearing, replace sprocket; Bent bracket;
4. Damaged pulley flange. 4. Replace pulley(s).
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 man-
ufacturers’ mileage replacement recommendations or we recommend timing belt replacement at around 60,000 miles.
Free Running Interference

No Valve/Piston Valve/Piston
Interference 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 cus-
tomer from expensive repairs:
1. Did you buy the car new? If yes, they’ll know if the belt has ever been replaced.
2. Did you buy the car used? If so, they won’t 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.
Here’s 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 refer-
ence 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 dur-
ing 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 auto-
motive 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 compart-
ments. 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 that’s 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 conve-
niently mounted on key chain with six different sizes to service a variety
of applications. Can also be used to hold certain serpentine belt tension-
ers 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 align-
ment. 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) PowerGrip Timing Systems Timing Belt Replacement
and Brochures (428-1438) Product Catalog (428-1448) 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 deter-
mine 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 Installation Installation Suggested Installation Installation

Belt Top Tension (lbs.) Tension (lbs.) Tension (lbs.) Belt Top Tension (lbs.) Tension (lbs.) Tension (lbs.)
Width Ranges Used Belts New Belts Width Ranges Used Belts New Belts
1/4" 45-65 60.0 80.0 13/16" 175-240 190.0 255.0
5/16" 60-85 75.0 100.0 7/8" 190-255 205.0 270.0
3/8" 85-115 100.0 130.0 1" 215-295 230.0 310.0
1/2" 105-145 120.0 160.0 1-1/16" 225-310 240.0 325.0
5/8" 135-185 150.0 200.0 1-1/8" 245-330 260.0 345.0
11/16" 155-200 170.0 215.0 1-5/16" 285-385 300.0 400.0
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.
Suggested Installation Installation Suggested Installation Installation

Number Tension (lbs.) Tension (lbs.) Tension (lbs.) Number Tension (lbs.) Tension (lbs.) Tension (lbs.)
of Ribs Ranges Used Belts New Belts of Ribs Ranges Used Belts New Belts
3 45-60 67.5 90.0 9 135-180 202.5 270.0
4 60-80 90.0 120.0 10 150-200 225.0 300.0
5 75-100 112.5 150.0 11 165-220 247.5 333.0
6 90-125 135.0 187.5 12 180-240 270.0 360.0
7 105-145 157.5 217.5 14 210-280 292.5 420.0
8 120-160 180.0 240.0
NOTE: A belt is considered "used" once it has been "run-in".
A14
ALPHABETICAL MODEL LISTING
Make Timing Timing Recommended
Model/ Belt Component Timing Timing Replacement
Year Engine Part No. Kit Part No. Tensioners Pulleys Interval (Miles) Page
ACURA
Passenger Cars
EL (Canadian)
1997-00 1.6L 4-Cyl. *# T224 105,000 3 1
Integra
1986-89 1.6L 4-Cyl. *# T130 TCK130 T41018 Not Applicable 60,000 1 4
1992-93 1.7L 4-Cyl. *# T227 TCK227 T41016 Not Applicable 90,000 5
1990-94 1.8L 4-Cyl. (Exc. VTEC) *# T184 TCK184 T41016 Not Applicable 90,000 6
1995-96 1.8L 4-Cyl. (Exc. VTEC) *# T184 TCK184 T41016 Not Applicable 90,000 Normal 6
60,000 Severe 6
1997-01 1.8L 4-Cyl. (Exc. VTEC) *# T184 TCK184 T41016 Not Applicable 105,000 3 6
1994 1.8L 4-Cyl. (VTEC) *# T247 TCK247 T41016 Not Applicable 90,000 6
1995-96 1.8L 4-Cyl. (VTEC) *# T247 TCK247 T41016 Not Applicable 90,000 Normal 6
60,000 Severe 6
1997-01 1.8L 4-Cyl. (VTEC) *# T247 TCK247 T41016 Not Applicable 105,000 3 6
Legend
1986-87 2.5L V6 *# T129 TCK129 T41015 Not Applicable 60,000 1 12
1990 2.7L V6 *# T129 TCK129 T41015 Not Applicable 90,000 12
1991-94 3.2L V6 (C32A1) *# T193 TCK193 T41021 Not Applicable 90,000 26
1995 3.2L V6 (C32A1) *# T193 TCK193 T41021 Not Applicable 90,000 Normal 26
60,000 Severe 26
MDX
2001-04 3.5L V6 (J35A3) *# T286 TCK286 Not Available Not Available 105,000 3 23
NSX
4
1991-96 3.0L V6 Inspect at 90,000, 14
replace if needed 14
4
1997-04 3.0L V6 105,000 3 14
4
1997-04 3.2L V6 105,000 3 14
NSX-T
4
1995-96 3.0L V6 Inspect at 90,000, 14
4
1997-03 3.0L V6 105,000 3 14
4
1997-03 3.2L V6 105,000 3 14
Vigor
1992-94 2.5L 5-Cyl. *# T211 T41020 Not Applicable 90,000 10
2.2CL
1997 2.2L 4-Cyl. *#
Balance Shaft T186 TCK244 T41013 Not Applicable 90,000 Normal 2 8
60,000 Severe 8
Camshaft T244 TCK244 T41014 Not Applicable 90,000 Normal 2 8
60,000 Severe 8
2.3CL
1998-99 2.3L 4-Cyl. *#
Balance Shaft T186 TCK244 T41013 Not Applicable 105,000 3 8
Camshaft T244 TCK244 T41014 Not Applicable 105,000 3 8
2.5TL
1995-96 2.5L 5-Cyl. *# T211 T41020 Not Applicable 90,000 Normal 10
60,000 Severe 10
1997-98 2.5L 5-Cyl. *# T211 T41020 Not Applicable 105,000 3 10
3.0CL
1997-99 3.0L V6 (J30A1) *# T286 TCK286 Not Available Not Available 105,000 3 20
3.2CL
2001-03 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.)
ACURA (Cont.)
3.2TL
1996 3.2L V6 (C32A6) *# T193 TCK193 T41021 Not Applicable 90,000 Normal 26
60,000 Severe 26
1997-98 3.2L V6 (C32A6) *# T193 TCK193 T41021 Not Applicable 105,000 3 26
1999 3.2L V6 (J32A1/A2) *# T286 TCK286** T41090** T42038 105,000 3 20
2000 3.2L V6 (J32A1/A2) *# T286 TCK286** T41090** T42038 105,000 3 23
2001-03 3.2L V6 (J32A1/A2) *# T286 105,000 3 23
2004 3.2L V6 (J32A3) *# T329 105,000 3 23
3.5RL
1996-04 3.5L V6 (C35A1) *#
Balance Shaft T280 105,000 3 29
Camshaft T279 105,000 3 29
Light Trucks
SLX
1996-97 3.2L V6 (SOHC) # T221 TCK221** T41028** T42002 60,000 35
1999-98 3.5L V6 (DOHC) # T303 75,000 33
ALFA ROMEO
GTV Coupe
1982-86 2.5L V6 T120 50,000 37
164L, LS & S
1991-93 3.0L V6 T120 50,000 39
AMERICAN MOTORS
Alliance
1985-87 1.7L 4-Cyl. * T119 60,000 1 609
Concord
1978-79 2.0L 4-Cyl. * T017 TCK017 T41079 Not Applicable 60,000 1 41
Encore
1985-86 1.7L 4-Cyl. * T119 60,000 1 41
Gremlin
Spirit
1979 2.0L 4-Cyl. * T017 TCK017 T41079 Not Applicable 60,000 1 41
ASUNA
Passenger Cars
Sunfire (Canadian)
1993 1.8L 4-Cyl. (DOHC) # T205 60,000 292
Light Trucks
Sunrunner (Canadian)
1989-95 1.6L 4-Cyl. (SOHC, VIN U) T164 TCK164 T41064 Not Applicable 60,000 1 298
1994-02 1.6L 4-Cyl. (SOHC, VIN 6) T212 TCK212 T41065 Not Applicable 60,000 300
AUDI
Allroad
2001-04 2.7L V6 Twin Turbo (APB) *# T297 105,000 72
A4
1997-98 1.8L 4-Cyl. Turbo (AEB) *
152 Tooth Belt 5 T291 105,000 Normal 47
52,500 Severe 47
153 Tooth Belt T317 105,000 Normal 47
52,500 Severe 47
1
2
3
4
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
AUDI (Cont.)
A4 (Cont.)
1999-00 1.8L 4-Cyl. Turbo
(AEB & ATW) *
52,500 Severe 47
52,500 Severe 47
2000-01 1.8L 4-Cyl. Turbo (AWM) * T306 120,000 59
2002-04 1.8L 4-Cyl. Turbo (AWM) * T306 90,000 59
1996 2.8L V6, 12-Valve *# T218 60,000 1 80
1997 2.8L V6, 12-Valve *# T218 90,000 80
1998 2.8L V6, 30-Valve *# T297 90,000 82
1999 2.8L V6, 30-Valve *# T297 75,000 82
2000-01 2.8L V6, 30-Valve *# T297 105,000 82
A4 Avant & Sedan
2002-04 1.8L 4-Cyl. Turbo (AMB) *# T306 105,000 Normal 49
52,500 Severe 49
2002-04 3.0L V6, 30-Valve (AVK) *# T330 105,000 Normal 86
52,500 Severe 86
A4 Cabriolet
2003-04 1.8L 4-Cyl. Turbo (AMB) *# T306 105,000 Normal 49
52,500 Severe 49
52,500 Severe 86
A4 Quattro
1997-98 1.8L 4-Cyl. Turbo (AEB) *
52,500 Severe 47
1999-00 1.8L 4-Cyl. Turbo
(AEB & ATW) *
52,500 Severe 47
52,500 Severe 47
2000-01 1.8L 4-Cyl. Turbo (AWM) * T306 120,000 59
2002-04 1.8L 4-Cyl. Turbo (AWM) * T306 90,000 59
1996 2.8L V6, 12-Valve *# T218 60,000 1 80
1997 2.8L V6, 12-Valve *# T218 90,000 80
1998 2.8L V6, 30-Valve *# T297 90,000 82
1999 2.8L V6, 30-Valve *# T297 75,000 82
1
2
3
4
5
A17
AUDI (Cont.)
A6
1995-96 2.8L V6, 12-Valve *# T218 60,000 1 80
1997 2.8L V6, 12-Valve *# T218 90,000 80
1998 2.8L V6, 12-Valve *# T297 90,000 80
1998 2.8L V6, 30-Valve *# T297 90,000 82
1999 2.8L V6, 30-Valve *# T297 75,000 82
2000 2.8L V6, 30-Valve *# T297 105,000 82
52,500 Severe 86
A6 Quattro & Quattro Turbo
2000-04 2.7L V6, Twin Turbo *# T297 105,000 72
1995-96 2.8L V6, 12-Valve *# T218 60,000 1 80
1997 2.8L V6, 12-Valve *# T218 90,000 80
1998 2.8L V6, 12-Valve *# T297 90,000 80
1998 2.8L V6, 30-Valve *# T297 90,000 82
1999 2.8L V6, 30-Valve *# T297 75,000 82
2000-01 2.8L V6, 30-Valve *# T297 105,000 82
2000-04 4.2L V8 *# T297 105,000 Normal 111
52,500 Severe 111
A8
1997-98 3.7L V8 (AEW) *# T207 90,000 104
1999 3.7L V8 (AEW) *# T207 75,000 104
2000-03 4.2L V8 *# T297 105,000 108
A8 Quattro
1997-98 4.2L V8 (ABZ Engine) *# T207 90,000 104
1999 4.2L V8 (ABZ Engine) *# T207 75,000 104
2000 4.2L V8 (ABZ Engine) *# T297 105,000 108
Cabriolet
1994-96 2.8L V6, 12-Valve *# T218 60,000 1 80
1997-98 2.8L V6, 12-Valve *# T218 90,000 80
Coupe
1981-83 2.2L 5-Cyl. # T065 60,000 1 118
1984-85 2.2L 5-Cyl. #
113 Tooth Belt T065 60,000 1 118
120 Tooth Belt T127 60,000 1 118
Coupe GT
1986-87 2.2L 5-Cyl. # T127 60,000 1 118
Coupe Quattro
1990-91 2.3L 5-Cyl. # T197 60,000 1 68
Fox
1973-79 1.6L 4-Cyl. # T017 TCK017 T41079 Not Applicable 60,000 1 43
Quattro
1983 2.2L 5-Cyl. # T065 60,000 1 118
1984-85 2.2L 5-Cyl. #
113 Tooth Belt T065 60,000 1 118
120 Tooth Belt T127 60,000 1 118
S4
1992-94 2.2L 5-Cyl. Turbo T225 60,000 1 66
S4 Quattro
2000-02 2.7L V6 Twin Turbo *# T297 105,000 76
S4 Sedan
1992-94 2.2L 5-Cyl. Turbo # T225 60,000 1 66
1
2
3
4
A18
AUDI (Cont.)
S6
1995 2.2L 5-Cyl. Turbo # T225 60,000 1 66
S6 Avant Quattro
2002-03 4.2L V8 # T297 105,000 Normal 111
52,500 Severe 111
S6 Quattro
1995 2.2L 5-Cyl. Turbo # T225 60,000 1 66
S8
2001-03 4.2L V8 *# T297 105,000 108
TT Coupe & Roadster
2000-04 1.8L 4-Cyl. Turbo *# T306 120,000 56
V8 Quattro
1990-91 3.6L V8 (PT Engine) *# T207 60,000 98
1992-94 4.2L V8 (ABH Engine) *# T207 90,000 98
80
1991-92 2.3L 5-Cyl. # T170 60,000 1 70
80 Quattro
1988 2.3L 5-Cyl. # T127 60,000 1 70
1989 2.3L 5-Cyl. #
Up To Chas. 89J394742 T127 60,000 1 70
From Chas. 89J394743 T170 60,000 1 70
1990-92 2.3L 5-Cyl. # T170 60,000 1 70
90
1988 2.3L 5-Cyl. # T127 60,000 1 70
1989 2.3L 5-Cyl. #
Up To Chas. 89J396702 T127 60,000 1 70
From Chas. 89J396703 T170 60,000 1 70
1990-91 2.3L 5-Cyl. # T170 60,000 1 70
1993-95 2.8L V6, 12-Valve *# T218 60,000 1 80
90 Quattro
1988 2.3L 5-Cyl. # T127 60,000 1 70
1989 2.3L 5-Cyl. #
Up To Chas. 89J394742 T127 60,000 1 70
From Chas. 89J394743 T170 60,000 1 70
1990-92 2.3L 5-Cyl. # T170 60,000 1 70
1993-95 2.8L V6, 12-Valve *# T218 60,000 1 80
100
1989-91 2.3L 5-Cyl. #
Up To Chas. 063969 T127 60,000 1 70
From Chas. 063970 T170 60,000 1 70
1990-91 2.3L 5-Cyl. # T170 60,000 1 70
1992-94 2.8L V6, 12-Valve *# T218 60,000 1 80
100 Quattro
1989-91 2.3L 5-Cyl. #
Up To Chas. 063969 T127 60,000 1 70
From Chas. 063970 T170 60,000 1 70
1990-91 2.3L 5-Cyl. # T170 60,000 1 70
1992-94 2.8L V6, 12-Valve *# T218 60,000 1 80
1
2
3
4
A19
AUDI (Cont.)
200
1989 2.2L 5-Cyl. #
Up To Chas. 44K400000 T127 60,000 1 118
From Chas. 44K400001 T170 60,000 1 118
1990-91 2.2L 5-Cyl. # T170 60,000 1 118
200 Quattro
1989 2.2L 5-Cyl. #
Up To Chas. 44K004457 T127 60,000 1 118
From Chas. 44K004458 T170 60,000 1 118
1990-91 2.2L 5-Cyl. # T170 60,000 1 118
4000
1982-83 1.6L 4-Cyl. Diesel T043 60,000 1 42
1980-81 2.2L 5-Cyl. # T065 60,000 1 118
4000CS
1986-87 2.2L 5-Cyl. # T127 60,000 1 118
4000CS Quattro
1987 2.2L 5-Cyl. # T127 60,000 1 118
4000S
4000S Quattro
1984-85 2.2L 5-Cyl. #
113 Tooth Belt T065 60,000 1 118
120 Tooth Belt T127 60,000 1 118
1986 2.2L 5-Cyl. # T127 60,000 1 118
5000
1979-83 2.0L 5-Cyl. Diesel *#
1, 2
Camshaft T083 60,000 65
1, 2
Injection Pump T082 60,000 65
1979-83 2.0L 5-Cyl.Turbo Diesel *#
Camshaft T083 60,000 1, 2 65
Injection Pump T082 60,000 1, 2 65
1978-83 2.2L 5-Cyl. Turbo # T065 60,000 1 118
5000 Quattro
1988 2.3L 5-Cyl. # T127 60,000 1 118
5000CS Quattro
1987-88 2.2L 5-Cyl. # T127 60,000 1 118
5000S
1987-88 2.3L 5-Cyl. # T127 60,000 1 70
1984-85 2.2L 5-Cyl. #
113 Tooth Belt T065 60,000 1 118
120 Tooth Belt T127 60,000 1 118
1986-87 2.2L 5-Cyl. # T127 60,000 1 118
5000S Quattro
1988 2.3L 5-Cyl. # T127 60,000 1 70
BMW
325 Series
1987 2.5L 6-Cyl. *
127 Tooth Belt T131 60,000 3 120
128 Tooth Belt T106 60,000 3 120
1
2
3
4
A20
BMW (Cont.)
325 Series (Cont.)
1988 2.5L 6-Cyl. *
127 Tooth Belt T131 TCK131 T41083 Not Applicable 60,000 3 120
128 Tooth Belt T106 60,000 3 120
1984-87 2.7L 6-Cyl. *
127 Tooth Belt T131 60,000 3 120
128 Tooth Belt T106 60,000 3 120
1988 2.7L 6-Cyl. *
127 Tooth Belt T131 TCK131 T41083 Not Applicable 60,000 3 120
128 Tooth Belt T106 T41083 60,000 3 120
525i
1994-95 2.5L 6-Cyl. * T131 60,000 3 120
528e
1982-88 2.7L 6-Cyl. *
127 Tooth Belt T131 60,000 3 120
128 Tooth Belt T106 60,000 3 120
BUICK
Skyhawk
1982-86 1.8L 4-Cyl. # T081 TCK081 Not Applicable Not Applicable 60,000 1 271
1987-88 2.0L 4-Cyl. # T081 TCK081A Not Applicable Not Applicable 60,000 1 272
CADILLAC
Catera
1997-98 3.0L V6 (DOHC) *# T285 TCK285 Not Available Not Available 100,000 274
1999-01 3.0L V6 (DOHC) *# T285 TCK285A Not Available Not Available 100,000 274
CTS
2003-04 3.2L V6 * T285 100,000 278
CHEVROLET
Passenger Cars
Aveo
2004 1.6L 4-Cyl. # T310 60,000 266
Chevette
1976 1.4L 4-Cyl. T037 60,000 1 265
1977 1.4L 4-Cyl. T039 60,000 1 265
1976 1.6L 4-Cyl. T037 60,000 1 265
1977-78 1.6L 4-Cyl. T039 60,000 1 265
1979-87 1.6L 4-Cyl. T061 60,000 1 265
1981-86 1.8L 4-Cyl. Diesel * T076 60,000 1 270
Lumina (Exc. Van)
1991-95 3.4L V6 # T192 TCK192 Not Available Not Available 60,000 284
1996-97 3.4L V6 *# T273 TCK273 Not Available Not Available 60,000 284
Metro
1998-00 1.0L 3-Cyl. T194 TCK194A T41010 Not Applicable Inspect at 60,000; 294
replace at 100,000
1998-01 1.3L 4-Cyl. T194 100,000 296
Monte Carlo
1995 3.4L V6 # T192 TCK192 Not Available Not Available 60,000 284
1996-97 3.4L V6 *# T273 TCK273 Not Available Not Available 60,000 284
Nova
1988 1.6L 4-Cyl. (DOHC) T112 60,000 1 269
1985-88 1.6L 4-Cyl. (SOHC) T070 TCK070 T41066 Not Applicable 60,000 1 269
1
2
3
4
A21
CHEVROLET (Cont.)
Spectrum
1985-87 1.5L 4-Cyl. *#
Up To 4/30/87 T118 TCK118 Not Available Not Applicable 60,000 293
From 5/1/87 T162 TCK118 Not Available Not Applicable 60,000 293
1988 1.5L 4-Cyl. *# T162 60,000 293
Sprint (Includes Canadian)
1985-88 1.0L 3-Cyl. T095 60,000 294
1989-91 1.0L 3-Cyl. T166 T41009 Not Applicable 60,000 294
CHEVROLET/G.M.C.
Light Trucks
LUV
1981-82 2.2L 4-Cyl. Diesel * T075 60,000 405
S10 & S15 Pickups
1983-85 2.2L 4-Cyl. Diesel * T075 60,000 405
Tracker
CHRYSLER
Passenger Cars
Cirrus
2000 2.0L 4-Cyl. (SOHC, VIN C) *# T245 100,000 Federal 131
105,000 Calif. 131
1995-96 2.4L 4-Cyl. (DOHC, VIN X) # T265 105,000 150
1997 2.4L 4-Cyl. (DOHC, VIN X) # T265 T43005 Not Available 105,000 150
2000 2.4L 4-Cyl. (DOHC, VIN X) # T265 T43005 Not Available 100,000 Federal 150
105,000 California 150
1995-00 2.5L V6 *# T259 TCK259** T41039** T42018 60,000 3 162
(Exc. CA, CT & MA) 162
100,000 3 162
(CA, CT & MA) 162
Concorde (Includes Canadian)
1998-99 3.2L V6 *# T295 TCK295** T41084** Not Applicable 105,000 182
2000 3.2L V6 *# T295 TCK295** T41084** Not Applicable 100,000 Federal 182
1995-97 3.5L V6 *# T255 TCK255** T41002** 105,000 182
2000-01 3.5L V6 *# T295 TCK295** T41084** Not Applicable 100,000 Federal 182
E Class
Executive Limo (Includes Canadian)
1986 2.2L 4-Cyl. (SOHC) T071 TCK071 T41000 Not Applicable 60,000 1 143
Intrepid (Includes Canadian)
1
2
3
4
A22
CHRYSLER (Cont.)
Intrepid (Includes Canadian - Cont.)
1995-97 3.5L V6 *# T255 TCK255** T41002** T41002 105,000 182
Laser
1990-94 2.0L 4-Cyl. (DOHC, 4G6) *#
Balance Shaft T168 TCK167** T41047 Not Applicable 60,000 2 175
Camshaft T167 TCK167** T41046** T42017 60,000 2 175
1986 2.5L 4-Cyl. (SOHC) T114 TCK114 Not Applicable 60,000 1 143
LeBaron & LeBaron GTS
1986-87 2.5L 4-Cyl. (SOHC) T114 TCK114 Not Available Not Applicable 60,000 1 143
1988 2.5L 4-Cyl. (SOHC) T132 TCK132 Not Available Not Applicable 60,000 1 143
1990-93 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 3 164
1994-95 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 3 Federal 164
LHS
1994 3.5L V6 *# T219 TCK219** T41084** Not Applicable 105,000 182
1995-97 3.5L V6 *# T255 TCK255** T41002** T41002 105,000 182
New Yorker
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
1995-96 3.5L V6 *# T255 TCK255** T41002** T41002 105,000 182
PT Cruiser
2001 2.4L 4-Cyl. (DOHC, VIN B) *# T265 T43005 Not Available 120,000 152
2002 2.4L 4-Cyl. (DOHC, VIN B) *# T265 T43005 Not Available 90,000 152
2003-04 2.4L 4-Cyl. (DOHC, VIN B) *# T265 T43008 102,000 Non-Turbo 152
105,000 Turbo 152
90,000 Severe 152
Sebring Convertible
1996 2.4L 4-Cyl. (DOHC, VIN X) # T265 105,000 150
1997-98 2.4L 4-Cyl. (DOHC, VIN X) # T265 T43005 Not Available 105,000 150
1996-00 2.5L V6 *# T259 TCK259** T41039** T42018 60,000 3 162
100,000 3 162
(CA, CT & MA) 162
Sebring Coupe
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# T246 TCK246** T41002** T41002 60,000 3 200
100,000 3 200
(CA, CT & MA) 200
1
2
3
4
A23
CHRYSLER (Cont.)
Sebring Coupe (Cont.)
2001-02 2.4L 4-Cyl. (SOHC, VIN G) *#
(Exc. CA , CT & MA) 159
Camshaft T232 100,000 3 159
(CA , CT & MA) 159
2003-04 2.4L 4-Cyl. (SOHC, VIN G) *#
(Exc. CA & Select) 159
Camshaft T232 100,000 3 159
(CA & Select) 159
1995-00 2.5L V6 *# T259 TCK259** T41039** T42018 60,000 3 162
100,000 3 162
(CA, CT & MA) 162
2001-02 3.0L V6 (SOHC) *# T259 TCK259** T41039** T42018 60,000 3 168
100,000 3 168
(CA, CT & MA) 168
2003-04 3.0L V6 (SOHC) *# T259 60,000 3 168
100,000 3 168
(CA & Select) 168
Sebring Sedan
2001-04 2.4L 4-Cyl. (DOHC, VIN X) # T265 90,000 156
TC (Maserati)
1990 2.2L 4-Cyl. (DOHC, VIN R) T153 TCK153 T41001 Not Applicable 60,000 1 141
300M
2003-04 3.5L V6 *# T295 102,000 182
Light Trucks
Pacifica
2004 3.5L V6, 24-Valve *# T295 N/A 170
Town & Country
1986-87 2.5L 4-Cyl. (SOHC) T114 60,000 1 143
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
Voyager
2001-02 2.4L 4-Cyl. (DOHC, VIN B) *# T265 T43005 Not Available 120,000 156
2003 2.4L 4-Cyl. (DOHC, VIN B) *# T265 Not Available Not Available 120,000 156
DAEWOO
Lanos
1999-02 1.6L 4-Cyl. (DOHC) *# T310 60,000 Federal 205
102,000 Federal 3 205
Leganza
102,000 Federal 3 210
Nubira
102,000 Federal 3 208
1
2
3
4
A24
DAIHATSU
Passenger Cars
Charade
1988-92 1.0L 3-Cyl. *# T178 T41003 60,000 212
1989-92 1.3L 4-Cyl. *# T181 T41004 60,000 214
Light Trucks
Rocky
1990-92 1.6L 4-Cyl. *# T182 T41004 60,000 214
DATSUN (SEE NISSAN)
DODGE
Passenger Cars
Aries
1986-87 2.5L 4-Cyl. (SOHC) T114 TCK114 Not Applicable 60,000 1 143
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
Avenger
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# T246 TCK246** T41002** T41002 60,000 3 200
100,000 3 200
(CA, CT & MA) 200
1995-00 2.5L V6 *# T259 TCK259** T41039** T42018 60,000 3 162
100,000 3 162
(CA, CT & MA) 162
Challenger
1978-79 1.6L 4-Cyl. (SOHC)
w/o Balance Shaft T064 60,000 126
1978-79 1.6L 4-Cyl. (SOHC)
Camshaft T013 60,000 2 124
Charger
Colt
1979 1.4L 4-Cyl. * T073 60,000 122
1980-84 1.4L 4-Cyl. * T073 TCK073 Not Applicable 60,000 122
1985-86 1.5L 4-Cyl. * T073 TCK073 Not Applicable 60,000 173
1987-90 1.5L 4-Cyl. * T128 TCK128 T41042 Not Applicable 60,000 173
1991 1.5L 4-Cyl. * T191 TCK191 T41042 Not Applicable 60,000 173
1978-79 1.6L 4-Cyl. (SOHC, RWD)
1979-82 1.6L 4-Cyl. (SOHC, FWD)
1983-89 1.6L 4-Cyl. (SOHC)
1977-80 1.6L 4-Cyl. (SOHC)
Camshaft T013 60,000 2 124
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1
2
3
4
A25
DODGE (Cont.)
Colt (Cont.)
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 130
1992-94 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
Colt (Canadian)
1985-86 1.5L 4-Cyl. * T073 60,000 173
1992 & 1995 1.5L 4-Cyl. * T191 TCK191 T41051 Not Applicable 60,000 173
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
1984-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 180
1987-89 2.0L 4-Cyl. (SOHC)
Balance Shaft T159 TCK158A T41045 Not Applicable 60,000 2 180
Camshaft T158 TCK158A T41044 Not Applicable 60,000 2 180
1990-91 2.0L 4-Cyl. (SOHC)
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 203
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
Colt Wagon (Includes Canadian)
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 130
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 203
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
Colt 100 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
Colt 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
Daytona & Daytona Shelby
(Includes Canadian)
1992-93 2.2L 4-Cyl. (DOHC, VIN A) T206 60,000 1 139
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
1
2
3
4
A26
DODGE (Cont.)
Dynasty (Includes Canadian)
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
Expo (Canadian)
1987-88 2.2L 4-Cyl. T071 TCK071 T41000 Not Applicable 60,000 1 143
1989 2.2L 4-Cyl. T153 TCK153 T41001 Not Applicable 60,000 1 143
Intrepid (Includes Canadian)
1998-99 3.2L V6 *# T295 TCK295 T41084** Not Applicable 105,000 182
2001 3.2L V6 *# T295 100,000 Federal 182
2003-04 3.5L V6 *# T295 102,000 182
Lancer
1986-87 2.5L 4-Cyl. (SOHC) T114 60,000 1 143
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# T246 TCK246** T41002** T41002 105,000 200
1995-97 2.0L 4-Cyl. (SOHC, VIN C) *# T245 TCK245** T41002** Not Applicable 105,000 131
1998-99 2.0L 4-Cyl. (SOHC, VIN C) *# T245 105,000 131
2000-02 2.0L 4-Cyl. *#
(SOHC, VINs C & F) T245 T43001 105,000 134
2003-04 2.0L 4-Cyl. *#
(SOHC, VINs C & F) T245 105,000 134
2003-04 2.4L 4-Cyl. (DOHC, VIN S) *# T265 105,000 Normal 152
90,000 Severe 152
Omni
Rampage
Shadow
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
1994 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 3 Federal 164
100,000 3 California 164
Spirit
1991-92 2.2L 4-Cyl. (DOHC, VIN A) T206 60,000 1 139
1
2
3
4
A27
DODGE (Cont.)
Spirit (Cont.)
Stealth
1991-93 3.0L V6 *# T195 TCK195 T41039 T42018 60,000 3 189
(DOHC Non-Turbo)
1991-93 3.0L V6 (DOHC Turbo) *# T195 60,000 3 189
1994-96 3.0L V6 *# T195 TCK195 T41039 T42018 60,000 3 Federal 189
(DOHC Non-Turbo) 100,000 3 California 189
1994-96 3.0L V6 (DOHC Turbo) *# T195 60,000 3 Federal 189
Stratus
1995-99 2.0L 4-Cyl. (SOHC, VIN C) *# T245 TCK245** T41002** Not Applicable 100,000 Federal 131
1995-96 2.4L 4-Cyl. (DOHC, VIN X) # T265 105,000 150
2003-04 2.4L 4-Cyl. (DOHC, VIN X) # T265 90,000 156
2001-04 2.4L 4-Cyl. (SOHC, VIN G) #
Balance Shaft T168 60,000 2, 3 159
Camshaft T232 (Exc. CA & Select) 159
100,000 2, 3 159
(CA & Select) 159
1995-00 2.5L V6 *# T259 TCK259** T41039** T42018 60,000 3 162
Stratus Coupe
2001-04 3.0L V6 (SOHC) *# T259 TCK259** T41039** T42018 60,000 3 168
100,000 3 168
(CA & Select) 168
024
400
600
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
2000 GTX (Canadian)
1989-90 2.0L 4-Cyl. (SOHC)
1991-92 2.0L 4-Cyl. (SOHC)
Camshaft T155 60,000 2 180
1
2
3
4
A28
DODGE/PLYMOUTH
Light Trucks
Caravan
1982-83 2.2L 4-Cyl. (SOHC) T071 T41000 Not Applicable 60,000 1 143
1988 2.2L 4-Cyl. (SOHC) T071 T41000 Not Applicable 60,000 1 143
1996 2.4L 4-Cyl. (DOHC, VIN B) # T265 Not Available Not Available 120,000 148
1997-00 2.4L 4-Cyl. (DOHC, VIN B) # T265 T43005 Not Available 120,000 148
2001-02 2.4L 4-Cyl. (DOHC, VIN B) *# T265 T43005 Not Available 120,000 156
2003-04 2.4L 4-Cyl. (DOHC, VIN B) *# T265 120,000 156
1986 2.5L 4-Cyl. (SOHC) T114 60,000 1 143
Dakota
Mini Ram Van
1987 2.5L 4-Cyl. (SOHC) T114 60,000 1 143
Raider
1989 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 3 164
Ram 50
1983-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 180
1987-89 2.0L 4-Cyl. (SOHC)
1983-85 2.3L 4-Cyl. Turbo Diesel *#
Balance Shaft T092 T41049 50,000 2 185
Camshaft T091 T41050 50,000 2 185
1990-92 2.4L 4-Cyl. (SOHC)
1993 2.4L 4-Cyl. (SOHC)
Camshaft T229 60,000 2 187
Scamp Pickup
Voyager
1996 2.4L 4-Cyl. (DOHC, VIN B) # T265 Not Available Not Available 120,000 148
1997-00 2.4L 4-Cyl. (DOHC, VIN B) # T265 T43005 Not Available 120,000 148
1987 2.5L 4-Cyl. T114 TCK114 Not Available Not Applicable 60,000 1 143
1988 2.5L 4-Cyl. T132 TCK132 Not Available Not Applicable 60,000 1 143
1
2
3
4
A29
DODGE/PLYMOUTH (Cont.)
Voyager (Cont.)
1997-00 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,0003 164
EAGLE
Medallion
1989 2.2L 4-Cyl. T140 60,000 1 216
Summit
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1992-96 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
1992 2.4L 4-Cyl.
Balance Shaft T159 60,000 2, 3 203
Camshaft T204 60,000 2, 3 203
1993-96 2.4L 4-Cyl.
Balance Shaft T168 60,000 2, 3 203
Camshaft T230 60,000 2, 3 203
Summit Wagon
1992-96 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
Talon
1993-94 1.8L 4-Cyl.
1990-94 2.0L 4-Cyl. (DOHC) *
Camshaft T167 TCK167** T41046** T42017 60,000 2 175
1995-97 2.0L 4-Cyl. *#
(DOHC, VIN Y, Non-Turbo) T246 TCK246** T41002** T41002 60,000 2, 3 Federal 200
100,0002, 3 California 200
1998 2.0L 4-Cyl. *#
(DOHC, VIN Y, Non-Turbo) T246 TCK246** T41002** T41002 60,000 2, 3 200
100,000 2, 3 200
(CA, CT & MA) 200
1995-96 2.0L 4-Cyl. (DOHC Turbo) *
Balance Shaft T168 60,000 2, 3 Federal 175
Camshaft T167 100,000 2, 3 California 175
1997-98 2.0L 4-Cyl. (DOHC Turbo) *

Balance Shaft T168 60,000 2, 3 175
Camshaft T167 100,000 2, 3 175
(CA, CT & MA) 175
Vision
Vista (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1
2
3
4
A30
EAGLE (Cont.)
Vista (Canadian - Cont.)
1989 1.6L 4-Cyl. (SOHC)
1989-91 2.0L 4-Cyl. (SOHC)
2000 GTX (Canadian)
1989-93 2.0L 4-Cyl. (DOHC) *
Camshaft T167 TCK167 T41046 T42017 60,000 2 175
1989-92 2.0L 4-Cyl. (SOHC)
Camshaft T155 60,000 2 180
FIAT
Brava
1974-78 1.8L 4-Cyl. * T020 25,000 218
1979-81 2.0L 4-Cyl. * T068 30,000 220
Spider 2000
1979-82 2.0L 4-Cyl. * T068 30,000 220
Strada
1979-82 1.5L 4-Cyl. * T069 30,000 217
X1/9
1974-78 1.3L 4-Cyl. * T018 36,000 217
1979-83 1.5L 4-Cyl. * T069 30,000 217
124 Series
1971-74 1.6L 4-Cyl. * T020 25,000 218
1974-78 1.8L 4-Cyl. * T020 25,000 218
128 Series
1973-79 1.3L 4-Cyl. * T018 36,000 217
131 Series
1975-78 1.8L 4-Cyl. * T020 25,000 218
FORD
Passenger Cars
Aspire
1994-97 1.3L 4-Cyl. T185 TCK185 T41030 Not Applicable 60,000 Federal 221
Contour
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) T258 TCK285 T41008 T42032 (LH) 60,000 1 234
T42033 (RH)
1998 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000; 236
T42034 (Lwr) replace if needed 236
1999 2.0L 4-Cyl. (DOHC, VIN 3)
Up To 3/28/1999 T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000; 236
From 3/29/1999 T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000; 236
2000 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000; 236
Escort
1981-85 1.6L 4-Cyl. (SOHC) *# T067 TCK067 T41006 Not Applicable 60,000 224
1991-96 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 227
1
2
3
4
A31
FORD (Cont.)
Escort (Cont.)
1991 1.9L 4-Cyl. (SOHC) *#
Up To 3/25/1991 T067 TCK067 T41006 Not Applicable 60,000 224
From 3/26/1991 T194 TCK194 T41007 Not Applicable 60,000 224
1992-96 1.9L 4-Cyl. (SOHC) # T194 TCK194 T41007 Not Applicable 60,000 224
1984-87 2.0L 4-Cyl. Diesel *#
Camshaft T103 100,000 2 229
Injection Pump T102 100,000 2 229
1997-00 2.0L 4-Cyl. (SOHC, VIN P) T283 TCK283 T43004 Not Applicable Inspect at 120,000; 250
2001-02 2.0L 4-Cyl. (SOHC, VIN P) T283 TCK283 T43004 Not Applicable 120,000 250
Escort Coupe & ZX2
1998-2/9/99 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000; 240
2/10/99-2003 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294A T43003 T42036 (Upr) 120,000 240
T42034 (Lwr)
EXP
Fairmont
Festiva
1988-89 1.3L 4-Cyl. T141 TCK141 T41030 Not Applicable 60,000 221
Focus
2000-04 2.0L 4-Cyl. (DOHC, VIN 3) * T294 TCK294A T43003 T42036 (Upr) 120,000 242
T42034 (Lwr)
2002-04 2.0L 4-Cyl. (DOHC, VIN 5) * T294 TCK294A T43003 T42036 (Upr) 120,000 246
T42034 (Lwr)
2000 2.0L 4-Cyl. (SOHC, VIN P) T283 TCK283 T43004 Not Applicable Inspect at 120,000; 250
2001-04 2.0L 4-Cyl. (SOHC, VIN P) T283 TCK283 T43004 Not Applicable 120,000 250
Granada
LTD
Mustang
1974-79 2.3L 4-Cyl. T014 TCK014 Not Applicable 60,000 1 254
1992 2.3L 4-Cyl.
Round Tooth Sprocket T210 T41005 60,000 1 254
Square Tooth Sprocket T014 TCK014 T41005 Not Applicable 60,000 1 254
1993 2.3L 4-Cyl. T210 60,000 1 254
Mustang II
Pinto
1971-74 2.0L 4-Cyl. T013 60,000 1 226
Probe
1993-97 2.0L 4-Cyl. * T228 TCK228 T41091 T42008 60,000 Federal 252
1989-92 2.2L 4-Cyl. * T134 TCK134 T41029 T42003 60,000 252
1
2
3
4
A32
FORD (Cont.)
Probe (Cont.)
1993-97 2.5L V6 *# T214 TCK214** T41034** T42010 (Upr) 60,000 Federal 260
T42009 (Lwr) 105,000 California 260
Taurus SHO
1989-95 3.0L V6 T248 100,000 263
1993-95 3.2L V6 T248 100,000 263
Tempo
1984-86 2.0L 4-Cyl. Diesel *#
Camshaft T103 100,000 2 229
Thunderbird
Light Trucks
Aerostar
Courier
Escape
2001-04 2.0L 4-Cyl. (DOHC, VIN B) * T294 TCK294A T41085 T42036 (Upr) 120,000 231
T42034 (Lwr)
Ranger
1983-88 2.0L 4-Cyl. T014 60,000 1 254
1992 2.3L 4-Cyl.
Round Tooth Sprocket T210 TCK210 T41005 Not Applicable 60,000 1 254
Square Tooth Sprocket T014 TCK014 T41005 Not Applicable 60,000 1 254
1985-87 2.3L 4-Cyl. Diesel *
Camshaft T091 60,000 1 256
1998-00 2.5L 4-Cyl. T276 TCK276 T41005 Not Applicable Inspect at 120,000; 259
2001 2.5L 4-Cyl. T276 TCK276 T41005 Not Applicable 120,000 259
G.M.C. (SEE CHEVROLET/G.M.C.)
GEO
Passenger Cars
Metro
1993 1.0L 3-Cyl.
4-Bolt Sprocket T166 TCK166 T41009 Not Applicable 60,000 294
5-Bolt Sprocket T241 TCK241 60,000 294
1994-95 1.0L 3-Cyl. T241 TCK241 60,000 294
1996-97 1.0L 3-Cyl. T194 TCK194A T41010 Not Applicable 60,000 294
1998-00 1.0L 3-Cyl. T194 TCK194A T41010 Not Applicable Inspect at 60,000; 294
replace at 100,000 294
1992-93 1.3L 4-Cyl. T095 60,000 296
1994 1.3L 4-Cyl. T243 60,000 296
1998-01 1.3L 4-Cyl. T194 Inspect at 60,000; 296
1
2
3
4
A33
GEO (Cont.)
Metro (Canadian)
1992-93 1.3L 4-Cyl. T095 60,000 296
1994 1.3L 4-Cyl. T243 60,000 296
Prizm
1989-92 1.6L 4-Cyl. (DOHC, VIN 6) * T036 TCK036 T41066 Not Applicable Inspect at 30,000 3, 290
Prizm GSI
1990-92 1.6L 4-Cyl. (DOHC, VIN 5) T176 60,000 287
Spectrum
1989 1.5L 4-Cyl. *# T162 60,000 293
Storm
1990-91 1.6L 4-Cyl. (DOHC) # T169 T41027 T42001 60,000 292
1990-93 1.6L 4-Cyl. (SOHC) *# T177 TCK177 Not Available Not Applicable 30,000 288
1992-93 1.8L 4-Cyl. (DOHC) # T205 60,000 292
Light Trucks
Tracker
HONDA
Passenger Cars
Accord (Includes Canadian)
1976-78 1.6L 4-Cyl. (SOHC) * T041 TCK041 Not Available Not Applicable 60,000 1 314
1979-83 1.6L 4-Cyl. (SOHC) * T041 60,000 1 314
1979-83 1.8L 4-Cyl. * T041 60,000 1 324
1990-93 2.2L 4-Cyl. (SOHC) *#
1994 (EX) 2.2L 4-Cyl. (SOHC) *#
1994 (Exc. EX) 2.2L 4-Cyl. (SOHC) *#
1995 (EX) 2.2L 4-Cyl. (SOHC) *#
Balance Shaft T186 TCK244 T41013 Not Applicable 90,000 2 Normal 338
60,000 2 Severe 338
Camshaft T244 TCK244 T41014 Not Applicable 90,000 2 Normal 338
60,000 2 Severe 338
1995 (Exc. EX) 2.2L 4-Cyl. (SOHC) *#
60,000 2 Severe 338
60,000 2 Severe 338
1
2
3
4
A34
HONDA (Cont.)
Accord (Includes Canadian - Cont.)
1996 2.2L 4-Cyl. (SOHC) *#
Balance Shaft T186 T41013 Not Applicable 90,000 2 Normal 338
60,000 2 Severe 338
Camshaft (w/o VTEC) T187 TCK186 T41014 Not Applicable 90,000 2 Normal 338
60,000 2 Severe 338
Camshaft (w/ VTEC) T244 TCK244 T41014 Not Applicable 90,000 2 Normal 338
60,000 2 Severe 338
1997 2.2L 4-Cyl. (SOHC) *#
Balance Shaft T186 T41013 Not Applicable 105,000 2, 3 338
Camshaft (w/o VTEC) T187 TCK186 T41014 Not Applicable 105,000 2, 3 338
Camshaft (w/ VTEC) T244 TCK244 T41014 Not Applicable 105,000 2, 3 338
1998-02 2.3L 4-Cyl. (SOHC) *#
Balance Shaft T186 T41013 Not Applicable 105,000 2, 3 342
Camshaft T244 TCK244 T41014 Not Applicable 105,000 2, 3 342
1996 2.7L V6 *# T263 90,000 Normal 347
60,000 Severe 347
1997 2.7L V6 *# T263 105,000 3 347
1998-00 3.0L V6 (J30A1) *# T286 TCK286 T41090 T42038 105,000 3 348
2001-02 3.0L V6 (J30A1) *# T286 105,000 3 348
2003-04 3.0L V6 (J30A1) *# T329 105,000 3 348
Civic
1973-79 1.2L 4-Cyl. * T028 60,000 1 302
1980-83 1.3L 4-Cyl. *#
Canada T028 60,000 1 303
USA T073 60,000 1 303
1980-83 1.5L 4-Cyl. *# T041 60,000 1 306
1995 1.5L 4-Cyl. *# T143 TCK143 T41011 Not Applicable 90,000 Normal 306
60,000 Severe 306
1999-00 1.6L 4-Cyl. (DOHC) *# T227 TCK227 T41016 Not Applicable 105,000 3 312
1988-89 1.6L 4-Cyl. (SOHC) *# T145 TCK145 T41011 Not Applicable 60,000 1 314
1991 1.6L 4-Cyl. (SOHC) *# T145 TCK145 T41011 Not Applicable 90,000 314
1992
Except Si 1.6L 4-Cyl. (SOHC) *# T145 TCK145 T41011 Not Applicable 90,000 314
Si 1.6L 4-Cyl. (SOHC) *# T224 TCK244 T41023 Not Applicable 90,000 314
1995 1.6L 4-Cyl. (SOHC) *# T224 TCK244 T41023 Not Applicable 90,000 Normal 314
60,000 Severe 314
60,000 Severe 318
1997-00 1.6L 4-Cyl. (SOHC) *# T224 TCK224 T41023 Not Applicable 105,000 3 318
2001-04 1.7L 4-Cyl. (SOHC) *# T312 110,000 3 321
Civic (Canadian)
1980-83 1.3L 4-Cyl. * T028 60,000 1 303
Civic CVCC
1975 1.5L 4-Cyl. * T036 60,000 1 306
1976-79 1.5L 4-Cyl. * T041 TCK041 Not Available Not Applicable 60,000 1 306
1
2
3
4
A35
HONDA (Cont.)
Civic CRX
1984 1.3L 4-Cyl. *# T099 TCK161 T41017 Not Applicable 60,000 1 303
1988-89 1.6L 4-Cyl. (SOHC) *# T145 60,000 1 314
Civic del Sol (Except VX)
1995 1.5L 4-Cyl. *# T143 TCK143 T41011 Not Applicable 90,000 Normal 306
60,000 Severe 306
60,000 Severe 314
60,000 Severe 318
1997 1.6L 4-Cyl. (SOHC) *# T224 TCK224 T41023 Not Applicable 105,000 3 318
1994 1.6L 4-Cyl. (DOHC) *# T227 TCK227 T41016 Not Applicable 90,000 312
1995-96 1.6L 4-Cyl. (DOHC) *# T227 TCK227 T41016 Not Applicable 90,000 Normal 312
60,000 Severe 312
1997 1.6L 4-Cyl. (DOHC) *# T227 TCK227 T41016 Not Applicable 105,000 3 312
Civic del Sol VX
1993-94 1.5L 4-Cyl. *# T223 90,000 306
1995 1.5L 4-Cyl. *# T223 90,000 Normal 306
60,000 Severe 306
Civic VX
1992-94 1.5L 4-Cyl. *# T223 90,000 306
1995 1.5L 4-Cyl. *# T223 90,000 Normal 306
60,000 Severe 306
Prelude
1980-82 1.6L 4-Cyl. (SOHC) * T041 60,000 1 314
1979-82 1.8L 4-Cyl. * T041 60,000 1 324
1983 1.8L 4-Cyl. *# T094 60,000 1 324
1985 2.0L 4-Cyl. (SOHC) * T094 TCK160 T41012 Not Applicable 60,000 1 329
1986-87 2.0L 4-Cyl. (SOHC) * T160 TCK160 T41012 Not Applicable 60,000 1 329
1988-89 2.0L 4-Cyl. (SOHC) *# T144 T41019 60,000 1 329
1990 2.0L 4-Cyl. (SOHC) *# T144 T41019 90,000 329
1988-89 2.0L 4-Cyl. (DOHC) *# T142 TCK142 T41019 Not Applicable 60,000 1 331
1990-91 2.0L 4-Cyl. (DOHC) *# T142 TCK142 T41019 Not Applicable 90,000 331
1990-91 2.1L 4-Cyl. (DOHC) *# T142 TCK142 T41019 Not Applicable 90,000 331
1993-94 2.2L 4-Cyl. (DOHC) *#
1995-96 2.2L 4-Cyl. (DOHC) *#
60,000 2 Severe 333
60,000 2 Severe 333
1997-01 2.2L 4-Cyl. (DOHC) *#
Balance Shaft T186 TCK186 T41022 Not Applicable 105,000 2, 3 333
1
2
3
4
A36
HONDA (Cont.)
Prelude (Cont.)
1992-94 2.2L 4-Cyl. (SOHC) *#
1995-96 2.2L 4-Cyl. (SOHC) *#
60,000 2 Severe 338
60,000 2 Severe 338
1992-94 2.3L 4-Cyl. (DOHC) *#
1995-96 2.3L 4-Cyl. (DOHC) *#
60,000 2 Severe 338
60,000 2 Severe 338
Light Trucks
CR-V
Odyssey
1995-96 2.2L 4-Cyl. (SOHC) *#
1997 2.2L 4-Cyl. (SOHC) *#
1998 2.3L 4-Cyl. (SOHC) *#
1999-04 3.5L V6 (J35A1 & J35A4) *# T286 105,000 3 348
Passport
1994-97 3.2L V6 (SOHC) # T221 TCK221 T41028 T42002 60,000 35
1998-99 3.2L V6 (DOHC) # T303 75,000 351
2000-02 3.2L V6 (DOHC) # T303 105,000 3 351
Pilot
3
2003-04 3.5L V6 (J35A1 & J35A4) *# T286 105,000 348
HYUNDAI
Accent
1996 1.5L 4-Cyl. (DOHC) * T282 T41037 T42016 60,000 353
1997 1.5L 4-Cyl. (DOHC) * T282 T41037 T42016 60,000 3 353
1995-96 1.5L 4-Cyl. (SOHC) * T191 TCK191 T41051 Not Applicable 60,000 354
2000-02 1.5L 4-Cyl. (SOHC) * T324 T41037 Not Applicable 60,000 3 354
2001-04 1.6L 4-Cyl. (DOHC) * T282 T41037 Not Available 60,000 3 356
Elantra
1992-95 1.6L 4-Cyl. (DOHC) *
2
Balance Shaft T168 TCK165 T41047 Not Applicable 60,000 357
2
Camshaft T165 TCK165 T41046 T42017 60,000 357
1
2
3
4
A37
HYUNDAI (Cont.)
Elantra (Cont.)
1993-95 1.8L 4-Cyl. (DOHC) *
Camshaft T167 TCK167** T41046** T42017 60,000 2 357
1996-98 1.8L 4-Cyl. * T278 TCK278 T41041 T42015 60,000 3 361
1999-01 2.0L 4-Cyl. (DOHC) * T284 TCK284 T41041 T42015 60,000 3 361
2002-03 2.0L 4-Cyl. (DOHC) * T284 60,000 3 361
2004 2.0L 4-Cyl. (DOHC) * T284 60,000 3 362
Excel
1986-89 1.5L 4-Cyl. (SOHC) * T073 TCK073 Not Available Not Applicable 60,000 354
Santa Fe
2001-04 2.4L 4-Cyl. (DOHC) *#
2
Balance Shaft T314 60,000 371
2
Camshaft T313 60,000 371
3
2001-04 2.7L V6 (DOHC) *# T315 T42014 Not Available 60,000 383
Scoupe
Sonata
1992-98 2.0L 4-Cyl. (DOHC) *
2, 3
2, 3
Camshaft T167 TCK167 T41046 T42017 60,000 368
1989-91 2.4L 4-Cyl. (SOHC) *
2
2
Camshaft T124 TCK124 T41044 Not Applicable 60,000 374
1999-2003 2.4L 4-Cyl. (DOHC) *#
Balance Shaft T314 60,000 2, 3 371
Camshaft T313 60,000 2, 3 371
1999-01 2.5L V6 (DOHC) *# T315 T42014 60,000 3 381
2002-04 2.7L V6 (DOHC) *# T315 T42014 60,000 3 383
Tiburon
1997 1.8L 4-Cyl. * T278 TCK278 T41041 T42015 60,000 3 361
1997 2.0L 4-Cyl. * T284 T41041 T42015 60,000 3 361
1998-01 2.0L 4-Cyl. * T284 TCK284 T41041 T42015 60,000 3 361
2003-04 2.0L 4-Cyl. * T284 60,000 3 361
2003-04 2.7L 4-Cyl. *# T315 T42014 60,000 3 383
XG300
2001 3.0L V6 (DOHC) *# T322 60,000 3 385
XG350
2002-03 3.5L V6 (DOHC) *# T323 T41040 T42014 60,000 3 385
2004 3.5L V6 (DOHC) *# T323 T41040 T42014 60,000 3 378
INFINITI
Passenger Cars
J30
1993 3.0L V6 * T180 60,000 388
1994-97 3.0L V6 * T251 60,000 388
M30
1990-92 3.0L V6 * T104 TCK104 T41059 Not Applicable 60,000 391
1
2
3
4
A38
INFINITI (Cont.)
Light Trucks
QX4
1997-00 3.3L V6 (SOHC) * T249 TCK249 T41059 Not Applicable 105,000 393
ISUZU
Passenger Cars
I-Mark (Includes Canadian)
1985-87 1.5L 4-Cyl. *#
Up To 6/30/86 T118 TCK118 Not Available Not Applicable 60,000 293
From 7/1/86 T162 TCK118 Not Available Not Applicable 60,000 293
1988-90 1.5L 4-Cyl. *# T162 TCK118 Not Available Not Applicable 60,000 293
1989 1.6L 4-Cyl. (DOHC) # T169 T41027 T42001 60,000 397
1981-84 1.8L 4-Cyl. Diesel * T076 60,000 400
Impulse
1990-92 1.6L 4-Cyl. Non-Turbo # T169 T41027 T42001 60,000 397
1991-92 1.6L 4-Cyl. Turbo # T169 T41027 T42001 60,000 397
1992 1.8L 4-Cyl. # T205 T41027 T42001 60,000 397
1985-89 2.0L 4-Cyl. Turbo * T121 60,000 402
Stylus
1991 1.6L 4-Cyl. (DOHC) # T169 T41027 T42001 60,000 397
1991 1.6L 4-Cyl. (SOHC) *# T177 TCK177 Not Available Not Applicable 60,000 397
1992-93 1.6L 4-Cyl. (SOHC) *# T177 TCK177 Not Available Not Applicable 60,000 397
1992-93 1.8L 4-Cyl. (SOHC) # T205 T41027 T42001 60,000 397
Light Trucks
Amigo
1998 2.2L 4-Cyl. (DOHC) *# T305 75,000 407
1999-00 2.2L 4-Cyl. (DOHC) *# T305 100,000 Normal 407
75,000 Severe 407
1998 3.2L V6 (DOHC) # T303 75,000 416
1999-00 3.2L V6 (DOHC) # T303 100,000 Normal 416
75,000 Severe 416
Axiom
2002-04 3.5L V6 (DOHC) *# T303 100,000 Normal 416
75,000 Severe 416
Oasis
1996 2.2L 4-Cyl. (SOHC) *#
60,000 2 Severe 409
60,000 2 Severe 409
1997 2.2L 4-Cyl. (SOHC) *#
1998-99 2.3L 4-Cyl. (SOHC) *#
Pickup & P’UP
1981-87 2.2L 4-Cyl. Diesel * T075 60,000 405
1
2
3
4
A39
ISUZU (Cont.)
Rodeo
1998 2.2L 4-Cyl. (DOHC) *# T305 75,000 407
75,000 Severe 407
60,000 Severe 407
1993-97 3.2L V6 (SOHC) # T221 TCK221** T41028** T42002 60,000 414
1998 3.2L V6 (DOHC) # T303 75,000 416
1999-04 3.2L V6 (DOHC) # T303 100,000 Normal 416
75,000 Severe 416
2004 3.5L V6 (DOHC) # T303 100,000 Normal 416
75,000 Severe 416
Rodeo Sport
60,000 Severe 407
2001-03 3.2L V6 (DOHC) *# T303 100,000 Normal 416
75,000 Severe 416
Trooper
1992-95 3.2L V6 (DOHC) # T220 T41028 T42002 60,000 414
1992-97 3.2L V6 (SOHC) # T221 TCK221** T41028** T42002 60,000 414
1998 3.5L V6 (DOHC) # T303 75,000 416
1999-02 3.5L V6 (DOHC) # T303 100,000 Normal 416
75,000 Severe 416
Trooper II
1984-87 2.2L 4-Cyl. Diesel * T075 60,000 405
VehiCROSS
1999-01 3.5L V6 (DOHC) # T303 100,000 Normal 416
75,000 Severe 416
JEEP
Liberty
2002 2.4L 4-Cyl. (DOHC, VIN 1) *# T265 T43005 Not Available 120,000 Normal 145
90,000 Severe 145
2003-04 2.4L 4-Cyl. (DOHC, VIN 1) *# T265 T43008 Not Available 120,000 Normal 145
90,000 Severe 145
Wrangler
2003-04 2.4L 4-Cyl. (DOHC, VIN 1) *# T265 T43008 Not Available 120,000 Normal 145
90,000 Severe 145
KIA
Passenger Cars
Amanti
2004 3.5L V6 (DOHC) *# T323 60,000 3 385
Optima
2001-04 2.4L V6 (DOHC) *
Balance Shaft T314 T41038 Not Applicable 105,000 (CA) 3 428
60,000 (Exc. CA) 428
Camshaft T313 T41087** T42017 105,000 (CA) 3 428
60,000 (Exc. CA) 428
1
2
3
4
A40
KIA (Cont.)
Optima (Cont.)
2001 2.5L V6 (DOHC) *# T315 T41040** T42014 105,000 (CA) 3 381
60,000 (Exc. CA) 381
2002-04 2.7L V6 (DOHC) *# T315 T41040** T42014 105,000 (CA) 3 383
60,000 (Exc. CA) 383
Rio
2001-02 1.5L 4-Cyl. (DOHC) * T318 105,000 (CA) 3 418
60,000 (Exc. CA) 418
2003-04 1.6L 4-Cyl. (DOHC) * T318 105,000 (CA) 3 418
60,000 (Exc. CA) 418
Sephia
1994-95 1.6L 4-Cyl. (SOHC) * T185 TCK185 T41030 Not Applicable 105,000 (CA) 3 421
60,000 (Exc. CA) 421
1996-97 1.6L 4-Cyl. (DOHC) * T179 TCK179 T41031 T42005 105,000 (CA) 3 420
60,000 (Exc. CA) 420
60,000 (Exc. CA) 420
1998-01 1.8L 4-Cyl. (DOHC) * T302 T41032 T42005 105,000 (CA) 3 423
60,000 (Exc. CA) 423
1996-97 1.8L 4-Cyl. (SOHC) * T185 105,000 (CA) 3 421
60,000 (Exc. CA) 421
Spectra
2000-04 1.8L 4-Cyl. (DOHC) * T302 T41032 Not Available 105,000 (CA) 3 423
60,000 (Exc. CA) 423
Light Trucks
Sedona
2002-04 3.5L V6 (DOHC) *# T323 T41039** T42018 60,000 3 385
Sorento
2003 3.5L V6 (DOHC) *# T323 T41039** T42018 60,000 3 Normal 385
40,000 Severe 385
2004 3.5L V6 (DOHC) *# T323 60,000 3 Normal 385
40,000 Severe 385
Sportage
60,000 (Exc. CA) 425
1995 2.0L 4-Cyl. (SOHC) * T264 T41029 T42003 105,000 (CA) 3 427
60,000 (Exc. CA) 427
LANCIA
Beta
1976-78 1.8L 4-Cyl. * T020 25,000 430
LAND ROVER
Freelander
2002-04 2.5L KV6 (DOHC) *#
Front T327 72,000 3 431
Rear T326 72,000 3 431
LEXUS
ES 250
1990-91 2.5L V6 (2VZ-FE) # T157 TCK157** T41057** T42030 60,000 1, 3 442
ES 300
1992-93 3.0L V6 (3VZ-FE) # T200 TCK200** T41057** T42030 60,000 1, 3 442
1994-98 3.0L V6 (1MZ-FE) # T257 60,000 1, 3 442
1999-01 3.0L V6 (1MZ-FE) # T257 90,000 451
1
2
3
4
A41
LEXUS (Cont.)
ES 300 (Cont.)
2002-03 3.0L V6 (1MZ-FE) # T257 90,000 451
ES 330
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
GS 300
1993-97 3.0L 6-Cyl. (2JZ-GE) T215 60,000 1, 3 446
1998-04 3.0L 6-Cyl. (2JZ-GE) * T215 90,000 448
GS 400
1998-99 4.0L V8 (1UZ-FE) *# T298 90,000 458
2000 4.0L V8 (1UZ-FE) *# T298 Not Available T42031 90,000 458
GS 430
2001-04 4.3L V8 (3UZ-FE) * T298 Not Available T42031 90,000 462
IS 300
2001-04 3.0L 6-Cyl. (2JZ-GE) * T215 90,000 448
LS 400
1990-94 4.0L V8 (1UZ-FE) # T190 60,000 1, 3 454
1995-97 4.0L V8 (1UZ-FE) # T190 90,000 Normal 454
60,000 Severe 454
1998-00 4.0L V8 (1UZFE) *# T298 90,000 458
LS 430
SC 300
1993-97 3.0L 6-Cyl. (2JZ-GE) * T215 60,000 1, 3 446
1998-00 3.0L 6-Cyl. (2JZ-GE) T215 90,000 448
SC 400
1992-94 4.0L V8 (1UZ-FE) # T190 60,000 1, 3 454
1995-97 4.0L V8 (1UZ-FE) # T190 90,000 Normal 454
60,000 Severe 454
1998-00 4.0L V8 (1UZ-FE) # T298 90,000 458
SC 430
Light Trucks
GX 470
2003-04 4.7L V8 (2UZ-FE) *# T298 90,000 482
LX 470
1998-04 4.7L V8 (2UZ-FE) *# T298 90,000 477
RX 300
1999-01 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 451
2002-03 3.0L V6 (1MZ-FE) *# T257 90,000 451
RX 330
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
MAZDA
Passenger Cars
Miata & MX-5 Miata
1990-92 1.6L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 489
1993 1.6L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 Federal 489
1994-96 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 Federal 492
1997 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 492
(Exc. CA & MA) 492
105,000 (CA & MA) 492
1
2
3
4
A42
MAZDA (Cont.)
Miata & MX-5 Miata (Cont.)
1999-00 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 3 492
105,000 3 492
(CA & Select) 492
2001-04 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 492
Millenia
1995-96 2.3L V6 T267 60,000 Federal 514
1997-98 2.3L V6 T267 60,000 3 514
(Exc, CA & MA) 514
105,000 3 (CA & MA) 514
1999-00 2.3L V6 T267 60,000 3 514
105,000 3 514
(CA & Select) 514
2001-02 2.3L V6 T267 60,000 514
1995-96 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 Federal 518
1997-98 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 3 518
T42009 (Lwr) (Exc. CA & MA) 518
105,000 3 (CA & MA) 518
1999-00 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 3 518
T42009 (Lwr) (Exc. CA & Select) 518
105,000 3 518
(CA & Select) 518
2001-02 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 105,000 3 518
T42009 (Lwr)
MX-3
1992 1.6L 4-Cyl. (SOHC) T185 TCK185 T41030 Not Applicable 60,000 489
1993 1.6L 4-Cyl. (SOHC) T185 TCK185 T41030 Not Applicable 60,000 Federal 489
1992 1.8L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 499
T42009 (Lwr)
1993 1.8L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 Federal 499
MX-3 (Canadian)
1995 1.8L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 Federal 499
MX-6
1993 2.0L 4-Cyl. (DOHC) T228 TCK228 T41091 T42008 60,000 504
105,000 Calif. 504
1997 2.0L 4-Cyl. (DOHC) T228 TCK228 T41091 T42008 60,000 3 504
(Exc. CA & MA) 504
105,000 3 (CA & MA) 504
1988-92 2.2L 4-Cyl. * T134 TCK134 T41029 T42003 60,000 571
1993 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 578
T42009 (Lwr)
1
2
3
4
A43
MAZDA (Cont.)
MX-6 (Cont.)
1997 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 3 578
105,000 3 578
(CA & Select) 578
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
1998 1.5L 4-Cyl.
Up To Eng. No. 19472 T266 TCK266 Not Available Not Available 60,000 (Ex. CA & MA) 486
105,000 (CA & MA) 3 486
From Eng. No. 19473 T308 TCK266 Not Available Not Available 60,000 (Ex. CA & MA) 486
105,000 (CA & MA) 3 486
1999-00 1.6L 4-Cyl. (DOHC) T308 60,000 3 487
105,000 3 487
(CA & Select) 487
2001 1.6L 4-Cyl. (DOHC) T308 105,000 3 487
1990-92 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 489
1997-98 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 3 492
(Exc. CA & MA) 492
105,000 3 (CA & MA) 492
1999-00 1.8L 4-Cyl. (DOHC) T316 60,000 3 497
105,000 3 497
(CA & Select) 497
1990-92 1.8L 4-Cyl. (SOHC) T185 TCK185 T41030 Not Applicable 60,000 489
1993-94 1.8L 4-Cyl. (SOHC) T185 TCK185 T41030 Not Applicable 60,000 Federal 489
2001-03 2.0L 4-Cyl. (DOHC) * T228 TCK228 T41091 T42008 105,000 3 504
Protege5
2002-03 2.0L 4-Cyl. (DOHC) * T228 TCK228 T41091 T42008 105,000 3 504
Serenia (Canadian)
1992-95 3.0L V6 (DOHC) * T183 60,000 Federal 521
323
1988-89 1.6L 4-Cyl. (DOHC) T149 60,000 489
1986 1.6L 4-Cyl. (SOHC) T123 60,000 489
1993-94 1.6L 4-Cyl. (SOHC) T185 TCK185 T41030 Not Applicable 60,000 Federal 489
626
1984-85 2.0L 4-Cyl. Diesel *
Camshaft T103 100,000 502
1983 2.0L 4-Cyl. (SOHC) * T088 60,000 511
1
2
3
4
A44
MAZDA (Cont.)
626 (Cont.)
1984-85 2.0L 4-Cyl. (SOHC) *
Round Tooth Sprocket T113 60,000 511
Square Tooth Sprocket T088 60,000 511
1993 2.0L 4-Cyl. (DOHC) T228 TCK228 T41091 T42008 60,000 504
1997-00 2.0L 4-Cyl. (DOHC) T228 TCK228 T41091 T42008 60,000 3 504
105,000 3 504
(CA & Select) 504
2001-02 2.0L 4-Cyl. (DOHC) T228 TCK228 T41091 T42008 105,000 3 504
1988-92 2.2L 4-Cyl. * T134 TCK134 T41029 T42003 60,000 511
1993 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 518
T42009 (Lwr)
1997-00 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 60,000 3 518
105,000 3 518
(CA & Select) 518
2001-02 2.5L V6 T214 TCK214** T41034** T42010 (Upr) 105,000 3 518
T42009 (Lwr)
929
1990-91 3.0L V6 (DOHC) * T183 TCK183A** T41036** T42007 (Upr) 60,000 Federal 521
1992-95 3.0L V6 (DOHC) * T183 TCK183** T41036** T42013 (Upr) 60,000 Federal 521
1988-91 3.0L V6 (SOHC) * T146 TCK146** T41033** T42011 (Upr) 60,000 523
T42001 (Lwr)
Light Trucks
B2000
1986 2.0L 4-Cyl. (SOHC) *
Up To Chas. 568707 T113 60,000 511
From Chas. 568708 T117 60,000 511
1987 2.0L 4-Cyl. (SOHC) * T117 TCK117 T41035 Not Applicable 60,000 511
B2200
1987-93 2.2L 4-Cyl. * T134 TCK134 T41029 T42003 60,000 511
B2300
1994 2.3L 4-Cyl. T210 TCK210 T41005 Not Applicable 60,000 513
B2500
MPV
1989-93 3.0L V6 (SOHC) * T146 TCK146** T41033** T42011 (Upr) 60,000 523
T42001 (Lwr)
1994-96 3.0L V6 (SOHC) * T146 TCK146** T41033** T42011 (Upr) 60,000 Federal 523
1997-98 3.0L V6 (SOHC) * T146 TCK146** T41033** T42011 (Upr) 60,000 3 523
T42001 (Lwr) (Exc. CA & MA) 523
105,000 3 (CA & MA) 523
1
2
3
4
A45
MAZDA (Cont.)
Tribute
2001-04 2.0L 4-Cyl. (DOHC) T294 TCK294A T43003 T42036 (Upr) 90,000 508
T42034 (Lwr)
MERCURY
Passenger Cars
Bobcat
1974 2.0L 4-Cyl. T013 60,000 1 226
Capri
1972 1.6L 4-Cyl. T013 60,000 1 226
1991-94 1.6L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 222
1971-74 2.0L 4-Cyl. T013 60,000 1 226
Cougar
1999 2.0L 4-Cyl. (DOHC, VIN 3)
Up To 3/28/1999 T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000, 236
From 3/29/1999 T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000, 236
2000 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000, 236
2001-02 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294A T43003 T42036 (Upr) 120,000 236
T42034 (Lwr)
LN7
Lynx
1984-87 2.0L 4-Cyl. Diesel *#
Camshaft T103 100,000 2 229
Marquis
Mystique
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) T258 TCK258 T41008 T42032 (LH) 60,000 1 234
T42033 (RH)
1998 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000, 236
1999 2.0L 4-Cyl. (DOHC, VIN 3)
Up To 3/28/1999 T294 TCK294 T43003 T42035 (Upr) Inspect at 120,000, 236
From 3/29/1999 T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000, 236
2000 2.0L 4-Cyl. (DOHC, VIN 3) T294 TCK294A T43003 T42036 (Upr) Inspect at 120,000, 236
Topaz
1984-86 2.0L 4-Cyl. Diesel *#
Camshaft T103 100,000 2 229
1
2
3
4
A46
MERCURY (Cont.)
Tracer
1991-96 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 227
1991 1.9L 4-Cyl. (SOHC) *#
Up To 3/25/1991 T067 TCK067 T41006 Not Applicable 60,000 224
From 3/26/1991 T194 TCK194 T41007 Not Applicable 60,000 224
1992-96 1.9L 4-Cyl. (SOHC) # T194 TCK194 T41007 Not Applicable 60,000 224
1997-99 2.0L 4-Cyl. (SOHC, VIN P) T283 Inspect at 120,000, 250
Zephyr
Light Trucks
Villager
1993 3.0L V6 (SOHC) T104 TCK104 T41059 Not Applicable 105,000 262
1994-98 3.0L V6 (SOHC) T249 TCK249 T41059 Not Applicable 105,000 262
1999-02 3.3L V6 (SOHC) * T249 105,000 393
MERKUR
XR4Ti
MITSUBISHI
Passenger Cars
Cordia & Tredia
1983-84 1.8L 4-Cyl.
Camshaft T089 60,000 2 530
1985-86 1.8L 4-Cyl.
Camshaft T089 60,000 2 530
1987-88 1.8L 4-Cy
1984 2.0L 4-Cyl.
Camshaft T089 60,000 2 530
1985-86 2.0L 4-Cyl.
Camshaft T089 60,000 2 530
1987-88 2.0L 4-Cyl.
Camshaft T158 60,000 2 530
Diamante
1992-93 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 189
1994-95 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 3 Federal 189
1992-93 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 563
1994-96 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 Federal 563
1997-02 3.5L V6 (SOHC) *# T287 TCK287 Not Available Not Available 60,000 3 575
100,000 3 575
(CA & Select) 575
1
2
3
4
A47
MITSUBISHI (Cont.)
Diamante (Cont.)
2003-04 3.5L V6 (SOHC) *# T287 60,000 3 575
100,000 3 575
(CA & Select) 575
Eclipse
1990-94 1.8L 4-Cyl.
1990-94 2.0L 4-Cyl. (DOHC) *
Camshaft T167 TCK167** T41046 T42017 60,000 2 537
1995-97 2.0L 4-Cyl. Non-Turbo *#
(DOHC, VIN Y) T246 TCK246** T41002** T41002 60,000 3 Federal 200
1998-99 2.0L 4-Cyl. Non-Turbo *#
(DOHC, VIN Y) T246 TCK246** T41002** T41002 60,000 3 200
100,000 3 200
(CA, CT & MA) 200
1995-97 2.0L 4-Cyl. (DOHC) Turbo *
100,000 2, 3 California 537
Camshaft T167 60,000 2, 3 Federal 537
100,000 2, 3 California 537
1998-99 2.0L 4-Cyl. (DOHC) Turbo *
Balance Shaft T168 60,000 2, 3 537
100,000 2, 3 537
(CA, CT & MA) 537
Camshaft T167 60,000 2, 3 537
100,000 2, 3 537
(CA, CT & MA) 537
1996 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 Federal 558
Camshaft T230 60,000 2 Federal 558
1997-99 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2, 3 558
100,000 2, 3 558
(CA, CT & MA) 558
Camshaft T230 60,000 2, 3 558
100,000 2, 3 558
(CA, CT & MA) 558
1
2
3
4
A48
MITSUBISHI (Cont.)
Eclipse (Cont.)
2000 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2, 3 558
100,000 2, 3 558
(CA, CT & MA) 558
Camshaft T232 60,000 2, 3 558
100,000 2, 3 558
(CA, CT & MA) 558
2001 2.4L 4-Cyl. (SOHC, VIN G) *
100,000 2, 3 California 558
100,000 2, 3 California 558
2002-03 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2, 3 558
100,000 2, 3 558
(CA & Select) 558
Camshaft T232 60,000 2, 3 558
100,000 2, 3 558
(CA & Select) 558
2004 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2, 3 558
100,000 2, 3 558
(CA & Select) 558
Camshaft T332 60,000 2, 3 558
100,000 2, 3 558
(CA & Select) 558
2000 3.0L V6 (SOHC, 24-Valve) *# T259 TCK259** T41039** T42018 60,000 3 568
100,000 3 568
(CA, CT & MA) 568
2001 3.0L V6 (SOHC, 24-Valve) *# T259 TCK259** T41039** T42018 60,000 Federal 568
2002-04 3.0L V6 (SOHC, 24-Valve) *# T259 TCK259** T41039** T42018 60,000 3 568
100,000 3 568
(CA & Select) 568
Expo & Expo LRV
1992-93 1.8L 4-Cyl. (VINs C & D) # T201 TCK201 T41052 Not Applicable 60,000 198
1994 1.8L 4-Cyl. (VINs C & D) # T201 TCK201 T41052 Not Applicable 60,000 3 Federal 198
1992 2.4L 4-Cyl.
Balance Shaft T159 60,000 2, 3 203
Camshaft T204 60,000 2, 3 203
1993-95 2.4L 4-Cyl.
Balance Shaft T168 60,000 2, 3 203
Camshaft T230 60,000 2, 3 203
1
2
3
4
A49
MITSUBISHI (Cont.)
Galant
1989-92 2.0L 4-Cyl. (SOHC)
1993 2.0L 4-Cyl. (SOHC)
1989-92 2.0L 4-Cyl. (DOHC) *
Balance Shaft T168 TCK167** T41047** Not Applicable 60,000 2 537
Camshaft T167 TCK167** T41046** T42017 60,000 2 537
1993 2.0L 4-Cyl. (DOHC) *
1994 2.4L 4-Cyl. (DOHC) *
Balance Shaft T168 T41038 60,000 2 Federal 544
Camshaft
Up To May, 1994 T256 TCK256** T41054** T42017 60,000 2 Federal 544
1985-87 2.4L 4-Cyl. (SOHC)
1994-96 2.4L 4-Cyl. (SOHC, VIN G) *
100,000 2, 3 California 558
100,000 2, 3 California 558
1997-98 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 558
(Exc. CA , CT & MA) 558
100,000 2 , 3 558
(CA , CT & MA) 558
Camshaft T230 60,000 2 , 3 558
(Exc. CA , CT & MA) 558
100,000 2 , 3 558
(CA , CT & MA) 558
1999-00 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 558
(Exc. CA , CT & MA) 558
100,000 2 , 3 558
(CA , CT & MA) 558
Camshaft T232 60,000 2 , 3 558
(Exc. CA , CT & MA) 558
100,000 2 , 3 558
(CA , CT & MA) 558
2001 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 Federal 558
Camshaft T232 60,000 2 , 3 Federal 558
1
2
3
4
A50
MITSUBISHI (Cont.)
Galant (Cont.)
2002-03 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 558
100,000 2 , 3 558
(CA & Select) 558
Camshaft T232 60,000 2 , 3 558
100,000 2 , 3 558
(CA & Select) 558
2004 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 558
100,000 2 , 3 558
(CA & Select) 558
Camshaft T332 60,000 2 , 3 558
100,000 2 , 3 558
(CA & Select) 558
100,000 3 568
(CA, CT & MA) 568
2001 3.0L V6 (SOHC, 24-Valve) *# T259 TCK259** T41039** T42018 60,000 3 Federal 568
100,000 3 568
(CA & Select) 568
4
2004 3.8L V6 (SOHC) 60,000 3 582
(Exc. CA, MA & VT) 582
100,000 3 582
(CA , MA & VT) 582
Galant Sigma
1988 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 563
Lancer
2002-04 2.0L 4-Cyl. (SOHC) *# T201 60,000 3 542
(Exc. CA , MA & VT) 542
100,000 3 542
(CA , MA & VT) 542
2004 2.4L 4-Cyl. (SOHC) * T332 60,000 3 547
100,000 3 547
(CA & Select) 547
Lancer Evolution Turbo
2003-04 2.0L 4-Cyl. (DOHC) *# 60,000 3 532
Balance Shaft T168 (Exc. CA , MA & VT) 532
Camshaft T167 100,000 3 532
(CA , MA & VT) 532
Mirage
1985-86 1.5L 4-Cyl. *
Up To 5/31/1986 T073 TCK073 Not Applicable 60,000 525
From 6/1/1986 T073 60,000 525
1
2
3
4
A51
MITSUBISHI (Cont.)
Mirage (Cont.)
1994-96 1.5L 4-Cyl. * T191 TCK191 T41051 Not Applicable 60,000 Federal 525
1997-99 1.5L 4-Cyl. * T289 TCK289 Not Available Not Applicable 60,000 3 525
100,000 3 525
(CA, CT & MA) 525
2000-02 1.5L 4-Cyl. * T289 60,000 3 525
100,000 3 525
(CA, CT & MA) 525
1985-86 1.6L 4-Cyl. (SOHC) * T093 T41055 Not Applicable 60,000 528
1987-88 1.6L 4-Cyl. (SOHC) * T093 T41056 Not Applicable 60,000 528
1989 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1991-92 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1993 1.8L 4-Cyl. (VINs C & D) # T201 TCK201 T41052 Not Applicable 60,000 198
1994-96 1.8L 4-Cyl. (VINs C & D) # T201 TCK201 T41052 Not Applicable 60,000 Federal 198
1997-02 1.8L 4-Cyl. (VINs C & D) # T288 60,000 3 198
100,000 3 198
(CA, CT & MA) 198
Precis
1987-89 1.5L 4-Cyl. * T073 TCK073 Not Available Not Applicable 60,000 525
1994 1.5L 4-Cyl. * T128 TCK128 T41042 Not Applicable 60,000 Federal 525
Sigma
Tredia (See Cordia)
3000GT
1991-93 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 189
1994-95 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 3 Federal 189
1996-98 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 3 189
100,000 3 189
(CA & Select) 189
1999 3.0L V6 (DOHC) *# T195 TCK195** T41039** T42018 60,000 3 189
(Ex. CA & MA) 189
100,000 (CA & MA) 189
1997-99 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 3 563
(Ex. CA, CT & MA) 563
100,000 563
(CA, CT & MA) 563
1
2
3
4
A52
MITSUBISHI (Cont.)
Light Trucks
Endeavor
4
2004 3.8L V6 (SOHC) *# 60,000 3 582
(Exc. CA, MA & VT) 582
100,000 3 582
(CA, MA & VT) 582
Montero
1994 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 3 Federal 563
1995-96 3.0L V6 (SOHC, 24-Valve) *# T259 TCK259** T41039** Not Applicable 60,000 3 Federal 568
1994-96 3.5L V6 (DOHC) *# T253 60,000 3 Federal 572
100,000 3 575
(CA & Select) 575
2001-02 3.5L V6 (SOHC) *# T320 60,000 3 575
100,000 3 575
(CA & Select) 575
2003-04 3.8L V6 (SOHC) *# T320 60,000 3 586
(Exc. CA , MA & VT) 586
100,000 3 586
(CA , MA & VT) 586
Montero Sport
1997-98 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2, 3 558
(Exc. CA , CT & MA) 558
100,000 2, 3 558
(CA , CT & MA) 558
Camshaft T230 60,000 2 , 3 558
(Exc. CA , CT & MA) 558
100,000 2, 3 558
(CA , CT & MA) 558
1999 2.4L 4-Cyl. (SOHC, VIN G) *
Balance Shaft T168 60,000 2 , 3 558
Camshaft T232 60,000 2 , 3 558
(Exc. CA , CT & MA) 568
100,000 2, 3 568
(CA , CT & MA) 568
2003 3.0L V6 (SOHC, 24-Valve) *# T259 60,000 3 568
(Exc. CA , CT & MA) 568
100,000 2, 3 568
(CA , CT & MA) 568
1999-00 3.5L V6 (SOHC) *# T287 60,000 3 575
100,000 3 575
(CA & Select) 575
1
2
3
4
A53
MITSUBISHI (Cont.)
Montero Sport (Cont.)
100,000 3 575
(CA & Select) 575
2003-04 3.5L V6 (SOHC) *# T287 60,000 3 575
100,000 3 575
(CA & Select) 575
Outlander
2003-04 2.4L 4-Cyl. (SOHC, VIN G) * 60,000 3 547
Balance Shaft T168 (Ex. CA & Select) 547
Camshaft (2003) T232 100,000 547
Camshaft (2004) T332 (CA & Select) 547
Pickup
1983-86 2.0L 4-Cyl.
Camshaft T089 60,000 2 530
1987-89 2.0L 4-Cyl.
1983-85 2.3L 4-Cyl. Turbo Diesel *
Balance Shaft T092 T41049 50,000 2 185
Camshaft T091 T41050 50,000 2 185
1990-92 2.4L 4-Cyl. (SOHC)
1993-96 2.4L 4-Cyl. (SOHC)
Camshaft T229 60,000 2 187
1994 3.0L V6 (SOHC, 12-Valve) # T139 TCK139 T41048 Not Applicable 60,000 Federal 563
Van
1987-90 2.4L 4-Cyl. (SOHC)
NISSAN
Passenger Cars
Maxima
1985 3.0L V6 (SOHC) * T104 TCK104 T41059 Not Applicable 60,000 1 596
1992-94 3.0L V6 (SOHC) *
Round Tooth Sprocket T249 TCK249 T41059 Not Applicable 60,000 596
Square Tooth Sprocket T104 TCK104 T41059 Not Applicable 60,000 596
Pulsar & Pulsar NX (Includes Canadian)
1987 1.6L 4-Cyl. (DOHC) * T137 T41058 Not Applicable 60,000 590
1988-89 1.8L 4-Cyl. (DOHC) * T137 60,000 590
1
2
3
4
A54
NISSAN (Cont.)
Sentra (Includes Canadian)
1983-85 1.7L 4-Cyl. Diesel *
Camshaft T096 60,000 1 592
1986-87 1.7L 4-Cyl. Diesel *
Camshaft T096 60,000 592
Stanza
Stanza Wagon
200SX (Includes Canadian)
1984-85 1.8L 4-Cyl. Turbo T100 60,000 1 593
1986-87 1.8L 4-Cyl. Turbo T100 60,000 593
1984-85 2.0L 4-Cyl. * T078 TCK078A T41089 Not Applicable 60,000 1 593
1986-87 2.0L 4-Cyl. * T078 TCK078A T41089 Not Applicable 60,000 593
300ZX
1984-85 3.0L V6 (SOHC) * T104 TCK104 T41059 Not Applicable 60,000 1 596
1990-92 3.0L V6 (DOHC) * T180 T41085** T42021 (Upr) 60,000 594
T42020 (Lwr)
1993 3.0L V6 (DOHC) * T180 T41085** T42021 (Upr) 60,000 (Convertible) 594
T42020 (Lwr) 105,000 594
(Non-Convertible) 594
1994-96 3.0L V6 (DOHC) Turbo * T251 T41085** T42021 (Upr) 60,000 594
T42020 (Lwr)
1994-96 3.0L V6 *
(DOHC) Non-Turbo T251 T41085** T42021 (Upr) 105,000 594
T42020 (Lwr)
310
Light Trucks
Frontier
2004 3.3L V6 (SOHC) * T249 TCK249 105,000 393
Pathfinder
1993-94 3.0L V6 (SOHC) *
Pickup
1
2
3
4
A55
NISSAN (Cont.)
Pickup (Cont.)
1993-94 3.0L V6 (SOHC) *
1995 3.0L V6 (SOHC) * T249 TCK249 T41059 Not Applicable 60,000 596
Quest
1993-94 3.0L V6 (SOHC) *
Xterra
OLDSMOBILE
Cutlass Supreme
1996 3.4L V6 *# T273 TCK273 Not Available Not Available 60,000 284
Firenza
1987-88 2.0L 4-Cyl. # T081 60,000 1 272
OPTIMA
Optima (Canadian)
1988-92 1.6L 4-Cyl. # T148 60,000 1 599
1988-89 2.0L 4-Cyl. # T081 60,000 1 599
PEUGEOT
405
1989-91 1.9L 4-Cyl. (DOHC) T188 60,000 1 600
1989-91 1.9L 4-Cyl. (SOHC) T189 60,000 1 600
505
1986-91 2.2L 4-Cyl. (Exc. Turbo) T140 60,000 1 602
PLYMOUTH
Passenger Cars
Acclaim
1989-93 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 164
Arrow
1978-80 1.6L 4-Cyl. (SOHC)
1977-80 1.6L 4-Cyl. (SOHC)
Camshaft T013 60,000 2 124
Breeze
1996-99 2.0L 4-Cyl. (SOHC, VIN C) *# T245 TCK245** T41002** Not Applicable 100,000 Federal 131
1
2
3
4
A56
PLYMOUTH (Cont.)
Breeze (Cont.)
Caravelle
1986-87 2.5L 4-Cyl. (SOHC) T114 TCK114 Not Applicable 60,000 1 143
1988 2.5L 4-Cyl. (SOHC) T132 TCK132 Not Applicable 60,000 1 143
Champ
1979 1.4L 4-Cyl. * T073 60,000 122
1979-82 1.6L 4-Cyl. (SOHC)
1979-80 1.6L 4-Cyl. (SOHC)
Camshaft T013 60,000 2 124
Colt
1979-82 1.4L 4-Cyl. * T073 60,000 122
1978-79 1.6L 4-Cyl. (RWD)
1979-82 1.6L 4-Cyl. (FWD)
1983-89 1.6L 4-Cyl. w/o Bal. Shaft
1977-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 124
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 130
1992-94 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
Colt (Canadian)
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) # T201 60,000 198
1984-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 180
1987-89 2.0L 4-Cyl. (SOHC)
1990-91 2.0L 4-Cyl. (SOHC)
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 203
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
1
2
3
4
A57
PLYMOUTH (Cont.)
Colt Vista (Includes Canadian - Cont.)
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 203
Colt 100 & 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) * T165 60,000 192
Horizon
Laser
1990-94 1.8L 4-Cyl.
1990-94 2.0L 4-Cyl. (DOHC) *
Camshaft T167 TCK167** T41046** T42017 60,000 2 175
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# T246 TCK246** T41002** T41002 105,000 200
2000-04 2.0L 4-Cyl. *#
(SOHC, VINs C & F) T245 105,000 134
Prowler
1999 3.5L V6 *# T295 105,000 182
2000-02 3.5L V6 *# T295 100,000 Federal 182
Reliant
1988 2.5L 4-Cyl. (SOHC) T132 60,000 1 143
Sapporo
1978-80 1.6L 4-Cyl. (SOHC)
1977-80 1.6L 4-Cyl. (SOHC)
Camshaft T013 60,000 2 124
Scamp Pickup
Sundance
1994 3.0L V6 (SOHC) # T139 TCK139 T41048 Not Applicable 60,000 3 164
TC3
1
2
3
4
A58
PLYMOUTH (Cont.)
Turismo
Light Trucks
(See DODGE/PLYMOUTH Light Trucks)
PONTIAC
Passenger Cars
Acadian (Canadian)
1976 1.4L 4-Cyl. T037 60,000 1 265
1977 1.4L 4-Cyl. T039 60,000 1 265
1976 1.6L 4-Cyl. T037 60,000 1 265
1977-78 1.6L 4-Cyl. T039 60,000 1 265
1979-87 1.6L 4-Cyl. T061 60,000 1 265
1981-85 1.8L 4-Cyl. Diesel * T076 60,000 1 270
Firefly (Canadian)
1985-88 1.0L 3-Cyl. T095 60,000 294
1989-91 1.0L 3-Cyl. T166 TCK166 Not Available Not Available 60,000 294
1994-95 1.0L 3-Cyl. T241 TCK241 Not Available Not Available 60,000 294
1998-00 1.3L 4-Cyl. T194 100,000 296
Grand Am
1989 2.0L 4-Cyl. # T163 TCK163 T43002 Not Applicable 60,000 1 272
Grand Prix
1996 3.4L V6 *# T273 TCK273 Not Available Not Available 60,000 285
J2000
1982 1.8L 4-Cyl. # T081 TCK081 Not Applicable Not Applicable 60,000 1 271
LeMans
1990 1.6L 4-Cyl. *#
With Tensioner T203 60,000 1 268
Without Tensioner T148 TCK148 Not Applicable Not Applicable 60,000 1 268
1991-93 1.6L 4-Cyl. *# T203 60,000 1 268
1989 2.0L 4-Cyl. #
First Design T081 TCK081A Not Applicable Not Applicable 60,000 1 272
Second Design T163 TCK163 T43002 Not Applicable 60,000 1 272
1990 2.0L 4-Cyl. # T163 TCK163 T43002 Not Applicable 60,000 1 272
Sunbird
Sunburst (Canadian)
1985-88 1.5L 4-Cyl. *# T118 TCK118 Not Available Not Applicable 60,000 293
T1000
1981-82 1.6L 4-Cyl. T061 60,000 1 265
1000
1983-87 1.6L 4-Cyl. T061 60,000 1 265
2000
1
2
3
4
A59
PONTIAC (Cont.)
2000 Sunbird
Light Trucks
Sunrunner (Canadian)
PORSCHE
924
1987-88 2.5L 4-Cyl. *#
Camshaft T107 45,000 604
928
1978-82 4.5L V8 *# T196 60,000 607
1983-84 4.7L V8 *# T196 60,000 607
1985-91 5.0L V8 *# T196 60,000 607
1992-95 5.4L V8 *# T196 60,000 607
944
1983-89 2.5L 4-Cyl. *#
Camshaft T107 45,000 604
1989 2.7L 4-Cyl. *#
Camshaft T107 45,000 604
1989-91 3.0L 4-Cyl. *#
Camshaft T152 45,000 604
944S & 944 Turbo
1987-88 2.5L 4-Cyl. *#
Camshaft T152 45,000 604
968
1992-95 3.0L 4-Cyl. *#
Camshaft T152 45,000 604
RENAULT
Alliance & Encore
1985-87 1.7L 4-Cyl. * T119 60,000 1 609
Fuego
1984-85 2.2L 4-Cyl. T140 60,000 1 610
Sportwagon
1984-86 2.2L 4-Cyl. T140 60,000 1 610
SAAB
900
1994-97 2.5L V6 * T285 60,000 612
9000
1995-97 3.0L V6 * T285 TCK285 Not Available Not Available 60,000 612
9-5
1999-03 3.0L V6 (DOHC) T285 90,000 613
1
2
3
4
A60
SATURN
LS2 & LW2
2000 3.0L V6 (DOHC, VIN R) *# T285 100,000 619
L300 & LW300
2001 3.0L V6 (DOHC, VIN R) *# T285 100,000 619
2002-04 3.0L V6 (DOHC, VIN R) *#
Up To S/N 578511 T285 100,000 619
From S/N 578512 T285 100,000 616
Vue
2002-03 3.0L V6 (DOHC, VIN B) *# T285 100,000 616
2004 3.5L V6 (SOHC) *# T329 100,000 622
STERLING
825
827
SUBARU
Passenger Cars
Coupe
1985-89 1.8L 4-Cyl.
Left Hand Belt T299 TCK299 T41061 T42022 52,000 2 628
Right Hand Belt T300 TCK299 T41062 Not Applicable 52,000 2 628
Forester
1998 2.5L 4-Cyl. (DOHC) # T277 105,000 637
1999-04 2.5L 4-Cyl. (SOHC) * T304 105,000 635
Impreza & Outback Sport
1993 1.8L 4-Cyl. T172 TCK172** T41063** T42023 (Upr-L) 60,000 627
T42023 (Lwr-L)
T42024 (Lwr-R)
1994 1.8L 4-Cyl. T254 TCK254** T41063** T42023 (Upr-L) 60,000 627
T42023 (Lwr-L)
T42024 (Lwr-R)
1995-97 1.8L 4-Cyl. T254 TCK254** T41063** T42023 (Upr-L) 60,000 Federal 627
T42023 (Lwr-L) 105,000 California 627
T42024 (Lwr-R)
2002-04 2.0L 4-Cyl. (DOHC) Turbo * T328 105,000 630
1995-96 2.2L 4-Cyl. (SOHC) T254 TCK254** T41063** T42023 (Upr-L) 60,000 Federal 627
T42023 (Lwr-L) 105,000 California 627
T42024 (Lwr-R)
1997-98 2.2L 4-Cyl. (SOHC) T254 60,000 Federal 627
1999-01 2.2L 4-Cyl. (SOHC) * T304 105,000 635
1998 2.5L 4-Cyl. (DOHC) # T277 TCK277** T41092** T42023 (Upr-L) 105,000 637
T42023 (Lwr-L)
T42024 (Lwr-R)
1999-04 2.5L 4-Cyl. (SOHC) *# T304 105,000 635
Justy
1987-95 1.2L 3-Cyl. T135 T41060 60,000 626
Legacy & Outback
1990-93 2.2L 4-Cyl. T172 TCK172** T41063** T42023 (Upr-L) 60,000 627
T42023 (Lwr-L)
T42024 (Lwr-R)
1
2
3
4
A61
SUBARU (Cont.)
Legacy & Outback (Cont.)
1994 2.2L 4-Cyl. T254 TCK254** Not Applicable 60,000 627
1995-96 2.2L 4-Cyl. T254 TCK254** Not Applicable 60,000 Federal 627
1997-98 2.2L 4-Cyl. T254 60,000 Federal 627
1999 2.2L 4-Cyl. (SOHC) * T304 105,000 635
1996-97 2.5L 4-Cyl. (DOHC) # T277 TCK277** T41092** T42023 (Upr-L) 60,000 637
T42023 (Lwr-L)
T42024 (Lwr-R)
1998-99 2.5L 4-Cyl. (DOHC) # T277 TCK277** T41092** T42023 (Upr-L) 105,000 637
T42023 (Lwr-L)
T42024 (Lwr-R)
2000-03 2.5L 4-Cyl. (SOHC) * T307 105,000 635

Loyale
1990-94 1.8L 4-Cyl.
Left Hand T299 TCK299 T41061 T42022 52,000 2 628
Right Hand T300 TCK299 T41062 Not Applicable 52,000 2 628
RX
1985-89 1.8L 4-Cyl.
Left Hand T299 TCK299 T41061 T42022 52,000 2 628
Sedan & Station Wagon
1985-89 1.8L 4-Cyl.
Left Hand T299 TCK299 Not Applicable 52,000 2 628
Right Hand T300 TCK299 Not Applicable 52,000 2 628
SVX
1992-94 3.3L 6-Cyl. T209 60,000 644
1995-97 3.3L 6-Cyl. T209 60,000 Federal 644
105,000 Calif. 644
XT
1985-91 1.8L 4-Cyl.
Left Hand T299 TCK299 T41061 T42022 52,000 2 628
XT6
1988-91 2.7L 6-Cyl.
Left Hand T151 60,000 2 641
Right Hand T150 60,000 2 641
Light Trucks
Baja
2003-04 2.5L 4-Cyl. (SOHC) * T307 105,000 635
SUZUKI
Passenger Cars
Esteem
Esteem (Canadian)
Forenza
2004 2.0L 4-Cyl. T309 Inspect at 30,000 651
Replace at 60,000 651
1
2
3
4
A62
SUZUKI (Cont.)
Swift
1989-92 1.3L 4-Cyl. (DOHC) * T171 60,000 1 645
1993-94 1.3L 4-Cyl. (DOHC) * T171 60,000 645
1993 1.3L 4-Cyl. (SOHC) T095 TCK095 T41064 Not Applicable 60,000 647
1994 1.3L 4-Cyl. (SOHC) T243 60,000 647
1998-01 1.3L 4-Cyl. (SOHC) T194 TCK194A Not Applicable 60,000 647
Light Trucks
Samurai
1985 1.3L 4-Cyl. (SOHC) T095 60,000 1 647
1993 1.3L 4-Cyl. (SOHC) T095 TCK095 Not Applicable 60,000 647
1994 1.3L 4-Cyl. (SOHC)
Up To VIN R4100375 T095 TCK095 T41064 Not Applicable 60,000 647
From VIN R4100376 T243 60,000 647
1995 1.3L 4-Cyl. (SOHC) T243 60,000 647
Sidekick
1992 1.6L 4-Cyl.
Convertible T164 TCK164 T41064 Not Applicable 60,000 1 649
Hardtop T212 TCK212 T41065 Not Applicable 60,000 1 649
1993-95 1.6L 4-Cyl.
Convertible T164 TCK164 T41064 Not Applicable 60,000 649
Hardtop T212 TCK212 T41065 Not Applicable 60,000 649
Vitara (Includes Canadian)
X-90
TOYOTA
Passenger Cars
Avalon
1995-97 3.0L V6 # T257 TCK257** T41075** T42030 60,000 Severe 683
1998-04 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 697
Camry
1984-86 1.8L 4-Cyl. Diesel T098 T41077 T42027 60,000 667
1983-85 2.0L 4-Cyl. # T087 TCK087 T41070 T42025 60,000 1 669
1986 2.0L 4-Cyl. # T087 TCK087 T41070 T42025 60,000 Severe 669
1987 2.0L 4-Cyl. #
GT-S T125 T41067 T42025 60,000 Severe 669
Exc. GT-S T138 TCK199 T41067 T42025 60,000 Severe 669
1988-91 2.0L 4-Cyl. # T138 TCK199 T41067 T42025 60,000 Severe 669
1998-01 2.2L 4-Cyl. T199 TCK199 T41067 T42025 90,000 678
1988-91 2.5L V6 # T157 TCK157** T41075** T42030 60,000 Severe 683
1992-93 3.0L V6 # T200 TCK200** T41075** T42030 60,000 Severe 683
1994-97 3.0L V6 # T257 TCK257** T41075** T42030 60,000 Severe 683
1998-02 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 697
2003-04 3.0L V6 (1MZ-FE) *# T257 90,000 697
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
1
2
3
4
A63
TOYOTA (Cont.)
Camry Solara
1999-00 2.2L 4-Cyl. T199 TCK199 T41067 T42025 90,000 678
2001 2.2L 4-Cyl. T199 TCK199 T41067 T42025 90,000 678
1999-03 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 697
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
Celica, Celica GT & ST
1990-92 1.6L 4-Cyl. (DOHC) T036 TCK036 T41066 Not Applicable 60,000 Severe 664
1993 1.6L 4-Cyl. (DOHC) T239 60,000 Severe 664
1994-97 1.8L 4-Cyl. (DOHC) T235 TCK235 T41072 Not Applicable 60,000 Severe 664
1990 2.0L 4-Cyl. # T125 T41067 T42025 60,000 Severe 669
1991-93 2.0L 4-Cyl. # T125 60,000 Severe 669
1990-91 2.2L 4-Cyl. T138 TCK199 T41067 T42025 60,000 Severe 678
1998-99 2.2L 4-Cyl. T199 TCK199 T41067 T42025 90,000 678
Celica GTS
1986 2.0L 4-Cyl. # T125 T41070 T42025 60,000 Severe 669
1987-88 2.0L 4-Cyl. # T125 60,000 Severe 669
Celica Supra
1982-83 2.8L 6-Cyl. T074 60,000 1 687
1984-85 2.8L 6-Cyl. T101 TCK101 T41069 Not Applicable 60,000 Severe 687
Corolla
1986-87 1.6L 4-Cyl. (SOHC) T070 TCK070 T41066 Not Applicable 60,000 Severe 662
1988 1.6L 4-Cyl. (SOHC) T036 TCK036 T41066 Not Applicable 60,000 Severe 662
1988-92 1.6L 4-Cyl. (DOHC, 4A-FE) T036 TCK036 T41066 Not Applicable 60,000 Severe 664
1993-97 1.6L 4-Cyl. (DOHC, 4A-FE) T236 TCK236 T41072 Not Applicable 60,000 Severe 664
1984-85 1.8L 4-Cyl. Diesel T098 T41077 T42027 60,000 667
1993-97 1.8L 4-Cyl. (7A-FE) T235 TCK235 T41072 Not Applicable 60,000 Severe 664
Corolla FX & FX-16
1987-88 1.6L 4-Cyl. (SOHC) T070 TCK070 T41066 Not Applicable 60,000 Severe 662
1985 1.6L 4-Cyl. (DOHC, 4A-GE) T112 TCK176 T41074 Not Applicable 60,000 1 660
1986-88 1.6L 4-Cyl. (DOHC, 4A-GE) T112 TCK176 T41074 Not Applicable 60,000 Severe 660
Corolla GTS
1985 1.6L 4-Cyl. (DOHC, 4A-GE) T112 TCK176 T41074 Not Applicable 60,000 1 660
1986-88 1.6L 4-Cyl. (DOHC, 4A-GE) T112 TCK176 T41074 Not Applicable 60,000 Severe 660
1989 1.6L 4-Cyl. (4A-GE/GELC) T176 TCK176 T41074 Not Applicable 60,000 Severe 660
1990-91 1.6L 4-Cyl. (4A-GE/GELC) T176 60,000 Severe 660
Corolla SR5
1988 1.6L 4-Cyl. T036 TCK036 T41066 Not Applicable 60,000 Severe 662
Corolla Sport
1985 1.6L 4-Cyl. (4A-GE) T112 TCK176 T41074 Not Applicable 60,000 1 660
1986-87 1.6L 4-Cyl. (4A-GE) T112 TCK176 T41074 Not Applicable 60,000 Severe 660
Corolla Tercel
Cressida
1983 2.8L 6-Cyl. T074 60,000 1 687
1
2
3
4
A64
TOYOTA (Cont.)
Cressida (Cont.)
1989-91 3.0L 6-Cyl. (7M-GE) T126 60,000 Severe 695
1992 3.0L 6-Cyl. (7M-GE) T237 60,000 Severe 695
MR2
1985 1.6L 4-Cyl. (4A-GE) T112 TCK176 T41074 Not Applicable 60,000 1 660
1986-88 1.6L 4-Cyl. (4A-GE) T112 TCK176 T41074 Not Applicable 60,000 Severe 660
1989 1.6L 4-Cyl. (4A-GE) T176 TCK176 T41074 Not Applicable 60,000 Severe 660
1991-95 2.0L 4-Cyl. # T125 60,000 Severe 669
Paseo (Includes Canadian)
1992-97 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 60,000 Severe 658
1998 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 90,000 Severe 658
1999 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 90,000 658
Supra
1986 2.8L 6-Cyl. T101 TCK101 T41069 Not Applicable 60,000 Severe 687
1986-90 3.0L 6-Cyl. (7M-GE & GTE) T126 60,000 Severe 695
1991-92 3.0L 6-Cyl. (7M-GE & GTE) T237 60,000 Severe 695
1993-97 3.0L 6-Cyl.
(2JZ-GE & 2JZ-GTE) T215 60,000 Severe 689
1998 3.0L 6-Cyl.
(2JZ-GE & 2JZ-GTE) T215 90,000 Severe 691
Tercel
1983-86 1.5L 4-Cyl. (3A-C) T070 TCK070 T41066 Not Applicable 60,000 1 653
1988-94 1.5L 4-Cyl. (3E) *# T233 TCK233 T41076 T42028 60,000 Severe 655
1995-97 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 60,000 Severe 658
1998 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 90,000 Severe 658
Tercel (Canadian)
1999 1.5L 4-Cyl. (5E-FE) T208 TCK208 T41071 T42029 90,000 658
Tercel Sedan
1987 1.5L 4-Cyl. (3E) * T136 60,000 Severe 655
Tercel Wagon
1987-88 1.5L 4-Cyl. (3A-C) T070 TCK070 T41066 Not Applicable 60,000 Severe 653
Light Trucks
Highlander
2001-03 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 697
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
Land Cruiser
1998-01 4.7L V8 (2UZ-FE) *# T298 T41078 T42031 90,000 477
2002-04 4.7L V8 (2UZ-FE) *# T298 T41078 T42031 90,000 477
Pickup
1981 2.2L 4-Cyl. Diesel * T079 T41068 T42026 100,000 676
1982 2.2L 4-Cyl. Diesel *
Up To 5/31/1982 T079 T41068 T42026 100,000 676
From 6/1/1982 T084 T41068 T42026 100,000 676
1983 2.2L 4-Cyl. Diesel * T084 T41068 T42026 100,000 676
1984-87 2.4L 4-Cyl. Diesel * T084 100,000 681
1988-91 3.0L V6 (3V-ZE) # T154 TCK240** T41073** T42037 60,000 Severe 702
1992 3.0L V6 (3V-ZE) #
Up To 8/92 T154 TCK240** T41073** T42037 60,000 Severe 702
From 9/92 T240 TCK240A** Not Available T42037 60,000 Severe 702
1993-95 3.0L V6 (3V-ZE) # T240 TCK240A** Not Available T42037 60,000 Severe 702
1
2
3
4
A65
TOYOTA (Cont.)
RAV4
1999-00 2.0L 4-Cyl. # T199 TCK199 T41067 T42025 90,000 674
Sequoia
2001-03 4.7L V8 (2UZ-FE) *# T298 90,000 477
Sienna
1998-03 3.0L V6 (1MZ-FE) *# T257 TCK257** T41075** T42030 90,000 697
2004 3.3L V6 (3MZ-FE) *# T257 90,000 472
Tacoma
1995-97 3.4L V6 (5VZ-FE) *# T271 TCK271 Not Available Not Available 60,000 Severe 705
1998-04 3.4L V6 (5VZ-FE) *# T271 TCK271 Not Available Not Available 90,000 705
Tundra
2000-01 4.7L V8 (2UZ-FE) *# T298 T41078** T42031 90,000 477
2002-03 4.7L V8 (2UZ-FE) *# T298 90,000 477
T100
1998 3.4L V6 (5VZ-FE) *# T271 TCK271 Not Available Not Available 90,000 705
4Runner
1988-91 3.0L V6 (3V-ZE) # T154 TCK240** T41073** T42037 60,000, Severe 702
1992 3.0L V6 (3V-ZE) #
Up To 8/92 T154 TCK240** T41073** T42037 60,000 Severe 702
From 9/92 T240 TCK240A** Not Available T42037 60,000 Severe 702
2003-04 4.7L V8 (2UZ-FE) *# T298 90,000 482
VOLKSWAGEN
Passenger Cars
Beetle (New Beetle)
1999-04 1.8L 4-Cyl. *# T306 105,000 715
(APH, AWP, & AWV)
1998 1.9L 4-Cyl. Diesel (ALH) *# T301 T43007 Not Available 60,000 733
1999 1.9L 4-Cyl. Diesel (ALH) *# T301 or T43007 Not Available 60,000 733
T321
2001 1.9L 4-Cyl. Diesel (ALH) *#
Up To Eng. No. 500,000 T301 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
From Eng. No. 500,001 T321 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
2003-04 1.9L 4-Cyl. Diesel (ALH) *# T321 T43007 Not Available 100,000 733
2004 1.9L 4-Cyl. Diesel (BEW) *# T321 90,000 736
1998-00 2.0L 4-Cyl. (Exc. ABA) *# T296 TCK296 T43010 Not Available 60,000 1 743
2001-03 2.0L 4-Cyl. (Exc. ABA) *# T296 TCK296 T43010 Not Available 105,000 743
2004 2.0L 4-Cyl. (Exc. ABA) *# T296 TCK296 T43010 Not Available N/A 743
Cabrio
1995-02 2.0L 4-Cyl. (ABA) * T262 TCK262 T41079 Not Applicable 60,000 1 740
1
2
3
4
A66
VOLKSWAGEN (Cont.)
Cabriolet
Corrado
Dasher
1979-80 1.5L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1981 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
Fox
Golf
1985-87 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
2000-01 1.8L 4-Cyl. Turbo *# T306 120,000 712
1993-97 1.9L 4-Cyl. Diesel *
(AAZ, AHU & 1Z) T242 T43006 Not Available 60,000 728
T321
Eng. No. 500,000 & Before T301 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
Eng. No. 500,001 & After T321 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
2004 1.9L 4-Cyl. Diesel (BEW) *# T321 90,000 736
2001-03 2.0L 4-Cyl. (Exc. BBW) *# T296 TCK296 T43010 Not Available 60,000 1 743
2004 2.0L 4-Cyl. (Exc. BBW) *# T296 TCK296 T43010 Not Available N/A 743
2004 2.0L 4-Cyl. (BBW) *# T296 TCK296 T43010 Not Available N/A 746
Golf (Canadian)
1988-92 1.6L 4-Cyl. Diesel * T043 60,000 1 710
1995 2.0L 4-Cyl. (ABA) * T262 TCK262 T41079 Not Applicable 60,000 1 740
Golf III
1993-95 1.9 4-Cyl. Turbo Diesel * T242 60,000 3 728
GTI
1987-89 1.8L 4-Cyl. (DOHC) * T292 60,000 1 726
2000-04 1.8L 4-Cyl. Turbo *# T306 120,000 712
1990-92 2.0L 4-Cyl. (DOHC) * T292 60,000 1 726
1999-00 2.0L 4-Cyl. (Exc. ABA) *# T296 TCK296 T43010 Not Applicable 60,000 1 743
GTI (Canadian)
Jetta
1981-86 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1989-92 1.6L 4-Cyl. Diesel * T043 60,000 1 710
1
2
3
4
A67
VOLKSWAGEN (Cont.)
Jetta (Cont.)
1987-89 1.8L 4-Cyl. (DOHC) * T292 60,000 1 726
2000-04 1.8L 4-Cyl. Turbo *# T306 120,000 712
1993-98 1.9L 4-Cyl. Diesel *
(AAZ, AHU & 1Z) T242 T43006 Not Available 60,000 728
T321
Up To Eng. No. 500,000 T301 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
From Eng. No. 500,001 T321 T43007 Not Available 40,000 (A/T) 733
60,000 (M/T) 733
2004 1.9L 4-Cyl. Diesel (BEW) *# T321 90,000 736
1990-92 2.0L 4-Cyl. (DOHC) * T292 60,000 1 726
2001-03 2.0L 4-Cyl. (Exc. BBW) *# T296 TCK296 T43010 Not Available 60,000 1 743
2004 2.0L 4-Cyl. (Exc. BBW) *# T296 TCK296 T43010 Not Available N/A 743
2004 2.0L 4-Cyl. (BBW) *# T296 TCK296 T43010 Not Available N/A 746
Jetta (Canadian)
1986 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1988-92 1.6L 4-Cyl. Diesel * T043 60,000 1 710
Jetta III
1993-95 1.9L 4-Cyl. Turbo Diesel * T242 60,000 3 728
Passat
1996-97 1.9L 4-Cyl. Turbo Diesel * T242 T43006 Not Available 60,000 3 728
1998-99 1.8L 4-Cyl. (AEB) *#
152 Tooth Belt 5 T291 90,000 718
153 Tooth Belt T317 90,000 718
2000 1.8L 4-Cyl. (AEB & ATW) *#
152 Tooth Belt 5 T291 105,000 3 718
153 Tooth Belt T317 105,000 3 718
2000-04 1.8L 4-Cyl. (AUG & AWM) *# T306 105,000 3 720
1990-92 2.0L 4-Cyl. (DOHC) * T292 60,000 1 726
1998 2.8L V6 *# T297 90,000 755
1999 2.8L V6 *# T297 75,000 755
2000-04 2.8L V6 *# T297 105,000 755
Passat (Canadian)
1993-94 1.9L 4-Cyl. Turbo Diesel * T242 60,000 3 728
1995-97 1.9L 4-Cyl. Turbo Diesel * T242 T43006 Not Available 60,000 3 728
1998 1.9L 4-Cyl. Turbo Diesel * T242 60,000 3 728
1
2
3
4
5
A68
VOLKSWAGEN (Cont.)
Quantum
1982-85 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1985 1.8L 4-Cyl. (SOHC) * T017 TCK017 T41079 Not Applicable 60,000 1 724
1984-85 2.1L 5-Cyl. #
1
.70” Belt Width T127 60,000 118
1
.75” Belt Width T065 60,000 118
1983-86 2.2L 5-Cyl. #
1
.70” Belt Width T127 60,000 118
1
.75” Belt Width T065 60,000 118
1
1987-88 2.2L 5-Cyl. # T127 60,000 118
Rabbit
1977-78 1.5L 4-Cyl. Diesel * T043 60,000 1 710
1979-80 1.5L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1981-84 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
Scirocco (Includes Canadian)
1985-89 1.8L 4-Cyl. (DOHC) * T292 60,000 1 726
Light Trucks
Eurovan
4
1992-96 2.5L 5-Cyl. * 60,000 1 750
Pickup & Rabbit Pickup
1980 1.5L 4-Cyl. Diesel * T043 T41080 60,000 1 710
1981-83 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
Transporter (Canadian)
4
1992-96 2.5L 5-Cyl. * 60,000 1 750
Vanagon
1982 1.6L 4-Cyl. Diesel * T043 T41080 60,000 1 710
VOLVO
C70
1998 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-01 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.3L 5-Cyl. Turbo *# T252 105,000 775
1
2
3
4
5
A69
VOLVO (Cont.)
C70 (Cont.)
1998 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-01 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.4L 5-Cyl. Turbo *# T331 105,000 775
Coupe
1991 2.3L 4-Cyl. (B230, F & FT) * T032 TCK032 T41081 Not Applicable 50,000 770
DL & GL
1980-83 2.1L 4-Cyl. (B21) * T032 TCK032 T41081 Not Applicable 40,000 765
1982 2.3L 4-Cyl. (B23) * T032 TCK032 T41081 Not Applicable 40,000 765
1980-84 2.4L 6-Cyl. Diesel *
Camshaft T083 75,000 2 780
DL (Canadian)
GLE (Canadian)
GLT
GLT (Canadian)
GT Turbo
S40
2000-01 1.9L 4-Cyl. Turbo *#
To Eng. VIN 1219110 T252 105,000 3 758
From Eng. VIN 1219111 T311 105,000 3 758
2002-04 1.9L 4-Cyl. Turbo *# T311 105,000 3 762
2004 1/2 2.4L 5-Cyl. Turbo *# T331 120,000 777
2004 1/2 2.5L 5-Cyl. Turbo *# T331 120,000 777
S60
2001 2.3L 5-Cyl. *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.3L 5-Cyl. Turbo *# T252 105,000 775
2001 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.4L 5-Cyl. Non-Turbo *# T252 105,000 775
2002-04 2.4L 5-Cyl. Turbo *# T331 105,000 775
S70
1998 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-00 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
1
2
3
4
A70
VOLVO (Cont.)
S70 (Cont.)
1998 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-00 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
S80
1999 2.8L 6-Cyl. Turbo * T270 105,000 3 782
2000-01 2.8L 6-Cyl. Turbo * T319 105,000 3 782
2002-03 2.9L 6-Cyl. Turbo * T319 105,000 3 782
1999 2.9L 6-Cyl. Non-Turbo * T270 105,000 3 782
2000-03 2.9L 6-Cyl. Non-Turbo * T319 105,000 3 782
S90
1997-98 2.9L 6-Cyl. Turbo *# T270 70,000 768
V40
2000-01 1.9L 4-Cyl. Turbo *#
To Eng. VIN 1219110 T252 105,000 3 758
From Eng. VIN 1219111 T311 105,000 3 758
2002-04 1.9L 4-Cyl. Turbo *# T311 105,000 3 762
V70
1998 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-01 2.3L 5-Cyl. Turbo *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.3L 5-Cyl. Turbo *# T252 105,000 775
1998 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 70,000 766
From Eng. VIN 1266128 T311 70,000 766
1999-01 2.4L 5-Cyl. *#
To Eng. VIN 1266127 T252 105,000 3 766
From Eng. VIN 1266128 T311 105,000 3 766
2002-04 2.4L 5-Cyl. Non-Turbo *# T252 105,000 775
2002-04 2.4L 5-Cyl. Turbo *# T331 105,000 775
V90
1997-98 2.9L 6-Cyl. Turbo *# T270 70,000 768
XC90
2003 2.5L 5-Cyl. Turbo *# T331 120,000 775
2004 2.5L 5-Cyl. Turbo *# T331 120,000 (AWD) 775
105,000 (FWD) 775
2003-04 2.9L 6-Cyl. Turbo * T319 120,000 3 782
240
1986-92 2.3L 4-Cyl. (B230, F & FT) * T032 TCK032 T41081 Not Applicable 50,000 770
1993 2.3L 4-Cyl. (B230, F & FT) * T234 TCK234 Not Available Not Applicable 50,000 770
242, 244 & 245
740 Series
1985-86 2.4L 6-Cyl. Diesel *
Camshaft T083 75,000 2 780
1
2
3
4
A71
VOLVO (Cont.)
740 Series (Canadian)
1986-88 2.3L 4-Cyl. (B234, DOHC) *#
Camshaft T173 50,000 2 771
1989 2.3L 4-Cyl. (B234, DOHC) *#
Automatic Tensioner
Camshaft T198 50,000 2 771
Manual Tensioner
Camshaft T173 50,000 2 771
1990 2.3L 4-Cyl. (B234, DOHC) *#
Camshaft T173 50,000 2 771
760 Series
1985 2.4L 6-Cyl. Diesel *
Camshaft T083 75,000 2 780
760 GLE
1983-84 2.4L 6-Cyl. Diesel *
Camshaft T083 75,000 2 780
780 Series
850
1994 2.3L 5-Cyl. Turbo *#
Up To Eng. No. 131034 T217 70,000 768
From Eng. No. 131035 T252 70,000 768
1995-97 2.3L 5-Cyl. Turbo *# T252 70,000 768
1993 2.4L 5-Cyl. Turbo *#
Up To Eng. No. 131034 T217 50,000 768
From Eng. No. 131035 T252 70,000 768
1994-97 2.4L 5-Cyl. Turbo *# T252 70,000 768
850 (Canadian)
1996 2.3L 5-Cyl. Turbo *# T252 70,000 768
1995 2.4L 5-Cyl. Turbo *#
Up To Eng. No. 131034 T217 70,000 768
From Eng. No. 131035 T269 70,000 768
940 Series
1993 2.3L 4-Cyl. (B230, F & FT) * T234 TCK234 Not Available Not Applicable 50,000 770
1994-95 2.3L 4-Cyl. (B230, F & FT) * T234 TCK234 Not Available Not Applicable 50,000 w/o EGR 770
100,000 w/ EGR 770
940 (Canadian)
1991 2.3L 4-Cyl. (B234, DOHC) *#
Camshaft T198 50,000 2 771
1992 2.3L 4-Cyl. (B234, DOHC) *#
1
2
3
4
A72
VOLVO (Cont.)
960
1992-93 2.9L 6-Cyl. *# T217 30,000 3 768
1994 2.9L 6-Cyl. *# T252 50,000 768
1995-97 2.9L 6-Cyl. *# T270 70,000 768
YUGO
GV Series
1986-89 1.1L 4-Cyl. * T018 60,000 1 785
1987 1.3L 4-Cyl. * T018 60,000 1 785
1
2
3
4
A73
ACURA 1
1.6L 4-Cylinder – EL
TIMING BELT APPLICATION 2) Set camshaft pulley to TDC. TDC marks should align with top surface
Application Labor Time Belt of cylinder head. See Fig. 3.
Part No. 3) Install timing belt in this sequence: timing belt drive pulley, tension
1.6L 4-Cyl. – SOHC adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO
EL (Canadian) NOT bend or twist belt excessively. Ensure arrow on used belt points in
1
1997-00 .................................................... 2.0 Hours .. ..... T224 original rotation direction. Ensure crankshaft and camshaft pulley timing
1
– With Air Conditioning, add .4 hours. mark are aligned with TDC marks.
With Cruise Control, add .3 hours. 4) Loosen and retighten adjusting bolt to tension timing belt. Install lower
cover. Install crankshaft pulley. Tighten pulley bolt to specification. See
NOTE: For information about tensioners and/or pulleys (when TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns coun-
available), see ALPHABETICAL MODEL LISTING.
terclockwise so timing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.

MANUFACTURER’S SUGGESTED
SCHEDULED MAINTENANCE 5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC
mark on crankshaft pulley aligned with pointer on cover). Loosen
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 adjusting bolt 180 degrees. See Fig. 5. Rotate crankshaft counterclock-
temperatures (over 110 degrees F, or under -20 degrees F). wise 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
REMOVAL & INSTALLATION not, timing belt will need to be removed and repositioned. To complete
CAUTION: This application is an interference engine. Do not rotate installation, reverse removal procedure. Tighten bolts to specification.
camshaft or crankshaft when timing belt is removed, or engine See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
damage may occur.
TORQUE SPECIFICATIONS
TIMING BELT
NOTE: If the radio has a coded theft protection circuit, be sure to Application Ft. Lbs. (N.m)
get the customer’s code before disconnecting battery. A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 17 (24)
Removal – 1) Disconnect battery negative cable. Remove engine lower Alternator Adjusting Bolt ............................................................................................ 17 (24)
splash shield. Remove power steering, alternator, and A/C compressor Alternator Mount Bolt ................................................................................................ 33 (45)
Camshaft Pulley Center Bolt .................................................................................... 27 (37)
drive belts. Rotate crankshaft counterclockwise to TDC of compression
Crankshaft Pulley Bolt 1
stroke. See Fig. 3.
Step 1 ...................................................................................................................... 14 (20)
2) Remove engine oil dipstick. Remove power steering pump, and set Step 2 ............................................................................ ...................... Plus 90° Clockwise
aside with hoses attached. Remove timing belt upper cover and A/C Engine Mount Bracket Nuts ...................................................................................... 54 (74)
drive belt idler pulley bracket. Power Steering Pump Bracket Bolt
3) Use jack to support engine. Working from front of engine, remove Power Steering Pump Lock Bolt .............................................................................. 17 (24)
engine mount bracket nuts. Remove crankshaft pulley. Remove lower Timing Belt Tensioner Adjusting Bolt ........................................................................ 33 (45)
cover and dipstick tube. INCH Lbs. (N.m)
4) Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump.
Loosen the timing belt tension adjusting bolt 180 degrees. Push CKF Sensor Bolt ..................................................................................................... 106 (12)
tensioner to release belt tension. Retighten tension adjusting bolt. Mark Engine Lower Splash Shield .................................................................................... 89 (10)
Timing Belt Cover Bolt .............................................................................................. 89 (10)
rotation direction of timing belt if it is to be reused. Remove timing belt
Water Pump Bolt ..................................................................................................... 106 (12)
from pulleys. See Fig. 1.
1
Installation – 1) Ensure No. 1 cylinder is at TDC of compression stroke. – Lubricate bolt threads and bolt head shoulder.
Timing belt drive pulley TDC mark must align with pointer on oil pump
housing. See Fig. 2.

MOTORES CHECK
2 ACURA
1.6L 4-Cylinder – EL (Cont.)
Courtesy of American Honda Motor Co., Inc.
Fig. 1: Exploded View Of Timing Belt & Components
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark

ACURA 3
1.6L 4-Cylinder – EL (Cont.)
Fig. 3: Aligning Timing Belt Marks
Fig. 4: Timing Belt Installation Sequence
Fig. 5: Locating Timing Belt Adjuster Bolt

4 ACURA
1.6L 4-Cylinder – Integra
TIMING BELT APPLICATION
Application Labor Time Component Belt
Kit No. Part No.
1.6L 4-Cyl.
Integra
1
1986-89 .............................. 2.8 Hours .. .. TCK130 .. ..... T130
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

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.

TIMING BELT
Removal – 1) Disconnect negative battery cable. Turn crankshaft Fig. 1: Exploded View Of Timing Belt & Components
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 discon-
necting 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. Courtesy of American Honda Motor Co., Inc.
Fig. 2: Locating Camshaft Timing Marks

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)
ACURA 5
1.7L 4-Cylinder
Kit No. Part No.
1.7L 4-Cyl.
Integra
1
1992-93 .............................. 2.8 Hours .. .. TCK227 .. ..... T277
1


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

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 Fig. 1: Exploded View Of Timing Belt & Components
crankshaft counterclockwise to bring No. 1 piston to TDC of its com-
pression 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.
Fig. 2: Aligning Timing Marks
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).

6 ACURA
1.8L 4-Cylinder
Kit No. Part No.
1.8L 4-Cyl. (Exc. VTEC)
Integra
1990-01 ............................... 2.8 Hours ... .. TCK184 .. ..... T184
1.8L 4-Cyl. (VTEC)
Integra
1994-01 ............................... 2.8 Hours ... .. TCK247 .. ..... T247
1


For 1990-94 models, manufacturer recommends the belt be replaced
every 90,000 miles. For 1995-96 models, the manufacturer recom-
mends the belt be replaced every 90,000 miles for normal service and
60,000 miles for severe service. For 1997-01 models, normal replace-
ment 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 inop- Fig. 1: Exploded View Of Timing Belt & Components
erative until proper code is entered by vehicle owner.
REMOVAL & INSTALLATION TORQUE SPECIFICATIONS
CAUTION: This application is an interference engine. Do not rotate A/C Compressor/Bracket Bolts ................................................................................. 17 (23)
camshaft or crankshaft when timing belt is removed, or engine Alternator Belt Adjustment Bolt ................................................................................. 17 (23)
damage may occur.
TIMING BELT 1990-92 .................................................................................................................. 87 (118)
1993-01 .............................................................................................................. 1 133 (180)
Removal – 1) Disconnect negative battery cable. Raise and support Engine Block-To Transaxle Bolt ................................................................................ 47 (64)
vehicle. Remove left front wheel. Remove left front wheelwell splash Engine Mount Bolts ....................................................................... ..................................... 2
shield. Remove all drive belts. Remove power steering pump with hoses Power Steering Bolt .................................................................................................. 17 (23)
attached. Set power steering pump aside. Timing Belt Tension Adjuster Bolt ............................................................................. 40 (54)
2) Remove valve cover and upper timing belt cover. See Fig. 1. Turn INCH Lbs. (N.m)
crankshaft counterclockwise to bring No. 1 piston to TDC of its com-
pression stroke. Position UP mark on sprockets at top. See Fig. 2. Align Valve Cover Nuts ...................................................................................................... 88 (10)
grooves on sprockets. Remove crankshaft pulley. Water Pump Bolt ..................................................................................................... 106 (12)
3) Remove left engine mount bolts and nut. Remove engine mount. See 1
– Tighten crankshaft pulley bolt to 147 ft. lbs. (200 N.m), loosen, then retorque to 133 ft.
Fig. 3. Remove lower timing belt cover. Loosen timing belt tension lbs. (180 N.m).
adjuster bolt. Push tensioner to relieve tension on timing belt. Retighten 2
– See Fig. 3.
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.
ACURA 7
1.8L 4-Cylinder (Cont.)
Fig. 4: Positioning Camshaft
Fig. 3: Engine/Transaxle Mount Location & Tightening Sequence

MOTORES CHECK
8 ACURA
2.2L & 2.3L 4-Cylinder
TIMING BELT APPLICATION 5) Push tensioner to remove tension from balance shaft belt adjuster,
Application Labor Time Component Belt then retighten nut.
Kit No. Part No. 6) Scribe a line 2.9″ (74 mm) from the end of a 6x100 mm bolt. See
2.2L 4-Cyl. Fig. 5. Remove bolt from side of engine block. To align balance shaft,
2.2CL insert bolt through hole and into balance shaft.
1997 7) Align groove on balance shaft pulley with pointer on oil pump housing.
Balance Shaft ............... .......... 1 .......... .. TCK244 .. ..... T186 See Fig. 6. Install balance shaft belt. Loosen adjuster nut about one turn
Camshaft .......................... 3.1 Hours ... .. TCK244 .. ..... T244 to tension balance shaft belt.
2.3L 4-Cyl. 8) Remove 6x100 mm bolt from balance shaft. Install sealing bolt in side
2.3CL of engine block. Install crankshaft pulley and bolt. Rotate crankshaft
1998-99 about one turn counterclockwise, then tighten adjuster nut. Remove
Balance Shaft ............... .......... 1 .......... .. TCK244 .. ..... T186 6x1.0 mm bolt from timing belt adjuster arm.
Camshaft .......................... 3.1 Hours ... .. TCK244 .. ..... T244
9) Remove crankshaft pulley. Install lower cover. Install rubber seal
1
– With balance shaft belt, add .2 hour. around adjuster nut. DO NOT loosen adjuster nut. Install crankshaft
pulley. To complete installation, reverse removal procedure. Adjust drive
NOTE: A timing belt component kit is available for this application. belts to proper tension.

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).

damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to Courtesy of American Honda Motor Co., Inc.
get the customer’s code before disconnecting battery. 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 connec-
tor. 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 crank-
shaft 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. Courtesy of American Honda Motor Co., Inc.
See Fig. 1. Align camshaft pulley with mating marks on back cover upper
surface. Ensure “UP” mark is at 12 o’clock position. See Fig. 2. Fig. 2: Aligning Camshaft Sprocket Timing Marks
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.
ACURA 9
2.2L & 2.3L 4-Cylinder (Cont.)
Fig. 3: Timing Belt Installation Sequence
Fig. 5: Aligning & Locking Balance Shaft
Fig. 4: Timing Belt Adjuster Nut
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)
Fig. 6: Identifying Balance Shaft Pulley

10 ACURA
2.5L 5-Cylinder
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

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).

damage may occur.
NOTE: Before disconnecting negative battery cable, obtain radio

anti-theft code from vehicle owner.
TIMING BELT Courtesy of American Honda Motor Co., Inc.

Removal – 1) Disconnect negative battery cable. Remove accessory Fig. 1: Exploded View of Timing Belt Components
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. Courtesy of American Honda Motor Co., Inc.
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.
ACURA 11
Fig. 3: Aligning Crankshaft Timing Marks

Fig. 5: Positioning Camshaft

Fig. 4: Aligning Camshaft Timing Marks
Fig. 6: Identifying Timing Belt Installation Sequence
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)
Power Steering Pump Mount .................................................................................... 33 (45)
Timing Belt Tension Adjuster Bolt ............................................................................. 33 (45)
INCH Lbs. (N.m)
Cylinder Head Cover Nuts ...................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)
12 ACURA
2.5L & 2.7L V6
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


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 manu-
facturer recommends the belt be replaced every 90,000 miles or 72
months.

damage may occur.
TIMING BELT Courtesy of American Honda Motor Co., Inc.

Removal – 1) Remove negative battery cable. Turn crankshaft clock- Fig. 1: Adjusting Timing Belt
wise 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. NOTE: After timing belt installation, rotate engine clockwise sev-
2) Support front of engine. On right side of engine compartment, remove eral times to ensure valves DO NOT contact pistons.
engine-to-body mount (on front of engine). Remove lower engine splash
shield. Remove A/C, power steering, and all other drive belts. TORQUE SPECIFICATIONS
3) Remove alternator. Leaving hoses connected, remove power steering
pump and secure out of way. Remove upper timing belt pulley covers. TORQUE SPECIFICATIONS
Remove crankshaft pulley. Remove timing belt lower cover. Application Ft. Lbs. (N.m)
4) Loosen timing belt tensioner to relieve tension on timing belt. See A/C Compressor Bolts .............................................................................................. 16 (22)
Figs. 1 and 2. Check belt for damage, missing teeth or cracks. A/C Compressor Bracket Bolts ................................................................................. 33 (45)
Installation – 1) Remove spark plugs. Turn crankshaft clockwise to Alternator Bracket Bolts ............................................................................................ 33 (45)
bring No. 1 piston to TDC of compression stroke. Advance crankshaft an Alternator Mount Bolts .............................................................................................. 16 (22)
additional 15 degrees from TDC position. Camshaft Pulley Bolts ............................................................................................... 23 (31)
2) Rotate camshaft pulleys to compression stroke (TDC position) of Crankshaft Pulley Bolt ........................................................................................... 123 (170)
No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC Engine Mount Bolts ................................................................................................... 40 (54)
position.
Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
3) Push timing belt tensioner to full release position and snug adjuster
bolt. Install timing belt over crankshaft pulley, front camshaft pulley, INCH Lbs. (N.m)
water pump pulley, tensioner and rear camshaft pulley. See Fig. 1. Timing Belt Cover Bolts ............................................................................................ 86 (10)
4) Note position of timing belt pulley guides on both sides of crankshaft. Valve Cover Bolts .................................................................................................... 106 (12)
Install pulley guides so guides form a “V” groove for belt to ride in. Water Pump Bolts ................................................................................................... 106 (12)
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.
ACURA 13
2.5L & 2.7L V6 (Cont.)

14 ACURA
3.0L & 3.2L – NSX & NSX-T
Part No.
3.0L V6
NSX
1991-04 ..................................................... 4.8 Hours ... ....... N/A
NSX-T
1995-03 ..................................................... 4.8 Hours ... ....... N/A
3.2L V6
NSX
1997-04 ..................................................... 4.8 Hours ... ....... N/A
NSX-T
1997-03 ..................................................... 4.8 Hours ... ....... N/A
Fig. 1: Removing Intake Manifold Plate & Top Cover
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).

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 compres-
sion 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 elec-
trical 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 Courtesy of American Honda Motor Co., Inc.
and pad oil pan for protection. Using a floor jack, tilt front of engine 5°. Fig. 2: Identifying Camshaft & Crankshaft Positions With No. 1
See Fig. 6. Cylinder At TDC
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.
ACURA 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.
Fig. 5: Removing Side Engine Mount Bolts & Transmission

Mount Through-Bolt
Fig. 3: Removing Generator (1991-94)
Fig. 6: Tilting Engine For Timing Belt Removal
Fig. 7: Removing Generator Bracket Stiffener

2) Ensure water pump pulley turns freely (both directions on 1991-94
Fig. 4: Removing Generator (1995-04) models; counterclockwise on 1995 and later models). Check for signs of
seal leakage. Small amount of “weeping” from bleed holes is normal.
Inspection – 1) Inspect timing belt for cracks or damaged teeth. Ensure See Figs. 10 and 11.
timing belt is not contaminated with oil or coolant. If one edge of belt is Installation – 1) To install, reverse removal procedure. Clean middle
damaged, check alignment of gears and tensioner. Replace as neces- and lower timing belt covers, and timing belt drive pulley. Ensure No. 1
sary. piston is at TDC of compression stroke. On 1991-94 models, set timing
belt drive pulley (crankshaft) keyway pointing upward. See Fig. 12.
16 ACURA
3.0L & 3.2L – NSX & NSX-T (Cont.)
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 Fig. 10: Inspecting Water Pump (1991-96)
Figs. 12-14.
ACURA 17
3.0L & 3.2L – NSX & NSX-T (Cont.)
Fig. 13: Setting Front Camshaft Pulleys For

Timing Belt Installation
Fig. 11: Inspecting Water Pump (1997-04)
Fig. 14: Setting Rear Camshaft Pulleys For

Fig. 12: Setting Crankshaft For Timing Belt Installation
5) Remove slack in timing belt between timing belt drive pulley (crank-
shaft) 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 Courtesy of American Honda Motor Co., Inc.
camshaft pulley SLIGHTLY.
Fig. 15: Installing Timing Belt
18 ACURA
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 SPECI-
FICATIONS.
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 o’clock position. See Fig. 16. Loosen adjusting bolt.
Retighten adjusting bolt to specification. See TORQUE SPECIFICA-
TIONS.
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.
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 specifi-
cation, adjust A/C compressor belt and generator belt tension.
Fig. 17: Checking Crankshaft & Camshaft Pulleys At TDC
ACURA 19
3.0L & 3.2L – NSX & NSX-T (Cont.)

Camshaft Holder Bolts (8 mm) ................................................................................. 16 (22)
Camshaft Holder Bridge Bolts .................................................................................. 16 (22)
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)
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).

MOTORES CHECK
20 ACURA
3.0L & 3.2L V6 – 3.0CL & 1999 3.2TL
TIMING BELT APPLICATION REMOVAL & INSTALLATION
Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate
3.0L V6 (J30A1) camshaft or crankshaft when timing belt is removed, or engine
3.0CL damage may occur.
1997-99 ............................... 4.0 Hours ... .. TCK286 .. ..... T286
3.2L V6 (J32A1/A2)
3.2TL TIMING BELT
1999 .................................... 4.0 Hours ... .. TCK286 .. ..... T286 Removal – 1) Disconnect negative battery cable. Turn crankshaft pulley
so that No. 1 piston is at TDC on compression stroke. White mark on
NOTE: For information about tensioners and/or pulleys (when crankshaft pulley should align with pointer on front cover. Remove
available), see ALPHABETICAL MODEL LISTING. rubber plugs from front and rear upper timing belt covers. Ensure
camshaft sprocket timing marks are aligned with tabs on bottom of
MANUFACTURER’S SUGGESTED access holes. Remove lower engine splash shield. Remove the genera-
tor and power steering pump drive belts.
SCHEDULED MAINTENANCE 2) Remove dipstick tube from front of engine. Support engine with a
Normal replacement interval is at 105,000 miles or 84 months. Replace jack, and remove engine side mount from front of engine. Remove
at 60,000 miles if car is regularly driven in extreme temperatures (over crankshaft pulley center bolt and pulley.
110 degrees F, or under -20 degrees F). 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.

ACURA 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 screw-
driver 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 specifica-
tion. 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.
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks
Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner
Fig. 4: Compressing Auto-Tensioner

22 ACURA
3.0L & 3.2L V6 – 3.0CL & 1999 3.2TL (Cont.)
Camshaft Sprocket Center Bolt ................................................................................ 67 (90)
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)
INCH Lbs. (N.m)
Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)
Courtesy of American Honda Motor Co., Inc. Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
Lower Engine Splash Shield Bolts ......................................................................... 106 (12)
Fig. 5: Installing Timing Belt Timing Belt Cover Bolts .......................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)

MOTORES CHECK
ACURA 23
3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL)

5) Using a battery hold-down bolt, grind threaded end to a slight bevel.
NOTE: For timing belt replacement information on 3.2L NSX and Hand tighten bolt into timing belt adjuster to hold position. See Fig. 3.
NSX-T, see 3.0L & 3.2L – NSX & NSX-T article. For timing belt 6) Remove engine mount bracket on end of front cylinder head. Loosen
replacement information on 3.5L 3.5RL, see 3.5L V6 – 3.5RL article. idler pulley bolt about 5-6 turns, then remove timing belt.

Kit No. Part No.
3.2L V6 (J32A1/A2)
3.2CL
2001-03 ............................... 4.0 Hours ... .. TCK286 .. ..... T286
3.2TL
2000 .................................... 4.0 Hours ... . 1 TCK286 . ..... T286
2001-03 ............................... 4.0 Hours ... ...... ..... ...... ..... T286
TL
2004 ................................. ........ N/A ........ ...... ..... ...... ..... T329
3.5L V6 (J35A3)
MDX
2001-04 ............................... 4.0 Hours ... .. TCK286 .. ..... T286
1
– Timing component kit does not include camshaft tensioner
hydraulic assembly.


MANUFACTURER’S SUGGESTED Courtesy of American Honda Motor Co., Inc.

SCHEDULED MAINTENANCE 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).

damage may occur.
NOTE: Radio and navigation system (if equipped) contain an anti-

theft 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 Courtesy of American Honda Motor Co., Inc.
ensure camshaft pulley mark and rear cover mark are aligned.
2) Raise vehicle and remove front wheels. Remove splash shield. Using Fig. 2: Exploded View Of Timing Belt & Components
lever tool, move auto-tensioner to relieve tension from generator belt. Removal (2003-04 MDX) – 1) Set No. 1 piston to TDC by turning
Remove generator belt. crankshaft so White mark aligns with pointer. Ensure marks on front
3) Loosen power steering pump adjusting nut, lock nut and mounting
camshaft pulley and front cover are aligned.
bolt. Remove power steering pump belt. Support engine with jack and
2) Raise vehicle and remove front wheels. Remove splash shield. Using
wood block under oil pan. Remove side engine mount bracket. See
lever tool, move auto-tensioner to relieve tension from generator belt.
Fig. 1.
Remove generator belt.
4) Remove dipstick and tube. Discard “O” ring. Hold crankshaft pulley,
and remove pulley bolt. Remove upper timing belt covers and lower 3) Support engine with jack and wood block under oil pan. Remove side
timing belt cover. See Fig. 2. 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).
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 contamina-
tion. 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 han-
dling.
CAUTION: Do NOT exceed 2200 lbs. of pressure when compress-

ing 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 Courtesy of American Honda Motor Co., Inc.
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 SPECIFICA-
TIONS. 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, Courtesy of American Honda Motor Co., Inc.
then horizontal mounting bolt). See TORQUE SPECIFICATIONS. Fig. 5: Compressing Auto-Tensioner
Reconnect negative battery cable. Reset radio and navigation system (if
equipped) anti-theft code. Reset preset radio frequencies.
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 Diag-
nostic 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).
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
Courtesy of American Honda Motor Co., Inc. data is cleared from PCM, you must do the CKP pattern relearn
procedure by test drive. See CKP PATTERN LEARN PROCEDURE.
Installation (Used Belt – All Models) – 1) Clean timing belt pulleys, NOTE: Enable criteria: Engine coolant temperature must be 176°F
(80°C) or higher.
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 Crankshaft Position (CKP) Pattern Learn Procedure – 1) Having
position by aligning TDC marks on camshaft pulleys with pointers on cleared the CKP pattern from PCM, leave Honda PGM Tester or the
back covers. HDS connected to DLC and turn ignition switch off. Turn ignition switch
2) On 2003-04 MDX, apply liquid thread lock to idler pulley bolt, and on. Wait for 30 seconds.
loosely install idler pulley. If auto-tensioner has extended and timing belt 2) Start vehicle and test drive on a level road. Decelerate (with throttle
cannot be installed, perform new belt installation procedure. See fully closed) from engine speed of 2500 RPM to 1000 RPM with A/T in
INSTALLATION (NEW BELT – ALL MODELS). On all other models, if “2” or “D3” position.
auto-tensioner has extended and timing belt cannot be installed, remove 3) Stop vehicle. DO NOT turn the ignition switch off. Select the ALL
and compress auto-tensioner. Install auto-tensioner. 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
3) Install timing belt, working in counterclockwise direction, until belt is
was probably not met. Repeat the procedure from beginning.
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. TORQUE SPECIFICATIONS
4) Tighten idler pulley bolt to specification. See TORQUE SPECIFICA- TORQUE SPECIFICATIONS
TIONS. Remove battery hold-down bolt from back cover. Install engine
mount bracket. If timing belt guide plate was removed, install with
Camshaft Sprocket Center Bolt ................................................................................ 67 (90)
concave side facing outward. Install upper and lower timing belt covers.
5) Clean crankshaft pulley and bolt. Lubricate pulley bolt and washer. Engine Mount Bracket
Install crankshaft pulley, and tighten bolt to specification while holding 6 x 1.0 mm Bolt ..................................................................................................... 8.7 (12)
pulley. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 10 x 1.25 mm Bolt .................................................................................................. 33 (44)
about 5-6 turns clockwise so timing belt properly sets on all pulleys. Engine Side Mount Bracket
6) Turn crankshaft pulley to align TDC mark. Check TDC mark alignment 10 x 1.25 mm Bolt .................................................................................................. 33 (44)
of camshaft pulleys. If camshaft pulley marks are at TDC, go to next 12 x 1.25 mm Bolt .................................................................................................. 40 (54)
step. If camshaft pulley marks are not at TDC, repeat installation Idler Pulley Bolt ......................................................................................................... 33 (44)
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 INCH Lbs. (N.m)
models, install generator belt. Install side engine mount bracket, and Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8)
tighten bolts to specification (tighten shorter vertical mounting bolts first, Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
then horizontal mounting bolt). See TORQUE SPECIFICATIONS. Dipstick & Tube ....................................................................................................... 106 (12)
Reconnect negative battery cable. Reset radio and navigation system
anti-theft code. Reset preset radio frequencies. Water Pump Bolts ................................................................................................... 106 (12)
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).
26 ACURA
3.2L V6 – Legend & 1996-98 3.2TL
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


For 1991-94 model years, manufacturer recommends belt be replaced
every 90,000 miles or 72 months. For 1995-96 model years, replace-
ment 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).

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 Courtesy of American Honda Motor Co., Inc.
bracket. Remove accessory drive belts.
Fig. 1: Exploded View Of Intake Manifold (1991-93)
2) Remove timing belt upper covers. See Fig. 2. Rotate crankshaft
clockwise until No. 1 piston is at TDC of compression stroke. Ensure 5) Loosen timing belt adjusting bolt 180 degrees. Tighten timing belt
timing marks are aligned. Remove A/C belt tensioner pulley. Remove adjusting bolt to 31 ft. lbs. (42 N.m). Verify crankshaft and camshaft
crankshaft pulley. Remove engine oil dipstick tube. timing marks are still aligned. If timing marks are not aligned, repeat
3) Remove timing belt lower cover. If timing belt is to be reused, mark timing belt installation procedure. To complete installation, reverse
belt with arrow indicating direction of rotation. Loosen timing belt removal procedure. Coat crankshaft pulley center bolt threads with oil
adjusting bolt 1/2 turn. Push tensioner to release belt tension, then before installation. Adjust accessory drive belt to proper tension.
retighten adjusting bolt. Remove timing belt.
NOTE: After installing timing belt, slowly rotate engine clockwise
CAUTION: DO NOT turn crankshaft or camshaft with timing belt several times to be sure valves do not contact pistons.
removed, because pistons may hit valves, causing damage. Do
Removal (1994-98) – 1) Disconnect negative battery cable. Use jack to
NOT rotate crankshaft when tension adjusting bolt is loose.
support engine. Remove center bracket and mount from front, lower part
Installation (1991-93) – 1) Remove spark plugs. When installing timing of engine. Remove the generator, A/C compressor, and power steering
belt, turn crankshaft clockwise 15 degrees past No. 1 cylinder TDC. After belts.
adjusting left and right camshaft pulleys to TDC, turn crankshaft pulley 2) If equipped, remove Traction Control System (TCS) valve assembly
counterclockwise back to TDC. brackets. Disconnect TCS throttle sensor and actuator connectors. See
2) Install timing belt in this sequence: Crankshaft pulley, tensioner pulley, Fig. 4. Remove TCS control valve assembly, leaving breather pipe
left camshaft, water pump pulley, right camshaft. To ease installation, by-pass hose connected.
advance right camshaft pulley about a half tooth from TDC position. 3) Remove engine front wiring harness cover with oil pressure switch
3) Loosen timing belt tension adjusting bolt, and retighten it after and engine ground cable connectors. Remove idler pulley bracket,
tensioning the timing belt. Temporarily install lower timing belt cover and dipstick, and dipstick pipe. Remove crankshaft pulley.
crankshaft pulley. Rotate crankshaft about 5-6 turns clockwise to seat 4) Remove timing belt upper and lower covers. See Fig. 2. Rotate
timing belt. Place No. 1 piston at TDC of compression stroke. crankshaft clockwise until No. 1 piston is at TDC of compression stroke.
4) Rotate crankshaft clockwise 9 teeth on camshaft pulley. Blue mark on Align timing marks. See Fig. 5. Loosen timing belt adjusting bolt 180
crankshaft pulley will should line up with pointer on lower cover. See degrees to remove tension from belt. Retighten adjusting bolt.
Fig. 3.
ACURA 27
3.2L V6 – Legend & 1996-98 3.2TL (Cont.)

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 crank-
shaft 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 compres-
sion 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. Courtesy of American Honda Motor Co., Inc.
NOTE: After installing timing belt, slowly rotate engine clockwise Fig. 3: Aligning Timing Marks For Timing Belt Tension
several times to be sure valves do not contact pistons.
28 ACURA
3.2L V6 – Legend & 1996-98 3.2TL (Cont.)
Center Bracket Bolts ................................................................................................. 40 (54)
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)
Fig. 4: Locating TCS Connectors & Control Valve
Fig. 5: Aligning Timing Marks (TDC)

MOTORES CHECK
ACURA 29
3.5L V6 – 3.5RL
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.

SCHEDULED MAINTENANCE Courtesy of American Honda Motor Co., Inc.
at 60,000 miles if car is regularly driven in extreme temperatures (over Fig. 1: Locating TCS Connectors & Control Valve
110 degrees F, or under –20 degrees F). 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
CAUTION: This application is an interference engine. Do not rotate about half a tooth from TDC position. Ensure crankshaft pulley and
camshaft or crankshaft when timing belt is removed, or engine left camshaft pulley are at TDC.
damage may occur. 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
NOTE: Some vehicles may be equipped with radio/cassette or belt (in sequence) on timing belt drive (crankshaft) pulley, adjusting
radio/CD players that contain anti-theft protection circuit. When pulley, left camshaft pulley, water pump pulley, and right camshaft pulley.
battery is disconnected, radio will go into anti-theft mode. When See Fig. 4. Ensure camshaft and crankshaft pulleys remain at TDC.
battery is reconnected, radio will display CODE and will be inop- Loosen and retighten timing belt adjusting bolt. Install lower cover and
erative until proper code is entered by vehicle owner. 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
TIMING & BALANCER BELTS
compression stroke. White mark on crankshaft pulley must be aligned
Removal – 1) Turn crankshaft until No. 1 piston is at TDC of compres- with pointer on lower cover. See Fig. 5. Rotate crankshaft clockwise 10
sion stroke. Remove engine cover, intake air duct, and air cleaner teeth on camshaft pulley. Blue mark on crankshaft pulley should align
assembly. with pointer on lower cover. Loosen timing belt adjusting bolt 180
2) Loosen alternator mounting bolt, lock bolt and adjusting rod, then degrees. Tighten adjusting bolt to specification. See TORQUE SPECI-
remove alternator belt. Loosen idler pulley center nut and adjuster bolt. FICATIONS.
Remove A/C belt. Remove Traction Control System (TCS) control valve 4) Remove crankshaft pulley and lower cover. Install timing belt guide
upper and lower brackets. Loosen adjusting bolt, lock nut and mounting plate and balancer belt drive pulley on crankshaft. See Fig. 2. Ensure
bolt, then remove power steering pump belt. guide plate is installed in correction direction.
3) Disconnect TCS throttle sensor connector, TCS throttle actuator 5) Remove 12-mm sealing bolt from side of engine block. See Fig. 6.
connector and throttle position sensor connector. Remove TCS control Align maintenance hole and balancer shaft hole. Insert a 6-mm bolt into
valve assembly. See Fig. 1. Disconnect vehicle speed sensor sub- sealing bolt hole. Ensure balancer belt pulley pointer aligns with pointer
harness connector, then remove wire harness holder. on balancer gear case. See Fig. 7.
4) Remove crankcase breather hose and vacuum hoses from front of 6) Set timing belt drive pulley so that No. 1 piston is at TDC. Install
right upper cover. Remove Ignition Control Module (ICM) bracket from balancer belt pulley. Install balancer belt. Loosen and retighten balancer
right upper cover. Remove idler pulley bracket, dipstick, and dipstick belt adjusting bolt to tension balancer belt. Remove 6-mm bolt. Install
tube. Remove crankshaft pulley. See Fig. 2. sealing bolt in maintenance hole, using a new washer.
5) Remove upper and lower covers. If reusing balancer timing belt, mark 7) Install crankshaft pulley. Rotate crankshaft pulley about 5 or 6 turns
direction of belt rotation for installation reference. Loosen balancer clockwise to position balancer belt on pulleys. Loosen balancer belt
timing belt adjuster bolt 180 degrees. Push on tensioner to release belt adjusting bolt 180 degrees. Tighten balancer belt adjusting bolt to
tension, then retighten adjusting bolt. Remove balancer timing belt. specification. See TORQUE SPECIFICATIONS.
6) If camshaft timing belt is to be reused, mark direction of rotation 8) Remove crankshaft pulley. Install upper and lower covers, then install
before removing. Loosen camshaft timing belt adjuster bolt 180 crankshaft pulley. Ensure crankshaft pulley and camshaft pulley are at
degrees. Push on tensioner to release belt tension, then retighten TDC. Remove inspection plugs in upper camshaft covers to check
adjusting bolt. Remove camshaft timing belt. pulley alignment.
CAUTION: DO NOT rotate crankshaft pulley or camshaft pulley 9) To complete installation, reverse removal procedure. Tighten all
with timing belt removed. Pistons may hit valves and cause fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
damage. drive belts to proper tension.
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
30 ACURA
3.5L V6 – 3.5RL (Cont.)

ACURA 31
3.5L V6 – 3.5RL (Cont.)
Fig. 4: Identifying Timing Belt Routing

Fig. 5: Aligning Timing Marks (TDC)
Fig. 3: Aligning TDC Timing Marks
32 ACURA
3.5L V6 – 3.5RL (Cont.)
Balancer Belt Tension Adjusting Bolt ........................................................................ 33 (44)
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 (10)
Dipstick Tube Bolt ................................................................................................... 106 (12)
Ignition Control Module (ICM) Bracket Bolts ......................................................... 106 (12)
Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106 (12)
Wire Harness Holder Bolts ..................................................................................... 106 (12)
1
– Tighten bolts to 106 INCH lbs. (12 N.m).
Fig. 6: Installing Balancer Shaft Lock Bolt
Fig. 7: Aligning Balancer Shaft Marks

ACURA 33
3.5L V6 – SLX
Part No.
3.5L V6 – DOHC
SLX
1998-99 ..................................................... 2.4 Hours ... ..... T303

Normal replacement interval is at 75,000 miles for 1998-99 model years.
Courtesy of Isuzu Motor Co.
REMOVAL & INSTALLATION Fig. 2: Aligning Crankshaft Timing Marks
TIMING BELT water pump pulley and install on other left hand camshaft sprocket,
Removal – 1) Disconnect negative battery cable. Remove air cleaner aligning the White alignment mark on timing belt with camshaft sprocket
assembly. Remove upper fan shroud. Remove serpentine drive belt. mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack
2) Remove cooling fan and drive pulley. Remove serpentine drive belt in belt between camshaft pulleys.
idler pulley assembly. Remove serpentine drive belt tensioner assembly. 4) Install timing belt around idler pulley and tensioner pulley. Temporarily
3) Remove power steering pump with hoses attached, and set aside. install crankshaft pulley. Turn pulley clockwise slightly to give some belt
Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, slack between the crankshaft sprocket and right hand camshaft
remove crankshaft pulley. sprocket.
4) Remove timing belt covers. Rotate crankshaft to align timing marks.
NOTE: It will take about 220 lbs. (100 kg) to compress timing belt
See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be
tensioner rod.
at TDC.
5) If reusing timing belt, mark belt with arrow to indicate original rotation 5) Holding tensioner upright, SLOWLY compress timing belt tensioner
direction. Also place mating marks on timing belt and camshaft sprock- rod until hole in top of rod and holes in housing are aligned. Install a
ets for reassembly reference. Remove timing belt tensioner, and set locking pin through the holes. See Fig. 5.
aside with push rod facing up. Remove timing belt. 6) Install tensioner on engine with locking pin in place. Tighten bolts to
CAUTION: To prevent air from entering timing belt tensioner, 7) Remove locking pin from timing belt tensioner. Remove clips from
tensioner rod must always face up. 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.
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 Courtesy of American Honda Motor Co., Inc.
sprocket with spring clip. Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket
2) Align timing mark on right hand (passenger’s 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 (driver’s side) camshaft sprocket with
alignment mark on valve cover. See Fig. 4. Route timing belt around
34 ACURA
3.5L V6 – SLX (Cont.)
Cooling Fan Pulley Bolt ............................................................................................ 16 (22)
Power Steering Pump Bolt
M8 Bolt .................................................................................................................... 16 (22)
M10 .......................................................................................................................... 34 (46)
Timing Belt Idler Arm Pulley Bolt ............................................................................. 38 (52)
Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42)
Water Pump Bolt ....................................................................................................... 18 (25)
Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket
Fig. 5: Installing Locking Pin In Timing Belt Tensioner
Fig. 6: Installing Timing Belt Cover Bushings

ACURA & HONDA 35
3.2L V6 – 1994-97
TIMING BELT APPLICATION Installation – 1) Ensure all timing marks are aligned. Install belt over
Application Labor Time Component Belt one pulley at a time starting at crankshaft sprocket working counter-
Kit No. Part No. clockwise. Belt should go over tensioner last. Secure belt at each pulley
3.2L V6 – SOHC during installation with pinch clips. See Fig. 3.
Passport
CAUTION: To ensure correct timing belt installation, ensure direc-
1994-97 .............................. 1 2.8 Hours .. .. TCK221 .. ..... T221
SLX tion of rotation arrows are pointing in proper direction. If timing
1996-97 ............................... 2.8 Hours ... .. TCK221 .. ..... T221 belt is being reused, install belt in original direction of rotation.
1
– With Air Conditioning, add .4 hours. 2) Compress timing belt tensioner pusher and insert pin to retain pusher.
With Power Steering, add .3 hours. Apply pressure to tensioner against belt and install tensioner pusher.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.
NOTE: For information about tensioners and/or pulleys (when 3) Loosen tensioner pulley bolt. Apply pressure on belt by rotating
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED pulley, tightening center bolt finger tight. Rotate crankshaft 2 turns
SCHEDULED MAINTENANCE clockwise. Ensure timing belt tensioner pusher rod protrudes proper
amount. See Fig. 4.
The manufacturer recommends the belt be replaced every 60,000 miles. 5) If timing belt tensioner pusher rod protrusion is not within specifica-
tion, remove pusher, loosen tensioner pulley bolt and readjust. Reset
timing belt tensioner pusher rod and repeat timing belt tensioning
REMOVAL & INSTALLATION procedure. Remove crankshaft pulley and install timing belt cover. To
TIMING BELT complete installation, reverse removal procedure. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
Removal – 1) Disconnect negative battery cable. Remove air cleaner
proper tension.
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.
Fig. 3: Installing Pinch Clips On Timing Belt
Fig. 4: Adjusting Timing Belt Tensioner Pusher


36 ACURA & HONDA
3.2L V6 – 1994-97 (Cont.)
Fan Pulley Bolt .......................................................................................................... 16 (22)
Front Plate Bolt ......................................................................................................... 14 (19)
Idler Arm Retaining Bolt ............................................................................................ 33 (44)
Power Steering Pump Bolt ....................................................................................... 34 (46)
Timing Belt Tensioner Pulley Bolt ............................................................................. 32 (43)
Timing Belt Tensioner Pusher Bolt ........................................................................... 14 (19)
Upper Intake Manifold Bolt ....................................................................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ....................................................................................... 87 (10)
Cooling Fan Assembly Nut ......................................................................................... 69 (8)
Fig. 5: Exploded View Of Cylinder Head Components

ALFA ROMEO 37
2.5L V6 – GTV
Part No.
2.5L V6
GTV Coupe
1982-86 ..................................................... 3.9 Hours ... ..... T120


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. Courtesy of Alfa Romeo Auto S.p.A.
2) Disconnect idle speed adjustment hose from air intake box. See
Fig. 1: Replacing Timing Belt
Fig. 2. Disconnect air hose and wiring to auxiliary air solenoid valve.
Remove auxiliary air solenoid valve from timing belt cover. TORQUE SPECIFICATIONS
3) Disconnect distributor vacuum hose from throttle body. Disconnect oil
vapor hose from timing belt cover. Disconnect fuel vapor canister hose TORQUE SPECIFICATIONS
from air intake box. Application Ft. Lbs. (N.m)
4) Disconnect pressure regulator hose. Remove air filter cover, air intake Belt Tensioner Pulley Bolt ......................................................................................... 15 (20)
duct, and oil vapor separator. Remove air filter. Disconnect spark plug Camshaft Hub Nut .................................................................................................. 85 (115)
leads, coil lead, and remove distributor cap. Remove timing belt covers. Crankshaft Pulley Nut ........................................................................................... 174 (235)
5) Remove all fan belts. Disconnect coolant hoses and wiring from INCH Lbs. (N.m)
thermostat housing. Remove coolant temperature sending unit from Front Cover Bolts .......................................................................... ..................... 72-82 (8-9)
thermostat housing. Clean spark plug seats and remove spark plugs. Valve Cover Bolts .............................................................................................. 82-96 (9-11)
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 refer-
ence notch. Press belt tensioner against timing belt and tighten ten-
sioner arm nuts. Lift tensioner arm slightly and remove adjustment pin.
Reverse removal procedure to complete installation. Adjust drive belts to
proper tension.
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
Part No.
3.0L V6
164
1991-93 ..................................................... 4.8 Hours ... ..... T120

The manufacturer recommends the belt be replaced every 50,000 miles.

TIMING BELT
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 Fig. 1: Identifying Flywheel Timing Marks
transmission, disconnect kickdown cable. On S models, disconnect
4) Position No. 1 cylinder at TDC compression stroke. Ensure crank-
engine throttle sensor electrical connector. On all models, disconnect
shaft and camshaft timing marks are aligned. If timing marks are not
fuel vapor and cruise control hoses.
aligned, timing belt must be removed and repositioned. Install spark
4) Disconnect fuel pressure regulator and power brake unit vacuum
plugs. Install timing belt covers.
hoses. Disconnect ground strap from air intake box. Remove air intake
box attaching screws and clamps, and remove air intake box. 5) On models with heat exchanger, connect oil cooler tubes. On all
5) Disconnect spark plug wires for cylinders No. 1, 2 and 3. Remove models, connect coolant hose to thermostat unit, and return hose to
intake ducts and gaskets. Remove right valve cover and gasket. water pump. Plug in coolant switch and sensor electrical connectors.
Disconnect spark plug wires for cylinders No. 4, 5 and 6. Remove left Install left side valve cover and gasket.
side valve cover and gasket. 6) Connect spark plug wires for cylinders No. 4, 5 and 6. Install right side
6) Partially drain cooling system. Disconnect coolant hose from thermo- valve cover and gasket. Install intake ducts and gaskets. Connect spark
stat unit. Disconnect return hose from water pump. Disconnect coolant plug wires for cylinders No. 1, 2 and 3. Install air intake box. Connect
temperature switch and sensor electrical connectors. If equipped, ground strap to air intake box. Connect fuel pressure regulator and
disconnect oil cooling tubes from heat exchanger. power brake unit vacuum hoses. Connect fuel vapor and cruise control
7) Remove timing belt covers. Remove spark plugs Rotate crankshaft so hoses.
No. 1 cylinder is at TDC of compression stroke. Flywheel and transmis- 7) On S models, connect engine throttle sensor electrical connector.
sion housing timing marks should align. See Fig. 1. Camshaft sprocket Connect accelerator cable. On models with automatic transmission,
timing marks should align with bearing cap marks. See Fig. 2. connect kickdown cable. Install throttle body cover. Connect throttle
8) Lift belt tensioner arm from timing belt. Insert Holding Tool body switch electrical connector.
(1.820.053.00) or equivalent into hole on arm to lock in position. Loosen 8) Connect oil vapor separator hoses. Connect constant idle speed
hydraulic belt tensioner retaining nuts. Push tensioner downward to limit actuator electrical connector. Install crankshaft position sensor and
of travel, and tighten upper retaining nut. Remove timing belt.
electrical connector. Install hydraulic drive belt tensioner. Install power
Installation – 1) Position Adapter (1.825.007.000), or equivalent, and a steering pump, A/C compressor, and water pump drive belts.
dial indicator into No. 1 cylinder spark plug hole. See Fig. 2. Ensure
9) Install front right inner fenders. Install right front wheel and tire
camshaft and crankshaft timing marks align.
assembly, then lower vehicle. Connect negative battery cable. Adjust
2) Install timing belt over crankshaft sprocket, left camshaft sprocket,
accessory drive belt tension.
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.
40 ALFA ROMEO
3.0L V6 (Cont.)
Fig. 2: Identifying Camshaft Timing Marks

AMERICAN MOTORS 41
2.0L 4-Cylinder
1
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


Courtesy of American Motors/Renault Corp.

every 60,000 miles.

TIMING BELT

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 Courtesy of American Motors/Renault Corp.
retaining screw and remove camshaft drive belt. See Fig. 2.
CAUTION: Use hands to install belt. DO NOT pry with tool. TORQUE SPECIFICATIONS
Installation – 1) Mount belt onto crankshaft sprocket. Position belt in
tensioning pulley groove and install belt to camshaft sprocket. See
Fig. 2. Application Ft. Lbs. (N.m)
Camshaft Belt Tensioning Idler Screw ..................................................................... 29 (39)
CAUTION: Excessive tension may cause pulley to fail. Camshaft Sprocket Screw ........................................................................................ 58 (78)
Crankshaft Sprocket Screw .................................................................................. 181 (123)
2) Turn offset adjusting nut on tensioning pulley clockwise to tighten belt Water Pump Screw (Large) ...................................................................................... 16 (21)
tension. When belt can be twisted 90° with thumb and forefinger, belt is INCH Lbs. (N.m)
properly tensioned.
3) Reverse removal procedure to complete installation. Adjust drive Camshaft Rear Bearing Cap Screw ......................................................................... 84 (10)
Water Pump Screw (Small) ...................................................................................... 84 (10)
belts to proper tension.
42 AUDI
1.6L 4-Cylinder – Diesel
Part No.
1.6L 4-Cyl.
4000
Diesel
1982-83 ..................................................... 2.3 Hours ... ..... T043

Courtesy of Audi of America, Inc.
maintenance interval, belt manufacturers suggest the belt be replaced at Fig. 1: Installing Camshaft Locking Tool
60,000 mile intervals.

TIMING BELT & SPROCKET
Removal – 1) Disconnect negative battery cable. Remove accessory
drive belts. Remove timing belt cover and camshaft cover. Turn crank-
shaft 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. Courtesy of Audi of America, Inc.
Installation – 1) Check that TDC mark on flywheel is still aligned with Fig. 2: Using Timing Belt Tension Gauge
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 TORQUE SPECIFICATIONS
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 Application Ft. Lbs. (N.m)
between camshaft and injection pump sprockets. Tension is correct if Camshaft Sprocket Bolt ............................................................................................ 33 (45)
gauge reads 12-13. See Fig. 2. Crankshaft Pulley/Damper
4) Turn crankshaft clockwise 2 turns. Strike timing belt with a rubber Standard .............................................................................................................. 108 (150)
mallet midway between camshaft sprocket and injection pump sprocket. Turbo .................................................................................................................... 145 (200)
Injection Pump Sprocket ........................................................................................... 33 (45)
Using Tension Gauge (210), recheck timing belt tension.
Intermediate Shaft Pulley .......................................................................................... 33 (45)
5) If necessary, readjust timing belt tension. Check injection pump
Timing Belt Tensioner ................................................................................................ 33 (45)
timing. Install remaining components in reverse order of removal. Adjust
drive belts to proper tension.
AUDI 43

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


Although the manufacturer does not recommend a specific scheduled Courtesy of Audi of America, Inc.
maintenance interval, belt manufacturers suggest the belt be replaced at
60,000 mile intervals. Fig. 2: Aligning Timing Marks (1.6L)

TIMING BELT
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 Fig. 3: Aligning Camshaft Sprocket With Upper Edge Of Gasket
turned 90° with thumb and index finger at a point midway between (1.7L)
camshaft sprocket and intermediate sprocket. Check valve timing. To
complete installation, reverse removal procedure. Adjust drive belts to
proper tension.
Fig. 4: Adjusting Timing Belt Tension (1.7L)
Fig. 1: Exploded View Of Timing Belt & Components (1.7L)

44 AUDI
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 Installation – 1) Set crankshaft at point just before TDC compression
Application Labor Time Component Belt for No. 1 cylinder. Place timing belt on crankshaft and intermediate shaft
Kit No. Part No. sprockets. Install crankshaft pulley and tighten all 4 bolts. Align mark on
1.8L 4-Cyl. crankshaft pulley with mark on intermediate shaft sprocket at TDC. See
4000S Fig. 2.
1984-87 ............................... 1.1 Hours ... .. TCK017 .. ..... T017 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
NOTE: A timing belt component kit is available for this application. should point upward at 45 degrees from camshaft follower so both
See page A1 for information on component kits. 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
MANUFACTURER’S SUGGESTED and finger pressure. Rotate engine by hand through 2 revolutions in
clockwise direction. Check all timing marks. To complete installation,
SCHEDULED MAINTENANCE 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.

damage may occur.
TIMING BELT
CAUTION: Never use camshaft sprocket attaching bolt to turn Courtesy of Audi of America, Inc.
engine, as timing belt could be stretched.
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.
Fig. 3: Setting Camshaft Timing Marks


(16-Valve Shown)
46 AUDI
1.8L 4-Cylinder – 1984-87 (Cont.)
Camshaft Sprocket Bolt
8-Valve ..................................................................................................................... 58 (80)
16-Valve ................................................................................................................... 48 (65)
Crankshaft Pulley Nut ............................................................................................... 14 (20)
Crankshaft Sprocket Bolt ...................................................................................... 148 (200)
Intermediate Shaft Sprocket Bolt
8-Valve ..................................................................................................................... 58 (80)
16-Valve ................................................................................................................... 48 (65)
Timing Belt Tensioner Nut ........................................................................................ 33 (45)
Fig. 4: Adjusting Timing Belt Tension

AUDI 47
1.8L 4-Cylinder Turbo – AEB & ATW Engines – 1997-00 A4

Part No.
1.8L 4-Cylinder Turbo (AEB & ATW)
A4 & A4 Quattro
1997-00
152 Tooth Belt ........................................ 4.7 Hours ... ..... T291

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.

damage may occur.
NOTE: ATW engines use T317 (153 tooth belt). AEB engines are
originally equipped with T291 (152 tooth belt), but may have had 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 ten-
sioner. 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. Manufac-

turer 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 Courtesy of Audi of America, Inc.
lower timing belt cover. Fig. 2: Positioning Lock Carrier Support Tool (3369)
5) Mark timing belt running direction. Using Torx T45 bit, loosen timing
belt tensioner. Push timing belt tensioner down, and remove timing belt. 4) Tighten tensioner pulley bolt to specification. See TORQUE SPECI-
FICATIONS. Rotate crankshaft 2 revolutions in normal direction of
CAUTION: To prevent pistons from hitting valves, make sure rotation. Make sure camshaft and crankshaft timing marks are aligned.
crankshaft is NOT at TDC for any piston before turning camshaft. 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
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 mm) (dimension “D”). See Fig. 5. Check for wear in Areas “B” and “C”.
crankshaft sprocket. Install lower timing belt cover. Install vibration 6) Install upper timing belt cover. Install serpentine drive belt tensioner
damper pulley, and tighten bolts to specification. See TORQUE SPECI- and belt. To complete installation, reverse removal procedure. Ensure
FICATIONS. lock carrier Torx bolts are installed in correct position. See Fig. 6.
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.
48 AUDI
1.8L 4-Cylinder Turbo – AEB & ATW Engines – 1997-00 A4 (Cont.)
Fig. 6: Positioning Lock Carrier Assembly Torx Bolts

Fig. 3: Identifying Top Dead Center (TDC) Position

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)
Lock Carrier-To-Fender Torx Bolts ............................................................................ 89 (10)
Courtesy of Audi of America, Inc. Timing Belt Tensioner Bottom Bolt ........................................................................... 89 (10)
Water Pump Bolt ....................................................................................................... 89 (10)
Fig. 4: Tensioning Camshaft Belt
1
– REPLACE torque-to-yield bolt if loosened or removed.
2
– Bolt strength grade is 10.9.
Fig. 5: Identifying Tensioner Dimensions

AUDI 49
1.8L 4-Cylinder Turbo – AMB Engine – 2002-04 A4

Application Labor Time Belt NOTE: Take special note of the installed position of the upper part
Part No. of the timing belt cover, particularly where it meets the center part
1.8L 4-Cylinder Turbo (AMB) of the timing belt cover.
A4 Avant & Sedan
2002-04 ..................................................... 4.4 Hours ... ..... T306 CAUTION: The engine must only be turned in the direction of
A4 Cabriolet engine rotation (clockwise) at the crankshaft. To turn engine over,
2003-04 ..................................................... 4.4 Hours ... ..... T306 use center bolt on the crankshaft.
NOTE: For information about tensioners and/or pulleys (when 14) Remove upper part of timing belt cover. Bring engine to TDC
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED CAUTION: Timing belt tensioner is oil-damped and can only be
SCHEDULED MAINTENANCE compressed slowly and with evenly applied force.
The manufacturer suggests the belt be replaced at 105,000 mile 15) When compressing the tensioner, excessive force can damage the
intervals under normal driving conditions, 52,500 mile intervals under tensioning pulley. Push pulley counter-clockwise in direction of arrow
severe driving conditions. 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.
camshaft or crankshaft when timing belt is removed, or engine NOTE: Mark direction of rotation of timing belt with chalk or felt tip
damage may occur. pen.
16) To release tension from timing belt, loosen nut on pulley and rotate
TIMING BELT 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. Fig. 1: Removing Under-Car Noise Insulation (Sedan & Avant)
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. Courtesy of Audi of America, Inc.
See Fig. 11. To install, reverse placing in service position procedure. Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts
(Sedan & Avant)
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.
50 AUDI
1.8L 4-Cylinder Turbo – AMB Engine – 2002-04 A4 (Cont.)
Fig. 6: Identifying Bumper Fasteners (Sedan & Avant)
Fig. 3: Locating Wheelhousing Fasteners (Sedan & Avant)

Fig. 7: Identifying Washer Hoses & Harness Connectors

(Sedan & Avant)
Fig. 4: Identifying Front Bumper-To-Fender Fasteners

(Sedan & Avant)
Fig. 8: Identifying Lock Carrier Components (Sedan & Avant)
Fig. 5: Removing Grilles (Sedan & Avant)

AUDI 51
Courtesy of Volkswagen United States, Inc.
Fig. 9: Identifying Support Tool (Part No. 3369)
Fig. 13: Locking Ribbed Belt Tensioner
Fig. 10: Installing Support Tool (3369) Into Chassis

(Sedan & Avant)
Fig. 14: Identifying Top Dead Center (TDC) Position
Fig. 11: Securing Lock Carrier In Service Position
Fig. 15: Compressing Timing Belt Tensioner
Fig. 12: Removing/Installing Ribbed Belt

52 AUDI
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.
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 Courtesy of Audi of America, Inc.
between lock carrier and air cleaner (air duct is bolted to lock carrier).
Fig. 17: Identifying Bumper Cover Fasteners (Cabriolet)
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.
NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior
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. Courtesy of Audi of America, Inc.
Fig. 18: Identifying Bumper Cover Fasteners At Wheel Opening

CAUTION: The engine must only be turned in the direction of
(Cabriolet)
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 CAUTION: To prevent pistons from hitting valves, make sure
1. Mark on camshaft sprocket and mark on crankshaft must be at TDC crankshaft is NOT at TDC for any piston before turning camshaft.
cylinder 1. See Fig. 14. Remove vibration damper. Remove center and Installation (Sedan & Avant) – 1) Place timing belt on crankshaft
lower part of timing belt cover. sprocket (if reusing belt, observe direction of rotation). Install lower part
of timing belt cover. Install vibration dampener. The hole in the vibration
CAUTION: Timing belt tensioner is oil-damped and can only be
damper must be located over the raised part on the crankshaft timing
compressed slowly and with evenly applied force.
belt sprocket. Tighten vibration damper/pulley to specification. See
9) When compressing the tensioner, excessive force can damage the TORQUE SPECIFICATIONS.
tensioning pulley. Push pulley counter-clockwise in direction of arrow 2) If necessary, align camshaft sprocket-to-cylinder head cover position-
with a socket head wrench using even but not excessive application of ing marks and vibration damper-to-timing belt cover positioning marks.
force until tensioner piston can be locked with Locking Plate (T10008). See Fig. 14. Install timing belt in this order: water pump, tensioning
See Fig. 15. pulley, camshaft sprocket.
AUDI 53

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 position-
ing 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.
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.
Fig. 19: Removing Bumper Cover (Cabriolet)
3) Turn eccentric bolt counter-clockwise in direction of arrow using
special tool (3387). See Fig. 21. Hold eccentric bolt in this position and
NOTE: If the timing belt tensioner has not been restrained and is at remove locking plate. Turn eccentric bolt clockwise to right in direction of
its travel limit, it must be pushed back in the installed position arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed
together with the pulley. This procedure can take up to 5 minutes. between tensioning lever and tensioner housing. See Fig. 22. Hold
When compressing the tensioner, excessive force can damage the eccentric bolt in this position and tighten pulley nut to specification. See
tensioning pulley. Push pulley on counter-clockwise in direction of TORQUE SPECIFICATIONS.
arrow with a socket head wrench using even but not excessive 4) Turn crankshaft two complete turns by hand in direction of engine
application of force until tensioner piston can be locked with rotation until crankshaft is at TDC again. Mark on camshaft sprocket and
locking plate (T10008). See Fig. 15. mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check
3) Turn eccentric bolt counter-clockwise in direction of arrow using dimension between tensioning lever and tensioner housing with a
special tool (3387). See Fig. 21. Hold eccentric bolt in this position and gauge. Dimension should be 6-10 mm. If dimension is not obtained,
remove locking plate. Turn eccentric bolt clockwise to right in direction of tension timing belt again. Go to step 3).
arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed 5) Install center and upper timing belt cover and ribbed belt tensioner.
between tensioning lever and tensioner housing. See Fig. 22. Hold Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
eccentric bolt in this position and tighten pulley nut to specification. See When installing ribbed belt, make sure that direction of rotation is correct
TORQUE SPECIFICATIONS. and that belt is installed correctly to pulleys. On vehicles with A/C, install
4) Turn crankshaft two complete turns by hand in direction of engine ribbed belt to A/C compressor last.
rotation until crankshaft is at TDC again. Mark on camshaft sprocket and 6) To install lock carrier, reverse removal procedures outlined in
mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check REMOVAL (CABRIOLET). Torque all fasteners to specification. See
dimension between tensioning lever and tensioner housing with a TORQUE SPECIFICATIONS.
gauge. Dimension should be 6-10 mm. If dimension is not obtained,
tension timing belt again. Go to step 3). NOTE: Prior to installation of the bumper cover check for presence
5) Install center and upper timing belt cover and ribbed belt tensioner. of threaded pins (2) at the bumper extensions as well as grommets
Tighten fasteners to specification. See TORQUE SPECIFICATIONS. (3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m).
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 7) To install bumper cover, reverse removal procedures outlined in
ribbed belt to A/C compressor last. REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and
6) To install lock carrier, reverse removal procedures outlined in connect the hose of headlight washer unit as necessary. Reconnect
REMOVAL (SEDAN & AVANT). Torque all fasteners to specification. See connectors as necessary. Ensure that the threaded pins in the bumper
TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for side extensions engage in the holes at the fender.
torque support with its own weight and tighten bolts to 21 ft. lbs. (28 8) Clip in side extensions and fasten using the bolts (8). See Fig. 19.
N.m). See Fig. 23. 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
NOTE: Before installing bumper, check for the presence of
overlap or gap dimension of bumper cover with respect to the hood. If
threaded pins at bumper rear edge as well as expanding clips and
sleeves in the fenders. Always replace bumper retaining bolts. 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
7) Slide bumper onto impact absorber and re-connect hose (1) of N.m).
headlight cleaning system and electrical harness connectors (2). See 9) Verify fender gaps as follow: A = 2 mm +/– 0.5 mm, B = 0 mm +/– 0.5
Fig. 7. Move bumper into installation position. Make sure threaded pins mm and C = 0 mm +/– 0.5 mm. See Fig. 24. Gap dimensions can be
in bumper side edges engage into holes at the fenders. Install bumper checked using Audi special tool (3371). Adjust gaps as necessary.
retaining bolts until bumper can stay in place without any assistance.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
8) Do not tighten completely allowing for any necessary adjustments.
Remainder of installation is the reverse of removal.
Pull back wheelhousing liner (A). See Fig. 3. Engage bumper rear edge
into catch (B). Torque nuts. Repeat procedure on opposite side of the
54 AUDI
Fig. 20: Exploded View Of Lock Carrier Components (Cabriolet)
Courtesy of Audi of America, Inc. Fig. 23: Identifying Torque Support Bolts (Sedan & Avant)
Fig. 21: Releasing Locking Plate From Tensioner
Fig. 24: Bumper Cover Gaps (Cabriolet)
Fig. 22: Adjusting Timing Belt Tensioner

AUDI 55

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-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
– After achieving torque, tighten an additional quarter turn (90°).
2
– Install with locking fluid D 000 600 A2.
3
– Replace bolts.
56 AUDI
1.8L 4-Cylinder Turbo
AMU, ATC, AWP & BEA Engines – TT
Application Labor Time Belt CAUTION: To prevent engine damage, DO NOT turn camshaft while
Part No. the crankshaft is at TDC.
1.8L 4-Cylinder Turbo (AMU, ATC & AWP)
11) SLOWLY turn hex nut on stud to compress timing belt tensioner.
TT Coupe & Roadster
Compress tensioner just enough so that a locking pin or drill bit can be
2000-04 ..................................................... 3.4 Hours ... ..... T306
inserted through the tensioner body, locking the tensioner in place. Pull
NOTE: Engine code is located on machined pad on bellhousing out timing belt through space between engine support and cylinder
flange, where engine connects to transaxle. block.

intervals.

damage may occur.
TIMING BELT Courtesy of Audi of America, Inc.

Removal – 1) On ATC and AWP engines, disconnect charge air cooler
duct at bottom of right-hand crossmember. See Fig. 1. To identify Fig. 1: Identifying Air Duct (ATC & AWP Engines)
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. Fig. 2: Identifying Engine Code
NOTE: Crankshaft sprocket center bolt is a torque-to-yield type. If Installation – 1) Install timing belt onto crankshaft sprocket. Install lower
removed, manufacturer recommends replacing the bolt. timing belt cover. Install vibration damper pulley, making sure notch in
center hole of vibration damper is aligned with projection on crankshaft
7) Remove 4 bolts around center bolt on vibration damper. Remove sprocket. Tighten bolts to specification. See TORQUE SPECIFICA-
vibration damper. It is NOT necessary to remove crankshaft center bolt. TIONS.
DO NOT move crankshaft during removal of vibration dampener. 2) Ensure camshaft and crankshaft timing marks are still aligned. See
Fig. 6. Install timing belt on water pump, tensioner pulley and camshaft
NOTE: Engine console and right-hand engine support bolts are
sprocket.
torque-to-yield type. Manufacturer recommends replacing the
3) Remove locking pin or drill bit from timing belt tensioner. Remove M5
bolts if they are removed.
x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions
8) Remove center and bottom timing belt covers. Remove bolts from in normal direction of rotation. Align camshaft and crankshaft timing
engine console and right-hand engine support arm. See Fig. 7. Remove marks.
engine console and right-hand engine support arm. 4) Install engine right-hand engine support arm and console using NEW
9) Remove bolts for engine support, but do not remove engine support. bolts. Adjust engine console and right-hand engine support arm so
See Fig. 8. If reusing old timing belt, mark belt with arrow to indicate clearance is about 0.50″ (13 mm). See Fig. 7.
original direction of rotation. 5) Remove Engine Support Bracket (10-222) or floor jack from under
10) Screw a M5 x 55 stud into the timing belt tensioner bracket. See vehicle. Install center and upper timing belt covers. Install serpentine
Fig. 9. Install hex nut and washer onto stud. belt tensioner and serpentine belt.
AUDI 57

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. Fig. 5: Exploded View Of Timing Belt & Components
Fig. 3: Identifying Noise Insulation Panels
Fig. 4: Identifying Serpentine Belt & Tensioner

58 AUDI
AMU, ATC, AWP & BEA Engines – TT (Cont.)
Step 1 ...................................................................................................................... 66 (90)
Engine Console-To-Body 1
Step 1 ...................................................................................................................... 30 (40)
Engine Support Arm-To-Engine Bracket 1
Step 1 ...................................................................................................................... 44 (60)
Timing Belt Tensioner
Bottom Bolt .............................................................................................................. 11 (15)
Top Bolt ................................................................................................................... 15 (20)
Vibration Damper-To-Crankshaft Sprocket ............................................................... 18 (25)
Water Pump Bolt ....................................................................................................... 11 (15)
Fig. 7: Locating Right-Hand Engine Support Arm INCH Lbs. (N.m)
1
– Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.
Fig. 8: Identifying Right-Hand Engine Support

AUDI 59
1.8L 4-Cylinder Turbo – AWM Engine – 2000-04 A4

Part No.
1.8L 4-Cylinder Turbo (AWM Engine)
A4 & A4 Quattro
2000 ........................................................... 4.7 Hours ... ..... T306
2001-04 ..................................................... 4.4 Hours ... ..... T306

MANUFACTURER’S SUGGESTED 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.

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 Courtesy of Audi of America, Inc.
Fig. 2. Remove inner end of grille first. Remove bolt/washer assembly
Fig. 2: Removing Inner End Of Air Inlet Grill (A4)
(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 CAUTION: To prevent pistons from hitting valves, make sure
cover. crankshaft is NOT at TDC for any piston before turning camshaft.
4) Remove lower air duct hose-to-charge air cooler. See Fig. 4. Remove
Installation – 1) Align marking on camshaft sprocket with marking at
air duct between lock carrier and air filter housing. Disconnect harness
cylinder head cover. See Fig. 12. Place timing belt on crankshaft
retaining clips from left side of radiator shroud.
sprocket (if reusing old belt, observe direction of rotation noted during
5) Remove bolt and install Lock Carrier Support Tool (3369) through lock
removal). Install lower timing belt guard. Secure vibration damper/belt
carrier to chassis. See Figs. 5, 6 and 7. Install Lock Carrier Support Tool
pulley with one bolt (note installation arrangement). Set crankshaft to
into bore on opposite side of vehicle. See Fig. 5. Remove lock carrier
TDC for cylinder No. 1. Install timing belt onto coolant pump, then
support bolts securing lock carrier to vehicle. Slide lock carrier forward
tensioning roller, and finally camshaft sprocket.
onto support tool. Secure lock carrier to vehicle using holes in lock
2) Remove socket head fastener (T10092) and pull out pin (T40011)
carrier and fender. See Fig. 8. This will allow servicing of front engine
from tensioner. See Fig. 10.
components.
3) Turn crankshaft two full turns in direction of rotation (by turning central
6) Remove engine cover and loosen bolts securing ribbed belt tension-
bolt on crankshaft sprocket by hand) and check that camshaft and
ing roller for A/C compressor. Remove A/C compressor belt. Rotate
crankshaft marks align with their reference points. Install remaining
tensioner in direction of arrow to loosen ribbed belt. See Fig. 9. Remove
vibration damper bolts and torque to specification. See TORQUE
ribbed belt from generator and release tensioner.
SPECIFICATIONS.
NOTE: When lock carrier is in the service position, ribbed belt 4) Install timing belt guard (center and top sections). Install viscous fan.
tensioner can be secured to prevent from turning by inserting a Install tensioner for ribbed belt. Attach ribbed belt to pulleys from
suitable pin or Allen key into holes. See Fig. 10. 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
7) Secure pulley for viscous fan with pin punch (1) and remove using ribbed belt over generator pulley last. Release tensioner and check that
Allen key (2). See Fig. 11. Remove viscous fan from mounting. ribbed belt is properly seated.
5) Fit ribbed belt for A/C compressor. Attach torque wrench at 7 o’clock
NOTE: If serpentine belt is to be reused, mark direction of timing
position to hex on tensioner and pretension to 22 ft. lbs. (30 N.m). While
belt rotation with chalk or felt pen before removing the belt. If belt
applying tension, tighten tensioner bolts to 17 ft. lbs. (23 N.m).
rotates in the wrong direction when it is refitted, belt breakage may
6) For installation of lock carrier, reverse removal procedures outlined in
result.
REMOVAL. After installing lock carrier, ensure harness next to radiator
8) Remove upper timing belt guard. Set crankshaft to markings for TDC is routed correctly. Attach limit stop for torque reaction support to rest on
of No. 1 cylinder by turning central bolt on crankshaft sprocket in rubber buffer for reaction support under its own weight. See Fig. 14.
direction of rotation. See Fig. 12. Torque bolts to specification. See TORQUE SPECIFICATIONS.
9) Unbolt and remove vibration damper. Remove lower and center 7) For installation of bumper, reverse removal procedures outlined in
sections of timing belt guard. Attach Socket Head Fastener (T10092 or REMOVAL. Bumper height is adjusted by shifting the threaded sleeve in
any M5 x 55 stud) into tensioner for timing belt. See Fig. 13. Only tension the impact absorber. See Fig. 15. Tighten combination bolt to 17 ft. lbs.
pressure piston of tensioner until pressure piston can be secured with (23 N.m) when installing bumper. Bolt (4) is for securing impact absorber
pin (T40011). Remove timing belt. to lock carrier for service position. Torque to 3 ft. lbs. (4 N.m).
60 AUDI
1.8L 4-Cylinder Turbo – AWM Engine – 2000-04 A4 (Cont.)
Fig. 3: Identifying Front Bumper Components (A4)
Fig. 4: Identifying Air Charge Cooler Hose (A4)
Fig. 5: Exploded View Of Lock Carrier Assembly (A4)

AUDI 61
Fig. 6: Identifying Support Tool (3369)
Fig. 9: Removing/Installing Alternator Belt (A4)
Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.
Fig. 7: Positioning Lock Carrier Support Tool (3369) Fig. 10: Securing Tensioner

Fig. 11: Removing Viscous Fan
Fig. 8: Positioning Lock Carrier Assembly Torx Bolts
62 AUDI
Fig. 12: Identifying Top Dead Center (TDC) position
Fig. 15: Adjusting Front Bumper Height (A4)
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)
Fig. 13: Compressing Timing Belt Tensioner 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
– After achieving torque, tighten an additional quarter turn (90°).
2
– Install with locking fluid D 000 600 A2.
3
– Replace bolts.
Fig. 14: Adjusting Stop For Torque Reaction Support

AUDI 63
2.0L 4-Cylinder
TIMING BELT APPLICATION Installation – 1) Align flywheel/flexplate “0” mark with pointer. Remove
Application Labor Time Component Belt distributor cap, and check position of ignition rotor. Rotate intermediate
Kit No. Part No. shaft and position rotor at No. 1 cylinder mark on housing. See Fig. 2.
2.0L 4-Cyl. Install timing belt on crankshaft and intermediate shaft gears.
80 2) With intermediate shaft/ignition rotor positioned, rotate crankshaft and
1988-90 ............................... 1.8 Hours ... .. TCK017 .. ..... T017 align mark on crankshaft pulley with mark on intermediate shaft
90 sprocket. Position camshaft sprocket mark even with base of valve
1988 .................................... 1.8 Hours ... .. TCK017 .. ..... T017 cover. See Fig. 3 or 4. Install timing belt on camshaft sprocket.
3) Rotate tensioner clockwise to tighten belt and install lock nut. Proper
NOTE: A timing belt component kit is available for this application. tension is achieved when belt can be twisted 90 degrees. See Fig. 5.
See page A1 for information on component kits. Rotate crankshaft 2 revolutions and check timing mark alignment. To
NOTE: For information about tensioners and/or pulleys (when proper tension.
Fig. 2: Aligning Ignition Rotor

TIMING BELT

damage may occur.
Removal – 1) Disconnect negative battery cable. Use exploded view to
locate components. See Fig. 1. Match mark all components for reas-
sembly 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.
Fig. 3: Aligning Timing Marks (8-Valve)
Fig. 1: Exploded View of Timing Belt & Components

64 AUDI
Crankshaft Pulley Nut ................................................................................................. 5 (20)
Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45)
Water Pump Pulley ................................................................................................... 15 (20)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .............................................................................................. 53 (6)
Fig. 4: Aligning Timing Marks (16-Valve)
Fig. 5: Checking Proper Timing Belt Tension

AUDI 65
2.0L 5-Cylinder – Diesel & Turbo Diesel

Part No.
2.0L 5-Cyl. – Diesel
5000
1979-83
Camshaft ................................................ 2.6 Hours ... ..... T083
Inject. Pump ........................................... 1.1 Hours ... ..... T082
2.0L 5-Cyl. – Turbo Diesel
5000
1979-83
Camshaft ................................................ 2.6 Hours ... ..... T083
Inject. Pump ........................................... 1.1 Hours ... ..... T082

SCHEDULED MAINTENANCE Courtesy of Audi of America, Inc.
60,000 mile intervals. 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.
REMOVAL & INSTALLATION 7) Adjust fuel injection pump drive belt tension by loosening mounting
bolts and repositioning mounting plate and support on engine. Using
CAUTION: This application is an interference engine. Do not rotate Tension Tester (VW 210), check belt tension midway between fuel
camshaft or crankshaft when timing belt is removed, or engine injection pump and drive sprockets.
damage may occur. 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
TIMING BELT & INJECTION PUMP BELT are correct. Adjust drive belts to proper tension.
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 Courtesy of Audi of America, Inc.
aligned. Install crankshaft damper/pulley with sprocket and timing belt.
Using Support Tool (2084) to hold crankshaft, install and tighten center Fig. 2: Replacing Injection Pump Drive Belt
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 TORQUE SPECIFICATIONS
cover, tap camshaft sprocket loose from camshaft taper.
3) Attach timing belt to camshaft sprocket. To adjust timing belt tension,
Camshaft Sprocket
turn water pump until pump sprocket provides tension against timing
Front ......................................................................................................................... 33 (45)
belt. Rear ....................................................................................................................... 72 (100)
4) Using tension tester (VW210), check timing belt tension midway Crankshaft Damper/Pulley (Locktite) .................................................................... 258 (350)
between camshaft and water pump sprockets. Tension is correct when Water Pump Bolts ..................................................................................................... 14 (20)
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.
66 AUDI
2.2L 5-Cylinder – Turbo, 1992-95
Part No.
2.2L 5-Cyl. – Turbo
S4
1992-94 ..................................................... 1.8 Hours ... ..... T225
S6 & S6 Quattro
1995 ........................................................... 3.4 Hours ... ..... T225


Removal – 1) Disconnect negative battery cable. Raise and support Fig. 1: Relieving Tension On Accessory Drive Belt
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.
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. Courtesy of Audi of America, Inc.
Installation – 1) Ensure crankshaft and camshaft are at TDC of cylinder
No. 1. TDC marking must be positioned below edge in inspection hole. Fig. 2: Locating No. 1 Cylinder TDC 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 ten-
sioner. To complete installation, reverse removal procedure. Adjust drive
Fig. 3: Aligning Camshaft Sprocket Timing Marks

AUDI 67
2.2L 5-Cylinder – Turbo, 1992-95 (Cont.)

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)

68 AUDI
2.3L 5-Cylinder – Coupe Quattro
Part No.
2.3L 5-Cyl.
Coupe Quattro
1990-91 ..................................................... 1.8 Hours ... ..... T197


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.
Fig. 1: Exploded View Of Timing Belt & Components Courtesy of Audi of America, Inc.
Installation – 1) Ensure both camshaft lobes on No. 1 cylinder point Fig. 2: Aligning Timing Marks
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 Courtesy of Audi of America, Inc.
removal. Adjust drive belts to proper tension.
AUDI 69
2.3L 5-Cylinder – Coupe Quattro (Cont.)

Water Pump Bolt ....................................................................................................... 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 84 (10)
Fig. 4: Checking Proper Timing Belt Tension

70 AUDI
2.3L 5-Cylinder – Except Coupe Quattro
Part No.
2.3L 5-Cyl.
80
1991-92 ..................................................... 1.8 Hours ... ..... T170
80/90 Quattro
1988 ........................................................... 1.8 Hours ... ..... T127
1989
Thru Chassis No. 89 J 394 742 ............ 1.8 Hours ... ..... T127
From Chassis No. 89 J 394 743 ........... 1.8 Hours ... ..... T170
1990-92 ..................................................... 1.8 Hours ... ..... T170
90
1988 ........................................................... 1.8 Hours ... ..... T127
1989
Thru Chassis No. 89 J 396 702 ............ 1.8 Hours ... ..... T127
From Chassis No. 89 J 396 703 ........... 1.8 Hours ... ..... T170
1990-91 ..................................................... 1.8 Hours ... ..... T170
100/100 Quattro
1989-91
Thru Chassis No. 063 969 .................... 1.8 Hours ... ..... T127
From Chassis No. 063 970 ................... 1.8 Hours ... ..... T170
1990-91 ..................................................... 1.8 Hours ... ..... T170
5000S
1987-88 ..................................................... 2.2 Hours ... ..... T127
5000S Quattro Fig. 1: Exploded View Of Timing Belt & Components
1988 ........................................................... 2.2 Hours ... ..... T127


TIMING BELT
upper radiator cover. Remove drive belts. Remove power steering pump Courtesy of Volkswagen United States, Inc.
with pressure hoses connected. Set pump aside. Remove valve cover
and outer timing belt covers. See Fig. 1. Fig. 2: Aligning Camshaft Sprocket
2) Using crankshaft bolt, turn crankshaft clockwise to TDC of No. 1 Installation (1991-92) – 1) Ensure timing marks are aligned. See Fig. 3.
cylinder compression stroke. Align timing mark on back of camshaft With crankshaft sprocket attached to vibration damper, loop timing belt
sprocket with upper edge of gasket. See Fig. 2. around crankshaft sprocket. Install vibration damper/crankshaft
3) Loosen water pump adjusting bolts to relieve tension on timing belt. sprocket with belt onto crankshaft end, ensuring belt is not jammed
Remove timing belt. Remove water pump to check “O” ring. DO NOT between crankshaft sprocket and front cover.
allow crankshaft or camshaft to move. 2) Slightly loosen 3 water pump bolts. Pivot water pump toward center
Installation (1987-90) – 1) Ensure both camshaft lobes on No. 1 of engine to allow belt to be looped around camshaft sprocket and idler
cylinder point upward. Mark (notch or dot) on back of camshaft sprocket pulley. Take up all slack in belt between camshaft and water pump, and
must be aligned with top of valve cover gasket or rear timing belt cover. between water pump and crankshaft.
Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must 3) Pivot water pump away from engine until belt is tight. To check belt
be aligned with index point on transmission housing. tension, grasp belt with thumb and forefinger between camshaft and
2) Install water pump with new sealing “O” ring. Install timing belt. Turn water pump sprocket. Belt tension is correct if belt can be twisted 90
water pump body counterclockwise to increase belt tension. Tension is degrees. Tighten water pump bolts to specification. Complete installa-
correct when belt can be twisted 90 degrees using finger pressure at tion in reverse order of removal. Adjust drive belts to proper tension.
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.
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.
AUDI 71
2.3L 5-Cylinder – Except Coupe Quattro (Cont.)

Water Pump Bolt ....................................................................................................... 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 89 (10)

72 AUDI
2.7L V6 DOHC – APB Engine – A6 Quattro & Allroad
TIMING BELT APPLICATION larger holes in the securing plates on the camshaft sprockets must face
Application Labor Time Belt one another on the inside. If this is not the case, rotate crankshaft one
Part No. revolution more.
2.7L V6, Twin Turbo (APB Engine)
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
A6 Quattro
could result.
2000-04 ..................................................... 5.2 Hours ... ..... T297
Allroad 9) Remove sealing plug from left side of cylinder block. See Fig. 11. The
2001-04 ..................................................... 5.2 Hours ... ..... T297 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
SCHEDULED MAINTENANCE Fig. 12.
Manufacturer recommends belt and belt tensioner be replaced at 11) Remove idler wheel for accessory drive belt. Remove timing belt
105,000 miles. 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
REMOVAL & INSTALLATION oil-damped and can be compressed slowly by applying constant pres-
sure. Turn until tensioning lever compresses the oil-damped tensioner
CAUTION: This application is an interference engine. Do not rotate element enough to enable Pin (T40011) to be fitted through the holes in
camshaft or crankshaft when timing belt is removed, or engine the tensioner body and the plunger. This will secure plunger in position.
damage may occur. 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 Fig. 1: Removing Noise Insulation
at lock carrier.
• Remove bolts from lock carrier. Installation – 1) Insert Camshaft Locator Bar (3391) into securing
• On right side, remove bolt and install Support Tool (3369) into right plates of the two camshafts. See Fig. 15. Loosen both camshaft bolts
bore. See Fig. 3. and unscrew approximately 5 turns.
• On left side, install Support Tool (3369) into threaded hole. Remove
NOTE: Camshaft sprockets should be just tight enough on the
bolts on left and right. See Figs. 3 and 4.
camshaft tapers so that they can still be rotated, but do not move
• Remove bolts and pull lock carrier forward until rear hole in lock
axially (up and down).
carrier aligns with front threaded hole in fender flange. Secure lock
carrier using bolts. See Fig. 5. 2) Remove Camshaft Locator Bar (3391). Loosen, but do not remove,
both camshaft sprockets with Gear Puller (T40001). See Fig. 16.
NOTE: Viscous fan has left-hand threads. 3) Reinstall both camshaft sprockets with securing plates and tighten
4) Remove viscous fan using spanner wrench and Pin Wrench (3212) to hand tight.
hold fan. See Fig. 6. 4) Position timing belt over camshaft sprockets. See Fig. 17. Install
Camshaft Locator Bar (3391) on camshafts. Using hex key, turn timing
CAUTION: Mark the direction of the accessory drive belt rotation belt tensioner clockwise 8 mm until pin can be removed from tensioner.
with chalk or felt pen before removing. A used belt can break if it See Fig. 14.
rotates in the opposite direction when reinstalled. 5) Pre-tension timing belt by turning tensioner pulley center bolt clock-
wise with a torque of 11 ft. lbs. (15 N.m). Tighten bolts on camshaft
5) Using a 17-mm wrench turn belt tensioner to the right until two holes sprockets to specification. See TORQUE SPECIFICATIONS.
are aligned. Hold tensioner in position with Mandrel (3204). Remove 6) Remove camshaft locator bar. Remove crankshaft holding tool. Install
accessory drive belt. See Fig. 7. plug in engine block. Install timing belt guards.
6) Unscrew bolts and remove center engine cover panel. Remove 7) Remaining installation is reverse of removal procedure. For acces-
pressure hoses between charge air coolers and pressure pipes on left sory drive belt routing, see Fig. 18. Ensure lock carrier-to-fender Torx
and right sides. See Fig. 8. Remove turbocharger pressure pipes. bolts are installed correctly. See Fig. 5.
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
AUDI 73
2.7L V6 DOHC – APB Engine – A6 Quattro & Allroad (Cont.)
Fig. 4: Positioning Lock Carrier Support Tool (3369)
Fig. 2: Removing Front Bumper
Fig. 5: Securing Lock Carrier
Fig. 3: Moving Lock Carrier To Service Position

74 AUDI

Fig. 7: Loosening Accessory Drive Belt Fig. 10: Aligning Crankshaft Timing Marks
Fig. 8: Removing Pressure Hoses

Fig. 11: Using Crankshaft Holding Tool
Fig. 9: Removing Accessory Drive Belt Tensioner &

Timing Belt Covers Courtesy of Audi of America, Inc.
Fig. 12: Removing Vibration Damper

AUDI 75
Fig. 13: Removing Timing Belt Guard Fig. 16: Removing Camshaft Sprockets With Gear Puller
Fig. 17: Installing Timing Belt On Sprockets
Fig. 18: Accessory Drive Belt Routing
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)
Courtesy of Audi of America, Inc. Viscous Fan ............................................................................................................... 52 (70)
Fig. 15: Installing Camshaft Locking Bar INCH Lbs. (N.m)

Lock Carrier-To-Fender Torx Bolt ............................................................................. 89 (10)
Water Pump Bolt ....................................................................................................... 89 (10)
1
– ALWAYS replace bolt if loosened or removed.
76 AUDI
2.7L V6 DOHC – APB Engine – S4 Quattro
TIMING BELT APPLICATION larger holes in the securing plates on the camshaft sprockets face one
Application Labor Time Belt another on the inside. See Fig. 14. If this is not the case, rotate
Part No. crankshaft one revolution more.
2.7L V6 Twin Turbo (APB Engine)
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
S4 Quattro
could result.
2000-02 ..................................................... 5.5 Hours ... ..... T297
11) Remove sealing plug from left side of cylinder block. The TDC mark
NOTE: For information about tensioners and/or pulleys (when in crankshaft must be visible (or be able to be felt) in line with sealing
available), see ALPHABETICAL MODEL LISTING. plug hole.
NOTE: The center bolt does not have to be loosened to remove the
MANUFACTURER’S SUGGESTED vibration damper.
SCHEDULED MAINTENANCE 12) Screw Crankshaft Holding Tool (Audi 3242) into sealing plug and
For 2000 model vehicles, manufacturer recommends belt be replaced at tighten. See Fig. 10. Remove crankshaft vibration damper. See Fig. 11.
105,000 miles. 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
REMOVAL & INSTALLATION 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.
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. 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 Courtesy of Audi of America, Inc.
from bracket, and remove toward front. Fig. 1: Removing Noise Insulation
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.
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. Courtesy of Audi of America, Inc.
7) Loosen accessory drive belt by using a 17-mm wrench to turn belt Fig. 2: Removing Front Bumper (Up to VIN 8DXA200000 Shown;
tensioner to the right until two holes are aligned. Hold tensioner in Later Models Are Similar)
position with Mandrel (3204). Remove accessory drive belt. See Fig. 6.
8) Unscrew bolts and remove center engine cover panel. Remove
NOTE: Camshaft sprockets should be just tight enough on the
pressure hoses between charge air coolers and pressure pipes on left
camshaft tapers so that they can still be turned, but do not move
and right sides. See Fig. 7. Remove pressure pipes, noting installed
axially (up and down).
position of retaining strips.
9) Remove timing belt tensioner “1”. Remove left and right timing belt Installation – 1) Insert Camshaft Locator Bar (3391) into securing
guards “2” and center guard “3”. See Fig. 8. plates of the two camshafts. See Fig. 14. Loosen both camshaft bolts
10) Rotate crankshaft by hand to TDC. Ensure notch “A” is aligned with and unscrew approximately 5 turns. Remove Camshaft Locator Bar
notch “B”. See Fig. 9. Check position of camshafts. Ensure that the (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.
Fig. 3: Removing Inner End Of Air Inlet Grill
Fig. 6: Loosening Accessory Drive Belt
Fig. 7: Removing Pressure Hoses

78 AUDI

Fig. 8: Removing Accessory Drive Belt Tensioner
Fig. 11: Removing Vibration Damper
Fig. 9: Aligning Crankshaft Timing Marks Fig. 12: Removing Timing Belt Guard

AUDI 79
Fig. 17: Routing Accessory Drive Belt
Fig. 14: Installing Camshaft Locking Bar
Fig. 18: Positioning Lock Carrier Torx Bolts
Bumper Combination Bolts ....................................................................................... 17 (23)
Courtesy of Audi of America, Inc. Camshaft Sprocket Bolt ............................................................................................ 40 (55)
Fig. 15: Removing Camshaft Sprockets With Gear Puller 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)
1
– Plus 190 degrees. Always use new bolt.

80 AUDI
2.8L V6 – 12-Valve
Part No.
2.8L V6
A4
1996-97 ..................................................... 4.9 Hours ... ..... T218
A4 Quattro
1996-97 ..................................................... 4.9 Hours ... ..... T218
A6
1995-97 ..................................................... 3.4 Hours ... ..... T218
1998 ........................................................... 4.9 Hours ... ..... T297
A6 Quattro
1995-97 ..................................................... 3.4 Hours ... ..... T218
1998 ........................................................... 4.9 Hours ... ..... T297
Cabriolet
1994-98 ..................................................... 2.5 Hours ... ..... T218
90 & 90 Quattro
1993-95 ..................................................... 2.5 Hours ... ..... T218
100 & 100 Quattro
1992-94 ..................................................... 2.5 Hours ... ..... T218 Courtesy of Audi of America, Inc.
NOTE: For information about tensioners and/or pulleys (when Fig. 1: Aligning Crankshaft Timing Marks
For 1997-98 model vehicles, manufacturer recommends belt be
replaced at 90,00 miles. For 1996 and earlier model years, the manu-
facturer does not recommend a specific scheduled maintenance inter-
val. However, belt manufacturers suggest the belt be replaced at 60,000
mile intervals.

damage may occur.
CAUTION: Before removal, mark an arrow indicating direction of Fig. 2: Using Crankshaft Holding Tool
rotation on accessory drive belt or timing belt. Damage may result
if belts are installed in opposite direction of rotation.
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 Courtesy of Audi of America, Inc.
remove timing belt. See Fig. 4.
Fig. 3: Using Camshaft Holding Tool
NOTE: Camshaft sprockets must be loose enough to rotate on
camshaft, but not loose enough to tilt.
AUDI 81
2.8L V6 – 12-Valve (Cont.)

Camshaft Bearing Cap Nut ....................................................................................... 11 (15)
Crankshaft Damper Bolt ........................................................................................ 295 (400)
INCH Lbs. (N.m)
Crankshaft Position (CKP) Sensor ........................................................................... 96 (10)
Valve Cover Bolt ........................................................................... ................... 53-89 (6-10)
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
82 AUDI
2.8L V6 – 30-Valve
TIMING BELT APPLICATION 10) Remove lower timing belt guard (if equipped). Remove timing 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

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.

damage may occur.
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 LEFT-
HAND threaded.
4) Use a 17-mm box wrench to turn serpentine belt tensioner counter-
clockwise 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 Fig. 2: Exploded View Of Bumper Assembly (A6)
of engine, rotate crankshaft one revolution. See Fig. 8. Ensure crank-
shaft timing marks are still aligned.
NOTE: Camshaft sprockets must be loose enough to rotate on
NOTE: DO NOT turn crankshaft while checking for TDC mark. camshaft, but not loose enough to tilt.
Personal injury may result.
Installation – 1) Install Camshaft Locator Bar (3391) into locking plates
7) Remove sealing plug from left side of engine block. TDC mark on of camshafts. See Fig. 12. Loosen camshaft sprocket bolts about 5
crankshaft must be visible or be felt through sealing plug hole. Install turns. Remove locator bar. Leaving camshaft sprocket bolts in place,
Crankshaft Holding Tool (Audi 3242) into sealing plug hole. See Fig. 9. use gear puller to loosen camshaft sprockets on camshaft taper.
8) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley 2) Ensure all timing marks are still aligned. Install timing belt on engine.
clockwise to compress timing belt tensioner. See Fig. 10. Compress Ensure belt routing is correct and there is no slack in belt. See Fig. 13.
timing belt tensioner just enough so that a 2-mm pin can be inserted
Install Camshaft Locator Bar (3391) into locking plates of camshafts.
through the holes in top of tensioner body and push rod. This will hold
3) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner
the tensioner in the compressed position.
so that 2-mm pin can be removed from tensioner.
9) Remove crankshaft vibration damper from crankshaft. It is NOT
4) Using 8-mm hex socket, place torque wrench on timing belt tensioner
necessary to remove center bolt. If center bolt is removed, manufacturer
recommends using NEW bolt on reassembly. Remove serpentine belt pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in direction of tension
idler pulley. (clockwise). This will preload belt tension.
AUDI 83

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.
Fig. 5: Positioning Lock Carrier Support Tool (3369)
Fig. 6: Aligning Crankshaft Timing Marks (1 Of 2)

Fig. 7: Aligning Crankshaft Timing Marks (2 Of 2)

84 AUDI
Courtesy of Audi of America, Inc. Fig. 11: Marking Timing Chain & Sprockets
Fig. 8: Locating Camshaft Sprocket Holes
Courtesy of Audi of America, Inc. Fig. 12: Installing Camshaft Locator Bar

AUDI 85

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 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
– If removed, manufacturer recommends using NEW bolt.
Fig. 14: Positioning Lock Carrier Torx Bolts

86 AUDI
3.0L V6 – AVK Engine – A4 & A6
Application Labor Time Belt CAUTION: Before removing ribbed belt, mark direction of rotation
Part No. with chalk or felt-tip marker. Reversing the direction of rotation of
3.0L V6 (AVK Engine) a run-in belt can destroy the belt.
A4 Avant & Sedan 13) Remove front engine cover. See Fig. 12. Using Ribbed Belt
2002-04 ..................................................... 5.4 Hours ... ..... T330 Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner
A4 Cabriolet
in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of
2003-04 ..................................................... 5.4 Hours ... ..... T330
A6 power steering pump.
2002-04 ..................................................... 5.8 Hours ... ..... T330 14) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear
of power steering vane pump (arrows) using 3212 spanner wrench as
NOTE: For information about tensioners and/or pulleys (when 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.
SCHEDULED MAINTENANCE 15) Remove 8 bolts attaching harmonic balancer to crankshaft and
remove balancer. Remove thrust washer if equipped.
The manufacturer recommends belt be replaced at 105,000 miles under 16) Without disconnecting coolant hoses, remove bolts (1, 2) attaching
normal driving conditions, 52,500 miles under severe driving conditions. 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
REMOVAL & INSTALLATION attaching expansion tank to vehicle. Disconnect Engine Coolant Level
(ECL) warning switch harness connector at bottom of expansion tank.
CAUTION: This application is an interference engine. Do not rotate Without disconnecting coolant hoses, tie expansion tank off to side.
camshaft or crankshaft when timing belt is removed, or engine 18) Disconnect Mass Air Flow (MAF) sensor harness connector (1). See
damage may occur. 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
TIMING BELT 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.
NOTE: Lock carrier is slid forward onto alignment tools. This will 20) Remove ignition coils from right valve cover. Remove hose of
allow servicing of front engine components. Lock carrier can be crankshaft housing ventilation located at rear of valve cover. Remove
removed at technicians discretion. 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 com- CAUTION: Turning of the engine must only occur in direction of
pletely. engine rotation (clockwise) at the crankshaft.
Removal (A4) – 1) Raise vehicle, remove front tires. Remove bolts and 21) Turn engine at crankshaft central bolt. Turn engine until the cams
quick release screws (1 and 2). See Fig. 1. Rear noise insulation (3) (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder
remains installed. bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster
2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of Gauge (T40030) at camshafts of right cylinder head. See Fig. 22.
parking/auxiliary heater at noise insulation. See Fig. 2. 22) Slightly turn crankshaft back and forth so that the claw of camshaft
3) Remove right cover in engine compartment. Unbolt air guide between adjuster gauge can properly grab the camshafts. Spread and tighten
lock carrier and air filter on lock carrier. Remove left cover in engine camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until
compartment. Pull off hood seal from lock carrier and fender edges. seated without axial play. Repeat procedure for left cylinder head.
4) Loosen left and right wheelhousing liners in front area. See Fig. 3. Pull 23) If installed, disconnect after-run coolant pump harness connector.
back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip Remove sealing plug of TDC mark at cylinder block. Install Locking Pin
bumper rear edge from catch (arrow B). See Fig. 4. Repeat procedure (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
on opposite side of the vehicle.
bottom in crankshaft properly.
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 NOTE: During next step, catch escaping oil using a rag.
right retaining bolts until bumper is fully released. See Fig. 6.
24) Pry off securing rings (1) for caps (2) at all camshaft gears. See
6) If installed, disconnect hose (1) to headlight cleaning system.
Fig. 24. Loosen but do not remove bolts for camshaft gears.
Disconnect harness connectors (2) and remove bumper. See Fig. 7.
7) Inspect headlight and turn signal electrical connectors and wiring CAUTION: If reusing timing belt, mark rotational direction of belt.
harness (which may hang up when lock carrier is moved forward). 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
See Fig. 10 .
housing of tensioner. See Fig. 25. The timing belt tensioner is oil-
10) Remove on both sides, all bolts (2). See Fig. 8. dampened. Compress it by slowly applying constant pressure. Loosen
11) Remove on both sides, all bolts (3 and 4). See Fig. 8. Slide lock bolt of eccentric pulley on opposite side of tensioner and remove timing
carrier forward unit the rear bolt hole in lock carrier aligns with the belt.
forward threaded fender bolt hole. Removal (Cabriolet) – 1) Loosen bolts or quick release fasteners (1
12) Secure lock carrier in this position, by placing fender bolts in holes. and 2). See Fig. 26. The rear noise insulation quick-release fasteners (3)
See Fig. 11. To install, reverse placing in service position procedure. 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. NOTE: During next step, catch escaping oil using a rag.
Unclip bumper extension from catch (B). 17) Pry off securing rings (1) for caps (2) at all camshaft gears. See
3) Remove bolts and tilt front grille slightly forward and pull it out in an Fig. 24. Loosen but do not remove bolts for camshaft gears.
upward direction from bumper cover. Remove bolts (1-8) and pull side
extensions out of guide piece. See Fig. 28. Pull bumper cover forward CAUTION: If reusing timing belt, mark rotational direction of belt.
slightly. Reversing the direction can ruin timing belt.
4) If equipped, disconnect hose for headlight washer unit. Disconnect 18) Using an 8 mm hex socket wrench, turn timing belt tensioner in
connector(s) and remove bumper cover from vehicle. direction of arrow until tensioning lever pushes the tensioner together far
5) Remove left and right engine compartment covers. Remove air duct enough so pin (T40011) can be inserted into the bore of the piston and
between lock carrier and air cleaner (air duct is bolted to lock carrier). housing of tensioner. See Fig. 25. The timing belt tensioner is oil-
Install Lock Carrier Support Tool (3369) into thread on left and right side dampened. Compress it by slowly applying constant pressure. Loosen
near impact absorbers. See Figs. 9 and 29. bolt of eccentric pulley on opposite side of tensioner and remove timing
6) Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier belt.
forward until rear hole in lock carrier aligns with front threaded hole in
fender flange. See Fig. 11. NOTE: It is not necessary to completely remove noise insulation
from beneath the engine. Only remove the quick release fasteners
CAUTION: Before removing ribbed belt, mark direction of rotation that attach to the front bumper assembly.
with chalk or felt-tip marker. Reversing the direction of rotation of Removal (A6) – 1) Raise and support vehicle. Remove front tires.
a run-in belt can destroy the belt. Remove lower front engine shield (noise insulator). See Fig. 30. Loosen
7) Remove front engine cover. See Fig. 12. Using Ribbed Belt Installa- front half of wheel housing splash shield (liner). See Fig. 31. Remove
flange nut (10) on both sides. See Fig. 32.
tion 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
lock carrier and air filter on lock carrier. Remove left cover in engine
of power steering vane pump (arrows) using 3212 spanner wrench as compartment. Pull off hood seal from lock carrier and fender edges.
retainer. See Fig. 15. Remove 8 bolts attaching harmonic balancer to 4) Release catches (1-4) using a screwdriver and remove air inlet grille
crankshaft and remove balancer. Remove thrust washer if equipped. 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
number 06C 105 063. Thrust washer is NOT installed for timing belt (5). See Fig. 32. Disconnect any wiring harness that attach to the front
gear with part number 06C 105 063 B. bumper. Remove socket-head bolts (7) and remove bumper cover
9) Without disconnecting coolant hoses, remove bolts (1, 2) attaching together with impact absorber towards front. See Fig. 32.
front coolant pipe (3) and remove timing belt guards (4, 5, 6). See 6) Inspect headlight and turn signal harness connectors and wiring
Fig. 16. harness (which may hang up when lock carrier is moved forward).
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.
See Fig. 10.
Without disconnecting coolant hoses, tie expansion tank off to side.
9) Remove on both sides, all (2, 3 and 4) bolts. See Fig. 8. Slide lock
11) Disconnect electrical harness connector (1) at Mass Air Flow (MAF) carrier forward unit the rear bolt hole in lock carrier aligns with the
sensor. See Fig. 17. Remove air guide hose (2) together with Mass Air forward threaded fender bolt hole.
Flow (MAF) sensor. Remove air filter housing (arrows). 10) Secure lock carrier in this position, by placing fender bolts in holes.
12) Remove bolts (1) and (3). See Fig. 18. Disconnect hose (4) from line See Fig. 11. To install, reverse placing in service position procedure.
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. CAUTION: Before removing ribbed belt, mark direction of rotation
13) Remove ignition coils from right valve cover. Remove hose of with chalk or felt-tip marker. Reversing the direction of rotation of
crankshaft housing ventilation located at rear of valve cover. Remove a run-in belt can destroy the belt.
bolts for right valve cover in the sequence 12 to 1 and remove valve 11) Remove front engine cover. See Fig. 12. Using Ribbed Belt
cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20. Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner
in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of
CAUTION: Turning of the engine must only occur in direction of power steering pump.
engine rotation (clockwise) at the crankshaft.
14) Turn engine at crankshaft central bolt. Turn engine until the cams number 06C 105 063. Thrust washer is NOT installed for timing belt
(arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder gear with part number 06C 105 063 B.
bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster
Gauge (T40030) at camshafts of right cylinder head. See Fig. 22. 12) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear
of power steering vane pump using 3212 spanner wrench as retainer.
15) Slightly turn crankshaft back and forth so that the claw of camshaft
See Fig. 15. Remove 8 bolts attaching harmonic balancer to crankshaft.
adjuster gauge can properly grab the camshafts. Spread and tighten
Remove thrust washer.
camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until
13) Without disconnecting coolant hoses, remove bolts (1 and 2)
seated without axial play. Repeat procedure for left cylinder head.
attaching front coolant pipe (3) and remove timing belt guards (4, 5, and
16) If installed, disconnect electrical harness connector at after-run 6). See Fig. 16.
coolant pump. Remove sealing plug of TDC mark at cylinder block. 14) Remove rear engine cover at rear of intake manifold. Remove screw
Install Locking Pin (T40026) into the hole of the removed sealing plug attaching expansion tank to vehicle. Disconnect Engine Coolant Level
and tighten. See Fig. 23. Slightly turn crankshaft back and forth to allow (ECL) warning switch harness connector at bottom of expansion tank.
locking pin to bottom in crankshaft properly. Without disconnecting coolant hoses, tie expansion tank off to side.
88 AUDI
15) Disconnect Evaporative Emission (EVAP) Canister Purge Regulator 5) Insert caps with new “O” rings at camshaft gears and secure with ring.
Valve (1) at air filter housing. Disconnect Mass Air Flow (MAF) sensor Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove
harness connector (2). See Fig. 35. Remove air guide hose (3) together Alignment Bolt (T10026) and install sealing plug of TDC marking with
with MAF sensor. Remove air filter housing (arrows). new “O” ring into cylinder block. See Fig. 23. Install valve covers and
16) Remove bolts (1 and 3). See Fig. 18. Disconnect hose (4) from line tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See
of secondary air injection. Pull out dipstick tube (2) from the oil pan Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to
(upper part) toward top and swing it forward for removal. specification. See TORQUE SPECIFICATIONS.
17) Remove ignition coils from right valve cover. Remove hose of 6) To install lock carrier, reverse removal procedures outlined in
crankshaft housing ventilation located at rear of valve cover. Remove REMOVAL (A4). Torque all fasteners to specification. See TORQUE
bolts for right valve cover in the sequence 12 to 1 and remove valve SPECIFICATIONS. Let support stop rest on rubber buffer for torque
cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20. support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See
Fig. 40.
CAUTION: Turning of the engine must only occur in direction of
engine rotation (clockwise) at the crankshaft. NOTE: Before installing bumper, check for the presence of
threaded pins at bumper rear edge as well as expanding clips and
18) Turn engine at crankshaft central bolt. Turn engine until the cams
sleeves in the fenders. Always replace bumper retaining bolts.
(arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder
bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster 7) Slide bumper onto impact absorber and re-connect hose (1) of
Gauge (T40030) at camshafts of right cylinder head. See Fig. 22. headlight cleaning system and electrical harness connectors (2). See
19) Slightly turn crankshaft back and forth so that the claw of camshaft Fig. 7. Move bumper into installation position. Make sure threaded pins
adjuster gauge can properly grab the camshafts. Spread and tighten in bumper side edges engage into holes at the fenders. Install bumper
camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until it retaining bolts until bumper can stay in place without any assistance.
is seated without axial play. 8) Do not tighten completely allowing for any necessary adjustments.
20) Repeat procedure for left cylinder head. If installed, disconnect Pull back wheelhousing liner (arrow A). See Fig. 3. Engage bumper rear
electrical harness connector at after-run coolant pump. Remove sealing edge into catch (arrow B). Torque nuts. Repeat procedure on opposite
plug of TDC mark at cylinder block. Install Locking Pin (T40026) into the side of the vehicle. Torque left and right retaining bolts to specification.
hole of the removed sealing plug and tighten. See Fig. 23. Slightly turn See TORQUE SPECIFICATIONS. Install left and right air inlet grille on
crankshaft back and forth to allow locking pin to bottom in crankshaft bumper. Remainder of installation is the reverse of removal.
properly.
CAUTION: Before installation, ensure camshafts are aligned,
NOTE: During next step, catch escaping oil using a rag. crankshaft is locked in place and camshaft gear bolts are loose as
21) Pry off securing rings (1) for caps (2) at all camshaft gears. See described in removal procedures. When turning camshaft, crank-
Fig. 24. Loosen but do not remove bolts for camshaft gears. shaft must not be at TDC for any cylinder. Valves and/or pistons
may be damaged.
CAUTION: Mark rotational direction of timing belt. Reversing the
direction in which it runs can ruin it. Installation (Cabriolet) – 1) Ensure bolts (1-4) attaching camshaft
gears are in far enough to allow camshaft gears to spin freely without
22) Using an 8 mm hex socket wrench, turn timing belt tensioner in wobbling. See Fig. 36. Install timing belt. For exact valve timing
direction of arrow until tensioning lever pushes the tensioner together far adjustment, the timing belt must make exact contact with front edge of
enough so pin (T40011) can be inserted into the bore of the pistons and
all timing belt gears.
housing. See Fig. 25. The timing belt tensioner is oil-dampened.
2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise
Compress it by slowly applying constant pressure. Loosen bolt of
direction until the handle of the pin wrench is exactly above the center
eccentric pulley on opposite side of tensioner and remove timing belt.
axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this
CAUTION: Before installation, ensure camshafts are aligned, position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench
crankshaft is locked in place and camshaft gear bolts are loose as horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45
described in removal procedures. When turning camshaft, crank- N.m) in direction of arrow to pre-tension timing belt. See Fig. 38.
shaft must not be at TDC for any cylinder. Valves and/or pistons 3) Using 8 mm socket head wrench, turn timing belt tensioning roller in
may be damaged. opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25.
Installation (A4) – 1) Ensure bolts (1-4) attaching camshaft gears are in Place torque wrench horizontally on socket-head of tensioning lever.
far enough to allow camshaft gears to spin freely without wobbling. See Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt.
Fig. 36. Install timing belt. For exact valve timing adjustment, the timing See Fig. 38.
belt must make exact contact with front edge of all timing belt gears. 4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on
2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs.
direction until the handle of the pin wrench is exactly above the center (10 N.m) up to stop. See Fig. 39. Turn rotor of camshaft adjuster at right
axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this cylinder bank clockwise to 7.5 ft. lbs. (10 N.m) up to stop. Torque bolts
position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench for all four camshaft gears to 74 ft. lbs. (100 N.m).
horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45 5) Insert caps with new “O” rings at camshaft gears and secure with ring.
N.m) in direction of arrow to pre-tension timing belt. See Fig. 38. Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove
3) Using 8 mm socket head wrench, turn timing belt tensioning roller in Alignment Bolt (T10026) and install sealing plug of TDC marking with
opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25. new “O” ring into cylinder block. See Fig. 23. Install valve covers and
Place torque wrench horizontally on socket-head of tensioning lever. tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See
Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt. Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to
See Fig. 38. specification. See TORQUE SPECIFICATIONS.
4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on
6) To install lock carrier, reverse removal procedures outlined in
left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs.
REMOVAL (CABRIOLET). Torque all fasteners to specification. See
(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).
AUDI 89
NOTE: Prior to installation of the bumper cover check for presence NOTE: The impact absorber is installed vertical to the cross mem-
of threaded pins (2) at the bumper extensions as well as grommets ber and has height compensating elements. See Fig. 33.
(3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m). 9) Torque left and right retaining bolts to specification. See TORQUE
7) To install bumper cover, reverse removal procedures outlined in SPECIFICATIONS. Install left and right air inlet grille on bumper.
REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and Remainder of installation is the reverse of removal.
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. Courtesy of Audi of America, Inc.
CAUTION: Before installation, ensure camshafts are aligned, Fig. 1: Removing Under-Car Noise Insulation (A4)
crankshaft is locked in place and camshaft gear bolts are loose as
described in removal procedures. When turning camshaft, crank-
shaft 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 Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts (A4 & A6)
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
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. Courtesy of Audi of America, Inc.
8) Latch bumper cover (1) into guide (2). See Fig. 32. Torque flange nuts
Fig. 3: Locating Wheelhousing Fasteners (A4)
(10) to 53 INCH lbs. (6 N.m).
90 AUDI
Fig. 4: Identifying Front Bumper-To-Fender Fasteners (A4)
Fig. 8: Identifying Lock Carrier Components (A4 & A6)
Fig. 5: Removing Grilles (A4 & A6)
Fig. 9: Identifying Support Tool (Part No. 3369)
Fig. 6: Identifying Bumper Fasteners (A4 & A6)
Fig. 10: Installing Support Tool (3369) Into Chassis (A4 & A6)
Fig. 7: Identifying Washer Hoses & Harness Connectors (A4)

AUDI 91

Fig. 14: Identified Ribbed Belt Tensioner Bolts
Fig. 12: Identifying Front Engine Cover Courtesy of Audi of America, Inc.
Fig. 15: Removing/Installing Power Steering Vane Pump Pulley
Fig. 13: Removing/Installing Ribbed Belt
Fig. 16: Identifying Timing Belt Guards

92 AUDI

Fig. 20: Left Valve Cover Bolt Sequence
Fig. 17: Air Filter Housing Components
Fig. 21: Lining Up Cylinder #3 Camshaft Lobes

(Right Cylinder Bank)
Fig. 18: Identifying Secondary Air Injection Component
Fig. 22: Installing Cam Adjuster Gauge On Cam Lobes

(Right Bank Shown; Left Bank Similar)
Fig. 19: Right Valve Cover Bolt Sequence

AUDI 93
Fig. 23: Installing Locking Pin Into Cylinder Block
Fig. 26: Identifying Bumper Cover Fasteners (Cabriolet)
Fig. 24: Removing Securing Rings
Fig. 27: Identifying Bumper Cover Fasteners At Wheel Opening

(Cabriolet)
Fig. 25: Compressing & Securing Timing Belt Tensioner
Fig. 28: Removing Bumper Cover (Cabriolet)

94 AUDI
Fig. 29: Exploded View Of Lock Carrier Components (Cabriolet)
Fig. 30: Identifying Lower Engine Shield (Noise Insulator)

Mounting Points (A6)
Fig. 31: Identifying Wheel Housing Liner Components (A6)

AUDI 95
Fig. 32: Identifying Front Bumper Components (A6) Courtesy of Audi of America, Inc.
Fig. 34: Identifying Bumper Guide Components (A6)
Fig. 33: Identifying Bumper Attaching Point To Impact Absorber (A6)

96 AUDI
Fig. 35: Identifying EVAP & MAF Connectors (A6) Fig. 38: Adjusting Timing Belt Tension (A4 & A6)
Fig. 36: Timing Belt Routing (A4 & A6) Fig. 39: Preloading Camshaft Adjuster (Left Shown;
Right Is Similar – A4 & A6)
Fig. 40: Identifying Torque Support Bolts (A4 & A6)
Fig. 37: Adjusting Eccentric Pulley (A4 & A6)
Fig. 41: Bumper Cover Gaps (Cabriolet)

AUDI 97

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 ........................................................................................... 89 (10)
Front Coolant Pipe Bolts ........................................................................................... 89 (10)
Valve Cover Bolts ...................................................................................................... 89 (10)
1
– Use NEW bolts.
Fig. 42: Identifying Bumper Cover Attaching Points For

Removal & Installation (A6)
98 AUDI
3.6L & 4.2L V8 – 1990-94
TIMING BELT APPLICATION 11) Noting positions for reassembly, disconnect ignition secondary wires
Application Labor Time Belt at ignition coils. Remove both ignition distributor caps.
Part No. 12) Rotate crankshaft to TDC of compression stroke. Ensure TDC mark
3.6L V8 (PT Engine) on crankshaft pulley aligns with mark on timing belt cover. See Fig. 10.
V8 Quattro 13) Ensure distributor rotor points to mark on distributor housing. If not,
1990-91 ..................................................... 4.3 Hours ... ..... T207 turn crankshaft one more revolution. See Fig. 11. Remove both distribu-
4.2L V8 (ABH Engine) tors.
V8 Quattro 14) For 3.6L engine, loosen stop plate at timing belt tensioner. See
1992-94 ..................................................... 4.3 Hours ... ..... T207 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
NOTE: For information about tensioners and/or pulleys (when timing belt damper top bolt. Remove timing belt tensioner pulley with
available), see ALPHABETICAL MODEL LISTING. eccentric center.
15) Fit Locating Flange (3199) at end of each camshaft. Locating pin on
MANUFACTURER’S SUGGESTED distributor flange should fit in slot in locating flange. See Fig. 14. Secure
locating flange with distributor mounting bolts.
SCHEDULED MAINTENANCE 16) Using spanner wrench, hold camshaft sprocket. Loosen camshaft
The manufacturer recommends belt be replaced at 60,000 miles on 3.6L sprocket bolts about 2 turns. DO NOT use Locating Flange (3199) to
engines, and 90,000 miles on 4.2L engines. Replacement interval hold camshaft while loosening sprocket bolt.
revision is from Audi technical service bulletin 93-02, September 1, 17) Using a plastic hammer, LIGHTLY tap edge of camshaft sprockets
1993. until camshaft sprockets are loose. Remove camshaft sprocket Woo-
druff keys.
18) Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket.
REMOVAL & INSTALLATION Remove crankshaft center bolt and remove crankshaft pulley. It is not
necessary to remove sprocket from crankshaft. Remove timing belt.
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. Courtesy of Audi of America, Inc.
3) Working from under vehicle, remove lower timing belt cover. In engine
compartment, remove bolt securing intake air ducts. Remove left and Fig. 1: Locating Coolant Temperature Sensor
right side intake air ducts. Remove upper part of air cleaner housing and Inspection – Inspect tensioner and idler pulley for ease of rotation and
air filter. rough bearings. Replace as necessary.
4) Remove bolts securing lower part of air cleaner housing. Lift out lower Installation – 1) Ensure crankshaft is still at TDC position. Place timing
part of air cleaner housing. Remove upper radiator hose. Remove belt over crankshaft sprocket. Install crankshaft pulley on crankshaft.
electric cooling fan bolts. See Fig. 4. Remove electric cooling fan. Install 4 bolts that hold crankshaft pulley to sprocket. Hand tighten
Remove serpentine belt. temporarily.
5) Remove lower radiator hose from thermostat housing. Move lower 2) Apply locking sealant (AMV 188 0012), or equivalent, to crankshaft
radiator hose to right at rear. Remove viscous fan shroud. Remove bolts center bolt threads. Install crankshaft pulley center bolt and hand tighten
securing viscous fan to pulley and remove fan. temporarily.
6) Disconnect fan shrouds for viscous fan and electric fan. 3) Loosen camshaft sprocket center bolts by about 1 turn. Camshaft
7) Hold viscous cooling fan mount with a spanner wrench. Loosen sprocket should still be loose on camshaft. Install Vibration Damper
viscous cooling fan by turning clockwise. Viscous cooling fan is LEFT- Locking Tool (3211). If there is no hole to accept Vibration Damper
HAND threaded. See Fig. 5. Lift out fan and shroud. Locking Tool, ensure TDC mark on vibration damper is aligned with
8) Remove front engine support mount. Note number and position of pointer before and after tightening camshaft sprockets.
shims for reassembly. Remove lower radiator hose. Loosen center bolt 4) Position timing belt in position over idler pulleys, water pump pulley
of crankshaft pulley one turn while using Crankshaft Pulley Holder and camshaft sprockets. Install tensioner pulley with eccentric center.
(3197). See Fig. 6. Leave center nut loose so that eccentric can be turned. Fully tighten 4
9) Remove flanged nuts and left side timing belt cover. See Fig. 7. crankshaft pulley bolts to specification. See TORQUE SPECIFICA-
Remove lower radiator hose support from front of engine. TIONS.
10) Turn serpentine belt tensioner clockwise and insert Setting Tool 5) On 3.6L engine, insert Adjusting Tool (3204) into tensioner lever so
(3204) below mounting bolt. See Figs. 8 and 9. Remove 2 lower that tool engages recess on back of stop plate. See Fig. 15. Firmly press
mounting bolts from right side timing belt cover. Do not loosen upper tensioner lever once by hand clockwise. See Fig. 16.
mounting bolt yet. Remove Setting Tool (3204). Remove top mounting 6) On 3.6L and 4.2L engines, set basic timing belt tension by turning
bolt from right side timing belt cover. Remove right side timing belt cover. tensioner pulley with eccentric center in clockwise direction. Use span-
AUDI 99
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
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 neces-
sary. 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 212°F (100°C). 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.
Fig. 2: Exploded View Of Serpentine Belt Assembly

100 AUDI
3.6L & 4.2L V8 – 1990-94 (Cont.)
Fig. 5: Removing Viscous Cooling Fan (Left-Hand Thread)

Fig. 3: Removing Serpentine Belt
Fig. 6: Loosening Crankshaft Pulley Center Bolt
Fig. 4: Removing Electric Cooling Fan
Fig. 7: Removing Left Side Timing Belt Cover

AUDI 101
3.6L & 4.2L V8 – 1990-94 (Cont.)
Fig. 8: Exploded View Of Timing Belt Assembly
Fig. 10: Aligning Crankshaft Pulley Timing Marks
Fig. 9: Positioning Serpentine Belt Tension

102 AUDI
3.6L & 4.2L V8 – 1990-94 (Cont.)
Fig. 11: Aligning Distributor Rotor To Housing Fig. 14: Positioning Camshafts With Locating Flange (3199)
Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate

(3.6L Engine)
Fig. 13: Timing Belt Tensioner With Eccentric Center Fig. 16: Rotating Tensioner Lever In Direction Of Arrow
AUDI 103
3.6L & 4.2L V8 – 1990-94 (Cont.)

Alternator Bottom Mount Bolt ................................................................................... 18 (25)
Alternator Top Mounting Bolt .................................................................................... 33 (45)
Crankshaft Pulley Center Bolt ............................................................................ 1 332 (450)
Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 18 (25)
Engine Front Support Mount Bolt ............................................................................. 30 (40)
Serpentine Belt Idler Pulley Bolt .............................................................................. 18 (25)
Timing Belt Adjustment Damper Bolts ...................................................................... 18 (25)
Timing Belt Damper Mount Bolt ............................................................................... 18 (25)
INCH Lbs. (N.m)
Fan Shroud Bolts ...................................................................................................... 89 (10)
Stop Plate Mounting Bolt (3.6L) ............................................................................... 89 (10)
Timing Belt Cover Flanged Nut ................................................................................ 89 (10)
Fig. 17: Setting Timing Belt Damper Length Water Pump Bolts ..................................................................................................... 89 (10)
1
– Install with thread locking sealant AMV 18800102.
104 AUDI
3.7L & 4.2L V8 – 1997-99
TIMING BELT APPLICATION TIMING BELT
Part No. CAUTION: If serpentine or timing belt are being reused, mark belt
3.7L V8 (AEW Engine) with an arrow indicating direction of rotation. Damage may result if
A8 belts are installed in opposite direction of rotation.
1997-99 ..................................................... 4.9 Hours ... ..... T207 Removal – 1) Disconnect negative battery cable. Remove noise insu-
4.2L V8 (ABZ Engine)
lation panel from under front of vehicle. Remove air intake grille from
A8 Quattro
1997-99 ..................................................... 4.9 Hours ... ..... T207 front of bumper. Drain coolant from radiator.
2) Using box wrench, turn serpentine belt tensioner clockwise to relieve
NOTE: For information about tensioners and/or pulleys (when tension. Remove serpentine belt. See Fig. 1. Remove engine top trim
available), see ALPHABETICAL MODEL LISTING. cover. Remove coolant hose retaining clamp on right side upper timing
belt cover.
3) Remove air intake duct between air cleaner and throttle body.
MANUFACTURER’S SUGGESTED Disconnect fan shrouds for viscous fan and electric fan.
SCHEDULED MAINTENANCE 4) Hold viscous cooling fan pulley with a spanner wrench. Remove
viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded.
For 1997 and 1998 model vehicles, manufacturer recommends belt be
See Fig. 2.
replaced at 90,000 miles. For 1999 model year, the manufacturer
5) Remove right front engine mount. See Fig. 3. Remove coolant hoses
recommends the belt be replaced at 75,000 miles.
at front of engine. Rotate crankshaft to TDC of compression stroke.
Ensure TDC mark on crankshaft pulley aligns with mark on timing belt
REMOVAL & INSTALLATION cover. See Fig. 4.

damage may occur.
Fig. 1: Exploded View Of Serpentine Belt Assembly

AUDI 105
3.7L & 4.2L V8 – 1997-99 (Cont.)
CAUTION: Manufacturer recommends that crankshaft pulley cen-

ter 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 Courtesy of Audi of America, Inc.
plate and housing. See Fig. 6. Install Camshaft Locking Device (3341) at Fig. 3: Removing Right Front Engine Mount
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.
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. Courtesy of Audi of America, Inc.
Remove crankshaft center bolt and remove crankshaft pulley. It is not
Fig. 4: Aligning Crankshaft Pulley TDC Marks
necessary to remove sprocket from crankshaft. Remove timing belt.
Fig. 5: Loosening Crankshaft Pulley Center Bolt

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.
Fig. 2: Removing Viscous Cooling Fan (Left-Hand Thread) 4) Push timing belt over tensioner pulley. Tighten tensioner pulley center
nut hand tight. Eccentric insert should still be able to turn.
Installation – 1) Ensure crankshaft is still at TDC position. Place timing 5) Tighten 4 crankshaft pulley-to-crankshaft sprocket mounting nuts.
belt over crankshaft sprocket. Install crankshaft pulley on crankshaft. See TORQUE SPECIFICATIONS.
Install 4 bolts that hold crankshaft pulley to sprocket. Hand tighten 6) To set basic timing belt tension, turn tensioner pulley eccentric insert
temporarily. clockwise. Use a spanner wrench inserted into the 2 holes in the
eccentric insert. Adjust position of timing belt tensioner until damper
CAUTION: Manufacturer recommends that crankshaft pulley cen-
length is within specified range. See Fig. 11.
ter bolt be REPLACED whenever the bolt is loosened or removed.
7) Tighten timing belt tensioner center nut to specification. See
2) Lightly oil threads and contact surfaces of NEW center bolt. Using TORQUE SPECIFICATIONS. Holding camshaft sprockets in place,
locking compound AMV 00102, or equivalent, install crankshaft pulley tighten camshaft sprocket center bolts to specification.
center bolt and hand-tighten temporarily.
106 AUDI
3.7L & 4.2L V8 – 1997-99 (Cont.)
Courtesy of Audi of America, Inc. Fig. 8: Installing Camshaft Locking Device (3341)
Fig. 6: Locating Camshaft Position Sensor & Housing 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.

Fig. 7: Loosening Camshaft Sprocket Bolts
8) Remove Camshaft Locking Device (3341) from rear of each cam- Camshaft Position Sensor Housing Bolt .................................................................. 15 (20)
shaft. Install housing behind camshaft position sensor and tighten bolts Camshaft Sprocket Bolt ............................................................................................ 41 (55)
to specification. Camshaft position sensor plate MUST engage in Crankshaft Pulley Center Bolt ............................................................................ 1 332 (450)
camshaft with catch. Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 18 (25)
9) Turn crankshaft at least 2 revolutions in normal direction of rotation. Serpentine Belt Idler Pulley Bolt .............................................................................. 18 (25)
Tighten crankshaft center bolt to specification. Check timing belt damper Timing Belt Adjustment Damper Bolts ...................................................................... 18 (25)
length. Readjust timing belt tension, if necessary. Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25)
10) To complete installation, reverse removal procedure. When refilling Timing Belt Tensioner Nut ........................................................................................ 18 (25)
cooling system, use Audi coolant additive G12-A8D TL 774D (Red INCH Lbs. (N.m)
color). Use 50/50 mix of coolant and water. Timing Belt Cover Flanged Nut ................................................................................ 89 (10)
11) Before filling cooling system, open vent screws at heater core feed Water Pump Bolts ..................................................................................................... 89 (10)
and return lines (rear of engine). Remove cap from radiator expansion 1
tank. Add coolant until it flows from vent valves. Close vent valves. – Use NEW bolt if loosened or removed. Oil threads. Install with thread locking compound
AMV 00102, or equivalent.
Install cap on radiator expansion tank.
AUDI 107
3.7L & 4.2L V8 – 1997-99 (Cont.)
Fig. 10: Locating Timing Belt Tensioner Pulley

Fig. 11: Adjusting Timing Belt Damper Length

108 AUDI
4.2L V8 – AKB, AUX & AYS Engines – A8 & S8
TIMING BELT APPLICATION sprocket. Remove timing belt along with camshaft sprocket for cylinders
Application Labor Time Belt No. 1 through No. 4 (passenger side cylinder head).
Part No.
4.2L V8 (AKB, AUX & AYS Engines)
A8
2000-03 ..................................................... 4.9 Hours ... ..... T297
S8
2001-03 ..................................................... 4.9 Hours ... ..... T297

The manufacturer recommends belt be replaced at 105,000 miles.

damage may occur.

TIMING BELT
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 Courtesy of Audi of America, Inc.
TDC mark on vibration dampener aligns with mark on engine. See
Fig. 3. Fig. 2: Removing & Installing Serpentine Belt
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.
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 cam-
shafts. See Fig. 8. Courtesy of Audi of America, Inc.
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
AUDI 109
4.2L V8 – AKB, AUX & AYS Engines – A8 & S8 (Cont.)
Fig. 4: Aligning Camshaft Sprocket Securing Plate Holes
Fig. 7: Relieving Timing Belt Tension
Fig. 5: Locating Crankshaft Clamping Bolt (3242)
Fig. 8: Installing Camshaft Bar (T40005)

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 counter-
clockwise until Spring Pin (T40011) can be removed from hydraulic
tensioner.
Courtesy of Audi of America, Inc. 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
Fig. 6: Locating Viscous Cooling Fan Mounting Bracket
hydraulic tensioner body. Tighten camshaft sprocket bolts to specifica-
Installation – 1) Ensure crankshaft is still at TDC position. Place timing tion. See TORQUE SPECIFICATIONS. Keep Camshaft Bar (T40005) in
belt over crankshaft sprocket, tensioner pulleys, camshaft sprocket for place to prevent camshafts from moving.
cylinders No. 5 through No. 8, water pump pulley and dampener pulley. 7) Remove Camshaft Bar (T40005) after camshaft sprocket bolts are
Then take camshaft sprocket for cylinder bank 1-4, install toothed belt tightened. Remove 7-mm drill bit. Remove Crankshaft Clamping Bolt
and bolt sprocket onto camshaft. (3242) from side of engine block. Install sealing plug in hole. Turn
2) Lightly secure both camshaft sprockets with securing plates by crankshaft 2 revolutions in normal direction of rotation.
tightening hand-tight. Camshaft sprockets must be tight enough on 8) Measure distance between tensioning lever and top of hydraulic
camshaft tapers to be turned, but should not tilt back and forth. 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).
110 AUDI
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.
Fig. 11: Measuring Timing Belt-To-Guard Clearance

(Right-Side Cylinder Head)
Fig. 9: Setting Initial Timing Belt Tension
Fig. 12: Measuring Timing Belt-To-Guard Clearance

(Left-Side Cylinder Head)
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)
Courtesy of Audi of America, Inc. INCH Lbs. (N.m)
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 12) Using a 19-mm wrench, rotate drive belt tensioner clockwise to
Application Labor Time Belt loosen belt tensioner. Secure belt tensioner using Drift (3204). Remove
Part No. drive belt. Ensure belt has no splits, cracks or other damage. Replace
4.2L V8 (ART, AWN & BBD Engines) drive belt if necessary. See Fig. 13.
A6 Quattro 13) Remove upper cylinder head covers. Disengage clips and remove
2000-04 ..................................................... 6.4 Hours ... ..... T297 timing belt cover. Remove noise insulation panel. Rotate crankshaft by
S6 Avant Quattro to Top Dead Center (TDC). See Fig. 14.
2002-03 ..................................................... 6.4 Hours ... ..... T297 14) Check position of camshafts. Larger holes of camshaft securing
NOTE: For information about tensioners and/or pulleys (when plates (located on front of camshaft sprockets) must be on inside and
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 15) Remove sealing plug from alignment access hole in left side of
SCHEDULED MAINTENANCE engine block. Ensure that hole in crankshaft is visible through alignment
The manufacturer recommends belt be replaced at 105,000 miles under access hole. Install Crankshaft Holder (3242) into alignment access hole
normal driving conditions, and 52,500 miles under severe driving to prevent crankshaft from rotating. See Fig. 16.
conditions. 16) Remove accessory drive belt tensioner. Loosen 8 Allen-headed
bolts and remove crankshaft vibration damper (center bolt does not
REMOVAL & INSTALLATION have to be removed). Remove engine torque support. See Fig. 17.
CAUTION: This application is an interference engine. Do not rotate NOTE: Timing belt tensioner is oil-dampened. Compress it by
camshaft or crankshaft when timing belt is removed, or engine slowly applying constant pressure.
damage may occur.
17) Using an 8-mm wrench, turn timing belt tensioning roller clockwise
until tensioning lever compresses tensioner so a pin (2 mm in diameter)
TIMING BELT can be inserted into plunger. See Fig. 18. Insert pin and release tension.
18) Install Camshaft Locator Bar (3391) into camshaft locking plates.
NOTE: Lock carrier is slid forward onto alignment tools to allow Loosen camshaft bolts and back bolts out 5 turns. Remove camshaft
servicing of front engine components. Lock carrier can be locator bar. Using Camshaft Sprocket Puller (T40001), remove camshaft
removed at technician’s discretion. 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.
lock carrier and air filter on lock carrier. Remove left cover in engine Courtesy of Audi of America, Inc.
compartment. Pull off hood seal from lock carrier and fender edges. Fig. 1: Identifying Lower Engine Shield (Noise Insulator)
4) Release catches (1-4) using a screwdriver, and remove air inlet grille Mounting Points
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). CAUTION: Before installation, ensure camshafts are aligned,
See Fig. 3. Disconnect any wiring harness that attaches to the front crankshaft is locked in place and camshaft gear bolts are loose as
bumper. Remove socket-head bolts (7), and remove bumper cover described in removal procedures. When turning camshaft, crank-
together with impact absorber towards front. See Fig. 3. shaft must not be at TDC for any cylinder. Valves and/or pistons
6) Inspect headlight and turn signal electrical connectors and wiring may be damaged.
harness (which may hang up when lock carrier is moved forward).
7) On passenger’s side, remove bolt (5) and install Support Tool (3369) Installation – 1) Install timing belt first to crankshaft, then to tensioner,
in its place. See Figs. 8 and 9. water pump, timing belt tensioning roller and right camshaft sprocket.
8) On driver’s side, install Support Tool (3369) in threaded hole in See Fig. 20. Install left camshaft sprocket to camshaft with timing belt,
chassis. See Fig. 10. and hand tighten camshaft sprocket bolts. Camshaft sprockets must be
9) Remove bolts (2, 3 and 4) from both sides. See Fig. 8. Slide lock able to move on tapered camshaft.
carrier forward unit the rear bolt hole in lock carrier aligns with the 2) Install Camshaft Holding Bar. See Fig. 21. Insert a 5-mm drill bit
forward-threaded fender bolt hole. between timing belt tensioner and tensioner piston. See Fig. 22. Using
10) Secure lock carrier in this position by placing fender bolts in holes. Spanner (T40009) and torque wrench, apply 35 INCH lbs. (4 N.m) to
See Fig. 11. timing belt tensioning roller. See Fig. 23. Remove drill bit.
3) Using an 8-mm Allen wrench, turn timing belt tensioner clockwise until
NOTE: Fan clutch is fitted with left-handed threads. Turn clockwise
tensioning lever compresses and remove pin. See Fig. 18. Continue
to loosen.
turning timing belt tensioner clockwise until a 7-mm drill bit can be
11) Remove air intake hose to air cleaner. Remove engine cover. See inserted between timing belt tensioner and tensioner piston. Tighten
Fig. 12. Using Spanner Wrench (3212) to hold fan clutch pulley, use camshaft sprockets to 41 ft. lbs. (55 N.m).
Open-End Spanner (3312) or equivalent to loosen fan clutch. Remove
radiator fan and fan shroud from vehicle.
112 AUDI
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 SPECIFICA-
TIONS.
REMOVAL. Torque all fasteners to specification. See TORQUE SPECI-
FICATIONS. 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 mem-

ber 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)

Fig. 2: Identifying Wheelhousing Liner Components
Fig. 4: Identifying Front Bumper Components (2 Of 2)
AUDI 113

Fig. 5: Identifying Auxiliary Heater Exhaust Pipe Bolts
Fig. 9: Identifying Support Tool (3369)
Fig. 6: Removing Grilles

Fig. 10: Installing Support Tool (3369) Into Chassis
Fig. 7: Identifying Bumper Fasteners
Fig. 12: Removing Engine Cover

Fig. 8: Identifying Lock Carrier Components

114 AUDI
Fig. 13: Drive Belt Routing
Fig. 16: Installing Crankshaft Holder
Fig. 17: Removing Engine Torque Support
Fig. 15: Aligning Camshaft Securing Plates

AUDI 115
Fig. 19: Installing Sprocket Puller
Fig. 23: Tensioning Timing Belt Tensioning Roller
Fig. 24: Checking Timing Belt Tensioner Adjustment

Fig. 21: Installing Camshaft Holding Bar
Fig. 22: Setting Up Timing Belt Tensioner

116 AUDI
Fig. 27: Identifying Bumper Cover Attaching Points For

Removal & Installation
Fig. 25: Checking Timing Belt Guard Adjustment
Fig. 26: Identifying Torque Support Bolts

AUDI 117
Fig. 28: Identifying Bumper Attaching Point To Impact Absorber
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 ........................................................................................... 89 (10)
Valve Cover Bolts ...................................................................................................... 89 (10)
1
– Use NEW bolts.
118 AUDI & VOLKSWAGEN
2.1L & 2.2L 5-Cylinder, 1978-91
Part No. TIMING BELT
2.1L 5-Cyl. Removal – 1) Disconnect negative battery cable. Remove upper
Quantum radiator cover. Remove drive belts. Remove power steering pump with
1984-85 pressure hoses connected. Set pump aside. Remove valve cover and
.70″ Belt T.W. ......................................... 1 2.3 Hours .. ..... T127
outer timing belt covers. See Fig. 1.
.75″ Belt T.W. ......................................... 1 2.3 Hours .. ..... T065
2.2L 5-Cyl. 2) Using crankshaft bolt, turn crankshaft clockwise to TDC of No. 1
Coupe cylinder compression stroke. Align timing mark on back of camshaft
1981-83 ..................................................... 1.8 Hours ... ..... T065 sprocket with upper edge of gasket. See Fig. 2.
1984-85 3) Loosen water pump adjusting bolts to relieve tension on timing belt.
113 Tooth Belt ........................................ 1.8 Hours ... ..... T065 Remove timing belt. Remove water pump to check “O” ring. DO NOT
120 Tooth Belt ........................................ 1.8 Hours ... ..... T127 allow crankshaft or camshaft to move.
1986-87 ..................................................... 1.8 Hours ... ..... T127
Quantum
1983-85
.70″ Belt T.W. ......................................... 1 2.3 Hours .. ..... T127
.75″ Belt T.W. ......................................... 1 2.3 Hours .. ..... T065
1986
.70″ Belt T.W. .......................................... 2.3 Hours ... ..... T127
.75″ Belt T.W. .......................................... 2.3 Hours ... ..... T065
1987-88 ..................................................... 2.3 Hours ... ..... T127
Quattro
1983 ........................................................... 1.8 Hours ... ..... T065
1984-85
200
1989
Thru Chassis No. 44 K 400 000 ........... 2.5 Hours ... ..... T127
From Chassis No. 44 K 400 001 .......... 2.5 Hours ... ..... T170
1990-91 ..................................................... 2.5 Hours ... ..... T170
200 Quattro
1989
Thru Chassis No. 44 K 004 457 ........... 2.5 Hours ... ..... T127
From Chassis No. 44 K 004 458 .......... 2.5 Hours ... ..... T170
1990-91 ..................................................... 2.5 Hours ... ..... T170
4000 Courtesy of Audi of America, Inc.
1980-81 ..................................................... 1.8 Hours ... ..... T065
4000CS
1986-87 ..................................................... 1.8 Hours ... ..... T127
4000CS Quattro
1987 ........................................................... 1.8 Hours ... ..... T127
4000S Quattro
1984-85
1986 ........................................................... 1.8 Hours ... ..... T127
5000
1978-83 ..................................................... 1.1 Hours ... ..... T065
5000CS Quattro
1987-88 ..................................................... 2.2 Hours ... ..... T127
5000S
1984-85
1986-87 ..................................................... 2.2 Hours ... ..... T127
1
– With Air Conditioning, Without Factory Air Conditioning,
With Radiator removal, labor time is 3.9 hours. Fig. 2: Aligning Camshaft Sprocket
NOTE: For information about tensioners and/or pulleys (when Installation – 1) Ensure both camshaft lobes on No. 1 cylinder point
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED be aligned with index point on transmission housing. See Fig. 3.
2) Install water pump with new sealing “O” ring. Install timing belt. Turn
SCHEDULED MAINTENANCE water pump body counterclockwise to increase belt tension. Tension is
Although the manufacturer does not recommend a specific scheduled correct when belt can be twisted 90 degrees using finger pressure at
maintenance interval, belt manufacturers suggest the belt be replaced at point midway between camshaft sprocket and water pump sprocket.
60,000 mile intervals. 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
Water Pump Bolt ....................................................................................................... 15 (20)
INCH Lbs. (N.m)
Radiator Mounting Bolts ............................................................................................ 89 (10)
Valve Cover Nuts/Bolts ............................................................................................. 89 (10)

120 BMW
TIMING BELT APPLICATION 2) Using a puller, remove vibration damper hub from crankshaft.
Application Labor Time Component Belt Remove distributor cap and rotor. Remove cover from distributor
Kit No. Part No. housing. Ensure cylinder No. 1 is set to TDC on compression stroke.
2.5L 6-Cyl. See Fig. 1. Remove alternator tension bracket and move aside.
325 Series 3) Remove front cover. Loosen timing belt tensioner mounting bolts, and
1987-88 press in on tension roller. Tighten upper mounting bolt to hold tensioner
127 Tooth Belt ................. 3.2 Hours ... ...... ..... ...... ..... T131 in place. Remove timing belt. See Fig. 2.
128 Tooth Belt ................. 3.2 Hours ... ...... ..... ...... ..... T106
1989-91 ............................... 3.2 Hours ... .. TCK131 .. ..... T131
525i
1989-95 ............................... 3.2 Hours ... ...... ..... ...... ..... T131
2.7L 6-Cyl.
325 Series
1984-88
528e
1982-88
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.

MANUFACTURER’S SUGGESTED Courtesy of BMW of North America, Inc.
SCHEDULED MAINTENANCE Fig. 1: Aligning Timing Sprockets
The manufacturer recommends the belt be replaced every 60,000 miles Installation – 1) Ensure arrow on camshaft sprocket is still aligned with
or whenever tensioner roller has been released. timing mark on cylinder head. Ensure timing mark on crankshaft
sprocket is aligned with notch in cover (about one o’clock position). See
Fig. 1.
REMOVAL & INSTALLATION 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
damage may occur.
intermediate shaft to align front cover.
4) Using new gasket, install and tighten timing belt cover. When
TIMING BELT installing crankshaft sprocket, lettering must face forward. Install
remaining components in reverse order of removal procedure. Adjust
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.
BMW 121
Courtesy of BMW of North America, Inc.
Fig. 2: Exploded View Of Camshaft Drive Assembly
Camshaft Sprocket ........................................................................ ................. 47-50 (65-70)
Intermediate Shaft Sprocket ......................................................... ................. 40-47 (55-64)
Vibration Damper Hub ............................................................................ 283-311 (390-430)
122 CHRYSLER
1.4L 4-Cylinder
1
Kit No. Part No.
1.4L 4-Cyl.
Colt
1979 .................................... 1.1 Hours ... ...... ..... ...... ..... T073
1980-84 ............................... 1.1 Hours ... .. TCK073 .. ..... T073
Champ
1979 .................................... 1.1 Hours ... ...... ..... ...... ..... T073
1980-82 ............................... 1.1 Hours ... .. TCK073 .. ..... T073
1



camshaft or crankshaft when timing belt is removed, or engine Courtesy of DaimlerChrysler Corp.
damage may occur.
Fig. 1: Removing & Installing Timing Belt
4) Check belt tension by pushing tension side of timing belt in horizon-
TIMING BELT
tally using about 11 lbs. (5 kg) force. Timing belt tooth end should be
Removal – 1) Disconnect negative battery cable. On front wheel drive
approximately 1/4 of tensioner mounting bolt head width (across flats)
models, remove air cleaner assembly, then disconnect accelerator cable
away from bolt head center. See Fig. 3. Adjust drive belts to proper
and oxygen sensor lead. On all models, mark position of spark plug
wires for installation, then remove wires from spark plugs. On front tension.
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 crank-
shaft sprocket timing mark at TDC. Do not push or shake belt while
turning or turn crankshaft in counterclockwise direction. Loosen ten- Courtesy of DaimlerChrysler Corp.
sioner spring bolt first then slotted adjustment hole bolt. Tighten ten- Fig. 2: Installing Timing Belt Tensioner
sioner bolts by tightening slotted adjustment hole bolt first and tensioner
spring bolt last.
CHRYSLER 123

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

124 CHRYSLER
1.6L 4-Cylinder – With Balance Shaft
Part No.
1.6L 4-Cyl. – SOHC
Arrow & Sapporo
1 2
1977-80 .................................................... 1.8 Hours .. ... T013
1 3
1977-80 .................................................... 1.9 Hours .. ... T062
Challenger
1 2
1978-79 .................................................... 1.8 Hours .. ... T013
1 3
1978-79 .................................................... 1.9 Hours .. ... T062
Champ
1 2
1979-80 .................................................... 1.8 Hours .. ... T013
1 3
1979-80 .................................................... 1.9 Hours .. ... T062
Colt
1 2
1977-80 .................................................... 1.8 Hours .. ... T013
1 3
1977-80 .................................................... 1.9 Hours .. ... T062
1
– Counterbalance shaft belt included in labor time. With Air
Conditioning, add .2 hours. With Power Steering, add .2 hours.
2
– Camshaft timing belt.
3
– Counterbalance shaft belt.


SCHEDULED MAINTENANCE Fig. 1: Identifying Counterbalance & Timing Belt Routing

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. Courtesy of DaimlerChrysler Corp.
3) Remove outer crankshaft sprocket and flange. Loosen center bolt on Fig. 2: Holding Counterbalance (Silent) Shaft In
counterbalance belt tensioner pulley. Remove counterbalance shaft Stationary Position
belt.
7) Ensure all camshaft timing marks are still aligned. Turn crankshaft
Installation – 1) Align counterbalance shaft and crankshaft sprocket one revolution in normal direction of rotation (clockwise). Do NOT turn
timing marks. See Fig. 3. Install counterbalance shaft belt so that there crankshaft counterclockwise.
is no slack on tension side of belt.
2) Position counterbalance shaft tensioner so that the eccentric in the CAUTION: Do NOT push or twist camshaft timing belt during final
center of the pulley is located to the left and above the bolt. See Fig. 4. tension adjustment.
Ensure pulley flange faces toward front of engine. While keeping tension
8) Loosen tensioner mounting bolt and nut. This will take any slack out
on counterbalance shaft belt, tighten tensioner pulley bolt. DO NOT
of timing belt. Final tighten tensioner mounting nut to specified torque.
allow tensioner pulley to rotate while tightening center bolt.
See TORQUE SPECIFICATIONS. Tighten tensioner mounting bolt.
3) If camshaft timing belt tensioner was removed, install tensioner.
9) To check timing belt tension, grasp camshaft timing belt between
Ensure tension spring is seated in correct position on water pump body.
thumb and forefinger. Clearance between back of timing belt and edge
See Fig. 5. Secure tensioner away from timing belt.
of rear timing case seal line should be .47″ (12 mm). See Fig. 6.
4) Install outer crankshaft sprocket. Install camshaft timing belt first on
Readjust camshaft timing belt tension, if necessary.
crankshaft sprocket, then around the oil pump sprocket and camshaft
10) Remove crankshaft pulley. Install timing belt covers. Install crank-
sprocket. Keep slack out of belt during installation. Ensure crankshaft,
shaft pulley. Tighten crankshaft sprocket center bolt and pulley bolts to
camshaft and oil sprocket timing marks are still aligned.
specification. See TORQUE SPECIFICATIONS. Install accessory drive
5) Remove screwdriver inserted in left side of engine block. Install plug.
belts. Adjust drive belts to proper tension.
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.
CHRYSLER 125
1.6L 4-Cylinder – With Balance Shaft (Cont.)
Fig. 6: Checking Camshaft Timing Belt Tension

Fig. 3: Aligning Counterbalance Shaft Timing Marks
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)
Fig. 4: Positioning Counterbalance Pulley
Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring

126 CHRYSLER
1.6L 4-Cylinder – Without Balance Shaft
TIMING BELT APPLICATION 3) Ensure all timing marks are still aligned. Temporarily install crankshaft
Application Labor Time Belt pulley.
Part No. 4) Loosen tensioner mounting bolt so that spring-loaded tensioner
1.6L 4-Cyl. – SOHC, Without Balance Shaft applies pressure to the timing belt. Lightly push tensioner up by hand to
Arrow & Sapporo ensure timing belt completely meshes with drive sprockets. Tighten
1978-80 .................................................... 1 1.6 Hours .. ..... T064 tensioner mounting nut, then tighten mounting bolt. See Fig. 3.
Challenger & Colt (RWD) 5) Turn crankshaft one turn in normal direction of rotation. Do NOT turn
1978-79 .................................................... 1 1.6 Hours .. ..... T064 in opposite direction. Loosen the timing belt tensioner mounting bolt and
Champ
nut. This will take out any slack in belt. Tighten mounting nut to specified
1979-82 ..................................................... 2.8 Hours ... ..... T064
Colt (FWD) torque. See TORQUE SPECIFICATIONS. Tighten timing belt tensioner
1979-82 .................................................... 1 2.8 Hours .. ..... T064 bolt.
1983-89 .................................................... 1 2.8 Hours .. ..... T093 6) To check timing belt tension, grasp belt between thumb and forefinger
Vista (Canadian) near timing belt tensioner. See Fig. 4. Tension is correct when distance
1989 .......................................................... 1 2.8 Hours .. ..... T093 between back of belt and edge of rear timing case cover is .47″ (12 mm)
1
– With Air Conditioning, add .2 hours. with finger pressure. Readjust tension, if necessary.
With Power Steering, add .2 hours. 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.

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.
Fig. 2: Installing Timing Belt Tensioner
Courtesy of Mitsubishi Motor Sales of America.

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 installa-
tion.
CHRYSLER 127
1.6L 4-Cylinder – Without Balance Shaft (Cont.)

Timing Belt Tensioner Nut/Bolt ..................................................... ................. 16-21 (22-29)
INCH Lbs. (N.m)

128 CHRYSLER
1.7L 4-Cylinder
Kit No. Part No.
1.7L 4-Cyl.
Charger
1
1983 ................................... 3.1 Hours .. .. TCK017 .. ..... T017
Horizon
1
1978-83 .............................. 3.1 Hours .. .. TCK017 .. ..... T017
Omni
1
1978-83 .............................. 3.1 Hours .. .. TCK017 .. ..... T017
TC3
1
1981 ................................... 3.1 Hours .. .. TCK017 .. ..... T017
2
1982 ................................... 3.1 Hours .. .. TCK017 .. ..... T017
Turismo
2
1983 ................................... 3.1 Hours .. .. TCK017 .. ..... T017
024
2
1981-82 .............................. 3.1 Hours .. .. TCK017 .. ..... T017
1
– With Air Conditioning, add .2 hours. With Air Pump, add .2
hours. With Power Steering, add .2 hours.
2
– With Air Conditioning, add .2 hours. With Air Pump, add .1


MANUFACTURER’S SUGGESTED Courtesy of DaimlerChrysler Corp.
SCHEDULED MAINTENANCE Fig. 1: Exploded View Of Timing Belt & Components


TIMING BELT
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 ten- Courtesy of DaimlerChrysler Corp.
sioner and remove timing belt.
Installation – 1) Align timing marks on crankshaft and intermediate Fig. 2: Locating Crankshaft & Intermediate Sprocket
sprockets. See Fig. 2. Turn camshaft sprocket until timing mark on Timing Marks
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
CHRYSLER 129

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)
Fig. 3: Locating Camshaft Timing Mark
Fig. 4: Tensioning Timing Belt

130 CHRYSLER
1.8L 4-Cylinder – VIN T
Part No.
1.8L 4-Cyl.
Colt & Colt Wagon
1
1989-90 .................................................... 2.4 Hours .. ..... T093
1
With Power Steering, add .2 hours.


REMOVAL & INSTALLATION Fig. 2: Positioning Timing Belt Tensioner
TIMING BELT shaft sprocket, in counterclockwise direction, to apply tension on tension
Removal – 1) Disconnect negative battery cable. Remove protective side of belt. Ensure all timing marks are aligned.
cover below engine. Support engine and remove engine mount from 3) Loosen belt tensioner bolt, then loosen nut to place tension on timing
timing belt end of engine. Remove spark plug wires and rocker cover. belt. Rotate camshaft sprocket clockwise until timing mark is offset by 2
Remove drive belts and water pump pulley. Remove A/C belt tensioner teeth to apply tension on belt. Ensure all timing marks are aligned.
(if equipped). Tighten tensioner nut, then tighten bolt.
2) Remove crankshaft pulley assembly. Remove upper front and lower 4) Check belt tension by applying slight thumb pressure to timing belt in
timing belt covers. Note bolt lengths and locations. Rotate engine direction of timing belt lower rear cover. See Fig. 3. Ensure distance
clockwise (as viewed from timing belt end of engine) to align timing mark between back of timing belt (smooth side) and timing belt lower rear
on camshaft sprocket with mark on upper rear cover. See Fig. 1. cover is approximately .23″ (6 mm). To complete installation, reverse
3) If reusing belt, mark timing belt position on camshaft sprocket and removal procedure. Adjust accessory drive belts to proper tension.
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.
Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
Courtesy of DaimlerChrysler Corp. Engine Support Bracket Bolt ........................................................ ................. 22-30 (30-41)
Front Cover Bolt .............................................................................................. 11-13 (15-18)
Fig. 1: Identifying Timing Mark Alignment & Belt Arrangement Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
Inspection – Check belt teeth for cracks, damage or oil contamination. Water Pump Bolt
8 X 70 mm .................................................................................. ................. 15-19 (20-26)
Inspect all sprockets for damage. Check belt tensioner for signs of
All Others ................................................................................................................. 10 (14)
grease leakage or roughness in tensioner rotation. Replace components
if damaged. INCH Lbs. (N.m)
Installation – 1) Rotate tensioner toward water pump and temporarily Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
tighten retaining nut. See Fig. 2. Ensure camshaft and crankshaft timing Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
marks are aligned. See Fig. 1. Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)
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-
CHRYSLER 131
2.0L 4-Cylinder – VIN C – 1995-00

Part No.
Breeze
1996-00 ..................................................... 2.6 Hours ... ..... T245
Cirrus
2000 ........................................................... 2.6 Hours ... ..... T245
Neon
1995-99 ..................................................... 2.4 Hours ... ..... T245
Stratus
1995-00 ..................................................... 2.6 Hours ... ..... T245

MANUFACTURER’S SUGGESTED Courtesy of DaimlerChrysler Corp.

On Neon, the manufacturer recommends the belt be replaced at
On Breeze, Cirrus and Stratus, the manufacturer recommends the belt
be replaced at 100,000 mile intervals on vehicles with Federal emis-
sions, and 105,000 mile intervals with California emissions.

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.
CAUTION: To prevent pistons from hitting valves, do not rotate
Fig. 2: Aligning Timing Marks & Adjusting Belt Tension
camshaft or crankshaft after removing the timing belt.
(Hydraulic Timing Belt Tensioner)
NOTE: When tensioner is removed from engine, it is necessary to Inspection – Check belt teeth for damage or oil contamination. Inspect
compress plunger into tensioner body. Index tensioner in vise the belt for glossy, hardened or non-elastic surface. Ensure the belt is not
same way it is installed on engine to ensure proper pin orientation cracked, separated or showing canvas fiber. Inspect all sprockets for
when tensioner is installed on engine. 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
CAUTION: The following revised information regarding the ten- vise and slowly compress plunger. See Fig. 5. When plunger is
sioner pulley pivot bolt is from Chrysler technical service bulletin
compressed into tensioner body, install a 5/16″ (1.9 mm) hex wrench or
09-06-96; March 29, 1996.
locking pin through body and plunger to hold plunger in place until
Timing Belt Tensioner Bracket Precaution – On models with hydrau- tensioner is installed.
lic timing belt tensioner, do not loosen, tighten, or remove timing belt 2) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil
tensioner pivot bolt. Bolt is installed at factory with special threadlocking pump housing, then back off to 3 notches before TDC.
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.
132 CHRYSLER
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 manufacturer’s
instructions to access the cam/crank relearn procedure. Perform cam/
crank relearn procedure.
Fig. 3: Exploded View Of Splash Shield Components Courtesy of DaimlerChrysler Corp.
Fig. 5: Compressing Hydraulic Timing Belt Tensioner

Fig. 4: Locating Right Engine Mount Bracket (Typical)
Fig. 6: Aligning Crankshaft Sprocket Timing Marks
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
NOTE: Chrysler recommends replacing worn mechanical tension-
before TDC for belt installation. See Fig. 6. Install timing belt by starting
ers with updated hydraulic tensioner kits. Information is from
at crankshaft, then around water pump sprocket and then camshaft
Chrysler technical service bulletin 09-06-00; March 10, 2000.
sprocket.
4) Move crankshaft sprocket to TDC to take up belt slack. Install Removal (Mechanical Tensioner) – 1) Remove No. 1 spark plug.
tensioner to block, but do not final tighten bolts. Using a torque wrench Using dial indicator, set number one cylinder to TDC of compression
on tensioner pulley, apply 21 ft. lbs. (28 N. m) of torque in clockwise stroke. Remove access plug from top of timing belt cover. See Fig. 1.
direction. With torque applied to tensioner pulley, move the tensioner up Ensure timing mark on camshaft aligns with mark on rear cover. See
against the tensioner pulley bracket. Final tighten tensioner bolts. See Fig. 7.
Fig. 1. 2) Disconnect negative battery cable. Remove accessory drive belts.
5) Pull tensioner plunger locking pin. Pretension is correct when pin can Raise vehicle and remove right inner splash shield. See Fig. 3. Remove
be removed and installed. Rotate crankshaft 2 revolutions. Check crankshaft damper bolt. Use gear puller to remove crankshaft damper.
alignment of the timing marks. Install front timing belt cover. Install 3) On Breeze and Stratus, lower vehicle and place a jack under engine
engine mount bracket. Install generator and bracket (Breeze and to support weight. Remove right engine mount from engine and body.
Stratus) or power steering pump (Neon). Remove generator (with wiring attached) and bracket, and secure out of
6) Install right engine mount. Remove jack from under engine. Install way. Remove engine mount bracket from engine. For 2000 Breeze and
Stratus, remove accessory drive belt idler pulley from generator bracket.
crankshaft damper, and tighten bolt to specification. See TORQUE
Remove generator bracket-to-engine bolts. Move bracket away from
SPECIFICATIONS.
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: 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
Installation (Mechanical Tensioner) – 1) Set crankshaft sprocket to
TDC by aligning sprocket with arrow on oil pump housing, then back off Fig. 7: Aligning Timing Marks & Adjusting Belt Tension
to 3 notches before TDC. (Mechanical Timing Belt Tensioner)
of timing belt cover. See Fig. 7. Move crankshaft to 1/2 mark before TDC TORQUE SPECIFICATIONS
for belt installation. See Fig. 6. Install timing belt by starting at crank- TORQUE SPECIFICATIONS
shaft, then around water pump sprocket and then camshaft sprocket.
See Fig. 7. Move crankshaft sprocket to TDC to take up belt slack. Application Ft. Lbs. (N.m)
3) Remove Allen wrench from timing belt tensioner pulley. Rotate Camshaft Sprocket Bolt .......................................................................................... 85 (115)
crankshaft clockwise 2 revolutions. Check alignment of camshaft and Crankshaft Damper Bolt ........................................................................................ 105 (142)
crankshaft timing marks. If timing marks do not align, remove timing belt Engine Mount Bolt ..................................................................................................... 45 (61)
Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61)
and realign timing marks.
Generator Mounting Bolts ......................................................................................... 45 (61)
4) Install front timing belt cover. Install engine mount bracket to engine. Power Steering Pump Mounting Bolts ..................................................................... 40 (54)
Continue installation in reverse of removal procedure. Tighten all Timing Belt Tensioner Bolt (Hydraulic Tensioner) .................................................... 23 (31)
fasteners to specification. See TORQUE SPECIFICATIONS. Adjust Timing Belt Tensioner Bracket Bolt (Mechanical Tensioner) ................................... 23 (31)
accessory drive belts to proper tension.
INCH Lbs. (N.m)
5) On 1998-99 Neon, connect scan tool to Data Link Connector (DLC)
under lower left edge of dash. Follow scan tool manufacturer’s instruc- Timing Belt Cover Bolts (M6) ................................................................................. 106 (12)
tions to access the cam/crank relearn procedure. Perform cam/crank Water Pump Mounting Bolts ................................................................................... 106 (12)
relearn procedure.
134 CHRYSLER
2.0L 4-Cylinder – VINs C & F – 2000-04
Part No.
Neon
2000-04 ..................................................... 2.6 Hours ... ..... T245

Manufacturer recommends the timing belt be replaced at 105,000 mile
intervals or at 84 months.
ADJUSTMENTS
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 crossmem-
ber. See Fig. 2. Verify that torque struts are free to move within shock
tower bracket and crossmember. Reinstall torque strut bolt(s), but DO Courtesy of DaimlerChrysler Corp.
NOT tighten.
3) Carefully apply upward force, allowing upper engine to rotate Fig. 3: Measuring Engine Position (Top View)
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 CAUTION: This application is an interference engine. Do not rotate
torque strut bolts to specification. See TORQUE SPECIFICATIONS. camshaft or crankshaft when timing belt is removed, or engine
Remove floor jack. damage may occur.
TIMING BELT
NOTE: For identification of timing belt with hydraulic tensioner and

related components, refer to illustration. See Fig. 4.
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
Fig. 1: Positioning Floor Jack 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.

Fig. 6: Removing Right Front Splash Shield

(With Hydraulic Tensioner)
Fig. 7: Removing Crankshaft Damper
Fig. 5: Identifying Camshaft Sprocket & Rear Cover Timing Marks
CAUTION: The following revised information regarding the ten-

sioner pulley pivot bolt is from Chrysler technical service bulletin
09-06-96; March 29, 1996.
Timing Belt Tensioner Bracket Precaution – On models with hydrau-
lic timing belt tensioner, do not loosen, tighten, or remove timing belt
tensioner pivot bolt. Pivot bolt is located on timing belt tensioner Courtesy of DaimlerChrysler Corp.
assembly. See Fig. 10. Bolt is installed at factory with special thread-
locking compound that is not reusable. If tensioner pivot bolt is dis- Fig. 8: Removing Right Engine Mount Bolt
turbed, entire bracket assembly must be replaced. The tensioner pulley
center bolt MAY be removed and installed.
136 CHRYSLER
NOTE: When hydraulic tensioner is removed from engine, it is

necessary to compress plunger into tensioner body.
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.
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
Fig. 9: Locating Engine Mount Bracket Upper & Lower Bolts 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
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 MISCEL-
LANEOUS, then select RELEARN CAM CRANK and follow directions
on scan tool screen.
Fig. 10: Aligning Timing Marks & Adjusting Belt Tension Courtesy of DaimlerChrysler Corp.
(Hydraulic Timing Belt Tensioner)
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
CAUTION: Mechanical timing belt tensioner is serviced as an

damage, DO NOT separate tensioner pulley from tensioner bracket.
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.
Courtesy of DaimlerChrysler Corp. before TDC for belt installation. See Fig. 12. Install timing belt starting at
crankshaft sprocket, then around water pump sprocket, and then
Fig. 12: Adjusting Crankshaft Sprocket For Timing Belt camshaft sprocket, and finally around timing belt tensioner pulley.
3) Move crankshaft sprocket to TDC to take up belt slack. Install a 6-mm
NOTE: Chrysler recommends replacing worn mechanical tension- Allen wrench into hexagon opening of top plate tensioner pulley. Rotate
ers with updated hydraulic tensioner kits. Information is from tensioner counterclockwise with 6-mm Allen wrench. See Fig. 13. The
tensioner pulley will move against timing belt and tensioner setting notch
Chrysler technical service bulletin 09-06-00; March 10, 2000.
will eventually start to move clockwise. Watching movement of notch,
Removal (With Mechanical Tensioner) – 1) Remove No. 1 spark plug. continue rotating tensioner counterclockwise until the setting notch is
Using dial indicator, set No. 1 cylinder to TDC of compression stroke. aligned with spring tang. See Fig. 13. Hold tensioner setting notch
Remove access plug from top of timing belt cover and ensure timing aligned with spring tang, and tighten tensioner bolts to specification. See
mark on camshaft aligns with mark on rear cover. See Fig. 5. TORQUE SPECIFICATIONS.
2) Disconnect negative cable from battery, and ground strap from engine 4) Remove Allen wrench from timing belt tensioner pulley. Rotate
mount bracket. Remove upper torque strut from front of engine. See crankshaft clockwise 2 revolutions. Check alignment of camshaft and
Fig. 2. Remove accessory drive belts. Raise vehicle and remove right crankshaft timing marks. See Fig. 15. Also check if spring tang is within
inner splash shield. See Fig. 6. Remove crankshaft damper bolt, and tolerance window. See Fig. 16. If timing marks align and spring tang is
use gear puller to remove crankshaft damper. See Fig. 7. Remove lower within specification, go to next step. If timing marks do not align or if
engine torque strut. See Fig. 2. spring tang is not within specification, repeat step 3).
3) Lower vehicle and place a jack under engine. Raise jack enough to 5) Install front timing belt cover. Install engine mount bracket and power
support engine weight. Remove right engine mount-to-engine mount steering pump. Install right engine mount and remove jack from under
bracket bolt. See Fig. 8. Lower engine enough with jack to remove lower engine. Install and adjust upper and lower engine torque struts. See
engine mount bracket bolt. See Fig. 9. Raise engine with jack to allow ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS.
engine-to-body clearance for engine bracket removal. Remove power Install crankshaft damper, and tighten bolt to specification. See
steering pump with hoses attached, and secure out of way. Remove two TORQUE SPECIFICATIONS.
remaining upper engine mount bracket bolts and remove engine mount 6) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle.
bracket. See Fig. 9. Remove front timing belt cover bolts and remove Install accessory drive belts. Adjust drive belts to proper tension.
front timing belt cover. See Fig. 14. 7) Connect scan tool to Data Link Connector (DLC), located under lower
4) Install a 6-mm Allen wrench into hexagon opening of top plate left edge of instrument panel. Turn ignition on. Perform cam/crank
tensioner pulley. Slowly rotate tensioner clockwise with 6-mm Allen relearn procedure by accessing ENGINE diagnostics. Select MISCEL-
wrench until there is enough slack in timing belt to allow removal. If LANEOUS, then select RELEARN CAM CRANK and follow directions
reusing old timing belt, mark belt with arrow to indicate direction of on scan tool screen.
rotation. See Fig. 13. Remove timing belt.

Fig. 13: Identifying Mechanical Tensioner &

Adjusting Timing Belt
138 CHRYSLER
Fig. 14: Exploded View Of Timing Belt & Components (With Mechanical Tensioner)
Fig. 16: Timing Belt Tension Verification
Fig. 15: Aligning Camshaft & Crankshaft Timing Marks
Camshaft Sprocket Bolt .......................................................................................... 85 (115)
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

TIMING BELT APPLICATION tensioner clockwise to obtain a tension of 110 lbs. (445 N.) for a new
Application Labor Time Belt belt, or 70 lbs. (311 N.) for a used belt. Tighten timing belt tensioner
Part No. center bolt to specification. See TORQUE SPECIFICATIONS.
2.2L 4-Cyl. – DOHC, Turbo III
Daytona (Includes Canadian) CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate
1 crankshaft using camshaft or intermediate shaft bolt.
1992-93 .................................................... 2.6 Hours .. ..... T206
Spirit
1991-92 .................................................... 1
2.6 Hours .. ..... T206 5) Rotate crankshaft clockwise 2 revolutions. Check alignment of
1
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
NOTE: For information about tensioners and/or pulleys (when TORQUE SPECIFICATIONS.
available), see ALPHABETICAL MODEL LISTING. 7) Install valve covers, spark plugs and ignition wire covers. Install fresh
air duct. To complete installation, reverse removal procedure. Adjust
every 60,000 miles.

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 Courtesy of DaimlerChrysler Corp.
camshaft sprockets. Fig. 1: Identifying Rocker Arm Loosening & Tightening Sequence
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
140 CHRYSLER
2.2L 4-Cylinder – DOHC, VIN A (Cont.)
Crankshaft Sprocket Center Bolt .................................................. .......................... 85 (115)
Intermediate Shaft Bolt ............................................................................................. 65 (88)
Right Engine Mount
To-Engine Bracket Through-Bolt ......................................................................... 100 (136)
To-Frame Rail Bolts ................................................................................................ 50 (68)
Water Pump Pulley Bolt ............................................................................................ 21 (28)
Wheel Lug Nut ........................................................................................................ 95 (129)
INCH Lbs. (N.m)
Rocker Arm Shaft Bolts
Step 1 .................................................................................................................... 106 (12)
Step 2 .................................................................................................................... 210 (24)

CHRYSLER 141
2.2L 4-Cylinder – DOHC, VIN R

TIMING BELT APPLICATION 9) To complete installation, reverse removal procedure. Adjust drive
Application Labor Time Component Belt belts to proper tension.
Kit No. Part No.
2.2L 4-Cyl. – DOHC, Turbo
TC (Maserati)
1990 .................................... 2.9 Hours ... .. TCK153 .. ..... T153


every 60,000 miles.
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.
contamination. Check timing belt tensioner for worn bearing. Check
camshaft, crankshaft and intermediate shaft seals for leaks. Replace
damaged components. Fig. 2: Installing Pin Punches In Camshafts
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. Courtesy of DaimlerChrysler Corp.

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.
142 CHRYSLER
2.2L 4-Cylinder – DOHC, VIN R (Cont.)
Fig. 4: Aligning Camshaft, Crankshaft & Intermediate Shafts
Crankshaft Sprocket Center Bolt .............................................................................. 50 (68)
Generator Drive Belt Idle Pulley Bolt ....................................................................... 40 (54)
Intermediate Shaft Bolt ............................................................................................. 65 (88)
Right Engine Mount
To-Engine Bracket Through-Bolt ........................................................................... 75 (102)
To-Frame Rail Bolts ................................................................................................ 21 (28)
INCH Lbs. (N.m)
Water Pump Pulley Bolt .......................................................................................... 106 (12)
CHRYSLER 143

TIMING BELT APPLICATION TIMING BELT APPLICATION (Cont.)
Application Labor Time Component Belt Application Labor Time Component Belt
Kit No. Part No. Kit No. Part No.
2.2L 4-Cyl. – SOHC Dakota
1
Aries & Reliant 1989-95 ............................ ... 1.1 Hrs. ... .. TCK153 .. ..... T153
1981-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 Daytona
1989 ................................. ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1986-87 ............................ ... 1
2.2 Hrs. ... .. TCK114 ........ T114
1
Caravan, Town & Country & Voyager 1988 ................................. ... 2.2 Hrs. ... ...... ..... ...... ..... T132
1982-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1989-93 ............................ ... 1
2.2 Hrs. ... .. TCK153 .. ..... T153
Caravelle, New Yorker & 600 Dynasty
1983-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1988 ................................. ... 1
2.2 Hrs. ... ...... ..... ...... ..... T132
1
Charger & Turismo 1989-93 ............................ ... 2.2 Hrs. ... .. TCK153 .. ..... T153
1983-87 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 Lancer
1
Dakota 1986-87 ............................ ... 2.2 Hrs. ... ...... ..... ............ T114
1987-88 ............................ ... 2 1.1 Hrs. ... .. TCK071 .. ..... T071 1988 ................................. ... 1
2.2 Hrs. ... ...... ..... ...... ..... T132
1
Daytona 1989 ................................. ... 2.2 Hrs. ... .. TCK153 .. ..... T153
1984-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 Laser
1989-93 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1986 ................................. ... 1
2.2 Hrs. ... .. TCK114 ........ T114
E Class LeBaron & LeBaron GTS
1983-84 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1986-87 ............................ ... 1
2.2 Hrs. ... .. TCK114 ........ T114
1
Executive Limo (Canadian) 1988 ................................. ... 2.2 Hrs. ... .. TCK132 .. ..... T132
1986 ................................. ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1989-94 ............................ ... 1
2.2 Hrs. ... .. TCK153 .. ..... T153
Expo (Canadian) Mini Ram Van
1987-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1987 ................................. ... 1
2.2 Hrs. ... ...... ..... ............ T114
1989 ................................. ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1988 ................................. ... 1
2.2 Hrs. ... .. TCK132 .. ..... T132
Horizon & Omni New Yorker
1981-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1986-87 ............................ ... 1
2.2 Hrs. ... .. TCK114 ........ T114
1989-90 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1988 ................................. ... 1
2.2 Hrs. ... ...... ..... ...... ..... T132
Lancer Shadow
1985-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1988 ................................. ... 1
2.2 Hrs. ... ...... ..... ...... ..... T132
1989 ................................. ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1989-94 ............................ ... 1
2.2 Hrs. ... .. TCK153 .. ..... T153
Laser Spirit
1984-86 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1989-95 ............................ ... 1
2.2 Hrs. ... .. TCK153 .. ..... T153
LeBaron & LeBaron GTS Sundance
1982-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 1988 ................................. ... 1
2.2 Hrs. ... .. TCK132 .. ..... T132
1989-90 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 1989-94 ............................ ... 1
2.2 Hrs. ... .. TCK153 .. ..... T153
Mini Ram Van 1
1984-87 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 With Power Steering, add .2 hours.
New Yorker 2
1983-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 With Power Steering, add .2 hours.
Rampage
1982-84 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 NOTE: A timing belt component kit is available for this application.
Scamp Pickup See page A1 for information on component kits.
1983 ................................. ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071
Shadow & Sundance
1987-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 NOTE: For information about tensioners and/or pulleys (when
1989-94 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 available), see ALPHABETICAL MODEL LISTING.
TC3
1981-82 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071
Turismo MANUFACTURER’S SUGGESTED
1983-87 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 SCHEDULED MAINTENANCE
024
1981-82 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 Although the manufacturer does not recommend a specific scheduled
400 maintenance interval, belt manufacturers suggest the belt be replaced at
1982-83 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 60,000 mile intervals.
600
1983-88 ............................ ... 1 2.2 Hrs. ... .. TCK071 .. ..... T071 REMOVAL & INSTALLATION
Acclaim
TIMING BELT
1989-95 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 Removal – 1) Disconnect negative battery cable. Remove all accessory
Aries, Lancer & Reliant drive belts. If necessary, remove alternator, mounting brackets, and A/C
1986-87 ............................ ... 1 2.2 Hrs. ... .. TCK114 ........ T114 compressor (if equipped). DO NOT disconnect refrigerant lines.
1988 ................................. ... 1 2.2 Hrs. ... ...... ..... ...... ..... T132 Remove A/C belt idler pulley.
1989 ................................. ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 2) Raise and support vehicle. Remove right inner splash shield. Remove
Caravan, Town & Country & Voyager water pump and crankshaft pulleys. Remove upper and lower timing belt
1986 ................................. ... 1 2.2 Hrs. ... ...... ..... ............ T114 covers. See Fig. 1. Support engine using a jack.
1987 ................................. ... 1 2.2 Hrs. ... .. TCK114 ........ T114
1988 ................................. ... 1 2.2 Hrs. ... .. TCK132 .. ..... T132 NOTE: If timing belt is to be reused, mark direction of rotation for
1989-95 ............................ ... 1 2.2 Hrs. ... .. TCK153 .. ..... T153 reassembly reference.
Caravelle & 600
1986-87 ............................ ... 1 2.2 Hrs. ... .. TCK114 ........ T114 3) Remove right engine mount bolt, and raise engine slightly. Loosen the
1988 ................................. ... 1 2.2 Hrs. ... .. TCK132 .. ..... T132 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
144 CHRYSLER
Fig. 3: Aligning Crankshaft, Intermediate Shaft & Camshaft

Timing Marks
Fig. 1: Removing Timing Belt Covers
Bracket-To-Block Bolt ................................................................................................ 70 (95)
Courtesy of DaimlerChrysler Corp. Damper Weight .............................................................................. ................. 21-23 (28-30)
Fig. 3. Rotate camshaft sprocket until 2 marked arrows on sprocket hub INCH Lbs. (N.m)
align with camshaft bearing cap-to-cylinder head parting line. Small hole
in camshaft sprocket must be at 12 o’clock relative to cylinder head line. Balance Shaft Chain Guide Nut ............................................................................. 106 (12)
Balance Shaft Chain Pivot & Tensioner Bolt ......................................................... 106 (12)
See Fig. 4.
Balance Shaft Cover Bolt ....................................................................................... 106 (12)
2) Install timing belt. Ensure timing belt is installed in original direction of Intermediate Shaft Retainer Bolt ............................................................................ 106 (12)
rotation. Install Timing Belt Tensioner (C-4703) horizontally on large hex Timing Belt Cover Bolt ................................................................................................ 44 (5)
of belt tensioner pulley. Loosen tensioner lock nut (if necessary) to reset Valve Cover Bolt ..................................................................................................... 106 (12)
belt tensioner to within a 15-degree axis of horizontal position of tool. Water Pump Pulley Bolt .......................................................................................... 106 (12)
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
CHRYSLER 145
2.4L 4-Cylinder – DOHC, VIN 1

Part No.
2.4L 4-Cyl. – DOHC, VIN 1
Liberty
2002-04 ..................................................... 1.1 Hours ... ..... T265
Wrangler
2003-04 ..................................................... 1.0 Hours ... ..... T265

SCHEDULED MAINTENANCE Courtesy of DaimlerChrysler Corp.
Manufacturer recommends the timing belt be replaced every 120,000 Fig. 1: Removing Crankshaft Vibration Damper
miles for normal service, or every 90,000 miles for severe service.

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 compo-
nents 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 Courtesy of DaimlerChrysler Corp.
edge of sprocket tooth). See Fig. 3. Fig. 2: Identifying Upper & Lower Timing Belt Covers &
Drive Belt Tensioner
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.
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 push-
ing 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).
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 Courtesy of DaimlerChrysler Corp.
Special Tool (6792) is required to set the sprocket to original
installation depth. An incorrectly installed sprocket will result in Fig. 3: Aligning Crankshaft & Camshaft Timing Marks
timing belt and engine damage. sprocket with arrow on oil pump housing. See Fig. 6. Also set camshaft
Installation – 1) If necessary, install crankshaft sprocket to crankshaft timing marks so that exhaust camshaft sprocket is a 1/2 notch below
using Special Tool (6792). Set crankshaft sprocket to TDC by aligning intake camshaft sprocket. See Figs. 5 and 6.
146 CHRYSLER
2.4L 4-Cylinder – DOHC, VIN 1 (Cont.)
Fig. 5: Aligning Camshaft Sprockets For Timing Belt Installation
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 reposi-
tioned to TDC. Check alignment of camshaft and crankshaft timing
marks. See Fig. 3. If timing marks do not align, remove timing belt and Courtesy of DaimlerChrysler Corp.
realign timing marks.
5) Check if spring tang is within tolerance window. See Fig. 8. If spring Fig. 6: Installing Timing Belt
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.

CHRYSLER 147
2.4L 4-Cylinder – DOHC, VIN 1 (Cont.)

Crankshaft Vibration Damper Bolt ........................................................................ 105 (142)
Drive Belt Tensioner Bracket Bolts ........................................................................... 30 (41)
Drive Belt Tensioner Pulley Bolt ............................................................................... 45 (61)
Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
Timing Belt Tensioner Lock Nut ............................................................................... 22 (30)
INCH Lbs. (N.m)
Water Pump Bolts ................................................................................................... 106 (12)
Fig. 8: Verifying Timing Belt Tension

148 CHRYSLER
2.4L 4-Cylinder – DOHC, VIN B
Part No.
2.4L 4-Cyl. – DOHC, VIN B
Caravan & Voyager
1
1996-00 .................................................... 2.0 Hours .. ..... T265
1
– With Power Steering, add .2 hours.

The manufacturer recommends the belt be replaced every 120,000
miles.

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). Courtesy of DaimlerChrysler Corp.
4) Remove 2 right engine mount vertical bolts from frame rail. Remove Fig. 1: Aligning Crankshaft & Camshaft Timing Marks
the one horizontal fastener. DO NOT remove large nut from center bolt
of insulator rubber. Remove horizontal and vertical fasteners from
engine side of mount. Remove right engine mount assembly. Rotate
crankshaft to align timing marks on camshafts and oil pump housing.
See Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing

edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth with oil pump housing mark will cause camshaft marks to be
misaligned.
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 counterclock-
wise, 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. Courtesy of DaimlerChrysler Corp.
contamination. Check timing belt tensioner for worn bearing. Replace Fig. 2: Adjusting Timing Belt Tension (Mechanical)
damaged components. Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner
against tensioner pulley bracket and final tighten tensioner bolts. See
NOTE: If timing belt tensioner needs to be replaced, camshaft
TORQUE SPECIFICATIONS. Remove holding pin from tensioner. Tim-
sprockets and rear timing belt cover will need to be removed.
ing belt tension is correct when pin can be removed and installed freely.
Installation – 1) Ensure camshaft and crankshaft timing marks are still Skip next step.
aligned. See Fig. 1. Set camshafts timing marks together by aligning 5) On models with mechanical timing belt tensioners, pull locking Allen
notches on sprockets. Turn exhaust camshaft sprocket clockwise about wrench from timing belt tensioner.
1/2 notch below intake camshaft sprocket. See Fig. 3. 6) On all models, rotate crankshaft 2 revolutions and check alignment of
2) Install timing belt starting at crankshaft, around water pump sprocket, timing marks. If timing marks are not correct, reposition timing belt.
idler pulley, camshafts sprockets and then around tensioner pulley. 7) Install right engine mount support and support bracket. Install upper
3) Move exhaust camshaft counterclockwise to take out belt slack and and lower timing belt covers. Install generator idler pulley. Install
align timing marks. See Fig. 1. crankshaft vibration damper.
4) On 1996 models with hydraulic timing belt tensioner, install tensioner 8) To complete installation, reverse removal procedure. Adjust drive
on engine block, but do NOT final tighten bolts. See Fig. 4. Apply 21 ft. belts to proper tension.
lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See
CHRYSLER 149
2.4L 4-Cylinder – DOHC, VIN B (Cont.)
Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)
Crankshaft Vibration Damper ................................................................................ 105 (142)
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)
Fig. 4: Installing Timing Belt Tensioner Assembly 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)
150 CHRYSLER
2.4L 4-Cylinder – DOHC, VIN X
Part No.
2.4L 4-Cyl. – DOHC, VIN X
Breeze
1
1996-00 .................................................... 3.6 Hours .. ..... T265
Cirrus
1
1995-00 .................................................... 3.6 Hours .. ..... T265
Sebring Convertible
1
1996-99 .................................................... 3.6 Hours .. ..... T265
Stratus
1
1995-00 .................................................... 3.6 Hours .. ..... T265
1

Up to 1999 model year, the manufacturer recommends the timing belt be
replaced every 105,000 miles. For 2000 model years, the manufacturer
recommends the timing belt be replaced at 100,000 miles for Federal
vehicles and at 105,000 miles for California vehicles.

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.
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

tooth with oil pump housing mark will cause camshaft marks to be Courtesy of DaimlerChrysler Corp.
misaligned. Fig. 2: Adjusting Timing Belt Tension (Mechanical)
7) On models equipped with hydraulic tensioner, remove hydraulic Installation – 1) Ensure camshaft and crankshaft timing marks are still
tensioner bolts and remove tensioner. Place hydraulic tensioner in vise, aligned. See Fig. 1. Set camshafts timing marks together by aligning
and SLOWLY compress tensioner plunger. Align the holes in the notches on sprockets. Turn exhaust camshaft sprocket clockwise about
tensioner body and plunger, and insert a pin through the body and 1/2 notch below intake camshaft sprocket. See Fig. 3.
plunger to lock the plunger in place. Skip next step. 2) Install timing belt starting at crankshaft, around water pump sprocket,
8) On models with a mechanical timing belt tensioner, insert a 6-mm
idler pulley, camshafts sprockets and then around tensioner pulley.
Allen wrench into tensioner. Insert long end of 3-mm Allen wrench into
3) On models with hydraulic timing belt tensioner, install tensioner on
pin hole on front of tensioner. While rotating the tensioner counterclock-
engine block, but do NOT final tighten bolts. See Fig. 4. Apply 21 ft. lbs.
wise, push in lightly on the 3-mm Allen wrench until it can be pushed into
(28 N.m) of torque to tensioner pulley in a clockwise direction. See
locking hole. See Fig. 2.
9) On all models, if reusing old timing belt, mark belt with arrow to Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner
indicate original direction of rotation. Remove timing belt. against tensioner pulley bracket and final tighten tensioner bolts. See
TORQUE SPECIFICATIONS. Remove holding pin from tensioner. Tim-
ing belt tension is correct when pin can be removed and installed freely.
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components. Skip next step.
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
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)

Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position
Crankshaft Vibration Damper ................................................................................ 105 (142)
Generator Drive Belt Idler Pulley Bolt ...................................................................... 40 (54)
Right Engine Mount
Frame Rail Vertical Fasteners ................................................................................ 45 (61)
To-Engine Support Bracket ..................................................................................... 45 (61)
Timing Belt Tensioner (Hydraulic)
Mounting Bolt .......................................................................................................... 21 (28)
Timing Belt Tensioner (Mechanical)
Bracket Mounting Bolt ............................................................................................. 45 (61)
Wheel Lug Nut ...................................................................................................... 100 (135)
INCH Lbs. (N.m)
M6 (Outer-To-Inner) ................................................................................................ 40 (4.5)
M6 (Inner-To-Head) ............................................................................................... 105 (12)
Water Pump Bolt ..................................................................................................... 106 (12)
Fig. 4: Installing Timing Belt Tensioner Assembly

152 CHRYSLER
2.4L 4-Cylinder – DOHC, VINs B & S – Neon & PT Cruiser
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

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 Courtesy of DaimlerChrysler Corp.
102,000 miles or 102 months (non-turbo) or 105,000 miles or 84 months Fig. 1: Positioning Floor Jack
(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.
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 Courtesy of DaimlerChrysler Corp.
on the forward edge of transmission bellhousing. See Fig. 1. Fig. 2: Removing Pencil Strut
2) With engine supported, remove upper and lower torque struts
attachment bolt(s) at shock tower bracket and suspension crossmem-
ber. 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.
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.

CAUTION: This application is an interference engine. Do not rotate Courtesy of DaimlerChrysler Corp.
damage may occur. Fig. 3: Removing Upper & Lower Engine Torque Struts
2) On all models, remove upper timing belt cover bolts and remove
TIMING BELT cover. See Fig. 6. Raise vehicle on hoist and remove right front wheel.
Removal – 1) Disconnect negative battery cable. Remove upper engine Remove splash shield. See Fig. 7. Remove accessory drive belts.
torque strut attaching bolts and remove engine torque strut. See Fig. 5. Remove crankshaft damper. See Fig. 8. Remove pencil strut. See Fig. 2.
Remove engine torque strut bracket from strut tower. On PT Cruiser Remove lower engine torque strut. See Fig. 5.
(Turbo), discharge and evacuate A/C system. Disconnect A/C lines at
junction block near upper timing belt cover.
CHRYSLER 153
2.4L 4-Cylinder – DOHC, VINs B & S – Neon & PT Cruiser (Cont.)
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 Fig. 5: Locating Engine Mounting Components
disconnecting lines from power steering pump, remove pump and
bracket and set pump aside.
4) With engine properly supported, remove right engine mount through-
bolt. 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.

nents may occur.
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

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 Courtesy of DaimlerChrysler Corp.
belt to allow for removal. If reusing old timing belt, mark belt with arrow
Fig. 6: Removing Front Timing Belt Covers
to indicate original direction of rotation. Remove timing belt.
CAUTION: If timing belt was damaged due to incorrect rotating sprocket, idler pulley, camshaft sprockets, and then around tensioner.
tracking (alignment), belt tensioner pulley and bracket must be See Fig. 10. Move exhaust camshaft sprocket counterclockwise to align
replaced as an assembly. 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.
contamination. Check timing belt tensioner for worn bearing. Replace
damaged components as necessary.
CAUTION: Ensure that arrows on both camshaft sprockets are notch, continue rotating top plate counterclockwise until setting notch is
facing up. aligned with spring tang. See Fig. 11. Using Allen wrench to prevent top
plate from moving, tighten tensioner lock bolt to specification. See
Installation – 1) Set crankshaft sprocket to TDC by aligning sprocket TORQUE SPECIFICATIONS. Setting notch and spring tang should
with arrow on oil pump housing. Also set camshaft timing marks so that remain aligned after lock bolt is torqued. Remove Allen wrench and
exhaust camshaft sprocket is a 1/2 notch below intake camshaft torque wrench.
sprocket. See Fig. 12
.
154 CHRYSLER
Fig. 7: Removing Right Front Splash Shield
Fig. 10: Identifying Camshaft & Crankshaft TDC & Timing Marks

missed, rotate a further 2 revolutions until TDC is achieved. DO
NOT rotate crankshaft counterclockwise.
4) Rotate crankshaft clockwise two complete revolutions manually for
seating of belt until crankshaft is repositioned at TDC position. Verify that
Courtesy of DaimlerChrysler Corp. camshaft and crankshaft timing marks are in proper position. See
Fig. 9: Removing Engine Support Bracket Fig. 10.
5) Check if spring tang is within tolerance window. See Fig. 13. If spring
CHRYSLER 155

6) Install upper and lower timing belt covers, and tighten bolts to TORQUE SPECIFICATIONS
specification. See TORQUE SPECIFICATIONS. Install engine support
bracket. Ensure power steering pump is properly located in mounting TORQUE SPECIFICATIONS
location on bracket and tighten mount bracket bolts to specification. See Application Ft. Lbs. (N.m)
TORQUE SPECIFICATIONS. Camshaft Sprocket Bolt .......................................................................................... 85 (115)
7) Lower engine into mounting position and install right engine mount Crankshaft Vibration Damper ................................................................................ 100 (136)
through-bolt. See Fig. 5. Install power steering pump and bracket. Install Engine Mount Through-Bolt (Right) .............................................. .......................... 87 (118)
upper radiator closure panel. Install engine torque strut bracket to strut Engine Support Bracket Bolts ................................................................................... 45 (61)
tower. Connect ground strap to bracket. Tighten all bolts to specification. Engine Torque Strut Bolts ....................................................................................... 85 (115)
See TORQUE SPECIFICATIONS. Install upper torque strut attaching Pencil Strut Nut ......................................................................................................... 43 (58)
Power Steering Mounting Bracket ............................................................................ 40 (54)
bolts. See Fig. 5.
Timing Belt Idler Pulley ............................................................................................. 45 (61)
8) Connect A/C lines, evacuate and recharge system. Raise vehicle and Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
connect exhaust system to manifold. Connect A/C pressure switch Wheel Mounting Nuts ............................................................................................ 100 (136)
connector. Install crankshaft damper and accessory drive belts. Install
INCH Lbs. (N.m)
lower torque strut. Perform torque strut adjustment. See ENGINE
TORQUE STRUT ADJUSTMENT under ADJUSTMENTS. Install pencil Timing Belt Cover Bolts .............................................................................................. 50 (6)
Timing Belt Tensioner Lock Bolt ............................................................................. 220 (25)
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.
Fig. 12: Identifying Camshaft Sprocket Alignment For

Fig. 13: Verifying Timing Belt Tension

156 CHRYSLER
2.4L 4-Cylinder
DOHC, VINs B & X – Except Neon & PT Cruiser
Application Labor Time Belt CAUTION: If timing belt was damaged due to incorrect tracking
Part No. (alignment), belt tensioner pulley and bracket must be replaced as
2.4L 4-Cyl. – DOHC, VINs B & X an assembly.
Caravan
1
2001-04 .................................................... 2.0 Hours .. ..... T265
Sebring Convertible & Sedan
1
2001-04 .................................................... 3.6 Hours .. ..... T265
Stratus Sedan
1
2001-04 .................................................... 3.6 Hours .. ..... T265
Voyager
1
2001-03 .................................................... 2.0 Hours .. ..... T265
1

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 manufac-
turer, but is not required to maintain emission warranty).

camshaft or crankshaft when timing belt is removed, or engine Courtesy of DaimlerChrysler Corp.
damage may occur.
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.

nents may occur.
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 Fig. 2: Removing Timing Belt Cover & Engine Support Bracket
camshaft timing marks to be misaligned. (Sebring & Stratus)
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 contamination. Check timing belt tensioner for worn bearing. Replace
belt to allow for removal. If reusing old timing belt, mark belt with arrow damaged components as necessary.
to indicate original direction of rotation. Remove timing belt.
CHRYSLER 157
2.4L 4-Cylinder
DOHC, VINs B & X – Except Neon & PT Cruiser (Cont.)
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. 7.
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.
Fig. 4: Removing Drive Belt Tensioner 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.

missed, rotate a further two revolutions until TDC is achieved. DO
NOT rotate crankshaft counterclockwise.
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
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
Courtesy of DaimlerChrysler Corp. recovery bottle. On all models, install accessory drive belts. Install
splash shield and right front wheel. Connect negative battery cable.
Fig. 5: Identifying Crankshaft & Camshaft Timing Marks
158 CHRYSLER
2.4L 4-Cylinder
DOHC, VINs B & X – Except Neon & PT Cruiser (Cont.)
Fig. 7: Identifying Camshaft Sprocket Alignment For

Fig. 9: Timing Belt Tension Verification
Drive Belt Tensioner Bolt .......................................................................................... 40 (54)
Engine Mount Bracket Bolts ..................................................................................... 45 (61)
Right Engine Mount Bolt ........................................................................................... 45 (61)
Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61)
INCH Lbs. (N.m)
Timing Belt Tensioner Bolt ...................................................................................... 220 (25)
Fig. 8: Identifying Camshaft & Crankshaft TDC & Timing Marks

CHRYSLER 159
2.4L 4-Cylinder – SOHC, VIN G

Part No.
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.

For 2001-02 vehicles, manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts and Connecti-
cut. In California, Massachusetts and Connecticut, timing belt replace-
ment 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 Courtesy of Mitsubishi Motor Sales of America.
belt replacement is recommended, but not required, at 60,000 miles. In
these states, replace timing belt at 100,000 miles, unless previously Fig. 1: Exploded View Of Timing Belt & Components
changed.

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 Courtesy of DaimlerChrysler Corp.
near timing belt cover.
2) Remove all accessory drive belts. Remove water pump pulley. See Fig. 2: Installing Crankshaft Sprocket & Sensing Blade
Fig. 1. 2) Check timing belt and balance shaft belt tensioner pulleys for worn
3) Remove crankshaft pulley. Noting bolt lengths and locations, remove bearings. Replace as necessary.
upper and lower timing belt cover with gasket.
3) Check timing belt auto tensioner for leaks. Hold timing belt auto
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed tensioner upright. Apply 22-44 lbs. (98-196 N) of force to end of rod. If
from timing belt end of engine). If timing belt is to be reused, mark auto tensioner rod moves more than 0.39″ (1 mm), replace the auto
direction of rotation before removing. 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. Courtesy of DaimlerChrysler Corp.
6) Use crankshaft pulley mounting bolt to hold Special Tool (MB991367).
Loosen crankshaft sprocket mounting bolt, and remove sprocket. See Fig. 3: Inspecting Timing Belt Auto Tensioner
Fig. 2.
Installation – 1) Align crankshaft rear sprocket (sprocket “B”) and
7) If reusing old balance shaft belt, mark belt with arrow to indicate
balance shaft sprocket timing marks. See Fig. 5. Install balance shaft
rotation direction. Loosen balance shaft tensioner pulley center bolt.
belt. If reusing old belt, install in original direction of rotation. Ensure that
Remove balance shaft belt.
there is no slack in the 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.
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 sens-
ing 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
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 Courtesy of Mitsubishi Motor Sales of America.
auto-tensioner. 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 Courtesy of DaimlerChrysler Corp.
pulley does not turn with bolt.
Fig. 5: Aligning Balance Shaft Timing Marks
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.
Fig. 6: Adjusting Balance Shaft Timing Belt Tensioner
CHRYSLER 161
2.4L 4-Cylinder – SOHC, VIN G (Cont.)

Auto Tensioner Bolt ....................................................................... ................. 14-20 (20-26)
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
Courtesy of Mitsubishi Motor Sales of America. 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
– Apply engine oil to bolt threads.
2
– Final tighten bolt with weight of engine on mount.
Fig. 8: Holding Balance Shaft In Stationary Position

162 CHRYSLER
2.5L V6
Kit No. Part No.
2.5L V6
Avenger & Sebring Coupe
1
1995-00 .............................. 4.8 Hours .. .. TCK259 .. ..... T259
Cirrus & Stratus
1
1995-00 .............................. 4.8 Hours .. .. TCK259 .. ..... T259
Sebring Convertible
1
1996-00 .............................. 4.8 Hours .. .. TCK259 .. ..... T259
1
– With Air Conditioning add .2 hours.

See page A1 for information on component kits. Courtesy of DaimlerChrysler Corp.
Fig. 1: Setting Crankshaft Sprocket

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.

damage may occur. Courtesy of DaimlerChrysler Corp.
Fig. 2: Aligning Camshaft Sprockets

TIMING BELT 2) Remove accessory drive belts. Remove right engine support assem-
Removal (Avenger & Sebring Coupe) – 1) Disconnect negative bly vertical bolts from bottom side of frame rail (timing belt end of
battery cable. Remove coolant reservoir bottle. On models with cruise engine).
control, remove cruise control actuator and set aside. 3) Lower vehicle. Place floor jack under vehicle to support weight of
2) On all models, raise and support vehicle. Remove right front wheel. engine and transaxle assembly. Remove 3 bolts attaching engine
Remove side panel from right wheelwell. support assembly to engine block bracket.
3) Remove accessory drive belts. Remove generator and bracket from 4) Move the A/C drier aside with hoses attached. Remove coolant
engine block, and set aside. Remove crankshaft vibration damper. reservoir tank. Remove right engine support assembly. Remove 3 bolts
4) Lower vehicle. Place floor jack under vehicle to support weight of attaching engine support bracket to engine block, and remove bracket.
engine and transaxle assembly. Remove engine mount-to-frame 5) Remove crankshaft vibration damper. Remove power steering pump
through-bolt. Remove engine mount-to-engine bracket nuts and bolt. (hoses attached) and bracket from engine block. Remove timing belt
Remove engine mount. covers.
5) Remove 3 bolts attaching engine support bracket to engine block. Top 6) Rotate crankshaft to align camshaft and crankshaft timing marks. See
reamer bolt may be heat seized on engine support bracket. Spray Figs. 1 and 2.
lubricant on bolt while removing. 7) If reusing old timing belt, mark timing belt direction of rotation for
NOTE: Reamer bolt head will have a “R” marking for identification. installation reference. Loosen timing belt automatic tensioner bolts.
Remove timing belt. Remove automatic tensioner.
6) Remove power steering pump (hoses attached) and bracket from
engine block, and set aside. Remove timing belt covers. CAUTION: DO NOT rotate crankshaft or camshaft with timing belt
7) Rotate crankshaft to align camshaft and crankshaft timing marks. See removed.
Figs. 1 and 2.
8) If reusing old timing belt, mark timing belt direction of rotation for NOTE: When automatic tensioner is removed from engine, it is
installation reference. Loosen timing belt tensioner pulley bolt. Remove necessary to compress plunger into tensioner body.
timing belt. Remove automatic tensioner.
Installation (All Models) – 1) Place automatic tensioner into vise, and
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt SLOWLY compress plunger. When plunger is compressed into ten-
removed. sioner body, install locking pin through body and plunger holes to retain
plunger until tensioner is installed. See Fig. 3.
NOTE: When automatic tensioner is removed from engine, it is 2) Index tensioner in vise the same direction as installed. This will
necessary to compress plunger into tensioner body. ensure proper pin orientation when tensioner is installed in engine. See
Fig. 3.
Removal (Cirrus, Sebring Convertible & Stratus) – 1) Disconnect 3) Set crankshaft mark with timing mark on oil pump housing, then back
negative battery cable from jumper terminal. Raise and support vehicle. off 3 notches before TDC. See Fig. 1. Set camshaft sprockets by
Remove right front wheel. Remove accessory drive belt splash shield aligning timing marks on sprockets with marks on rear timing belt cover.
from right wheelwell. See Fig. 2.
CHRYSLER 163
2.5L V6 (Cont.)
NOTE: If reusing old timing belt, install in original direction of
rotation. TORQUE SPECIFICATIONS
4) Install timing belt on right (next to firewall) camshaft sprocket first. Application Ft. Lbs. (N.m)
Install a spring clip to keep belt in position. Keeping belt taught, install Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Crankshaft Vibration Damper Bolt ........................................................................ 134 (182)
belt under water pump pulley and then around front camshaft sprocket.
Engine Mount Bracket-To-Engine Block
Install spring clip on front sprocket and belt. Cirrus, Sebring Convertible & Stratus .................................................................... 33 (45)
5) Rotate crankshaft clockwise to TDC. Continue routing belt around Engine Mount-To-Engine Support Bracket Bolt/Nut
idler pulley, crankshaft sprocket, and tensioner pulley. Apply rotating Avenger & Sebring Coupe ...................................................................................... 64 (86)
force to crankshaft sprocket in clockwise direction to tension belt. Engine Mount-To-Frame Through-Bolt
Ensure all timing marks are still aligned. Avenger & Sebring Coupe .......................................................................... 72-87 (98-118)
6) Loosen tensioner pulley center bolt. Position tensioner pulley with pin Engine Support Assembly-To-Engine Mount Bracket
holes facing down. Install Adapter (MD998767) or equivalent, and Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74)
Cirrus, Sebring Convertible & Stratus .................................................................... 45 (61)
torque wrench, to tensioner pulley. See Fig. 4. Apply 39 INCH lbs. (4.4
Engine Support Assembly-To-Frame Rail
N.m) in a counterclockwise direction to tensioner. Tighten tensioner bolt Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74)
to specification, without letting tensioner pulley rotate. Cirrus, Sebring Convertible & Stratus .................................................................... 45 (61)
7) With torque being applied to tensioner pulley, install automatic Engine Support Bracket-To-Engine Block Bolt
tensioner (with locking pin in place) to tensioner pulley bracket. Tighten Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74)
bolts to specification. See TORQUE SPECIFICATIONS. Pull tensioner Generator Mount Bracket-To-Engine Block
plunger locking pin. Avenger & Sebring Coupe ...................................................................................... 30 (41)
Power Steering Pump Bracket-To-Engine Bolts
8) Rotate crankshaft 2 revolutions clockwise, and check alignment of
Avenger & Sebring Coupe ...................................................................................... 16 (22)
timing marks. Install tensioner locking pin into automatic tensioner. Pin
Cirrus, Sebring Convertible & Stratus .................................................................... 40 (54)
should slide in and out with no resistance. Even if locking pin cannot be Timing Belt Idler Pulley Bolt ..................................................................................... 32 (44)
easily inserted, belt tension is okay if automatic tensioner plunger Timing Belt Tensioner Pivot Arm Bolt ....................................................................... 33 (45)
projection is within .149-.177″ (3.8-4.5 mm). Projection is measured Timing Belt Tensioner Pulley Bolt ............................................................................. 35 (48)
between top edge of automatic tensioner housing and arm of tensioner Timing Belt Tensioner-To-Engine Bolt ...................................................................... 17 (23)
pulley bracket. Retension timing belt, if necessary. Water Pump Bolt ....................................................................................................... 18 (24)
9) Install timing belt covers. Install crankshaft vibration damper. Tighten Wheel Lug Nut
crankshaft damper bolt to specification. See TORQUE SPECIFICA- Avenger & Sebring Coupe .......................................................... ............... 65-80 (88-108)
TIONS. Cirrus, Sebring Convertible & Stratus ................................................................ 100 (135)
INCH Lbs. (N.m)
NOTE: Reamer bolt head will have a “R” marking for identification.
Timing Belt Cover Bolts ................................................................ ............... 89-106 (10-12)
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.
Fig. 3: Compressing Tensioner

164 CHRYSLER
3.0L V6 – SOHC – 1987-00
Kit No. Part No.
3.0L V6
Acclaim & Spirit
1989-95 ............................... 3.5 Hours ... .. TCK139 .. ..... T139
Caravan, Mini Ram Van & Voyager
1987-00 .............................. 1 4.0 Hours .. .. TCK139 .. ..... T139
Daytona (Includes Canadian)
1990-93 ............................... 3.5 Hours ... .. TCK139 .. ..... T139
Dynasty (Includes Canadian)
1988-93 ............................... 3.5 Hours ... .. TCK139 .. ..... T139
LeBaron
1990-95 .............................. 1 3.5 Hours .. .. TCK139 .. ..... T139
New Yorker
1988-89 ............................... 3.5 Hours ... .. TCK139 .. ..... T139
Raider
1989 ................................... 2 3.5 Hours .. .. TCK139 .. ..... T139
Ram 50
1990-91 ............................... 3.5 Hours ... .. TCK139 .. ..... T139
Shadow & Sundance
1992-94 ............................... 3.5 Hours ... .. TCK139 .. ..... T139 Courtesy of DaimlerChrysler Corp.
Stealth
Fig. 1: Locating Timing Belt & Sprockets
1991-96 ............................... 2.0 Hours ... .. TCK139 .. ..... T139
TC Maserati 2) Raise and support vehicle. Remove right inner fender shield. Remove
1990-91 ............................... 3.5 Hours ... .. TCK139 .. ..... T139 crankshaft pulleys and vibration damper. Lower vehicle. Support engine
1
– With Air Conditioning, add .2 hours. with floor jack. Separate right (timing belt side) engine mount from
With Power Steering, add .2 hours. engine mount bracket located in front of timing belt cover.
2
– With Air Conditioning, add .7 hours. 3) Slightly raise engine. Remove engine mount bracket. Remove timing
With Power Steering, add .3 hours. belt covers, noting bolt length for installation reference. Rotate engine
NOTE: A timing belt component kit is available for this application. and align timing marks on camshaft sprockets and crankshaft sprocket.
See page A1 for information on component kits. 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
available), see ALPHABETICAL MODEL LISTING. 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).
MANUFACTURER’S SUGGESTED 5) If removing camshaft sprocket, hold camshaft by engaging Camshaft
SCHEDULED MAINTENANCE Sprocket Holder (MB990775) in the holes on front of camshaft sprocket.
Remove camshaft sprocket bolt and washer. Remove camshaft
Up to 1993 model year, the manufacturer recommends the timing belt be
sprocket.
replaced at 60,000. For 1994-96 model years, the manufacturer recom-
Caravan & Voyager – 1) Raise vehicle. Remove accessory drive belt
mends the timing belt be replaced at 60,000 miles, except in California.
In California, timing belt replacement is recommended, but not required splash shield. Remove accessory drive belts. Remove crankshaft
at 60,000 miles. Replace the timing belt at 100,000 miles, unless pulleys and vibration damper.
previously changed. 2) Lower vehicle. Support engine weight with floor jack. Remove purge
duty solenoid and wiring harness from right engine mount bracket.
For 1997-00 model years, the manufacturer recommends the belt be
inspected at 60,000, and replaced if necessary. Inspect belt at 90,000 3) Remove 2 right engine mount insulator vertical bolts Remove the one
miles, and replace if necessary. This maintenance is NOT required if belt horizontal fastener. DO NOT remove large nut from center bolt of
was replaced at 60,000. Inspect belt at 120,000 miles, and replace if insulator rubber. Remove horizontal and vertical fasteners from engine
necessary. This maintenance is NOT required if belt was replaced at side of mount. Remove engine mount.
90,000 miles. 4) Remove engine support bracket from front of engine. Remove timing
belt covers, noting bolt length for installation reference. Note direction of
REMOVAL & INSTALLATION flange installation on front of crankshaft, in front of crankshaft sprocket.
Remove flange.
TIMING BELT REMOVAL 5) Rotate crankshaft, and align timing marks on camshaft sprockets and
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker, crankshaft sprocket. See Fig. 1. If reusing timing belt, mark direction of
Shadow, Spirit & Sundance (1987-89) – 1) Disconnect negative timing belt rotation for installation reference.
battery cable. Support engine and transmission with floor jack. Remove 6) Loosen timing belt tensioner bolt. Move timing belt tensioner away
front engine mount bracket. Remove upper (front outer) timing belt from timing belt, and temporarily tighten bolt. Remove timing belt.
cover. Align timing marks on front and rear camshaft sprockets and Raider & Ram 50 – 1) Disconnect negative battery cable. Drain cooling
timing mark on crankshaft sprocket. See Fig. 1. system. Disconnect upper radiator hose. Remove upper radiator
2) Remove crankshaft pulleys and vibration damper. Loosen timing belt shroud. Remove cooling fan and fan clutch assembly. Remove cooling
tensioner bolt and remove timing belt.
fan pulley. Remove all accessory drive belts. Remove power steering
Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance & pump with pressure and return hoses connected, and set aside.
TC (1990-96) – 1) Disconnect negative battery cable. Remove acces-
2) Remove power steering pump brackets. Remove A/C tensioner pulley
sory drive belts. Remove A/C compressor and power steering pump with
and mounting bracket. Remove A/C compressor (with hoses connected)
hoses attached, and secure aside (if equipped). Remove A/C compres-
and mounting bracket. Remove cooling fan bracket assembly. Remove
sor mounting bracket and drive belt tensioner. Remove power steering/
timing belt No. 1 upper outer cover and gaskets. See Fig. 2.
alternator belt tensioner.
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.
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 tempo-
rarily 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 direc-

tion.
Courtesy of Mitsubishi Motor Sales of America. 4) Again line up all timing marks and tighten tensioner against belt.
Tighten tensioner locking bolt to specification. See TORQUE SPECIFI-
Fig. 2: Exploded View Of Timing Belt & Components CATIONS. To complete installation, reverse removal procedures. Adjust
(Raider & Ram 50) drive belts to proper tension.
Stealth – 1) Remove lower splash shields. Remove cruise control
CAUTION: When reusing timing belt, ensure timing belt is installed
actuator (if equipped). Remove all drive belts. Unplug electrical connec-
in original direction of rotation.
tor at power steering pump. Remove A/C tensioner pulley and mounting
bracket. Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance &
2) Remove power steering pump, leaving hoses connected, and wire TC (1990-96) – 1) Rotate timing belt tensioner counterclockwise and
aside. Support engine. Remove front engine mount through-bolt and temporarily tighten bolt. Ensure all timing marks are aligned. See Fig. 1.
front engine mount. Install timing belt on crankshaft sprocket while holding timing belt tight
on tension side. If reusing timing belt, ensure timing belt is installed in
NOTE: Apply spray lubricant on reamer bolt during removal, as original direction of rotation.
bolt is sometimes seized in engine support bracket. 2) Install timing belt on front (radiator side) camshaft sprocket, water
pump pulley, rear camshaft sprocket and then on timing belt tensioner.
3) Remove engine support bracket bolts in proper sequence. See Fig. 3. Ensure timing belt is installed in this order.
Remove engine support bracket. Remove timing cover cap, timing belt 3) Apply rotating force on front (radiator side) camshaft sprocket in
cover, and gaskets. Using Holder (MB990767) and Adapter Bolts opposite direction to apply pressure on tension side of timing belt.
(MD998719), remove crankshaft pulley. Ensure all timing marks align. See Fig. 1.
4) Remove lower timing belt cover, gaskets, and flange. Rotate crank- 4) Install flange on front of crankshaft sprocket (if removed) with flat side
shaft to align all timing marks. See Fig. 1. Loosen belt tensioner bolt. against timing belt and offset side toward front of crankshaft. Loosen
Rotate belt tensioner counterclockwise to relieve belt tension. timing belt tensioner bolt, allowing spring tension to be applied on timing
5) If reusing timing belt, place arrow on belt to indicate belt running belt tensioner and timing belt.
direction. Remove timing belt and belt tensioner. 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.
TIMING BELT INSPECTION 6) To install remaining components, reverse removal procedure. Ensure
Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs timing belt cover bolts are installed in original location. See Fig. 4.
of oil contamination, cracks, separation, worn or missing teeth, or Tighten bolts to specification. Adjust drive belts to proper tension.
hardened black surface. Replace belt if worn, damaged or contami- Caravan & Voyager – 1) If timing belt tensioner spring was removed,
nated. Inspect belt tensioner for smooth rotation. Replace if defective. install spring on tensioner arm with end of hook facing out (away from
engine).
166 CHRYSLER
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.
Fig. 5: Identifying Timing Belt Cover Bolt Lengths

(Raider & Ram 50)
Courtesy of DaimlerChrysler Corp. 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
Fig. 4: Identifying Timing Belt Cover Bolt Lengths spring pointing away from cylinder block. Rotate belt tensioner counter-
(Except Raider, Ram 50 & Stealth) clockwise as far as possible. Temporarily tighten bolt. Align all timing
2) Ensure all timing marks are aligned. See Fig. 1. Install timing belt on marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1.
crankshaft sprocket while holding timing belt tight on tension side. See 2) Install timing belt onto crankshaft sprocket, rear cylinder bank
Fig. 1. If reusing timing belt, ensure timing belt is installed in original camshaft sprocket, water pump pulley, front cylinder bank camshaft
direction of rotation. sprocket, and timing belt tensioner. Ensure belt is installed in original
3) Install timing belt on front (radiator side) camshaft sprocket, water direction of rotation, and all timing marks are aligned. Install flange onto
pump pulley, rear camshaft sprocket and then on timing belt tensioner. crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to
Ensure timing belt is installed in this order and there is no slack in belt. apply belt tension.
4) Install flange on front of crankshaft sprocket with flat side against 3) Using Crankshaft Socket (MD998716) or equivalent, rotate crank-
timing belt and offset side toward front of crankshaft. Loosen timing belt shaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign
tensioner bolt, allowing spring tension to be applied on timing belt
all timing marks. Tighten belt tensioner bolts to specification. See
tensioner and timing belt.
TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt
5) Slowly rotate crankshaft clockwise 2 full revolutions. DO NOT rotate
tension halfway between crankshaft sprocket and camshaft sprocket on
crankshaft counterclockwise. Realign all timing marks. Tighten timing
side opposite belt tensioner.
belt tensioner bolt to specification. See TORQUE SPECIFICATIONS.
6) Install timing belt covers. Ensure bolts are installed in original
NOTE: Engine support bracket reamer bolt must be tightened
locations. See Fig. 4. Install engine support bracket. Install right side
slowly. Apply lubricant onto bolt during installation.
engine mount. Install crankshaft vibration damper.
7) To install remaining components, reverse removal procedure. Adjust 4) Belt tension should be 44-66 lbs. (20-30 kg). To install remaining
drive belts to proper tension. components, reverse removal procedure. Install bolts into proper holes.
Install covers and engine support bracket. See Figs. 3 and 6. Tighten
NOTE: Engine support bracket reamer bolt must be tightened
bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive
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 Courtesy of Mitsubishi Motor Sales of America.
tensioner to apply belt tension.
4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions Fig. 6: Identifying Timing Belt Cover Bolt Lengths (Stealth)
clockwise. DO NOT rotate counterclockwise. Realign all timing marks.
Tighten belt tensioner bolts to specification. See TORQUE SPECIFICA-
TIONS. Using belt tension gauge, measure belt tension halfway
between crankshaft sprocket and camshaft sprocket on side opposite
belt tensioner.
CHRYSLER 167
3.0L V6 – SOHC – 1987-00 (Cont.)

TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 & STEALTH) TORQUE SPECIFICATIONS (STEALTH)
Application Ft. Lbs. (N.m) Application Ft. Lbs. (N.m)
A/C Compressor Drive Belt Idler Pulley Bolt ........................................................... 40 (54) Automatic Tensioner Bolt .......................................................................................... 17 (23)
Camshaft Sprocket Bolt ............................................................................................ 70 (95) Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Vibration Damper Bolt ........................................................................ 100 (135) Crankshaft Pulley Bolt
Engine Bracket-To-Engine Bolt ................................................................................. 35 (47) 1991 ....................................................................................................... 108-116 (146-157)
Engine Mount-To-Frame Bolt .................................................................................... 50 (68) 1992-94 ................................................................................................................ 136 (185)
Engine Mount Vertical Bolt ..................................................................................... 75 (102) Engine Support Bracket Bolt
Timing Belt Cover Bolt .............................................................................................. 10 (14) 10 X 40 mm ................................................................................ ................. 47-54 (64-73)
Timing Belt Tensioner Pulley Bolt ................................................. ................. 18-21 (25-28) 10 X 40 mm .............................................................................................. 76-83 (103-113)
Water Pump Bolts ..................................................................................................... 20 (27) Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42)
TORQUE SPECIFICATIONS (RAIDER & RAM 50) Water Pump Bolt ....................................................................................................... 17 (23)
Application Ft. Lbs. (N.m) INCH Lbs. (N.m)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
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)
168 CHRYSLER
3.0L V6 – SOHC, 2001-04
Part No.
3.0L V6 – SOHC
Sebring Coupe & Stratus Coupe
2001-04 ..................................................... 2.6 Hours ... ..... T259

every 60,000 miles except in California, Massachusetts and Connecti-
cut. In California, Massachusetts and Connecticut, timing belt replace-
ment is recommended, but not required, at 60,000 miles. In these states,
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.

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 crank-
shaft pulley bolt. Remove crankshaft pulley.
4) Remove upper and lower timing belt covers. See Fig. 1. Remove
engine support bracket from front of engine.
CAUTION: Do not turn crankshaft counterclockwise.
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. Courtesy of DaimlerChrysler Corp.
tensioner upright. See Fig. 3. Apply 22-44 lbs. (98-196 N) of force to end Fig. 3: Inspecting Timing Belt Auto Tensioner
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.
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 coun- Courtesy of DaimlerChrysler Corp.
terclockwise. Check all timing marks again.
Fig. 5: Measuring Auto Tensioner Push Rod Protrusion
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 revolu-
tions clockwise and align all timing marks. DO NOT rotate counterclock-
wise.
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 Fig. 6: Installing Engine Support Bracket
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 TORQUE SPECIFICATIONS
bolts. See Fig. 6. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt, then tighten bolt to specifica-
Auto Tensioner-To-Engine Block Bolt ........................................... ................. 15-19 (20-26)
tion. See TORQUE SPECIFICATIONS. Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
10) To install remaining components, reverse removal procedure. Adjust Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186)
drive belts to proper tension. 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)
Timing Belt Lower Cover Bolt ....................................................... ............... 89-106 (10-12)
Timing Belt Rear Cover Bolt ....................................................................... 115-133 (13-15)
Courtesy of DaimlerChrysler Corp. Timing Belt Upper Cover Bolt
6-mm ............................................................................................ ............... 89-106 (10-12)
Fig. 4: Adjusting Timing Belt Tension 8-mm .......................................................................................................... 115-133 (13-15)
1
– Apply engine oil to bolt threads before installation.
2
– Final tighten bolt with full weight of engine on mount.
170 CHRYSLER
3.5L V6 – 24 Valve
Part No.
3.5L V6
Pacifica
2004 ........................................................... 2.7 Hours ... ..... T295

Information is not available from manufacturer.

damage may occur. Courtesy of DaimlerChrysler Corp.

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. Fig. 2: Removing & Installing Front Timing Belt Cover
17) Remove the timing belt tensioner and remove timing belt.
Inspection – 1) Inspect both sides of the timing belt. Replace belt if any CAUTION: If camshafts have moved from the timing marks, always
of the following conditions exist. See Fig. 4: rotate camshaft toward the direction nearest the timing marks. DO
• Hardening of back rubber or back side is glossy without resilience NOT turn camshafts a full revolution or damage to valves and/or
and leaves no indent when pressed with fingernail. pistons could result.
• Cracks on rubber back.
• Crack on peeling of canvas.
• Cracks on rib root. CAUTION: Index tensioner in the vise the same way it is installed
• Cracks on belt sides. on the engine. This ensures proper pin orientation when tensioner
• Missing teeth. is installed on the engine.
• Abnormal wear on belt sides. The sides are normal if they are sharp
Installation – 1) Place tensioner into a vise and slowly compress the
as if cut by a knife.
plunger. See Fig. 5. Total bleed down of tensioner should take about 5
• Vehicle mileage or time at component maintenance requirement.
minutes.
See MANUFACTURER’S SUGGESTED SCHEDULED MAINTE-
2) When plunger is compressed into the tensioner body, install a pin
NANCE.
2) Inspect tensioner for fluid leakage around the plunger seal. Replace through the body and plunger to retain plunger in place until tensioner is
tensioner if leaking. installed.
3) Inspect the pivot and for free movement, bearing grease leakage, and 3) Align the crankshaft sprocket with the TDC mark on oil pump cover.
smooth rotation. If not rotating freely, replace arm and pulley assembly. See Fig. 3.
CHRYSLER 171
3.5L V6 – 24 Valve (Cont.)
Fig. 4: Inspecting Timing Belt

16) Install crankshaft damper bolt. See TORQUE SPECIFICATIONS.
Fig. 3: Aligning Timing Marks 17) Install accessory drive belt tensioner. See TORQUE SPECIFICA-
4) Align the camshaft sprockets timing reference mark with the mark on TIONS.
the rear cover. See Fig. 3. 18) Install accessory drive belt.
5) Install the timing belt starting at the crankshaft sprocket going in a 19) Install the accessory drive belt splash shield and right front wheel.
counterclockwise direction. Install the belt around the last sprocket. 20) Lower vehicle.
Maintain tension on the belt as it is positioned around the tensioner 21) Tighten the rocker arm assemblies and install cylinder head covers.
pulley. See TORQUE SPECIFICATIONS.
6) Holding the tensioner pulley against the belt, install the tensioner into 22) Connect negative battery cable.
the housing and tighten bolts. See TORQUE SPECIFICATIONS. Each
camshaft mark should remain aligned at the rear cover marks.
NOTE: If the camshaft gears have been removed, it is only neces-

sary 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
9) Install front timing cover.
10) Install the upper engine mount. See TORQUE SPECIFICATIONS. Courtesy of DaimlerChrysler Corp.
11) Connect fuel supply line at fuel rail. See Fig. 2.
12) Install air cleaner housing. Fig. 5: Installing Timing Belt Tensioner
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 SPECIFICA-
TIONS.
172 CHRYSLER
3.5L V6 – 24 Valve (Cont.)
Accessory Drive Belt Tensioner Bolt ........................................................................ 21 (28)
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)
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
– Tighten to 105 INCH Lbs. (12 N.m).
Fig. 6: Installing Crankshaft Damper

CHRYSLER & EAGLE 173
1.5L 4-Cylinder – SOHC

Kit No. Part No.
1.5L 4-Cyl.
Colt
1985-86 ............................... 2.8 Hours ... .. TCK073 .. ..... T073
1987-88 ............................... 2.8 Hours ... ...... ..... ...... ..... T128
1989-90 ............................... 2.4 Hours ... .. TCK128 .. ..... T128
1991-94 ............................... 2.4 Hours ... .. TCK191 .. ..... T191
Colt (Canadian)
1985-86 ............................... 2.8 Hours ... .. TCK073 .. ..... T073
1989-91 ............................... 2.8 Hours ... .. TCK128 .. ..... T128
1992 & 1995 ....................... 2.4 Hours ... .. TCK191 .. ..... T191
Summit
1989-90 ............................... 2.4 Hours ... .. TCK128 .. ..... T128
1991-96 ............................... 2.4 Hours ... .. TCK191 .. ..... T191
Vista (Canadian)
1989-91 ............................... 2.8 Hours ... .. TCK128 .. ..... T128
1992 .................................... 2.4 Hours ... .. TCK191 .. ..... T191
1
See page A1 for information on component kits. Fig. 1: Aligning Timing Marks
tensioner mounting bolts. See Fig. 3. Ensure timing belt is not out of
NOTE: For information about tensioners and/or pulleys (when 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.
MANUFACTURER’S SUGGESTED 2) Rotate crankshaft one full revolution clockwise, until crankshaft
SCHEDULED MAINTENANCE sprocket timing mark aligns with TDC position. Recheck belt tension. To
The manufacturer recommends the belt be replaced every 60,000 miles. 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.
REMOVAL & INSTALLATION 3) To complete installation, reverse removal procedure. Adjust drive
damage may occur.
TIMING BELT
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. Courtesy of Mitsubishi Motor Sales of America.
3) Loosen timing belt tensioner bolts. Move tensioner inward toward
water pump. Temporarily tighten bolt in slot side of tensioner. Remove Fig. 2: Installing Timing Belt Tensioner
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
174 CHRYSLER & EAGLE
1.5L 4-Cylinder – SOHC (Cont.)
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)
INCH Lbs. (N.m)
Fig. 3: Adjusting Timing Belt Tension 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)
1989-96 ........................................................................................ ................. 84-108 (9-12)
Water Pump Pulley Bolt
1986-88 ........................................................................................ ............. 108-120 (12-14)
1989-96 ........................................................................................ ..................... 72-84 (8-9)
2.0L 4-Cylinder – DOHC, Except VIN Y

TIMING BELT APPLICATION tensioner to relieve timing belt tension. Remove timing belt. Remove
Application Labor Time Component Belt timing belt auto tensioner. See Fig. 1.
Kit No. Part No. 5) Remove plug from left side of cylinder block. Install a .31″ (8.0 mm)
2.0L 4-Cyl. – DOHC (4G6) diameter Phillips screwdriver into the hole against balance shaft. See
Laser Fig. 4. Screwdriver must go in at least 2.36″ (60 mm) or more. If
1, 2 3
1990-94 ............................ 3.6 Hours . .. TCK167 .. ... T167 screwdriver will only go in about .79-.98″ (20-25 mm), turn sprocket one
1, 2 4
1990-94 ............................ 3.6 Hours . ...... ..... ...... ... T168 revolution and align timing mark. Keep screwdriver in place until timing
Talon (Non-Turbo & Turbo) belt is installed. This ensures that balance shaft driven by oil pump
1, 2 3
1990-94 ............................ 3.6 Hours . .. TCK167 .. ... T167
1, 2 4 sprocket remains in correct position.
1990-94 ............................ 3.6 Hours . ...... ..... ...... ... T168
Talon (Turbo) 6) To remove timing belt “B” (balance shaft belt), hold crankshaft
1995-98 ............................ 1, 2
4.5 Hours . .. TCK167 .. ... 3
T167 sprocket stationary with a spanner wrench. Remove crankshaft sprocket
1, 2 4
1995-98 ............................ 4.5 Hours . ...... ..... ...... ... T168 bolt. Using gear puller, remove outer crankshaft sprocket.
2000 GTX (Canadian) 7) Remove crankshaft sensing blade (if equipped). See Fig. 5. Loosen
1, 2 3
1989-93 ............................ 3.6 Hours . .. TCK167 .. ... T167 timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of
1, 2 4
1989-93 ............................ 3.6 Hours . ...... ..... ...... ... T168 belt rotation for reassembly reference. Remove timing belt ”B”.
1
– Balance shaft labor time included in camshaft labor time. Inspection – 1) Inspect timing belts for damaged teeth and cracking.
2
– With Air Conditioning, add .2 hours. Ensure belts are not contaminated with oil. Check tensioners for free
With Power Steering, add .2 hours. rotation and grease leakage. Replace components if damaged or if
3
– Timing belt.
4 grease leakage exists.
– Balance shaft belt.
NOTE: A timing belt component kit is available for this application. tensioner upright. Measure rod protrusion above edge of housing. See
See page A1 for information on component kits. 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),
NOTE: For information about tensioners and/or pulleys (when replace the auto tensioner.
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED with pin hole in rod, insert set pin. Replace tensioner assembly if rod can
SCHEDULED MAINTENANCE be retracted easily into housing. Install auto tensioner on engine with set
pin in place.
For 1990-94 vehicles, the manufacturer recommends the belt be
2) Align balance shaft and crankshaft timing marks with rear cover. See
replaced every 60,000 miles.
Fig. 7 or 8. Install timing belt “B” on sprockets. If using old belt, install belt
For 1995-97 vehicles, the manufacturer recommends the belt be in original direction of rotation. Ensure there is no slack in tension side
replaced every 60,000 miles except in California. In California, timing of belt.
California, replace timing belt at 100,000 miles. CAUTION: Ensure tensioner pulley shaft does not rotate when bolt
For 1998 vehicles, the manufacturer recommends the belt be replaced is tightened, or excessive pressure will be applied to timing belt.
every 60,000 miles except in California, Connecticut and Massachu-
3) Install timing belt “B” tensioner so center of tensioner pulley is to the
setts, timing belt replacement is recommended but not required at
left and above of retaining bolt center. See Fig. 9. Rotate tensioner
60,000 miles. In these states, replace timing belt at 100,000 miles.
inward toward timing belt until belt is tight. Tighten tensioner retaining
REMOVAL & INSTALLATION 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
CAUTION: This application is an interference engine. Do not rotate mm). Readjust timing belt if belt deflection is not within specification.
CAUTION: Install crankshaft sensing blade and crankshaft sprock-
damage may occur.
ets in correct positions, or timing belt may be damaged.
TIMING BELT & BALANCE SHAFT BELT 4) Install crankshaft sensing blade (if equipped) in front of crankshaft
sprocket “B”, with offset in proper direction. See Fig. 10. Install crank-
Removal – 1) Disconnect negative battery cable. Remove engine
shaft sprocket “A”. Apply light coat of engine oil to crankshaft sprocket
undercover. Place wooden block between jack and oil pan, and raise
bolt threads, and tighten bolt to specification. See TORQUE SPECIFI-
engine slightly. Remove engine mount assembly near timing belt cover.
CATIONS. Install idler pulley (if removed).
2) Remove clamp for power steering return hose near timing belt cover.
5) Ensure camshaft, crankshaft and oil pump timing marks are still
Remove all drive belts and tensioner bracket. See Fig. 1. Remove power
aligned. See Fig. 2 or 3. DO NOT remove screwdriver from side of
steering and water pump pulleys. Rotate crankshaft clockwise so that
engine block until timing belt is installed.
No. 1 cylinder is at TDC of compression stroke. Remove crankshaft
pulley. NOTE: Intake and exhaust camshafts use same camshaft sprocket.
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure Camshaft sprockets are provided with 2 timing marks. For exhaust
timing marks are aligned. If reusing timing belts, mark timing belts camshaft sprocket, use timing mark on right with dowel pin facing
for direction of rotation. up. On intake camshaft sprocket, use timing mark on the left with
dowel pin hole on top.
3) Remove upper timing belt cover and gasket. Remove stub bolt of
engine support bracket, and remove center timing belt cover. Remove 6) Rotate camshaft sprocket so dowel pins are upward and away from
lower timing belt cover. cylinder head and timing marks are aligned with cylinder head surface.
Timing marks should face each other. See Fig. 2 or 3.
NOTE: Camshaft sprocket dowel pins will be in 12 o’clock position 7) Install timing belt on intake camshaft sprocket. Install spring clip to
when timing marks are correctly aligned. retain timing belt on sprocket. See Fig. 11. Place a wrench on each
camshaft sprocket retaining bolt. Rotate camshafts so timing marks
4) Ensure camshaft, crankshaft and oil pump sprocket timing marks are
align with each other.
aligned. See Fig. 2 or 3. Loosen tensioner pulley center bolt. Move
2.0L 4-Cylinder – DOHC, Except VIN Y (Cont.)
Fig. 1: Exploded View Of Timing Belts & Components

8) Install timing belt over exhaust camshaft. Install spring clip to retain 3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or
timing belt. Install timing belt over idler pulley, oil pump sprocket, equivalent to tensioner eccentric. Install torque wrench on adapter. See
crankshaft sprocket and tensioner pulley. Remove spring clips from Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH
camshaft sprockets. lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley.
Timing Belt Tension Adjustment (1990-92) – 1) Position timing belt 4) Hold tensioner pulley at specified torque, and tighten tensioner center
tensioner pulley so that the 2 pin holes in the center eccentric are facing bolt to specification. Do not let tensioner pulley turn with bolt. See
to the left (as viewed from timing belt end of engine) of the center bolt. TORQUE SPECIFICATIONS.
Hand tighten center bolt. 5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are
2) Remove screwdriver from balance shaft hole in side of engine block. aligned. Allow engine to stand for 15 minutes without turning crankshaft.
Install plug. Distance between top of auto tensioner housing and tensioner arm
3) Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft should be .15-.18″ (3.8-4.5 mm). See Fig. 14, Dimension “A”. If distance
1/4 clockwise until timing marks are aligned again. No. 1 cylinder should is incorrect, repeat tensioning procedure until distance is correct. Once
be at TDC of compression stroke. distance is correct, go to FINAL ASSEMBLY.
4) Attach Adapter (MD998767) to tensioner pulley eccentric. Attach Final Assembly – To install remaining components, reverse removal
torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in procedure. Ensure proper length bolts are installed in timing belt covers.
a clockwise direction. See Fig. 12. With torque applied to eccentric, See Fig. 16. See TIMING COVER BOLT LENGTH & TORQUE table.
tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). Adjust drive belts to proper tension.
5) Insert Set Screw (MD998738) through inner timing belt cover until it TIMING COVER BOLT LENGTH & TORQUE
contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin
Application INCH Lbs. (N.m)
can be removed. Remove set screw from engine.
“A” 6 x 16 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes
“B” 6 x 18 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
without turning crankshaft. Measure distance between top of auto
“C” 6 x 25 mm Loose Washer Bolt .............. .......................................................... 58 (6.5)
tensioner body and tensioner arm. The distance should be .15-.18″ “D” 6 x 25 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
(3.8-4.5 mm). See Fig. 14, Dimension “A”. If distance is not correct, “E” 6 x 45 mm Flange Bolt ........................... ............................................... 89-106 (10-12)
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.
Fig. 2: Aligning Timing Belt “A” Timing Marks (1990-93)
Fig. 4: Holding Balance (Silent) Shaft Stationary
Fig. 3: Aligning Timing Belt “A” Timing Marks (1994-98)

Fig. 9: Installing Timing Belt “B” Tensioner
Fig. 5: Locating Timing Belt “B” (Balance Shaft Belt)

Components
Fig. 10: Installing Crankshaft Sprocket & Crankshaft Sensing

Blade
Fig. 6: Inspecting Timing Belt Auto Tensioner
Fig. 11: Installing Timing Belt On Intake Sprockets
Fig. 7: Aligning Timing Belt “B” (1990-92)
Fig. 8: Aligning Timing Belt “B” (1993-98)

Fig. 12: Adjusting Timing Belt Tension (1990-92)

Fig. 16: Installing Timing Belt Cover Bolts
Auto Tensioner Bolt ................................................................................................... 17 (24)
Balance Shaft Sprocket Bolt ..................................................................................... 33 (46)
Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26)
Courtesy of Mitsubishi Motor Sales of America. Engine Mount-To-Body Through-Bolt
1990-92 ........................................................................................ ................. 43-58 (60-80)
Fig. 13: Installing Set Screw On Tensioner Pulley 1993-98 ........................................................................................................ 72-87 (98-118)
Engine Mount-To-Engine Bolt/Nut
1990-92 ........................................................................................ ................. 36-47 (50-65)
1993-98 .................................................................................................................... 49 (67)
Timing Belt “B” (Balance Shaft) Tensioner Bolt ............................................. 11-16 (15-20)
Timing Belt Tensioner Pulley Center Bolt ................................................................ 35 (48)
Water Pump Bolt ....................................................................................................... 10 (14)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
Water Pump Pulley Bolt .............................................................................................. 80 (9)
Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion

Kit No. Part No.
Colt Vista
1984-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T090
Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... ..... T089
1987-91
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
Camshaft ......................... 2 2.8 Hours ... TCK158A . ..... T158
Ram 50
1983-86
Balance Shaft .................. 2.8 Hours ... ...... ..... ...... ..... T090
Camshaft ......................... 3 2.3 Hours .. ...... ..... ...... ..... T089
1987-89
Balance Shaft .................. 2.8 Hours ... ...... ..... ...... ..... T159
Vista (Canada)
1989-91
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
2000GTX (Canada)
1989-92
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... ..... T155
1
– Balance Shaft labor time included in camshaft labor time.
2 Fig. 1: Aligning Timing Marks
3


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 assem- Inspection – Inspect back of belt for hardness, non-elasticity and glossy
bly. On 1989-91 models, support engine and remove upper engine surface. If no mark is produced when fingernail is forced into it, replace
mount located near timing belt cover. belt. Check for rounded sides on belt, flaking, peeling, cracking and
2) On all models, position No. 1 cylinder at TDC of compression stroke. separating rubber. Cracks are most evident at base of tooth.
Loosen pulley bolts. Remove drive belts. Remove crankshaft, water Installation – 1) Install timing belt “B”, ensuring tension side has no
pump and power steering pulleys. Remove upper and lower front timing slack. Align crankshaft and balance shaft sprocket timing marks with
belt covers. marks on timing case. See Fig. 3. Install tensioner “B” so only light
3) On 1989-91 models, remove tensioner pulley bracket. pressure is on belt. Ensure flange on tensioner is mounted away from
4) On all models, relieve camshaft timing belt tensioner pressure and engine and finger-tighten bolt. Ensure that the pulley is to left of
secure tensioner toward water pump. If camshaft timing belt is to be installation bolt and pulley flange faces front of engine. See Fig. 4.
reused, mark belt with an arrow indicating direction of rotation and 2) Lift tensioner with finger tip until slack is removed from tension side of
remove camshaft timing belt. belt. Tighten tensioner bolt, being careful to prevent turning shaft.
5) Rotate crankshaft in direction of rotation and align timing marks. See Ensure timing marks are in alignment. Tighten right silent shaft bolt.
Fig. 1. Remove crankshaft sprocket attaching bolt. Loosen main ten- 3) Check belt tension by pressing center of tension side inward, using
sioner pivot and disengage spring from boss on water pump. Remove index finger and measuring belt deflection. Deflection should be
tensioner assembly. Remove balance shaft belt (belt “A”). .195-.265″ (5.0-7.0 mm). Readjust if not within specification.
6) Remove camshaft sprocket, then crankshaft sprocket and flange. 4) Ensure camshaft timing belt sprockets align with timing marks.
Remove plug from lower left side of cylinder block, then insert screw- Ensure tensioner is fully toward water pump and install camshaft timing
driver into hole to hold balance shaft in position while removing oil pump belt (belt “A”) in order of crankshaft sprocket, oil pump sprocket and
sprocket nut. See Fig. 2. camshaft sprocket. Ensure tension side of belt has no slack. Loosen
7) Loosen right side balance shaft sprocket bolt, then remove balance tensioner mounting bolt and nut, and allow tensioner spring to tension
shaft belt tensioner. Remove balance shaft timing belt (belt “B”). belt.

5) Tighten slot side bolt, and then tighten nut. Ensure all timing marks TORQUE SPECIFICATIONS
are in correct alignment. Turn crankshaft clockwise one revolution.
Loosen mounting nut and bolt to allow tensioner to readjust. Tighten slot TORQUE SPECIFICATIONS
side bolt, then tighten nut. Reverse removal procedure to complete Application Ft. Lbs. (N.m)
reassembly. Adjust drive belts to proper tension. Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
1983-85 .......................................................................................................... 11-15 (15-20)
1986-91 ........................................................................................ ................. 15-21 (20-29)
Front Cover Bolts
1983-88 ........................................................................................ ................. 15-19 (20-26)
1989 M8 X 30 Bolt ..................................................................... ................. 20-26 (27-35)
Except 1989 M8 X 30 Bolt ......................................................... ................. 14-20 (19-27)
Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
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
Fig. 3: Aligning Balance Shaft Sprocket Except 8 X 65 mm .......................................................................................... 9-11 (12-15)
8 X 65 mm .................................................................................. ................. 15-19 (20-26)
1
– Tighten bolts to 84-108 INCH lbs. (9-12 N.m).
Fig. 4: Installing Balance Shaft Tensioning Pulley

3.2L & 3.5L V6
TIMING BELT APPLICATION MANUFACTURER’S SUGGESTED
Kit No. Part No.
3.2L V6 The manufacturer recommends the belt be replaced every 105,000
Concorde & Intrepid (Includes Canadian) miles up to the 1999 model year. For 2000-02 model years, the
1998-01 .............................. 1 2.8 Hours .. .. TCK295 .. ..... T295 manufacturer recommends the timing belt be replaced at 100,000 miles
3.5L V6 for Federal vehicles, and 105,000 miles for California vehicles. For
Concorde & Intrepid (Includes Canadian) 2003-04 model years, the manufacturer recommends the timing belt be
1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. ..... T219 replaced at 102,000 miles.
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. ..... T255
2000-02 .............................. 1 2.7 Hours .. .. TCK295 .. ..... T295
2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... ..... T295 REMOVAL & INSTALLATION
LHS & 300M TIMING BELT
1994 ................................... 1 2.7 Hours .. .. TCK219 .. ..... T219
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. ..... T255 CAUTION: This application is an interference engine. Do not rotate
1999-02 .............................. 1 2.7 Hours .. .. TCK295 .. ..... T295
2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... ..... T295
damage may occur.
New Yorker
1994 ................................... 1 2.7 Hours .. .. TCK219 .. ..... T219
1995-96 .............................. 1 2.7 Hours .. .. TCK255 .. ..... T255 CAUTION: The following procedure can only be used if camshaft
Prowler sprockets have NOT been loosened or removed. If camshaft
1999-02 ............................... 2.8 Hours ... ...... ..... ...... ..... T295 sprockets have been removed, special tools and timing procedure
Vision are required.
1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. ..... T219
1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. ..... T255 Removal – 1) Disconnect negative battery cable from jumper terminal.
1 Remove upper radiator crossmember (may also be referred to as the
engine compartment support). Remove electric cooling fan module with
fans.

Fig. 1: Exploded View Of Timing Belt & Components (2000 & Up)
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.
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.
Installation – 1) When tensioner is removed from engine, it is neces-
sary to compress plunger into tensioner body. Place timing belt ten-
sioner 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 cam-
shafts 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 counter-
clockwise 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 proce-
dure. Adjust drive belts to proper tension.
8) Start engine and allow to idle for about one minute. If noise is present
Fig. 2: Aligning Camshaft Sprocket Timing Marks in timing belt tensioner, air has possibly entered tensioner. To remove
air, run engine at 1600-2000 RPM for 10 minutes to purge air.
CAUTION: This procedure can only be used when the camshaft

sprockets have NOT been loosened or removed from the cam-
shafts.
3.2L & 3.5L V6 (Cont.)
1993-97 .................................................................................................................. 85 (115)
1999-04 .................................................................................................................... 70 (95)
M6 ................................................................................................ ..................................... 1
M8 ............................................................................................................................ 21 (28)
M10 .......................................................................................................................... 40 (54)
Timing Belt Tensioner Pulley Assembly ................................................................... 45 (61)
INCH Lbs. (N.m)
Water Pump Bolts ................................................................................................... 106 (12)
1
– Tighten bolts to 106 INCH lbs. (12 N.m).
Fig. 4: Compressing Tensioner

CHRYSLER & MITSUBISHI 185

Part No.
2.3L 4-Cyl. – Turbo Diesel
Pickup
1983-85
1
Balance Shaft ........................................ 1.8 Hours .. ..... T092
1
Camshaft ............................................... 1.8 Hours .. ..... T091
Ram 50
1983-85
1
1
Camshaft ............................................... 1.8 Hours .. ..... T091
1


camshaft or crankshaft when timing belt is removed, or engine Fig. 2: Removing Silent Shaft Sprockets
damage may occur.
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
TIMING BELT & SPROCKETS spacer with chamfered end toward seal.
Removal – 1) Disconnect negative battery cable. Remove drive belts, 3) Install both silent shaft sprockets. Tighten nut and bolt to specification.
fan, pulleys, and timing belt covers. Position cylinder No. 1 at TDC of Keep silent shafts from turning by using method described in removal
compression stroke and ensure timing marks are in alignment. See procedure.
Fig. 1. 4) Position and secure tensioner “B” fully toward water pump. Align
2) Mark belts indicating direction of rotation. Loosen nuts and bolts timing marks on crankshaft sprocket and silent shaft sprockets. See
securing belt tensioners. Pivot tensioners toward water pump and Fig. 4. Install timing belt “B”, noting reference mark if refitting old belt.
secure. Remove timing belts and all necessary sprockets. 5) Install timing belt “B”, ensuring tension side has no slack. Check
3) Remove silent shaft sprockets by removing plug from right side of alignment of timing marks. Loosen tensioner “B” mounting nut and bolt,
block and cover from left side of block. Insert screwdriver and socket and allow tensioner spring pressure to adjust belt.
extension into holes to hold silent shafts in place. See Fig. 2. 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
Courtesy of DaimlerChrysler Corp. 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
Installation – 1) Install crankshaft sprocket and flange ensuring flange sprocket and injection pump sprocket. Measure belt deflection. Deflec-
on crankshaft sprocket “B” is installed correctly. See Fig. 3. Mount tion should be .16-.20″ (4-5 mm). Reverse removal procedure to
injection pump sprocket, if removed, and tighten nut to specifications. complete installation. Adjust drive belts to proper tension.
186 CHRYSLER & MITSUBISHI
2.3L 4-Cylinder – Diesel (Cont.)
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)
1
Courtesy of DaimlerChrysler Corp. – Tighten to 108-120 INCH lbs. (12-14 N.m).
Fig. 3: Installing Crankshaft Sprocket
Fig. 4: Aligning Timing Belt “B” Marks

2.4L 4-Cylinder
Kit No. Part No.
Pickup
1990-92
1
Balance Shaft ............... .......... .......... ...... ..... ...... ..... T159
Camshaft ......................... 2 2.3 Hours .. .. TCK124 .. ..... T124
1993-96
1
Balance Shaft ............... .......... .......... ...... ..... ...... ..... T168
Camshaft ......................... 2 2.3 Hours .. ...... ..... ...... ..... T229
Ram 50
1990-91
1
Balance Shaft ............... .......... .......... ...... ..... ...... ..... T159
1992
1
Balance Shaft ............... .......... .......... ...... ..... ...... ..... T159
1993
1
Balance Shaft ............... .......... .......... ...... ..... ...... ..... T168
Camshaft ......................... 3 2.3 Hours .. ...... ..... ...... ..... T229 Courtesy of DaimlerChrysler Corp.
1
– Balance shaft labor time included in camshaft labor time. Fig. 1: Aligning Front Timing Belt
2
3


REMOVAL & INSTALLATION Fig. 2: Holding Silent Shaft In Stationary Position

TIMING BELT Installation – 1) Install rear crankshaft sprocket and flange. Install right
Removal – 1) Disconnect negative battery cable. Remove radiator silent shaft sprocket and spacer. Spacer should be installed with
shroud, cooling fan and pulley. Remove all drive belts and crankshaft chamfered end into oil seal. Align timing marks. See Fig. 3. Install rear
pulley. Remove upper timing belt covers and gaskets. Note bolt length timing belt (belt “B”) on sprockets.
and location. 2) Install rear tensioner. Hold tensioner tightly against belt while tight-
ening bolts. Ensure deflection is .20-.28″ (5.0-7.1 mm). See Fig. 4.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed Install camshaft sprocket. Tighten camshaft sprocket bolt to specifica-
from timing belt end of engine). If timing belt is to be reused, mark tion. See TORQUE SPECIFICATIONS.
direction of rotation before removing. 3) Install front timing belt tensioner, tension spring and spacer. Ensure
spring is properly engaged against water pump case. Rotate tensioner
2) Remove crankshaft sprocket bolt and washer. Rotate crankshaft
toward water pump, and temporarily tighten bolts. Ensure timing marks
clockwise (as viewed from timing belt end of engine) until cylinder No. 1
are aligned. See Fig. 1. Install front timing belt (belt “A”) on crankshaft.
is at TDC of compression stroke. Align timing mark on camshaft
4) Apply pressure on tension side of timing belt while installing belt (in
sprocket with mark on cylinder head. See Fig. 1.
order) on crankshaft, oil pump and camshaft sprockets. Loosen ten-
3) Loosen timing belt tensioner adjustment bolt, and move tensioner
sioner to apply spring pressure to timing belt.
toward water pump. Tighten bolt to secure tensioner. Remove front
5) To apply tension to belt, rotate crankshaft clockwise until camshaft
timing belt (belt “A”) and tensioner. DO NOT rotate crankshaft after
sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten
timing belt has been removed.
tensioner spacer nut.
4) Remove camshaft sprocket (if necessary). Remove oil pump sprocket
6) To check belt tension, apply slight thumb pressure and measure
access plug from cylinder block. See Fig. 2. Insert a .31 (8.0 mm)
deflection between camshaft and oil pump sprocket. Belt deflection
diameter Phillips screwdriver to block left silent shaft.
should be .55″ (14.0 mm). See Fig. 5. To complete installation, reverse
5) Remove oil pump sprocket nut, and remove sprocket. Remove front
removal procedure. Adjust drive belts to proper tension.
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.
A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
Engine Support Bracket Bolt ........................................................ ................. 36-47 (49-64)
Timing Belt “A” Tensioner Bolt ...................................................... ................. 16-22 (22-30)
Timing Belt “B” Tensioner Bolt ........................................................................ 11-16 (15-22)
Courtesy of DaimlerChrysler Corp. Water Pump Bolt
Except 8 X 65 mm .................................................................................................. 10 (14)
Fig. 3: Aligning Rear Timing Belt 8 X 65 mm .................................................................................. ................. 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)
Fig. 5: Checking Timing Belt “A” Tension

3.0L V6 – DOHC
TIMING BELT APPLICATION sensor and crankshaft position sensor. Remove crankshaft pulley. On
Application 1
Labor Time Component Belt vehicles with ABS, remove overflow tank and bracket. Remove
Kit No. Part No. generator/air conditioning idler pulley.
3.0L V6 – DOHC
Diamante NOTE: Remove remaining engine mount bracket bolts in
1992-95 ............................... 4.7 Hours ... .. TCK195 .. ..... T195 sequence. Lubricate reamer bolt with penetrating oil before and
Stealth during removal. See Fig. 1.
1991-96
Non-Turbo ........................ 3.4 Hours ... .. TCK195 .. ..... T195 2) Remove timing belt covers. Turn crankshaft clockwise to align all
Turbo ................................ 3.6 Hours ... ...... ..... ...... ..... T195 timing marks. Loosen center bolt on tensioner pulley to relieve belt
3000GT tension. Remove timing belt. Mark rotation direction if belt is to be
1991-99 reused.
Non-Turbo ........................ 3.9 Hours ... .. TCK195 .. ..... T195
Turbo ................................ 4.3 Hours ... ...... ..... ...... ..... T195
1


SCHEDULED MAINTENANCE Courtesy of DaimlerChrysler Corp.
Fig. 1: Removing Engine Support Bracket Bolts

CHRYSLER
Up to 1993 model year, the manufacturer recommends the belt be Removal (Stealth & 3000GT) – 1) Disconnect negative battery cable.
replaced every 60,000 miles. For 1994-96 model years, the manufac- Remove lower splash shields. Remove cruise control actuator (if
turer recommends replacing the timing belt at 60,000 miles, except in equipped). Remove drive belts. Remove alternator. Remove drive belt
California. In California, belt replacement is recommended, but not tensioner.
required at 60,000 miles. Replace belt at 100,000 miles, unless previ- 2) Using Holder (MB990767) and Adapter Bolts (MD998754) or equiva-
ously changed. lent, 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.
MITSUBISHI
For 1991-93 model years, the manufacturer recommends the belt be NOTE: Engine support bracket reamer bolt may be seized. Apply
replaced every 60,000 miles. penetrating lubricant to bolt during removal.
3) Remove drive belt idler pulley. Remove engine support bracket bolts
replaced every 60,000 miles except in California. In California, timing
in sequence. See Fig. 1. Remove engine support bracket. Remove
belt replacement is recommended, but not required, at 60,000 miles.
timing belt upper and lower covers, noting length and location of cover
Replace timing belt at 100,000 miles, unless previously changed.
bolts.
For 1996-97 model years, the manufacturer recommends the belt be 4) Rotate crankshaft to align all timing marks. See Fig. 3. Loosen
replaced every 60,000 miles except in California and Massachusetts. In tensioner center bolt. Remove timing belt.
California and Massachusetts, timing belt replacement is recom-
Installation (All Models) – 1) Place automatic tensioner assembly in a
mended, but not required, at 60,000 miles. Replace timing belt at
soft-jawed vise. Slowly close vise to press rod back into tensioner until
100,000 miles, unless previously changed.
both rod and housing holes are aligned. Install a .055″ (1.40 mm)
For 1998 model year, the manufacturer recommends the belt be diameter wire through both holes.
replaced every 60,000 miles except in California, Connecticut, and 2) Remove tensioner from vise, and install assembly with wire in place.
Massachusetts. In California, Connecticut, and Massachusetts, timing Install crankshaft sprocket (if removed). Align timing marks on crank-
belt replacement is recommended, but not required, at 60,000 miles. In shaft and camshaft sprockets. See Fig. 3.
changed. CAUTION: Turning camshaft sprockets while No. 1 cylinder is at
TDC may damage valve and piston. Use care when aligning timing
marks.
REMOVAL & INSTALLATION 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.
damage may occur.
WARNING: Use care when aligning timing marks. When camshaft
TIMING BELT sprocket timing marks are in indicated area, camshaft is under
valve spring pressure and may rotate suddenly, pinching hand
Removal (Diamante) – 1) Disconnect negative battery cable. Remove
between sprockets.
left front and left side splash shields. Using engine hoist, lift engine to
remove weight from engine mounts. Remove alternator and drive belt 4) If camshaft sprocket timing mark is within indicated area, carefully
tensioner assembly. Remove engine support bracket. Disconnect power rotate camshaft sprocket until timing mark is located in nearest safe
steering connections. On 1993-95 models, remove camshaft position area. See Fig. 4.
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.
Fig. 2: Exploded View of Timing Belt Components
Fig. 4: Aligning Timing Marks to Prevent Valve & Piston Damage
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. Courtesy of Mitsubishi Motor Sales of America.
NOTE: If necessary, crankshaft sprocket may be turned one tooth Fig. 5: Aligning Timing Marks (Final Alignment)
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 sprock-
ets 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.

Automatic Tensioner Bolt .......................................................................................... 17 (23)
Engine Support Bracket Bolt
10 X 40 mm ................................................................................ ................. 47-54 (64-73)
Except 10 X 40 mm .................................................................................. 76-83 (103-113)
Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42)
Water Pump Bolt ....................................................................................................... 17 (23)
INCH Lbs. (N.m)

192 CHRYSLER, EAGLE & MITSUBISHI
1.6L 4-Cylinder – DOHC
TIMING BELT APPLICATION 2) Inspect auto tensioner for leaks. Replace, if necessary. Inspect
Application Labor Time Belt tensioner pulley and idler pulley for smooth rotation. Replace if bearings
Part No. are worn.
1.6L 4-Cyl. – DOHC
CAUTION: Install flange and crankshaft sprocket in correct direc-
Colt & Summit
1 tion to prevent damage to timing belt.
1989-90 .................................................... 3.6 Hours .. ..... T165
Colt 100, Colt 200 & Vista (Canada) Installation – 1) Rotate timing belt tensioner pulley so that the 2 pin
1
1989-90 .................................................... 3.6 Hours .. ..... T165 holes are to the left of the center bolt. See Fig. 4. Tighten center bolt
Mirage finger tight. Leave Allen wrench or pin installed in auto tensioner.
2
1989 & 1991-92 ....................................... 3.4 Hours .. ..... T165
2) Rotate camshaft sprockets so dowel pins face upward and timing
1
– With Air Conditioning, add .2 hours. marks on sprockets align. See Fig. 2. Outer marks on sprockets should
With Power Steering, add .3 hours. be aligned with cylinder head surface. When exhaust camshaft sprocket
2
– With Air Conditioning, add .4 hours. is released, camshaft will rotate one tooth in counterclockwise direction.
With Power Steering, add .2 hours. When installing timing belt, ensure this rotation is compensated for.
NOTE: For information about tensioners and/or pulleys (when 3) Rotate crankshaft and align timing marks on crankshaft and oil pump
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED 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
SCHEDULED MAINTENANCE camshaft sprocket.
The manufacturer recommends the belt be replaced every 60,000 miles. 5) Install box wrench on both camshaft sprocket bolts. Install timing belt
around exhaust camshaft sprocket while holding camshaft sprocket bolt
REMOVAL & INSTALLATION to align timing mark on camshaft sprocket with timing mark.
6) Install another spring-type paper clip on timing belt and exhaust
CAUTION: This application is an interference engine. Do not rotate camshaft sprocket to hold belt on sprocket. Install clip below cylinder
camshaft or crankshaft when timing belt is removed, or engine head surface, on outer side of camshaft sprocket.
damage may occur. 7) Install timing belt in the following order: around idler pulley, oil pump
sprocket, crankshaft sprocket and tensioner pulley. Remove both
NOTE: Replacement procedures include revised information from spring-type paper clips. Rotate tensioner pulley inward toward timing
Chrysler technical service bulletin 09-01-94; January 28, 1994. belt until belt is NOT sagging. Temporarily tighten center bolt on
tensioner pulley. Ensure all timing marks are aligned.
TIMING BELT CAUTION: Ensure all timing belt teeth are engaged with teeth on
Removal – 1) Raise and support vehicle. Remove lower left engine camshaft, oil pump and crankshaft sprockets.
compartment splash shield. Support weight of engine from above with
8) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise,
Support Fixture (C-4852 or 7137) or equivalent. On timing belt end of
then rotate clockwise until No. 1 cylinder is at TDC. Ensure timing marks
engine, remove engine mount bracket connecting engine to body.
are aligned. Loosen center bolt on tensioner pulley.
2) Loosen, but do not remove, water pump pulley bolts. Remove
9) Note pin holes in tensioner pulley. Use socket wrench to rotate
generator and power steering pump drive belts. Remove water pump
tensioner pulley. Using INCH lb. torque wrench and Socket Wrench
pulley.
(MD998752), apply a clockwise torque of 24 INCH lbs. (2.7 N.m) on
NOTE: It is necessary to lower engine slightly to remove the tensioner pulley. See Fig. 5. With torque applied to tensioner pulley,
crankshaft 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
3) Remove accessory drive belt tensioner pulley bracket. See Fig. 1. from auto tensioner. Remove set screw.
Remove A/C compressor drive belt (if equipped). Remove water pump 11) Rotate crankshaft clockwise 6 complete revolutions and leave in this
pulley. Remove crankshaft pulley-to-crankshaft sprocket bolts. Remove position for approximately 15 minutes. After 15 minutes, measure
crankshaft pulley. It is NOT necessary to remove crankshaft pulley distance between bottom edge of tensioner arm and top of auto
center bolt. tensioner body. Distance should be .15-.18″ (3.8-4.5 mm). See Dimen-
4) Remove upper and lower timing belt covers. sion “A” in illustration. See Fig. 6.
CAUTION: Crankshaft may need to be rotated up to 6 revolutions 12) If distance is not correct, loosen timing belt tensioner pulley center
before all sprockets are properly aligned. bolt. Use Set Screw to compress auto tensioner again. Readjust timing
belt tension using Socket Wrench (MD998752) and INCH lb. torque
5) Rotate engine clockwise (as viewed from timing belt end of engine) to wrench until correct distance of .15-.18″ (3.8-4.5 mm) is obtained.
align all timing marks so No. 1 cylinder is at TDC of compression stroke. 13) Remove set screw. Install rubber plug in rear timing belt cover. Install
See Fig. 2. If reusing belt, mark belt with original rotation direction. upper and lower timing belt covers. Ensure timing belt cover bolts are
6) Remove rubber plug from inner timing belt cover. Install Set Screw installed in correct location. See Fig. 7.
(MD998738) into engine support bracket until it contacts auto tensioner 14) Install crankshaft pulley. Install A/C compressor belt (if equipped).
arm. See Fig. 3. Remove auto tensioner. Loosen timing belt tensioner Install accessory drive belt tensioner bracket. Install water pump pulley.
pulley center retaining bolt. Install generator and power steering pump drive belts. Adjust drive belts
7) Compress auto tensioner push rod by SLOWLY rotating Set Screw to correct tension.
(MD998738) until hole in auto tensioner aligns with hole in auto 15) Install engine mount bracket on timing belt end of engine. Remove
tensioner body. Push rod may need to be rotated to align holes. Insert a engine support fixture. Install lower splash shield.
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 contami-
nation. Inspect all sprockets for damage. Check tensioner pulley and
idler pulley for grease leakage and roughness in rotation. Replace
components if damaged.
CHRYSLER, EAGLE & MITSUBISHI 193
1.6L 4-Cylinder – DOHC (Cont.)

Fig. 3: Retracting Auto Tensioner Rod
Fig. 4: Positioning Timing Belt Tensioner Pulley
Accessory Drive Belt Tensioner Pulley Bracket Bolt ................... ................. 17-20 (23-27)
Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30)
Crankshaft Sprocket Center Bolt .................................................. ............. 80-94 (109-127)
Engine Mount Bracket
To-Body Through-Bolt .................................................................. ................. 43-58 (60-80)
To-Engine Bracket Bolt/Nut ......................................................... ................. 36-47 (50-65)
Timing Belt Cover
Left Lower Rear Cover Bolt ........................................................ ................. 22-30 (30-41)
Courtesy of DaimlerChrysler Corp. INCH Lbs. (N.m)
Fig. 5: Adjusting Timing Belt Tension Timing Belt Cover Bolt .................................................................. ............... 84-106 (10-12)
Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

1.8L 4-Cylinder – VINs B & T

TIMING BELT APPLICATION Inspection – Inspect timing belts for damaged teeth or cracks. Ensure
Application Labor Time Component Belt belts are not contaminated by oil. Check tensioners for freedom of
Kit No. Part No. rotation. Replace components if damaged.
1.8L 4-Cyl.
CAUTION: Ensure right silent shaft spacer is installed with cham-
Eclipse & Laser
fered side toward oil seal, or damage to oil seal will result.
1990-94
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159 Installation – 1) Coat outer diameter of right silent shaft spacer with
Camshaft ......................... 2 2.4 Hours .. .. TCK158 .. ..... T158 engine oil. Install spacer with chamfered side toward oil seal. Install right
Talon silent shaft sprocket. Align crankshaft sprocket “B” and right silent shaft
1993-94 timing marks. See Fig. 4. Install timing belt “B” on sprockets. Ensure belt
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
is installed in original direction of rotation and no slack exists in belt.
1
– Balance shaft labor time included in camshaft labor time. CAUTION: When tightening bolt, ensure tensioner does not rotate,
2
– With Air Conditioning, add .2 hours. or excessive pressure will be applied to timing belt.
2) Install timing belt tensioner “B” so center of pulley is located left of
NOTE: A timing belt component kit is available for this application. tensioner bolt. See Fig. 5. Ensure flange on tensioner pulley is toward
See page A1 for information on component kits. 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
NOTE: For information about tensioners and/or pulleys (when should be .20-.28″ (5.0-7.1 mm). Readjust timing belt if belt deflection is
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED camshaft and oil pump sprockets. Tighten bolts to specification. See
SCHEDULED MAINTENANCE TORQUE SPECIFICATIONS.
5) Install tensioner spring, tensioner spacer and timing belt “A” ten-
The manufacturer recommends the belt be replaced every 60,000 miles. sioner. 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
REMOVAL & INSTALLATION pump sprocket timing marks, remove plug from cylinder block. See
TIMING BELT Fig. 3. Insert a .31″ (8.0 mm) diameter Phillips screwdriver into plug
hole.
CAUTION: To prevent engine damage, DO NOT rotate crankshaft 7) If screwdriver can only be inserted .79-.98″ (20.0-24.9 mm), rotate oil
counterclockwise (as viewed from timing belt end of engine). pump sprocket one revolution, and realign timing mark. Insert screw-
driver, and ensure it can be inserted at least 2.36″ (59.9 mm). DO NOT
Removal – 1) Disconnect negative battery cable. Disconnect power remove screwdriver until timing belt is installed.
steering hose clamp. Remove engine undercover. Place wooden block 8) Install timing belt “A” on sprockets. Ensure no slack exists on tension
between jack and oil pan. Raise engine slightly. side of belt. See Fig. 2. Install timing belt on crankshaft sprocket “A”, oil
2) Remove engine mount assembly near timing belt cover. Remove all pump sprocket, and then on camshaft sprocket. If reused, ensure belt is
drive belts and tensioner pulley bracket. See Fig. 1. Remove power installed in original direction of rotation.
steering, water pump and damper pulleys. Remove adapter and crank- 9) Loosen tensioner nut to allow spring tension to be applied to timing
shaft pulley. belt. Ensure all timing marks are aligned. Remove screwdriver and
install plug. To apply tension on timing belt, rotate crankshaft clockwise
NOTE: Ensure timing marks are aligned. Mark direction of rotation so camshaft sprocket moves 2 teeth past timing mark on rear timing belt
of all timing belts. cover. See Fig. 7. DO NOT rotate crankshaft counterclockwise.
3) Remove upper and lower timing belt covers and gaskets. Remove CAUTION: DO NOT tighten tensioner spacer nut before tightening
access cover. Remove crankshaft sprocket “A” bolt and washer. Rotate tensioner bolt, or timing belt tensioner will rotate and apply
crankshaft clockwise (as viewed from timing belt side of engine), and excessive pressure on timing belt.
align timing mark on camshaft sprocket with timing mark on rear upper 10) Rotate tensioner inward toward timing belt. Ensure timing belt fully
timing belt cover. See Fig. 2. engages camshaft sprocket. Tighten timing belt tensioner bolt. Tighten
4) Loosen timing belt tensioner bolt for timing belt “A”. Move tensioner tensioner spacer nut. At midway location between camshaft sprocket
toward water pump, and tighten tensioner bolt. Remove timing belt. and oil pump sprocket, push timing belt “A” outward toward lower timing
5) Remove timing belt tensioner, tensioner spacer and tensioner spring. belt cover. Note clearance between timing belt and cover. See Fig. 8.
See Fig. 1. Remove camshaft sprocket. Remove plug from side of Clearance should be .47″ (12.0 mm). Timing belt may need to be
cylinder block, and install a .31″ (8.0 mm) diameter Phillips screwdriver readjusted.
to hold left silent shaft. See Fig. 3. 11) To complete installation, reverse removal procedure. Ensure proper
6) Remove oil pump sprocket nut, and remove sprocket. Remove length bolts are installed in designated areas in timing belt covers. See
crankshaft sprocket “A” and flange. Remove timing belt tensioner “B”. If Fig. 9. Adjust drive belts to proper tension.
timing belt “B” is to be reused, mark direction of timing belt rotation for
reassembly reference. Remove timing belt “B”.
1.8L 4-Cylinder – VINs B & T (Cont.)

Fig. 2: Aligning Timing Belt “A” Timing Marks
Fig. 3: Holding Silent Shaft In Stationary Position
1.8L 4-Cylinder – VINs B & T (Cont.)

Fig. 4: Aligning Timing Belt “B” Timing Marks
Fig. 9: Identifying Timing Belt Cover Bolt Locations
Flywheel/Drive Plate Bolt .............................................................. ........... 94-101 (127-137)
Front Cover Bolt .............................................................................................. 11-13 (15-18)
Timing Belt “A” Tensioner Bolt ...................................................... ................. 16-22 (22-30)
Water Pump Bolt
Except 8 X 65 mm .................................................................................................. 10 (14)
8 X 65 mm .................................................................................. ................. 15-19 (20-26)
INCH Lbs. (N.m)
Fig. 6: Installing Crankshaft Sprockets Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
Fig. 7: Applying Tension To Timing Belt “A”

1.8L 4-Cylinder – VINs C & D
TIMING BELT APPLICATION 3) If timing belt is to be reused, mark direction of rotation before
Application Labor Time Component Belt removing. Loosen timing belt tensioner bolt. Using a screwdriver, move
Kit No. Part No. tensioner away from timing belt. Tighten bolt to secure tensioner.
1.8L 4-Cyl. Remove timing belt.
Colt
1
1992-94 .............................. 2.4 Hours .. ...... ..... ...... ..... T201
Colt Vista
1
1992-94 .............................. 2.4 Hours .. ...... ..... ...... ..... T201
Expo
2
1992-94 .............................. 2.4 Hours .. .. TCK201 .. ..... T201
Mirage
1
1993-96 .............................. 2.4 Hours .. .. TCK201 .. ..... T201
1
1997-02 .............................. 2.4 Hours .. ...... ..... ...... ..... T288
Summit
1
1992-96 .............................. 2.4 Hours .. ...... ..... ...... ..... T201
Summit Wagon
1
1992-96 .............................. 2.4 Hours .. ...... ..... ...... ..... T201
1
2


available), see ALPHABETICAL MODEL LISTING. Fig. 1: Exploded View Of Timing Belt & Components
CHRYSLER & EAGLE
MITSUBISHI
For 1992-93 models, the manufacturer recommends the belt be
replaced at 60,000 miles.
California, replace timing belt at 100,000 miles, unless previously
changed.
replaced every 60,000 miles except in California, Connecticut, and
Massachusetts. In California, Connecticut, and Massachusetts, timing
changed.
Fig. 2: Aligning Timing Marks (1992-96)

Inspection – Check belt teeth for cracks, damage and oil contamina-
TIMING BELT tion. Inspect all sprockets for damage. Check belt tensioner for grease
Removal – 1) Disconnect negative battery cable. Remove under cover. leakage or roughness in tensioner rotation. See Fig. 1. Replace com-
On Expo, remove condenser tank. On all models, remove A/C and ponents if damaged.
power steering hose mounting bracket from upper engine mount at Installation – 1) Install timing belt tensioner, leaving bolt loose. Using a
timing belt cover. Remove all accessory drive belts. Using End Yoke screwdriver, push tensioner toward engine mount. Tighten timing belt
Holder (MB990767) and Crankshaft Pulley Holder (MD998718) or
tensioner bolt.
equivalent, remove crankshaft pulley bolt and pulley.
2) Align camshaft sprocket and crankshaft sprocket timing marks with
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed timing marks on engine. Keeping tension applied between camshaft,
from timing belt end of engine). water pump and crankshaft sprockets, install timing belt in the following
sequence: crankshaft sprocket, water pump sprocket, camshaft
sprocket, then tensioner pulley.
flange. If necessary, remove power steering pump bracket stay and
3) Rotate camshaft in reverse direction and ensure that there is no slack
engine support bracket. Rotate crankshaft clockwise (as viewed from
in timing belt. Ensure timing marks are still aligned. Loosen timing belt
timing belt end of engine) until cylinder No. 1 is at TDC of compression
tensioner to apply spring pressure to timing belt.
stroke, and timing mark on camshaft sprocket and crankshaft sprocket
align with timing mark on engine. See Fig. 2 or 3.
1.8L 4-Cylinder – VINs C & D (Cont.)
Fig. 5: Identifying Timing Belt Cover Bolt Locations
TORQUE SPECIFICATIONS (EXCEPT MIRAGE)
Courtesy of Mitsubishi Motor Sales of America. Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18)
Crankshaft Center Pulley Bolt ...................................................... ............. 80-94 (109-127)
Fig. 3: Aligning Timing Marks (1997-02) Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
4) Rotate crankshaft 2 complete revolutions clockwise (as viewed from Front Cover Bolt .............................................................................................. 11-13 (15-18)
timing belt end of engine) and ensure timing marks are still aligned. Timing Belt “A” Tensioner Bolt ...................................................... ................. 16-22 (22-30)
Ensure timing belt teeth are properly seated in sprockets. Tighten timing
belt tensioner bolt. INCH Lbs. (N.m)
5) Install flange. See Fig. 4. To complete installation, reverse removal Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
procedure. Ensure proper length bolts are installed in designated areas Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7)
in timing belt covers. See Fig. 5. Adjust drive belts to proper tension.
TORQUE SPECIFICATIONS (MIRAGE)
A/C Tensioner Pulley Bracket Bolt ........................................................................... 18 (25)
Crankshaft Pulley Bolt ................................................................... ......... 131-139 (177-188)
Engine Support Bracket Bolt .................................................................................... 36 (49)
Power Steering Pump Bracket Stay Bolt ................................................................. 33 (44)
Water Pump Bolt ....................................................................................................... 18 (24)
INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America. Timing Belt Cover Bolt .............................................................................................. 97 (11)
Fig. 4: Installing Flange
2.0L 4-Cylinder – DOHC, VIN Y
TIMING BELT APPLICATION 2) Remove power steering pump (hoses attached) and mounting
Application Labor Time Component Belt bracket from engine. Move out of way.
Kit No. Part No. 3) Lower vehicle. Place jack under engine for support. Remove right
2.0L 4-Cyl. – DOHC, VIN Y side engine mount. Remove engine mount bracket from front of engine.
Avenger, Neon & Sebring Coupe Remove timing belt cover. Rotate engine clockwise to align the camshaft
1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246 and crankshaft timing marks. See Fig. 1.
Eclipse (Non-Turbo)
1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246 CAUTION: To prevent pistons from hitting valves, do not rotate
Talon (Non-Turbo) camshaft or crankshaft after removing the timing belt.
1995-98 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246
1
– With Air Conditioning. add .2 hours. 4) Install 8-mm Allen wrench into timing belt tensioner. See Fig. 1. Insert
With Power Steering, add .2 hours. 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
NOTE: A timing belt component kit is available for this application. pushing lightly on the 3-mm Allen wrench, until it slides into the locking
See page A1 for information on component kits. hole. If reusing old timing belt, mark belt with arrow to indicate direction
of rotation. Remove timing belt.
available), see ALPHABETICAL MODEL LISTING. CAUTION: Mechanical timing belt tensioner is serviced as an
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
these states, replace timing belt at 100,000 miles.
EAGLE
replaced every 60,000 miles, except in California. In California, timing
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
Fig. 1: Aligning Timing Marks & Adjusting Belt Tension
(Mechanical Timing Belt Tensioner)
belt replacement is recommended, but not required, at 60,000 miles. In Inspection – Check belt teeth for damage or oil contamination. Inspect
California, replace timing belt at 100,000 miles, unless previously belt for glossy, hardened or non-elastic surface. Ensure the belt is not
changed. For 1998-99 model years, the manufacturer recommends the cracked, separated or showing canvas fiber. Inspect all sprockets for
belt be replaced every 60,000 miles except in California, Connecticut, damage. Check tensioner pulley and idler pulley for signs of grease
and Massachusetts. In California, Connecticut, and Massachusetts, leakage or roughness in rotation. Replace components if damaged.
timing belt replacement is recommended, but not required, at 60,000 Installation (Mechanical Timing Belt Tensioner) – 1) Ensure cam-
miles. In these states, replace timing belt at 100,000 miles, unless shaft and crankshaft timing marks are aligned. Rotate crankshaft pulley
previously changed. sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2.
2) Install timing belt starting from crankshaft pulley sprocket, go around
REMOVAL & INSTALLATION water pump sprocket, idler pulley, camshaft sprockets, and then around
tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack.
CAUTION: This application is an interference engine. Do not rotate 3) Remove Allen wrench from timing belt tensioner pulley. Rotate
camshaft or crankshaft when timing belt is removed, or engine crankshaft clockwise 2 revolutions. Check alignment of camshaft and
damage may occur. 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
TIMING BELT
Removal (Mechanical Timing Belt Tensioner) – 1) On Avenger and
5) On Neon only, connect scan tool to Data Link Connector (DLC) under
Sebring, remove coolant reservoir and place out of way. On all models,
lower left edge of instrument panel. Follow scan tool instructions to
raise and support vehicle. Remove right inner splash shield. Remove
access the cam/crank relearn procedure. Perform cam/crank relearn
center bolt from crankshaft pulley. Use gear puller to remove crankshaft
procedure.
pulley.
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.
Timing Belt Tensioner Bracket Precaution – On models with hydrau-
lic 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.
Installation (Hydraulic Timing Belt Tensioner) – 1) Ensure camshaft
Courtesy of DaimlerChrysler Corp. and crankshaft timing marks are aligned. Rotate crankshaft pulley
Fig. 2: Aligning Crankshaft Timing Mark (Hydraulic Timing Belt sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2.
Tensioner Shown; Mechanical Tensioner Is Similar) 2) Install timing belt starting from crankshaft pulley sprocket, go around
water pump sprocket, idler pulley, camshaft sprockets, and then around
Removal (Hydraulic Timing Belt Tensioner) – 1) Raise and support
tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack.
vehicle. Remove right inner splash shield. Remove center bolt from
Install timing belt tensioner, but do not final tighten fasteners yet.
crankshaft pulley. Use gear puller to remove crankshaft pulley.
3) With 21 ft. lbs. (28 N.m) of torque applied to tensioner pulley, move
2) Remove power steering pump (hoses attached) and mounting
tensioner against pulley bracket and tighten bolts to specification. See
bracket from engine. Move out of way.
TORQUE SPECIFICATIONS. See Fig. 4.
3) Lower vehicle. Place jack under engine for support. Remove right
4) Remove tensioner plunger locking pin. Pretension is correct when
side engine mount. Remove engine mount bracket from front of engine.
locking pin can be removed and installed again.
Remove timing belt cover. Rotate engine clockwise to align the camshaft
5) Rotate crankshaft clockwise 2 revolutions and check timing belt
and crankshaft timing marks. See Fig. 3.
alignment marks. Reset belt if marks are not aligned. Install timing belt
CAUTION: To prevent pistons from hitting valves, do not rotate covers.
camshaft or crankshaft after removing the timing belt. 6) Continue installation in reverse of removal procedure. Adjust drive
4) Loosen timing belt tensioner to remove timing belt. If reusing old belt, 7) On Neon only, connect scan tool to Data Link Connector (DLC) under
mark belt with arrow to indicated direction of rotation. Remove timing lower left edge of instrument panel. Follow scan tool instructions to
belt. access the cam/crank relearn procedure. Perform cam/crank relearn
5) Remove tensioner from engine. It will be necessary to compress the procedure.
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.
Fig. 4: Adjusting Timing Belt Tension (Hydraulic Timing Belt

Courtesy of Mitsubishi Motor Sales of America. Tensioner)
Fig. 3: Aligning Timing Marks (Hydraulic Timing Belt Tensioner)
2.0L 4-Cylinder – DOHC, VIN Y (Cont.)
Engine Mount Bracket-To-Engine Nut/Bolt ............................................................... 30 (41)
Engine Mount-To-Body Bracket Through-Bolt .............................................. 72-87 (98-118)
Engine Mount-To-Engine Mount Bracket Nut/Bolt ................................................... 64 (86)
Engine Mount-To-Frame Rail Bolt (Neon) ................................................................ 40 (54)
Power Steering Pump Bolts ...................................................................................... 29 (39)
Hydraulic Belt Tensioner ......................................................................................... 30 (41)
Mechanical Belt Tensioner ...................................................................................... 21 (28)
Timing Belt Tensioner Pulley Bolt
Hydraulic Belt Tensioner ......................................................................................... 50 (68)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ............................................................................................ 106 (12)
Water Pump Bolt ..................................................................................................... 106 (12)
2.4L 4-Cylinder
Part No.
2.4L 4-Cyl.
Colt, Colt Vista & Colt Wagon (Canada)
1992
1
Balance Shaft ...................................... .......... .......... ..... T159
Camshaft ............................................... 2 2.4 Hours .. ..... T204
1993
1
Balance Shaft ...................................... .......... .......... ..... T159
Camshaft ............................................... 2 2.4 Hours .. ..... T230
1994
1
Balance Shaft ...................................... .......... .......... ..... T168
Camshaft ............................................... 2 2.4 Hours .. ..... T230
Expo
1992
1
Balance Shaft ...................................... .......... .......... ..... T159
Camshaft ............................................... 3 2.4 Hours .. ..... T204
1993-95
1
Balance Shaft ...................................... .......... .......... ..... T168
Camshaft ............................................... 3 2.4 Hours .. ..... T230
Summit
1992
1
Balance Shaft ...................................... .......... .......... ..... T159
Camshaft ............................................... 2 2.4 Hours .. ..... T204
1993-96
1 Courtesy of DaimlerChrysler Corp.
Balance Shaft ...................................... .......... .......... ..... T168
Camshaft ............................................... 2 2.4 Hours .. ..... T230
Fig. 1: Aligning Camshaft Timing Belt Marks
1
– Balance shaft labor time included in camshaft labor time.
2
3


TIMING BELT
Removal – 1) Disconnect negative battery cable. Loosen left front wheel Courtesy of DaimlerChrysler Corp.
lug nuts, then raise and support vehicle with jackstands. Remove left
front wheel and tire assembly. Remove left front inner splash shield Fig. 2: Aligning Balance Shaft Marks
through the wheel well. Remove coolant reservoir. Support engine with aligned, then check belt tension. See Fig. 2. There should be approxi-
jack and wooden block placed under the oil pan. Remove right side mately .20-.28″ (5.0-7.0 mm) slack on tension side of belt when belt is
engine mount. moved by hand.
2) Remove accessory drive belts and pulleys. Remove timing belt upper 3) Install crankshaft sprocket flange with the raised side facing outward,
and lower front covers. Rotate crankshaft in normal direction of rotation, then install crankshaft sprocket. Measure protrusion of auto-tensioner
and align timing marks. See Fig. 1. Remove auto-tensioner assembly, plunger from tensioner housing. Protrusion should be .47″ (11.9 mm).
then remove camshaft timing belt. Position timing belt tensioner in a soft-jawed vise, then carefully
3) Remove crankshaft sprocket bolt, then crankshaft sprocket and compress plunger. After plunger has been compressed, insert a .055″
flange. Remove balance shaft timing belt tensioner pulley bolt, then (1.4 mm) pin or wire through tensioner body to hold plunger in place.
remove tensioner pulley. Remove balance shaft timing belt. Ensure 4) Remove auto-tensioner from vise and install on engine. Ensure
balance shaft (silent shaft) sprocket and crankshaft sprocket timing crankshaft and camshaft timing marks are aligned. See Fig. 1. With oil
marks are properly aligned. See Fig. 2. pump sprocket timing marks aligned, remove plug from side of engine
Installation – 1) Align crankshaft and balance shaft sprocket timing and insert a screwdriver, with a shaft diameter of .31″ (8.0 mm), into the
marks with the marks on the timing case. See Fig. 2. Install balance hole. See Fig. 3. If screwdriver can be inserted 2.4″ (61.0 mm) or more,
shaft timing belt over crankshaft and balance shaft sprockets. When alignment is correct.
installing timing belt, be sure tension side of belt has no slack. Install 5) If screwdriver can only be inserted .8-1″ (20.3-25.4 mm), rotate oil
balance shaft belt tensioner. Assemble tensioner so that pulley is to the pump sprocket one revolution and realign timing marks. Ensure screw-
left of the installation bolt and pulley flange is facing the front of engine. driver can be inserted 2.4″ (61.0 mm) or more. Leave screwdriver
2) Raise the tensioner toward belt by hand. Apply sufficient pressure so inserted in hole until after timing belt has been installed.
that tension side of belt is taut, then tighten tensioner bolt. Ensure that 6) Install camshaft timing belt, first over crankshaft sprocket, then oil
tensioner does not rotate with bolt as it is tightened, as excessive pump sprocket, idler pulley, camshaft sprocket and tensioner pulley.
tension will be placed on the belt. Ensure that timing marks are still Hold belt so there is no slack on tension side. Apply counterclockwise
force on camshaft sprocket to aid in tensioning belt. Ensure that all TORQUE SPECIFICATIONS
timing marks remain aligned. Carefully position timing belt tensioner
pulley against timing belt, then tighten center bolt. Rotate crankshaft TORQUE SPECIFICATIONS
pulley 1/4 turn counterclockwise, then turn clockwise, aligning crank- Application Ft. Lbs. (N.m)
shaft and camshaft timing marks. Crankshaft Pulley Bolts ............................................................................................. 18 (25)
7) Loosen tensioner pulley retaining bolt, then position socket tool and a Right Side Engine Mount Bolt/Nuts .......................................................................... 42 (58)
suitable torque wrench to the pulley. Tighten to specification. See Through-Bolt Attaching Nuts ..................................................................................... 25 (34)
TORQUE SPECIFICATIONS. Tighten retaining bolt while holding the Through-Bolt Nut ....................................................................................................... 51 (70)
pulley in position. Install set screw tool through left hand engine support INCH Lbs. (N.m)
bracket. Engine may need to be raised slightly to install set screw tool.
Tensioner Pulley Bolt ............................................................................................... 31 (3.5)
Tighten set screw tool until it contacts tensioner arm, then tighten tool Timing Belt Front Cover Bolts ...................................................... .............. 84-108 (9.6-12)
slightly more. Remove pin or wire retaining auto-tensioner plunger, then Water Pump Pulley Bolts ......................................................................................... 78 (8.9)
remove set screw tool.
8) Rotate engine in the clockwise direction two turns. After approxi-
mately 15 minutes, measure auto-tensioner plunger protrusion from
tensioner housing. Plunger protrusion should be .15-.18″ (3.8-4.6 mm).
See 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 specifica-
tion. 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.
Fig. 3: Holding Silent Shaft In Stationary Position (Typical)
Fig. 4: Measuring Auto Tensioner Protrusion

DAEWOO 205

TIMING BELT APPLICATION 3) Rotate water pump until the adjust arm pointer on the automatic
Application Labor Time Belt tensioner is aligned with the pointer on the automatic tensioner bracket.
Part No. See Fig. 8. Final tighten water pump bolts. See TORQUE SPECIFICA-
1.6L 4-Cyl. DOHC TIONS.
Lanos 4) Remove crankshaft sprocket center bolt. Install power steering pump
1 (if equipped). Tighten bolts to specification. Install timing belt covers.
1999-2002 ................................................ 2.3 Hours .. ..... T310
1 Install crankshaft pulley. Tighten center bolt to specification.
5) Install power steering pump pulley (if removed). Install accessory
NOTE: For information about tensioners and/or pulleys (when drive belts. Install right front splash shield. Install right front wheel. Install
available), see ALPHABETICAL MODEL LISTING. air filter housing. Connect air intake temperature sensor connector.
Connect negative battery cable. Adjust the drive belts to correct tension.
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.

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
Courtesy of Daewoo Motor America, Inc.
right front splash shield from wheelwell. Remove accessory drive belts.
See Fig. 1. Fig. 1: Removing A/C Compressor Drive Belt
3) Remove power steering pump pulley bolts (if equipped). Remove
power steering pump pulley. Remove crankshaft pulley center bolt.
Remove crankshaft pulley. Lower vehicle.
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.
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. Courtesy of Daewoo Motor America, Inc.
2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed
from timing belt end of engine) 2 full revolutions. Loosen water pump Fig. 2: Removing Timing Belt Covers
bolts.
206 DAEWOO

Fig. 5: Moving Water Pump To Relieve Timing Belt Tension

DAEWOO 207

Crankshaft Pulley Center Bolt
Step 1 ...................................................................................................................... 70 (95)
Step 2 .................................................................................................................... Plus 30°
Step 3 .................................................................................................................... Plus 15°
Power Steering Pump Pulley Bolt ............................................................................ 18 (25)
Timing Belt Automatic Tensioner Bolt ....................................................................... 18 (25)
Water Pump Bolt ....................................................................................................... 10 (89)
Wheel Lug Nuts ...................................................................................................... 88 (120)
INCH Lbs. (N.m)
Fig. 7: Aligning Timing Belt Tensioner With Notch
Fig. 8: Aligning Timing Belt Tensioner With Pointer

208 DAEWOO
Part No.
2.0L 4-Cyl. DOHC
Nubira
1999-2002 ................................................. 1.8 Hours ... ..... T309


camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Supporting Engine Assembly
damage may occur.
TIMING BELT
valve cover. Remove the air filter housing.
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).
belt cover. See Fig. 3. Align camshaft sprocket timing marks with Courtesy of Daewoo Motor America, Inc.
notches on valve cover. See Fig. 4.
Fig. 2: Removing Engine Mount Bracket
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.
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.

DAEWOO 209
Step 1 ...................................................................................................................... 37 (50)
Step 2 .................................................................................................................... Plus 60°
Step 3 .................................................................................................................... Plus 15°
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)
Water Pump Bolt ....................................................................................................... 15 (20)
Wheel Lug Nuts ...................................................................................................... 88 (120)
INCH Lbs. (N.m)
Courtesy of Daewoo Motor America, Inc. Timing Belt Cover Bolt ................................................................................................ 53 (6)
Fig. 5: Locating Timing Belt Tensioner
210 DAEWOO
Part No.
2.2L 4-Cyl. DOHC
Leganza
1999-2002 ................................................. 1.8 Hours ... ..... T305


camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Supporting Engine Assembly
damage may occur.
TIMING BELT
valve cover. Remove resonator from throttle body. Remove air filter
housing.
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 Fig. 2: Removing Engine Mount Bracket
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).
belt cover. See Fig. 4. Align camshaft sprocket timing marks with
notches on valve cover. See Fig. 5.

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.
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 SPECIFICA-
TIONS.
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. Fig. 3: Identifying Front Timing Belt Cover & Bolts
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 connec-
tor. Connect negative battery cable.
DAEWOO 211
Fig. 4: Aligning Crankshaft Sprocket Timing Mark
Step 1 ...................................................................................................................... 37 (50)
Step 2 .................................................................................................................... Plus 60°
Courtesy of Daewoo Motor America, Inc. Step 3 .................................................................................................................... Plus 15°
Fig. 5: Aligning Camshaft Sprocket Timing Marks 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)
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)
Fig. 6: Identifying Timing Belt Tensioner

212 DAIHATSU
1.0L 3-Cylinder
Part No.
1.0L 3-Cyl.
Charade
1
1988-92 .................................................... 1.8 Hours .. ..... T178
1

Courtesy of Daihatsu Motor Co., LTD.
Fig. 1: Removing Engine Front Mounting Bracket Nuts

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, Courtesy of Daihatsu Motor Co., LTD.
apply slight pressure to oil pan to release pressure from front mounts. Fig. 2: Removing Cylinder Head Mounting Bracket
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 Courtesy of Daihatsu Motor Co., LTD.
crankshaft pulley retaining bolt. Remove crankshaft pulley. Remove
upper and lower timing belt covers. Remove flange on front of crank- Fig. 3: Aligning Flywheel Timing Marks
shaft 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 Courtesy of Daihatsu Motor Co., LTD.
are not to specification. Fig. 4: Installing Crankshaft Pulley & Flanges
DAIHATSU 213

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 COUN-
TERCLOCKWISE 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. Fig. 5: Aligning Crankshaft & Camshaft Mating Marks
6) Install outer flange on crankshaft pulley, with protruding side toward
crankshaft belt pulley. To complete installation, reverse removal proce- TORQUE SPECIFICATIONS
dure. Adjust drive belts to proper tension. TORQUE SPECIFICATIONS
Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98)
Water Pump Bolts ........................................................................................... 11-16 (15-22)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ................................................................ ..................... 18-36 (2-4)
214 DAIHATSU
Part No.
1.3L 4-Cyl.
Charade
1
1989-92 .................................................... 1.8 Hours .. ..... T181
1.6L 4-Cyl.
Rocky
1
1990-92 .................................................... 2.3 Hours .. ..... T182
1


damage may occur.
TIMING BELT
Removal (1.3L) – 1) Disconnect negative battery cable. Remove air Courtesy of Daihatsu Motor Co., LTD.
conditioner drive belt and idler assembly (if equipped). Remove air
conditioner compressor, leaving hoses attached. Fig. 2: Identifying Timing Belt Components (1.3L)
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 insula-
tors. 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.
Fig. 3: Locating Timing Belt Alignment Marks

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.
Courtesy of Daihatsu Motor Co., LTD. 4) Loosen timing belt tensioner bolt, and move tensioner away from belt.
Tighten timing belt tensioner, and remove timing belt from engine.
Fig. 1: Locating Service Hole Cover (Charade)
Inspection (All Models) – 1) Inspect timing belt for wear and defects.
Removal (1.6L) – 1) Disconnect negative battery cable. Remove air Check timing belt tensioner for smooth rotation. Ensure tensioner
cleaner assembly. Loosen and remove drive belts. Remove radiator contact surface is clean and not damaged. Check camshaft for smooth
reserve tank. Disconnect clutch cable clamps from upper radiator rotation. Check sides of belt. If belt side is damaged, check sprocket
shroud. flange.
2) Disconnect fan clutch. Remove radiator fan shroud and fan clutch. 2) Check for dirt or contamination on sprocket teeth. Measure sprocket
See Fig. 4. Remove water pump pulley and belt. Remove crankshaft diameter. Camshaft sprocket should be 4.717″ (119.8 mm). Crankshaft
pulley attaching bolts and remove pulley. Remove 8 timing belt cover sprocket should be 2.335” (59.37 mm). Clean and/or repair as neces-
bolts. sary.
DAIHATSU 215

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.

Fig. 5: Adjusting Timing Belt
Fig. 4: Identifying Timing Belt Components (1.6L)
Installation (All Models) – 1) Install crankshaft timing belt sprocket (if TORQUE SPECIFICATIONS
removed). Ensure recessed side of crankshaft sprocket flange faces
engine block. Ensure crankshaft sprocket timing notch (drilled mark) TORQUE SPECIFICATIONS
aligns with timing indicator on engine. See Fig. 3. Tighten crankshaft Application Ft. Lbs. (N.m)
timing belt sprocket bolt to 65-72 ft. lbs. (88-98 N.m). A/C Idler Pulley Bolt ...................................................................... ................. 23-35 (31-47)
2) Install camshaft timing belt sprocket (if removed). Tighten camshaft Camshaft Sprocket Bolts ................................................................................ 11-16 (15-22)
sprocket bolts to 11-16 ft. lbs. (15-22 N.m). Apply Sealant (Three Bond Crankshaft Pulley Bolts ................................................................. ................. 15-22 (20-30)
1104) or equivalent, to cylinder head near camshaft bearing cap contact Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98)
areas. Install cylinder head cover. Ensure camshaft and crankshaft Timing Belt Tensioner Bolt ............................................................ ................... 2-32 (30-44)
sprockets are aligned. See Fig. 3. Water Pump Bolts ........................................................................................... 11-16 (15-22)
3) Install timing belt on sprockets. If installing used belt, ensure there are INCH Lbs. (N.m)
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-
216 EAGLE
2.2L 4-Cylinder
Part No.
2.2L 4-Cyl.
Medallion
1989 ........................................................... 2.3 Hours ... ..... T140


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 Courtesy of DaimlerChrysler Corp.
serpentine drive belt adjustment bolt and nut. Loosen belt and remove
from water pump pulley. Remove water pump pulley bolt and pulley. Fig. 1: Checking Timing Belt Tensioner Clearance
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 interme-
diate 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
Application Ft. Lbs. (N.m) Courtesy of DaimlerChrysler Corp.
Crankshaft Pulley Bolt ............................................................................................. 96 (130) Fig. 2: Installing Timing Belt
FIAT 217

1
Part No.
1.3L 4-Cyl.
128
1973-78 ..................................................... 2.3 Hours ... ..... T018
1979 ........................................................... 2.4 Hours ... ..... T018
X1/9
1974-78 ..................................................... 2.3 Hours ... ..... T018
1.5L 4-Cyl.
Strada
1979-82 ..................................................... 2.0 Hours ... ..... T069
X1/9
1979-83 ..................................................... 2.0 Hours ... ..... T069
1

The manufacturer recommends the belt be replaced at the following
intervals: On 1974-78 models, replace belt every 36,000 miles. On 1979
1.3L 4-cylinder, replace belt every 36,000 miles. On 1979-82 1.5L
4-cylinder, replace belt every 30,000 miles. Courtesy of Fiat Motor Co.

3) Remove valve cover and check that camshaft lobes of No. 4 cylinder
CAUTION: This application is an interference engine. Do not rotate are pointing up. Remove distributor. Loosen idler pulley lock nut.
camshaft or crankshaft when timing belt is removed, or engine Remove timing belt starting at idler pulley.
damage may occur. Installation (X1/9) – 1) Install timing belt making sure that teeth are
properly engaged in sprockets. Start installation of timing belt at
TIMING BELT crankshaft pulley. Release idler pulley lock nut and retighten after
tension is on belt.
Removal (128 & Strada) – 1) Disconnect negative battery cable.
Remove right guard and loosen timing belt cover retaining screws, from
NOTE: Never allow engine to rotate backwards, or slack will
under vehicle. Remove timing belt cover. Check timing by aligning index
develop in belt and belt will jump timing.
marks on top and bottom of camshaft sprocket with index marks on
engine mounting and upper case. See Fig. 1. Index on crankshaft 2) Rotate engine 2 turns in direction of engine rotation. Loosen idler
sprocket should be in alignment with index on crankshaft seal case. pulley lock nut to ensure all slack is removed. Retighten lock nut. Rotate
2) Put vehicle in low gear, and apply hand brake to prevent crankshaft engine until No. 4 cylinder is in firing position (cam lobe up). Install
from turning. Remove fan belt, loosen tensioner pulley retaining nut and remaining components in reverse of removal order. Adjust drive belts to
relieve tension. Remove timing belt. proper tension.
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 TORQUE SPECIFICATIONS
tension.
Removal (X1/9) – 1) Disconnect negative battery cable. Rotate No. 4 TORQUE SPECIFICATIONS
cylinder into firing position at top dead center. Position transmission into Application Ft. Lbs. (N.m)
4th gear, to prevent crankshaft from turning. Apply parking brake. Camshaft Sprocket Bolt ............................................................................................ 61 (85)
Crankshaft Pulley/Sprocket Nut ............................................................................ 101 (137)
CAUTION: If camshaft is turned independently of engine, valves Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45)
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.
218 FIAT
1
Part No. CAUTION: This application is an interference engine. Do not rotate
1.6L 4-Cyl. camshaft or crankshaft when timing belt is removed, or engine
124 damage may occur.
1971-74 ..................................................... 1.9 Hours ... ..... T020
1.8L 4-Cyl.
Brava TIMING BELT
1974-78 ..................................................... 2.4 Hours ... ..... T020 Removal – 1) Disconnect negative battery cable. Drain cooling system
124 and remove upper radiator hose. Remove upper section of air duct.
1974-78 ..................................................... 1.9 Hours ... ..... T020 Remove spark plugs. Rotate crankshaft until marks on both camshaft
131 sprockets are aligned with fixed pointer on front of engine. See Fig. 1
1975-78 ..................................................... 1.9 Hours ... ..... T020
or 2. Number 4 piston should now be at TDC firing position. Place
1
– With Air Conditioning, add .2 hours. transmission in 4th gear and apply parking brake to prevent crankshaft
from turning.
available), see ALPHABETICAL MODEL LISTING. CAUTION: Do not turn crankshaft or camshafts independent of
each other, as valves may hit pistons.
MANUFACTURER’S SUGGESTED NOTE: Any time tension is relieved from timing belt, timing belt
SCHEDULED MAINTENANCE 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

2) Remove lower engine protection plate. Remove all drive belts. TORQUE SPECIFICATIONS
Disconnect coolant extension union at cylinder head. Loosen timing belt
idler pulley nut and mounting bracket bolt, and release timing belt TORQUE SPECIFICATIONS
tension. On 1.6L engines before No. 42577, pry pulley to release Application Ft. Lbs. (N.m)
tension. Tighten pulley nut and bracket bolt, and remove belt. Camshaft Sprocket Bolt .......................................................................................... 87 (118)
Installation – 1) Install timing belt, making sure not to move sprockets. Tensioner Nut ............................................................................................................ 33 (45)
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
Fig. 2: Aligning Camshaft & Crankshaft Timing Marks (1.8L)

220 FIAT
2.0L 4-Cylinder
Part No.
2.0L 4-Cyl.
Brava
1
1979-81 .................................................... 2.4 Hours .. ..... T068
Spider 2000
1
1979-82 .................................................... 3.1 Hours .. ..... T068
1


damage may occur.
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.
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
Timing Belt Tensioner Nut ........................................................................................ 33 (45) Fig. 2: Identifying Sprocket Alignment For Timing Belt
Installation
FORD 221
1.3L 4-Cylinder
Kit No. Part No.
1.3L 4-Cyl. – VIN H
Aspire
1
1994-97 .............................. 2.0 Hours .. .. TCK185 .. ..... T185
Festiva
1
1988-89 .............................. 2.0 Hours .. .. TCK141 .. ..... T141
1
1990-93 .............................. 2.0 Hours .. .. TCK185 .. ..... T185
1


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 Fig. 1: Removing Right Inner Fender Panel
vehicles. For Festiva, the manufacturer recommends the belt be

TIMING BELT
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 Courtesy of Ford Motor Co.
belt away from grease and oil. 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
A/C Compressor Bolt .................................................................... ................. 29-40 (39-54)
Camshaft Pulley Bolt ..................................................................... ................... 9-13 (12-17)
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)
INCH Lbs. (N.m) Courtesy of Ford Motor Co.
Camshaft Cover ................................................................................................ 71-97 (8-11) Fig. 3: Aligning Timing Marks

Timing Belt Cover Bolt ...................................................................................... 71-97 (8-11)
Valve Cover Bolt ........................................................................... ..................... 44-79 (5-9)
222 FORD
TIMING BELT APPLICATION Tighten tension pulley to specification. See TORQUE SPECIFICA-
Application Labor Time Component Belt TIONS. Rotate engine 2 full turns. Verify timing mark alignment.
Kit No. Part No. 4) Measure timing belt tension between camshaft pulleys. Belt deflection
1.6L 4-Cyl. – DOHC should be 0.33-0.45″ (8.5-11.5 mm). See Fig. 3. If incorrect, loosen
Capri tension pulley and repeat procedure. If correct tension cannot be
1991-94 ............................... 3.6 Hours ... .. TCK179 .. ..... T179 achieved, replace tension spring. To complete installation, reverse


TIMING BELT
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. 1: Exploded View Of Timing Belt & Components Courtesy of Ford Motor Co.
Installation – 1) Ensure sprockets, tensioner, and idler pulleys are clean Fig. 3: Checking Timing Belt Tension
and not worn, deformed, or damaged. Align timing marks on camshafts
and crankshaft. Intake cam should have letter “I” aligned with arrow on TECHNICAL SERVICE BULLETIN REVISION
belt cover. Exhaust cam should have letter “E” aligned with arrow on belt
cover. Crankshaft key should align with arrow. See Fig. 2.
NOTE: Information on revised service procedure is from Ford
CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with technical service bulletin 94-17-5; August 24, 1994. This bulletin
solvents. Wipe them clean only. supercedes 94-15-10; July 21, 1993.
2) Unloaded free length of timing belt tension spring should be 2.315″

(58.8 mm). Replace spring as necessary. Tighten tension pulley with “SWISH” NOISE FROM TIMING BELT
tension spring fully extended. If reusing timing belt, install belt in original Issue – Some 1990 1.6L and 1.6L engines built up to 10/1/1990 may
direction of rotation. Keep tension on opposite side of tensioner as tight exhibit a “swish” noise from the timing belt. This is caused be a belt
as possible. guide plate that does not maintain correct timing belt alignment.
3) Rotate crankshaft 2 full turns. Inspect alignment of timing marks. If Action – A revised timing belt guide plate and pulley boss is available to
any mark is not aligned, remove timing belt and reset timing. Loosen correct the noise. See Fig. 4. This procedure will also require replace-
tension pulley retaining bolt to allow tension spring to tighten belt. ment of the crankshaft and associated hardware.
FORD 223

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 SPECI-
FICATIONS 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
Camshaft Pulley Bolt ..................................................................... ................. 37-45 (49-61)
Crankshaft Pulley Center Bolt ................................................................ 115-123 (157-167)
Power Steering Adjuster Nut ........................................................ ................. 27-38 (37-52)
Timing Belt Tensioner Adjuster Bolt ............................................. ................. 14-19 (19-26)
INCH Lbs. (N.m)
Camshaft Cover ................................................................................................ 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
224 FORD
1.6L & 1.9L 4-Cylinder – SOHC
1
Kit No. Part No.
Escort, EXP, LN7 & Lynx
1981-85 ............................... 2.2 Hours ... .. TCK067 .. ..... T067
Tracer (Includes Canadian)
1987-90 ............................... 2.0 Hours ... .. TCK141 .. ..... T141
Escort & EXP
1985-90 ............................... 2.2 Hours ... .. TCK067 .. ..... T067
1991
Thru: 3-25-91 ................... 2.3 Hours ... .. TCK067 .. ..... T067
From: 3-26-91 .................. 2.3 Hours ... .. TCK194 .. ..... T194
1992-96 ............................... 2.3 Hours ... .. TCK194 .. ..... T194
Lynx
1985-87 ............................... 2.2 Hours ... .. TCK067 .. ..... T067
Tracer
1991 Courtesy of Ford Motor Co.
Thru: 3-25-91 ................... 2.3 Hours ... .. TCK067 .. ..... T067
From: 3-26-91 .................. 2.3 Hours ... .. TCK194 .. ..... T194 Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
1992-96 ............................... 2.3 Hours ... .. TCK194 .. ..... T194
1


CAUTION: The 1.6L and 1985-91 1.9L engines are interference

engines. Do not rotate camshaft or crankshaft when timing belt is Courtesy of Ford Motor Co.
removed, or engine damage may occur.
Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)

TIMING BELT
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 Fig. 3: Releasing Timing Belt Tension (Except Tracer)
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.
FORD 225
1.6L & 1.9L 4-Cylinder – SOHC (Cont.)

Fig. 6: Installing Timing Belt (Tracer)
Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)

TORQUE SPECIFICATIONS Fig. 7: Aligning Crankshaft Sprocket Timing Marks (Tracer)
A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30)
Belt Tensioner Bolt ........................................................................ ................. 17-22 (23-30)
Crankshaft Pulley Bolt ................................................................................. 81-96 (110-130)
Power Steering Pump Bolt ........................................................... ................. 30-41 (41-56)
Water Pump Bolt ........................................................................... ................. 15-22 (20-30)
INCH Lbs. (N.m)
Timing Belt Cover Nut .................................................................. ..................... 44-62 (5-7)
Valve Cover Bolt ........................................................................... ................. 44-106 (5-12)
226 FORD
1.6L & 2.0L 4-Cylinder – Bobcat, Capri & Pinto
Part No.
1.6L 4-Cyl.
Capri
1
1972 .......................................................... 1.3 Hours .. ..... T013
2.0L 4-Cyl.
Bobcat
1
1974 .......................................................... 1.3 Hours .. ..... T013
Capri
1
1971-74 .................................................... 1.3 Hours .. ..... T013
Pinto
1
1971-74 .................................................... 1.3 Hours .. ..... T013
1

60,000 mile intervals. Courtesy of Ford Motor Co.
Fig. 1: Checking Camshaft Timing

TIMING BELT TORQUE SPECIFICATIONS
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 Belt Tensioner ................................................................................ ................. 32-36 (42-48)
Crankshaft Pulley .......................................................................... ................. 39-43 (54-60)
adjustment bolt and force tensioner to one side to relieve belt tension.
Timing Belt Cover ......................................................................... ..................... 7-9 (10-12)
Hold tensioner in this position, and tighten bolt to hold tensioner. Lift belt Water Pump Bolts
off sprockets. 8 mm ........................................................................................... ................. 12-15 (15-21)
10 mm ......................................................................................... ................. 26-31 (35-41)
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 specifica-
tion. See TORQUE SPECIFICATIONS. Adjust drive belts to proper
tension.
FORD 227

TIMING BELT APPLICATION 2) Remove middle and lower timing belt covers. Rotate crankshaft
Application Labor Time Component Belt clockwise until No. 1 piston is at TDC. Ensure camshaft timing marks are
Kit No. Part No. aligned. See Figs. 2 and 3.
1.8L 4-Cyl. 3) Remove crankshaft pulley and hub. See Fig. 4. Mark direction of
Escort & Tracer timing belt rotation if timing belt is to be reused. Loosen timing belt
1 tensioner bolt, and remove timing belt.
1991-96 .............................. 2.8 Hours .. .. TCK179 .. ..... T179
1
– With Air Conditioning, add .2 hours. CAUTION: DO NOT rotate camshafts with timing belt removed, as
engine damage could result.
See page A1 for information on component kits. Installation – 1) Temporarily position belt tensioner with spring fully
extended, and tighten tensioner bolt. Ensure timing marks on crankshaft
NOTE: For information about tensioners and/or pulleys (when 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
MANUFACTURER’S SUGGESTED one mark.
SCHEDULED MAINTENANCE 2) Ensure camshaft sprocket timing marks are still aligned. See Figs. 2
The manufacturer recommends the belt be replaced every 60,000 miles. 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
REMOVAL & INSTALLATION timing belt. Tighten tensioner bolt. Rotate crankshaft clockwise 2 full
TIMING BELT revolutions. Ensure all timing marks are aligned. If timing marks are not
aligned, remove timing belt and repeat timing belt tensioning procedure.
NOTE: Mark direction of timing belt rotation if timing belt is to be 4) Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft timing
reused. mark with tension set mark (at approximately 10 o’clock position). See
Fig. 5. Loosen tensioner bolt. Apply tension to the tensioner. Tighten
Removal – 1) Disconnect negative battery cable. Remove accessory tensioner bolt to 27-38 ft. lbs. (37-52 N.m).
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.

228 FORD
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 ten-
sioner bolt.
7) To complete installation, reverse removal procedure. Tighten bolts to
proper tension.
Application Ft. Lbs. (N.m) Fig. 4: Identifying Crankshaft Pulley & Guide Plates
Water Pump Bolt ........................................................................... ................. 15-22 (20-30)
INCH Lbs. (N.m)
Timing Belt Cover Nut .................................................................. ..................... 44-61 (5-7)
Valve Cover Bolt ........................................................................... ................. 48-106 (5-12)
Fig. 6: Checking Timing Belt Deflection
Fig. 3: Identifying Camshaft Sprocket Timing Marks

FORD 229

Application 1
Labor Time Belt NOTE: DO NOT allow crankshaft to rotate with timing belt removed.
Part No. Installation – 1) Align camshaft and crankshaft sprockets with their
respective timing marks. See Figs. 1 and 2. Remove tensioner spring
Escort & Lynx
1984-87 from front timing belt upper cover pocket, and install in tensioner lever
Camshaft ................................................ 6.2 Hours ... ..... T103 slot and over crankcase stud. See Fig. 3. Push tensioner lever as far as
Injection Pump ....................................... 1.3 Hours ... ..... T102 possible toward water pump and tighten lock bolt.
Tempo & Topaz 2) Install timing belt. With tensioner pulley loose, adjust belt tension by
1984-86 rotating crankshaft pulley in direction of rotation twice until No. 1 cylinder
Camshaft ................................................ 6.2 Hours ... ..... T103 is at TDC (camshaft timing marks aligned). Tighten tensioner lock bolt.
Injection Pump ....................................... 1.3 Hours ... ..... T102 Adjust belt tension to 33-44 lbs. (15-20 kg). Remove tensioner spring
1
– With Air Conditioning, add .6 hours. 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.
miles.

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 assem-
bly. 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 Courtesy of Ford Motor Co.
on dash panel. Remove and save plastic retainer pins. Disconnect
Fig. 1: Cross Section Of 2.0L Diesel Engine
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. Discon-
nect 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-to-
transaxle 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. Discon-
nect 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 Courtesy of Ford Motor Co.
Removal – 1) With engine out of vehicle, remove front upper timing belt
cover and flywheel timing mark case. Fig. 2: Aligning Crankshaft Timing Marks
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.
230 FORD
Fig. 3: Installing Front Timing Belt Tensioner Spring

REAR TIMING BELT
Removal – 1) Remove rear timing belt cover and flywheel timing mark Fig. 6: Aligning Camshaft Timing Marks
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 screw-
driver 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. 7: Installing Rear Timing Belt
Courtesy of Ford Motor Co. TORQUE SPECIFICATIONS
Fig. 4: Aligning Camshaft & Injection Pump Timing Marks 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)
Fig. 5: Aligning Flywheel Timing Marks

FORD 231
2.0L 4-Cylinder – DOHC – Escape

Kit No. Part No.
2.0L 4-Cyl. – VIN B
Escape
2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294


MANUFACTURER’S SUGGESTED Courtesy of Ford Motor Co.
SCHEDULED MAINTENANCE Fig. 1: Removing Valve Cover

miles.

damage may occur.
TIMING BELT
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 Courtesy of Ford Motor Co.
monitor and heated oxygen sensor connectors, and detach the connec-
tors from the bracket. Remove wiring harness anchors from valve cover Fig. 2: Aligning Crankshaft Timing Marks Before TDC
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.
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 acces-
sory drive belt. Remove crankshaft pulley. Remove bolts and lower
timing belt cover. See Fig. 4. Install Engine Support Bar (303-F072). See Fig. 3: Removing Stud For Installation Of Crankshaft TDC Timing
Fig. 5. Peg (303-574)
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.
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 Courtesy of Ford Motor Co.
rotation for installation reference. Slide timing belt off of camshaft and
Fig. 4: Removing Lower Timing Belt Cover
crankshaft sprockets.
232 FORD
2.0L 4-Cylinder – DOHC – Escape (Cont.)

Fig. 9: Removing Engine Mount Lower Bracket
Fig. 5: Installing Engine Support Bar (303-F072)
Installation – 1) Slide crankshaft pulley onto crankshaft. Ensure crank-
shaft 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 counter-
clockwise, 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 SPECIFI-
CATIONS.
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
5) Install splash shield, then wheel and tire assembly. Remove Crank-
shaft TDC Timing Peg (303-574). Install stud. Install engine mount upper
bracket and ground strap. Remove Engine Support Bar (303-F072).
Fig. 6: Removing Engine Mount Upper Bracket Install coolant tube and catalytic converter. Remove Camshaft Align-
ment 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. Recon-
nect negative battery cable.
Fig. 7: Removing Upper Timing Belt Cover
Fig. 8: Installing Camshaft Alignment Tool (303-465)

FORD 233
2.0L 4-Cylinder – DOHC – Escape (Cont.)

Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45)
Catalytic Converter Bracket Bolts ............................................................................. 18 (25)
Coolant Tube Attachments ........................................................................................ 15 (20)
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)
Courtesy of Ford Motor Co. Ground Strap ............................................................................................................. 25 (34)
Spark Plugs ............................................................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) ................................................................... 18 (25)
Wheel Lug Nuts ...................................................................................................... 98 (133)
INCH Lbs. (N.m)
Inner ......................................................................................................................... 89 (10)
Lower ......................................................................................................................... 62 (7)
Upper ......................................................................................................................... 71 (8)
Splash Shield Bolts ..................................................................................................... 80 (9)
Valve Cover Bolts ........................................................................................................ 80 (9)

234 FORD
2.0L 4-Cylinder
DOHC, VIN 3 – Contour & Mystique (1995-97)
TIMING BELT APPLICATION 4) Install lower timing belt cover. Apply Silicone Gasket Sealer (F1AZ
Application Labor Time Timing Belt Belt 9562-A) or equivalent to crankshaft keyway. Install crankshaft pulley.
Kit No. Part No. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
2.0L 4-Cyl. 5) Ensure crankshaft timing marks are aligned. See Fig. 1. Loosen
Contour & Mystique timing belt tensioner pulley, and allow spring to pull pulley against timing
1995-97 ............................... 2.2 Hours ... .. TCK258 .. ..... T258 belt. Remove camshaft alignment tool. Rotate crankshaft clockwise 2
full revolutions.
NOTE: A timing belt component kit is available for this application. 6) Tighten timing belt tensioner pulley to specification. See TORQUE
See page A1 for information on component kits. 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
MANUFACTURER’S SUGGESTED Holding Tool (T74P-6256-B) or spanner wrench. Loosen, but do not
remove, camshaft sprocket center bolt. Rotate camshafts until camshaft
SCHEDULED MAINTENANCE alignment tool can be installed on rear of camshafts. Crankshaft MUST
Although the manufacturer does not recommend a specific scheduled remain at TDC when aligning camshafts. Tighten camshaft sprocket
maintenance interval, belt manufacturers suggest the belt be replaced at 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
REMOVAL & INSTALLATION water pump pulley. Install serpentine belt idler pulley and serpentine
bolt.
TIMING BELT 10) Install coolant recovery reservoir. To complete installation, reverse
Removal – 1) Noting position for installation reference, disconnect removal procedure.
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 connec-
tor from coolant recovery reservoir. Remove retainers attaching recov-
ery 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. Fig. 1: Aligning Crankshaft Timing Marks
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. Fig. 2: Installing Camshaft Alignment Tool
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.
FORD 235
2.0L 4-Cylinder
DOHC, VIN 3 – Contour & Mystique (1995-97) (Cont.)
Alternator Mounting Bolt ............................................................... ................. 30-41 (41-56)
Serpentine Belt Idler Pulley Bolt .............................................................................. 35 (48)
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)
Fig. 3: Exploded View Of Timing Belt Components

236 FORD
2.0L 4-Cylinder
DOHC, VIN 3 – Cougar, Contour & Mystique (1998-02)
Application Labor Time Component Belt CAUTION: DO NOT pull the spark plug cable when removing the
Kit No. Part No. spark plug connectors. If necessary, remove the ignition cables
2.0L 4-Cyl. – VIN 3 from the ignition coil to avoid kinking the cables. Turn the spark
Cougar plug connectors slightly before removing to loosen the seal.
1999 8) Disconnect throttle cable and cruise control cable from engine
Before 3/28/99 .................. 3.2 Hours ... .. TCK294 .. ..... T294
appearance cover. Disconnect solenoid valve electrical connector (1),
After 3/29/99 ..................... 3.2 Hours .... TCK294A . ..... T294
2000-02 ............................... 3.2 Hours .... TCK294A . ..... T294 and remove the engine appearance cover (2). See Fig. 6. Pull off the
Contour & Mystique spark plug connectors in line with the spark plugs. Remove the PCV
1998 .................................... 3.2 Hours ... .. TCK294 .. ..... T294 hose. Loosen 10 valve cover bolts from the outside to the inside,
1999 working diagonally. See Fig. 7. Remove the valve cover.
Before 3/28/99 .................. 3.2 Hours ... .. TCK294 .. ..... T294 9) Remove the spark plugs. Turn the engine to TDC on cylinder No. 1.
After 3/29/99 ..................... 3.2 Hours .... TCK294A . ..... T294 To remove the tension on timing belt, unscrew the timing belt tensioner
2000 .................................... 3.2 Hours .... TCK294A . ..... T294 bolt (1) 4 turns. See Fig. 8. Position the tensioner so the locating tab (2)
is at approximately the 4 o’clock position. Line up the hex key slot (3) in
NOTE: A timing belt component kit is available for this application. the tensioner adjusting washer with the pointer that is located behind the
See page A1 for information on component kits. pulley.
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.
10) Remove blanking plug (1) from center of exhaust camshaft pulley.
MANUFACTURER’S SUGGESTED See Fig. 9. Loosen, but do not remove, exhaust camshaft sprocket bolt
(2). Loosen, but do not remove, intake camshaft sprocket bolt (3).
SCHEDULED MAINTENANCE Remove timing belt.
inspected every 120,000 miles. Replace, if necessary. For 2001-02
model year, the manufacturer recommends the belt be replaced every
120,000 miles.

TIMING BELT
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 Courtesy of Ford Motor Co.
drive belt is to be reused, mark belt with arrow to indicate direction of
Fig. 1: Removing & Installing Accessory Drive Belt
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.
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 Courtesy of Ford Motor Co.
reservoir. Fig. 2: Identifying Lower Front Timing Cover Bolts
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.
FORD 237
2.0L 4-Cylinder
DOHC, VIN 3 – Cougar, Contour & Mystique (1998-02) (Cont.)
Fig. 3: Removing & Installing Front Support Insulator

Fig. 7: Locating Crankcase Ventilation Hose & Valve Cover Bolts
Fig. 4: Locating Upper Front Timing Cover Bolts Courtesy of Ford Motor Co.
Fig. 8: Removing Tension From Timing Belt
Fig. 5: Locating Center Timing Cover Bolts

Fig. 9: Identifying Camshaft Sprocket Holding/Removing Tool
Fig. 6: Removing & Installing Appearance Cover

238 FORD
2.0L 4-Cylinder
11) Attach the timing belt center cover/front engine mounting bracket.
NOTE: To achieve proper timing belt tension, camshaft sprocket See Fig. 5. Install the valve cover. See Fig. 7. Tighten the valve cover
bolts must be loosened enough to permit sprockets to turn freely bolts in 2 stages:
on camshafts. With cam sprocket bolts loose and cylinder No. 1 at • Step 1: 18 INCH lbs. (2 N.m).
TDC, crankshaft must be rotated to TDC in clockwise direction • Step 2: 62 INCH lbs. (7 N.m).
(install camshaft alignment tool in cam slots). Cylinders No. 1 and 4
NOTE: Check the seating of the timing belt upper cover gasket and
are at TDC when Woodruff key points straight up. correct it if necessary.
Installation – 1) Rotate the crankshaft clockwise to TDC cylinder No. 1. 12) Install the timing belt upper cover. See Fig. 4. Install the front engine
Remove the blanking plug, completely screw in the Crankshaft TDC mount. Connect the Power Assisted Steering (PAS) reservoir. Install the
Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to coolant expansion tank.
TDC. See Fig. 10. 13) Install the power steering pipe bracket to the engine lift eye. Install
2) Turn the camshafts to ignition position on cylinder No. 1, and insert the front support insulator. See Fig. 3. Remove the floor jack.
the Camshaft Alignment Plate (303-465, T94P-6256-CH) into the cam- 14) Install the coolant expansion tank. Attach the cruise control cable (if
shafts. See Fig. 11. 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 NOTE: Verify that the center bolt is centered in the support insu-
1.38″ (35 mm). DO NOT rotate the crankshaft, and check that it is lator.
still resting against the timing pin. The lug of the belt tensioner 15) Tighten the center bolt of the right engine support insulator. Tighten
must not be hooked into the sheet metal cover during timing belt the center bolt of the left engine support insulator. Install the lower part
installation. of the engine front cover. See Fig. 2. Tighten front cover bolts to
3) Starting from the crankshaft timing belt pulley and working counter-
clockwise, position a NEW timing belt in place while keeping it under NOTE: Use the access hole in the bottom of transaxle case to stop
tension. See Fig. 12. engine rotating.
4) Apply tension to the timing belt. Incorrect timing belt tension will cause
16) Install the crankshaft pulley/vibration damper and tighten to speci-
incorrect valve timing. Rotate the tensioner locating tab counterclock-
fication. See TORQUE SPECIFICATIONS. Install the accessory drive
wise and insert the locating tab into the slot in the rear timing cover. See
belt. See Fig. 1. Note the accessory drive belt direction mark if belt is
Fig. 13.
being reused. Install the belt idler pulley. Install the water pump pulley.
5) Position the hex key slot in the tensioner adjusting washer to the 4 17) Tension the belt tensioner clockwise, and position the accessory
o’clock position. Tighten the attaching bolt (3) enough to seat the drive belt in place. Tighten the water pump pulley bolts to specification.
tensioner firmly against the rear timing cover, but still allow the tensioner See TORQUE SPECIFICATIONS.
adjusting washer to be rotated using a 0.24″ (6 mm) hex key. 18) Install the right front lower splash shield. Install the engine splash
6) Tension the timing belt, working counterclockwise. Using the hex key, shield (if equipped). Lower the vehicle. Install the right front wheel, and
rotate the adjusting washer counterclockwise until the notch in the tighten nuts to specification. See TORQUE SPECIFICATIONS.
pointer is centered over the index line on the locating tab (the pointer will 19) Connect the negative battery cable. Check the fluid levels and
move clockwise during adjustment). See Fig. 14. correct as necessary. Check the routing of the vacuum hoses and wiring
7) While holding the adjusting washer in position, tighten the bolt to and secure them with cable ties.
specification. See TORQUE SPECIFICATIONS. DO NOT tighten the 20) When battery is disconnected, some abnormal driveability symp-
camshaft timing pulley bolts against the camshaft alignment plate. Use toms may occur until the PCM relearns its adaptive strategy. The vehicle
the camshaft sprocket holding tool to prevent movement. See Fig. 9. may need to be driven 10 miles or more to complete a relearn cycle.
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 align-
ment. Remove the crankshaft timing peg and camshaft alignment plate.
Screw in and tighten the blanking plug.
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 Courtesy of Ford Motor Co.
upper timing belt cover together with the center timing belt cover in Fig. 10: Aligning Crankshaft Timing Marks
place.
FORD 239
2.0L 4-Cylinder
Fig. 11: Installing Camshaft Alignment Tool
Fig. 14: Setting Timing Belt Tension
Intake ....................................................................................................................... 50 (68)
Exhaust
Step 1 .................................................................................................................... 44 (60)
Step 2 .................................................................................................................. 89 (120)
Center Bolt-Left & Right-Hand Support Insulator Bolts ......................................... 89 (120)
Engine Front Support Insulator Bolt/Nut .................................................................. 61 (83)
Engine Lifting Eye With Coolant Hose Brackets ..................................................... 13 (18)
Courtesy of Ford Motor Co. Exhaust Camshaft Center Blanking Plug ................................................................. 27 (37)
Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40)
Fig. 12: Identifying Timing Belt Installed Position
Spark Plugs ............................................................................................................... 11 (15)
Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25)
Water Pump Bolt ....................................................................................................... 13 (18)
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)
Fig. 13: Applying Pre-Tension To Timing Belt

240 FORD
2.0L 4-Cylinder – DOHC, VIN 3 – Escort & ZX2
Kit No. Part No.
Escort
1998 .................................... 2.8 Hours ... .. TCK294 .. ..... T294
1999
Before 2/9/99 .................... 2.8 Hours ... .. TCK294 .. ..... T294
After 2/10/99 ..................... 2.8 Hours .... TCK294A . ..... T294
2000-02 ............................... 2.8 Hours .... TCK294A . ..... T294
ZX2
2000-03 ............................... 2.8 Hours .... TCK294A . ..... T294


MANUFACTURER’S SUGGESTED Fig. 1: Installing Crankshaft TDC Timing Peg
inspected every 120,000 miles. Replace, if necessary. For 2001-03
model year, the manufacturer recommends the belt be replaced every
120,000 miles.

TIMING BELT
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. Fig. 2: Aligning Crankshaft Timing Marks
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 Courtesy of Ford Motor Co.
slots on camshafts at rear of engine. See Fig. 3.
5) Loosen timing belt tensioning pulley bolt. Disconnect tensioner tab Fig. 3: Installing Camshaft Alignment Timing Tool
from timing cover back plate to relieve tension on timing belt. If reusing Ensure camshafts are aligned. Install intake timing sprocket and loosely
timing belt, mark direction of rotation before removal. Remove timing
install bolt. Rotate oil control bushing one complete turn and check for
belt.
binding. Position bushing with single hole in 12 o’clock position.
CAUTION: Do not use camshaft alignment tool to hold camshafts
in place when removing or installing camshaft sprocket bolts, or CAUTION: The VCT sprocket has a rectangular tab on the backside
damage to camshaft ears may result. Use open-end wrench to keep of the sprocket which must align with the hole on the front face of
camshaft from rotating. the thrust bushing. Failure to align may result in poor engine
performance.
6) Remove camshaft alignment tool. Remove bolt and intake camshaft
timing sprocket. Remove VCT oil plug, bolt and exhaust camshaft 2) Install NEW exhaust sprocket “O” ring. Install exhaust sprocket.
sprocket. Ensure tab on sprocket engages hole in oil control bushing. Loosely
Installation – 1) Ensure crankshaft pulley timing marks are aligned. See install sprocket bolt. Loosely install timing belt tensioner. Install timing
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.
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. Courtesy of Ford Motor Co.
5) When alignment is correct, complete installation by reversing removal Fig. 6: Identifying Valve Cover Torque Sequence
procedure. When installing valve cover, clean gasket mating surfaces
before installing NEW gasket. Install and tighten valve cover bolts in a TORQUE SPECIFICATIONS
diagonal pattern starting from the inside working outward. See Fig. 6.
Tighten all nuts and bolts to specification. See TORQUE SPECIFICA-
TIONS. Application Ft. Lbs. (N.m)
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)
Crossmember Bolts ....................................................................... ............... 69-93 (94-126)
Engine Front Support Isolator Nut & Bolt .................................... ................. 50-68 (67-93)
Exhaust Camshaft (VCT) Sprocket Plug .................................................................. 27 (37)
Spark Plugs ................................................................................... ................. 10-12 (13-17)
Water Pump Bolt ....................................................................................................... 17 (24)
Wheel Lug Nut
Alloy Wheel ................................................................................. ........... 74-100 (100-135)
Steel Wheel ................................................................................................. 66-87 (89-117)
INCH Lbs. (N.m)
Splash Shield Assembly .................................................................................... 62-97 (7-11)
Timing Belt Backplate Bolt ................................................................................ 80-97 (9-11)
Center .......................................................................................... ..................................... 1
Lower ......................................................................................................................... 61 (7)
Upper ........................................................................................... ..................... 27-44 (3-5)
Courtesy of Ford Motor Co. Valve Cover Bolt ........................................................................... ..................... 54-70 (6-8)
Valve Cover Appearance Cover ................................................................................. 62 (7)
1
– Tighten bolts to 10 ft. lbs. (13 N.m).
Fig. 5: Index Marks For Timing Belt Tensioner

242 FORD
2.0L 4-Cylinder – DOHC, VIN 3 – Focus
TIMING BELT APPLICATION Position the tensioner so the locating tab (2) is at approximately the 4
Application Labor Time Component Belt o’clock position. Line up the hex key slot (3) in the tensioner adjusting
Kit No. Part No. washer with the pointer that is located behind the pulley.
2.0L 4-Cyl. – DOHC, VIN 3 7) Remove the timing belt. Loosen the camshaft pulley retaining bolts.
Focus Prevent sprocket from turning using the Cam Sprocket Holding/
2000-04 ............................... 2.8 Hours .... TCK294A . ..... T294 Removing Tool (303-098, T74P-6256-B). See Fig. 7.

The manufacturer recommends the belt be replaced at 120,000 miles.
REMOVAL & INSTALLATION Courtesy of Ford Motor Co.
Fig. 1: Removing & Installing Accessory Drive Belt

damage may occur.
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. Courtesy of Ford Motor Co.
NOTE: Numbers in parenthesis refer to numbers in figures. 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 Fig. 3: Locating Upper Front Timing Cover Bolts
front engine mounting is free from load.
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
Fig. 4: Locating Center Timing Cover Bolts
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.
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.
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 counterclock-
wise 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 o’clock 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,
Fig. 5: Locating Crankcase Ventilation Hose & Valve Cover Bolts 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.
crankshaft timing peg. Correct it if necessary:
Courtesy of Ford Motor Co. • Screw in crankshaft timing peg and make sure that the crankshaft is
touching it.
Fig. 6: Removing Tension From Timing Belt • 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.
grease to a depth of 0.20-0.39″ (5-10 mm).
10) Install the valve cover. See Fig. 5. Tighten the valve cover bolts in 2
stages:
• Step 1: 18 INCH lbs. (2 N.m).
Fig. 7: Identifying Cam Sprocket Holding/Removing Tool • 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
NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must
be able to turn freely on the camshafts.
11) Push in the spark plug connector until it engages. Put the upper
Installation – 1) Turn the camshafts to ignition position on cylinder No. 1 timing belt cover together with the center timing belt cover in place.
and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into Attach the timing belt center cover/front engine mounting bracket. See
the camshafts. See Fig. 8. Rotate the crankshaft clockwise to TDC Fig. 4.
cylinder No. 1. See Fig. 9.
NOTE: Check the seating of the timing belt upper cover gasket, and
correct it if necessary.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key
points straight up. 12) Install the timing belt upper cover. See Fig. 3. Install the front engine
mount. Connect the Power Assisted Steering (PAS) reservoir. Install the
2) Remove the blanking plug. Completely screw in the Crankshaft TDC
coolant expansion tank.
Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to 13) Pull the jack out towards the front of the vehicle. Raise and support
TDC. See Fig. 10. the vehicle. Install the lower timing belt cover. See Fig. 2. Attach the
crankshaft pulley/vibration damper and tighten to specification. See
CAUTION: DO NOT kink or bend the timing belt less than a
diameter of 1.38″ (35 mm). DO NOT rotate the crankshaft, and
14) Install the drive belt. If reusing drive belt note the direction previously
check that it is still resting against the timing pin. 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.
244 FORD
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.
Fig. 8: Installing Camshaft Alignment Timing Tool


Fig. 10: Installing Crankshaft Position Timing Peg

FORD 245

Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24)
Intake & Exhaust ..................................................................................................... 50 (68)
Engine Front Support
To-Engine Bracket Nut ............................................................................................ 59 (80)
To-Frame Bolts ........................................................................................................ 35 (48)
Spark Plugs ............................................................................................................... 11 (15)
Wheel Lug Nuts ...................................................................................................... 94 (128)
INCH Lbs. (N.m)
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)

MOTORES CHECK
246 FORD
2.0L 4-Cylinder – DOHC, VIN 5 – Focus
Application Labor Time Component Belt CAUTION: DO NOT pull the spark plug cable when removing the
Kit No. Part No. spark plug connectors. If necessary, remove the ignition cables
2.0L 4-Cyl. – DOHC, VIN 5 from the ignition coil to avoid kinking the cables. Turn the spark
Focus plug connectors slightly before removing to loosen the seal. Pull
2002-04 ............................... 2.8 Hours .... TCK294A . ..... T294 off the spark plug connectors in line with the spark plugs.
NOTE: A timing belt component kit is available for this application. 6) Pull off the spark plug connectors. Remove the PCV hose. Loosen 10
See page A1 for information on component kits. valve cover bolts from the outside to the inside, working diagonally. See
Fig. 9. Remove the valve cover. Remove the spark plugs.
NOTE: At TDC the crankshaft keyway is in the 12 o’clock position.
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
MANUFACTURER’S SUGGESTED intake camshaft pulley blanking plug. See Fig. 10. Using an open-ended
SCHEDULED MAINTENANCE wrench to prevent the camshaft from rotating, loosen the camshaft
pulley retaining bolts.
The manufacturer recommends the belt be replaced at 120,000 miles.
8) Remove the tension on timing belt. Unscrew the timing belt tensioner
bolt 4 turns (1). See Fig. 11.
REMOVAL & INSTALLATION 9) Position the tensioner so the locating tab (2) is at approximately the
4 o’clock 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.
damage may occur.
TIMING BELT
CAUTION: The camshaft must be held stationary with an open-
ended 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 Courtesy of Ford Motor Co.
remove coolant and ventilation hoses. Owing to special model
variants, some steps DO NOT apply to all vehicles. These are Fig. 1: Removing & Installing Accessory Drive Belt
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.

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. 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 Courtesy of Ford Motor Co.
retaining clip (2). See Fig. 5. Remove the ignition coil pack cover (3). Fig. 3: Locating Upper Front Timing Cover Bolts
Remove the engine upper cover. See Fig. 6. Disconnect the Variable
Cam Timing (VCT) valve electrical connector. See Fig. 7.
FORD 247
Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.
Fig. 4: Locating Center Timing Cover Bolts Fig. 8: Locating Center Timing Cover Bolts

Fig. 5: Identifying Ignition Coil Pack Cover Fig. 9: Locating Crankcase Ventilation Hose & Valve Cover Bolts
Courtesy of Ford Motor Co. Fig. 10: Locating Intake Camshaft Pulley Blanking Plug
Fig. 6: Locating Engine Upper Cover

Fig. 7: Locating Variable Cam Timing Valve Electrical Fig. 11: Removing Tension From Timing Belt
248 FORD
Attach the PCV hose. Coat the spark plug thread with Never Seize.
NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must Screw in the spark plugs. Tighten spark plugs to specification. See
be able to turn freely on the camshafts. TORQUE SPECIFICATIONS.
11) Push in the spark plug connector until it engages. Connect the VCT
Installation – 1) Turn the camshafts to ignition position on cylinder No. 1
valve electrical connector. Install the engine cover. Attach the retaining
and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into
clips. Attach the coolant pipe to the retaining clip. Install the ignition coil
the camshafts. See Fig. 12. Remove the blanking plug. Completely
pack cover. Put the upper timing belt cover together with the center
screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and
timing belt cover in place. Attach the timing belt center cover/front
auto-align the crankshaft to TDC. See Fig. 13.
engine mounting bracket. See Fig. 8.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key
NOTE: Check the seating of the timing belt upper cover gasket, and
points straight up.
correct it if necessary.
2) Rotate the crankshaft clockwise to TDC cylinder No. 1. See Fig. 14. 12) Install the timing belt upper cover and tighten bolts to specification.
Make sure that the crankshaft contacts the timing peg. See Fig. 3. Install the accessory drive belt idler and tighten bolt to
specification. Install the front engine mount and tighten bolts to specifi-
CAUTION: DO NOT kink or bend the timing belt less than a
cation. Connect the Power Assisted Steering (PAS) reservoir. Install the
diameter of 1.38″ (35 mm). DO NOT rotate the crankshaft, and
coolant expansion tank.
check that it is still resting against the timing pin.
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
NOTE: The lug of the belt tensioner must not be hooked into the crankshaft pulley/vibration damper and tighten to specification. See
sheet metal cover during timing belt installation. TORQUE SPECIFICATIONS.
14) Install the drive belt. If reusing drive belt note the direction previously
3) Position a NEW timing belt in place and starting from the crankshaft recorded in removal procedure. See Fig. 1. Attach the multi-groove belt
timing belt pulley and working counterclockwise, position the timing belt idler pulley (3). Install but DO NOT tighten the water pump pulley bolts
in place while keeping it under tension. See Fig. 15. (1). Install the drive belt by turning tensioner (2) clockwise and tension
4) Apply tension to the timing belt. Incorrect timing belt tension will cause it.
incorrect valve timing. Rotate the tensioner locating tab counterclock- 15) Tighten the bolts on the water pump pulley to specification. Attach
wise and insert the locating tab (1) into the slot in the rear timing cover. the drive belt cover. Lower the vehicle. Connect the negative battery
See Fig. 16. cable. Check fluid levels and correct if necessary. Check the routing of
5) Position the hex key slot (2) in the tensioner adjusting washer to the vacuum hoses and cables, and secure them with cable ties.
4 o’clock position. Tighten the attaching bolt (3) enough to seat the
tensioner firmly against the rear timing cover, but still allow the tensioner NOTE: When the battery has been disconnected and reconnected,
some abnormal drive symptoms may occur while the vehicle
adjusting washer to be rotated using a 0.24″ (6 mm) hex key.
relearns its adaptive strategy. The vehicle may need to be driven 10
6) Tension the timing belt, working counterclockwise. Using the hex key,
miles or more to relearn the strategy.
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.
crankshaft timing peg. Correct it if necessary:
• Screw in crankshaft timing peg and make sure that the crankshaft is
touching it. Courtesy of Ford Motor Co.
• Insert camshaft alignment plate into the camshafts. If necessary, Fig. 12: Installing Camshaft Alignment Timing Tool
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.
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.
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). Fig. 13: Installing Crankshaft Position Timing Peg
FORD 249
Accessory Drive Belt Idler Bolt ................................................................................. 35 (48)
Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24)
Blanking Plug (Intake Camshaft Pulley Blanking Plug) ........................................... 17 (37)
Exhaust .................................................................................................................... 50 (68)
Intake ..................................................................................................................... 89 (120)
Engine Front Mount Bracket ..................................................................................... 37 (50)
Engine Front Support
To-Engine Bracket Bolts .......................................................................................... 59 (80)
To-Frame Bolts/Nuts ................................................................................................ 35 (48)
Spark Plugs ............................................................................................................... 11 (15)
Wheel Lug Nuts ...................................................................................................... 94 (128)
INCH Lbs. (N.m)
Engine Cover ............................................................................................................. 89 (10)
Upper Timing Belt Cover Bolt ................................................................................... 10 (89)
Valve Cover Bolts
Stage 1 ...................................................................................................................... 18 (2)
Stage 2 ...................................................................................................................... 62 (7)

250 FORD
2.0L 4-Cylinder – SOHC, VIN P
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: For information about tensioners and/or pulleys (when Courtesy of Ford Motor Co.
Removal (Focus) – 1) Disconnect negative battery cable. Detach
MANUFACTURER’S SUGGESTED coolant expansion tank, and set to one side. Remove power steering
SCHEDULED MAINTENANCE fluid reservoir from shock tower, and set aside with hoses attached.
Up to 2000 model year, the manufacturer recommends that the timing 2) Raise and support vehicle. Remove the accessory drive belt splash
belt be inspected at 120,000 miles. Replace, if necessary. For shield. Lower the vehicle. Using a 3/8 inch square drive breaker bar in
2001-2004 model years, the manufacturer recommends that the timing the hole provided, rotate the tensioner clockwise to relieve tension, and
belt be replaced at 120,000 miles. remove serpentine drive belt.
NOTE: Remove power steering pump, if necessary.

3) Hold power steering pump pulley stationary, and remove power
TIMING BELT steering pump center nut. Remove power steering pump pulley.
Removal (Escort & Tracer) – 1) Disconnect negative battery cable. Remove power steering pump mounting nuts. Set power steering pump
Place cylinder No. 1 to TDC of compression stroke. Remove accessory aside with hoses attached.
drive belt and tensioner. Remove timing belt cover. Raise and support 4) Raise and support vehicle. Remove right front wheel.
vehicle. Remove right hand splash shield. Remove crankshaft pulley.
Align timing marks. See Fig. 1. CAUTION: When removing spark plug connectors, do not pull on
2) Loosen timing belt tensioner. Using an 8-mm hex wrench, turn ignition wire. If necessary, remove ignition coil plug to avoid
tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit to lock tensioner bending ignition wire. Turn spark plug connector slightly before
in place. See Fig. 2. If reusing old belt, mark belt with arrow to indicate removing to loosen gasket.
original direction of rotation. Remove timing belt.
5) Remove the crankshaft pulley and vibration damper. Lower vehicle.
Noting position for reassembly reference, disconnect spark plug sec-
ondary 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
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 clock-
wise 2 revolutions. Recheck timing mark alignment. If not correct,
readjust timing belt.
Courtesy of Ford Motor Co. 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.
Installation – 1) Ensure timing marks are still aligned. Install timing belt Remove jack from under engine.
in a counterclockwise direction starting at the crankshaft. If reusing old 4) Install spark plugs in cylinders from which they were removed (new
belt, ensure it is installed in original direction of rotation. Keep belt span spark plugs may be installed in any cylinder). Using a blunt object (such
between crankshaft and camshaft tight while installing timing belt over as a plastic cable tie), coat inside of spark plug connector with silicone
camshaft. grease to a depth of 5-10 mm. Install spark plug connectors using a
2) Remove drill bit and tighten tensioner bolt. Rotate crankshaft clock- straight movement. Raise vehicle. Install crankshaft pulley and vibration
wise 2 revolutions. Recheck timing mark alignment. To complete instal- damper. Tighten center bolt to specification. Position drive belt on
lation, reverse removal procedure. crankshaft pulley.
FORD 251
2.0L 4-Cylinder – SOHC, VIN P (Cont.)

5) Install lower drive belt cover. Install right front wheel. Lower vehicle. TORQUE SPECIFICATIONS (FOCUS)
Install power steering pump, if removed. Install power steering pump Application Ft. Lbs. (N.m)
pulley. Tighten center bolt to specification. See TORQUE SPECIFICA- Camshaft Sprocket Bolt .......................................................................................... 77 (105)
TIONS. Install serpentine drive belt. Install power steering fluid reservoir Crankshaft Pulley Bolt ............................................................................................. 89 (120)
and coolant expansion tank. Connect negative battery cable. Engine Mount
Bracket-To-Engine ................................................................................................... 35 (48)
To-Engine Nuts ........................................................................................................ 59 (80)
TORQUE SPECIFICATIONS To-Frame Bolts ........................................................................................................ 35 (48)
Power Steering Pump
TORQUE SPECIFICATIONS (ESCORT & TRACER) Mount Bolt ............................................................................................................... 17 (23)
Application Ft. Lbs. (N.m) Pulley Bolt ............................................................................................................... 35 (47)
Spark Plugs ............................................................................................................... 11 (15)
Camshaft Sprocket Bolt ................................................................................ 70-85 (95-115)
Lower ........................................................................................... ..................................... 1
Engine Mounting Bracket Bolts .................................................... ................. 31-42 (41-57)
Upper ....................................................................................................................... 35 (48)
Power Steering Pump
Mount Bolt ................................................................................... ................. 15-22 (20-30)
Wheel Lug Nut ........................................................................................................ 94 (128)
Pulley Bolt ................................................................................... ................. 15-22 (20-30)
Spark Plugs ............................................................................................................... 11 (15) INCH Lbs. (N.m)
Timing Belt Tensioner Bolt ............................................................ ................. 15-22 (20-30) Valve Cover Bolts ........................................................................................................ 80 (9)
Water Pump Bolts ......................................................................... ................. 15-22 (20-30)
1
Wheel Lug Nuts ............................................................................................ 66-86 (89-117) – Tighten bolt to 89 INCH lbs. (10 N.m).
INCH Lbs. (N.m)
Splash Shield Assembly Bolts .......................................................................... 71-97 (8-11)
Timing Belt Cover Bolts .................................................................................... 71-97 (8-11)
252 FORD
2.0L & 2.2L 4-Cylinder – Probe
Probe damage may occur.
1
1993-97 .............................. 2.8 Hours .. .. TCK228 .. ..... T228
2.2L 4-Cyl.
Probe TIMING BELT
1
1989-92 .............................. 2.3 Hours .. .. TCK134 .. ..... T134
1 CAUTION: DO NOT rotate crankshaft or camshafts with timing belt
removed. Damage to valve/piston may result.
NOTE: A timing belt component kit is available for this application. Removal – 1) Disconnect negative battery cable. Remove accessory
See page A1 for information on component kits. drive belts. Remove spark plug wires and valve cover. Install Three Bar
Engine Support (014-00750) or equivalent. Slightly raise engine with a
NOTE: For information about tensioners and/or pulleys (when jack. Remove right engine mount. Remove dipstick bolt. Remove upper
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED crankshaft pulley and crankshaft pulley guide plate. Remove lower
SCHEDULED MAINTENANCE timing belt cover. Temporarily install crankshaft pulley bolt.
For the 2.0L engine, the manufacturer recommends the belt be replaced NOTE: Mark direction of timing belt rotation if reusing belt.
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 3) Rotate crankshaft clockwise and align crankshaft sprocket timing
recommends the belt be replaced at every 60,000 miles. 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.
Fig. 1: Exploded View Of Timing Belt Components (2.0L)

FORD 253
2.0L & 2.2L 4-Cylinder – Probe (Cont.)
Fig. 2: Exploded View Of Timing Belt Components (2.2L)

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
Alternator Mounting Bolt ............................................................... ................. 27-38 (37-52)
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) Fig. 5: Locating Timing Belt Tensioner & Spring (2.2L)
254 FORD
2.0L & 2.3L 4-Cylinder – 1974-94 Except Probe
Kit No. Part No. TIMING BELT
2.0L 4-Cyl. – OHC Removal – 1) Disconnect negative battery cable. Rotate engine clock-
Ranger wise and position cylinder No. 1 on TDC of compression stroke. Ensure
1983-88 .............................. 1 2.2 Hours .. .. TCK014 .. ..... T014 “O” mark on crankshaft pulley aligns with “O” mark on outer timing belt
2.3L 4-Cyl. – OHC
cover.
Aerostar
1987 ................................... 2 2.2 Hours .. .. TCK014 .. ..... T014 2) Looking through plug hole of outer timing belt cover, ensure camshaft
Bobcat & Pinto sprocket timing mark aligns with cover pointer. See Fig. 1.
1974-80 .............................. 3 2.0 Hours .. .. TCK014 .. ..... T014 3) Remove fan guard, cooling shroud, cooling fan and fan shroud.
Cougar Remove drive belt, water pump pulley and automatic belt tensioner.
1981 ................................... 2 1.3 Hours .. .. TCK014 .. ..... T014 Discharge A/C system (if equipped) using approved refrigerant recovery
1984-86 .............................. 2 1.3 Hours .. .. TCK014 .. ..... T014 equipment. Remove A/C compressor mounting bracket with power
Courier steering pump attached, and position aside. Drain cooling system.
1977-82 .............................. 3 2.2 Hours .. .. TCK014 .. ..... T014
Remove upper radiator hose. Remove thermostat housing and gasket.
Fairmont & Zephyr
1978-83 .............................. 3 1.6 Hours .. .. TCK014 .. ..... T014 4) Remove retaining bolt and crankshaft pulley. Remove hub assembly
Granada retaining bolt from crankshaft. Remove outer timing belt cover. Ensure
1981-82 .............................. 3 1.6 Hours .. .. TCK014 .. ..... T014 camshaft sprocket timing mark aligns with cover pointer. See Fig. 1.
LTD & Marquis 5) Loosen belt tensioner bolts. Using Camshaft Belt Tensioner
1983 ................................... 3 1.6 Hours .. .. TCK014 .. ..... T014 (T74P-6254-A) or equivalent, release spring tension on belt tensioner.
1984-86 .............................. 3 1.5 Hours .. .. TCK014 .. ..... T014 Rotate belt tensioner away from timing belt and tighten bolts.
Merkur XR4Ti
6) Remove retaining bolts and pull crankshaft sensor from dowel pins.
1985-89 .............................. 2 1.5 Hours .. .. TCK014 .. ..... T014
Mustang, Mustang II & Capri See Fig. 1. Remove hub assembly and belt guide. Note direction of belt
1974-91 .............................. 3 1.6 Hours .. .. TCK014 .. ..... T014 guide installation. Remove timing belt.
1992 Installation – 1) Install crankshaft sprocket (if removed) with recessed
With Round Tooth area toward crankshaft. See Fig. 1. Install belt guide with flat side toward
Sprockets .................... 2 2.0 Hours .. ...... ..... ...... ..... T210 camshaft sprocket. Install camshaft sprocket with timing mark outward.
With Square Tooth
Sprockets .................... 2 2.0 Hours .. .. TCK014 .. ..... T014 CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt.
Mustang
1993 ................................... 3 2.0 Hours .. .. TCK210 .. ..... T210 2) Install NEW camshaft sprocket bolt, and tighten to specification while
Ranger holding camshaft with camshaft sprocket holder. See TORQUE SPECI-
1983-91 .............................. 4 1.6 Hours .. .. TCK014 .. ..... T014 FICATIONS.
1992 3) Align camshaft sprocket timing mark with pointer. Properly position
With Round Tooth crankshaft so timing mark aligns with notch in front cover casting. See
Sprockets .................... 4 1.6 Hours .. .. TCK210 .. ..... T210 Fig. 2. Install timing belt over crankshaft sprocket, then counterclock-
With Square Tooth
wise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner
Sprockets .................... 4 1.6 Hours .. .. TCK014 .. ..... T014
bolt, allowing tension to be applied on timing belt.
1993-94 .............................. 4 1.6 Hours .. .. TCK210 .. ..... T210
Thunderbird
NOTE: It may be necessary to push belt tensioner against timing
1983-88 .............................. 3 1.3 Hours .. .. TCK014 .. ..... T014
1
belt, as spring tension may not move belt tensioner against timing
– With Air Conditioning, add .3 hours. belt.
2
– With Air Conditioning, add 1.0 hours. 4) Remove one spark plug from each cylinder. Rotate engine clockwise
3
– With Air Conditioning, add .5 hours. (viewed from front of engine) 2 complete revolutions. Tighten timing belt
4
– With Air Conditioning, add .9 hours. tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Ensure all timing marks align properly. See Figs. 1 and 3. Install belt
NOTE: A timing belt component kit is available for this application. guide on crankshaft.
See page A1 for information on component kits. 5) Install crankshaft sensor over dowel pins. Tighten long crankshaft
sensor bolts to 14-22 ft. lbs. (19-30 N.m). Rotate crankshaft counter-
clockwise 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 specifi-
cation. See TORQUE SPECIFICATIONS. Install crankshaft sensor
MANUFACTURER’S SUGGESTED positioner. See Fig. 4. Rotate crankshaft clockwise approximately 90
degrees so outer vane of hub assembly engages with crankshaft sensor
SCHEDULED MAINTENANCE positioner. Tighten short crankshaft sensor bolts to 14-22 ft. lbs. (19-30
Although the manufacturer does not recommend a specific scheduled N.m).
maintenance interval, belt manufacturers suggest the belt be replaced at 7) To install remaining components, reverse removal procedure. Tighten
60,000 mile intervals. 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.)
Fig. 4: Positioning Crankshaft Sensor
Auxiliary Shaft Sprocket Bolt ........................................................ ................. 29-40 (39-54)
Belt Tensioner
Adjusting Bolt .............................................................................. ................. 14-22 (19-30)
Pivot Bolt ..................................................................................... ................. 29-40 (39-54)
Fig. 1: Exploded View Of Timing Belt & Components 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
– Install NEW bolt. DO NOT reuse bolt.
2
– Apply thread sealant on bolt threads.
Fig. 2: Positioning Crankshaft
Fig. 3: Aligning Camshaft & Oil Pump Timing Marks

256 FORD
Part No.
Ranger
1985-87
1
1
Camshaft ............................................... 1.6 Hours .. ..... T091
1


CAUTION: This application is an interference engine. Do not rotate Courtesy of Ford Motor Co.
Fig. 1: Locating Silent Shaft Timing Belt Tensioner Nut
damage may occur.
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 Fig. 2: Timing Belt Tensioner
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.
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.
Fig. 3: Removing Tensioner Bolt Access Cover

FORD 257
Fig. 4: Loosening Belt Tensioner Bolts

Fig. 6: Aligning Mark On Timing Cover With Mark On

Camshaft Sprocket
Crankshaft Pulley Bolts ................................................................. ......... 123-137 (167-186)
Injection Pump Sprocket Nut ........................................................ ................. 40-50 (54-68)
Timing Belt Tensioner Nut ............................................................ ................. 16-21 (22-29)
INCH Lbs. (N.m)
Front Case Bolts ........................................................................... ............. 108-120 (12-14)
Rocker Cover Bolts ....................................................................... ..................... 48-60 (5-7)
Silent Shaft Chamber Cover Bolts ............................................... ..................... 36-48 (4-5)
Fig. 5: Identifying Timing Mark Alignment

258 FORD
2.3L 4-Cylinder – Gasoline
Kit No. Part No.
2.3L 4-Cyl.
Ranger
1
1995-97 .............................. 1.6 Hours .. .. TCK276 .. ..... T276
1


TIMING BELT 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 CAUTION: Always rotate engine in direction of normal rotation
are aligned with inner cover timing marks. See Fig. 1. Remove fan (clockwise as viewed from front of engine). Reverse rotation may
guard. Remove fan shroud and position aside. Remove fan retaining cause timing belt to jump time, causing engine damage.
screws, and remove fan and shroud. Rotate drive belt tensioner and
Installation – 1) Ensure crankshaft is set at TDC, and camshaft
remove belt.
sprocket timing mark and oil pump sprocket timing mark are aligned with
2) Remove cooling fan and water pump pulley. Discharge A/C system (if
inner cover timing marks. See Fig. 1.
equipped) using approved refrigerant recovery/recycling equipment.
2) Install NEW timing belt. Loosen tensioner bolt. Allow tensioner to
Remove A/C compressor and position aside. Remove A/C compressor
adjust itself, and retighten bolt. Rotate crankshaft clockwise 2 complete
mounting bracket with power steering pump attached, and position revolutions to remove slack from belt.
aside. 3) Loosen tensioner bolt. Allow tensioner to adjust itself and retighten
3) Remove timing belt outer cover retaining bolt. Release 7 cover bolt. To complete installation, reverse removal procedure. Adjust drive
interlocking tabs. Remove timing belt cover. Holding timing belt ten- belts to proper tension.
sioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equiva-
lent, loosen adjusting bolt and slowly release tension. See Fig. 2. Pry TORQUE SPECIFICATIONS
tensioner away from timing belt and tighten bolt to hold tensioner in
place. Remove timing belt. TORQUE SPECIFICATIONS
A/C Compressor Bolts .................................................................. ................. 15-21 (21-28)
Alternator Bracket Bolts ................................................................ ................. 30-40 (41-54)
Alternator Retaining Bolts ............................................................. ................. 30-40 (41-54)
Cooling Fan Bolts .......................................................................... ................. 13-16 (17-23)
Crankshaft Damper Bolt ................................................................ ......... 103-133 (140-180)
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 259
2.5L 4-Cylinder
Kit No. Part No.
2.5L 4-Cyl.
Ranger
1
1998-01 .............................. 1.6 Hours .. .. TCK276 .. ..... T276
1


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.

TIMING BELT TORQUE SPECIFICATIONS
Removal – 1) Disconnect battery ground cable. Remove exhaust side
spark plugs.
2) Remove fan shroud bolts and fan shroud, and position aside. Loosen, A/C Compressor Mount Bolts ....................................................... ................. 15-21 (21-28)
A/C Compressor Mounting Bracket-To-Engine
but do not remove, water pump pulley bolts. Remove accessory drive
M8 Bolt .................................................................................................................... 18 (25)
serpentine belt. M10 Bolt & Stud ...................................................................................................... 35 (48)
3) Remove fan and clutch assembly retaining screws. Remove fan and Alternator Bracket Bolts ................................................................ ................. 30-40 (41-54)
clutch assembly. Remove fan shroud. Remove water pump pulley. Alternator Retaining Bolts ............................................................. ................. 30-40 (41-54)
4) On models with A/C, discharge A/C system using approved refriger- Camshaft Sprocket Bolt ................................................................ ................. 52-70 (70-95)
ant recovery/recycling equipment. Remove A/C compressor from Cooling Fan-To-Water Pump Bolts ............................................... ................. 13-16 (17-23)
mounting bracket. Remove A/C compressor mounting bracket with Crankshaft Damper Bolt ................................................................ ........... 93-121 (125-165)
power steering pump attached, and position aside.
5) Remove timing belt outer cover retaining bolt. Release 7 cover Timing Belt Tensioner Pivot Bolt .................................................. ................. 28-40 (40-55)
interlocking tabs. Remove timing belt cover.
6) Rotate crankshaft in normal direction of rotation so that No. 1 cylinder INCH Lbs. (N.m)
is at TDC of compression stroke. Align camshaft, crankshaft and oil Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12)
pump timing marks. See Fig. 1. Crankshaft keyway should be pointing Spark Plug ..................................................................................... ................. 80-177 (9-20)
straight up, and circle on crankshaft sprocket must align with notch in Valve Cover Bolt ............................................................................................. 80-115 (9-13)
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.
260 FORD
2.5L V6
2.5L V6
Probe CAUTION: This application is an interference engine. Do not rotate
1993-97 .................................................... 1
4.0 Hours .. ..... T214 camshaft or crankshaft when timing belt is removed, or engine
1 damage may occur.
Removal – 1) Disconnect negative battery cable. Disconnect engine
NOTE: For information about tensioners and/or pulleys (when coolant temperature sensor and temperature gauge sender connectors
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED using Crankshaft Pulley Holder (T92C-6316-AH) or equivalent. Remove
SCHEDULED MAINTENANCE crankshaft damper. Remove 2 timing belt cover bolts from behind
The manufacturer recommends the belt be replaced every 60,000 miles crankshaft damper. Remove timing belt cover lower bolts. Using Power
for Federal vehicles and 105,000 miles for California vehicles. Steering Pump Pulley Remover (D85L-6000-A) or equivalent, remove
power steering pump pulley.

FORD 261
2.5L V6 (Cont.)
3) Using Water Pump Pulley Remover (T92C-631 2-AH) or equivalent, Installation – 1) Place timing belt tensioner in a press, using a flat
remove water pump pulley bolts and pulley. Lower vehicle. Remove oil washer to prevent damage to timing belt tensioner plug.
dipstick tube. Remove upper timing belt cover bolts. Remove 2) Compress automatic belt tensioner until hole in piston aligns with
A/C-alternator belt idler bracket. Remove left timing belt cover, then right second hole in housing. Insert a .06″ (1.5 mm) diameter pin, or drill
cover. through hole to keep piston in compressed position. See Fig. 2.
4) Remove 3 nuts and through-bolt from right engine mount. Remove 3) Ensure camshafts and crankshaft timing marks align. See Fig. 3. Turn
right engine mount. Align crankshaft timing sprocket by turning crank- crankshaft counterclockwise until crankshaft timing sprocket is offset
shaft in normal direction of engine rotation only. Remove timing belt from TDC by one tooth. See Fig. 4. Install timing belt.
tensioner arm by removing lower and then upper tensioner arm bolts. 4) Turn crankshaft clockwise until crankshaft timing mark is back to
5) Mark direction of timing belt rotation if reusing belt. Using an Allen TDC. This should put slack on tensioner portion of belt. Install automatic
wrench, loosen timing belt tensioner bolt. Remove timing belt. timing belt tensioner, and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Remove pin from automatic tensioner.
CAUTION: DO NOT rotate camshafts or crankshaft with timing belt 5) Turn crankshaft 2 complete revolutions. Recheck timing marks to
removed, as engine damage could result. ensure timing is still correct. See Fig. 3. To complete installation, reverse
Inspection – 1) Inspect timing belt for damaged teeth, cracking and oil removal procedure. Tighten bolts to specification. Check ignition timing.
contamination. Ensure upper and lower timing belt idlers rotate freely. Adjust drive belts to proper tension.
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).
Fig. 4: Positioning Crankshaft For Removing Slack

Courtesy of Ford Motor Co. From Timing Belt
Fig. 2: Checking & Compressing Automatic Timing Belt TORQUE SPECIFICATIONS
Tensioner
A/C Compressor Bracket-To-Cylinder Block Bolt ......................... ................. 28-38 (38-51)
Camshaft Sprocket Bolt ................................................................ ........... 90-103 (122-140)
Crankshaft Pulley Bolt ............................................................................. 116-122 (157-165)
Engine Mount Nuts ....................................................................... ............... 54-76 (73-103)
Engine Mount Through-Bolts ........................................................................ 50-68 (86-116)
Front Suspension Crossmember Bolt ........................................... ............... 69-93 (94-126)
Knock Sensor ................................................................................ ................. 14-25 (20-34)
Power Steering Pump Bracket Bolt .............................................. ................. 24-33 (32-46)
Spark Plug ....................................................................................................... 11-16 (15-23)
Tensioner Pulley Bolt .................................................................... ................. 27-33 (37-45)
Water Pump Bolt ........................................................................... ................. 14-18 (19-24)
Wheel Lug Nut .............................................................................................. 65-87 (88-118)
INCH Lbs. (N.m)
Valve Cover Bolt ........................................................................... ..................... 43-78 (5-8)
Courtesy of Mazda Motors Corp.
Fig. 3: Aligning Camshaft & Crankshaft To TDC

262 FORD
3.0L V6 SOHC – Villager
Kit No. Part No.
3.0L V6 – SOHC
Villager (Mercury)
1
1993 ................................... 3.6 Hours .. .. TCK104 .. ..... T104
1
1994-98 .............................. 3.6 Hours .. .. TCH249 .. ..... T249
1


MANUFACTURER’S SUGGESTED Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Timing Belt & Sprocket
miles. This application is not an interference engine. crankshaft sprocket. White lines ensure correct number of teeth exist
between timing marks on sprockets.
REMOVAL & INSTALLATION 3) Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by
turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock
TIMING BELT nut. Rotate crankshaft clockwise at least 2 revolutions.
Removal – 1) Disconnect negative battery cable. Raise and support 4) Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull
vehicle. Remove covers from below engine. Drain cooling system. Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to
Remove right front wheel and engine side cover. Remove accessory timing belt between right camshaft sprocket and tensioner. Hold ten-
drive belts. Remove crankshaft pulley bolt and pulley. sioner in position with Allen wrench, and loosen tensioner lock nut.
2) Remove upper radiator hose and water inlet hose. Remove A/C 5) Place a .0138″ (.351 mm) feeler gauge at tensioner pulley and timing
compressor idler pulley and bracket. Remove water pump pulley. belt, and rotate crankshaft until feeler gauge is centered between
Remove upper and lower timing belt front covers. See Fig. 1. tensioner pulley and timing belt. See Fig. 3. Tighten tensioner lock nut to
3) Temporarily install crankshaft pulley bolt so crankshaft can be rotated. specification. See TORQUE SPECIFICATIONS.
Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft 6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clock-
until marks on camshaft sprockets align with marks on timing belt upper wise at least 2 revolutions until cylinder No. 1 is at TDC of compression
rear cover, and mark on crankshaft sprocket aligns with mark on front stroke. Measure timing belt deflection halfway between camshaft
cover housing. See Fig. 2. sprockets.
4) Loosen timing belt tensioner nut. Release tension on belt. Remove 7) If deflection is not .51-.59″ (13-15 mm), readjust timing belt tension.
timing belt. Check timing belt tensioner, spring and timing belt. To complete installation, reverse removal procedure. Adjust drive belts
to proper tension.
Fig. 3: Adjusting Timing Belt
Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133)
Courtesy of Ford Motor Co. Rocker Shaft Bolts ........................................................................ ................. 13-16 (16-20)
Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58)
Fig. 1: Exploded View Of Timing Belt Components Water Pump Bolt ........................................................................... ................. 13-16 (16-20)
Installation – 1) Ensure cylinder No. 1 is at TDC of compression stroke. INCH Lbs. (N.m)
See Fig. 2. Install tensioner and return spring if removed. If return spring Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)
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
FORD 263
3.0L & 3.2L V6 – SHO

Part No.
3.0L V6 – SHO
Taurus
1989-95 ..................................................... 3.0 Hours ... ..... T248
3.2L V6 – SHO
Taurus
1993-95 ..................................................... 3.0 Hours ... ..... T248

SCHEDULED MAINTENANCE Courtesy of Ford Motor Co.
The manufacturer recommends the belt be replaced every 100,000 Fig. 2: Locating Crankshaft Pulley Timing Marks
miles.

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. 1: Exploded View Of Intake Manifold & Brackets
Fig. 4: Adjusting Timing Belt Tension (3.0L SHO)

264 FORD
3.0L & 3.2L V6 – SHO (Cont.)
4) Mount Timing Belt Tensioner Tool (T93P-6254-B) or equivalent, using
NOTE: To prevent timing belt whine on models with 3.0L engine power steering pump bracket bolt holes. Using INCH-lb. torque wrench
and manual transaxle, the timing belt must be correctly tensioned. and Torque Wrench Attachment (T93P-6254-A) or equivalent, rotate
The revised tensioning procedure is from Ford technical service tensioner clockwise to 4.3 INCH lbs. (.5 N.m). Tighten belt tensioner
bulletin 95-22-10; November 6, 1995. bolt. Remove tensioner tool. Tighten bolts to specification.
5) Raise and support vehicle. Install timing belt guide and lower timing
Installation (3.0L SHO) – 1) Ensure No. 1 piston is at TDC of belt cover. Install crankshaft damper. Rotate crankshaft clockwise 60
compression stroke. Ensure camshaft timing marks align with timing belt degrees until White mark on crankshaft damper aligns with “0” mark on
cover marks, and crankshaft sprocket timing mark aligns with mark on lower timing belt cover.
oil pump housing. See Fig. 3. 6) Ensure camshaft timing marks align with timing belt cover marks. See
2) Install timing belt on crankshaft, and route around left camshaft and Fig. 3. Ensure crankshaft sensor wiring is properly routed. Install
onto right camshaft sprockets. Ensure used timing belt is installed in remaining timing belt covers. To install remaining components, reverse
original direction of rotation. Loosen timing belt tensioner lock nut and removal procedure. Adjust drive belts to proper tension.
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
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 crank- Courtesy of Ford Motor Co.
shaft damper aligns with “0” mark on lower timing belt cover. Lower Fig. 5: Compressing Timing Belt Tensioner (3.2L SHO)
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 Courtesy of Ford Motor Co.
at TDC. Ensure White mark on crankshaft damper aligns with “0” mark Fig. 6: Installing Rubber Grommets (3.2L SHO)
on lower timing belt cover, and camshaft timing marks align with marks
on timing belt cover. See Fig. 3. TORQUE SPECIFICATIONS
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 Application Ft. Lbs. (N.m)
front of crankshaft sprocket. Ensure timing marks align. See Fig. 3. Camshaft Pulley Bolts ................................................................... ................. 15-18 (20-24)
5) If reusing timing belt, place reference mark on timing belt, camshaft Camshaft Timing Belt Sprocket Bolt ............................................ ................. 15-18 (20-24)
Engine Damper Bracket Bolt ........................................................ ................. 21-30 (28-41)
sprockets, and crankshaft sprocket. Mark direction of belt rotation for
Idler Pulley Nut .............................................................................. ................. 25-37 (34-50)
reassembly reference. Slowly loosen timing belt tensioner bolt and Intake Manifold Crossover Tube Bolt ............................................................. 11-16 (15-22)
remove tensioner. Lower vehicle. Remove timing belt. Timing Belt Upper Cover Bolt (3.2L) ............................................ ................. 12-17 (16-23)
Installation (3.2L SHO) – 1) Ensure No. 1 piston is at TDC of Timing Belt Tensioner Arm Nut (3.2L) .......................................... ................. 27-37 (36-50)
compression stroke. Ensure camshaft timing marks align with timing belt Timing Belt Tensioner Bolt (3.2L) ................................................. ................. 12-17 (16-23)
cover marks, and crankshaft sprocket timing mark aligns with mark on Timing Belt Tensioner Lock Nut (3.0L) ......................................... ................. 25-37 (34-50)
oil pump housing. See Fig. 3. Place timing belt tensioner in a soft-jawed Water Pump Pulley Bolt ................................................................ ................. 12-17 (16-23)
Wheel Lug Nut .......................................................................................... 85-105 (115-142)
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 INCH Lbs. (N.m)
tensioner in retracted position. See Fig. 5. Camshaft Sensor Bolt ....................................................................................... 62-97 (7-11)
2) Install timing belt on crankshaft, and route belt around left camshaft Crankshaft Sensor ......................................................................... ..................... 18-27 (2-3)
and onto right camshaft sprockets. Ensure used timing belt is installed in Timing Belt Cover Bolt (3.0L) ........................................................................... 62-97 (7-11)
original direction of rotation. Valve Cover Bolt ........................................................................... ............... 89-142 (10-16)
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.
GENERAL MOTORS 265

TIMING BELT APPLICATION Be sure gauge finger is engaged in slot between teeth of timing belt. Use
Application 1
Labor Time Belt 1/4″ Allen wrench on idler pulley to obtain correct tension. Reverse
Part No. removal procedure to complete installation. Adjust drive belts to proper
1.4L 4-Cyl. tension.
Acadian & Chevette TIMING BELT ADJUSTMENT SPECIFICATIONS
1976 ........................................................... 1.4 Hours ... ..... T037
1977 ........................................................... 1.4 Hours ... ..... T039 Belt Size Operating Range Specification
1.6L 4-Cyl. 3/4″ (19 mm) ................. 50-80 Lbs. (110-176 kg) .................... 63-77 Lbs. (140-160 kg)
Acadian, Chevette, T-1000 & 1000
1976 ........................................................... 1.4 Hours ... ..... T037
1977-78 ..................................................... 1.4 Hours ... ..... T039
1979-87 ..................................................... 1.4 Hours ... ..... T061
1


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 Courtesy of General Motors Corp.
retaining screws and nuts. Remove cover. Rotate crankshaft until timing
Fig. 2: Identifying Sprocket Timing Marks
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.
Courtesy of General Motors Corp. Application Ft. Lbs. (N.m)
Camshaft Sprocket Bolts ........................................................................................ 75 (101)
Fig. 1: Locating Timing Belt Idler Pulley Crankshaft Pulley Bolt ........................................................................................... 100 (135)
Installation – 1) With No. 1 piston at TDC, install belt on sprockets and Idler Pulley Bolts ....................................................................................................... 15 (20)
use 1/4″ Allen wrench to move idler pulley counterclockwise until all Water Pump Bolts ..................................................................................................... 15 (20)
slack is removed from belt. Tighten idler pulley bolt. Rotate crankshaft INCH Lbs. (N.m)
clockwise a minimum of one revolution. Stop with No. 1 piston at TDC.
Front Cover (Nuts & Bolts) ......................................................................................... 70 (8)
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.
266 GENERAL MOTORS
1.6L 4-Cylinder – Aveo
Part No.
1.6L 4-Cyl.
Aveo
2004 ........................................................... 1.5 Hours ... ..... T310

The manufacturer requires that the belt be replaced every 60,000 miles.

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 Courtesy of General Motors Corp.
and pulley. See Fig. 1.
5) Remove the upper front timing belt cover bolts and cover. See Fig. 2. Fig. 2: Removing Front Timing Belt Covers
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 counter-
clockwise to release the tension on the timing belt. See Fig. 4. Remove
the timing belt behind the power steering pump. See Fig. 5.
Fig. 3: Aligning Crankshaft Timing Mark
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. Courtesy of General Motors Corp.
2) Using the Timing Belt Adjuster (J-42492-A or KM-421-A), rotate the
Fig. 4: Rotating Coolant Pump Using Timing Belt Adjuster
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.
GENERAL MOTORS 267
1.6L 4-Cylinder – Aveo (Cont.)
Fig. 7: Aligning Automatic Tensioner With Bracket Notch

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
5) Remove the crankshaft pulley bolt. Install the upper and lower front
timing belt covers and bolts. See Fig. 2. Tighten the bolts to specifica-
6) Install the crankshaft pulley and bolt. See Fig. 1. Tighten the bolt to
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. Courtesy of General Motors Corp.
8) Install the air filter housing and bolts. Tighten bolts to specification. Fig. 8: Aligning Automatic Tensioner With Bracket Pointer
9) Connect the air intake tube and breather tube to the throttle body. TORQUE SPECIFICATIONS
Connect the IAT sensor connector. Connect the negative battery cable.
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
– Tighten using torque wrench.
2
– Tighten using Angle Meter (J-45059) or Angular Torque Gauge (KM-470-B).

268 GENERAL MOTORS
1.6L 4-Cylinder – LeMans
1
Kit No. Part No.
1.6L 4-Cyl.
LeMans
1988-89 ............................... 2.0 Hours ... .. TCK148 .. ..... T148
1990
With Tensioner Pulley ..... 2.0 Hours ... ...... ..... ...... ..... T203
W/O Tensioner Pulley ..... 2.0 Hours ... .. TCK148 .. ..... T148
1991-93 ............................... 2.0 Hours ... ...... ..... ...... ..... T203
1



CAUTION: For 1990-93 models, this application is an interference
engine. Do not rotate camshaft or crankshaft when timing belt is
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 SPECIFICA-
TIONS. Adjust drive belts to proper tension.
INCH Lbs. (N.m)
Timing Belt Cover Bolt (Front & Rear) .................................................................... 88 (10)
Water Pump Bolt ......................................................................................................... 71 (8)
Fig. 1: Identifying Timing Belt & Pulley Alignment

GENERAL MOTORS 269
1.6L 4-Cylinder – Nova

Kit No. Part No.
1.6L 4-Cyl.
Nova
DOHC
1
1988 ................................. 3.1 Hours .. ...... ..... ............ T112
SOHC
1
1985-88 ............................ 3.1 Hours .. .. TCK070 .. ..... T070
1
– With Air Conditioning, add .4 hours. With Power Steering, add
.4 hours. With Cruise Control, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when Fig. 1: Aligning Camshaft Sprockets (DOHC)

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 Fig. 2: Identifying Timing Belt & Pulley Alignment
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
8-Valve ................................................................................................................... 87 (117)
16-Valve ............................................................................................................... 137 (186) Courtesy of General Motors Corp.
Timing Belt Idler Mount Bolt ......................................................... ................. 26-36 (36-49)
Fig. 3: Locating Timing Belt Deflection Points
270 GENERAL MOTORS
TIMING BELT APPLICATION 3) Finger tighten tensioner bolts in sequence to prevent movement of
Application Labor Time Belt tensioner pulley. See Fig. 3. Tighten camshaft pulley bolt. Remove
Part No. injection pump gear lock bolt. Remove fixing plate on end of camshaft.
1.8L 4-Cyl. – Diesel 4) Install damper pulley on hub and check that No. 1 cylinder is at TDC.
Acadian (Canadian) DO NOT turn crankshaft if adjustment is needed. Be sure mark on
1 injection pump pulley aligns with mark on plate. See Fig. 1. Fixing plate
1981-85 .................................................... 3.1 Hours .. ..... T076
Chevette should fit smoothly into slot at rear of camshaft. Remove fixing plate.
1
1981-86 .................................................... 3.1 Hours .. ..... T076 5) Loosen tensioner pulley and plate bolts. Concentrate belt looseness
1
– With Air Conditioning, add .4 hours. on tensioner and tighten bolts in sequence. See Fig. 3. Belt tension
With Power Steering, add .4 hours. should be checked at point between camshaft gear and injection pump
gear using Belt Tension Gauge (J-29771) or equivalent. Belt tension
NOTE: For information about tensioners and/or pulleys (when should be 46-63 lbs. (20-28 kg).
available), see ALPHABETICAL MODEL LISTING. 6) Remove damper pulley and install belt holder in position away from
timing bolt. Install by-pass hose, dust covers, and damper pulley. Install
MANUFACTURER’S SUGGESTED cooling fan, belt and pulley. Install fan shroud. Refill system with coolant
and connect battery. Adjust drive belts to proper tension.

damage may occur.
TIMING BELT
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. Courtesy of General Motors Corp.
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.
Fig. 3: Identifying Tension Pulley Bolt Tightening Sequence
Damper Pulley Bolt ................................................................................................... 12 (20)
Courtesy of General Motors Corp. Tension Pulley
Center Bolt .............................................................................................................. 54 (73)
Fig. 1: Locating Injection Pump Gear Alignment Marks & Lock Bolt Side Bolts ................................................................................................................ 15 (20)
Installation – 1) Remove bolt attaching camshaft gear. Using Gear Water Pump Bolts ..................................................................................................... 15 (20)
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. Con-
centrate belt looseness on tension pulley. Depress tension pulley with
finger and install tension spring.
GENERAL MOTORS 271

TIMING BELT APPLICATION 2) Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent,
Application 1
Labor Time Component Belt check belt tension between water pump and camshaft sprocket. Initial
Kit No. Part No. new belt tension should be 38 lbs. (17 kg). Used belt tension should be
1.8L 4-Cyl. – OHC 27-36 lbs. (12-16 kg).
Firenza 3) Reassemble components and run engine to operating temperature
1982-86 ............................... 2.7 Hours ... .. TCK081 .. ..... T081 (thermostat open). As new belt takes a set position, substantial tension
J2000 loss will occur. After belt has been run, recheck tension with gauge on
1982 .................................... 2.7 Hours ... .. TCK081 .. ..... T081 belt.
Skyhawk 4) If belt tension is incorrect, loosen water pump bolts and rotate pump
1982-86 ............................... 2.7 Hours ... .. TCK081 .. ..... T081 until correct tension is obtained. Hot timing belt tension specification is
Sunbird 30 lbs. (13 kg).
1985-86 ............................... 2.7 Hours ... .. TCK081 .. ..... T081 5) DO NOT leave tension gauge on belt during retightening, or reading
2000
will be inaccurate. Tighten water pump bolts. Reverse removal proce-
1983 .................................... 2.7 Hours ... .. TCK081 .. ..... T081
dure to complete installation. Adjust drive belts to proper tension.
2000 Sunbird
1984 .................................... 2.7 Hours ... .. TCK081 .. ..... T081
1



TIMING BELT
Removal – 1) Disconnect negative battery cable. Remove belts, brack-
ets and shields necessary to gain access to crankshaft pulley. Remove Fig. 1: Adjusting Timing Belt Tension
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 TORQUE SPECIFICATIONS
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. Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 20 (27)
Installation – 1) Install new timing belt on sprockets. Install crankshaft Crankshaft Sprocket Retaining Bolt .............................................. ........................ 115 (156)
pulley and check for alignment of timing marks. Using Adjuster Timing Belt Rear Cover Bolt ..................................................................................... 19 (25)
(J-33039) or equivalent, rotate water pump clockwise until slack is Water Pump Retaining Bolts .................................................................................... 19 (25)
removed from timing belt. Tighten water pump bolts. See Fig. 1. INCH Lbs. (N.m)
NOTE: If new timing belt has been installed, check final tension Camshaft Thrust Plate Bolt ......................................................................................... 72 (8)
with engine at operating temperature. If new head gasket is Timing Belt Front Cover Bolt ...................................................................................... 60 (7)
installed, cylinder head must be retightened AFTER initial warm-
up. Timing belt tension MUST then be rechecked.
272 GENERAL MOTORS
2.0L 4-Cylinder
Kit No. Part No.
2.0L 4-Cyl. – OHC
Firenza
1987-88 ............................... 2.7 Hours ... ...... ..... ...... ..... T081
Grand Am
1987-88 ............................... 2.7 Hours .... TCK081A . ..... T081
1989 .................................... 2.7 Hours ... .. TCK163 .. ..... T163
LeMans
1989
1st Design ........................ 2.7 Hours .... TCK081A . ..... T081
2nd Design ....................... 2.7 Hours ... .. TCK163 .. ..... T163
1990 .................................... 2.7 Hours ... .. TCK163 .. ..... T163
Skyhawk
1987-88 ............................... 2.7 Hours .... TCK081A . ..... T081
Sunbird
1987-88 ............................... 2.7 Hours .... TCK081A . ..... T081
1989-94 ............................... 2.7 Hours ... .. TCK163 .. ..... T163
1


TIMING BELT
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 Courtesy of General Motors Corp.
slack is removed from timing belt. Tighten water pump bolts. See Fig. 2. Fig. 2: Adjusting Timing Belt Tension
NOTE: If new timing belt has been installed, check final tension Removal (1989-94) – 1) Disconnect negative battery cable. Remove
with engine at operating temperature. If new head gasket is serpentine belt, brackets, and shields necessary to gain access to
installed, cylinder head must be retightened AFTER initial warm- crankshaft pulley. Remove front timing belt cover. See Fig. 1.
up. Timing belt tension MUST then be rechecked. 2) Remove crankshaft pulley. Loosen water pump retaining bolts. Using
2) Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent, Timing Belt Adjuster (J-33039-A) or equivalent, rotate water pump to
check belt tension between water pump and camshaft sprocket. Initial release timing belt tension. Remove timing belt.
new belt tension should be 38 lbs. (17 kg). Used belt tension should be Installation (1989-94) – 1) To install camshaft and crankshaft sprockets
27-36 lbs. (12-16 kg). (if removed), reverse removal procedure. Tighten retaining bolts to
3) Reassemble components and run engine to operating temperature specification. See TORQUE SPECIFICATIONS.
(thermostat open). As new belt takes a set position, substantial tension 2) Rotate crankshaft and camshaft clockwise to align timing marks on
loss will occur. After belt has been run, recheck tension with gauge on sprockets with marks on rear cover. Install new timing belt on sprockets.
belt. Ensure belt has tension on it between the camshaft sprocket and
4) If belt tension is incorrect, loosen water pump bolts and rotate pump crankshaft sprocket.
until correct tension is obtained. Hot timing belt tension specification is
NOTE: Adjust timing belt with engine coolant temperature at 68°F
30 lbs. (13 kg).
(20°C).
5) DO NOT leave tension gauge on belt during retightening, or reading
will be inaccurate. Tighten water pump bolts to specification. See 3) Using timing belt tension adjuster, rotate water pump clockwise until
TORQUE SPECIFICATIONS. Reverse removal procedure to complete tensioner contacts the high torque stop. See Fig. 3. Slightly tighten water
installation. Adjust drive belts to proper tension. pump retaining bolts.
GENERAL MOTORS 273

4) Using crankshaft sprocket bolt, rotate engine clockwise 2 revolutions TORQUE SPECIFICATIONS
to fully seat timing belt. Rotate water pump eccentric counterclockwise
until hole in tensioner arm aligns with hole in base. TORQUE SPECIFICATIONS
5) Tighten water pump bolts to specification. See TORQUE SPECIFI- Application Ft. Lbs. (N.m)
CATIONS. Ensure tensioner holes remain in alignment as stated. Camshaft Pulley-To-Sprocket Bolt
Ensure all timing marks are properly aligned. To install remaining 1987-88 .................................................................................................................... 20 (27)
components, reverse removal procedure. Adjust drive belts to proper 1989-92 .................................................................................................................... 15 (20)
tension. Serpentine Belt Tensioner Bolt ................................................................................. 35 (47)
Water Pump Bolt ....................................................................................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Carrier Cover Bolt .................................................................................... 84 (10)
Fig. 3: Identifying Timing Belt Tensioner (1989-94)

274 GENERAL MOTORS
3.0L V6
Application Labor Time Component Belt NOTE: Do not move camshafts with belt removed. Do not remove
Kit No. Part No. Camshaft Holders (J42069) with timing belt removed.
3.0L V6 – DOHC
11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing
Catera
1997-98 ............................... 2.6 Hours ... .. TCK285 .. ..... T285 belt, mark belt with arrow to indicate original direction of rotation.
1999-01 ............................... 2.6 Hours .... TCK285A . ..... T285 Remove timing belt.


intervals.

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. Courtesy of General Motors Corp.
3) Never remove timing belt without first setting camshaft gears and
crankshaft drive gear to TDC and locking them in place. Fig. 1: Identifying Timing Belt Front Cover Components
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.
NOTE: Using scan tool, check cold start counter (also called a
heavy duty register). If there were any cold starts below –20°F
(–28°C), 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 Courtesy of General Motors Corp.
not remove, power steering pump pulley bolts. Remove A/C compressor
hose strap from AIR injection crossover bracket. Remove accessory Fig. 2: Positioning Crankshaft At 60 Degrees BTDC
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-to-
crankshaft 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 clock-
wise 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 Courtesy of General Motors Corp.
and J42069-2). See Fig. 6. It may be necessary to loosen timing belt
idler pulley and turn eccentric until holder can be inserted. Fig. 3: Installing Crankshaft Holder
GENERAL MOTORS 275
3.0L V6 (Cont.)
Fig. 6: Installing Camshaft Gear Holders
NOTE: Timing belt configuration changed in mid-1999 model year.

Courtesy of General Motors Corp. For both designs, use the marks on each side of the direction of
rotation arrows to line up the left (driver’s side) camshaft sprock-
Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks
ets. For early design (up to mid-1999), use the remaining 3 White
(Up To 1999 Early Design)
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 (pas-
senger’s side) camshaft gears, idler pulley, and left bank (driver’s 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.

(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. Courtesy of General Motors Corp.
Make sure belt is installed with arrows pointing in correct direction
Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley
of rotation.
Timing Belt Deflection Adjustment – 1) If timing belt deflection
Installation – 1) To install timing belt, remove crankshaft holder. Raise
adjustment is necessary, loosen left (driver’s) side idler pulley bolt. (This
and support vehicle. Start installation of belt at crankshaft pulley. Install
is NOT the idler pulley positioned between camshaft sprockets in top,
timing belt with double dash marks aligned with oil pump and drive gear
center of engine). Turn left idler pulley counterclockwise until high point
marks. See Fig. 7. Install Timing Belt Holder (J42069-30) or equivalent
of eccentric nut is in about 12 o’clock position. See Fig. 5. Snug idler
plastic wedge to hold belt against crankshaft sprocket.
pulley bolt while holding eccentric so it does not move. Go to next step.
276 GENERAL MOTORS
3.0L V6 (Cont.)
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 CAM-
SHAFTS).
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 Courtesy of General Motors Corp.
point of eccentric to 9 o’clock position. Tighten idler pulley bolt while
holding eccentric so it does not rotate. Go to TIMING BELT TENSION Fig. 10: Installing Checking Gauge On Camshaft Sprockets
ADJUSTMENT.
Timing Belt Tension Adjustment – Loosen timing belt tensioner lock NOTE: When readjusting timing belt tension, Crankshaft Holder
nut. Turn tensioner eccentric counterclockwise to full stop. Turn eccen- (J42069-10) must be in position on engine.
tric 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 Timing Belt Readjustment (Left Bank Camshafts) – 1) If timing belt
nut will be final tightened after final adjustments are made. Go to readjustment is required, always start with left bank (driver’s side)
CHECKING CAMSHAFT SPROCKET ALIGNMENT. camshafts first. Install Checking Gauge (J42069-20) to left bank cam-
shafts.
2) Loosen idler pulley on driver’s 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 o’clock 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 (driver’s side)
Courtesy of General Motors Corp. camshafts first. Install Checking Gauge (J42069-20) to right bank
Fig. 9: Adjusting Timing Belt Tension (New Design Engine (passenger’s side) camshafts.
Shown; Early Design Engine Is Similar) 2) Loosen bolt on idler pulley that is located in the center and below the
left bank and right bank camshafts.
Checking Camshaft Sprocket Alignment – 1) Ensure timing belt
3) Using Wrench (J42069-40) or equivalent, turn idler pulley eccentric
alignment marks are still aligned with reference points on camshaft
COUNTERCLOCKWISE until timing marks on camshaft sprockets and
sprockets and rear timing belt cover. Remove all locking tools from
checking gauge are in alignment. High point of idler pulley eccentric
camshafts and timing belt.
should be in about the 9 o’clock position. Tighten idler pulley bolt while
2) Rotate crankshaft clockwise 2 revolutions, stopping at 60 degrees
holding eccentric from turning.
before TDC mark. See Fig. 2. Install Crankshaft Holder (J42069-10) to
crankshaft flange. Secure moveable lever of tool to water pump pulley 4) Remove checking gauge and crankshaft holder. Rotate crankshaft
flange. clockwise 2 revolutions, stopping at 60 degree BTDC. Install Crankshaft
Holder (J42069-10) to crankshaft drive gear. Rotate crankshaft to
NOTE: Alignment marks on timing belt will no longer align with secure lever of holder to water pump flange. Install Checking Gauge
camshaft sprocket marks after one or more crankshaft revolutions. (J42069-20) to right bank camshafts. If camshaft sprockets are now
3) Ensure crankshaft timing mark aligns with mark on oil pump housing. properly aligned, go to FINAL TIMING BELT TENSIONING & INSTAL-
Ensure camshaft timing marks align with notches on rear cover. LATION. If not, repeat readjustment procedure.
GENERAL MOTORS 277
3.0L V6 (Cont.)
Final Timing Belt Tensioning & Installation – 1) To set final timing belt TORQUE SPECIFICATIONS
tension, loosen timing belt tensioner eccentric lock nut. Turn timing belt
eccentric counterclockwise to full stop. Turn tensioner back until refer- TORQUE SPECIFICATIONS
ence mark is .079-.157″ (2-4 mm) ABOVE reference mark on flange. Application Ft. Lbs. (N.m)
See Fig. 9. Tighten tensioner eccentric lock nut to specification. See Camshaft Sprocket Bolt
TORQUE SPECIFICATIONS. Step 1 ...................................................................................................................... 37 (50)
2) If timing belt idler pulley bolts were loosened, final tighten them to Step 2 ........................................................................................................... Additional 60°
specification. Inspect high points of timing belt tensioner eccentrics. Left Step 3 ........................................................................................................... Additional 15°
side idler pulley (viewed from rear of engine) eccentric high point should Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
be in about the 12 o’clock position. Top center idler pulley eccentric high Crankshaft Sprocket Center Bolt
Step 1 .................................................................................................................. 184 (250)
point should be in about the 9 o’clock position. See Fig. 5.
Step 2 ........................................................................................................... Additional 45°
3) Remove crankshaft holding tool. Rotate crankshaft clockwise 2 Step 3 ........................................................................................................... Additional 15°
revolutions, stopping at 60 degrees before TDC mark. Install Crankshaft Generator Bolt ........................................................................................................... 30 (40)
Holder (J42069-10) to crankshaft drive gear. Power Steering Pump Pulley Bolt ............................................................................ 15 (20)
4) Turn crankshaft clockwise until lever of holder firmly contacts water Serpentine Drive Belt Tensioner Bolt ....................................................................... 30 (40)
pump pulley flange. Secure moveable lever of tool to water pump pulley Timing Belt Idler Pulley Bolt ..................................................................................... 30 (40)
flange. Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40)
Timing Belt Tensioner Eccentric Lock Nut ............................................................... 15 (20)
5) Ensure camshaft timing marks align with notches on rear cover and
crankshaft timing mark align with mark on oil pump housing. Use INCH Lbs. (N.m)
Checking Gauge (J42069-20) to inspect alignment of left bank and right Timing Belt Front Cover Bolt ...................................................................................... 71 (8)
bank camshaft gears. Water Pump Pulley Bolt .............................................................................................. 71 (8)
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.
278 GENERAL MOTORS
3.2L V6
TIMING BELT APPLICATION on camshaft gears should be aligned with corresponding notches on
Application Labor Time Belt rear timing belt cover, and marks on crankshaft sprocket and oil pump
Part No. housing should align. See Fig. 5.
3.2L V6 11) Using crank hub torx socket, rotate crankshaft counterclockwise until
CTS 60 degrees BTDC. The 60 degree BTDC point can be identified by index
2003-04 ..................................................... 2.4 Hours ... ..... T285 mark on oil pump cover. See Fig. 6.
NOTE: For information about tensioners and/or pulleys (when NOTE: Ensure moveable lever is positioned toward crankshaft.
available), see ALPHABETICAL MODEL LISTING. 12) Install the Crankshaft Holder (J-42069-10) from Timing Belt Align-
ment Kit (J-42069) to the crankshaft sprocket with the knurled bolt. See
MANUFACTURER’S SUGGESTED Fig. 7. Using crank hub torx socket, rotate crankshaft clockwise until
lever of crankshaft holder firmly contacts water pump pulley flange.
SCHEDULED MAINTENANCE Ensure No. 1 cylinder is at TDC. Secure moveable lever of tool to water
The manufacturer recommends that the timing belt be replaced at pump pulley flange.
100,000 miles or every 96 months, whichever occurs first.
CAUTION: Ensure crankshaft is not 180 degrees off TDC. Refer-
ence marks on camshaft gears should be aligned with correspond-
REMOVAL & INSTALLATION ing notches on rear timing belt cover at this point. If they are not
aligned, engine is 180 degrees off.
camshaft or crankshaft when timing belt is removed, or engine 13) Install the Camshaft Gear Holders (J-42069-1 and J-42069-2) to
damage may occur. 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.
TIMING BELT 14) Loosen timing belt tensioner nut. Loosen upper idler pulley bolt.
Removal – 1) Using scan tool, inspect the cold start counter (also Remove lower idler pulley bolt. Remove lower idler pulley and spacer.
known as heavy duty register). If there are any cold starts below –20°F
(28°C), visually inspect timing belt for cracks and replace as necessary. CAUTION: DO NOT turn camshaft and crankshaft independently
If belt is replaced, clear the cold start counter. If belt is not replaced, do after timing belt is removed. If turned, interference may occur
not clear the cold start counter. among pistons and valves, and related components may be dam-
2) Disconnect air intake duct hose from Mass Airflow (MAF)/Intake Air aged.
Temperature (IAT) sensor. Remove bolt securing intake air resonator to
cooling fan assembly. Disconnect air intake duct hoses from throttle CAUTION: DO NOT remove the camshaft gear holders from cam-
body. Lift intake air resonator from front frame to access the electrical shaft gears while timing belt is removed.
connector and vacuum hoses. Disconnect intake resonance switchover
solenoid connector. 15) Remove the crankshaft holder from crankshaft sprocket. If belt is to
be reused, mark direction of rotation for reinstallation reference.
NOTE: Note vacuum hose routing for reassembly. Remove timing belt.
3) Disconnect vacuum hoses from the coolant by-pass solenoid, intake
plenum switchover solenoid and vacuum brake booster hose. Position-
ing 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 Fig. 1: Removing Crankcase Vent Adapter
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
GENERAL MOTORS 279
3.2L V6 (Cont.)

Fig. 2: Disconnecting Electrical Connector & Vacuum Hose From
Switchover Valve Fig. 4: Removing & Installing ECM Bracket

280 GENERAL MOTORS
3.2L V6 (Cont.)
Fig. 5: Rotating Crankshaft Clockwise
Fig. 7: Installing Crankshaft Holder & Other Tools
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 com- Courtesy of General Motors Corp.
ponents, jammed tensioner, heavy thrust loading against idler guide
Fig. 8: Installing Locking Tools To Camshaft Gears
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 CAUTION: Install timing belt with engine at room temperature.
scored cam sprockets. Ensure directional arrows on timing belt are matched with the
5) Check if there is a clean break across the fibers. Possible causes are clockwise rotation of the crankshaft, or excessive wear and timing
kinked belt before and/or during assembly or foreign material under belt. belt failure may occur.
6) Check if oil or coolant is impregnated and/or there is a swollen belt.
Installation – 1) Starting at crankshaft sprocket, align double dash TDC
Possible causes are poor oil sealing, coolant leak at pump or poor belt
mark on timing belt with marks on oil pump housing and crankshaft
cover seal.
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.
GENERAL MOTORS 281
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 counter-
clockwise 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 o’clock 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 counter-
clockwise 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 Courtesy of General Motors Corp.
Fig. 12. Remove the timing belt holder and the Camshaft Gear Holders Fig. 9: Aligning Timing Belt Marks On Crankshaft Pulley
(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.
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 Courtesy of General Motors Corp.
10) Using the wrench, hold upper idler pulley eccentric in place, and Fig. 10: Positioning Crankshaft At 3 Degrees BTDC
tighten pulley bolt to specification. See Fig. 7. See TORQUE SPECIFI-
CATIONS. 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.
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 Courtesy of General Motors Corp.
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.
282 GENERAL MOTORS
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 o’clock 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 SPECIFICA-
TIONS. 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 crank-

shaft.
4) Install the crankshaft holder to the crankshaft sprocket with the
knurled bolt. See Fig. 7. Rotate the crankshaft in the engine rotational
Courtesy of general motor corps. 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.
Courtesy of General Motors Corp. Timing Belt Readjustment (Right Bank Camshafts) – 1) Loosen the
upper idler pulley bolt. Slacken the timing belt by turning the eccentric on
Fig. 13: Inspecting Alignment Of Reference Marks
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 o’clock 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 SPECIFICA-
TIONS. 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 crank-

shaft.
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.
Ensure that the crankshaft is not 180 degrees off TDC. The reference
marks on the camshaft gears should be aligned with the corresponding
Courtesy of General Motors Corp. notches on the rear timing belt cover at this point. If they are not aligned,
Fig. 14: Setting Final Timing Belt Tension 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.
GENERAL MOTORS 283
3.2L V6 (Cont.)
7) Repeat the procedure again if the marks do not align. If camshaft TORQUE SPECIFICATIONS
gears No. 1 and 2 are properly aligned, set the final timing belt tensioner
as outlined in FINAL TIMING BELT TENSIONING & INSTALLATION. TORQUE SPECIFICATIONS
CAUTION: The following steps are the COMPLETION of adjusting
Crankshaft Balancer Bolts ........................................................................................ 15 (20)
the timing belt, and must not be performed as a stand-alone Drive Belt Tensioner Bolts ........................................................................................ 26 (35)
operation. Intake Plenum Bolts .................................................................................................. 15 (20)
Lower Idler Pulley Bolt .............................................................................................. 30 (40)
Final Timing Belt Tensioning & Installation – 1) With the Crankshaft
Power Steering Pump Mounting Bolts ..................................................................... 26 (35)
Holder (J-42069-10) in place locking the crankshaft at TDC, loosen the Timing Belt Tensioner Eccentric Locking Nut .......................................................... 15 (20)
timing belt eccentric locking nut. Turn the eccentric counterclockwise to Upper Idler Pulley Bolt .............................................................................................. 30 (40)
full stop, then back to the following specification:
INCH Lbs. (N.m)
• New Belt − Until the reference mark is 0.118-0.157″ (3-4 mm)
above the datum line. See Fig. 14. Crankcase Vent Tube Adapter Bolts .......................................................................... 71 (8)
Engine Control Module (ECM) Bracket Bolts ............................................................ 71 (8)
• Used Belt − Until the reference is aligned with the datum line. Intake Air Resonator Retaining Bolt ........................................................................... 80 (9)
Tighten the timing belt tensioner eccentric locking nut. See TORQUE Remote Power Steering Fluid Reservoir Mounting Bolts
SPECIFICATIONS. To Cylinder Head ........................................................................ ..................................... 1
2) If the timing belt upper idler pulley bolt has not been previously To Intake Plenum ...................................................................................................... 80 (9)
torqued to specification, tighten the timing belt upper idler pulley bolt Throttle Body Bolts ...................................................................................................... 71 (8)
while holding the eccentric in place with the Wrench (J-42069-40) to Throttle Body Heater Inlet Hose/Pipe Bolt ................................................................. 80 (9)
prevent movement. See Fig. 7. See TORQUE SPECIFICATIONS.
Water Pump Pulley Bolts ............................................................................................ 71 (8)
3) Remove the crankshaft holder and the Checking Gauge 1
(J-42069-20). For final inspection, once again rotate the crankshaft in – Tighten to 18 ft. lbs. (25 N.m).
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.
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.
284 GENERAL MOTORS
3.4L V6
TIMING BELT APPLICATION 10) Position timing belt tensioner actuator in vise with rod tip (rubber
Application 1
Labor Time Component Belt boot end) pointing down.
Kit No. Part No.
3.4L V6 – DOHC CAUTION: Allow oil to flow towards boot end of actuator for at
Cutlass Supreme & Grand Prix least 5 minutes prior to refilling.
1991-95 ............................... 4.5 Hours ... .. TCK192 .. ..... T192
1996 .................................... 4.5 Hours ... .. TCK273 .. ..... T273 NOTE: Tensioner actuator is oil filled. Removal of plug may allow
Lumina
oil to escape. DO NOT remove vent plug.
1991-95 ............................... 4.5 Hours ... .. TCK192 .. ..... T192
1996-97 ............................... 4.5 Hours ... .. TCK273 .. ..... T273 11) Straighten out a standard paper clip (.032” with no serrations) and
Monte Carlo form a loop at one end. See Fig. 2. Remove rubber end plug from rear
1995 .................................... 4.5 Hours ... .. TCK192 .. ..... T192
of tensioner actuator. Push paper clip through end of vent plug and into
1996-97 ............................... 4.5 Hours ... .. TCK273 .. ..... T273
pilot hole. Insert a small screwdriver into the screw slot inside actuator,
1
– With Air Conditioning, add .4 hours. behind rubber end plug.
NOTE: A timing belt component kit is available for this application. 12) Retract actuator plunger by rotating screw in a clockwise direction
See page A1 for information on component kits. 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 NOTE: Remove timing marks from camshaft and intermediate shaft
sprockets.
13) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
MANUFACTURER’S SUGGESTED stroke. Mark the timing indicator with White paint or equivalent on the
SCHEDULED MAINTENANCE crankshaft balancer and front cover. See Fig. 3.
The manufacturer recommends the belt be replaced at 60,000 mile 14) Position camshafts so that flat spots are “UP” for installation of
intervals. Camshaft Hold-Down Tools (J 38613-A). Install Camshaft Hold-Down
Tools (J 38613-A) on both camshaft carriers. See Fig. 4.
REMOVAL & INSTALLATION 15) Remove camshaft sprocket center bolts. Note difference between
early and late designs. See Fig. 5. Lightly tap on rear of sprockets to
CAUTION: For 1996-97 models, this application is an interference remove from camshaft.
engine. Do not rotate camshaft or crankshaft when timing belt is
TIMING BELT
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 cam-
shaft cover and crankcase vent from breather manifold. Remove
camshaft carrier covers.
NOTE: Actuator assembly uses a tapered bushing between the Courtesy of General Motors Corp.
actuator and mounting base. DO NOT lose or damage the bushing
when removing the actuator assembly. Fig. 1: Identifying Timing Belt Assembly Components
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.
GENERAL MOTORS 285
3.4L V6 (Cont.)
Fig. 2: Reworking Paper Clip
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 measure-
ment 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.
Fig. 6: Measuring Timing Belt Tensioner Actuator Length

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 TORQUE SPECIFICATIONS
bolts finger tight. Install timing belt onto camshaft sprockets in a
counterclockwise direction. Continue installing timing belt, making sure TORQUE SPECIFICATIONS
timing belt teeth are fully engaged with all sprockets. Application Ft. Lbs. (N.m)
2) Install timing belt tensioner pulley. Tighten timing belt tensioner pulley Camshaft Sprocket Bolt .......................................................................................... 96 (130)
bolt to 37 ft. lbs. (50 N.m). Crankshaft Balancer Bolt ........................................................................................ 79 (107)
NOTE: If tensioner oil has been lost, fill tensioner with Mobil 1 SAE EGR Valve Bolts ....................................................................................................... 18 (25)
5W-30 synthetic engine oii through plug hole. Fill to bottom of plug Front Cover Bolts
hole only when plunger is fully retracted and pin is installed. Large Bolts .............................................................................................................. 35 (47)
Small Bolts .............................................................................................................. 18 (25)
3) Install rubber end plug in rear of tensioner assembly until flush. Intermediate Shaft Belt Sprocket Bolt .................................................................... 96 (130)
Ensure plug is sealed against case. Serpentine Belt Tensioner Bolt ................................................................................. 33 (45)
Timing Belt Actuator Side Plate Bolt ........................................................................ 20 (27)
NOTE: Ensure actuator bushings and appropriate holes in side Timing Belt Tensioner Pulley Bolt ............................................................................. 37 (50)
plate are clean. DO NOT lubricate bushings. Timing Chain Tensioner Bolt ..................................................................................... 18 (25)
Upper Intake Manifold Bolts & Nuts ......................................................................... 22 (27)
4) Install actuator bushing into side plate. Install timing belt actuator and
INCH Lbs. (N.m)
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 Camshaft Carrier Cover Bolts ................................................................................... 97 (11)
N.m) to allow engagement of actuator shaft into pulley pocket arm Timing Belt Cover Bolts ............................................................................................ 89 (10)
Water Pump Bolt ....................................................................................................... 97 (11)
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.
GEO 287
1.6L 4-Cylinder DOHC – Prizm GSI

Part No.
1.6L 4-Cyl. – DOHC (VIN 5)
Prizm GSI
1
1990-92 .................................................... 3.1 Hours .. ..... T176
1

The manufacturer recommends the belt be inspected and adjusted at Courtesy of Toyota Motor Sales, U.S.A., Inc.
30,000 mile intervals, and replaced at 60,000 mile intervals.
REMOVAL & INSTALLATION hooked portion of spring (not coil length). Replace spring if free length is
greater than 1.618″ (41.09 mm). See Fig. 3.
TIMING BELT
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 Fig. 3: Measuring Tensioner Spring Free Length
valve covers.
4) Remove windshield washer reservoir. Remove engine wiring harness Installation – 1) Ensure all timing marks are aligned. See Fig. 2. Install
from upper timing belt cover. timing belt. If reusing old timing belt, ensure belt is installed in original
5) Support engine from above using Engine Support Bar (J 28467-A) or rotating direction.
equivalent. Remove engine mount through-bolt from mount on timing 2) If removed, install timing belt idler pulley spring. Loosen timing belt
belt end of engine. idler pulley bolt to allow tension to be applied on timing belt.
6) Remove water pump pulley. Remove upper, center and lower timing 3) Temporarily install crankshaft pulley center bolt. Rotate crankshaft
belt covers. See Fig. 1. Remove timing belt guide. Turn crankshaft so clockwise 2 revolutions, to TDC. Ensure all timing marks are aligned.
that camshaft and crankshaft timing marks are aligned. See Fig. 2. 4) Final tighten timing belt idler pulley bolt to specification. See TORQUE
Loosen timing belt idler pulley bolt. Remove timing belt. SPECIFICATIONS. Apply about 4.5 lbs. (2.04 kg) of downward pressure
to timing belt between camshaft sprockets. Belt deflection should be
NOTE: If timing belt is to be reused, mark direction of timing belt about .16″ (4 mm) if timing belt tension is correct.
rotation. Place mating marks on belt and sprockets for reference. 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.
Engine Mount Through-Bolt ...................................................................................... 64 (87)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Courtesy of General Motors Corp. Timing Belt Cover Bolt ................................................................................................ 44 (5)
Valve Cover Nut .......................................................................................................... 53 (6)
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
288 GEO
1.6L 4-Cylinder SOHC – Storm
Kit No. Part No.
Storm
1
1990-93 .............................. 1.5 Hours .. .. TCK177 .. ..... T177
1


intervals.

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 Courtesy of General Motors Corp.
and position No. 4 cylinder at TDC of compression stroke. Ensure timing
mark on crankshaft pulley aligns with “O” timing mark on timing belt Fig. 1: Exploded View of Timing Belt & Components
cover. Remove timing belt cover. See Fig. 1.
3) Ensure locating dowel on camshaft sprocket is at 12 o’clock 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.
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 o’clock position and timing mark aligns with cylinder Courtesy of General Motors Corp.
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 6) Rotate crankshaft back to about 50 degrees BTDC and back to TDC
sprocket, tensioner pulley, water pump and camshaft sprocket. See of No. 4 cylinder. Align crankshaft sprocket timing mark with mark on oil
Fig. 4. pump housing. Align camshaft sprocket timing mark with upper surface
3) Insert a hex wrench into the tensioner pulley hexagonal hole. Rotate of cylinder head.
pulley counterclockwise to tension the belt. Hold pulley stationary and 7) Measure timing belt deflection by applying 22 lbs. (98 N) of force to
temporarily tighten the tensioner pulley bolt. belt. See Fig. 5. Defection must be .63-.79″ (16-20 mm). If deflection is
4) Rotate crankshaft 2 revolutions counterclockwise, and align crank- not correct, retension timing belt. Ensure camshaft sprocket is still
shaft and camshaft timing marks. See Figs. 2 and 3. aligned correctly.
5) Loosen belt tensioner pulley bolt. Insert a hex key wrench into 8) Install timing belt cover. Install crankshaft pulley. Install engine
tensioner pulley hexagonal hole. Rotate the tensioner pulley counter- undercover. Install right engine mount. Install accessory drive belts.
clockwise to tension the timing belt. Tighten tensioner pulley bolt to 37 ft. Adjust drive belts to proper tension.
lbs. (50 N.m).
GEO 289
1.6L 4-Cylinder SOHC – Storm (Cont.)

Crankshaft Sprocket Center Bolt .................................................. .......................... 87 (118)
Engine Mount
Right Bracket Bolt ................................................................................................... 29 (39)
Right Through-Bolt .................................................................................................. 50 (68)
Water Pump Bolt ....................................................................................................... 18 (25)
Wheel Lug Nut ........................................................................................................ 87 (118)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Flange Bolt ............................................................................. 89 (10)
Fig. 3: Locating Crankshaft Sprocket Timing Mark Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Bolt ....................................................................................................... 89 (10)
Fig. 5: Measuring Timing Belt Tension

290 GEO
1.6L & 1.8L 4-Cylinder DOHC – Prizm
Kit No. Part No.
Prizm (Except GSI)
1
1989-92 .............................. 2.2 Hours .. .. TCK036 .. ..... T036
1
1993-97 .............................. 2.2 Hours .. .. TCK236 .. ..... T236
Prizm (Except GSI)
1
1993-97 .............................. 2.2 Hours .. .. TCK235 .. ..... T235
1



TENSIONER SPRING FREE LENGTH SPECIFICATIONS
The manufacturer recommends the belt be inspected and adjusted at
30,000 mile intervals, and replaced at 60,000 mile intervals. Application Maximum Free Length – In. (mm)
1989-92 .......................................................... ................................................... 1.512 (38.4)
1993-94 .......................................................... ................................................... 1.390 (35.3)
REMOVAL & INSTALLATION 1995-97 .......................................................... ................................................... 1.453 (36.9)

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 Fig. 2: Measuring Timing Belt Tensioner Spring Free Length
actuator cover. Disconnect cruise control electrical connector and Installation – 1) Ensure all timing marks are still aligned. See Fig. 3.
actuator cable. Remove cruise control actuator from vehicle. Install timing belt tensioner and spring. Move tensioner to the left and
3) On all vehicles, raise and support vehicle. Remove right front wheel. temporarily tighten bolt.
Remove right wheel housing. Loosen, but do not remove, water pump 2) Install timing belt. If old timing belt is reused, ensure belt is installed
pulley bolts. in original rotating direction. Ensure marks on belt align with camshaft
4) Lower vehicle. Remove accessory drive belts. Disconnect A/C and crankshaft sprockets.
compressor electrical connector. Remove A/C compressor mounting 3) Loosen timing belt tensioner bolt and allow tension to be applied on
bolts. Set compressor aside with hoses attached. Remove mounting timing belt. Rotate crankshaft CLOCKWISE 2 revolutions. DO NOT turn
bracket from engine. crankshaft counterclockwise. Ensure all timing marks are aligned.
5) Remove wiring harness from valve cover. Noting position for reas- Tighten timing belt tensioner bolts to specification. See TORQUE
sembly reference, remove spark plug secondary cables from spark SPECIFICATIONS.
plugs. Remove spark plugs. 4) Measure timing belt deflection at midway point between camshaft and
6) Remove PCV valve from valve cover. Remove valve cover. Turn crankshaft sprockets. See Fig. 4. With 4.4 lbs. (1.9 kg) applied on timing
crankshaft so that “0” mark on crankshaft pulley aligns with mark on belt, defection should be .20-.24″ (5.1-6.9 mm). If belt deflection is not
timing case cover. Ensure No. 1 piston is at TDC of compression stroke. within specification, repeat previous step.
If not, turn crankshaft one full revolution.
CAUTION: Ensure all timing marks are aligned once timing belt is
7) Using Support Fixture (J028467-A) or equivalent, support engine
adjusted.
from above. Remove engine mount from timing belt end of engine.
Remove water pump pulley. 5) Install timing belt guide with cupped side facing out. Install timing belt
8) Remove crankshaft pulley. Remove timing belt covers. See Fig. 1. covers, starting with bottom cover. Install crankshaft pulley. Tighten
Noting installed position, remove timing belt guide from crankshaft. center bolt to specification.
9) Remove timing belt tensioner bolt, tensioner and tensioner spring. 6) Install water pump pulley. Install engine mount. Install engine ground
Remove timing belt. wire (if equipped) to right fender apron. Install valve cover with new
Inspection – 1) Inspect timing belt for damaged teeth or cracking. gasket. Install spark plugs and spark plug secondary wires.
Ensure timing belt is not contaminated with oil. Check tensioner pulley 7) Install PCV valve and wiring harness on valve cover. Install A/C
for rotation freedom or grease leaks. Replace components if damaged. compressor mounting bracket (if removed). Install A/C compressor to
2) Check free length of idler pulley spring. Free length is measured bracket. Install accessory drive belts.
between inside edge of hooked portions of spring (not the coil area). See 8) Install cruise control actuator (if equipped). Install windshield washer
Fig. 2. Replace spring if free length is not as specified. See TENSIONER reservoir. To install remaining components, reverse removal procedure.
SPRING FREE LENGTH SPECIFICATIONS table. Adjust accessory drive belts to proper tension.
GEO 291
1.6L & 1.8L 4-Cylinder DOHC – Prizm (Cont.)

A/C Compressor Bracket-To-Engine Bolt ................................................................. 35 (47)
A/C Compressor-To-Bracket Bolt .............................................................................. 18 (25)
Water Pump Bolt ....................................................................................................... 11 (15)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Valve Cover Cap Nuts ................................................................................................ 53 (6)
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (Typical)
Fig. 4: Aligning Timing Marks & Checking Belt Deflection

292 GEO
1.6L & 1.8L 4-Cylinder DOHC – Storm
TIMING BELT APPLICATION 6) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1.
Application Labor Time Belt Loosen timing belt tensioner pulley bolt 1/2 turn. If timing belt is to be
Part No. reused, mark direction of timing belt rotation, and place reference marks
1.6L 4-Cyl. – DOHC on timing belt and sprockets for installation reference. Remove timing
Storm belt.
1 Inspection – Inspect timing belt for cracks or damage. Ensure belt is not
1990-91 .................................................... 2.0 Hours .. ..... T169
1.8L 4-Cyl. – DOHC contaminated with oil. Check belt tensioner pulley for smooth rotation.
Asuna Sunfire (Canadian) Replace damaged components.
1
1993 .......................................................... 2.4 Hours .. ..... T205 Installation – 1) Ensure all timing marks are aligned. See Fig. 1. Install
Storm timing belt. If reusing old timing belt, ensure belt is installed in original
1
1992-93 .................................................... 2.4 Hours .. ..... T205 rotating direction.
1
– With Air Conditioning, add .4 hours. 2) Install timing belt on crankshaft pulley, then water pump pulley, timing
With Power Steering, add .3 hours. belt idler pulley, exhaust camshaft sprocket, intake camshaft sprocket
and timing belt tensioner pulley. See Fig. 2.
NOTE: For information about tensioners and/or pulleys (when 3) Loosen belt tensioner bolt to allow tension to be applied on timing
available), see ALPHABETICAL MODEL LISTING. belt. Rotate crankshaft clockwise 2 revolutions. Ensure all timing marks
are still aligned. Tighten timing belt tensioner pulley bolt to specification.
MANUFACTURER’S SUGGESTED 4) Install lower timing belt cover. Install engine mount bracket on engine.
SCHEDULED MAINTENANCE Install crankshaft pulley and tighten center bolt to specification. Install
upper timing belt cover. Install engine mount.
The manufacturer recommends the belt be replaced at 60,000 mile 5) To install remaining components, reverse removal procedure. Adjust
intervals. drive belts to proper tension.

TIMING BELT
drive belts or serpentine belt. Raise and support vehicle. Remove right
splash shield.
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.
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)
Water Pump Bolt
1.6L .......................................................................................................................... 11 (15)
1.8L .......................................................................................................................... 18 (24)
Wheel Lug Nut ........................................................................................................ 87 (118)
INCH Lbs. (N.m)

GEO & ISUZU 293
1.5L 4-Cylinder
Kit No. Part No.
1.5L 4-Cyl.
I-Mark
1985-87
Thru 6/30/86 .............. ... 1 1.5 Hours ... .. TCK118 ........ T118
From 7/1/86 ............... ... 1 1.5 Hours ... .. TCK118 .. ..... T162
1988-89 ........................ ... 1 1.5 Hours ... .. TCK118 .. ..... T162
Spectrum (Chevrolet)
1985-86 ........................ .. 1, 2 1.5 Hours .. .. TCK118 ........ T118
1987
Thru 4/30/87 .............. . 1, 2, 3 1.5 Hours . .. TCK118 ........ T118
From 5/1/87 ............... . 1, 2, 3 1.5 Hours . .. TCK118 .. ..... T162
1988 .............................. . 1, 2, 3 1.5 Hours . ...... ..... ............ T118
Spectrum (Geo)
1989 .............................. .. 2, 4 1.5 Hours .. ...... ..... ...... ..... T162
Sunburst (Canada) Courtesy of General Motors Corp.
1985-88 ........................ ... 1 1.5 Hours ... .. TCK118 ........ T118
1
2
– With Engine removal, Automatic Transmission – Non-Turbo,
labor time is 7.7 hours. With Engine removal, Standard Trans-
mission – Non-Turbo, labor time is 7.5 hours.
3
– With Engine removal, Turbocharger, labor time is 8.2 hours.
4
– With Air Conditioning, add .4 hours. With Cruise Control, add
.2 hours. With Power Steering, add .4 hours.


available), see ALPHABETICAL MODEL LISTING. Fig. 2: Aligning Camshaft Sprocket Timing Marks
MANUFACTURER’S SUGGESTED belts to proper tension.

damage may occur.
TIMING BELT & SPROCKETS

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 equiva-
lent, remove timing belt crankshaft pulley. Confirm crankshaft is at TDC
before removing belt. See Fig. 1. Rotate crankshaft so camshaft pulley Courtesy of General Motors Corp.
dowel is at 12 o’clock and alignment mark aligns with edge of cylinder
head. See Fig. 2.
NOTE: The rear of timing belt crankshaft pulley has a small indent TORQUE SPECIFICATIONS
which aligns with small triangle on engine block at 12 o’clock. TORQUE SPECIFICATIONS
3) Loosen belt tensioner attaching bolt. Insert Allen wrench into pulley Application Ft. Lbs. (N.m)
tensioner attaching bolt. Loosen timing belt tensioner by rotating pulley Crankshaft Pulley Bolt ........................................................................................... 108 (147)
clockwise. Remove timing belt. Timing Belt Tensioner Bolt ........................................................................................ 37 (50)
Installation – 1) Ensure camshaft pulley mark is aligned with upper Water Pump Bolts ..................................................................................................... 17 (24)
surface of head and dowel pin is at 12 o’clock position. Ensure Woodruff INCH Lbs. (N.m)
key of crankshaft is in 12 o’clock position. Install timing belt. See Fig. 3.
Timing Cover Bolts .................................................................................................... 86 (10)
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.
294 GEO/CHEVROLET
1.0L 3-Cylinder
1
Kit No. Part No.
1.0L 3-Cyl.
Firefly (Canadian)
1985-88 ............................... 2.2 Hours ... ...... ..... ...... ..... T095
1989-91 ............................... 2.2 Hours ... .. TCK166 .. ..... T166
1994-95 ............................... 2.2 Hours ... .. TCK241 .. ..... T241
1996-00 ............................... 1.8 Hours .... TCK194A . ..... T194
Metro
1989-92 ............................... 2.2 Hours ... .. TCK166 .. ..... T166
1993 .................................... 2.2 Hours ... .. TCK166 .. ... 2 T166
1993 .................................... 2.2 Hours ... .. TCK241 .. ... 3 T241
1994-95 ............................... 2.2 Hours ... .. TCK241 .. ..... T241
1996-97 ............................... 2.2 Hours .... TCK194A . ..... T194
1998-00 ............................... 1.8 Hours .... TCK194A . ..... T194
Sprint (Includes Canadian)
1985-88 ............................... 2.2 Hours ... ...... ..... ...... ..... T095
1989-91 ............................... 2.2 Hours ... ...... ..... ...... ..... T166
1
2
– Four bolt sprocket.
3
– Five bolt sprocket.



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

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 genera-
tor 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.
contamination. Ensure tensioner rotates freely. Replace damaged com-
ponents. Fig. 2: Exploded View Of Timing Belt & Components (1998-00)
CAUTION: Ensure concave side of timing belt guide faces oil

pump. Flat side of timing belt guide goes against crankshaft
sprocket.
GEO/CHEVROLET 295
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. Crank-
shaft 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
Fig. 5: Rotating Camshaft & Crankshaft
A/C Compressor Mounting Bolt
12 mm ..................................................................................................................... 21 (29)
14 mm ..................................................................................................................... 33 (45)
Crankshaft Pulley-To-Crankshaft Bolt ....................................................................... 12 (16)
Courtesy of General Motors Corp. Tensioner Bolt ............................................................................................................ 20 (27)
Fig. 4: Aligning Timing Marks (1998-00) INCH Lbs. (N.m)
Timing Belt Tensioner Stud ....................................................................................... 97 (11)
Valve Cover Bolt ......................................................................................................... 44 (5)
Water Pump Bolt
1995-97 .................................................................................................................... 97 (11)
1998-00 .................................................................................................................. 115 (13)
296 GEO/CHEVROLET
1.3L 4-Cylinder
1
Kit No. Part No.
1.3L 4-Cyl.
Firefly (Canadian)
1995-97 ............................... 2.6 Hours ... .. TCK272 .. ..... T272
1998-00 ............................... 2.6 Hours ... ...... ..... ...... ..... T194
Metro
1992-93 ............................... 2.6 Hours ... ...... ..... ...... ..... T095
1994 .................................... 2.6 Hours ... ...... ..... ...... ..... T243
1995-97 ............................... 2.6 Hours ... .. TCK272 .. ..... T272
1998-01 ............................... 2.6 Hours ... ...... ..... ...... ..... T194
1
See page A1 for information on component kits. Fig. 2: Locking Flywheel In Position

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

TIMING BELT
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 cam-
shaft 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.
Fig. 3: Identifying Timing Marks (1992-97)

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.
Courtesy of General Motors Corp. 3) Turn crankshaft pulley bolt clockwise until punch mark on sprocket
aligns with arrow mark on oil pump case. See Fig. 3.
Fig. 1: Using Screwdriver To Lock Flywheel
4) Install timing belt on sprockets with drive-side of belt free of any slack
Inspection – Inspect timing belt for damaged teeth, cracking and oil when tensioner plate is pushed up with fingers. Loosen tensioner bolt
contamination. Check timing belt tensioner for worn bearing. Replace and allow tensioner to remove slack in timing belt. Skip the next step to
damaged components. continue.
NOTE: Ensure tensioner plate moves when tensioner is moved NOTE: On 1998-01 models, camshaft sprocket is marked with a
toward timing belt. If tensioner plate does not move, ensure lug is raised “E” for a timing mark.
engaged in hole on rear of tensioner.
5) On 1998-01 models, ensure camshaft and crankshaft timing marks
Installation – 1) Ensure that tensioner rotates smoothly. Install ten- are still aligned. See Fig. 4. If timing marks are not aligned, rotate
sioner plate on tensioner. Lug of tensioner plate must fit in hole of camshaft or crankshaft to align timing marks. DO NOT rotate camshaft
GEO/CHEVROLET 297
Fig. 5: Identifying Water Pump-To-Oil Case Seal
Fig. 4: Identifying Timing Marks (1998-01) Courtesy of General Motors Corp.
or crankshaft more than 90 degrees, or engine damage may result. Fig. 6: Adjusting Valve Lash (1992-97)
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. TORQUE SPECIFICATIONS
6) Turn crankshaft 2 rotations clockwise to take up slack. Ensure timing Application Ft. Lbs. (N.m)
marks are still aligned. Tighten tensioner adjustment stud nut and Crankshaft Pulley Bolt (1998-01) .............................................................................. 12 (16)
tensioner bolt. Ensure seal is between water pump and oil pump case. Crankshaft Sprocket Bolt
See Fig. 5. Install timing belt outside cover. 1992-97 .................................................................................................................. 79 (110)
7) On 1992-97 models, rotate crankshaft to position camshaft lobe and 1998-01 .................................................................................................................. 96 (130)
rocker arm to adjust valve lash. See Fig. 6. Ensure clearance is .010″
Valve Adjustment Lock Nut ............................................................................. 11-13 (15-18)
(.25 mm) at intake valves, and .011″ (.28 mm) at exhaust valves. To Water Pump Pulley Bolt ............................................................................................ 18 (24)
adjust clearance, turn adjusting screw until correct clearance is
INCH Lbs. (N.m)
obtained. Tighten lock nut to 11-13.5 ft. lbs. (15-18 N.m).
8) On all models, to complete installation, reverse removal procedure. Crankshaft Pulley Bolt (1992-97) .................................................. ............................ 97 (11)
Tensioner Stud .......................................................................................................... 97 (11)
Timing Belt Cover Nut/Bolts ..................................................................................... 97 (11)
Valve Cover Nuts ........................................................................................................ 44 (5)
298 GEO/CHEVROLET
1.6L 4-Cylinder – Tracker, 8-Valve
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


available), see ALPHABETICAL MODEL LISTING. Courtesy of General Motors Corp.
Fig. 2: Locking Camshaft During Sprocket Removal

MANUFACTURER’S SUGGESTED Inspection – Inspect timing belt for damaged teeth or cracking. Ensure
SCHEDULED MAINTENANCE timing belt is not contaminated with oil. Check tensioner for freedom of
Although the manufacturer does not recommend a specific scheduled rotation. Replace components if damaged.
maintenance interval, belt manufacturers suggest the belt be replaced at Installation – 1) If tensioner was removed, install tensioner plate on
60,000 mile intervals. 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
REMOVAL & INSTALLATION tensioner.
TIMING BELT CAUTION: Ensure tensioner plate moves when tensioner is moved
Removal – 1) Disconnect negative battery cable. Remove accessory toward timing belt. If tensioner plate does not move, ensure lug
drive belts. Remove cooling fan, fan shroud and water pump pulley. engages in tensioner bolt.
Remove outer bolts retaining crankshaft pulley.
2) Remove valve cover. Loosen all valve adjusting screws fully before
2) Remove 5 crankshaft pulley-to-sprocket bolts. Remove crankshaft
installing timing belt. Ensure camshaft rotates freely during belt tension
pulley. DO NOT remove center bolt from crankshaft pulley. The center
adjustment. Rotate camshaft clockwise, and align timing mark on
bolt holds crankshaft sprocket to crankshaft.
camshaft sprocket with “V” timing mark on timing belt inside cover. See
3) Remove timing belt cover and seal. See Fig. 1. Loosen tensioner
Fig. 3.
stud, and remove tensioner spring from tensioner plate and tensioner
3) Rotate crankshaft clockwise, and align timing mark on crankshaft
screw.
sprocket with timing mark on oil pump housing. See Fig. 3. Install timing
4) If reusing timing belt, mark timing belt with arrow to indicate rotation
belt on engine. If installing old belt, ensure arrow on timing belt aligns
direction. Remove timing belt.
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 speci-
fication. 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)

GEO/CHEVROLET 299
1.6L 4-Cylinder – Tracker, 8-Valve (Cont.)

A/C Compressor
8 mm Bolt ................................................................................................................ 21 (29)
10 mm Bolt .............................................................................................................. 33 (45)
Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 12 (16)
Valve Adjusting Screw Locknut ................................................................................. 13 (17)
INCH Lbs. (N.m)
Fan Clutch Nuts ........................................................................................................ 97 (11)
Tensioner Stud .......................................................................................................... 97 (11)
Valve Cover Bolt ......................................................................................................... 44 (5)
Water Pump Bolt ..................................................................................................... 106 (12)

300 GEO/CHEVROLET
1.6L 4-Cylinder – Tracker, 16-Valve
Kit No. Part No.
1.6L 4-Cyl. – SOHC, VIN 6
Tracker & Sunrunner (Canadian)
1994-02 .............................. 1 4.0 Hours .. .. TCK212 .. ... 3
T212
1


intervals.

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). Courtesy of General Motors Corp.
Remove 2 lower radiator shroud bolts. Remove 5 outer bolts retaining Fig. 1: Exploded View of Timing Belt & Components
crankshaft pulley to crankshaft. Remove crankshaft pulley. DO NOT
remove center bolt from crankshaft pulley. The center bolt holds
crankshaft sprocket to crankshaft.
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
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 Fig. 2: Aligning Timing Marks
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.
GEO/CHEVROLET 301
1.6L 4-Cylinder – Tracker, 16-Valve (Cont.)

Crankshaft Pulley Center Bolt ................................................................................ 81 (110)
Crankshaft Pulley-To-Crankshaft Bolt ....................................................................... 12 (16)
Front Skid Plate Bolt ................................................................................................. 40 (55)
INCH Lbs. (N.m)
Cooling Fan-To-Pulley Nut ........................................................................................ 97 (11)
Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11)
Fig. 3: Identifying Timing Belt Tensioner Assembly

302 HONDA
1.2L 4-Cylinder
Part No.
1.2L 4-Cyl.
Civic
1
1974 .......................................................... 1.5 Hours .. ..... T028
2
1975-79 .................................................... 2.0 Hours .. ..... T028
1
2
– With Air Conditioning, add .4 hours. Where Cruise Control
interferes, add .3 hours. Where Power Steering Interferes, add
.3 hours.


damage may occur.
TIMING BELT
Removal – 1) Disconnect negative battery cable. Remove wheelwell
splash shield. Remove air conditioning compressor adjustment pulley, Courtesy of American Honda Motor Co., Inc.
complete with bracket drive belt. Remove remaining accessory drive
belt(s). Remove valve cover. Remove water pump pulley and crankshaft Fig. 2: Exploded View Of Timing Belt & Components
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.
Fig. 1: Aligning Camshaft Marks
A/C Pulley Bolt .......................................................................................................... 17 (23)
Alternator
Adjustment Bolt ....................................................................................................... 17 (23)
Through-Bolt ............................................................................................................ 33 (45)
Engine Support Bolts/Nut .......................................................................................... 40 (55) Courtesy of American Honda Motor Co., Inc.
Side Bracket .............................................................................................................. 33 (45) Fig. 3: Aligning Crankshaft & Camshaft Timing Marks
INCH Lbs. (N.m)
Timing Belt Cover .................................................................................................... 84 (9.7)
Valve Cover .............................................................................................................. 84 (9.7)
HONDA 303
1.3L 4-Cylinder
Kit No. Part No.
1.3L 4-Cyl.
Civic
1980-83
1
Canada .......................... ... 2.0 Hrs. ... ...... ..... ...... ..... T028
1
US .................................. ... 2.0 Hrs. ... ...... ..... ...... ..... T073
1
1984-85 ............................ ... 2.0 Hrs. ..... 2521610 .. ..... T099
1
1986-87 ............................ ... 2.0 Hrs. ..... 2521610 .. ..... T161
Civic CRX
1
1984 ................................. ... 2.0 Hrs. ..... 2521610 .. ..... T099
1


camshaft or crankshaft when timing belt is removed, or engine Courtesy of American Honda Motor Co., Inc.
damage may occur.
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 Courtesy of American Honda Motor Co., Inc.
teeth. Inspect belt for signs of oil contamination. Replace belt if Fig. 2: Identifying Valve Cover Tightening Sequence
damaged or contaminated. Inspect all drive gears for wear in drive belt
area. Replace as necessary. TORQUE SPECIFICATIONS
Installation – 1) Ensure No. 1 piston is at TDC of compression stroke.
Ensure camshaft timing marks are aligned with valve cover surface and TORQUE SPECIFICATIONS
“UP” or “ROUND” mark is upward. See Fig. 4 or 5. Application Ft. Lbs. (N.m)
Alternator Adjustment Bolt ........................................................................................ 17 (23)
CAUTION: Belt tension must be adjusted when engine temperature Alternator Bracket Bolt .............................................................................................. 33 (45)
is cold. Camshaft Pulley Bolt ................................................................................................. 27 (37)
2) Install timing belt. Use care not to excessively bend or twist belt. Crankshaft Pulley Bolt
Ensure belt is installed in original direction of rotation. Belt tension must 1980-83 .................................................................................................................... 61 (81)
1984-87 .................................................................................................................. 83 (112)
be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft
Timing Belt Adjuster Bolt .......................................................................................... 35 (48)
pulley to create tension on belt. Tighten tensioner adjustment bolt to
specification. See TORQUE SPECIFICATIONS. INCH Lbs. (N.m)
3) Install washer on crankshaft bolt with flat side toward the pulley. See Timing Belt Cover Bolt ................................................................................................ 84 (9)
Fig. 1 or 3. Tighten retaining bolt to specification. Reverse removal Valve Cover Bolt ..................................................................................................... 108 (12)
procedure to complete installation. Tighten all bolts to specification. See Valve Cover Nut .......................................................................................................... 84 (9)
TORQUE SPECIFICATIONS. Valve cover bolts must be tightened in Water Pump Bolt ..................................................................................................... 108 (12)
proper sequence. See Fig. 2. Adjust drive belts to proper tension.
304 HONDA

HONDA 305

306 HONDA
1.5L 4-Cylinder
1
Kit No. Part No.
1.5L 4-Cyl.
Civic CVCC
1975 ................................. ..... 2.0 Hrs ..... ...... ..... ...... ..... T036
1976-79 ............................ ..... 2.0 Hrs ..... .. TCK041 .. ..... T041
Civic
1980-83 ............................ ..... 2.0 Hrs ..... ...... ..... ...... ..... T041
1984-85 ............................ ..... 2.0 Hrs ..... .. TCK161 .. ..... T099
1986-87 ............................ ..... 2.0 Hrs ..... .. TCK161 .. ..... T161
1988-95 ............................ ..... 2.0 Hrs ..... .. TCK143 .. ..... T143
Civic CRX
1984-85 ............................ ..... 2.0 Hrs ..... .. TCK161 .. ..... T099
1986-87 ............................ ..... 2.0 Hrs ..... .. TCK161 .. ..... T161
Civic VX
1992-95 ............................ ..... 2.0 Hrs ..... ...... ..... ...... ..... T223
Civic Del Sol
1993-95
Exc. VX .......................... ..... 2.0 Hrs ..... .. TCK143 .. ..... T143
VX .................................. ..... 2.0 Hrs ..... ...... ..... ...... ..... T223
1
.3 hours. Where Cruise Control interferes, add .3 hours.


MANUFACTURER’S SUGGESTED Courtesy of American Honda Motor Co., Inc.

SCHEDULED MAINTENANCE Fig. 1: Exploded View Of Timing Belt Components (1975-83)
3) Remove valve cover. Remove upper timing belt cover. Remove
maintenance interval for 1975-89 models, belt manufacturers suggest
crankshaft pulley. Loosen timing belt tension adjuster bolt 180 degrees.
the belt be replaced at 60,000 mile intervals. On 1990-94 models, the
Push tensioner to release belt tension. Retighten tension adjuster bolt.
manufacturer recommends the belt be replaced at 90,000 mile intervals.
Disengage timing belt from pulleys. See Fig. 1, 3 or 4.
For 1995 models, the manufacturer recommends the belt be replaced at
Installation (1980-95) – 1) Ensure No. 1 cylinder is at TDC of
90,000 mile intervals for normal service and 60,000 miles for severe
compression stroke. Install timing belt onto crankshaft pulley, tension
service.
adjuster pulley, water pump pulley, and camshaft sprocket. DO NOT
bend or twist belt excessively. Ensure crankshaft pulley timing mark
REMOVAL & INSTALLATION 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
CAUTION: This application is an interference engine. Do not rotate installing valve cover gasket, apply non-hardening sealant to rounded
camshaft or crankshaft when timing belt is removed, or engine surfaces of front and rear camshaft caps. To complete installation,
damage may occur. reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension.
TIMING BELT TIMING BELT ADJUSTMENT

Removal (1975-79) – Disconnect negative battery cable. Remove
wheelwell splash shield. Remove A/C compressor adjusting pulley CAUTION: Always adjust timing belt tension with engine cold.
together with bracket and A/C belt. Remove alternator bracket and belt. 1) Remove cylinder head cover. Remove upper timing belt cover. Rotate
Remove engine support bolts and nut. Remove rubber mount. Remove crankshaft counterclockwise until No. 1 cylinder is at TDC of compres-
valve cover. Remove crankshaft pulley. Remove upper timing belt cover sion stroke. Loosen but do not remove, timing belt adjuster bolt. See
from cylinder head and remove lower timing belt cover from engine Fig. 9.
block. Ensure that No. 1 cylinder is at TDC on compression stroke with 2) Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to
camshaft aligned with marks. Remove timing belt. create tension on timing belt. Tighten adjuster bolt to specification.
Installation (1975-79) – Ensure camshaft and crankshaft timing marks Retighten crankshaft pulley bolt to specification if it loosened during
are still aligned. See Figs. 1 and 2. Reverse removal procedure, using crankshaft rotation. See TORQUE SPECIFICATIONS.
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 compres-
sion 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.
HONDA 307
Fig. 3: Exploded View Of Timing Belt Components (1984-91)

308 HONDA
Fig. 4: Exploded View Of Timing Belt Components (1992-95)

HONDA 309

310 HONDA
Fig. 6: Aligning Timing Marks (1988-91 – Dual Point Injection)

HONDA 311
Courtesy of American Honda Motor Co., Inc. Fig. 9: Locating Timing Belt Adjuster Bolt
Fig. 7: Aligning Timing Marks (1988-91 Civic Si &
4WD Civic Wagon – Multipoint Injection)
A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Bolt .............................................................................................. 33 (45)
SOHC
1975-79 .................................................................................................................. 22 (30)
1980-95 .................................................................................................................. 28 (33)
SOHC ................................................................................................................... 134 (185)
Power Steering Pump Bracket Bolt .......................................................................... 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
1
– Lubricate bolt threads. Do not lubricate washer or washer mating surface of bolt.

312 HONDA
TIMING BELT APPLICATION Installation – 1) Ensure No. 1 cylinder is at TDC of compression stroke.
Application 1
Labor Time Component Belt Timing belt drive pulley TDC mark must align with pointer on oil pump
Kit No. Part No. housing. See Fig. 3. Set intake and exhaust camshaft pulleys to TDC.
1.6L 4-Cyl. – DOHC The TDC marks should align with each other with “UP” marks pointing
Civic up. See Fig. 3.
1 2) Install timing belt in this sequence: timing belt drive pulley, tension
1999-00 .............................. 2.0 Hours .. .. TCK227 .. ..... T227
Civic Del Sol adjusting pulley, water pump pulley, intake camshaft pulley, and exhaust
1
1994-97 .............................. 2.0 Hours .. .. TCK227 .. ..... T227 camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively.
1
– With Air Conditioning, add .4 hours. With Power Steering, add Ensure arrow on used belt points in original rotation direction. Ensure
.3 hours. crankshaft and camshaft pulleys remained aligned with TDC marks.
With Cruise Control, add .3 hours. 3) Loosen and retighten adjusting bolt to tension timing belt. Install lower
and middle covers. Install crankshaft pulley. Tighten pulley bolt to
NOTE: A timing belt component kit is available for this application. specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pul-
See page A1 for information on component kits. ley 5-6 turns counterclockwise so timing belt seats on pulleys.
CAUTION: Always adjust timing belt tension with engine cold.

available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque
SCHEDULED MAINTENANCE crankshaft pulley bolt.
For 1994 vehicles, the manufacturer recommends the belt be replaced
not, timing belt will need to be removed and repositioned. To complete
at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends
installation, reverse removal procedure. When installing valve cover
the belt be replaced at 90,000 miles for normal service and 60,000 miles
gasket, apply liquid gasket to 8 corners where gasket meets camshafts.
for severe service. For 1997-00 vehicles, normal replacement interval is Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
at 105,000 miles or 84 months. Replace at 60,000 miles if car is Adjust drive belts to proper tension.
regularly driven in extreme temperatures (over 110 degrees F, or under
-20 degrees F).
CAUTION: This application is an interference engine. Do not rotate A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 33 (44)
camshaft or crankshaft when timing belt is removed, or engine Alternator Mount Bolt ................................................................................................ 33 (45)
damage may occur. Camshaft Pulley Center Bolt .................................................................................... 41 (56)
Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177)
Engine Mount Bracket Nuts ...................................................................................... 54 (74)
TIMING BELT Engine Mount Bracket-To-Engine Bolts .................................................................... 40 (54)
Removal – 1) If the radio has a theft protection circuit, be sure to get the Power Steering Pump Bracket Bolt .......................................................................... 33 (44)
customer’s code before disconnecting battery. Disconnect negative Power Steering Pump-To-Bracket Bolts ................................................................... 17 (24)
battery cable. Remove engine lower splash shield. Remove power Timing Belt Adjusting Bolt ......................................................................................... 40 (54)
steering, alternator, and A/C compressor drive belts. Remove power Water Pump Bolt (10 x 1.25 mm) ............................................................................ 33 (44)
steering pump and hang out of way, leaving hoses connected. Rotate INCH Lbs. (N.m)
crankshaft counterclockwise to TDC of compression stroke. See Fig. 1.
2) Use jack to support engine. Working from front of engine, remove Valve Cover Nuts 2 .................................................................................................... 89 (10)
engine mount bracket nuts and bracket. Remove power steering pump Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106 (12)
lower bracket and heat shield from engine. Remove the crankshaft 1
– Lubricate bolt threads and bottom shoulder of bolt head.
pulley. 2
– Tighten nuts in 2-3 steps, starting from center outward.
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.
Fig. 1: Setting Crankshaft Pulley to TDC

HONDA 313

Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

314 HONDA
1.6L 4-Cylinder – SOHC, 1976-95
1
Kit No. Part No.
1.6L 4-Cyl.
Accord (Includes Canadian)
1976-78 ............................... 2.0 Hours ... .. TCK041 .. ..... T041
1979-83 ............................... 2.0 Hours ... ...... ..... ...... ..... T041
Civic
1988-91 ............................. 2.0 Hours ... .. TCK145 .. ..... T145
1992
Except Si .......................... 2.0 Hours ... .. TCK145 .. ..... T145
Si ....................................... 2.0 Hours ... .. TCK224 .. ..... T224
1993-95 ............................... 2.0 Hours ... .. TCK224 .. ..... T224
Civic del Sol
1993-95 ............................... 2.0 Hours ... .. TCK224 .. ..... T224
Civic CRX
1988-91 ............................... 2.0 Hours ... .. TCK145 .. ..... T145
Prelude
1980-82
Canada ............................. 2.1 Hours ... ...... ..... ...... ..... T041 Courtesy of American Honda Motor Co., Inc.
USA ................................... 2.0 Hours ... ...... ..... ...... ..... T041
1


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.

damage may occur.
NOTE: If the radio has a coded theft protection circuit, be sure to

get the customer’s code before disconnecting battery.
TIMING BELT
Removal – 1) Disconnect battery negative cable. Rotate crankshaft Courtesy of American Honda Motor Co., Inc.
counterclockwise until No. 1 cylinder is at TDC of compression stroke.
Remove wheelwell splash shield. Remove power steering pump if
(Accord & Prelude)
necessary, leaving hoses attached.
2) Remove A/C belt idler pulley bracket if necessary, and belt. Remove the car working for you. Use a high-strength, long-handled, breaker bar
alternator belt. Remove power steering pump bracket if necessary. with an impact socket to remove the bolt (which has right-hand threads).
Remove water pump pulley if not cam-driven. Remove cruise control Remove crankshaft pulley.
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
HONDA 315
1.6L 4-Cylinder – SOHC, 1976-95 (Cont.)
Fig. 3: Exploded View Of Timing Belt & Components (1992-95 Civic)

5) Remove lower timing belt cover bolts and timing belt cover. Remove 2) Install timing belt onto crankshaft pulley, tension adjuster pulley, water
crankshaft position sensor from oil pump (if equipped). Loosen tension pump pulley (if cam-driven), and camshaft sprocket. DO NOT bend or
adjuster bolt pivot bolt 180 degrees (if equipped). Loosen timing belt twist belt excessively. Take note of spacer installation. See Figs. 2 and 3.
tension adjuster bolt 180 degrees. See Fig. 1. Push tensioner to release Ensure arrow on used belt points in original rotation direction. Ensure
belt tension. Retighten tension adjuster bolt. Mark rotation direction of crankshaft and camshaft timing marks are still aligned.
timing belt if it is to be reused. Remove timing belt from pulleys. See 3) Adjust timing belt tension. See TIMING BELT ADJUSTMENT. Before
Figs. 2 and 3. installing valve cover gasket, apply non-hardening sealant to rounded
Installation – 1) Ensure No. 1 cylinder is at TDC of compression stroke. surfaces of front and rear camshaft caps. To complete installation,
On Civic models, crankshaft keyway will be at 12 o’clock position, and reverse removal procedure. Ensure beveled edge of crankshaft pulley is
away from pulley surface. Tighten bolts to specification. See TORQUE
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.
316 HONDA
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (Civic)
Fig. 6: Aligning Crankshaft & Camshaft Timing Marks (Prelude)

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks (Accord)

HONDA 317

TIMING BELT ADJUSTMENT TORQUE SPECIFICATIONS
1) Remove valve cover. Remove upper timing belt cover. Rotate
crankshaft counterclockwise until cylinder No. 1 is at TDC of compres-
sion stroke. Remove timing belt tensioner adjustment bolt access Application Ft. Lbs. (N.m)
plug(s) in lower timing belt cover. Loosen but do not remove, timing belt A/C Compressor Bracket Bolt ................................................................................... 33 (45)
adjuster bolt. See Figs. 1 and 2. Alternator Bracket Bolt .............................................................................................. 33 (45)
2) Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to Camshaft Sprocket Bolt
Accord & Prelude .................................................................................................... 22 (30)
create tension on timing belt. Tighten adjuster bolt. Retighten crankshaft
Civic, Civic del Sol & Civic CRX ............................................................................ 27 (38)
pulley bolt to specification if it loosened during crankshaft rotation. See Crankshaft Pulley Bolt 1
TORQUE SPECIFICATIONS. 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)
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)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt
Accord & Prelude .................................................................................................. 108 (12)
1
– Lubricate bolt threads but do not lubricate washer or mating surface of bolt.
2
– Pivot bolt and adjuster bolt.
318 HONDA
TIMING BELT APPLICATION 4) Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump.
Application Labor Time Component Belt Loosen the timing belt tension adjusting bolt 180 degrees. Push
Kit No. Part No. tensioner to release belt tension. Retighten tension adjusting bolt. Mark
1.6L 4-Cyl. – SOHC rotation direction of timing belt if it is to be reused. Remove timing belt
Civic from pulleys. See Fig. 2.
1 Inspection – 1) Inspect timing belt tensioner pulley for worn bearing.
1996-00 .............................. 2.0 Hours .. .. TCK224 .. ..... T224
Civic Del Sol Replace as necessary.
1
1996-97 .............................. 2.0 Hours .. .. TCK224 .. ..... T224
1
NOTE: The following revised timing belt tensioner information is
from Honda technical service bulletin 96-057; August 4, 1998.
.3 hours. With Cruise Control, add .3 hours.
2) If there was a customer complaint of a whine or chirping noise from
NOTE: A timing belt component kit is available for this application. the front of the engine at idle, or just above idle, this may be caused by
See page A1 for information on component kits. 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.
NOTE: For information about tensioners and/or pulleys (when 3) The timing belt tensioner kit is available under part number
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED housing. See Fig. 3.
2) Set camshaft pulley to TDC. TDC marks should align with top surface
SCHEDULED MAINTENANCE of cylinder head. See Fig. 4.
For 1996 vehicles, manufacturer recommends replacing belt at 90,000 3) Install timing belt in this sequence: timing belt drive pulley, tension
miles for normal service and 60,000 miles for severe service. For adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO
1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 NOT bend or twist belt excessively. Ensure arrow on used belt points in
months. Replace at 60,000 miles if car is regularly driven in extreme original rotation direction. Ensure crankshaft and camshaft pulley timing
temperatures (over 110 degrees F, or under -20 degrees F). 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
REMOVAL & INSTALLATION TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns coun-
terclockwise so timing belt seats on pulleys.
CAUTION: This application is an interference engine. Do not rotate CAUTION: Always adjust timing belt tension with engine cold.
5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC
damage may occur.
mark on crankshaft pulley aligned with pointer on cover). Loosen
adjusting bolt 180 degrees. See Fig. 5. Rotate crankshaft counterclock-
NOTE: If the radio has a coded theft protection circuit, be sure to wise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary,
get the customer’s code before disconnecting battery. retorque crankshaft pulley bolt.
not, timing belt will need to be removed and repositioned. To complete
TIMING BELT installation, reverse removal procedure. Tighten bolts to specification.
Removal – 1) Disconnect negative battery cable. Remove engine lower See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
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.
HONDA 319

320 HONDA
A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 17 (24)
Alternator Adjusting Bolt ............................................................................................ 17 (24)
Step 1 ...................................................................................................................... 14 (20)
Step 2 .......................................................................................... ........ Plus 90° Clockwise
Engine Mount Bracket Nuts ...................................................................................... 54 (74)
Power Steering Pump Lock Bolt .............................................................................. 17 (24)
Timing Belt Tensioner Adjusting Bolt ........................................................................ 33 (45)
INCH Lbs. (N.m)
CKF Sensor Bolt ..................................................................................................... 106 (12)
Courtesy of American Honda Motor Co., Inc. Engine Lower Splash Shield ..................................................................................... 89 (10)
Fig. 3: Aligning Crankshaft TDC Mark & Oil Pump Mark
Water Pump Bolt ..................................................................................................... 106 (12)
1
– Lubricate bolt threads and bolt head shoulder.

HONDA 321

TIMING BELT APPLICATION timing belt between camshaft pulley and water pump pulley. Auto-
Application Labor Time Belt tensioner should move smoothly. Replace auto-tensioner if it does not
Part No. move smoothly. Using socket on small allen at side of auto-tensioner,
1.7L 4-Cyl. – SOHC move auto tensioner to remove tension from timing belt, and remove
Civic timing belt. See Fig. 6.
1
2001-04 .................................................... 2.7 Hours .. ..... T312 Installation – 1) Clean timing belt pulleys and covers. Ensure No. 1
1
– With Power Steering, add .3 hours. cylinder is at TDC of compression stroke. Timing belt drive pulley TDC
mark must align with pointer on oil pump housing. See Fig. 7.
NOTE: For information about tensioners and/or pulleys (when 2) Set camshaft pulley to TDC. TDC marks should align with top surface
available), see ALPHABETICAL MODEL LISTING. of cylinder head. See Fig. 8.
3) Install timing belt counterclockwise in this sequence: timing belt drive
MANUFACTURER’S SUGGESTED pulley, tensioner pulley, water pump pulley, and camshaft pulley. See
Fig. 9. DO NOT bend or twist belt excessively. Ensure arrow on used
SCHEDULED MAINTENANCE belt points in original rotation direction. Ensure crankshaft and camshaft
Normal replacement interval is at 110,000 miles or 84 months. Replace pulley timing marks are aligned with TDC marks.
at 60,000 miles if car is regularly driven in extreme temperatures (over 4) Install CKP sensor, side engine mount bracket, lower timing belt
110 degrees F, or under -20 degrees F). cover, and crankshaft pulley. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns coun-
REMOVAL & INSTALLATION terclockwise so timing belt positions on pulley.
CAUTION: This application is an interference engine. Do not rotate CAUTION: Always adjust timing belt tension with engine cold.
5) Turn crankshaft pulley so No. 1 piston is at TDC (White TDC mark on
damage may occur.
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
TIMING BELT proper tension.
Removal – 1) Disconnect negative battery cable. Remove engine lower
splash shield. Rotate crankshaft counterclockwise to TDC of compres-
sion 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
4) Remove grommet from upper timing belt cover, and disconnect TDC
sensor connector. Remove both upper and lower timing belt covers. See Courtesy of American Honda Motor Co., Inc.
Fig. 4.
5) Remove side engine mount bracket. Remove CKP sensor from oil
pump without disconnecting connector. See Fig. 5. Check auto-
tensioner before removing belt. Apply a force of 22 ft. lbs. (98 N.m) to
322 HONDA
Fig. 3: Removing Crankshaft Pulley Courtesy of American Honda Motor Co., Inc.

HONDA 323
Fig. 5: Removing CKP Sensor From Oil Pump
Fig. 8: Aligning Camshaft TDC Marks
Fig. 6: Removing Tension From Timing Belt
Alternator Adjusting Bolt ............................................................................................ 17 (24)
Auto Tensioner Mounting Bolt ................................................................................... 33 (44)
Courtesy of American Honda Motor Co., Inc. Step 1 .................................................................................................................. 181 (245)
Fig. 7: Aligning Crankshaft TDC Mark & Oil Pump Mark Step 2 .......................................................................................... ........ Plus 90° Clockwise
Engine Side Mount Bracket Nuts ............................................................................. 33 (44)
Engine Upper Bracket Nuts ...................................................................................... 40 (54)
Power Steering Pump Lock Bolt .............................................................................. 17 (24)
INCH Lbs. (N.m)
CKP Sensor Bolt ..................................................................................................... 106 (12)
Engine Lower Splash Shield ..................................................................................... 89 (10)
Harness Holder & Cable Clamps ............................................................................. 89 (10)
Water Pump Bolt ..................................................................................................... 106 (12)
1
– Lubricate bolt threads and bolt head shoulder.
324 HONDA
1.8L 4-Cylinder
Kit No. Part No.
1.8L 4-Cyl.
Accord
1
1979-83 ............................ ... 2.0 Hrs. ... ...... ..... ...... ..... T041
1
1984-85 ............................ ... 2.0 Hrs. ... .. TCK160 .. ..... T094
Prelude
1
1979-82 ............................ ... 2.0 Hrs. ... ...... ..... ...... ..... T041
1
1983-85 ............................ ... 2.0 Hrs. ... .. TCK160 .. ..... T094
1
1986-87 ............................ ... 2.0 Hrs. ... .. TCK160 .. ..... T160
1



camshaft or crankshaft when timing belt is removed, or engine Courtesy of American Honda Motor Co., Inc.
damage may occur.
(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. Courtesy of American Honda Motor Co., Inc.
2) Remove engine valve cover and upper timing belt cover. See Fig. 1
or 3. Ensure camshaft timing marks are aligned with valve cover Fig. 2: Aligning Crankshaft & Camshaft Timing Marks
surface, and “UP” or “ROUND” mark is upward. See Fig. 2, 4 or 5. (1979-83 Accord & 1979-82 Prelude)
HONDA 325
Fig. 3: Exploded View Of Timing Belt & Components (1984-85 Accord & 1983-87 Prelude)
Installation (1984-85 Accord & 1983-87 Prelude) – 1) Ensure cylinder
CAUTION: Crankshaft pulley bolt may stick to the crankshaft No. 1 is at TDC of compression stroke. Ensure camshaft timing marks
threads when properly torqued. A properly torqued pulley bolt may are aligned with valve cover surface, and “UP” or “ROUND” mark is
require up to two or three times the installation torque to remove. upward. See Fig. 2, 4 or 5.
2) Install timing belt. Use care not to excessively bend or twist belt.
3) Remove crankshaft pulley. Remove lower timing belt cover from
Ensure belt is installed in original direction of rotation. Belt tension must
engine block. Loosen timing belt tensioner to relieve timing belt tension.
be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft
4) If timing belt is being reused, mark direction of belt rotation before
pulley to create tension on belt. Tighten tensioner adjustment bolt to
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.
326 HONDA
Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks Fig. 5: Aligning Crankshaft & Camshaft Timing Marks
(1984-85 Accord) (1983-87 Prelude)
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
1979-83 Accord & 1980-82 Prelude ....................................................................... 22 (23)
1984-85 Accord & 1983-87 Prelude ....................................................................... 27 (37)
Crankshaft Pulley Bolt 1 .......................................................................................... 83 (115)
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)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
1
– Lubricate bolt threads but do not lubricate washer or mating surface of bolt.
2
– Pivot bolt and adjuster bolt.
HONDA 327
2.0L 4-Cylinder – CR-V

TIMING BELT APPLICATION Installation – 1) Ensure No. 1 cylinder is at TDC of compression stroke.
Application Labor Time Component Belt Timing belt drive pulley TDC mark must align with pointer on oil pump
Kit No. Part No. housing. See Fig. 3.
2.0L 4-Cyl. 2) Set intake and exhaust camshaft pulleys to TDC. The TDC marks
CR-V should align with cylinder head surface with “UP” marks pointing up. See
1 Fig. 3.
1997-01 .............................. 2.7 Hours .. .. TCK184 .. ..... T184
1 3) Install timing belt in this sequence: timing belt drive pulley, tension
.3 hours. With Power Steering, add .3 hours. adjusting pulley, water pump pulley, exhaust camshaft pulley, and intake
camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively.
NOTE: A timing belt component kit is available for this application. Ensure arrow on used belt points in original rotation direction. Check
See page A1 for information on component kits. that crankshaft and camshaft pulleys remained aligned with TDC marks.
4) Loosen and retighten adjusting bolt to tension timing belt. Install lower
NOTE: For information about tensioners and/or pulleys (when and middle covers. Install crankshaft pulley. Tighten pulley bolt to
available), see ALPHABETICAL MODEL LISTING. specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pul-
ley 5-6 turns counterclockwise so timing belt positions on pulley.
MANUFACTURER’S SUGGESTED CAUTION: Always adjust timing belt tension with engine cold.
SCHEDULED MAINTENANCE 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
at 60,000 miles if car is regularly driven in extreme temperatures (over
3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque
110 degrees F, or under -20 degrees F).
crankshaft pulley bolt.
REMOVAL & INSTALLATION not, timing belt will need to be removed and repositioned.
7) To complete installation, reverse removal procedure. When installing
CAUTION: This application is an interference engine. Do not rotate cylinder head cover gasket, apply liquid gasket (Part No. 08718-0001 or
camshaft or crankshaft when timing belt is removed, or engine -0003) to 8 corners where gasket meets camshafts. Tighten fasteners to
damage may occur. specification. See TORQUE SPECIFICATIONS. Adjust drive belts to
proper tension.
get the customer’s code before disconnecting battery. TORQUE SPECIFICATIONS
TIMING BELT Application Ft. Lbs. (N.m)
Removal – 1) Disconnect battery negative cable. Remove engine guard
bar and lower splash shield. Remove power steering, alternator, and A/C Alternator Adjusting Lock Nut ................................................................................... 17 (24)
compressor drive belts. Remove cruise control actuator and vacuum Alternator Mount Bolt ................................................................................................ 33 (45)
tank from left side fenderwell (if equipped), and hang out of way. Rotate Camshaft Pulley Center Bolt .................................................................................... 27 (37)
crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177)
2) Use jack to support engine. Working from front of engine, remove Engine Mount Bracket Nuts ...................................................................................... 54 (74)
engine mount bracket nuts and bracket. Remove the crankshaft pulley. Engine Underguard Bar Bolts ................................................................................... 17 (24)
3) Remove cylinder head cover. Remove middle and lower covers. See Power Steering Pump Bracket Bolt .......................................................................... 33 (44)
Fig. 2. Loosen timing belt tension adjusting bolt 180 degrees. Push Power Steering Pump Lock Bolt .............................................................................. 17 (24)
tensioner to release belt tension. Retighten tension adjusting bolt. Mark Power Steering Pump-To-Bracket Bolts ................................................................... 17 (24)
rotation direction of timing belt if it is to be reused. Remove timing belt Timing Belt Adjusting Bolt ......................................................................................... 40 (54)
from pulleys. INCH Lbs. (N.m)
Cylinder Head Cover Nuts 2 ...................................................................................... 89 (10)
Water Pump Bolt ..................................................................................................... 106 (12)
1
– Lubricate bolt threads and bottom shoulder of bolt head.
2
– Tighten nuts in 2-3 steps, starting from center outward.
Fig. 1: Setting Crankshaft Pulley To TDC

328 HONDA
2.0L 4-Cylinder – CR-V (Cont.)
Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

HONDA 329
2.0L 4-Cylinder SOHC – Accord & Prelude

Kit No. Part No.
Accord
1
1986-89 ............................ ... 2.7 Hrs. ... .. TCK160 .. ..... T160
Prelude
1
1985 ................................. ... 2.7 Hrs. ... .. TCK160 .. ..... T094
1
1986-87 ............................ ... 2.7 Hrs. ... .. TCK160 .. ..... T160
1
1988-90 ............................ ... 2.7 Hrs. ... ...... ..... ...... ..... T144
1


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.

CAUTION: This application is an interference engine. Do not rotate Courtesy of American Honda Motor Co., Inc.
camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Exploded View Of Timing Belt & Components
damage may occur. (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 contami-
nated. 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 instal-
lation, reverse removal procedure. Tighten bolts to specification. See
Removal (1988-90 Prelude) – 1) Turn crankshaft counterclockwise (as Courtesy of American Honda Motor Co., Inc.
viewed from timing belt end of engine) so that No. 1 cylinder is at TDC Fig. 2: Aligning Crankshaft & Camshaft Timing Marks
of compression stroke. Ensure TDC mark (White paint) is at rear of (1985-87 Prelude Shown; Others Are Similar)
engine on transaxle mating flange. See Fig. 2.
330 HONDA
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. Fig. 4: Adjusting Timing Belt Tension (1988-90 Prelude)
3) Loosen, but DO NOT remove, timing belt adjusting bolt through
access hole in timing belt cover. See Fig. 4. Rotate crankshaft counter- TORQUE SPECIFICATIONS
clockwise 3 teeth on camshaft pulley to tension timing belt. Tighten TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE)
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
Alternator Bracket Adjustment Bolt ........................................................................... 51 (69)
accessory drive belts and adjust to proper tension. Install engine mount Alternator Bracket Bolt .............................................................................................. 18 (24)
and cruise control actuator. Camshaft Pulley Bolt ................................................................................................. 27 (37)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................................................................... 84 (9)
Water Pump Bolt ..................................................................................................... 106 (12)
TORQUE SPECIFICATIONS (1988-90 PRELUDE)

A/C Compressor Mounting Bolt ................................................................................ 18 (25)
Engine Mount-To-Engine Nut .................................................................................... 47 (65)
Generator Lower Mount Bolt .................................................................................... 33 (45)
Generator Upper Mount Bolt .................................................................................... 20 (27)
Power Steering Pump Upper Mount Bolt ................................................................. 20 (27)
INCH Lbs. (N.m)
(1988-90 Prelude)
Valve Cover Nut ........................................................................................................ 89 (10)
Water Pump Bolt ..................................................................................................... 106 (12)
HONDA 331
2.0L & 2.1L 4-Cylinder DOHC – Prelude

Application Labor Time Component Belt NOTE: For information about tensioners and/or pulleys (when
Kit No. Part No. available), see ALPHABETICAL MODEL LISTING.
Prelude
1988-91 ............................ ... 1
3.3 Hrs. ... .. TCK142 .. ..... T142 MANUFACTURER’S SUGGESTED
2.1L 4-Cyl. – DOHC SCHEDULED MAINTENANCE
Prelude
1 Although the manufacturer does not recommend a specific scheduled
1990-91 ............................ ... 3.3 Hrs. ... .. TCK142 .. ..... T142
1
– With Air Conditioning, add .5 hours. With Cruise Control, add the belt be replaced at 60,000 mile intervals. On 1990-91 models, the
.3 hours. With Power Steering, add .3 hours. manufacturer recommends belt be replaced every 90,000 miles.

332 HONDA
2.0L & 2.1L 4-Cylinder DOHC – Prelude (Cont.)
damage may occur.
TIMING BELT
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 contami-
nation. 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 Fig. 2: Aligning Camshaft & Crankshaft Timing Marks
used belt points in original rotation direction.
2) Adjust timing belt tension by rotating crankshaft counterclockwise TORQUE SPECIFICATIONS
until cylinder No. 1 is at TDC of compression stroke. Loosen, but do not
3 teeth on camshaft pulley to create tension on timing belt. Tighten Application Ft. Lbs. (N.m)
adjustment bolt to specification. See TORQUE SPECIFICATIONS. A/C Compressor Bracket Bolt ................................................................................... 33 (45)
Alternator Bracket Adjustment Bolt ........................................................................... 20 (27)
3) To complete installation, reverse removal procedure. Apply non-
hardening sealant to rounded surfaces of front and rear camshaft caps Camshaft Pulley Bolt ................................................................................................. 27 (37)
before installing valve cover gasket. Tighten bolts to specification. See Crankshaft Pulley Bolt ........................................................................................... 108 (146)
TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Power Steering Adjustment Nut ................................................................................ 31 (42)
Timing Belt Adjustment Bolt ...................................................................................... 31 (42)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 90 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
HONDA 333
2.2L 4-Cylinder DOHC – Prelude

TIMING BELT APPLICATION 4) Install auto-tensioner on engine with stopper in place. Install timing
Application Labor Time Component Belt belt around crankshaft drive pulley, adjusting pulley, water pump,
Kit No. Part No. exhaust camshaft pulley, then intake camshaft pulley. Ensure crankshaft
2.2L 4-Cyl. – DOHC (H22A) and camshaft pulleys remain aligned at TDC.
Prelude 5) Remove the auto-tensioner stopper. Install balancer belt drive pulley.
1993-01 Temporarily install lower cover, crankshaft pulley, and crankshaft pulley
Balancer Shaft Belt ...... .......... 1 .......... .. TCK186 .. ..... T186 bolt. Tighten bolt.
Camshaft Timing Belt .. ... 1 3.3 Hrs. ... .. TCK186 .. ..... T226 6) Rotate crankshaft about 5-6 times counterclockwise so that timing
1
– Balancer shaft belt included in camshaft belt labor time. With belt positions on the pulleys. Place crankshaft and camshaft pulleys at
Air Conditioning, add .5 hours. With Cruise Control, add .3 TDC positions. If either crankshaft or camshaft pulley is not positioned at
hours. With Power Steering, add .3 hours. TDC, timing belt will have to be repositioned.
7) Remove crankshaft pulley and lower cover. Loosen belt tension
NOTE: A timing belt component kit is available for this application. adjusting nut about one turn. Verify balancer belt adjuster moves freely.
See page A1 for information on component kits. Retighten tension adjusting nut.
8) Remove sealing bolt from maintenance hole in side of engine block.
NOTE: For information about tensioners and/or pulleys (when See Fig. 5. Insert a 6 x 100 mm bolt into maintenance hole to lock rear
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 9) Install balancer belt. Loosen adjusting nut to tension balancer belt.
SCHEDULED MAINTENANCE Remove 6 x 100 mm bolt from side of engine block. Install sealing bolt.
10) Install lower cover and crankshaft pulley. Lubricate crankshaft pulley
For 1993-94 vehicles, the manufacturer recommends camshaft and
bolt and underside of bolt shoulder. Install and tighten bolt to specifica-
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
11) Turn crankshaft pulley about one turn counterclockwise. Tighten belt
normal service or 60,000 miles for severe service.
tension adjusting nut. Install rubber seal around adjusting nut. Install
For 1997-01 vehicles, normal replacement interval is at 105,000 miles or accessory drive belts, and adjust tension.
84 months. Replace at 60,000 miles if car is regularly driven in extreme 12) Install middle cover. When installing cylinder head cover gasket,
temperatures (over 110 degrees F, or under -20 degrees F). apply liquid gasket (Part No. 08718-001 or -0003) to 8 corners where
gasket meets camshafts. Reverse removal procedure to complete
installation.
damage may occur.

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 Courtesy of American Honda Motor Co., Inc.
grip housing. Fig. 1: Identifying Camshaft & Crankshaft TDC Marks
3) Remove maintenance bolt from top of auto-tensioner. Use a flat-
bladed screwdriver to compress auto-tensioner to bottomed out posi-
tion. Place stopper on auto-tensioner. Refill any oil that may have spilled
out, and install maintenance bolt with new gasket.
334 HONDA
2.2L 4-Cylinder DOHC – Prelude (Cont.)
Fig. 4: Compressing Auto-Tensioner

Fig. 3: Aligning Timing Belt Drive Pulley With TDC Mark

HONDA 335
2.2L 4-Cylinder DOHC – Prelude (Cont.)

Auto-Tensioner Mount Bolts ...................................................................................... 16 (22)
Balance Shaft Pulley Bolt ......................................................................................... 22 (30)
Maintenance Hole Sealing Bolt ................................................................................ 22 (29)
Power Steering Pump Bolt/Lock Nut ........................................................................ 16 (22)
Timing Belt Tension Adjusting Nut ............................................................................ 33 (45)
INCH Lbs. (N.m)
Cylinder Head Cover Nut .......................................................................................... 90 (10)
Water Pump Bolt ..................................................................................................... 106 (12)
1
– Lubricate bolt threads and underside of bolt shoulder.
Fig. 5: Aligning & Locking Balancer Shaft
Fig. 6: Aligning Balancer Shaft Pulley

336 HONDA
2.2L 4-Cylinder SOHC – Odyssey
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
– Balance shaft belt included in camshaft belt labor time.
2


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).

damage may occur. Fig. 1: Exploded View Of Timing Belt, Balance Belt &
Related Components
TIMING BELT
Remove accessory drive belts. Remove alternator terminal and connec-
tor. 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
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.)

Fig. 5: Aligning Camshaft Pulley TDC Marks
Fig. 3: Loosening Tensioner Adjusting Nut
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
TORQUE SPECIFICATIONS Fig. 6: Identifying Timing Belt Installation Sequence
Power Steering Pump Mounting Nut ........................................................................ 16 (22)
INCH Lbs. (N.m)
Valve Cover Nut ....................................................................................................... 86 (9.8)
338 HONDA
2.2L & 2.3L 4-Cylinder – DOHC & SOHC
TIMING BELT APPLICATION 3) Support engine. Remove 2 rear bolts from engine center support
Application Labor Time Component Belt beam. Lower engine enough to permit removal of lower timing belt
Kit No. Part No. cover. Remove rubber seal from belt tension adjuster nut. Remove lower
2.2L 4-Cyl. – SOHC timing belt cover.
Accord
CAUTION: DO NOT rotate crankshaft or camshaft when removing
1990-93
Balance Shaft ............... .......... 1 .......... .. TCK186 .. ..... T186 timing belts.
Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... T187 4) Lock timing belt adjuster arm into position by installing one lower
1994-95 cover retaining bolt. Loosen belt tension adjuster bolt. See Fig. 5. Push
EX Model belt tensioner to release tension from belt. Tighten adjuster bolt.
Balance Shaft ............. .......... 1 .......... ...... ..... ...... ..... T186
Remove balance shaft and camshaft timing belts.
Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... ..... T244
Except EX Model Inspection – With belt or belt covers removed, inspect belts for wear,
Balance Shaft ............. .......... 1 .......... .. TCK186 .. ..... T186 cracks, or oil soaking. Inspect belt teeth for wear. Replace belt if worn,
Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... T187 oil soaked, or cracked.
1996-97 Installation – 1) Align White mark on flywheel or drive plate (flexplate)
W/VTEC with pointer on block. Ensure camshaft(s) is at TDC for No. 1 cylinder.
Balance Shaft ............. .......... 1 .......... ...... ..... ...... ..... T186 See Fig. 1, 2 or 3. Install camshaft timing belt. See Fig. 6. Align rear
Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... ..... T244 timing balance shaft belt pulley by inserting a 6 x 100 mm bolt 2.9″ (74
W/O VTEC mm) into alignment access hole. Align groove on front balance shaft
Balance Shaft ............. .......... 1 .......... .. TCK186 .. ..... T186 pulley with pointer on oil pump body. See Fig. 7.
Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... T187 2) Adjust timing belt tension by rotating crankshaft counterclockwise
Prelude until No. 1 piston is at TDC of compression stroke. Loosen, but do not
1992-96
Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... T187 3 teeth on camshaft pulley to create tension on timing belt. Tighten
2.3L 4-Cyl. – DOHC adjustment bolt to specification. See TORQUE SPECIFICATIONS.
Prelude 3) Reverse removal procedure to complete installation. Tighten crank-
1992-96 shaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
Balance Shaft ............... .......... 1 .......... .. TCK216 .. ..... T186 Adjust drive belts to proper tension.
1
– Balance shaft belt included in camshaft belt labor time. With
Air Conditioning, add .5 hours. With Cruise Control, add .3


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.

damage may occur.

TIMING & BALANCE SHAFT BELTS
Removal – 1) Disconnect negative battery cable. Position crankshaft Fig. 1: Positioning Camshaft Sprocket for Valve Adjustment
with cylinder No. 1 at TDC of compression stroke. See Fig. 1, 2 or 3. (2.2L SOHC – Accord)
Disconnect battery negative cable. Remove splash shield. Remove
cruise control actuator, leaving cable connected. Remove power steer-
ing 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.
HONDA 339
2.2L & 2.3L 4-Cylinder – DOHC & SOHC (Cont.)
Fig. 4: Removing & Installing Crankshaft Pulley (Typical)
Fig. 2: Positioning Camshaft Sprocket for Valve Adjustment

(2.2L SOHC – Prelude)
Fig. 3: Positioning Camshaft Sprockets for Valve Adjustment (Prelude 2.3L DOHC)
340 HONDA
Fig. 5: Locating Timing Belt Adjuster Nut (Typical)
Fig. 6: Removing & Installing Timing & Balance Shaft Belts

HONDA 341

Alternator Bracket Adjuster Bolt ................................................................................ 16 (22)
Balance Shaft Pulley Bolt ......................................................................................... 22 (30)
Camshaft Pulley Bolt
2.2L DOHC .............................................................................................................. 37 (51)
2.2L SOHC & 2.3L .................................................................................................. 27 (37)
Power Steering Belt Adjuster Nut ................................................. ............................ 11 (15)
Shift Cable Bracket Bolt ............................................................................................ 16 (22)
Timing Belt Tension Adjuster .................................................................................... 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 90 (10)
Water Pump Bolt ..................................................................................................... 108 (12)
Fig. 7: Aligning Balancer Belt Driven Pulley

342 HONDA
Part No.
2.3L 4-Cyl. – F23A, SOHC
Accord
1998-02
Balance Shaft ...................................... .......... 1 .......... ..... T186
Camshaft ............................................... 2 3.1 Hours .. ..... T244
Odyssey
1998
Balance Shaft ...................................... .......... 1 .......... ..... T186
Camshaft ............................................... 2 3.3 Hours .. ..... T244
1
2

at 60,000 miles if vehicle is regularly driven in extreme temperatures
(over 110 degrees F, or under -20 degrees F).

damage may occur.
NOTE: f the radio has a coded theft protection circuit, be sure to Fig. 1: Exploded View Of Timing Belt, Balancer Belt &
get the customer’s code before disconnecting battery. Related Components

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. Courtesy of American Honda Motor Co., Inc.
Installation – 1) Clean tensioner pulleys. Ensure cylinder No. 1 is at
TDC by aligning dimple on timing belt drive pulley with pointer on oil Fig. 2: Removing & Installing Timing Belt Covers
pump housing. See Fig. 4. Ensure camshaft pulley TDC marks are stroke. Loosen belt tensioner adjusting nut about one turn. Rotate
aligned. See Fig. 5. crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt
2) Install camshaft timing belt counterclockwise in sequence shown. See tensioner adjusting nut to specification. See TORQUE SPECIFICA-
Fig. 6. Loosen and retighten tensioner adjusting nut to tension camshaft TIONS.
timing belt. Install balancer belt drive pulley and lower cover. Install 4) Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC
crankshaft pulley. Install bolt. position. Ensure camshaft “UP” mark is facing up. If it is not, timing belt
3) Rotate crankshaft pulley COUNTERCLOCKWISE about 5-6 turns so will have to be repositioned.
timing belt positions on pulley. Set No. 1 piston at TDC of compression
HONDA 343

Courtesy of American Honda Motor Co., Inc. Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
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 Courtesy of American Honda Motor Co., Inc.
NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley
bolt and underside of bolt shoulder. Install and tighten crankshaft pulley Fig. 5: Aligning Camshaft Pulley TDC Marks
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.
344 HONDA
Fig. 8: Locking Balancer Shaft In Place
Alternator Adjusting Lock Nut ................................................................................... 16 (22)
Engine Block Sealing Bolt ........................................................................................ 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt
Accord ...................................................................................................................... 40 (54)
Engine Side Mount Through-Bolt
Odyssey ................................................................................................................... 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt
Odyssey ................................................................................................................... 47 (64)
Timing Belt Tensioner Adjusting Nut ........................................................................ 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ......................................................................................... 86 (9.8)
Courtesy of American Honda Motor Co., Inc. Timing Belt Cover Bolt ............................................................................................ 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)
Fig. 7: Aligning Balancer Belt Drive Pulley
HONDA 345
2.6L 4-Cylinder
1
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


camshaft or crankshaft when timing belt is removed, or engine Courtesy of Isuzu Motor Co.
damage may occur.
TIMING SPROCKET SPECIFICATIONS
TIMING BELT
Application Standard – In. (mm) Limit – In. (mm)
NOTE: Some procedures may differ slightly due to engine con- Camshaft ............................... .......... 5.202 (132.03) ................................. 5.198 (131.93)
Crankshaft ............................. ........... 2.574 (65.33) .................................... 2.570 (65.23)
struction.
Oil Pump ............................... .......... 4.485 (113.84) .......... ....................... 4.481 (113.74)
Removal – 1) Disconnect negative battery cable. Remove all necessary
Installation – 1) Pull tensioner fully toward water pump side, and
air ducts. Position No. 1 cylinder at TDC of compression stroke. Align
temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on
timing marks. See Fig. 1. Remove fan and fan shroud. Remove compression stroke by rotating crankshaft until keyway aligns with mark
accessory drive belts. Remove water pump pulley. If necessary, remove on front crankshaft seal housing (12 o’clock).
radiator and splash guard. 2) Rotate camshaft until timing mark on cam gear (arrow) aligns with
2) Prevent engine from rotating, and remove crankshaft timing pulley. mark on upper camshaft cover (notch). See Fig. 1.
Remove upper and lower timing belt covers. See Fig. 2. Remove spring 3) Position timing belt over crankshaft sprocket, oil pump sprocket,
from tension pulley. Loosen adjusting bolt, and move pulley toward camshaft sprocket and tensioner in that order. Ensure belt is positioned
water pump. Remove timing belt. in sequence given and without slack between sprockets. Loosen
tensioner pulley adjusting bolt, allowing spring tension to tighten belt.
CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft, Tighten adjusting bolt temporarily.
or damage may result. 4) Temporarily install crankshaft pulley bolt and rotate crankshaft 2
complete revolutions in opposite direction of engine rotation, until marks
Inspection – 1) Handle timing belt carefully. Avoid twisting or kinking on crankshaft and front oil seal retainer are aligned again. See Fig. 1.
belt. Do not allow belt to become contaminated by water, oil, dirt or other Loosen tensioner lock bolt, allowing tensioner spring to fully adjust
contaminates. Inspect belt for cracks or damage. Replace, if necessary. tension. Tighten tensioner lock bolt.
2) Measure tensioner pulley spring length and force. Spring length 5) Install timing belt covers. To complete installation, reverse removal
should not exceed 2.76″ (70.2 mm), and spring force should not be less procedures. Tighten all bolts to specification. See TORQUE SPECIFI-
than 197-343 lbs. (27-48 kg). Replace tensioner pulley spring if not CATIONS. Adjust drive belts to proper tension.
within specification.
3) Check timing sprockets. See TIMING SPROCKET SPECIFICATIONS
table. Replace, if necessary.
346 HONDA
Front Cover ............................................................................................................... 14 (19)
Tensioner Pulley
Bolts ......................................................................................................................... 18 (24)
Nut ........................................................................................................................... 10 (14)
Water Pump Bolt ....................................................................................................... 14 (19)
INCH Lbs. (N.m)
Fig. 3: Installing Belt Guide
HONDA 347
2.7L V6
TIMING BELT APPLICATION Inspection – Inspect camshaft and crankshaft seals, and replace if
Application 1
Labor Time Belt leaking. Inspect timing belt for wear or rounded edges of drive teeth.
Part No. Inspect belt for signs of oil contamination. Replace belt if damaged or
2.7L V6 contaminated.
Accord Installation – 1) Clean timing belt covers and ensure No. 1 piston is at
1996-97 ..................................................... 4.0 Hours ... ..... T263 TDC of compression stroke. Ensure crankshaft and camshaft pulleys
1 are at TDC, and install timing belt in sequence shown. See Fig. 2.
.3 hours. With Power Steering, add .3 hours. 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
NOTE: For information about tensioners and/or pulleys (when compression stroke. Loosen adjusting bolt 180 degrees, then retighten
available), see ALPHABETICAL MODEL LISTING. adjusting bolt. See Fig. 2. Adjust drive belts to proper tension.
at 90,000 miles for normal service or 60,000 miles for severe service.

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. Courtesy of American Honda Motor Co., Inc.
Remove crankshaft pulley. Remove timing belt covers. See Fig. 1. Fig. 2: Identifying TDC Marks, Timing Belt Adjusting Bolt &
3) If timing belt is being reused, mark direction of belt rotation before Installation Sequence
removing. Rotate crankshaft clockwise until No. 1 piston is at TDC of
compression stroke. See Fig. 2. TORQUE SPECIFICATIONS
4) Loosen timing belt adjusting bolt 180 degrees, and push tensioner to
remove tension from timing belt. Retighten adjusting bolt and remove
timing belt. 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)
Engine Mount Bolts ................................................................................................... 43 (59)
Idler Pulley Center Nut ............................................................................................. 33 (44)
INCH Lbs. (N.m)
Dipstick Bracket Bolts ................................................................................................. 84 (9)
Fig. 1: Removing & Installing Lower & Upper Timing Belt Covers
348 HONDA
3.0L & 3.5L V6
Kit No. Part No.
3.0L V6 (J30A1)
Accord
1998-00 .............................. 1 4.4 Hours .. . 2 TCK286 . ..... T286
2001-02 .............................. 1 4.4 Hours .. ...... ..... ...... ..... T286
2003-04 .............................. 1 4.0 Hours .. ...... ..... ...... ..... T329
3.5L V6 (J35A1 & J35A4)
Odyssey
1999-04 .............................. 1 4.0 Hours .. ...... ..... ...... ..... T286
Pilot
2003-04 ............................... 4.0 Hours ... ...... ..... ...... ..... T286
1
– With Cruise Control, add .3 hours.
2
– Timing component kit does not include camshaft tensioner
hydraulic assembly.
Fig. 1: Removing Crankshaft Pulley Bolt
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.
NOTE: For information about tensioners and/or pulleys (when (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.
MANUFACTURER’S SUGGESTED DO NOT grip auto-tensioner housing. Insert flat-bladed screwdriver into
maintenance hole. Place stopper on auto-tensioner while turning screw-
SCHEDULED MAINTENANCE driver clockwise to compress tensioner to bottom.
Normal replacement interval is at 105,000 miles or 84 months. Replace 4) Replace any oil that may have spilled out of auto-tensioner. Reinstall
at 60,000 miles if car is regularly driven in extreme temperatures (over maintenance bolt with NEW gasket. Ensure no oil is leaking around
110°F, or under –20°F). maintenance bolt, then reinstall auto-tensioner onto engine with stopper
in place.
NOTE: When compressing sealed auto-tensioners, compression

REMOVAL & INSTALLATION pressure should not exceed 2200 lbs. (9800 N).
CAUTION: The 3.0L is an interference engine. Do not rotate cam- 5) Place sealed auto-tensioner in press. SLOWLY compress tensioner
shaft or crankshaft when timing belt is removed, or engine damage until pin can be inserted through tensioner body, and insert pin. See
may occur. 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
TIMING BELT pulley. On all models, install timing belt in counterclockwise direction in
Removal – 1) Disconnect negative battery cable. Turn crankshaft pulley the following sequence: Crankshaft pulley, idler pulley, front camshaft
so that No. 1 piston is at TDC on compression stroke. White mark on pulley, water pump pulley, rear camshaft pulley and tension adjust
crankshaft pulley should align with pointer on front cover. Remove right pulley. See Fig. 7. Ensure crankshaft and camshaft pulleys remained
aligned with marks on back cover. Tighten idler pulley bolt to specifica-
front wheel, if necessary. Remove lower engine splash shield. Remove
the generator and power steering pump drive belts.
7) Remove stopper or pin from auto-tensioner. Remove battery clamp
2) Support engine with a jack and wood block under the oil pan. Remove
bolt from back cover. Install engine mount bracket to the front of engine
ground cable (if necessary), then remove engine side mount bracket.
(above water pump pulley). If removed, install timing belt guide plate
Remove dipstick tube from front of engine. Using Holder, remove with concave surface facing out. Install lower cover, then upper front and
crankshaft pulley. See Fig. 1. rear covers. Install crankshaft pulley. Lubricate crankshaft pulley bolt
3) Remove upper and lower timing belt covers. See Fig. 2. If reusing threads and install bolt. Tighten crankshaft pulley bolt to specification.
timing belt, mark direction of belt rotation for installation reference. See TORQUE SPECIFICATIONS.
4) Remove one of the battery clamp bolts from battery tray. Grind 8) Rotate crankshaft about 5-6 turns clockwise to position timing belt on
threaded end of bolt to a partial point (about 45 degree chamfer). Thread pulleys. Ensure crankshaft and camshaft pulleys are aligned at TDC.
battery bolt into rear cover to hold timing belt adjuster in installed Crankshaft pulley White mark should be aligned with pointer on front
position. Hand tighten ONLY. See Fig. 3. cover. Remove rubber plugs from upper covers to check camshaft pulley
5) Remove engine mount bracket from front of engine (above water positions.
pump pulley). On 2003-04 Accord and Pilot, remove idler pulley bolt and 9) If either camshaft is not at TDC, remove timing belt and readjust
idler pulley, then remove timing belt. On all other models, loosen timing position. To complete installation, reverse removal procedure. Tighten
belt idler pulley bolt 5-6 turns and remove timing belt. all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
Installation – 1) Ensure that engine is at TDC. Align dimple on timing drive belts to proper tension.
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.)
Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner

350 HONDA
3.0L & 3.5L V6 (Cont.)
Fig. 6: Compressing Auto-Tensioner (2000-03 Odyssey & Pilot)
Camshaft Sprocket Center Bolt 1 .............................................................................. 67 (90)
Courtesy of American Honda Motor Co., Inc. Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Engine Mount Bracket (Front)
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks 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)
INCH Lbs. (N.m)
Auto-Tensioner Mount Bolts .................................................................................... 106 (12)
Dipstick & Tube 4 ..................................................................................................... 106 (12)
Ground Cable Bolt .................................................................................................. 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)
Courtesy of American Honda Motor Co., Inc. 1
2
Fig. 5: Compressing Auto-Tensioner (Accord & 1999 Odyssey) – Tighten bolt to 106 INCH lbs. (12 N.m).
3
– Tighten these bolts first.
4
– Use a NEW “O” ring.
HONDA 351
3.2L V6 – DOHC
Part No.
3.2L V6
Passport
1998-02 ..................................................... 3.2 Hours ... ..... T303

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. Fig. 2: Aligning Crankshaft Timing Marks
REMOVAL & INSTALLATION 3) Align timing mark on left hand (driver side) camshaft sprocket with
alignment mark on valve cover. See Fig. 4. Route timing belt around
TIMING BELT water pump pulley and install on other left hand camshaft sprocket,
Removal – 1) Disconnect negative battery cable. Remove air cleaner aligning the White alignment mark on timing belt with camshaft sprocket
assembly. Remove upper fan shroud. Remove serpentine drive belt. mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack
2) Remove cooling fan and drive pulley. Remove serpentine drive belt in belt between camshaft pulleys.
idler pulley assembly. Remove serpentine drive belt tensioner assembly. 4) Install timing belt around idler pulley and tensioner pulley. Temporarily
3) Remove power steering pump with hoses attached, and set aside. install crankshaft pulley, and tighten center bolt by hand. Turn pulley
Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, clockwise slightly to give some belt slack between the crankshaft
remove crankshaft pulley. sprocket and right hand camshaft sprocket.
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
tensioner rod.
at TDC.
5) If reusing timing belt, mark belt with arrow to indicate original rotation 5) Holding tensioner upright, SLOWLY compress timing belt tensioner
direction. Also place mating marks on timing belt and camshaft sprock- rod until hole in top of rod and holes in housing are aligned. Install a
ets for reassembly reference. Remove timing belt tensioner, and set locking pin through the holes. See Fig. 5.
aside with push rod facing up. Remove timing belt. 6) Install tensioner on engine with locking pin in place. Tighten bolts to
CAUTION: To prevent air from entering timing belt tensioner, 7) Remove locking pin from timing belt tensioner. Remove clips from
tensioner rod must always face up. 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
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

Installation – 1) Align groove on crankshaft sprocket with mark on oil
dotted line on belt with timing mark on crankshaft pulley. Secure belt to
sprocket with spring clip. Courtesy of American Honda Motor Co., Inc.
2) Align timing mark on right hand (passenger side) camshaft sprocket Fig. 3: Installing Timing Belt On Right Hand 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.
352 HONDA

M8 Bolt .................................................................................................................... 16 (22)
M10 Bolt .................................................................................................................. 34 (46)
Water Pump Bolt ....................................................................................................... 18 (25)

HYUNDAI 353

TIMING BELT APPLICATION 7) Ensure belt cog will reach half the width of timing belt tensioner bolt
Application Labor Time Belt on slot-side of belt tensioner. Install crankshaft flange. Install timing belt
Part No. cover. To install remaining components, reverse removal procedure.
1.5L 4-Cyl. Adjust drive belts to proper tension.
Accent
1
1996-97 .................................................... 1.8 Hours .. ..... T282
1

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.

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 direc-
Courtesy of Hyundai Motor Co.
tion of rotation before removal.
2) Remove timing belt covers and gaskets, noting bolt length and Fig. 1: Aligning Timing Marks
location. Rotate crankshaft clockwise to align timing marks on crank-
shaft 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.
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. Fig. 2: Checking Timing Belt Tension
3) Apply counterclockwise force on camshaft sprocket to apply tension
on tension side of belt. Ensure all timing marks are aligned. See Fig. 1. TORQUE SPECIFICATIONS
CAUTION: Slot-side timing belt tensioner bolt must be tightened TORQUE SPECIFICATIONS
before pivot-side to prevent belt tensioner from rotating, causing Application Ft. Lbs. (N.m)
belt to be over-tightened. Camshaft Sprocket ........................................................................ ............... 59-74 (80-100)
4) Loosen timing belt tensioner bolts to place tension on timing belt. See Crankshaft Pulley-To-Sprocket Bolt ........................................................ 103-111 (140-150)
Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150)
Timing Belt Idler Pulley Bolt ......................................................... ................. 32-41 (43-55)
SPECIFICATIONS.
5) Smoothly rotate crankshaft clockwise for one full revolution. Realign
crankshaft and camshaft timing marks. Loosen pivot-side bolt and then INCH Lbs. (N.m)
slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specifi- Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
cation. See TORQUE SPECIFICATIONS. Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
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
354 HYUNDAI
Kit No. Part No.
1.5L 4-Cyl.
Accent
1
1995-99 ............................ ... 1.8 Hrs. ... .. TCK191 .. ..... T191
2
2000-02 ............................ ... 2.0 Hrs. ... ...... ..... ...... ..... T324
Excel
1
1986-89 ............................ ... 2.2 Hrs. ... .. TCK073 .. ..... T073
1
1990-94 ............................ ... 2.2 Hrs. ... .. TCK128 .. ..... T128
Scoupe
1
1991-93 ............................ ... 2.2 Hrs. ... .. TCK128 .. ..... T128
1
1994-95 ............................ ... 2.2 Hrs. ... .. TCK191 .. ..... T191
1
2
– With Air conditioning, add .2 hour (1995-99) or .3 hour
(2000-02). With Power Steering, add .2 hour.


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.

damage may occur.
TIMING BELT
Removal – 1) Remove all accessory drive belts. Remove pulleys from Courtesy of Hyundai Motor Co.
crankshaft and water pump. Fig. 2: Locating Camshaft & Crankshaft Sprocket Marks
CAUTION: DO NOT rotate engine counterclockwise. If reusing

timing belt, place reference mark on timing belt to indicate direc- CAUTION: Slot-side timing belt tensioner bolt must be tightened
tion of rotation before removal. before pivot-side to prevent belt tensioner from rotating, causing
belt to be over-tightened.
2) Remove timing belt covers and gaskets, noting bolt length and
4) Loosen timing belt tensioner bolts to place tension on timing belt. See
Fig. 3. Tighten timing belt tensioner bolts to specification. See TORQUE
shaft and camshaft sprockets. See Figs. 1 and 2.
SPECIFICATIONS.
rotation. Move tensioner inward toward water pump, and temporarily
crankshaft and camshaft timing marks. Loosen pivot-side bolt, and then
tighten bolt in slotted side of tensioner. Remove timing belt. slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specifi-
Inspection – Check timing belt for cracks, cracked or missing teeth, and cation. See TORQUE SPECIFICATIONS.
separating canvas. Inspect timing belt tensioner for worn bearing. 6) To check belt tension, hold belt tensioner and timing belt together and
Installation – 1) Ensure camshaft and crankshaft timing marks are still apply slight thumb pressure (about 11 lbs.) at center point of belt
aligned. See Figs. 1 and 2. Move timing belt tensioner toward water tensioner. See Fig. 3.
pump and tighten bolt. 7) Ensure belt cog will reach half the width of timing belt tensioner bolt
2) Install timing belt on crankshaft and camshaft sprockets. Make sure on slot-side of belt tensioner. Install timing belt cover. To install remain-
there is no slack in belt. If reusing old belt, ensure belt is installed in ing components, reverse removal procedure. Adjust drive belts to proper
original direction of rotation. tension.
on tension side of belt. Ensure all timing marks are aligned. See Figs. 1
and 2.
HYUNDAI 355

Camshaft Sprocket ........................................................................ ............... 59-74 (80-100)
Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150)
INCH Lbs. (N.m)
Water Pump Pulley Bolt ................................................................ ............. 106-133 (12-15)

356 HYUNDAI
1.6L 4-Cylinder – DOHC – 2001-04
Part No.
1.6L 4-Cyl.
Accent
1
2001-04 .................................................... 2.0 Hours .. ..... T282
1

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.

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. Courtesy of Hyundai Motor Co.
CAUTION: DO NOT rotate engine counterclockwise. If reusing Fig. 1: Aligning Timing Marks
timing belt, place reference mark on timing belt to indicate direc-
tion of rotation before removal.
2) Remove timing belt covers and gaskets, noting bolt length and
shaft and camshaft sprockets. See Fig. 1.
rotation. Loosen timing belt tensioner bolts, and move tensioner inward
toward water pump. Temporarily tighten bolt in slotted side of tensioner.
Remove timing belt.
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. Fig. 2: Checking Timing Belt Tension
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 TORQUE SPECIFICATIONS
on tension side of belt. Ensure all timing marks are aligned. See Fig. 1. Application Ft. Lbs. (N.m)
Camshaft Sprocket ........................................................................ ............... 59-74 (80-100)
CAUTION: Slot-side timing belt tensioner bolt must be tightened Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150)
before pivot-side to prevent belt tensioner from rotating, causing Timing Belt Idler Pulley Bolt ......................................................... ................. 32-41 (43-55)
belt to be overtightened. Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27)
4) Loosen timing belt tensioner bolts to place tension on timing belt. See INCH Lbs. (N.m)
Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
SPECIFICATIONS. Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
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.
HYUNDAI 357
1.6L & 1.8L 4-Cylinder – DOHC – 1992-95

TIMING BELT APPLICATION Compressing Automatic Tensioner – 1) Check if plug at bottom of
Application Labor Time Component Belt tensioner protrudes past tensioner housing. If plug protrudes past
Kit No. Part No. housing, place a washer over plug to prevent plug from contacting vise
1.6L 4-Cyl. – DOHC when pushing rod into tensioner housing. Place tensioner assembly in a
Elantra soft-jawed vise.
1992 ................................. ... 1 3.0 Hrs. ... .. TCK165 .. ..... T165 2) SLOWLY squeeze rod back into automatic tensioner. Replace
1993-95 tensioner if rod can be retracted easily into automatic tensioner. Align
Balance Shaft ............... .......... 2 .......... .. TCK165 .. ..... T168 holes in rod and automatic tensioner body. See Fig. 4. Insert drill bit or
pin through holes to retain rod in retracted position.
Elantra
NOTE: If right (viewed from rear of engine) balance shaft sprocket
1993-95
Balance Shaft ............... .......... 2 .......... .. TCK167 .. ..... T168 was removed, ensure right balance shaft spacer is installed with
Camshaft ....................... ... 1 3.0 Hrs. ... .. TCK167 .. ..... T167 chamfer toward engine. Before installation, apply light coat of
1 engine oil to spacer.
With Power Steering, add .3 hours. Installation (Balance Shaft Belt) – 1) Ensure crankshaft sprocket and
2
– Balance shaft belt included in camshaft belt labor time. right side balance shaft sprocket timing marks are aligned with marks on
NOTE: A timing belt component kit is available for this application. oil pump housing. See Fig. 5. Install balance shaft belt. If removed,
See page A1 for information on component kits. install balance shaft tensioner pulley and center bolt.
2) Install balance shaft belt (timing belt “B”). No slack should be present
NOTE: For information about tensioners and/or pulleys (when in belt. Lift tensioner toward belt so that large part of center eccentric is
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED Check belt tension by applying finger pressure to side of belt opposite
SCHEDULED MAINTENANCE tensioner. See Fig. 6. Deflection should be .20-.28″ (5-7 mm). If not,
The manufacturer recommends the belt be replaced every 60,000 miles. readjust belt tension.
4) Install crankshaft flange and outer sprocket. Install flange in correct
REMOVAL & INSTALLATION direction to prevent damage to timing belt. See Fig. 7.
Installation (Camshaft Timing Belt) – 1) If crankshaft sprocket was
CAUTION: This application is an interference engine. Do not rotate removed, ensure sprocket, spacer and flange are installed correctly.
camshaft or crankshaft when timing belt is removed, or engine See Fig. 8.
damage may occur. 2) Remove automatic tensioner from vise, and install onto engine with
wire in place. Install tensioner arm. Position tensioner pulley so that pin
TIMING BELT holes are left of center bolt. See Fig. 9. Temporarily tighten camshaft
Removal – 1) Remove cover from under engine (if equipped). Support tension pulley center bolt.
engine weight with floor jack. Remove engine mount located near timing
belt cover. Remove all accessory drive belts. Remove water pump CAUTION: The same camshaft sprocket is used on intake and
pulley and crankshaft pulley. Remove timing belt covers and gaskets, exhaust camshafts. Each has two timing marks. Both camshaft
noting bolt lengths and locations. sprockets are positioned correctly when the center dowel pin holes
face up (12 o’clock position).
from timing belt end of engine). If reusing timing belt, place 3) Rotate camshaft sprockets so dowel pins face up and timing marks on
reference mark on timing belt to indicate direction of rotation sprockets align. See Fig. 2. Inner marks on sprockets should be aligned
before removing. with cylinder head surface. When exhaust camshaft sprocket is
released, camshaft will rotate one tooth in counterclockwise direction.
2) Rotate engine clockwise to align all timing marks so No. 1 cylinder is When installing timing belt, compensate for rotation.
at TDC of compression stroke. See Fig. 2. Remove automatic tensioner. 4) Rotate crankshaft, and align timing marks on crankshaft and oil pump
Place mark on timing belt to indicate direction of belt rotation. Remove sprockets. If installing old timing belt, ensure it is installed in original
timing belt. direction of rotation.
3) On models equipped with balance shaft, remove outer crankshaft 5) Install timing belt on tensioner pulley and crankshaft sprocket. Hold
sprocket. See Fig. 1. Align oil pump sprocket timing mark with mark on belt in place using left hand. Pull belt around oil pump sprocket using
oil pump case. See Fig. 2. right hand. Pull belt around idler pulley.
6) Install timing belt around intake camshaft sprocket. Ensure exhaust
CAUTION: Leave screwdriver inserted in block until timing belt is
timing mark on camshaft sprocket aligns with cylinder head surface. See
installed. This will lock left side balance shaft in correct position.
Fig. 2. Using both hands, install timing belt around exhaust camshaft
4) Remove plug at left side of cylinder block. See Fig. 3. Insert sprocket.
screwdriver to hold left balance shaft in place. Screwdriver should insert 7) Rotate tensioner pulley in toward timing belt until belt does not sag.
at least 2.4″ (60 mm) into hole. If not, rotate oil pump sprocket one full Temporarily tighten center bolt on tensioner pulley. Ensure all timing
turn and align timing mark. Ensure screwdriver inserts correct amount. marks are still aligned.
5) Loosen balance belt tensioner bolt. Remove balance belt. 8) To adjust camshaft belt tension, rotate crankshaft 1/4 turn counter-
Inspection – 1) Check belt teeth for cracks, damage and oil contami- clockwise, and then rotate until No. 1 cylinder is at TDC. Loosen center
nation. Inspect all sprockets for damage. Check tensioner pulley and bolt on camshaft belt tensioner pulley.
idler pulley for grease leakage and roughness in rotation. Replace 9) Install Socket Wrench (MD998752) into pin holes offset to left center
components if damaged. of pulley. See Fig. 10. Using INCH-lb. torque wrench and socket wrench,
2) Check end of automatic tensioner rod for wear. Measure distance apply a clockwise torque of 23-25 INCH lbs. (2.6-2.8 N.m) on tensioner
from end of automatic tensioner rod to top of automatic tensioner pulley. With torque applied to tensioner pulley, tighten tensioner pulley
housing. Distance should be .47″ (12 mm). If out of specification, replace center bolt to 31-40 ft. lbs. (42-54 N.m). DO NOT allow pulley to rotate
automatic tensioner. while tightening center bolt.
358 HYUNDAI
1.6L & 1.8L 4-Cylinder – DOHC – 1992-95 (Cont.)
12) If engine is in vehicle or distance cannot be measured due to lack of
NOTE: If engine is in vehicle, it may be necessary during tensioner clearance, an alternate method can be used. Install Set Screw
pulley adjustment to jack up engine slightly for clearance. (09244-28000) until it contacts tensioner arm.
13) Turn set screw inward, counting number of turns until tensioner arm
10) Install Set Screw (09244-28000) or equivalent, in left engine support
contacts automatic tensioner housing. Set screw should rotate 2 1/2-3
bracket until screw end contacts tensioner arm. See Fig. 11. Turn set
turns inward if belt tension is correct. Repeat timing belt tensioning
screw further until wire can be removed from automatic tensioner.
procedure until correct distance is obtained. Remove set screw.
Remove set screw.
14) Install rubber plug in rear timing belt cover. To complete installation,
11) Rotate crankshaft clockwise 2 complete revolutions, and leave in
reverse removal procedure. Ensure timing belt cover bolts are installed
this position for approximately 15 minutes. After 15 minutes, measure
in proper location. See Fig. 13. Adjust drive belts to proper tension.
distance between bottom of tensioner arm and top of automatic ten-
sioner 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 dis-
tance can be measured, go to step 14). If correct distance CANNOT be
measured, go to next step.
Fig. 1: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)
HYUNDAI 359
Fig. 5: Aligning Crankshaft & Balance Shaft Sprockets
Fig. 6: Checking Balance Shaft Tension Pulley Alignment
Fig. 3: Holding Silent Shaft In Stationary Position
Fig. 7: Installing Flange & Crankshaft Sprocket

(Engines With Balance Shaft Belt)
Fig. 4: Retracting Automatic Tensioner Rod
Fig. 8: Installing Flange & Crankshaft Sprocket

(Engines Without Balance Shaft Belt)
360 HYUNDAI
Fig. 9: Installing Tensioner Pulley
Fig. 10: Adjusting Camshaft Belt Tension Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27)
Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100)
Crankshaft Sprocket Center Bolt ................................................................ 80-94 (110-130)
Front Cover Bolt
8 x 30 mm Bolt ........................................................................... ................. 20-26 (27-35)
Except 8 x 30 mm Bolt ............................................................... ................. 14-20 (19-27)
Timing Belt Cover
Left Lower Rear .......................................................................... ................. 22-30 (30-42)
Except Left Lower Rear .............................................................. ..................................... 1
1
Courtesy of Hyundai Motor Co. – Tighten to 89-106 INCH lbs. (10-12 N.m).
Fig. 11: Removing Timing Belt Automatic Tensioner Lock Wire
Fig. 12: Measuring Timing Belt Tensioner Protrusion

HYUNDAI 361

DOHC – 1996-04 (Except Sonata & 2004 Elantra)
TIMING BELT APPLICATION Inspection – Check belt teeth for cracks, damage, and oil contamina-
Application Labor Time Component Belt tion. Inspect all sprockets for damage. Check tensioner pulley and idler
Kit No. Part No. pulley for grease leakage and worn bearings. Replace components if
1.8L 4-Cyl. – DOHC damaged.
Elantra Installation – 1) Ensure camshaft and crankshaft timing marks are still
1996-98 .............................. 1 2.4 Hours .. .. TCK278 .. ..... T278 aligned. Outer marks on sprockets should be aligned with rocker cover
Tiburon surface. Verify timing chain timing mark alignment, if necessary. See
1997 ................................... 1 2.4 Hours .. .. TCK278 .. ..... T278 Fig. 2. Install timing belt tensioner pulley. Install timing belt. If reusing old
2.0L 4-Cyl. – DOHC belt, ensure belt is installed in original direction of rotation.
Elantra 2) Loosen timing belt tensioner bolt, allowing tensioner pulley to contact
1999-01 ............................... 2.8 Hours ... .. TCK284 .. ..... T284 belt. Tighten timing belt tensioner pulley bolt. Rotate crankshaft one turn
2002-03 ............................... 2.8 Hours ... ...... ..... ...... ..... T284 clockwise. Realign camshaft and crankshaft timing marks.
Tiburon
3) Adjust timing belt tension until .15-.24″ (4-6 mm) deflection is present
1997 .................................... 3.0 Hours ... ...... ..... ...... ..... T284
midway between idler pulley and camshaft sprocket, with a force of 4.4
1998-01 ............................... 3.0 Hours ... .. TCK284 .. ..... T284
2003-04 ............................... 3.0 Hours ... ...... ..... ...... ..... T284 lbs. (2 kg) applied to belt.
1
4) Rotate engine clockwise 2 revolutions. Ensure timing marks are still
– With Air Conditioning, add .2 hours. aligned and proper belt tension still exists. Install timing belt covers.
Install crankshaft pulley. To complete installation, reverse removal
NOTE: A timing belt component kit is available for this application. procedure. Adjust drive belt to proper tension.

The manufacturer requires that the belt be replaced every 60,000 miles,
except in California. In California, timing belt replacement is recom- Courtesy of Hyundai Motor Co.
mended, but not required at 60,000 miles. Fig. 2: Aligning Timing Chain Marks
REMOVAL & INSTALLATION TECHNICAL SERVICE BULLETIN

TIMING BELT NOISE: FRONT CASE
CAUTION: This application is an interference engine. Do not rotate Description – Some 1999-00 Elantras and Tiburons produced before
camshaft or crankshaft when timing belt is removed, or engine Sept. 22, 1999 may exhibit an unusual noise at the front of the engine.
damage may occur. The noise may be caused by the timing belt rubbing against the front of
the engine. Some timing belt idler pulley mounting surfaces were
TIMING BELT machined incorrectly. This can cause the timing belt to ride off of the
timing belt sprockets and into the front cover.
NOTE: On some models, engine is equipped with a timing belt and
Service Procedure – If this condition exists, the forward edge of the
timing chain. Inspect timing chain when replacing timing belt.
timing belt will shredded and the inside of the upper timing belt cover will
Removal – 1) Remove all drive belts and drive pulleys from crankshaft be worn. Replace the front case, idler pulley, timing belt and any other
and water pump. Remove generator bolt, if necessary. Remove crank- damaged components.
shaft pulley and water pump pulley.
2) Remove timing belt covers and gaskets, noting bolt lengths and NOTE: This information is from the Hyundai technical service
locations. DO NOT rotate engine counterclockwise, as viewed from bulletin 00-20-002-1; May, 2000.
timing belt side of engine. Remove timing belt tensioner pulley.
3) Rotate engine clockwise to align all timing marks so No. 1 cylinder is TORQUE SPECIFICATIONS
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.
Camshaft Sprocket Bolt ................................................................ ............. 74-89 (100-120)
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)
Water Pump Bolt
1996-97 ............................................................................................................ 9-11 (12-15)
1998-04 ........................................................................................ ................. 14-20 (20-27)
INCH Lbs. (N.m)

362 HYUNDAI
2.0L 4-Cylinder – DOHC – Elantra
TIMING BELT APPLICATION • Remove the PCV hose and breather hose. See Fig. 15.
Application Labor Time Belt • Remove the cylinder head cover. See Fig. 16.
Part No.
2.0L 4-Cyl. – DOHC CAUTION: Be careful not to damage the cylinder head and valve
Elantra lifter with the wrench.
1
2004 .......................................................... 2.4 Hours .. ..... T284
19) Hold the hexagonal head wrench portion of the camshaft with a
1
– With Air Conditioning, add .4 hours. wrench, and remove the bolt and camshaft sprocket. See Fig. 17.
Inspection – Check belt teeth for cracks, damage, and oil contamina-
tion. Inspect all sprockets for damage. Check tensioner pulley and idler
pulley for grease leakage and worn bearings. Replace components if
damaged.
MANUFACTURER’S SUGGESTED Installation – 1) Install the camshaft sprocket and tighten the bolt to
specification. See TORQUE SPECIFICATIONS. Temporarily install the
SCHEDULED MAINTENANCE camshaft sprocket bolt. Hold the hexagonal head wrench portion of the
The manufacturer requires that the belt be replaced every 60,000 miles, camshaft with a wrench, and tighten the camshaft sprocket bolt. See
except in California. In California, timing belt replacement is recom- Fig. 17.
mended, but not required at 60,000 miles. 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
REMOVAL & INSTALLATION head cover. See Fig. 14. Install the spark plug cable.
3) Install the crankshaft sprocket. See Fig. 13.
CAUTION: This application is an interference engine. Do not rotate 4) Align the timing marks of the camshaft sprocket and crankshaft
camshaft or crankshaft when timing belt is removed, or engine sprocket with the No. 1 piston placed at top dead center and its
damage may occur. 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.
TIMING BELT 6) Temporarily install the timing belt tensioner with plain washer. See
Fig. 20.
NOTE: On some models, engine is equipped with a timing belt and
7) Install belt so as not to give slack at each center of shaft. Install timing
timing chain. Inspect timing chain when replacing timing belt.
belt starting with crankshaft sprocket, idler pulley, camshaft sprocket to
Removal – 1) Remove the engine cover. See Fig. 1. timing belt tensioner. See Fig. 21.
2) Remove right front wheel. 8) Temporarily fasten tensioner pulley by center bolt to add force at belt.
3) Remove right side cover. See Fig. 2. 9) Adjust timing belt tension:
• Rotate crankshaft in regular direction (clock wise view from front)
NOTE: Place wooden block between the jack and engine oil pan.
through angle equivalent to two teeth (18°) of camshaft sprocket.
4) Set the jack to the engine oil pan. Remove the engine mount bracket. See Fig. 22.
See Fig. 3. Remove the stay plate. See Fig. 4. • Give tension to timing belt by rotating tensioner in arrow direction
5) Temporarily loosen the water pump pulley bolts. with tool and set timing belt not to give slack to tension side.
6) Remove alternator belt. • Tighten tensioner bolt.
7) Remove air compressor belt. • Recheck the belt tension. See Fig. 23. When the tension side of
8) Remove power steering belt. timing belt is pushed horizontally with a moderate force, 5 ft. lbs. (20
9) Remove water pump pulley. N.m). The timing belt cog end sags in 0.16-0.24″ (4-6 mm).
10) Remove timing belt upper cover. See Fig. 5. 10) Turn the crankshaft two turns in the operating direction (clockwise)
11) Turn the crankshaft pulley, and align its groove with timing mark “T” and realign crankshaft sprocket and camshaft sprocket timing mark.
on the timing belt cover. See Fig. 6. 11) Install the timing belt lower cover. See Fig. 9. See TORQUE
12) Remove the crankshaft pulley bolt and crankshaft pulley. See Fig. 7. SPECIFICATIONS.
13) Remove the crankshaft flange. See Fig. 8. 12) Install the flange and crankshaft pulley. See Fig. 7. See TORQUE
14) Remove the timing belt lower cover. See Fig. 9. SPECIFICATIONS. Make sure that crankshaft sprocket pin fits the small
hole in the pulley.
NOTE: If the timing belt is reused, make an arrow indicating the
13) Install the timing belt upper cover. See Fig. 5.
turning direction to make sure that the belt is reinstalled in the
14) Install the coolant pump pulley.
same direction as before.
15) Install power steering belt.
15) Remove the timing belt tensioner and timing belt. See Figs. 10 16) Install air compressor bolt.
and 11. 17) Install alternator belt.
16) Remove the bolt and timing belt idler. See Fig. 12. 18) Install the stay plate. See Fig. 4. See TORQUE SPECIFICATIONS.
17) Remove the crankshaft sprocket. See Fig. 13. Install engine mount bracket. See Fig. 3. See TORQUE SPECIFICA-
18) Remove the cylinder head cover: TIONS.
• Remove the spark plug cable. 19) Install right side cover. See Fig. 2.
• Remove the accelerator cable from the cylinder head cover. See 20) Install right front wheel.
Fig. 14. 21) Install engine cover. See Fig. 1.
HYUNDAI 363
2.0L 4-Cylinder – DOHC – Elantra (Cont.)
Fig. 4: Removing & Installing Stay Plate
Fig. 1: Removing & Installing Engine Cover
Fig. 5: Removing & Installing Timing Belt Upper Cover
Fig. 2: Removing & Installing Side Cover
Fig. 6: Identifying Timing Marks

Fig. 3: Removing & Installing Engine Mount Bracket

364 HYUNDAI
Fig. 7: Removing & Installing Crankshaft Pulley

Fig. 10: Removing Timing Belt Tensioner
Fig. 8: Removing Crankshaft Flange
Fig. 11: Removing Timing Belt
Fig. 9: Removing & Installing Timing Belt Lower Cover

Fig. 12: Removing & Installing Timing Belt Idler

HYUNDAI 365
Fig. 13: Removing & Installing Crankshaft Sprocket
Fig. 16: Removing & Installing Cylinder Head Cover
Fig. 14: Removing & Installing Accelerator Cable
Fig. 17: Removing & Installing Camshaft Sprocket
Fig. 15: Locating PCV Hose & Breather Hose

366 HYUNDAI
Fig. 18: Locating Camshaft Sprocket Timing Marks
Fig. 19: Locating Crankshaft Sprocket Timing Marks
Fig. 21: Locating Timing Belt Components

HYUNDAI 367

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)
Water Pump Bolt ........................................................................... ................. 14-20 (20-27)
INCH Lbs. (N.m)
Fig. 22: Adjusting Camshaft Sprocket Water Pump Pulley Bolt ................................................................ ................... 71-86 (8-10)

368 HYUNDAI
2.0L 4-Cylinder – Sonata
TIMING BELT APPLICATION 5) Replace automatic tensioner assembly if rod can be easily pushed
Application Labor Time Component Belt into automatic tensioner. While automatic tensioner is in vise, align holes
Kit No. Part No. in end of tensioner rod and housing. Install pin through holes to lock
2.0L 4-Cyl. – DOHC tensioner in position.
Sonata Installation – 1) Align timing marks on balance shaft sprockets with
1992-98 timing marks on engine case. Install balance shaft timing belt and
Balance Shaft ............... .......... 1 .......... .. TCK167 .. ..... T168 crankshaft flange. Install crankshaft flange in correct direction. See
Camshaft ......................... 2 3.8 Hours .. .. TCK167 .. ..... T167 Fig. 5.
1
– Balance shaft belt included in camshaft belt labor time. 2) Position balance shaft tensioner so that the center of the pulley is to
2
– With Air Conditioning, add .4 hours. the left and above the tensioner bolt. See Hold tensioner tightly against
belt. Tighten tensioner pulley bolt without letting tensioner rotate.
NOTE: A timing belt component kit is available for this application. 3) To check balance shaft belt tension, depress belt with finger midway
See page A1 for information on component kits. between sprockets (opposite tensioner pulley). Deflection should be
between .20-.29″ (57 mm). If not, readjust belt tension.
NOTE: For information about tensioners and/or pulleys (when 4) Place crankshaft sprocket on crankshaft. Tighten bolt to specification.
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED block with rod locked in place.
SCHEDULED MAINTENANCE 6) Rotate camshaft sprockets so dowel pins face upward and timing
marks on sprockets align. See Fig. 1. Outer marks on sprockets should
The manufacturer recommends the belt be replaced every 60,000 miles,
be aligned with cylinder head surface.
except in California. In California, timing belt replacement is recom-
mended, but not required at 60,000 miles. NOTE: The same camshaft sprockets are installed on intake and
exhaust camshafts. Timing marks are correctly aligned when
REMOVAL & INSTALLATION dowel pin holes are facing straight up.
CAUTION: This application is an interference engine. Do not rotate 7) Align crankshaft sprocket timing marks and oil pump sprocket timing
camshaft or crankshaft when timing belt is removed, or engine marks. See Fig. 1. Install timing belt around tensioner pulley and
damage may occur. 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
TIMING BELT sprocket with top of cylinder head. Pulling belt with both hands, install it
Removal – 1) Remove all drive belts. Remove crankshaft pulley and around exhaust camshaft sprocket.
water pump pulley. Remove upper and lower timing belt covers, noting 9) Gently raise tensioner pulley so belt does not sag. Position timing belt
bolt lengths and locations. tensioner pin holes so that they face up. Temporarily tighten center bolt.
2) Turn crankshaft clockwise and align timing marks so No. 1 cylinder is See Fig. 6.
at TDC. Timing marks on camshaft sprockets should be aligned at upper 10) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise,
surface of cylinder head. See Fig. 1. Camshaft sprocket dowel pins and then rotate clockwise until No. 1 cylinder is at TDC. Ensure all timing
should face upward. marks are aligned.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed 11) Loosen center bolt on tensioner pulley. Note location of pin holes in
from timing belt end of engine). If reusing timing belt, mark tensioner pulley.
direction of belt rotation before removing. 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
3) Remove timing belt automatic tensioner. See Fig. 2. Mark timing belt torque applied to tensioner pulley, tighten tensioner pulley center bolt to
to indicate original direction of rotation. Remove timing belt. specification. See Fig. 7. See TORQUE SPECIFICATIONS.
4) Remove balance shaft access plug from cylinder block. Insert Phillips 13) Install Set Screw (09244-28000), or equivalent, in left engine
screwdriver to block left balance shaft. See Fig. 3. Balance shaft is support bracket until set screw end contacts tensioner arm. Rotate set
correctly locked in place if screwdriver can be inserted at least 2.36″ (60 screw further until locking pin can be removed from automatic tensioner.
mm). If not, rotate oil pump sprocket so screwdriver can be inserted to See Fig. 6. Remove set screw.
correct depth. 14) Rotate crankshaft clockwise 2 complete revolutions. Allow engine to
5) Loosen balance shaft belt tensioner bolt. Remove front crankshaft sit in this position for about 15 minutes. Measure distance between
sprocket and flange. Remove balance shaft timing belt. tensioner arm and automatic tensioner body. Distance should be
Inspection – 1) Check belt teeth for damage and oil contamination. .15-.18″ (3.8-4.5 mm). See Fig. 8, Dimension “A”. If distance is incorrect,
Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is repeat timing belt tensioning procedure. If distance is okay, go to
not cracked, separated or showing canvas fiber. step 17).
2) Inspect all sprockets for damage. Check tensioner pulley and idler 15) If distance between automatic tensioner and tensioner arm cannot
pulley for grease leakage and roughness in rotation. Replace compo- be measured easily, use this alternate method. Install Set Screw
nents if damaged. (09244-28000) until it contacts tensioner arm.
3) Inspect automatic tensioner for leaks. Check rod end of automatic 16) Rotate set screw inward while counting number of turns until
tensioner for wear. Measure distance from tensioner rod end to ten- tensioner arm contacts automatic tensioner housing. Turn set screw 2
sioner housing. Distance should be .47″ (12 mm). If not, replace 1/2-3 turns to correctly tension belt. Remove set screw.
automatic tensioner. 17) Install rubber plug in rear timing belt cover. Install timing belt covers.
Install timing belt cover bolts in correct locations. See Fig. 9.
NOTE: If plug at bottom of tensioner protrudes past tensioner
18) To complete installation, reverse removal procedure. Apply sealant
housing, place a washer over plug to prevent contacting vise when
to contact areas on semi-circular packing and rocker cover before
pushing rod into tensioner housing.
installing. Ensure correct bolts are installed in proper location in timing
4) Retract rod into tensioner housing by placing automatic tensioner belt covers. Adjust drive belts to proper tension.
assembly in a soft-jawed vise. Close vise SLOWLY to push rod back into
HYUNDAI 369
2.0L 4-Cylinder – Sonata (Cont.)
Fig. 2: Exploded View Of Timing Belt & Courtesy of Hyundai Motor Co.
Related Components Fig. 3: Locking Left Balance Shaft In Place
370 HYUNDAI
2.0L 4-Cylinder – Sonata (Cont.)

Fig. 4: Retracting Automatic Tensioner Rod
Fig. 5: Installing Crankshaft Flange
Automatic Tensioner Bolt .............................................................. ................. 15-20 (20-27)
Balance Shaft Sprocket Bolt ......................................................... ................. 32-36 (43-49)
Fig. 6: Tensioning Camshaft Timing Belt Balance Shaft Tensioner Retaining Bolt ......................................................... 11-16 (15-22)
Crankshaft Sprocket Center Bolt ................................................................ 81-96 (110-130)
Front Tensioner Pulley Bolt ........................................................... ................. 32-41 (43-55)
Oil Pump Sprocket Nut ................................................................. ................. 37-44 (50-60)
Water Pump Mounting Bolt ............................................................................... 9-11 (12-15)
INCH Lbs. (N.m)
Fig. 7: Adjusting Timing Belt Tensioner Pulley

HYUNDAI 371

Part No.
Sonata
1999-03
Balance Shaft Belt ................................ 1 3.0 Hours .. ..... T314
Camshaft Belt ........................................ 2.4 Hours ... ..... T313
Santa Fe
2001-04
Balance Shaft Belt ................................ 1 3.1 Hours .. ..... T314
1
– Includes camshaft belt.

except in California. In California, inspect timing belt at 60,000 miles,
and replace as necessary.
REMOVAL & INSTALLATION Fig. 1: Identifying Timing Belt Alignment Marks

damage may occur.
TIMING & COUNTERBALANCE SHAFT BELTS

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.
nation. Inspect sprockets for damage. Check tensioner pulley and idler
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 Courtesy of Hyundai Motor Co.
easily pushed in with light vise pressure, replace auto tensioner.
Installation – 1) Install crankshaft sprocket “B” onto crankshaft. Ensure Fig. 2: Exploded View Of Timing Belt & Components
flange is properly positioned. Lightly oil outer surface of spacer, and then 3) When installing timing belt “B”, ensure there is no slack in tension
install spacer onto right counterbalance shaft, with rounded edge of side. Install tensioner “B” in center of pulley of left side of mounting bolt,
spacer inward. and in pulley flange toward front of engine. See Fig. 3. Align timing mark
2) Install counterbalance shaft sprocket. Tighten flange bolt tightly by of right counterbalance shaft sprocket with timing mark on front case.
hand. Align timing marks on each sprocket and on front case.
372 HYUNDAI
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
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 SPECIFICA- Courtesy of Hyundai Motor Co.
TIONS. Fig. 4: Measuring Auto Tensioner Protrusion
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 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 tempo-
rarily 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 Courtesy of Hyundai Motor Co.
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. Fig. 5: Identifying Timing Belt Cover Bolts
(Santa Fe & 2002-03 Sonata)
Fig. 3: Installing Tensioner “B”

HYUNDAI 373

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)
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)
INCH Lbs. (N.m)
Fig. 6: Identifying Timing Belt Cover Bolts (1999-01 Sonata) Valve Cover Bolts .......................................................................... ................... 71-89 (8-10)
1
– Tighten to 71-89 INCH lbs. (8-10 N.m).
2
374 HYUNDAI
2.4L 4-Cyl. – SOHC camshaft or crankshaft when timing belt is removed, or engine
Sonata damage may occur.
1989-91
Camshaft ......................... 2 2.7 Hours .. .. TCK124 .. ..... T124 TIMING BELT
1
– Balance Shaft Belt included in Camshaft Belt labor time. Removal – 1) Disconnect negative battery cable. Remove all drive belts
2
– With Air Conditioning, add .4 hours. and crankshaft pulley. Remove upper timing belt cover and gasket.
Remove timing belt lower cover and gasket, noting bolt lengths and
NOTE: A timing belt component kit is available for this application. locations. See Fig. 1.
See page A1 for information on component kits. 2) Remove crankshaft sprocket bolt access cover. Remove crankshaft
sprocket bolt and washer. Rotate engine clockwise to align timing mark
NOTE: For information about tensioners and/or pulleys (when on camshaft sprocket with mark on cylinder head. See Fig. 2. Loosen
available), see ALPHABETICAL MODEL LISTING. front timing belt tensioner adjustment bolt, and move tensioner toward
water pump.
3) Tighten bolt to secure tensioner. Remove front timing belt. Remove
MANUFACTURER’S SUGGESTED camshaft sprocket. Remove oil pump sprocket access plug from cylin-
SCHEDULED MAINTENANCE der block. Insert 8-mm Phillips screwdriver to block left silent (counter-
balance) 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.

HYUNDAI 375
Fig. 4: Positioning Timing Belt Crankshaft Flange
Fig. 2: Aligning Front Timing Belt
Fig. 5: Aligning Rear Timing Belt Marks

Fig. 3: Blocking Left Silent Shaft
Inspection – Check belt teeth for cracks, damage or oil contamination. Application Ft. Lbs. (N.m)
Inspect all sprockets for damage. Check belt tensioner for damage.
Check belt tensioner for signs of grease leakage or roughness in Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
tensioner rotation. Replace components if damaged. Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30)
Installation – 1) Install rear timing belt gear on crankshaft. Install spacer Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
to right silent shaft with chamfer of spacer facing toward engine block. Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Properly install flange on crankshaft. See Fig. 4. Install rear belt and Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
align rear belt marks. See Fig. 5. Install crankshaft gear, camshaft timing Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
belt, washer and bolt. Align timing marks. See Fig. 2. INCH Lbs. (N.m)
2) Install rear tensioner. Hold tensioner tight against belt while tightening Crank Angle Sensor Nut ............................................................... ................. 84-108 (9-12)
bolts. Depress belt with finger to ensure deflection is between .20-30” Timing Belt Cover Bolt
(5-7 mm). Install camshaft and oil pump sprocket (if removed). Tighten Left Lower Rear Cover Bolt ........................................................ ..................... 44-61 (5-7)
camshaft sprocket retaining bolt to specification while holding hexagon All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12)
area of camshaft. See TORQUE SPECIFICATIONS. Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)
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
tension.
376 HYUNDAI
3.0L V6
Kit No. Part No.
3.0L V6
Sonata
1
1990-98 ............................ ... 3.1 Hrs. ... .. TCK139 .. ..... T139
1



Fig. 1: Identifying Engine Support Loosening & Tightening
SCHEDULED MAINTENANCE Sequence
The manufacturer requires the belt be replaced every 60,000 miles,
except for 1998 California vehicles. For 1998 California vehicles, timing
separating canvas. Inspect timing belt tensioner for worn bearing.
belt replacement is recommended, but not required at 60,000 miles.
Installation – 1) Align camshaft and crankshaft timing marks. See
Fig. 3. If tensioner spring has been removed, install spring on tensioner
REMOVAL & INSTALLATION 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
damage may occur. 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.
TIMING BELT 4) Loosen tensioner bolt, allowing tensioner to take up slack in left side
Removal – 1) Support engine oil pan with jack and block of wood. of timing belt. Tighten tensioner bolt. Rotate crankshaft 2 turns clock-
Remove all drive belts. Remove power steering pump with hoses wise.
connected, and set aside. Remove engine mount on timing belt end of 5) Realign timing marks. Measure timing belt tension using belt tension
engine. Remove engine support bracket bolts in sequence. Slowly gauge midway between crankshaft and camshaft sprockets, on side
remove reamer bolt. See Fig. 1. opposite tensioner. For new belt, tension should be 57-84 lbs. (26-38
NOTE: Reamer bolt may sometimes become seized on engine kg).
support bracket. Remove reamer bolt carefully without damaging 6) Install flange on crankshaft sprocket with flat side facing timing belt.
threads. Install front timing belt cover. Install crankshaft pulley and tighten bolt to
2) Ensure engine is on No. 1 cylinder compression stroke and timing 7) Install engine support bolts and tighten in sequence. See Fig. 1. To
marks are aligned. Remove crankshaft pulley and timing belt covers.
complete installation, reverse removal procedure. Tighten nuts and bolts
See Fig. 2.
to specfication. See TORQUE SPECIFICATIONS. Adjust drive belts to
3) Rotate crankshaft clockwise to align camshaft and crankshaft timing
proper tension.
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.
HYUNDAI 377
3.0L V6 (Cont.)
Crankshaft Sprocket Bolt .............................................................. .......... 111-118 (150-160)
Water Pump Bolt
Headmark “4” Bolt ........................................................................................... 9-11 (12-15)
Headmark “7” Bolt ....................................................................... ................. 15-20 (20-27)
INCH Lbs. (N.m)

378 HYUNDAI
3.5L V6 – DOHC
Application Labor Time Belt CAUTION: Before removing the engine mounting bracket support
Part No. the engine oil pan with a jack or equivalent.
3.5L V6 – DOHC 5) Remove the engine mounting bracket. See Fig. 1.
XG350 6) Disconnect the connectors from the timing belt upper cover and
1
2004 .......................................................... 4.0 Hours .. ..... T323
remove the upper cover.
1
– Includes Upper and Lower Timing Covers removal and instal- 7) Remove the drive belt and loosen the 2 alternator mounting nuts (14
lation. 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.
MANUFACTURER’S SUGGESTED NOTE: Rotate the crankshaft clockwise and align the timing mark
SCHEDULED MAINTENANCE to set the No.1 cylinder’s piston to TDC (compression stroke). See
Fig. 2. At this time, the timing marks of the camshaft sprocket and
Manufacturer recommends the belt be replaced every 60,000 miles, cylinder head cover should coincide with each other.
except in California. In California, inspect timing belt at 60,000 miles,
and replace as necessary. 10) Remove the auto tensioner. See Fig. 3.
REMOVAL & INSTALLATION 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.
damage may occur.
Inspect the belt for signs of oil contamination, cracks, separation, worn
or missing teeth, or hardened black surface. Replace belt if worn,
TIMING BELT
damaged or contaminated. Inspect belt tensioner pulley for smooth
Removal – 1) Remove the wheel of passenger side.
rotation. Replace if defective. Check timing belt auto tensioner for leaks.
2) Remove the side cover.
Replace if necessary.
3) Remove the engine cover.
4) Disconnect the power steering hose fixing on the engine mounting
bracket.

HYUNDAI 379

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.
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
Courtesy of Hyundai Motor Co. rod is aligned with set hole in the cylinder.
• Insert a set pin through the auto tensioner body and rod. Leave
Fig. 2: Rotating Crankshaft 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.

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.
Courtesy of Hyundai Motor Co. • Intake camshaft sprocket (right).
• Exhaust camshaft sprocket (right).
Fig. 3: Removing Auto Tensioner • Tensioner pulley.

380 HYUNDAI
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 com-
pression 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. Courtesy of Hyundai Motor Co.
11) Install the alternator and drive belt.
Fig. 7: Camshaft Sprocket Initial Installation
12) Install the engine mounting bracket.
13) Install the side cover.
14) Install the wheel of passenger side.
Fig. 8: Checking Timing Belt Tensioner Projected Length
Courtesy of Hyundai Motor Co. Application Ft. Lbs. (N.m)
Auto Tensioner Fixed Bolt ............................................................. ................. 15-20 (20-27)
Fig. 5: Identifying Crankshaft Sprocket Components Camshaft Sprocket Bolt ................................................................................ 66-81 (90-110)
Drive Belt Pulley Bolt .................................................................... ................. 26-41 (35-55)
Drive Belt Tensioner Bolt/Nut ........................................................ ................. 33-37 (45-50)
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)
1

HYUNDAI & KIA 381
2.5L V6 – DOHC
Part No.
2.5L V6 – DOHC
Optima
2001 .......................................................... 1 2.4 Hours .. ..... T315
Sonata
1999-01 ..................................................... 2.6 Hours ... ..... T315
1

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.

CAUTION: This application is an interference engine. Do not rotate Courtesy of Hyundai Motor Co.
damage may occur. Fig. 1: Identifying Timing Belt Components &
Aligning Belt Timing Marks
TIMING BELT (this will result in valves touching pistons). If camshaft sprocket is
accidentally rotated more than 3 teeth, rotate crankshaft counterclock-
Removal – 1) Remove engine trim cover. Using 16-mm spanner
wrench, rotate serpentine belt tension arm clockwise about 14 degrees wise 3 teeth before rotating camshaft sprocket.
to relieve belt tension. Remove serpentine drive belt. Remove water 3) Compress timing belt auto tensioner, and install set pin to hold in
pump pulley, idler pulley, tensioner pulley and crankshaft pulley. retracted position. Install timing belt auto tensioner to front case. Align
Remove upper and lower timing belt covers. timing marks of each sprocket and install timing belt around pulleys and
2) Support engine with padded jack, and remove engine mount insulator sprockets in the following order: crankshaft sprocket, idler pulley, left
and bracket in front of timing belt. Rotate engine clockwise to align intake cam sprocket, water pump pulley, right intake cam sprocket and
timing mark so No. 1 cylinder is at TDC of compression stroke. Ensure tensioner pulley. See Fig. 1.
camshaft sprocket timing marks line up with marks on upper surface of 4) Pull set pin from timing belt auto tensioner to apply tension to timing
rocker cover. See Fig. 1. If reusing timing belt, place mark on timing belt belt. Adjust tension and seat timing belt by rotating crankshaft 2
to indicate direction of belt rotation. Remove timing belt auto tensioner. complete revolutions clockwise. Check auto tension pin extended
Remove timing belt. length. Extended length should be .24-.32″ (6.1-8.1 mm). If length is
Inspection – Check belt teeth for cracks, damage and oil contamina- greater than specification, belt is stretched. Install NEW timing belt.
tion. Inspect all sprockets for damage. Check tensioner pulley and idler Ensure sprocket timing marks are properly aligned. If marks are not
pulley for grease leakage and roughness in rotation. Check sprockets properly aligned, repeat installation procedure.
and pulleys for wear, cracks or damage. Replace components if 5) Install engine mount bracket and insulator. Install upper and lower
necessary. timing belt covers. Install all external pulleys. Rotate auto tensioner arm
Installation – 1) Install idler pulley onto pin spring pressed into water about 14 degrees clockwise, and install serpentine drive belt onto
pump boss. Install tensioner arm and flat washer to cylinder block. Install pulleys. See Fig. 2. Release tensioner. Tensioner indicator mark should
pulley on tensioner arm.
be between range marks. See Fig. 3. If tensioner indicator is not within
2) Before installing timing belt, ensure camshaft and crankshaft timing
range marks, replace serpentine drive belt. Install engine cover.
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
382 HYUNDAI & KIA
Fig. 3: Identifying Tensioner Mark Location
Auto Tensioner Arm 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)
Fig. 2: Identifying Drive Belt Routing & Pulley Locations

HYUNDAI & KIA 383
2.7L V6 – DOHC
Part No.
2.7L V6
Optima
1
2002-04 .................................................... 2.4 Hours .. ..... T315
Santa Fe
2001-04 ..................................................... 2.6 Hours ... ..... T315
Sonata
1
2002-04 .................................................... 2.4 Hours .. ..... T315
Tiburon
2
2003-04 .................................................... 2.7 Hours .. ..... T315
1
2

SCHEDULED MAINTENANCE Courtesy of Hyundai Motor Co.
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.

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 Courtesy of Hyundai Motor Co.
No. 1 cylinder compression stroke. Ensure camshaft timing marks are
aligned. See Fig. 2. Fig. 2: Aligning Timing Belt Marks
3) If reusing timing belt, mark direction of rotation on belt. Remove timing 4) Pull set pin from timing belt auto tensioner to apply tension to timing
belt auto tensioner. Remove timing belt. belt. Adjust tension and seat timing belt by rotating crankshaft 2
Inspection – Check timing belt for cracks, cracked or missing teeth, and complete revolutions clockwise. Check auto tension pin extended length
separating canvas. Inspect timing belt tensioner and idler pulleys for after 5-minute wait. Extended length should be .24-.32″ (6.1-8.1 mm). If
worn bearings. length is greater than specification, belt is stretched. Install NEW timing
Installation – 1) Install idler pulley onto roll pin pressed into water pump belt. Ensure sprocket timing marks are properly aligned. If marks are not
boss. Install tensioner arm and flat washer onto cylinder block. Install properly aligned, repeat installation procedure.
pulley onto tensioner arm. 5) Install engine mount bracktet and mounting insulator, if necessary.
2) Before installing timing belt, ensure camshaft and crankshaft timing Install upper and lower timing belt covers. Install all external pulleys.
marks are aligned. See Fig. 2. If timing marks are not aligned, DO NOT Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
turn camshaft sprockets more than 3 teeth in either direction to align Rotate auto tensioner arm about 14 degrees clockwise, and install
(this will result in valves touching pistons). If camshaft sprocket is serpentine drive belt onto pulleys. See Fig. 3. Release tensioner.
accidentally rotated more than 3 teeth, rotate crankshaft counterclock- Tensioner indicator mark should be between range marks. See Fig. 4. If
wise a bit before rotating camshaft sprocket. tensioner indicator is not within range marks, replace serpentine drive
3) Compress timing belt auto tensioner, and install set pin to hold in belt. Install engine cover.
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 cam-
shaft sprocket, water pump pulley, right intake camshaft sprocket and
tensioner pulley. See Fig. 2.
384 HYUNDAI & KIA
Fig. 4: Identifying Tensioner Mark Location
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)
Water Pump Bolt ............................................................................................. 11-16 (15-22)
INCH Lbs. (N.m)
Fig. 3: Drive Belt Routing & Pulley Locations

HYUNDAI & KIA 385
3.0L & 3.5L V6 – DOHC

3.0L V6 – DOHC camshaft or crankshaft when timing belt is removed, or engine
XG300 damage may occur.
2001 ........................................................... 4.0 Hours ... ..... T322
3.5L V6 – DOHC TIMING BELT
Amanti Removal – 1) Disconnect negative battery cable. Remove engine cover.
2004 ........................................................ ........ N/A ........ ..... T323
Using 16-mm spanner wrench, rotate serpentine belt tension arm
Sedona
clockwise about 14 degrees to relieve belt tension. Remove serpentine
2002-04 .................................................... 1 3.1 Hours .. ..... T323
Sorento drive belt. Remove power steering pump pulley, idler pulley, tensioner
2003-04 .................................................... 1 3.1 Hours .. ..... T323 pulley and crankshaft pulley. Remove upper and lower timing belt
XG350 covers. See Fig. 1 or 2.
2002-03 ..................................................... 4.0 Hours ... ..... T323
NOTE: Rotate crankshaft clockwise and align timing mark to set
1
– With Air Conditioning, add .2 hours. No. 1 cylinder to TDC on compression stroke.
NOTE: For information about tensioners and/or pulleys (when 2) Ensure timing marks of camshaft sprocket and cylinder head cover
available), see ALPHABETICAL MODEL LISTING. are matching. See Fig. 5. On Sedona, support engine with jack and
remove engine mounting insulator. On all models, remove auto ten-
sioner. See Fig. 3.
NOTE: If timing belt is to be reused, mark rotational direction on
SCHEDULED MAINTENANCE belt for reinstallation reference.
For Sorento, the manufacturer recommends the belt be inspected every
20,000 miles, and replaced at 40,000 miles (severe service) or 60,000 3) Unbolt timing belt tensioner pulley, and remove timing belt.
miles (normal service). For all other models, the manufacturer recom-
CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the
mends the belt be replaced every 60,000 miles, except in California. In
compression stroke and the corresponding camshaft on the same
California, inspect timing belt at 60,000 miles, and replace as necessary.
cylinder head is rotated 180 degrees while the timing belt is
removed, intake and exhaust valves may contact each other.
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 SPECIFICA-
TIONS.
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 Fig. 3: Removing Auto Tensioner
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.

HYUNDAI & KIA 387
3.0L & 3.5L V6 – DOHC (Cont.)
Amanti, Sedona & Sorento ......................................................... ................. 58-72 (79-98)
XG300 & XG350 ......................................................................................... 66-81 (90-110)
Courtesy of Hyundai Motor Co. Drive Belt Tensioner Bolt/Nut
Amanti .......................................................................................... ................. 25-40 (34-54)
Fig. 6: Camshaft Sprocket Initial Installation
Except Amanti ............................................................................. ................. 33-37 (45-50)
6-mm ............................................................................................ ..................................... 1
8-mm ............................................................................................ ................. 15-20 (20-27)
1
Fig. 7: Checking Timing Belt Tensioner Projected Length

388 INFINITI
3.0L V6 – J30
3.0L V6 camshaft or crankshaft when timing belt is removed, or engine
J30 damage may occur.
1993 ........................................................... 4.4 Hours ... ..... T180
1994-97 ..................................................... 4.4 Hours ... ..... T251
TIMING BELT
available), see ALPHABETICAL MODEL LISTING. 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 crank-
MANUFACTURER’S SUGGESTED shaft position sensor before removing to ensure proper installa-
SCHEDULED MAINTENANCE tion during reassembly.
The manufacturer recommends the belt be replaced every 60,000 miles. 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.

INFINITI 389
3.0L V6 – J30 (Cont.)

starter. Remove crankshaft pulley bolt. Using puller, remove crankshaft Fig. 3. Remove all spark plugs. Install timing belt with White marks on
pulley. Remove coolant inlet and outlets for access to timing belt cover. timing belt aligned with timing mark on crankshaft sprocket and cam-
Remove upper and lower timing belt covers. See Fig. 1. shaft sprockets. Ensure arrow on timing belt points toward front of
2) Install a 6 x 16 mm stopper bolt on automatic tensioner to prevent engine.
tensioner from pushing outward. See Fig. 2. Rotate engine so No. 1
CAUTION: Ensure stopper bolt is removed before adjusting clear-
cylinder is at TDC on compression stroke (No. 1 cylinder is front cylinder
ance on automatic tensioner, or stopper bolt and automatic ten-
on right side when viewed from rear of engine). Ensure timing marks on sioner may be damaged.
camshaft sprockets and crankshaft sprocket are aligned. See Fig. 3.
Remove bolts and automatic tensioner. Remove timing belt. DO NOT 2) Remove stopper bolt from automatic tensioner. Using vise, adjust
rotate crankshaft or camshafts with timing belt removed, or engine tensioner arm on automatic tensioner so .16″ (4.0 mm) clearance exists
damage may result. 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 specifi-
cation 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
Courtesy of Nissan Motor Co., U.S.A. is at TDC on compression stroke and all timing marks are aligned. See
Fig. 5.
Fig. 2: Installing Stopper Bolt On Automatic Tensioner
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 specifi-
cation 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 ten-
sioner 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.
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.
Fig. 3: Aligning Timing Marks 9) To install remaining components, reverse removal procedure. Tighten
all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust
Inspection – Inspect timing belt for cracks, worn teeth or oil contami-
nation. Inspect crankshaft sprocket and camshaft sprockets for dam-
aged 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.
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
Fig. 4: Adjusting Automatic Tensioner Clearance & Identifying

Bolt/Nut Tightening Sequence
390 INFINITI
3.0L V6 – J30 (Cont.)
Fig. 7: Fabricating Belt Tension Plate & Checking Timing Belt

Deflection
Courtesy of Nissan Motor Co., U.S.A. TORQUE SPECIFICATIONS
Fig. 5: Aligning Crankshaft & Camshaft Timing Marks Application Ft. Lbs. (N.m)
Automatic Tensioner Bolt/Nut ........................................................ ................. 12-15 (16-20)
Exhaust .......................................................................................................... 11-14 (15-19)
Intake ........................................................................................... ............. 91-97 (123-132)
Crankshaft Position Sensor Brackets ........................................... ................. 12-15 (16-20)
Engine Mount-To-Frame Nut ......................................................... ................. 41-49 (56-66)
Idler Pulley Nut .............................................................................. ................. 32-43 (45-58)
Water Pump Bolt ........................................................................... ................. 12-15 (16-20)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ................................................................................. 44 (5)
Rear Cover Bolt ........................................................................................................ 53 (6)
Fig. 6: Adjusting Automatic Timing Belt Tensioner Upper & Lower .......................................................................................................... 27 (3)
Valve Cover Bolt/Screw
Exhaust Camshaft Cover .......................................................................................... 71 (8)
Intake Camshaft Cover ............................................................................................. 27 (3)
INFINITI 391
3.0L V6 – M30
TIMING BELT APPLICATION 2) Remove A/C drive belt idler bracket. Disconnect coolant inlet hose
Application Labor Time Component Belt from thermostat housing. Remove crankshaft pulley retaining bolt. Using
Kit No. Part No. puller, remove crankshaft pulley. Remove front upper and lower timing
3.0L V6 belt covers. See Fig. 1.
M30 3) Temporarily install crankshaft pulley retaining bolt. Using crankshaft
1990-92 ............................... 4.0 Hours ... .. TCK104 .. ..... T104 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
NOTE: A timing belt component kit is available for this application. timing belt tensioner retaining nut. Rotate timing belt tensioner to
See page A1 for information on component kits. release timing belt tension. Remove timing belt.
NOTE: For information about tensioners and/or pulleys (when NOTE: No. 1 cylinder is front cylinder on left when viewed from
available), see ALPHABETICAL MODEL LISTING. front of engine.
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt

MANUFACTURER’S SUGGESTED removed, or engine damage may result.
SCHEDULED MAINTENANCE Inspection – Inspect timing belt for damaged teeth, cracking or oil
The manufacturer recommends the belt be replaced every 60,000 miles. contamination. Ensure timing belt tensioner rotates smoothly. Inspect
tensioner spring for damage. Replace components if damaged.
REMOVAL & INSTALLATION 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.
damage may occur.
2) Rotate timing belt tensioner fully outward (away from timing belt
area), and temporarily tighten retaining nut. Align White marks on timing
TIMING BELT
belt with timing marks on camshaft and crankshaft sprocket, and install
Removal – 1) Disconnect negative battery cable. Remove lower engine
timing belt.
covers. Drain cooling system. Remove radiator, cooling fan and acces-
sory drive belts. Remove water pump pulley, spark plugs and distributor
cover. Remove fresh air tube from rocker arm cover.

392 INFINITI
3.0L V6 – M30 (Cont.)
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 Fig. 3: Checking Timing Belt Clearance
marks on right and left camshafts, and 43 teeth between timing
mark on left camshaft sprocket and timing mark on crankshaft TORQUE SPECIFICATIONS
sprocket. See Fig. 2. TORQUE SPECIFICATIONS
3) Using an Allen wrench, hold tension on timing belt tensioner and Application Ft. Lbs. (N.m)
loosen retaining nut. Rotate timing belt tensioner clockwise 70-80 Camshaft Locating Plate Bolt ....................................................... ................. 58-65 (79-88)
degrees, and tighten retaining nut. Rotate crankshaft clockwise 2 full Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
revolutions, and realign timing marks so No. 1 cylinder is at TDC on Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133)
compression stroke. Apply 22 lbs. (10 kg) of pressure on timing belt at Crossmember-To-Body Bolt .......................................................... ................. 32-41 (43-56)
Timing Belt Tensioner Nut ............................................................ ................. 32-43 (43-58)
midway point between timing belt tensioner and camshaft sprocket. See
Water Pump Bolt ........................................................................... ................. 12-15 (16-20)
Fig. 1.
4) Loosen timing belt tensioner retaining nut while maintaining pressure INCH Lbs. (N.m)
on timing belt tensioner using an Allen wrench. Insert a .0138″ (.350 Rocker Arm Cover Bolt ................................................................. ....................... 9-27 (1-3)
mm) thick and 1/2″ wide feeler gauge between timing belt tensioner and Timing Belt Cover Bolt .................................................................. ..................... 27-44 (3-5)
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 SPECIFICA-
TIONS.
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.
INFINITI, MERCURY & NISSAN 393
3.3L V6 – SOHC
Kit No. Part No.
3.3L V6 – VG33E & VG33ER (SOHC)
Frontier
1999-04 .............................. 1 3.1 Hours .. .. TCK249 .. ..... T249
Pathfinder
1996-00 .............................. 1 3.3 Hours .. .. TCK249 .. ..... T249
QX4
1997-00 ............................... 3.9 Hours ... .. TCK249 .. ..... T249
Quest
1999-02 .............................. 1 2.6 Hours .. .. TCK249 .. ..... T249
Villager
1999-02 ............................... 2.6 Hours ... ...... ..... ...... ..... T249
Xterra
2000-04 .............................. 1 3.1 Hours .. .. TCK249 .. ..... T249
1
– With Air Conditioning, add .3 hours. Courtesy of Nissan Motor Co., U.S.A.
Fig. 1: Setting Crankshaft To TDC

The manufacturer recommends the timing belt be replaced at 105,000
mile intervals.

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 nega-
tive battery cable. Remove the engine undercover. Drain coolant and Fig. 2: Exploded View Of Timing Belt & Components
remove the radiator. Remove engine cooling fan and water pump pulley.
arrow on timing belt toward front belt cover. There should be 40 teeth
Remove accessory drive belts. Remove spark plugs.
between left and right camshaft sprockets, and 43 teeth between left
2) Remove distributor protector. Remove A/C compressor drive belt idler
camshaft sprocket and crankshaft sprocket.
bracket. Remove fresh air intake tube from rocker cover. Remove
thermostat housing hose. 3) If engine was overhauled or reassembled (rocker covers removed),
3) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. go to step 6). If only the timing belt was replaced, go to next step.
See Fig. 1. Remove crankshaft pulley bolt and remove crankshaft pulley. 4) Loosen tensioner lock nut. Using hex wrench, turn tensioner clock-
Remove front upper and lower timing belt covers. See Fig. 2. wise and counterclockwise at least 2 times. Tighten tensioner lock nut.
4) Align punch mark on left camshaft sprocket with punch mark on timing Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1
belt upper rear cover. Align punch mark on crankshaft sprocket with cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to
notch on oil pump housing. See Fig. 3. Install crankshaft pulley bolt so belt (downward direction) midway between camshaft sprockets. Belt
that crankshaft can be rotated. deflection should be 0.51-0.59″ (13-15 mm). If not, readjust belt tension.
5) Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and 5) Install lower and upper belt covers. Install crankshaft pulley. Tighten
remove timing belt. bolt to specification. See TORQUE SPECIFICATIONS. To complete
Inspection (Frontier, Pathfinder, QX4 & Xterra) – Check timing belt for installation, reverse removal procedures. Fill and bleed cooling system.
cracks and broken or worn teeth. Check belt tensioner for smooth See COOLING SYSTEM BLEEDING. Adjust drive belts to proper
turning. Check condition of tensioner spring. Replace parts as neces- tension.
sary. 6) Loosen rocker shaft bolts to relieve belt tension caused by camshafts.
Installation (Frontier, Pathfinder, QX4 & Xterra) – 1) Install timing belt Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by
when engine is cold. Ensure No. 1 cylinder is at TDC on compression turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock
stroke. Crankshaft sprocket mark should align with mark on rear cover. nut. Rotate crankshaft clockwise at least 2 revolutions.
See Fig. 5. If removed, install timing belt tensioner and tensioner spring. 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
NOTE: If stud for tensioner spring is removed, apply thread sealant
belt between right camshaft sprocket and tensioner. Hold tensioner in
to stud threads before installing.
position with Allen wrench, and loosen tensioner lock nut.
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
394 INFINITI, MERCURY & NISSAN
3.3L V6 – SOHC (Cont.)
Fig. 5: Positioning Camshaft & Crankshaft Sprockets
Fig. 3: Aligning Camshaft & Crankshaft Punch Marks
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
9) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clock-
wise at least 2 revolutions, then slowly set cylinder No. 1 at TDC of Courtesy of Nissan Motor Co., U.S.A.
compression stroke. While applying 22 lbs. (10 kg) of pressure, measure
timing belt deflection halfway between camshaft sprockets. If deflection Fig. 7: Adjusting Timing Belt
is not .51-.59″ (13-15 mm), repeat steps 6)-8). To complete installation, 3) Remove upper radiator hose and water inlet hose from timing belt end
reverse removal procedure. Fill and bleed cooling system. See COOL- of engine. Remove A/C compressor drive belt idler bracket. Remove
ING SYSTEM BLEEDING. Adjust drive belts to proper tension. water pump pulley. Remove breather pipe from timing belt front upper
Removal (Quest & Villager) – 1) Raise and support vehicle. Remove cover. Remove front upper and lower belt covers. See Fig. 2.
the engine undercover. Remove right side wheel and engine side cover. 4) Align punch mark on left camshaft sprocket with punch mark on timing
Drain coolant from radiator. Remove accessory drive belts. belt upper rear cover. Align punch mark on crankshaft sprocket with
2) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. notch on oil pump housing. See Fig. 3. Temporarily install crankshaft
See Fig. 1. Remove crankshaft pulley bolt, and remove crankshaft pulley bolt so that crankshaft can be rotated.
pulley using a gear puller. 5) Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and
remove timing belt.
INFINITI, MERCURY & NISSAN 395
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 Courtesy of Nissan Motor Co., U.S.A.
temporarily tighten lock nut. Align white lines on timing belt with punch Fig. 9: Locating Heater Core Inlet Hose (Frontier, Pathfinder,
marks on camshaft sprockets and crankshaft sprocket. See Fig. 6. Point QX4 & Xterra)
arrow on timing belt toward front belt cover. There should be 40 teeth
lbs. (8-12 N.m). If removed, apply sealant to threads of cylinder block
between left and right camshaft sprockets, and 43 teeth between left
drain plugs, and tighten to 25-33 ft. lbs. (34-44 N.m). Install reservoir
camshaft sprocket and crankshaft sprocket.
3) Loosen tensioner lock nut. Using hex wrench, turn tensioner clock- tank, if necessary. Tighten air relief plug to 62-71 INCH lbs. (7-8 N.m).
wise and counterclockwise at least 2 times. Tighten tensioner lock nut. See Fig. 8. Reattach upper radiator hose at engine side.
Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1 2) Set vehicle heater controls to full HOT and heater ON positions. Turn
cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to ignition on (engine off) to activate heater mode. Install Coolant Refill Tool
belt (downward direction) midway between camshaft sprockets. Belt (J-45695) by installing radiator cap adapter onto radiator neck opening.
deflection should be 0.51-0.59″ (13-15 mm). If not, readjust belt tension. Attach gauge body assembly with refill tube and venturi assembly to
4) Install lower and upper belt covers. Install crankshaft pulley. Tighten radiator cap adapter. See Fig. 10.
bolt to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedures. Fill and bleed cooling system. CAUTION: Compressed air supply must be equipped with an air
See COOLING SYSTEM BLEEDING. Adjust drive belts to proper dryer.
tension.
3) Insert refill hose into coolant mixture container that is placed at floor
COOLING SYSTEM BLEEDING level. Ensure ball valve is in closed position. Install air hose to venturi
Frontier, Pathfinder, QX4 & Xterra (1999-02) – 1) If vehicle is equipped assembly, and adjust air pressure to 80-120 psi (5.6-8.4 kg/cm2).
with manual A/C, move temperature control lever to full HOT position. If 4) The vacuum gauge will begin to rise and there will be an audible
vehicle is equipped with automatic A/C, turn ignition on. Remove air hissing noise. During this process, open ball valve on refill hose slightly.
relief plug on intake manifold collector. See Fig. 8. On Pathfinder, Coolant will be visible rising in refill hose. Once refill hose is full of
remove heater hose from heater core inlet. See Fig. 9. On all models, fill coolant, close the ball valve. This will purge any air trapped in refill hose.
radiator slowly until coolant starts to drip from air relief plug. Tighten air 5) Continue to draw vacuum until gauge reaches 28 inches of vacuum.
relief plug to 61-69 INCH lbs. (7-8 N.m). On Pathfinder, install heater In high altitude locations, the gauge may not reach 28 inches. See
hose to heater core inlet. VACUUM GAUGE SPECIFICATIONS table.
2) On all models, fill radiator and coolant reservoir tank to MAX mark.
VACUUM GAUGE SPECIFICATIONS
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 Altitude Above Sea Level Vacuum Gauge Reading
engine and allow it to cool. Refill radiator and coolant reservoir as 0-328 Ft. (0-100 m) ....................................... ....................................................... 28 Inches
necessary. 984 Ft. (300 m) ............................................. ....................................................... 27 Inches
3) Repeat previous step at least 3 times with temperature control lever 1641 Ft. (500 m) ........................................... ....................................................... 26 Inches
at several different positions between full COLD and full HOT positions. 3281 Ft. (1000 m) ........................................................................................... 24-25 Inches
System is full when water noise is no longer heard at heater core and 6) When vacuum gauge has reached specified amount, disconnect air
coolant level no longer drops.
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. COOLING SYSTEM SPECIFICATIONS
Fig. 8: Locating Air Relief Plug (Frontier, Pathfinder, Application Specification

QX4 & Xterra) Engine Coolant Capacity (Without Reservoir Tank) .................... ...... 10 3/4 Qts. (10.15L)
Reservoir Tank ................................................................................................... 7/8 Qt. (0.8)
Frontier & Xterra (2003-04) – 1) Ensure radiator is completely empty of
coolant and water. Install radiator drain plug, and tighten to 71-106 INCH
396 INFINITI, MERCURY & NISSAN
Fig. 11: Holding Negative Pressure Relief Valve Open

(Quest & Villager)
Courtesy of Nissan Motor Co., U.S.A. Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88)
Fig. 10: Installing Coolant Refill Tool (J-45695)
Spark Plugs ................................................................................... ................. 14-22 (20-29)
Quest & Villager – 1) Install radiator drain plug. If removed, apply Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58)
sealant to threads of cylinder block drain plug and tighten to 25-33 ft. lbs. Water Pump Bolt ........................................................................... ................. 12-15 (16-20)
(34-44 N.m). Slowly add coolant through radiator filler neck allowing Wheel Lug Nut
several minutes for air to escape. Add fluid until filler neck is full. Quest ........................................................................................................... 72-87 (98-118)
2) Continue adding coolant while gently moving upper radiator hose up INCH Lbs. (N.m)
and down until coolant no longer lowers in filler neck. Place wire under Cooling Fan & Water Pump Pulley Bolts ..................................... ................... 52-89 (6-10)
radiator filler cap negative pressure relief valve. See Fig. 11. Install Radiator Mounting Bolts ................................................................ ............... 34-42 (3.8-4.8)
radiator cap. Disconnect coolant reservoir hose from radiator neck Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)
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
90°F 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.
ISUZU 397
1.6L & 1.8L 4-Cylinder – Gasoline

Kit No. Part No.
I-Mark
1989 .................................... 2.0 Hours ... ...... ..... ...... ..... T169
Impulse
1990-92 Non-Turbo ............ 2.0 Hours ... ...... ..... ...... ..... T169
1991-92 Turbo .................... 2.4 Hours ... ...... ..... ...... ..... T169
Stylus
1991 .................................... 2.0 Hours ... ...... ..... ...... ..... T169
Stylus
1991-93 ............................... 1.5 Hours ... .. TCK177 .. ..... T177
Impulse
1992 .................................... 2.4 Hours ... ...... ..... ...... ..... T205
Stylus
1992-93 ............................... 2.4 Hours ... ...... ..... ...... ..... T205
1

See page A1 for information on component kits. Courtesy of Isuzu Motor Co.
Fig. 1: Aligning Timing Marks (DOHC)


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.
TIMING BELT Fig. 2: Removing Engine Stiffener Brace

Removal (DOHC) – 1) Disconnect negative battery cable. Remove
2) Loosen bolt and allow tensioner pulley to apply tension on timing belt.
accessory drive belts. Remove upper timing belt cover. Support engine.
Hold tensioner pulley, and tighten tensioner pulley bolt.
Remove engine mounting bracket located at timing belt cover. Rotate
crankshaft and position No. 1 cylinder at TDC of compression stroke. CAUTION: On new timing belts, push tensioner pulley sightly
Ensure timing mark on crankshaft pulley aligns with “0” timing mark on inward to apply more pressure on timing belt. On used timing belts,
timing belt cover.
allow only spring tension to be applied to timing belt.
2) Ensure timing marks on camshaft sprockets are aligned with cylinder
head surface. See Fig. 1. Disconnect front exhaust pipe. Remove bolts 3) Rotate crankshaft 2 revolutions in direction of engine rotation. Ensure
attaching torque rod bracket to cylinder block. Remove bolt attaching all timing marks align. Rotate crankshaft 60 degrees. Measure timing
torque rod to vehicle frame. Remove torque rod and bracket as an belt deflection at midpoint between camshaft sprockets. Ensure timing
assembly. belt defection is within specification. See TIMING BELT DEFLECTION
3) Remove engine stiffener brace. See Fig. 2. Remove flywheel dust SPECIFICATIONS table. If belt deflection is not within specification,
cover. Hold flywheel while removing crankshaft pulley bolt. Remove repeat the last two steps.
crankshaft pulley. Remove lower timing belt cover.
4) Ensure timing mark (notch) on crankshaft sprocket aligns with timing CAUTION: Ensure timing marks align after belt adjustment.
mark on oil pump. See Fig. 1. Loosen tensioner pulley bolt 1/2 turn.
Rotate tensioner pulley clockwise. Mark timing belt direction of rotation 4) To install remaining components, reverse removal procedure. See
if reusing old belt. Remove timing belt. Fig. 4. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Inspection (DOHC) – Inspect timing belt for damaged teeth, cracking or Adjust drive belts to proper tension.
oil contamination. Ensure tensioner pulley and idler pulley rotate freely. TIMING BELT DEFLECTION SPECIFICATIONS
Replace components if damaged. Application In. (mm)
Installation (DOHC) – 1) Rotate camshafts so timing marks align with
DOHC
cylinder head surface. Install 6 mm bolts in lock bolt holes to secure New Belt ................................................................................................... .28-.33 (7.1-8.4)
camshafts. Ensure timing mark (notch) on crankshaft sprocket aligns Used Belt ................................................................................................ .35-.41 (8.9-10.4)
with timing mark on oil pump. See Fig. 1. Install timing belt in the SOHC
following order: over crankshaft sprocket, water pump, idler pulley, New Or Used Belt ...................................................................................... .63-.79 (16-20)
exhaust camshaft, intake camshaft and belt tensioner. Ensure no slack
exists in belt. See Fig. 3.
398 ISUZU
1.6L & 1.8L 4-Cylinder – Gasoline (Cont.)

Fig. 5: Aligning Timing Marks (SOHC)
Fig. 3: Routing Timing Belt (DOHC) 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 SPECIFICA-
TIONS table. If belt deflection is not within specification, repeat this step.
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 com-
ponents if damaged.
Fig. 6: Routing Timing Belt (SOHC)

ISUZU 399
1.6L & 1.8L 4-Cylinder – Gasoline (Cont.)

DOHC .................................................................................................................. 109 (148)
SOHC ....................................................................................................................... 62 (84)
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)
INCH Lbs. (N.m)
Fig. 7: Checking Timing Belt Tension (SOHC) Timing Belt Cover Bolt .............................................................................................. 89 (10)

MOTORES CHECK
400 ISUZU
Part No.
I-Mark
1
1981-84 .................................................... 3.1 Hours .. ..... T076
1

REMOVAL & INSTALLATION Courtesy of Isuzu Motor Co.
Fig. 2: Camshaft Fixing Plate

damage may occur.
TIMING BELT & VALVE TIMING

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 equiva-
lent, 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. 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
Courtesy of Isuzu Motor Co. timing belt holder does not rub against timing belt. Reverse removal
procedure to complete installation. Adjust drive belts to proper tension.
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.
ISUZU 401

Crankshaft Pulley ............................................................................................ 11-18 (15-24)
Injection Pump Timing Pulley ....................................................... ................. 42-52 (57-71)
Tensioner Pulley
Center Bolt .................................................................................. ................. 47-64 (64-87)
Pivot Bolt ....................................................................................................... 11-18 (15-24)
Fig. 5: Locating Tensioner Pulley

402 ISUZU
2.0L, 2.3L & 2.6L 4-Cylinder
Kit No. Part No.
2.0L 4-Cyl. – Turbo The manufacturer recommends the belt be replaced every 60,000 miles.
Impulse
1985-89
1
A/T ................................. ... 3.6 Hrs. ... ...... ..... ...... ..... T121
1
M/T ................................. ... 3.4 Hrs. ... ...... ..... ...... ..... T121 CAUTION: This application is an interference engine. Do not rotate
Amigo damage may occur.
1989-93
1
A/T ................................. ... 1.9 Hrs. ... .. TCK122 .. ..... T122
1
M/T ................................. ... 1.6 Hrs. ... .. TCK122 .. ..... T122 TIMING BELT
Impulse
1988-89 NOTE: Some procedures may differ slightly due to engine con-
1
A/T ................................. ... 3.6 Hrs. ... .. TCK122 .. ..... T122 struction.
1
M/T ................................. ... 3.4 Hrs. ... .. TCK122 .. ..... T122
Pickup Removal – 1) Disconnect negative battery cable. Remove all necessary
1986-95 air ducts. Position No. 1 cylinder at TDC of compression stroke. Align
1
A/T ................................. ... 1.9 Hrs. ... .. TCK122 .. ..... T122 timing marks. See Fig. 1. Remove fan and fan shroud. Remove
1
M/T ................................. ... 1.6 Hrs. ... .. TCK122 .. ..... T122 accessory drive belts. Remove water pump pulley. If necessary, remove
Trooper II radiator and splash guard.
1986-87 2) Prevent engine from rotating, and remove crankshaft timing pulley.
1
A/T ................................. ... 1.9 Hrs. ... .. TCK122 .. ..... T122 Remove upper and lower timing belt covers. See Fig. 2. Remove spring
1
M/T ................................. ... 1.6 Hrs. ... .. TCK122 .. ..... T122
from tension pulley. Loosen adjusting bolt and move pulley toward water
2.6L 4-Cyl.
pump. Remove timing belt.
Amigo
1989-94 CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft,
1
A/T ................................. ... 1.9 Hrs. ... .. TCK147 .. ..... T147
1 or damage may result.
M/T ................................. ... 1.6 Hrs. ... .. TCK147 .. ..... T147
Pickup
1988-95
1
A/T ................................. ... 1.9 Hrs. ... .. TCK147 .. ..... T147
1
M/T ................................. ... 1.6 Hrs. ... .. TCK147 .. ..... T147
Rodeo
1991-97
1
A/T ................................. ... 1.9 Hrs. ... .. TCK147 .. ..... T147
1
M/T ................................. ... 1.6 Hrs. ... .. TCK147 .. ..... T147
Trooper
1990-91
1
A/T ................................. ... 1.9 Hrs. ... .. TCK147 .. ..... T147
1
M/T ................................. ... 1.6 Hrs. ... .. TCK147 .. ..... T147
Trooper II
1988-89
1
A/T ................................. ... 1.9 Hrs. ... .. TCK147 .. ..... T147
1
M/T ................................. ... 1.6 Hrs. ... .. TCK147 .. ..... T147
1



ISUZU 403
2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)

Inspection – 1) Handle timing belt carefully. Avoid twisting or kinking Installation – 1) Pull tensioner fully toward water pump side, and
belt. DO NOT allow belt to become contaminated by water, oil, dirt or temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on
other contaminates. Inspect belt for cracks or damage. Replace, if compression stroke by rotating crankshaft until keyway aligns with mark
necessary. on front crankshaft seal housing (12 o’clock). Rotate camshaft until
2) On 2.0L engines, measure outside diameter of crankshaft, camshaft timing mark on cam gear (arrow) aligns with mark on upper camshaft
and oil pump sprockets. If specifications are exceeded, replace sprock- cover (notch). See Fig. 1.
et(s). See TIMING SPROCKET SPECIFICATIONS (2.0L) table. 2) Position timing belt over crankshaft sprocket, oil pump sprocket,
3) On all engines, measure tension pulley spring length and force. On camshaft sprocket and tensioner in that order. Ensure belt is positioned
2.3L and 2.6L engine, spring length should not exceed 2.76″ (70.2 mm) in sequence given and without slack between sprockets. Loosen
tensioner pulley adjusting bolt allowing spring tension to tighten belt.
and spring force should not be less than 60-106 lbs. (27-48 kg).
Tighten adjusting bolt temporarily.
4) On 2.0L, spring length should not exceed 3.11″ (79 mm), and spring
3) Temporarily install crankshaft pulley bolt and rotate crankshaft 2
force should not be less than 53-57 lbs. (24-26 kg). On all engines,
complete revolutions in opposite direction of engine rotation, until marks
replace tension pulley spring if not within specification. on crankshaft and front oil seal retainer are aligned again. See Fig. 1.
TIMING SPROCKET SPECIFICATIONS (2.0L) Loosen tensioner lock bolt, allowing tensioner spring to fully adjust
Application Standard – In. (mm) Limit – In. (mm) tension. Tighten tensioner lock bolt.
4) Install timing belt covers. To complete installation, reverse removal
Camshaft ............................... .......... 5.202 (132.03) ................................. 5.198 (131.93)
Crankshaft ............................. ........... 2.574 (65.33) .................................... 2.570 (65.23) procedures. Tighten all bolts to specification. See TORQUE SPECIFI-
Oil Pump ............................... .......... 4.485 (113.84) .......... ....................... 4.481 (113.74) CATIONS. Adjust drive belts to proper tension.
404 ISUZU
Front Cover ............................................................................................................... 14 (19)
Tensioner Pulley
Bolts ......................................................................................................................... 18 (24)
Nut ........................................................................................................................... 10 (14)
Water Pump ............................................................................................................... 14 (19)
INCH Lbs. (N.m)
Fig. 3: Installing Belt Guide
ISUZU 405

1
Part No.
LUV (Chevrolet)
1981-82 ..................................................... 2.7 Hours ... ..... T075
Pickup (Isuzu)
1983-85 ..................................................... 2.7 Hours ... ..... T075
P’UP
1981-87 ..................................................... 2.7 Hours ... ..... T075
S10 & S15 Pickup (Chevrolet/GMC)
1983-85 ..................................................... 1.0 Hours ... ..... T075
Trooper II
1984-87 ..................................................... 2.7 Hours ... ..... T075
1
With Power Steering, add .3 hours. Courtesy of Isuzu Motor Co.
NOTE: For information about tensioners and/or pulleys (when Fig. 2: Removing Tension Spring

damage may occur.
TIMING BELT
cover. Drain cooling system. Remove battery. Remove fan, fan shroud,
top radiator hose and drive belts. Remove 4 crankshaft pulley bolts and Courtesy of Isuzu Motor Co.
crankshaft pulley. Remove timing belt covers. See Fig. 1.
Fig. 3: Identifying Timing Belt Sprocket Alignment
2) Remove tension spring. See Fig. 2. Position No. 1 cylinder at TDC of
compression stroke. Ensure injection pump and camshaft sprocket Installation – 1) Ensure that timing marks on injection pump, camshaft
timing marks are aligned. See Fig. 3. Remove injection pump pulley sprockets, crankshaft pulley and timing pointer are aligned. See Fig. 4.
flange bolts, and remove flange. Remove tensioner spring without using Install timing belt over crankshaft sprocket, camshaft sprocket and
excess force on spring. Remove tension pulley nut and tensioner injection pump sprocket.
2) Install tensioner assembly so that end of tensioner is in contact with
assembly. Remove timing belt.
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 crank-
shaft 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

406 ISUZU

Fig. 6: Aligning Injection Pump Timing Marks
Fig. 4: Aligning Timing Marks TORQUE SPECIFICATIONS

Injection Pump Timing Pulley Bolt ................................................ ................. 42-52 (57-71)
Tension Spring Nut ........................................................................ ................. 22-36 (30-49)
Timing Belt Tensioner Bolts .......................................................... ............. 79-94 (107-127)

ISUZU 407

Part No.
Amigo
1998-00
Auto. Trans. ........................................... 1 1.9 Hours .. ..... T305
Man. Trans. ............................................ 1 1.6 Hours .. ..... T305
Rodeo
1998-03
Auto. Trans. ........................................... 1 1.9 Hours .. ..... T305
Man. Trans. ............................................ 1 1.6 Hours .. ..... T305
Rodeo Sport
2001-03
Auto. Trans. ............................................ 1.9 Hours ... ..... T305
Man. Trans. ............................................. 1.6 Hours ... ..... T305
1

MANUFACTURER’S SUGGESTED Fig. 1: Aligning Timing Marks
SCHEDULED MAINTENANCE 4) Remove camshaft locking tool. Turn crankshaft 2 turns in normal
For 1998 vehicles, the manufacturer recommends the belt be replaced direction of rotation until No. 1 cylinder is at TDC. Check alignment of
every 75,000 miles. For 1999-00 vehicles, the manufacturer recom- timing belt tensioner pointer. If marks do NOT align, repeat timing belt
mends the belt be replaced every 100,000 miles for normal service, or tensioning procedure.
75,000 miles for severe service. For 2001-03 vehicles, the manufacturer 5) Install timing belt cover. Install engine harness cover. Connect engine
recommends the belt be replaced every 75,000 miles for normal service, harness electrical connectors. To complete installation, reverse removal
or 60,000 miles for severe service. procedure.

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.
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 Courtesy of Isuzu Motor Co.
Fig. 1. Place Camshaft Locking Tool (J-43037) between camshafts to Fig. 2: Adjusting Timing Belt Tension
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
408 ISUZU
Camshaft Sprocket Bolt 1
Step 1 ...................................................................................................................... 36 (50)
Step 2 ........................................................................................................... Additional 60°
Step 3 (1998-00 Engines Only) ................................................................... Additional 15°
Step 1 .................................................................................................................... 94 (130)
Step 2 ........................................................................................................... Additional 45°
Water Pump Bolt ....................................................................................................... 18 (25)
INCH Lbs. (N.m)
Engine Harness Cover-To-Engine .............................................................................. 52 (6)
1
– Replace bolt if loosened or removed.
ISUZU 409
2.2L 4-Cylinder – Oasis

Kit No. Part No.
2.2L 4-Cyl. – RA1
Oasis
1996-97
Balancer Shaft .............. .......... 1 .......... .. TCK186 .. ..... T186
1
– Balancer shaft belt included in camshaft belt labor time.
2
.3 hours


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).

damage may occur. Courtesy of American Honda Motor Co., Inc.
Fig. 1: Exploded View Of Timing Belt, Balance Belt &

NOTE: If the radio has a coded theft protection circuit, be sure to Related Components
TIMING BELT
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
proper tension.

410 ISUZU
2.2L 4-Cylinder – Oasis (Cont.)
Fig. 5: Aligning Camshaft Pulley TDC Marks
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
INCH Lbs. (N.m)
Valve Cover Nut ....................................................................................................... 86 (9.8)
ISUZU 411
2.3L 4-Cylinder – Oasis

Part No.
2.3L 4-Cyl. – F23A, SOHC
Oasis
1998-99
1
Balancer Shaft ...................................... 2.7 Hours .. ..... T186
1
Camshaft ............................................... 2.7 Hours .. ..... T244
1

at 60,000 miles if vehicle is regularly driven in extreme temperatures
(over 110 degrees F, or under -20 degrees F).

damage may occur.


counterclockwise until cylinder No. 1 is at TDC of compression stroke. Fig. 1: Exploded View Of Timing Belt, Balancer Belt &
While rotating crankshaft, check water pump for signs of seal leakage. Related Components
Raise and support vehicle. Remove engine lower splash shield.
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 Courtesy of American Honda Motor Co., Inc.
pulley. Install bolt.
3) Rotate crankshaft pulley COUNTERCLOCKWISE about 5-6 turns so Fig. 2: Removing & Installing Timing Belt Covers
timing belt positions on pulley. Set No. 1 piston at TDC of compression 5) Remove crankshaft pulley and lower cover. Set timing belt drive
stroke. Loosen belt tensioner adjusting nut about one turn. Rotate pulley to TDC position.
crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt 6) Lock camshaft timing belt adjuster arm in place by installing a 6 x 10
tensioner adjusting nut to specification. See TORQUE SPECIFICA- mm timing cover bolt. Loosen belt tension adjusting nut about one turn.
TIONS. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push
4) Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC balancer belt tensioner up, then retighten belt tensioner adjusting nut.
position. Ensure camshaft “UP” mark is facing up. If they are not, timing
belt will have to be repositioned.
412 ISUZU

Courtesy of American Honda Motor Co., Inc. Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
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
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. Courtesy of American Honda Motor Co., Inc.
12) Install alternator and harness. Install accessory drive belts. Install
engine mount bracket to engine and frame. Connect negative battery Fig. 5: Aligning Camshaft Pulley TDC Marks
cable. Adjust drive belts to proper tension.
ISUZU 413
Fig. 8: Aligning Balancer Belt Drive Pulley
Alternator Adjusting Lock Nut ................................................................................... 16 (22)
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)
Timing Belt Tensioner Adjusting Nut ........................................................................ 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ......................................................................................... 86 (9.8)
Water Pump Bolts ................................................................................................... 106 (12)
Fig. 7: Locking Balancer Belt Shaft In Place

414 ISUZU
3.2L V6 – 1992-97
Kit No. Part No.
3.2L V6 – DOHC
Trooper
1
1992-95 ............................ . 2.6. Hours . ...... ..... ...... ..... T220
3.2L V6 – SOHC
Rodeo
1
1993-97 .............................. 2.8 Hours .. .. TCK221 .. ..... T221
Trooper
1
1992-97 .............................. 2.8 Hours .. .. TCK221 .. ..... T221
1

Fig. 3: Aligning Camshaft Timing Marks (SOHC)

TIMING BELT
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 Courtesy of Isuzu Motor Co.
cooler hose from timing cover. Remove timing belt cover. Align all timing
marks prior to belt removal. See Figs. 1-4. Remove belt tensioner Fig. 4: Aligning Crankshaft Timing Marks (All Models)
pusher and timing belt.
CAUTION: To ensure correct timing belt installation, ensure direc-
tion of rotation arrows are pointing in proper direction. If timing
belt is being reused, install belt in original direction of rotation.
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
Courtesy of Isuzu Motor Co. tensioner. Tighten tensioner pulley bolt to specification.. See TORQUE
SPECIFICATIONS. Remove pin from timing belt tensioner pusher.
Fig. 1: Aligning Timing Belt Sprockets (DOHC) 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 specifica-
tion, 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
Fig. 2: Aligning Camshaft Timing Marks (DOHC)

ISUZU 415
3.2L V6 – 1992-97 (Cont.)
Fig. 5: Installing Pinch Clip On Timing Belt
Courtesy of Isuzu Motor Co. Courtesy of Isuzu Motor Co.
Fig. 6: Adjusting Timing Belt Tensioner Pusher Fig. 7: Exploded View Of Cylinder Head Components
(SOHC Shown; DOHC Is Similar)
Fan Pulley Bolt .......................................................................................................... 16 (22)
Front Plate Bolt ......................................................................................................... 14 (19)
Idler Arm Retaining Bolt ............................................................................................ 33 (44)
Timing Belt Tensioner Pusher Bolt ........................................................................... 14 (19)
Upper Intake Manifold Bolt ....................................................................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ....................................................................................... 87 (10)
Cooling Fan Assembly Nut ......................................................................................... 69 (8)
416 ISUZU
3.2L & 3.5L V6 – DOHC, 1998-04
Part No.
3.2L V6
Amigo
1
1998-00 .................................................... 3.2 Hours .. ..... T303
Rodeo
1
1998-04 .................................................... 3.2 Hours .. ..... T303
Rodeo Sport
1
2001-03 .................................................... 3.2 Hours .. ..... T303
3.5L V6
Axiom
1
2002-04 .................................................... 3.2 Hours .. ..... T303
Rodeo
1
2004 .......................................................... 3.2 Hours .. ..... T303
Trooper
1 Courtesy of Isuzu Motor Co.
1998-02 .................................................... 2.4 Hours .. ..... T303
VehiCROSS Fig. 1: Aligning Camshaft Timing Marks (3.2L Shown;
1
1999-01 .................................................... 2.0 Hours .. ..... T303 3.5L Is Similar)
1

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.

CAUTION: This application may be an interference engine. DO NOT
rotate camshaft or crankshaft when timing belt is removed, or
engine damage may occur.
Installation – 1) Align grove on crankshaft sprocket with mark on oil
TIMING BELT
dotted line on belt with timing mark on crankshaft pulley. Secure belt to
sprocket with spring clip.
assembly. Remove upper fan shroud. Relieve tension on serpentine
2) Align timing mark on right hand (passenger side) camshaft sprocket
drive belt tensioner and remove serpentine drive belt.
with alignment mark on valve cover. See Fig. 3. It may require up to 4
2) Remove 4 cooling fan assembly mounting nuts and remove cooling
revolutions of camshaft pulley to achieve alignment of all timing marks.
fan assembly. Remove cooling fan drive pulley. Remove serpentine Install timing belt on right hand camshaft sprocket, aligning the White
drive belt idler pulley assembly. Remove serpentine drive belt tensioner alignment mark on timing belt with camshaft sprocket mark. If reusing
assembly. old timing belt, align mating marks on belt and camshaft sprocket that
3) On Rodeo, remove power steering pump with hoses attached, and were made during removal. Secure belt with spring clip.
set aside. On all models, using Crankshaft Holder (J-8614-01) or 3) Align timing mark on left hand (driver side) camshaft sprocket with
equivalent, hold crankshaft from turning and remove crankshaft pulley alignment mark on valve cover. See Fig. 4. Route timing belt around
bolt. Remove crankshaft pulley. water pump pulley, and install on other left hand camshaft sprocket,
4) Disconnect harness connector from right side timing belt cover (if aligning the White alignment mark on timing belt with camshaft sprocket
equipped). Remove timing belt covers. Remove fan bracket (if mark. Install spring clip to hold belt on sprocket. Ensure there is no slack
equipped). in belt between camshaft pulleys.
5) On all models, rotate crankshaft to align timing marks. See Figs. 1 4) Install timing belt around idler pulley and tensioner pulley. Temporarily
and 2. When timing marks are aligned, No. 2 piston will be at TDC. install crankshaft pulley. Turn crankshaft pulley clockwise slightly to give
6) If reusing timing belt, mark belt with arrow to indicate original rotation some belt slack between the crankshaft sprocket and right hand
direction. Also place mating marks on timing belt and camshaft sprock- camshaft sprocket.
ets for reassembly reference. Remove timing belt tensioner, and set
aside with push rod facing up. Remove timing belt. tensioner rod.
CAUTION: To prevent air from entering timing belt tensioner, 5) Holding tensioner upright, SLOWLY compress timing belt tensioner
tensioner rod must always face up. 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
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
Fig. 6.
10) Install crankshaft pulley. Using Crankshaft Holder (J-8614-01) or
equivalent, hold crankshaft from turning and tighten crankshaft pulley
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

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket
Cooling Fan Bracket Bolts ........................................................................................ 16 (22)
Cooling Fan & Clutch Assembly ................................................... ..................................... 1
M8 Bolt .................................................................................................................... 16 (22)
M10 Bolt .................................................................................................................. 34 (46)
Water Pump Bolt ....................................................................................................... 18 (25)
1
– Tighten cooling fan and clutch assembly nuts to 89 INCH lbs. (10 N.m).

418 KIA
1.5L & 1.6L 4-Cylinder – DOHC – 2001-04
Part No.
Rio
2001-02 ..................................................... 1.9 Hours ... ..... T318
Rio
1
2003-04 .................................................... 1.9 Hours .. ..... T318
1

SCHEDULED MAINTENANCE Courtesy of Kia Motors America, Inc.
Manufacturer recommends the belt be replaced every 60,000 miles, Fig. 1: Removing & Installing Accessory Drive Belt
except in California. In California, inspect timing belt at 60,000 miles and
90,000 miles, and replace belt at 105,000 miles.

damage may occur.
TIMING BELT
Removal – 1) Disconnect negative battery cable. Loosen power steer-
ing 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 Courtesy of Kia Motors America, Inc.
with timing mark on engine. See Figs. 2 and 3. Ensure “I” mark on intake
Fig. 2: Aligning Crankshaft Timing Mark (1 Of 2)
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.
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 dam-
age. Fig. 3: Aligning Crankshaft Timing Mark (2 Of 2)
NOTE: Replace tensioner spring whenever timing belt is replaced. 3) Loosen tensioner pulley lock bolt, and allow tensioner spring to apply
Replace any component that shows damage or excessive wear. tension to timing belt. DO NOT add additional tension. Tighten tensioner
pulley lock bolt to specification. See TORQUE SPECIFICATIONS.
Installation – 1) Install tensioner pulley. Pull tensioner pulley to its
4) Rotate crankshaft two full turns (clockwise only), and align timing
furthest point, and tighten lock bolt. Check that timing mark on crank-
mark on crankshaft sprocket with timing mark on engine block. See
shaft sprocket is aligned with timing mark on engine. See Figs. 2 and 3.
Fig. 6. Ensure that marks on camshaft sprockets align with marks on
Ensure that camshaft sprockets are aligned with marks on cylinder head
cylinder head cover. See Figs. 2, 3 and 4. If marks do not align, remove
cover. See Fig. 4.
2) Install timing belt onto crankshaft sprocket first, then idler pulley, timing belt and repeat process from tensioner installation.
exhaust camshaft sprocket, intake camshaft sprocket, and finally, ten- 5) Measure timing belt deflection by applying moderate pressure
sioner pulley. See Fig. 6. Ensure there is no looseness in belt between midway between camshaft sprockets. If deflection is not 0.39-0.50″
idler pulley and exhaust camshaft sprocket, or between intake and (11-13 mm) with 22 lbs. (10 kg) of force applied, repeat installation
exhaust camshaft sprockets. process from tensioner installation.
KIA 419

6) Install lower and upper timing belt covers, timing belt guide plate and
crankshaft pulley. Install water pump pulley. Tighten all bolts to specifi-
cation. 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.

Fig. 6: Identifying Rotation & Routing Of Timing Belt
Fig. 4: Locating Camshaft Sprocket & Cylinder Head Cover
Marks TORQUE SPECIFICATIONS
Crankshaft Pulley Bolt ................................................................... ................... 9-13 (12-17)
Timing Belt Guide Plate Bolt ........................................................ ................... 9-13 (12-17)
Timing Belt Tensioner Pulley Lock Bolt ........................................ ................. 28-38 (38-51)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .................................................................................... 70-97 (8-11)

420 KIA
1.6L & 1.8L 4-Cylinder – DOHC – 1995-97
Kit No. Part No.
1.6L 4-Cyl.
Sephia
1
1996-97 .............................. 2.4 Hours .. .. TCK179 .. ..... T179
1.8L 4-Cyl.
Sephia
1
1995-97 .............................. 2.4 Hours .. .. TCK179 .. ..... T179
1



Inspection – Check timing belt for cracks, peeling, abrasion or other
SCHEDULED MAINTENANCE damage. Check tensioner bearing for looseness or roughness of
On California models, the manufacturer recommends inspecting the belt rotation. Inspect tensioner spring for stretching. Replace parts as
at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For necessary.
all other models, the manufacturer recommends the belt be replaced Installation – 1) Ensure camshaft and crankshaft timing marks are still
every 60,000 miles. aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt
pulled tight on right side (facing engine), route belt around camshaft
REMOVAL & INSTALLATION sprockets.
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
CAUTION: This application is an interference engine. Do not rotate tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2
camshaft or crankshaft when timing belt is removed, or engine complete turns. Ensure timing marks align. If timing marks are not
damage may occur. aligned, remove belt, realign all timing marks, and repeat installation
procedure.
3) Check timing belt deflection. Check timing belt deflection with 22 lbs.
TIMING BELT (10 kg) of pressure applied to belt. Timing belt deflection should be
Removal – 1) Disconnect negative battery cable. Remove all accessory .36-45″ (9.0-10.7 mm). If timing belt deflection is not within specification,
drive belts. Remove water pump pulley. Remove crankshaft pulley bolts, repeat timing belt tensioning procedure or replace tensioner spring. If
and remove pulley only. timing belt deflection is within specification, reverse removal procedure
2) Remove upper and lower timing belt covers. See Fig. 1. Disconnect to complete installation.
spark plug wires and remove spark plugs. Rotate crankshaft clockwise 4) Before installing valve cover, apply silicone sealer to areas next to
until No. 1 cylinder is at TDC of compression stroke. Ensure camshaft front camshaft journals and rear distributor mounting cap. Also apply thin
sprockets and crankshaft sprocket timing marks align. See Fig. 2. bead of silicone sealer around spark plug holes on underside of valve
3) If timing belt is to be reused, mark direction of timing belt rotation. cover. Adjust drive belts to proper tension.
Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
away from belt with spring fully extended. Remove timing belt. TORQUE SPECIFICATIONS
Crankshaft Pulley Center Bolt ................................................................ 116-123 (157-167)
Spark Plug ..................................................................................... ................. 14-17 (19-23)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11)
Valve Cover Bolt ........................................................................... ............... 44-78 (5.0-8.8)
Water Pump Pulley Bolt ................................................................................. 69-97 (7.8-11)
Fig. 1: Identifying Timing Belt Covers

KIA 421

Sephia damage may occur.
1
1994-95 .............................. 2.0 Hours .. .. TCK185 .. ..... T185
1.8L 4-Cyl.
Sephia TIMING BELT
1
1996-97 .............................. 2.0 Hours .. .. TCK179 .. ..... T179 Removal – 1) Disconnect negative battery cable. Remove all accessory
1
– With Air Conditioning, add .2 hours. drive belts. Remove water pump pulley. Remove crankshaft pulley bolts,
With Power Steering, add .2 hours. and remove pulley only. See Fig. 1. Remove upper and lower timing belt
covers. Disconnect spark plug wires and remove spark plugs. Rotate
NOTE: A timing belt component kit is available for this application. crankshaft clockwise until No. 1 cylinder is at TDC of compression
See page A1 for information on component kits. stroke. Ensure camshaft sprocket and crankshaft sprocket timing marks
align. See Fig. 2.
NOTE: For information about tensioners and/or pulleys (when 2) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
available), see ALPHABETICAL MODEL LISTING. away from belt with spring fully extended. Remove timing belt.
damage. Check tensioner bearing for looseness or roughness of
MANUFACTURER’S SUGGESTED rotation. Inspect tensioner spring for stretching. Replace parts as
SCHEDULED MAINTENANCE 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.

422 KIA
Installation – 1) Ensure camshaft and crankshaft timing marks are still TORQUE SPECIFICATIONS
aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt
pulled tight on right side (facing engine), route belt around camshaft TORQUE SPECIFICATIONS
sprocket. Application Ft. Lbs. (N.m)
2) Loosen timing belt tensioner lock bolt, and allow spring to apply Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60)
tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2 Crankshaft Pulley Lock Bolt .................................................................... 116-123 (157-167)
complete turns. Ensure timing marks align. If timing marks are not Spark Plug ..................................................................................... ................. 14-17 (19-23)
aligned, remove belt, realign all timing marks, and repeat installation Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25)
procedure. INCH Lbs. (N.m)
3) Rotate crankshaft clockwise 2 more turns, and check timing belt
Camshaft Thrust Plate Bolt ......................................................................................... 71 (8)
deflection. Check timing belt deflection with 22 lbs. (10 kg) of pressure Crankshaft Pulley Bolt ................................................................... ............. 106-152 (12-17)
applied to belt, midway between camshaft and crankshaft pulleys, on Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11)
side opposite tensioner. Timing belt deflection should be .43-51″ Water Pump Pulley Bolt ................................................................................. 69-97 (7.8-11)
(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.

KIA 423
1.8L 4-Cylinder – DOHC – 1998-04

Part No.
Sephia
1
1998-01 .................................................... 2.4 Hours .. ..... T302
Spectra
1
2000-04 .................................................... 2.4 Hours .. ..... T302
1

all other models, the manufacturer recommends the belt be replaced Fig. 2: Aligning Camshaft Timing Marks
every 60,000 miles.

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. Courtesy of Kia Motors America, Inc.
direction of rotation. Remove timing belt tensioner pulley. See Fig. 4. Fig. 3: Aligning Crankshaft Timing Marks
Remove timing belt.
Courtesy of Kia Motors America, Inc. Fig. 4: Timing Belt Tensioner & Idler Pulley
Fig. 1: Removing Timing Belt Guide Plate

424 KIA
1.8L 4-Cylinder – DOHC – 1998-04 (Cont.)
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 cam-
shaft 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 clock-
wise 2 complete revolutions. Ensure timing marks align. If timing marks Courtesy of Kia Motors America, Inc.
are not aligned, remove belt, realign all timing marks, and repeat
Fig. 5: Cross Section of Timing Belt Tensioner
installation procedure.
4) Check timing belt deflection with 22 lbs. (10 kg) of downward pressure TORQUE SPECIFICATIONS
applied to belt, midway between camshaft sprockets. Timing belt
deflection should be .36-.45″ (9.0-11 mm). TORQUE SPECIFICATIONS
5) If timing belt deflection is not within specification, repeat timing belt Application Ft. Lbs. (N.m)
tensioning procedure. If timing belt deflection is within specification, Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61)
install timing belt covers. Install crankshaft and water pump pulleys. To Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51)
complete installation, reverse removal procedure. Adjust drive belts to INCH Lbs. (N.m)
proper tension.
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

Kit No. Part No.
2.0L 4-Cyl.
Sportage
1
1995-02 .............................. 3.2 Hours .. .. TCK281 .. ..... T281
1

every 60,000 miles.
REMOVAL & INSTALLATION Fig. 2: Aligning Crankshaft Pulley Timing Marks

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.
Fig. 3: Aligning Camshaft Pulley Mating Marks
Fig. 4: Loosening Tensioner


426 KIA
Installation – 1) Ensure crankshaft and camshaft pulleys are still TORQUE SPECIFICATIONS
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 TORQUE SPECIFICATIONS
installed in original direction of rotation. Loosen tensioner pulley bolt. Application Ft. Lbs. (N.m)
2) Turn crankshaft 2 revolutions in normal direction of rotation. Check Camshaft Pulley Center Bolt ........................................................ ................. 35-48 (47-65)
that timing marks are correctly aligned. If timing marks are not correctly Cooling Fan Clutch-To-Pulley Nuts ........................................................................... 24 (32)
aligned, remove belt and realign. After realigning belt, repeat rotation Crankshaft Center Bolt ............................................................................ 116-123 (157-167)
prodecure. Crankshaft Pulley-To-Crankshaft Bolts ......................................... ................... 9-13 (12-17)
3) Turn crankshaft to align “S” mark of exhaust camshaft pulley with rear Generator Mount Bolts
cover seal plate mating mark. Tighten tensioner pulley bolt. Top Generator Bolt .................................................................................................. 16 (22)
Bottom Generator Bolt ............................................................................................ 32 (45)
4) Check that belt deflection is .30-.33″ (7.5-8.5 mm) with 22 lbs. (10 kg)
Power Steering Pump Bolts .......................................................... ................. 27-34 (37-46)
of downward pressure on belt, midway between two camshaft pulleys. Timing Belt Idler Pulley Bolt ......................................................... ................. 27-38 (37-52)
5) Install timing belt guide plate with flat side toward belt. Install timing Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-52)
belt covers. Water Pump Bolt ....................................................................................................... 16 (22)
6) To complete installation, reverse removal procedure. Adjust drive 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

Part No.
Sportage
1
1995 .......................................................... 2.3 Hours .. ..... T264
1

every 60,000 miles.

CAUTION: This application is an interference engine. Do not rotate Fig. 1: Identifying Timing Belt &
camshaft or crankshaft when timing belt is removed, or engine Related Components
damage may occur.
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) Courtesy of Kia Motors America, Inc.
pressure on belt between camshaft pulley and crankshaft pulley. To Fig. 2: Camshaft Pulley Mating Marks
proper tension.
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)
Fig. 3: Crankshaft Pulley Mating Marks

428 KIA
Part No.
Optima
2001-04
1, 2
Balance Shaft ...................................... 2.3 Hours . ..... T314
1, 2
Camshaft ............................................. 2.6 Hours . ..... T313
1
– Balance Shaft Belt labor time included in
2

except in California. In California, inspect timing belt at 60,000 miles and
90,000 miles, and replace at 105,000 miles.

camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Identifying Timing Belt Alignment Marks
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 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.
nation. Inspect sprockets for damage. Check tensioner pulley and idler
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. Courtesy of Hyundai Motor Co.
2) Install right counterbalance shaft sprocket. Tighten flange bolt tightly
by hand. Align timing marks on each sprocket and on front case. See Fig. 2: Exploded View Of Timing Belt Components
Fig. 4. 4) To tighten timing belt “B”, lift tensioner “B” so tension side is pulled
3) When installing timing belt “B”, ensure there is no slack in tension tight. Tighten bolt to secure tensioner “B”. DO NOT turn shaft, or belt will
side. Install tensioner “B” in center of pulley on left side of mounting bolt, be over-tightened.
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.
KIA 429
Fig. 4: Identifying Front Case Timing Marks


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
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 Courtesy of Hyundai Motor Co.
housing. Insert stiff wire to hold rod in this position. Install auto tensioner,
Fig. 5: Installing Tensioner “B”
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 TORQUE SPECIFICATIONS
direction, or valve and piston will touch. If necessary, remove and Application Ft. Lbs. (N.m)
reposition camshaft sprocket. Auto Tensioner Bolt ....................................................................... ................. 15-20 (20-27)
9) Install crankshaft sensor. Set timing marks of camshaft sprockets with Block Plug Cap ............................................................................. ................. 15-20 (20-27)
notches on upper side of rocker cover and dowel pins straight up. Align
crankshaft sprocket timing marks. Align oil pump sprocket timing marks. Crankshaft Sprocket Bolt ............................................................................ 80-94 (110-130)
10) Install timing belt in order around crankshaft sprocket, oil pump Oil Pump Sprocket Nut ................................................................. ................. 36-43 (50-60)
sprocket, idler pulley, exhaust camshaft sprocket, intake camshaft Timing Belt Cover Bolts
sprocket and tensioner pulley. Lower & Upper Cover Bolt ......................................................... ..................................... 1
11) Gently raise tensioner pulley so belt will not sag, and then tempo- Left Rear Cover Bolt
rarily tighten center bolt. Ensure timing mark of each sprocket is still Lower ......................................................................................... ................. 22-30 (30-41)
Upper ......................................................................................... ..................................... 2
aligned. Remove wire from auto tensioner.
Right Rear Cover Bolt ................................................................. ..................................... 2
12) Rotate crankshaft 2 complete turns clockwise. Leave in this position Timing Belt Idler Pulley Bolt ......................................................... ................. 33-40 (45-54)
for about 5 minutes. Measure auto tensioner protrusion “A” (distance Timing Belt Tensioner Pulley Bolt ................................................. ................. 31-40 (42-54)
between tensioner arm and auto tensioner body). Ensure auto tensioner Timing Belt Tensioner Pulley Bracket Bolt ................................... ................. 17-20 (23-27)
protrusion is .22-.35″ (6-9 mm). See Fig. 3. Install timing belt lower cover Water Pump Mounting Bolt ............................................................................. 11-15 (15-20)
and upper cover. INCH Lbs. (N.m)
Rocker Cover Bolt ......................................................................... ................... 71-89 (8-10)
Valve Cover Bolts .......................................................................... ................... 71-89 (8-10)
1
2
430 LANCIA
1.8L 4-Cylinder
TIMING BELT APPLICATION Installation – 1) Align reference mark on crankshaft pulley with timing
Application Labor Time Belt mark on Locking Fixture (88013039) or equivalent. When both marks
Part No. correspond exactly, cylinders No. 1 and 4 will be at TDC. Fixture
1.8L 4-Cyl. reference hole should also line up with ancillary drive shaft reference
Beta hole. Check alignment by inserting dowel pin.
1 2) Install timing belt. Unlock the belt stretcher bolt while applying
1976-78 .................................................... 2.7 Hours .. ..... T020
1 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
NOTE: For information about tensioners and/or pulleys (when few times, partially release the belt stretcher, and finally relock it
available), see ALPHABETICAL MODEL LISTING. properly. Install timing reference pointers bracket. Adjust drive belts to
proper tension.
MANUFACTURER’S SUGGESTED VALVE TIMING

SCHEDULED MAINTENANCE 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
The manufacturer recommends the belt be replaced every 25,000 miles. 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
REMOVAL & INSTALLATION BELT.

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
Camshaft Housing Nuts ............................................................................................ 16 (22)
Fig. 1: Aligning Camshaft Timing Marks With Bearing Reference

Marks
LAND ROVER 431
2.5L KV6 – DOHC, 2002-04

TIMING BELT APPLICATION engine steady away from top arm. Install wooden block to jack, position
Application Labor Time Belt jack under engine sump to support engine.
Part No. 3) Remove nut and 4 bolts securing engine top arm bracket to right
2.5L KV6 – VIN 2 hydramount and to engine front mounting bracket. See Fig. 3. Release
Freelander power steering pipe support bracket from hydramount and position pipe
2002-04 aside. Remove top arm.
Front Belt ............................................... 5.6 Hours ... ..... T327 4) Remove 4 bolts securing engine mounting bracket to engine front
Rear Belts ............................................ .......... 1 .......... ..... T326 plate and remove bracket. See Fig. 4. Using a 3/8″ square drive socket
1
– Engine set (front/rear timing belts) labor time is 6.8 hours. bar, raise ancillary drive belt tensioner and release drive belt from
alternator pulley. Release and remove ancillary drive belt from remain-
ing pulleys.
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
Fig. 3: Removing Top Engine Arm Bracket

NOTE: Examine drive belt for signs of wear. A drive belt with
Fig. 1: Locating Timing Belts & Related Components (2.5L KV6) cracked ribs is acceptable. A drive belt that has loose or missing
parts of ribs must be changed.
REMOVAL & INSTALLATION Installation – 1) Clean pulley grooves and tensioner pulley running
WARNING: This application is an interference engine. DO NOT surface. Install new drive belt to crankshaft pulley. Raise belt tensioner
rotate camshafts or crankshaft when timing belt is removed, or and connect drive belt to steering pump, alternator and compressor
engine damage may occur. 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
ANCILLARY DRIVE BELT top arm to front engine mounting bracket, install and tighten bolts to
Removal – 1) Disconnect battery ground lead. Remove underbelly specification.
panel. See UNDERBELLY PANEL. Remove engine acoustic cover. See 3) Lower and remove jack supporting engine. Position power steering
ENGINE ACOUSTIC COVER. pipe support bracket to hydramount. Install nut securing top arm to right
2) Remove bolt securing upper right engine steady to top arm. See hydramount and tighten to specification. See TORQUE SPECIFICA-
Fig. 2. Loosen bolt securing upper right engine steady to body, pivot TIONS.
432 LAND ROVER
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.
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.
Fig. 4: Locating Engine Mounting Front Bracket & Ancillary Drive 2) Remove 3 bolts securing camshaft left rear timing belt cover and
Belt Tensioner remove cover. See Fig. 7.
4) Position engine upper right steady to top arm, install and tighten bolt 3) On vehicles up to 2003, remove intake manifold chamber to gain
to specification. See TORQUE SPECIFICATIONS. Tighten bolt securing access to right rear timing belt cover. See INTAKE MANIFOLD CHAM-
engine upper right steady to body to specification. BER. Remove 2 bolts securing right rear timing belt cover heat shield
5) Install underbelly panel. See UNDERBELLY PANEL. Install engine and remove heat shield. Remove 3 bolts securing right rear timing belt
acoustic cover. See ENGINE ACOUSTIC COVER. Connect battery cover and remove cover. See Fig. 7.
ground lead.
CAUTION: DO NOT use camshaft gear bolts or timing belt to rotate
crankshaft. DO NOT use arrow on oil pump body as a timing
ENGINE ACOUSTIC COVER reference.
Removal & Installation – 1) Loosen clip and disconnect fresh air intake
4) Using a socket on crankshaft pulley bolt, rotate crankshaft in a
hose from acoustic cover. See Fig. 5. Loosen clip and disconnect air
clockwise direction. Align the engine SAFE position notch on crankshaft
intake hose from Mass Air Flow (MAF) sensor. Release 2 turnbuckles
pulley with the ARROW on front mounting plate and timing marks
securing acoustic cover to left camshaft cover. Release retaining strap
aligned on the rear camshaft gears. See Fig. 8.
and remove acoustic cover.
2) To install, position and secure engine acoustic cover. Connect air CAUTION: Ensure hole immediately adjacent to side of lower
intake and air bypass hoses, secure clip. Connect fresh air intake hose crankcase is used.
to acoustic cover and tighten clip screw.
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 alterna-
tor. 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. 8) Remove 3 bolts securing camshaft timing belt front covers and
Fig. 5: Removing & Installing Engine Acoustic Cover 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 crank-
shaft 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. NOTE: To prevent timing belt from disengaging from crankshaft
gear during installation, install a suitable wedge between the belt
9) Remove 3 bolts securing camshaft timing belt lower cover to cylinder and oil pump belt guard.
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 2) Position timing belt to crankshaft gear. Install tool LRT-12-197 into
mounting plate and cylinder block. Release A/C compressor and heat each exhaust camshaft in turn. See Fig. 17. Using assistance, rotate
each exhaust camshaft slightly clockwise and align timing marks on left
shield and position aside.
and right rear camshaft gears. See Fig. 18. Remove tool LRT-12-197
10) Remove bolt securing dipstick tube to cylinder block. Depress and
from exhaust camshaft. Install tools LRT-12-175 to left and right rear
hold down dipstick tube locking collar, remove dipstick tube from engine
camshaft gears.
sump. Remove rubber blanking plug from around camshaft front timing
belt tensioner assembly. See Fig. 12. Remove 3 bolts securing engine CAUTION: Timing gears MUST NOT be rotated counterclockwise
front mounting plate and lifting bracket to cylinder block. Remove bolt more than one tooth.
securing lifting bracket to right cylinder head and remove lifting bracket.
3) Rotate both front intake camshaft gears fully clockwise as viewed
11) Remove 2 bolts securing Intermediate Reduction Drive (IRD)
from front of engine. Using fingers only, install front timing belt to gears,
support bracket to engine front mounting plate. Remove 5 bolts and 2 starting at the crankshaft gear and working in a counterclockwise
pillar bolts securing engine front mounting plate to cylinder block. See direction. Keep belt run as tight as possible and turn camshaft gears
Figs. 6 and 13. With care, release and remove front mounting plate from only a minimum amount counterclockwise to install timing belt.
engine.
CAUTION: Ensure timing belt tensioner plunger is contacting
NOTE: If holes in body and plunger are not aligned, move tensioner underside of tensioner backplate.
backplate using a suitable broad bladed screwdriver; this will
4) Position an Allen key in tensioner backplate and hold tensioner pulley
move plunger sufficiently to enable pin to be inserted.
against timing belt. See Fig. 19. With assistance, position tensioner,
12) Insert a suitable 1.5-mm diameter pin through hole in tensioner body install NEW Patchlok bolts and tighten to specification. See TORQUE
and into hole in plunger. See Fig. 14. SPECIFICATIONS. Remove tools LRT-12-175 from rear timing belt
gears.
CAUTION: Exercise great care when removing bolts, DO NOT apply
excessive torque. If bolts appear to be seized, apply suitable CAUTION: Special tools must be installed when tightening or
loosening gear retaining bolts, otherwise damage to camshafts
anti-seize lubricant prior to removing bolts. DO NOT loosen Allen
may occur.
screw securing tensioner pulley.
5) Install tools LRT-12-196 to intake camshaft front gears and into end
13) Remove and discard 2 Patchlok bolts securing tensioner to cylinder
of each exhaust camshaft. See Fig. 16. Tighten front intake camshaft
block and remove tensioner. See Fig. 14.
gear bolts in 2 stages to specification. See TORQUE SPECIFICA-
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt TIONS.
removed and cylinder heads installed. 6) Remove tools LRT-12-196 from both intake camshaft gears and
exhaust camshafts. Remove wedge from between drive belt and oil
14) If camshaft timing belt is to be reinstalled, mark direction of rotation pump belt guard. Remove 1.5-mm diameter pin from tensioner. Install
on timing belt before removal. With care, ease camshaft timing belt from rubber blanking plug around tensioner. Remove timing pin LRT-12-232.
gears using fingers only and remove timing belt.
CAUTION: The sealing edge of cap seal and mating face must be
CAUTION: Special tools must be installed when tightening or clean and dry.
loosening gear retaining bolts, otherwise damage to camshafts
7) Clean exhaust camshaft front cap seal locations and install NEW cap
may occur.
seals. Position engine front mounting plate and maneuver plate into
15) Remove and discard left and right exhaust camshaft cap seals. See position. Install bolts but DO NOT tighten at this stage. Install bolts
Fig. 15. Position tools LRT-12-196 to left and right front intake camshaft securing front mounting plate to cylinder block and Intermediate Reduc-
gears and into end of each exhaust camshaft. See Fig. 16. tion Drive (IRD) bracket, but DO NOT tighten at this stage.
16) Remove and discard bolts retaining front intake camshaft gears to 8) Tighten bolts in sequence shown and to specification by numbers
camshafts. Remove tools LRT-12-196 from both intake camshaft gears indicated. See Fig. 20. See TORQUE SPECIFICATIONS.
and exhaust camshafts. Remove camshaft drive gears and hub assem- 9) Position engine lifting bracket, install bolts securing lifting bracket and
blies. front mounting plate to cylinder block and right cylinder head. Tighten
M10 bolts and M8 bolt to specification. See TORQUE SPECIFICA-
NOTE: Following front or rear timing belt installation, it is possible TIONS.
that, after rotating engine and positioning crankshaft pulley to 10) Clean end of dipstick tube. Position dipstick tube to sump and
SAFE position, the timing marks on rear timing gears may be cylinder block, instal bolt and tighten to specification. See TORQUE
misaligned. This misalignment is acceptable provided that the SPECIFICATIONS. Position A/C compressor to front mounting plate and
timing belt installation procedure was carried out correctly. cylinder block, align heat shield, install and tighten bolts to specification.
11) Clean lower timing belt cover. Position lower timing belt cover, install
CAUTION: If sintered gears have been subjected to prolonged oil and tighten bolts to specification. See TORQUE SPECIFICATIONS.
contamination, they must be soaked in a solvent bath and then Clean crankshaft pulley. Install crankshaft pulley to crankshaft gear and
thoroughly washed in clean solvent before refitting. Because of the ensure that indent on pulley locates over lug on crankshaft gear. Install
porous construction of sintered material, oil impregnated in the crankshaft pulley bolt and washer. Position LRT-12-161 with
gears will emerge and contaminate the belt. LRT-12-199 tools into crankshaft pulley bolt and tighten to specification.
Installation – 1) Clean camshaft gears and hubs, crankshaft gear, See Fig. 11.
tensioner and water pump pulleys. Install hubs to camshaft gears and 12) Remove tools LRT-12-161 and LRT-12-199 from crankshaft pulley
install gears to camshafts. Install NEW bolts and tighten sufficiently to bolt. Clean ancillary drive belt tensioner. Position ancillary belt tensioner,
allow gears to rotate without tipping. install bolts and tighten to specification. See TORQUE SPECIFICA-
TIONS.
434 LAND ROVER
2.5L KV6 – DOHC, 2002-04 (Cont.)
Fig. 6: Locating Front Timing Belt Components (2.5L)

13) Clean left and right front timing belt covers. Position left and right 18) Install intake manifold chamber. See INTAKE MANIFOLD CHAM-
front timing belt covers, install and tighten bolts to specification. See BER. Install right road wheel and tighten nuts to specification. Install
TORQUE SPECIFICATIONS. Clean idler pulley, position pulley to ancillary drive belt. See ANCILLARY DRIVE BELT.
engine front mounting plate and tighten Allen bolt to specification.
14) Position alternator to front mounting plate. Install bolts and nut INTAKE MANIFOLD CHAMBER
securing alternator to front mounting plate and tighten to specification. Removal (Up To 2003 Model Year) – 1) Disconnect battery ground
See TORQUE SPECIFICATIONS. Connect alternator connector. Con- lead. Remove vacuum enhancer. Remove engine acoustic cover. See
nect battery lead to alternator, install and tighten nut to specification and ENGINE ACOUSTIC COVER. Release enhancer from support clips.
install terminal cover. Disconnect connector from solenoid valve, if equipped. Release and
15) Position PAS pump to front mounting plate, install and tighten bolts disconnect servo pipe. Release clip and disconnect from intake hose.
to specification. See TORQUE SPECIFICATIONS. Position PAS pipe to Release and remove enhancer assembly from intake manifold.
engine front mounting plate, install and tighten bolt to specification.
WARNING: The spilling of fuel is unavoidable during this opera-
Clean PAS pump pulley mating faces. Position PAS pump pulley, install
tion. Ensure that all necessary precautions are taken to prevent fire
and tighten Torx screws to specification.
and explosion.
16) Position lower engine steady to sump mounting, install and tighten
bolt to specification. See TORQUE SPECIFICATIONS. Tighten bolt 2) Position absorbent cloth around fuel feed pipe connection to collect
securing lower engine steady to subframe to specification. spillage. Pull back rubber sleeve on fuel pipe connector, release
17) Clean rear timing belt covers. Position rear timing belt covers, install connector and disconnect fuel pipe from fuel rail pipe. See Fig. 21.
and tighten bolts to specification. Position rear timing belt right cover Install plugs to open connections to prevent contamination.
heat shield, install bolts and tighten M6 bolt and M8 bolt to specifica- 3) Release clip and disconnect hose from purge control valve. Install
tions. plugs to open connections to prevent contamination. Disconnect con-
LAND ROVER 435
2.5L KV6 – DOHC, 2002-04 (Cont.)
Fig. 9: Inserting Timing Pin LRT-12-232 Through

Lower Crankcase Hole
Fig. 7: Removing Rear Timing Belt Covers
Fig. 10: Locating Lower Engine Steady At Front Subframe
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. Courtesy of Land Rover North America, Inc.
4) Depress locking collars and release vacuum/breather hose from
purge control valve and left camshaft cover. See Fig. 22. Release clip Fig. 11: Removing Or Installing Crankshaft Pulley Bolt
securing hose to “T” piece and remove hose. Depress locking collars 5) Disconnect connectors from IAT and MAF sensors. See Fig. 23.
and release vacuum/breather hoses from throttle body, left and right Disconnect engine breather pipe from intake hose. Disconnect injector
camshaft cover and remove hose. 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.
436 LAND ROVER
2.5L KV6 – DOHC, 2002-04 (Cont.)
Fig. 12: Removing Rubber Blanking Plug From

Front Timing Belt Tensioner
Fig. 14: Locking Timing Belt Tensioner Before Removal

Courtesy of Land Rover North America, Inc. Fig. 15: Removing Left Side Exhaust Camshaft Cap Seal,
Fig. 13: Removing Engine Front Mounting Plate 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 Courtesy of Land Rover North America, Inc.
seals to manifold chamber. Position intake manifold chamber, secure
right coil harness clips in intake manifold chamber support brackets. Fig. 16: Positioning LRT-12-196 To Left Side Camshafts,
Right Side Is Similar
2) Connect connectors to plug top coils and secure with locking clips.
Align intake manifold chamber to intake manifolds, install and tighten
LAND ROVER 437
2.5L KV6 – DOHC, 2002-04 (Cont.)
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
Fig. 21: Locating Fuel Pipe Connector (Up To 2003)

Fig. 18: Aligning Rear Timing Marks & Positioning LRT-12-175

Between Rear Camshaft Gears
Fig. 22: Locating Purge Control Valve & Left Camshaft Cover
Courtesy of Land Rover North America, Inc. Vacuum/Breather Hoses (Up To 2003)
4) Connect engine breather pipe. Connect connectors to IAT and MAF
Fig. 19: Installing Front Timing Belt Tensioner
sensors. Connect brake servo vacuum hose to intake manifold chamber.
3) Align intake manifold chamber support brackets to right camshaft Connect vacuum/breather hoses to left and right camshaft covers and to
cover, install and tighten bolts to specification. See TORQUE SPECIFI- throttle body. Connect cruise control actuator vacuum pipe.
CATIONS. Position engine harness brackets to intake manifold cham-
ber, install and tighten screws. Connect connectors to Variable Intake
System (VIS) motors.
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 opera-

tion. Ensure that all necessary precautions are taken to prevent fire
and explosion.
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 contami-
nation.
2) Release and disconnect EVAP hose from purge control valve. Install
plugs to open connections to prevent contamination. Disconnect con-
Courtesy of Land Rover North America, Inc. nector from purge control valve. Disconnect connector from Idle Air
Control Valve (IACV).
Fig. 23: Locating IAT & MAF Sensors (Up To 2003) 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 contami-
nation. 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
Courtesy of Land Rover North America, Inc. harness to intake manifold chamber support brackets. Remove intake
manifold chamber. Remove and discard seals from intake manifold
Fig. 24: Removing Intake Hose & MAF Sensor (Up To 2003)
chamber and “O” rings from right intake manifold.
Fig. 25: Locating VIS Motors Connectors & Brake Servo Hose
(Up To 2003)
5) Connect vacuum/breather hoses to left camshaft cover, “T” piece and Fig. 26: Locating Fuel Pipe & EVAP Hose Connections
(From 2003)
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.
LAND ROVER 439
2.5L KV6 – DOHC, 2002-04 (Cont.)

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.
Fig. 27: Locating Vacuum/Breather Pipes (From 2003) 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.
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 CHAM-
BER. 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.
Fig. 28: Disconnecting IAT & MAF Sensors Connectors
(From 2003) 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.
5) Remove and discard front exhaust camshaft cap seal from cylinder
Courtesy of Land Rover North America, Inc. head. See Fig. 15. Position LRT-12-175 to rear camshaft gears. See
Fig. 30. Remove and discard bolts securing gears to camshafts.
Fig. 29: Releasing Plug Top Coil Connector (From 2003)
Remove rear camshaft gears, timing belt and special tool as an
Installation – 1) Clean seal faces on intake manifold chamber and assembly.
intake manifolds. Install NEW “O” rings to right intake manifold and NEW
seals to intake manifold chamber. Position intake manifold chamber, CAUTION: DO NOT rotate crankshaft or camshafts with timing belt
secure right coil harness clips in intake manifold chamber support removed and cylinder heads installed.
brackets. Align intake manifold chamber to intake manifolds, install and 6) If camshaft timing belt is to be reinstalled, mark direction of rotation on
tighten bolts to specification. 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.)
Fig. 31: Rear Camshaft Gear Positions For Installation
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 mis-
aligned. 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 Courtesy of Land Rover North America, Inc.
facing each other. See Fig. 31.
Fig. 32: Installing LRT-12-195 & LRT-12-175 To
2) Keeping timing marks aligned, position timing belt onto gears.
Rear Camshaft 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.
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 Courtesy of Land Rover North America, Inc.
from lower crankcase. Fig. 33: Installing Rear Camshaft Gears To Camshafts
7) Install splash shield and secure with bolts. Install right road wheel and
tighten nuts to specification. See TORQUE SPECIFICATIONS. Clean 2) Remove 4 screws securing wheel arch liners to bumper valance, if
rear timing belt cover. Position rear timing belt cover, install bolts and equipped. Remove 2 bolts securing rear of underbelly panel. Remove 6
tighten to specification. bolts securing underbelly panel frame. Remove underbelly panel.
8) Install engine acoustic cover. See ENGINE ACOUSTIC COVER. 3) To install, position underbelly panel. Install bolts securing underbelly
Install underbelly panel. See UNDERBELLY PANEL. Connect battery panel frame and tighten to specification. See TORQUE SPECIFICA-
earth lead. TIONS. Install bolts securing rear of underbelly panel and tighten to
specification.
4) Install and tighten screws securing wheel arch liners to bumper
UNDERBELLY PANEL valance, if equipped. Install and tighten screws securing bumper val-
Removal & Installation – 1) Raise and support front of vehicle. DO ance to brackets. Remove stands and lower vehicle.
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.
LAND ROVER 441
2.5L KV6 – DOHC, 2002-04 (Cont.)

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
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)
Courtesy of Land Rover North America, Inc. Engine Mounting Bracket-To-Engine Front Plate Bolts ........................................... 33 (45)
Fig. 34: Installing NEW Camshaft Gear Retaining Bolts 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
– NEW bolts must be installed.
2
– Tighten bolts in sequence to specified torque value for each bolt. See Fig. 20.
3
– Apply sealant No. STC50552 to bolt threads.
442 LEXUS
2.5L & 3.0L V6 – 1990-98
TIMING BELT APPLICATION TIMING BELT
Application Labor Time Component Belt Removal (2.5L & 1992-93 3.0L V6) – 1) Disconnect negative battery
Kit No. Part No. cable. Remove cruise control actuator and vacuum pump. Remove
2.5L V6 power steering reservoir with hoses attached, and secure them aside.
ES 250 Raise and support vehicle. Remove right front wheel. Remove right
1990-91 ............................... 3.8 Hours ... .. TCK157 .. ..... T157 lower engine cover. Remove all drive belts.
3.0L V6 2) Remove top braces on right engine mount at timing belt cover. Slightly
ES 300 raise engine to remove weight from right engine mount. Remove
1992-93 ............................... 3.0 Hours ... .. TCK200 .. ..... T200
retaining bolts/nuts and right engine mount assembly. Remove spark
1994-98 ............................... 3.0 Hours ... ...... ..... ...... ..... T257
plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right
NOTE: For information about tensioners and/or pulleys (when engine mount bracket. See Fig. 1. Note bolt length and location of No. 2
available), see ALPHABETICAL MODEL LISTING. timing belt cover bolts for reassembly reference.
CAUTION: If timing belt is to be reused, mark direction of timing

MANUFACTURER’S SUGGESTED belt rotation and location on camshaft sprockets for reassembly
reference. Also place reference mark on timing belt at upper edge
SCHEDULED MAINTENANCE of No. 1 timing belt cover.
3) Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compres-
maintenance interval for normal operating conditions, belt manufactur-
sion stroke. Ensure timing mark on crankshaft pulley aligns with “0” mark
ers suggest the belt be replaced at 60,000 mile intervals. The manufac-
on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets
turer recommends the belt be replaced at 60,000 miles or 96 months for
are aligned with timing marks on No. 3 timing belt cover. See Fig. 2.
severe operating conditions.
Remove retaining bolts and timing belt tensioner.
4) Install Camshaft Sprocket Holder (09278-54012), or equivalent, in
REMOVAL & INSTALLATION holes on front of right camshaft sprocket. Slightly rotate right camshaft
sprocket clockwise to release tension on timing belt between camshaft
WARNING: To prevent air bag deployment, disconnect negative sprockets. Remove timing belt from camshaft sprockets.
battery cable at least 90 seconds before working on vehicle.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

LEXUS 443
2.5L & 3.0L V6 – 1990-98 (Cont.)

5) Using Pulley Holder (09213-54014) or equivalent, and Handle 6) Remove retaining bolts, timing belt tensioner and dust boot. Remove
(09330-00021), hold crankshaft pulley, and remove retaining bolt. If crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder
timing belt is to be reused, ensure reference mark placed on timing belt (09278-54012) or equivalent, in holes on front of right camshaft
aligns with upper edge of No. 1 timing belt cover when timing mark on sprocket. Slightly rotate right camshaft sprocket clockwise to release
crankshaft pulley is aligned with “0” mark on No. 1 timing belt cover. tension on timing belt between camshaft sprockets. Remove timing belt
6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft to from camshaft sprockets.
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).
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).
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
alternator bracket for access to timing belt covers. Remove No. 2 timing
belt cover. See Fig. 1. Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion
3) Use Pulley Holder (09213-54015) or equivalent, and Handle Installation (2.5L & 1992-93 3.0L V6) – 1) Install No. 1 idler pulley (if
(09330-00021) or equivalent, to hold crankshaft pulley. Remove crank- removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining
shaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 bolt. Install and tighten retaining bolt to specification. See TORQUE
timing belt cover. See Fig. 1. SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates
4) Remove engine mounting bracket. Note direction of timing belt guide smoothly.
installation for reassembly reference. Remove timing belt guide. 2) Install timing belt on crankshaft sprocket with installation mark on
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crank- timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2.
shaft pulley bolt, rotate crankshaft clockwise until timing mark on Install timing belt guide with cupped side away from crankshaft sprocket.
crankshaft sprocket aligns with timing mark on oil pump body. See Install No. 1 timing belt cover and gasket. Align crankshaft key with key
Fig. 3. Ensure timing marks on camshaft sprockets are aligned with groove of crankshaft pulley, and install crankshaft pulley. Tighten
timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not retaining bolt to specification.
aligned, rotate crankshaft clockwise one full revolution (360 degrees).
444 LEXUS
2.5L & 3.0L V6 – 1990-98 (Cont.)
Installation (1994-98 3.0L V6) – 1) Install timing belt plate. Install and
CAUTION: If reusing timing belt, ensure timing mark on crankshaft tighten bolt to specification. Install No. 1 and No. 2 idler pulleys (if
sprocket is aligned with reference mark placed on timing belt, and removed). Install and tighten bolts to specification. See TORQUE
timing belt is installed in original direction of rotation. SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly.
2) Temporarily install crankshaft pulley bolt in crankshaft. Using crank-
3) Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure
shaft pulley bolt, rotate crankshaft clockwise until timing mark on
idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on
crankshaft sprocket aligns with timing mark on oil pump body. See
crankshaft pulley aligns with “0” mark on No. 1 timing belt cover. Rotate
Fig. 3.
left camshaft so timing mark on camshaft sprocket aligns with timing 3) Using camshaft sprocket holder, rotate each camshaft sprocket so
mark on No. 3 timing belt cover. See Fig. 2. timing mark on camshaft sprocket aligns with timing mark on No. 3
4) Rotate right camshaft so knock pin hole in camshaft aligns with timing timing belt cover. See Fig. 3. Align reference marks on timing belt with
mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure dot on crankshaft sprocket and timing marks on camshaft sprocket. See
reference mark placed on timing belt aligns with upper edge of No. 1 Fig. 6. Ensure front mark is pointing toward timing belt end of engine.
timing belt cover when timing mark on crankshaft pulley is aligned with
“0” mark on No. 1 timing belt cover. CAUTION: Using camshaft sprocket holder, rotate each camshaft
5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket sprocket so timing mark on camshaft sprocket aligns with timing
clockwise, and install timing belt on camshaft sprocket. Ensure refer- mark on No. 3 timing belt cover. See Fig. 3. Align reference marks
ence mark on timing belt aligns with timing mark on camshaft sprocket. on timing belt with dot on crankshaft sprocket and timing marks on
6) Using camshaft sprocket holder, slightly rotate left camshaft sprocket, camshaft sprocket. Ensure front mark is pointing toward timing
belt end of engine.
and align timing mark on camshaft sprocket with timing mark on No. 3
timing belt cover. Ensure tension exists on timing belt between crank- 4) Install timing belt on crankshaft sprocket, water pump pulley, left
shaft sprocket and left camshaft reference mark on timing belt with camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then
timing mark on right camshaft sprocket. Install right camshaft sprocket on No. 1 idler pulley. Using press, apply pressure on rod of timing belt
on camshaft with flange side toward cylinder head. Ensure timing mark tension until rod is retracted, and holes in rod and housing are aligned.
on right camshaft sprocket aligns with timing mark on No. 3 timing belt Install hexagon wrench through holes in housing and rod to hold rod in
cover. See Fig. 2. retracted position. See Fig. 5. Release press and install dust boot on
7) Using camshaft sprocket holder, slightly rotate right camshaft timing belt tensioner. Install timing belt tensioner. Install and alternately
sprocket so knock pin hole in camshaft sprocket aligns with knock pin tighten bolts to specification. See TORQUE SPECIFICATIONS.
hole in camshaft. Install knock pin in right camshaft. Install right 5) Remove hexagon wrench from timing belt tensioner. Rotate crank-
shaft clockwise until timing mark on crankshaft sprocket aligns with
camshaft sprocket retaining bolt, and tighten it to specification. See
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.
8) Place washer on bottom side of timing belt tensioner. Using press,
See Fig. 3. If all timing marks are not aligned, remove timing belt and
apply pressure on rod of timing belt tension until rod is retracted, and
reinstall. Remove crankshaft pulley bolt.
holes in rod and housing are aligned. Install hexagon wrench through 6) Install timing belt guide with cupped side away from crankshaft
holes in housing and rod to hold rod in retracted position. See Fig. 5. sprocket and flat side toward timing belt. Install engine mounting bracket
Release press, and install dust boot on timing belt tensioner. Install on front of cylinder block. Install and tighten bolts to specification. Using
timing belt tensioner. Tighten retaining bolts to specification. See new gaskets, install No. 1 and No. 2 timing belt covers. Install and
TORQUE SPECIFICATIONS. tighten bolts to specification. See TORQUE SPECIFICATIONS.
9) Remove hexagon wrench from timing belt tensioner. Rotate crank- 7) Align crankshaft key with key groove of crankshaft pulley. Install
shaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica-
on camshaft sprockets align with those on No. 3 timing belt cover. See tion. To install remaining components, reverse removal procedure.
Fig. 2. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
CAUTION: Crankshaft must always be rotated clockwise. DO NOT
rotate crankshaft counterclockwise.
10) To install remaining components, reverse removal procedure.
Fig. 5: Retracting Timing Belt Tensioner Rod

Fig. 6: Identifying Timing Belt Reference Marks (1994-98 3.0L)

LEXUS 445
2.5L & 3.0L V6 – 1990-98 (Cont.)

TORQUE SPECIFICATIONS (2.5L V6) TORQUE SPECIFICATIONS (3.0L V6)
Camshaft Sprocket Bolt .......................................................................................... 80 (109) Camshaft Sprocket Bolt .......................................................................................... 94 (127)
Crankshaft Pulley Bolt ........................................................................................... 181 (245) Crankshaft Pulley Bolt ........................................................................................... 159 (215)
Engine Crossmember-To-Body Bolt .......................................................................... 29 (39) Front Engine Mount-To-Crossmember Bolt
Engine Mount Through-Bolt ...................................................................................... 64 (87) Toyota Motor Corporation Bolt ................................................................................ 59 (80)
Engine Mount-To-Engine Crossmember Bolt ........................................................... 54 (73) Toyota Motor Manufacturing Bolt ............................................................................ 49 (66)
Idler Pulley Bolt Front Engine Mount-To-Cylinder Block Bolt ............................................................. 47 (64)
No. 1 Idler Pulley .................................................................................................... 25 (34) Power Steering Pump Bolt ....................................................................................... 31 (42)
No. 2 Idler Pulley .................................................................................................... 29 (39) Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43)
Idler Pulley Support Bolt ........................................................................................... 13 (18) Pulsation Damper ...................................................................................................... 24 (33)
Right (Timing Belt Side) Engine Mount Right Engine Mount Brace Bolt ................................................................................ 23 (31)
Bolt ........................................................................................................................... 47 (64) Stabilizer Bar Link-To-Lower Control Arm Nut ......................................................... 29 (39)
Nut Timing Belt Idler Pulleys
Bracket Side .......................................................................................................... 38 (52) No. 1 Idler Pulley Bolt ............................................................................................ 25 (34)
Body Side .............................................................................................................. 65 (88) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 14 (19) Wheel Lug Nut ........................................................................................................ 76 (103)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
INCH Lbs. (N.m)
No. 1 & 2 Timing Belt Cover Bolt ........................................................................... 75 (8.5)
No. 3 Timing Belt Cover Bolt ..................................................................................... 65 (7) No. 3 Timing Belt Cover Bolt .................................................................................. 75 (8.5)
Valve Cover Nut .......................................................................................................... 52 (6) Timing Belt Plate Bolt .............................................................................................. 71 (8.0)
Valve Cover Bolt ...................................................................................................... 71 (8.0)
Water Pump Bolt/Nu ................................................................................................ 71 (8.0)
446 LEXUS
3.0L 6-Cylinder – 1993-97
Part No.
3.0L 6-Cyl.
GS 300
1993-97 ..................................................... 3.4 Hours ... ..... T215
SC 300
1993-97 ..................................................... 3.4 Hours ... ..... T215


TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative
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.
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
6) Using Handle (09330-00021) or equivalent, and Pulley Holder
(09213-70010), or equivalent, hold crankshaft pulley and remove crank- Fig. 2: Aligning Timing Marks
shaft pulley bolt. Using puller, remove crankshaft pulley.
7) Remove No. 1 timing belt cover and gaskets. Note direction of timing NOTE: Timing belt tensioner may have a small amount of oil on rod
belt guide installation for reassembly reference. See Fig. 1. Remove seal under normal conditions. If excessive amount of oil exists,
timing belt guide.
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
belt tensioner if oil leakage exists. Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion
3) Hold timing belt tensioner body, and press rod against solid surface.
Installation – 1) Install idler pulley and plate washer (if removed). Apply
Replace timing belt tensioner if rod moves.
Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to
specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is
of housing. See Fig. 3. Replace timing belt tensioner if distance is not
clean and rotates smoothly, and idler pulley bracket moves freely.
.315-.343″ (8.00-8.80 mm).
LEXUS 447
3.0L 6-Cylinder – 1993-97 (Cont.)

2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark TORQUE SPECIFICATIONS
on crankshaft sprocket with timing mark on oil pump body. See Fig. 1.
Install timing belt on crankshaft sprocket. TORQUE SPECIFICATIONS
CAUTION: If reusing timing belt, ensure reference marks on timing
A/C Compressor
belt and crankshaft sprocket align and timing belt is installed in Bolt ........................................................................................................................... 36 (49)
original direction of rotation. Nut ........................................................................................................................... 22 (30)
Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18)
3) Install timing belt guide with cupped side away from crankshaft
sprocket and flat side against timing belt. Install gaskets and No. 1 Crankshaft Pulley Bolt ........................................................................................... 181 (245)
timing belt cover. Distributor Housing Bolt ............................................................................................ 13 (18)
4) Align crankshaft pulley key groove with crankshaft key. Install Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica- Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
tion. See TORQUE SPECIFICATIONS. Power Steering Pump
5) If installing camshaft sprocket, align hole in camshaft sprocket with Bolt ........................................................................................................................... 29 (39)
dowel pin in camshaft. Install camshaft sprocket. Hold camshaft Nut ........................................................................................................................... 32 (43)
Power Steering Pump Pulley Nut ............................................................................. 32 (43)
sprocket with sprocket holder, and tighten bolt to specification. See
Pulsation Damper ...................................................................................................... 29 (39)
TORQUE SPECIFICATIONS. Spark Plug ................................................................................................................. 13 (18)
6) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
TDC on compression stroke. Ensure timing mark on crankshaft pulley Water Pump Bolt/Nut ................................................................................................ 13 (18)
aligns with “0” mark on timing belt cover. INCH Lbs. (N.m)
7) Using sprocket holder, rotate camshaft sprockets so timing marks on
Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4)
camshaft sprockets align with timing marks on No. 4 timing belt cover.
Valve Cover Bolt ...................................................................................................... 52 (5.9)
See Fig. 2. Install timing belt on camshaft sprockets. Ensure tension
exists on timing belt between camshaft sprockets.

belt and camshaft sprockets align and timing belt is installed in
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 SPECIFICA-
TIONS.
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate

crankshaft counterclockwise.
10) Remove hexagon wrench from timing belt tensioner. Rotate crank-
shaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate
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.

448 LEXUS
3.0L 6-Cylinder – 1998-04
3.0L 6-Cyl. – 2JZ-GE camshaft or crankshaft when timing belt is removed, or engine
GS 300 damage may occur.
1998-04 ..................................................... 3.4 Hours ... ..... T215
IS 300
2001-04 ..................................................... 3.2 Hours ... ..... T215 TIMING BELT
SC 300 Removal – 1) Raise and support vehicle. Remove engine undercover.
1998-00 ..................................................... 3.4 Hours ... ..... T215 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 COUNTER-
MANUFACTURER’S SUGGESTED CLOCKWISE and remove belt. Tensioner bolt has LEFT-HAND threads.
On 2000-04 models, rotate tensioner CLOCKWISE to remove serpen-
SCHEDULED MAINTENANCE tine belt.
or 72 months.

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 ten-
sioner.
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
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

and each camshaft timing pulley for reassembly reference.
8) DO NOT allow the crankshaft pulley to rotate. Remove crankshaft
pulley bolt.
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.

Fig. 3: Aligning Sub-Timing Marks

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.
450 LEXUS
3.0L 6-Cylinder – 1998-04 (Cont.)
9) Ensure timing marks on camshaft timing pulleys align with timing
NOTE: Timing belt tensioner may have a small amount of oil on rod marks on timing belt cover, and timing mark on crankshaft pulley aligns
seal under normal conditions. If excessive amount of oil exists, with “0” mark on timing belt cover. If timing marks are not aligned,
replace timing belt tensioner. remove timing belt and reinstall.
10) Tighten crankshaft pulley bolt to specification. Install drive belt
2) Hold timing belt tensioner body, and press push rod against solid tensioner. Install No. 2 and No. 3 timing belt covers. To install remaining
surface. Replace timing belt tensioner if push rod moves. Measure components, reverse removal procedure. Use care when installing drive
timing belt tensioner push rod protrusion from end of rod to edge of belt tensioner bolts to avoid dropping bolts into timing belt cover.
housing. See Fig. 4. Replace timing belt tensioner if distance is not 11) Tighten fasteners to specification. See TORQUE SPECIFICA-
.315-.346″ (8.00-8.80 mm). TIONS. Fill and bleed air from cooling system. See COOLING SYSTEM
3) On IS 300 M/T, compress and extend drive belt tensioner absorber BLEEDING.
rod. If there is abnormal resistance or operation, replace as necessary.
Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

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 Fig. 5: Retracting Timing Belt Tensioner Rod
freely.
COOLING SYSTEM BLEEDING
NOTE: The engine should be cold before adjusting timing marks. 1) Fill cooling system. Install radiator cap. Move heater control to
warmest position. Start engine. Maintain engine speed at 2000-2500
2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark RPM until engine is at normal operating temperature.
on crankshaft timing pulley with timing mark on oil pump body. See 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill
Fig. 3, STEP 3. Clean oil or water off of crankshaft timing pulley, and coolant level to FULL line on coolant reservoir if necessary.
install timing belt on crankshaft timing pulley and around idler pulley.

belt and crankshaft timing pulley align, and timing belt is installed TORQUE SPECIFICATIONS
in original direction of rotation. Application Ft. Lbs. (N.m)
3) Install timing belt guide with cupped side away from crankshaft timing Camshaft Timing Pulley Bolt .................................................................................... 60 (81)
pulley and flat side against timing belt. Install gasket and No. 1 timing Crankshaft Pulley Bolt ........................................................................................... 243 (330)
belt cover. Align crankshaft pulley key groove with crankshaft key. Install Drive Belt Tensioner Absorber Nut (IS 300 M/T) ..................................................... 14 (20)
crankshaft pulley.
Fan Clutch-To-Water Pump Nut (SC 300) ............................................................... 12 (16)
4) Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is Idler Pulley Bolt ....................................................................................................... 1 26 (35)
aligned with “0” timing mark of No. 1 timing belt cover. See Fig. 3, STEP Power Steering Pump Front Bracket Bolts
4. Temporarily install crankshaft pulley bolt. Bottom Bolt .............................................................................................................. 38 (52)
Top Bolts (2) ............................................................................................................ 43 (58)
CAUTION: If reusing timing belt, ensure reference marks on timing Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
belt and camshaft timing pulleys align and timing belt is installed in Water Pump Bolt ....................................................................................................... 15 (21)
original direction of rotation. INCH Lbs. (N.m)
5) If necessary, use spanner wrench to rotate camshaft timing pulleys so Fan-To-Fan Clutch Nuts (SC 300) .......................................................................... 65 (7.5)
timing marks on camshaft timing pulleys align with timing marks on No. 4 Timing Belt Cover Bolts .............................................................................................. 71 (8)
timing belt cover. See Fig. 2. Install timing belt on camshaft timing Timing Belt Plate Bolt ................................................................................................. 71 (8)
pulleys. Ensure tension exists on timing belt between camshaft timing 1
– Apply Loctite 242 or equivalent to bolt threads.
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
CAUTION: Always rotate crankshaft CLOCKWISE. DO NOT rotate

crankshaft COUNTERCLOCKWISE.
shaft CLOCKWISE 2 full revolutions from TDC to TDC.
LEXUS 451
3.0L V6 – 1999-03
Kit No. Part No.
3.0L V6 – 1MZ-FE
ES 300
1999-01 ............................... 3.0 Hours ... ...... ..... ...... ..... T257
2002-03 ............................... 3.0 Hours ... ...... ..... ...... ..... T257
RX 300
1999-01 ............................... 4.4 Hours ... . 1 TCK257 . ..... T257
2002-03 ............................... 4.4 Hours ... ...... ..... ...... ..... T257
1
– Timing belt component kit does not include camshaft ten-
sioner hydraulic assembly.


or 72 months. Courtesy of Toyota Motor Sales, U.S.A., Inc.

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-to-
engine 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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
mark on crankshaft sprocket aligns with timing mark on oil pump body.
See Fig. 2. Fig. 2: Aligning Crankshaft & Camshaft Timing Marks
5) Ensure timing marks on camshaft sprockets are aligned with timing Inspection (ES 300) – 1) Inspect timing belt for damaged teeth,
mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not cracking or oil contamination. Ensure idler pulleys rotate freely and are
aligned, rotate crankshaft clockwise one full revolution (360 degrees).
not leaking oil. Replace damaged components. Check water pump for
Remove crankshaft pulley bolt.
leaks or worn out bearing.
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 CAUTION: Never hold timing belt tensioner with push rod facing
it contacts the crankshaft and camshaft sprockets. Also, mark belt with downward.
arrow showing direction of rotation.
7) Alternately loosen 2 bolts, and remove timing belt tensioner and dust 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
boot. DO NOT hold tensioner with push rod facing downward. Remove belt tensioner if oil leakage exists. Hold timing belt tensioner body with
timing belt in the following sequence: No. 1 idler pulley, right camshaft push rod facing upward. Press rod against solid surface. Replace timing
sprocket (firewall side), No. 2 idler pulley, left camshaft sprocket (front of belt tensioner if push rod moves.
vehicle side), left camshaft sprocket (front of vehicle side), water pump 3) Measure timing belt tensioner push rod protrusion from end of rod to
pulley, then crankshaft sprocket. edge of timing belt tensioner housing. See Fig. 4. Replace timing belt
tensioner if distance is not .394-.425″ (10.01-10.8 mm).
452 LEXUS
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
11) Align crankshaft key with key groove of crankshaft pulley. Install
crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica-
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.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Connect engine ground strap. Adjust drive belts to proper tension.
Fig. 3: Identifying Timing Belt Reference Marks & Front Mark
Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 5: Retracting Timing Belt Tensioner Rod
Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion 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.
NOTE: Engine should be cold when installing timing belt.
2) Remove right side front wheel. Remove right fender apron seal.
Installation (ES 300) – 1) Install No. 1 and No. 2 idler pulleys (if Remove accessory drive belts. Lower vehicle. Remove cruise control
removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or actuator from right side of engine compartment.
equivalent. Install and tighten bolts to specification. See TORQUE 3) Disconnect engine coolant reservoir hose from water outlet, if
SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. necessary. Disconnect ground strap connectors.
2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, 4) Remove engine moving control rod and engine mounting bracket
use crankshaft pulley bolt to rotate crankshaft clockwise until timing No. 2 (right side), located near timing belt cover. Remove generator-to-
mark on crankshaft sprocket aligns with timing mark on oil pump body. engine bracket for access to timing belt covers.
See Fig. 2. 5) Using Pulley Holder (09213-54015) or equivalent, and Handle
3) Using spanner wrench, rotate each camshaft sprocket so timing mark (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2
See Fig. 2. timing belt covers and gaskets. See Fig. 1. Remove transverse engine
4) Install timing belt on crankshaft sprocket, water pump pulley, left mounting bracket from front of engine. Note direction of timing belt guide
camshaft sprocket (front of vehicle side), No. 2 idler pulley, right installation for reassembly reference. Remove timing belt guide.
camshaft sprocket (firewall side), and then on No. 1 idler pulley. If
reusing old belt, ensure belt installation marks align with camshaft and NOTE: Always turn crankshaft clockwise, as viewed from timing
crankshaft sprocket marks. Ensure front (or rotation direction mark) belt side of engine.
points in correct direction. 6) Temporarily install crankshaft pulley bolt in crankshaft. Using crank-
5) Using press, SLOWLY apply about 200-2200 lbs. of pressure on push shaft pulley bolt, rotate crankshaft clockwise until timing mark on
rod of timing belt tension until rod is retracted and holes in rod and crankshaft sprocket aligns with timing mark on oil pump body. See
housing are aligned. See Fig. 5. Align holes in housing and push rod to Fig. 2.
hold rod in retracted position. Install hexagon wrench through housing 7) Ensure timing marks on camshaft sprockets are aligned with timing
and push rod hole to secure push rod. Release press and install dust mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not
boot on timing belt tensioner. aligned, rotate crankshaft clockwise one full revolution (360 degrees).
6) Install timing belt tensioner. Install and alternately tighten bolts to Remove crankshaft pulley bolt.
specification. See TORQUE SPECIFICATIONS. 8) If reusing old belt, ensure there are 3 installation marks and front
7) Remove hexagon wrench from timing belt tensioner. Slowly rotate arrow marked on belt. See Fig. 3. If not, place mating mark on belt where
crankshaft clockwise 2 revolutions until timing mark on crankshaft it contacts the crankshaft and camshaft sprockets. Also, mark belt with
sprocket aligns with timing mark on oil pump body. arrow showing direction of rotation.
LEXUS 453
3.0L V6 – 1999-03 (Cont.)

9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust 4) Install timing belt on crankshaft sprocket, water pump pulley, left
boot. DO NOT hold tensioner with push rod facing downward. Remove camshaft sprocket (front of vehicle side), No. 2 idler pulley, right
timing belt. 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
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.
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
Ensure there are no gaps in gasket. Cut off excess gasket. Install and
tighten bolts to specification.
tion.
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).
Courtesy of Toyota Motor Sales, U.S.A., Inc. 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, Application Ft. Lbs. (N.m)
cracking or oil contamination. Ensure idler pulleys rotate freely and are Camshaft Sprocket Bolt
not leaking oil. Replace damaged components. Inspect water pump for ES 300 ................................................................................................................... 94 (125)
leaks or worn out bearing. RX 300
Left Hand (Front End Of Vehicle Side) .............................................................. 94 (125)
CAUTION: Never hold timing belt tensioner with push rod facing Right Hand (Firewall Side Of Vehicle) ................................................................. 65 (88)
downward. Crankshaft Pulley Bolt ........................................................................................... 159 (215)
Engine Mounting Bracket (Right Side) Bolts ........................................................... 47 (64)
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing Engine Moving Control Rod Bolts
belt tensioner if oil leakage exists. Hold timing belt tensioner body with Inboard Bolt (Small)
push rod facing upward. Press rod against solid surface. Replace timing Except 2002-03 ES 300 ........................................................................................ 23 (32)
belt tensioner if push rod moves. 2002-03 ES 300 .................................................................................................... 17 (23)
All Other Bolts ......................................................................................................... 47 (64)
3) Measure timing belt tensioner push rod protrusion from end of rod to
Generator Adjusting Lock Bolt .................................................................................. 13 (18)
edge of timing belt tensioner housing. See Fig. 4. Replace timing belt Generator Bracket-To-Engine Bolts .......................................................................... 21 (28)
tensioner if distance is not .394-.425″ (10.01-10.8 mm). Generator Pivot Bolt .................................................................................................. 41 (56)
Installation (RX 300) – 1) Install No. 1 and No. 2 idler pulleys (if Power Steering Pump Bolt ....................................................................................... 32 (43)
removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43)
equivalent. Install and tighten bolts to specification. See TORQUE Shock Tower Brace-To-Shock Tower Nuts (RX 300) ............................................... 59 (80)
SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt .......................................................................................... 1 25 (34)
2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,
No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
use crankshaft pulley bolt to rotate crankshaft clockwise until timing Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
mark on crankshaft sprocket aligns with timing mark on oil pump body. Transverse Engine Mount Bracket-To-Engine Bolts ................................................ 21 (28)
See Fig. 2. Wheel Lug Nut ........................................................................................................ 76 (103)
3) Using spanner wrench, rotate each camshaft sprocket so timing mark Wiper Arm Nuts (RX 300) ........................................................................................ 18 (24)
on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. INCH Lbs. (N.m)
See Fig. 2.
Timing Belt Cover Bolts ........................................................................................... 76 (8.5)
Timing Belt Plate Bolt ................................................................................................. 71 (8)
Water Pump Bolt/Nut .................................................................................................. 71 (8)
1
454 LEXUS
4.0L V8 – 1990-97
TIMING BELT APPLICATION 6) Timing marks on camshaft sprockets must align with timing marks on
Application Labor Time Belt timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate
Part No. crankshaft clockwise one complete revolution. Alternately loosen timing
4.0L V8 – 1UZ-FE belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot.
LS 400 See Fig. 2. Using Sprocket Holder (09278-54012) or equivalent, slightly
1990-97 ..................................................... 4.5 Hours ... ..... T190 rotate right camshaft sprocket clockwise to release tension on timing
SC 400 belt. Remove timing belt from camshaft sprockets.
1992-97 ..................................................... 4.8 Hours ... ..... T190 7) Using Pulley Holder (09213-70010) or equivalent and Handle
(0933000021) or equivalent, hold crankshaft pulley. Remove crankshaft
NOTE: For information about tensioners and/or pulleys (when pulley bolt. Using puller, remove crankshaft pulley. On LS 400, remove
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 8) Note direction of timing belt guide installation for reassembly refer-
SCHEDULED MAINTENANCE ence. Remove timing belt guide. Remove timing belt. Remove bolt, idler
pulleys and plate washer (if necessary).
For 1990-94 model years, although the manufacturer does not recom-
mend a specific scheduled maintenance interval for normal operating CAUTION: If reusing timing belt, ensure installation mark exists at
conditions, belt manufacturers suggest the belt be replaced at 60,000 crankshaft sprocket. If installation mark does not exist, place
mile intervals. The manufacturer recommends the belt be replaced at installation mark on timing belt and crankshaft sprocket.
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.

TIMING BELT

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 (driver’s side) ignition coil. Disconnect cam position Courtesy of Toyota Motor Sales, U.S.A., Inc.
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 Fig. 1: Removing/Installing Spark Plug Wires & Retainers
be necessary to remove coolant pipe to access No. 2 timing belt covers. Inspection – 1) Inspect timing belt for damaged teeth, cracking or oil
4) Remove bolts, distributor caps and rotors. Mark component location contamination. Replace timing belt if damaged or contaminated. Check
for reassembly reference. Disconnect electrical connector at distributor idler pulleys for smooth rotation. Replace idler pulleys if defective.
housings. Remove bolts and distributor housings. See Fig. 2. Remove Inspect timing belt tensioner for signs of oil leakage. Replace timing belt
alternator, drive belt tensioner and spark plugs. tensioner if oil leakage exists.
CAUTION: If reusing timing belt, ensure the 4 installation marks NOTE: Timing belt tensioner may weep a small amount of oil on
exist on timing belt. If installation marks do not exist, place rod seal under normal conditions. If excessive amount of oil exists,
installation mark on timing belt, all sprockets and edge of fan replace timing belt tensioner.
bracket (LS 400) or hydraulic pump (SC 400).
2) Hold timing belt tensioner body and press rod against solid surface.
5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compres- Replace timing belt tensioner if rod moves. Measure timing belt ten-
sion stroke. Cylinder No. 1 is front cylinder on left side when viewed from sioner rod protrusion from end of rod to edge of housing. See Fig. 4.
rear of engine. Ensure timing mark on crankshaft pulley aligns with “0” Replace timing belt tensioner if distance is not .413-.453″ (10.50-11.50
mark on No. 1 timing belt cover. See Fig. 3. mm).
LEXUS 455
4.0L V8 – 1990-97 (Cont.)

456 LEXUS
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.
CAUTION: Always rotate crankshaft clockwise as viewed from

Courtesy of Toyota Motor Sales, U.S.A., Inc. front of engine. DO NOT rotate crankshaft counterclockwise.
Fig. 3: Checking Camshaft Timing Mark Alignment 10) Remove hexagon wrench from timing belt tensioner. Rotate crank-
shaft 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 accord-
ing 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.
Courtesy of Toyota Motor Sales, U.S.A., Inc. 12) Install rotors so rotor protrusion aligns with camshaft sprocket
groove. See Fig. 7. Ensure spark plug wires are properly positioned and
Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion installed in retainers. See Fig. 1. Tighten all bolts/nuts to specification.
Installation – 1) Install No. 1 idler pulley and plate washer (if removed). See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
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.
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.
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
CAUTION: Ensure camshaft sprocket is installed with identifica-

tion mark facing forward, toward timing belt end of engine. Identi-
fication 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 compres-
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
7) Ensure timing mark on left camshaft sprocket still aligns with timing Fig. 5: Identifying Timing Belt Installation Marks
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.
LEXUS 457
4.0L V8 – 1990-97 (Cont.)

A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 22 (30)
Distributor Housing Bolt ............................................................................................ 13 (18)
Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Power Steering Pump
Courtesy of Toyota Motor Sales, U.S.A., Inc. Bolt ........................................................................................................................... 29 (39)
Fig. 6: Retracting Timing Belt Tensioner Rod Nut ........................................................................................................................... 32 (43)
Spark Plug ................................................................................................................. 13 (18)
Water Pump Bolt/Nut ................................................................................................ 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4)
Valve Cover Bolt ...................................................................................................... 52 (5.9)
Fig. 7: Installing Rotors

458 LEXUS
4.0L V8 – 1998-00
Application Labor Time Belt CAUTION: If reusing timing belt, check that there are 3 mating
Part No. marks on belt to show installed position on crankshaft and cam-
4.0L V8 – 1UZ-FE shaft timing pulleys. If marks are missing, place installation mating
GS 400 marks on timing belt and camshaft and crankshaft pulleys. Also,
1998-00 ..................................................... 4.5 Hours ... ..... T298 mark belt with arrow to indicate original direction of rotation.
LS 400
1998-00 ..................................................... 4.5 Hours ... ..... T298 8) Using Pulley Holder (09213-70010) or equivalent and Handle
SC 400 (09330-00021) or equivalent, hold crankshaft pulley. Loosen, but do not
1998-00 ..................................................... 4.8 Hours ... ..... T298 remove crankshaft pulley bolt.
sion 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.
MANUFACTURER’S SUGGESTED 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,
SCHEDULED MAINTENANCE rotate crankshaft CLOCKWISE one complete revolution.
The manufacturer recommends the belt be replaced at 90,000 miles or 11) Rotate crankshaft clockwise about 50 degrees clockwise. Place
72 months. 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 incor-
CAUTION: This application is an interference engine. Do not rotate rect angle can cause piston to contact valves while removing
camshaft or crankshaft when timing belt is removed, or engine crankshaft pulley.
damage may occur. 12) Without moving crankshaft pulley, remove pulley bolt. Alternately
loosen 2 bolts, and remove timing belt tensioner. DO NOT hold timing
TIMING BELT belt tensioner with push rod facing downward. See Fig. 1.
13) Using spanner wrench, slightly rotate right side camshaft pulley
WARNING: To prevent air bag deployment, disconnect negative clockwise to relieve tension on timing belt. Remove timing belt from
battery cable at least 90 seconds before working on vehicle. camshaft pulleys.
14) On GS 400, remove power steering pump pulley bolt and pulley. On
all models, remove generator. Remove serpentine drive belt tensioner.
cover. Drain cooling system. Remove air cleaner inlet. Remove “V” bank
Using gear puller, remove crankshaft pulley without rotating crankshaft.
cover from top of engine. Remove air cleaner assembly and intake air
15) Remove No. 1 timing belt cover. See Fig. 5. Noting installed direction
connector pipe.
for reassembly reference, remove timing belt guide from end of crank-
2) On all models, drain engine coolant. Remove upper radiator hose.
shaft. Remove timing belt cover spacer.
3) On GS 400 and LS 400, remove serpentine drive belt by turning drive
16) If reusing timing belt, place mating mark on timing belt and
belt tensioner pulley bolt counterclockwise. Tensioner pulley bolt is
crankshaft timing pulley. Remove timing belt.
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
idler pulleys for smooth rotation and oil seal leakage. Replace idler
electric cooling fan assembly. On SC 400, disconnect hydraulic fan
pulleys if defective.
motor pressure and return pipes from fan. Disconnect cooling fan inlet
pipe and reservoir tank from fan shroud. CAUTION: Never hold timing belt tensioner facing downward.
5) On all models, remove the radiator assembly. Remove No. 2 drive
belt idler pulley. See Fig. 1. Disconnect camshaft position sensor wiring
NOTE: Timing belt tensioner may weep a small amount of oil on
connector from No. 3 left side belt cover. Move engine wiring harness
rod seal under normal conditions. If excessive amount of oil exists,
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 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
reservoir-to-engine pipe from in front of No. 3 right side belt cover. On all belt tensioner if there are excessive oil leaks.
models, remove No. 3 right side (passenger side) belt cover. See Fig. 1. 3) Hold timing belt tensioner body with push rod facing UPWARD. Press
7) Remove A/C compressor from engine mount with hoses attached. push rod against solid surface. Replace timing belt tensioner if push rod
Move A/C compressor out of way. On GS 400, remove No. 1 drive belt moves. Measure timing belt tensioner push rod protrusion from end of
idler pulley and mount from engine. See Fig. 1. On LS 400, remove fan rod to edge of housing. See Fig. 6. Replace timing belt tensioner if
bracket from front of engine. On SC 400, remove fan hydraulic pump distance is not .413-.453″ (10.50-11.50 mm). Inspect water pump for
from front of engine. See Fig. 2. leaks or worn bearing.
LEXUS 459
4.0L V8 – 1998-00 (Cont.)
Fig. 1: Exploded View Of Timing Belt Covers (GS 400 Shown; Others Are Similar)
460 LEXUS
4.0L V8 – 1998-00 (Cont.)
Fig. 4: Setting Crankshaft At 50 Degrees ATDC
Fig. 2: Timing Belt Components (LS 400 & SC 400)
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks Courtesy of Toyota Motor Sales, U.S.A., Inc.
Installation – 1) Install No. 1 idler pulley and plate washer (if removed). Fig. 5: Exploded View Of Timing Belt & Idler Pulleys
Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt.
Install and tighten bolt to specification. See TORQUE SPECIFICA-
TIONS.
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.

3) Clean any oil or water off of crankshaft timing pulley. DO NOT use Courtesy of Toyota Motor Sales, U.S.A., Inc.
solvent. Temporarily install timing belt on crankshaft timing pulley, No. 1 Fig. 6: Measuring Timing Belt Tensioner Rod Protrusion
idler pulley, and No. 2 idler pulley. If reusing old belt, ensure mating mark
on timing belt aligns with mark on crankshaft timing pulley. 5) Without rotating crankshaft, align crankshaft key with key groove of
4) Install timing belt guide in original direction on end of crankshaft. crankshaft pulley. Using hammer and Pulley Installer (09223-46011) or
Install gasket and timing belt cover spacer. Install gaskets and No. 1 equivalent, install crankshaft pulley.
timing belt cover.
LEXUS 461
4.0L V8 – 1998-00 (Cont.)

6) Install serpentine drive belt tensioner. Tighten bolts to specification. TORQUE SPECIFICATIONS
See TORQUE SPECIFICATIONS. Install generator. On GS 400, install
power steering pump pulley. On all models, ensure crankshaft is still at TORQUE SPECIFICATIONS
50 degrees ATDC position. See Fig. 4. Application Ft. Lbs. (N.m)
7) Ensure camshaft timing pulleys are still aligned with mating marks on A/C Compressor
rear plate. See Fig. 3. Clean camshaft timing pulleys (do not use Bolt ........................................................................................................................... 36 (49)
solvent). Install timing belt on left side (driver’s side) camshaft pulley. If Nut ........................................................................................................................... 22 (30)
reusing old timing belt, ensure mating mark on belt aligns with mark on Crankshaft Pulley Bolt ........................................................................................... 181 (245)
left side camshaft pulley. Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
8) Using spanner wrench, turn left side camshaft pulley until there is Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16)
Fan Bracket-To-Engine Bolts (LS 400)
tension on timing belt between crankshaft timing pulley and left side
12 mm Head ........................................................................................................... 12 (16)
camshaft pulley. 14 mm Head ........................................................................................................... 24 (32)
9) Install timing belt on right side camshaft pulley. If reusing old belt, Generator Pivot & Lock Bolt ..................................................................................... 29 (39)
ensure mating mark on belt aligns with mark on right side camshaft Hydraulic Pump-To-Engine Bolts (SC 400)
pulley. Ensure there is tension on timing belt between left side and right 12 mm Head ........................................................................................................... 12 (16)
side camshaft pulleys. 14 mm Head ........................................................................................................... 24 (32)
10) Using press, SLOWLY apply about 200-2205 lbs. of pressure on No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS 400)
12 mm Head ........................................................................................................... 12 (16)
push rod of timing belt tensioner until rod is retracted. Ensure timing belt
14 mm Head ........................................................................................................... 24 (32)
tensioner is held with push rod facing upward. Holes in push rod and No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16)
housing must be aligned. See Fig. 7. No. 1 Timing Belt Idler Pulley Pivot Bolt ............................................................... 1 25 (35)
11) Install hexagon wrench through holes in housing and rod to hold rod No. 2 Timing Belt Idler Pulley Bolt ........................................................................... 25 (35)
in retracted position. See Fig. 7. Release press. Install dust boot on Power Steering Pump
timing belt tensioner. Install timing belt tensioner. Alternately tighten Bolt ........................................................................................................................... 29 (39)
bolts to specification. See TORQUE SPECIFICATIONS. Nut ........................................................................................................................... 32 (43)
Power Steering Pump Pulley Center Nut
CAUTION: Always rotate crankshaft clockwise as viewed from GS400 ...................................................................................................................... 32 (43)
front of engine. DO NOT rotate crankshaft counterclockwise. Spark Plug ................................................................................................................. 13 (18)
12) Remove hexagon wrench from timing belt tensioner. Temporarily Water Pump Bolt
install crankshaft pulley bolt. Slowly rotate crankshaft 2 full revolutions GS 400 & SC 400 .................................................................................................. 15 (21)
clockwise from TDC to TDC. Ensure timing marks on camshaft sprock- LS 400 ..................................................................................................................... 13 (18)
ets align with timing marks on timing belt rear plate. See Fig. 3. If timing INCH Lbs. (N.m)
marks are not aligned, remove timing belt and reinstall. Camshaft Timing Pulley Bolt ................................................................................... 66 (7.5)
13) Tighten crankshaft pulley bolt to specification. On GS 400, install No. 3 Camshaft Belt Cover Bolts ............................................................................ 66 (7.5)
No. 1 drive belt idler pulley. On LS 400, install fan bracket. On SC 400, 1
– Use Loctite 242 on bolt threads.
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.

462 LEXUS
4.3L V8 – GS 430 & LS 430
TIMING BELT APPLICATION 7) Rotate crankshaft clockwise so cylinder No. 1 is about 50 degrees
Application Labor Time Belt after TDC on compression stroke. Cylinder No. 1 is front cylinder on left
Part No. side when viewed from rear of engine. Ensure timing mark on crankshaft
4.3L V8 – 3UZ-FE pulley aligns with “0” mark on No. 1 timing belt cover. See Fig. 3.
GS 430 8) Timing marks on camshaft sprockets must align with timing marks on
2001-04 ..................................................... 4.5 Hours ... ..... T298 timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate
LS 430 crankshaft CLOCKWISE one complete revolution (360 degrees).
2001-04 ..................................................... 4.5 Hours ... ..... T298
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 crank-
MANUFACTURER’S SUGGESTED shaft pulley at the correct angle.
SCHEDULED MAINTENANCE 9) Rotate crankshaft CLOCKWISE about 50 degrees. Place timing mark
The manufacturer recommends the belt be replaced at 90,000 miles or on crankshaft pulley in line with centers of crankshaft pulley bolt and
72 months. No. 2 timing belt idler pulley bolt. See Fig. 3.
NOTE: When re-using timing belt: If the installation marks have

REMOVAL & INSTALLATION disappeared, before removal of the timing belt, place 2 new
CAUTION: This application is an interference engine. Do not rotate installation marks on the timing belt to match the timing marks of
camshaft or crankshaft when timing belt is removed, or engine the camshaft timing pulleys.
damage may occur.
NOTE: When replacing timing belt tensioner only: To avoid mesh-
TIMING BELT ing of the timing pulley and timing belt, secure one of them with
string. Place matchmarks on the timing belt and right side cam-
cover. Drain cooling system. Remove air cleaner inlet. Remove “V” bank shaft timing pulley.
cover from top of engine. On 2001-03 LS 430, also remove engine room 10) Without moving crankshaft pulley, remove pulley bolt. Alternately
side covers. On all models, remove air cleaner assembly and intake air loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT
connector pipe. hold timing belt tensioner with push rod facing DOWN. See Fig. 1.
2) Remove serpentine drive belt by turning drive belt tensioner pulley 11) Using spanner wrench, slightly rotate right side camshaft sprocket
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND
CLOCKWISE to relieve tension on timing belt. Remove timing belt from
threads.
camshaft sprockets.
3) Remove radiator hoses and disconnect ECM outlet duct. Disconnect
12) Remove camshaft timing sprockets, power steering pump pulley and
electric cooling fan wiring connectors and ECT switch connector for
generator. Remove serpentine drive belt tensioner. Using gear puller,
cooling fan. Disconnect automatic transmission oil cooler hoses from
radiator. Remove upper radiator supports, and remove radiator and remove crankshaft pulley without rotating crankshaft.
cooling fan assembly. 13) Remove No. 1 timing belt cover. See Fig. 4. Noting installed direction
4) Remove No. 2 drive belt idler pulley. See Fig. 1. Remove water for reassembly reference, remove timing belt guide from end of crank-
by-pass pipe from left side No. 3 timing belt cover. Remove No. 3 left shaft. Remove timing belt cover spacer.
side timing belt cover. See Fig. 1. On 2004 LS 430, disonnect power 14) If not present, place mating mark on timing belt and crankshaft
steering hoses from clamp on No. 3 right side timing belt cover. On all timing sprocket. Remove timing belt.
models, remove No. 3 right side timing belt cover and No. 2 timing belt
cover. NOTE: Note size and location of idler pulley bolts for reassembly
5) Remove A/C compressor from engine with hoses attached. Move A/C reference.
compressor out of way. Remove No. 1 drive belt idler pulley. See Fig. 1. 15) If necessary, use a 10-mm hexagon wrench to remove No. 1 idler
CAUTION: If reusing timing belt, check that there are 3 mating pulley bolt, idler pulley and plate washer. To remove No. 2 idler pulley,
marks on belt to show installed position on crankshaft and cam- remove the bolt and idler pulley. To remove crankshaft timing sprocket,
shaft timing sprockets. See Fig. 2. If marks are missing, place use Puller (09950–50013). Do not turn the timing pulley during removal.
installation mating marks on timing belt and camshaft and crank-
shaft sprockets. Also, mark belt with arrow to indicate original
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.
LEXUS 463
4.3L V8 – GS 430 & LS 430 (Cont.)

464 LEXUS
4.3L V8 – GS 430 & LS 430 (Cont.)
Fig. 2: Locating Timing Belt Installation Marks
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 Installation – 1) If removed, install crankshaft timing sprocket by
contamination. Replace timing belt if damaged or contaminated. Check aligning sprocket set key with key groove of sprocket. Using Special Tool
idler pulleys for smooth rotation and oil seal leakage. Replace idler (09223-46011) and a hammer, tap in timing sprocket with flange side
pulleys if defective. INWARD. See Fig. 6.
2) If removed, install No. 1 timing belt idler pulley, plate washer and pivot
CAUTION: Never hold timing belt tensioner facing downward. bolt. Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt.
Install and tighten bolt to specification. See TORQUE SPECIFICA-
NOTE: Timing belt tensioner may weep a small amount of oil on TIONS.
rod seal under normal conditions. If excessive amount of oil exists, 3) If removed, install No. 2 timing belt idler pulley and bolt. Tighten bolt
replace timing belt tensioner. to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys
are clean and rotate smoothly. Ensure idler pulley bracket moves
smoothly.
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
CAUTION: Check that crankshaft pulley timing mark is aligned with
centers of crankshaft pulley and No. 2 timing belt idler pulley bolt. Fig. 6: Installing Crankshaft Timing Sprocket
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 COUNTER-
CLOCKWISE 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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
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.
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 connec-
tors. 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 Fig. 8: Checking Timing Marks

1) Fill cooling system. Install radiator cap. Move heater control to
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.
466 LEXUS
4.3L V8 – GS 430 & LS 430 (Cont.)
A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 21 (29)
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)
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
Application Labor Time Belt CAUTION: If reusing timing belt, check that there are 3 mating
Part No. marks on belt to show installed position on crankshaft and cam-
4.3L V8 shaft timing sprockets. See Fig. 3. If marks are missing, place
SC 430 installation mating marks on timing belt and camshaft and crank-
2002-04 ..................................................... 3.6 Hours ... ..... T298 shaft sprockets. Also, mark belt with arrow to indicate original
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED aligned. See Fig. 4.
SCHEDULED MAINTENANCE 8) Turning hexagon wrench head portion of camshaft, align timing marks
The manufacturer recommends the belt be replaced at 90,000 miles or on camshaft sprockets with timing marks on timing belt rear plates. See
72 months. Fig. 5. If timing marks are not aligned, rotate crankshaft CLOCKWISE
one complete revolution (360 degrees).
REMOVAL & INSTALLATION CAUTION: If the timing belt is disengaged with the crankshaft
CAUTION: This application is an interference engine. Do not rotate sprocket at the wrong angle, this can cause the piston head and
camshaft or crankshaft when timing belt is removed, or engine valve head to come into contact with each other when you remove
damage may occur. the camshaft sprocket, causing damage. Always set the crankshaft
sprocket at the correct angle.
TIMING BELT 9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCK-

Removal – 1) Disconnect negative battery cable. Remove lower engine WISE about 50 degrees. See Fig. 6. Alternately loosen 2 bolts, and
cover. Drain cooling system. Remove air cleaner inlet. Remove “V” bank remove timing belt tensioner and dust boot. DO NOT hold timing belt
cover from top of engine. Remove intake air connector pipe. tensioner with push rod facing DOWN. See Fig. 1.
2) Remove radiator hoses and oil cooler tubes from radiator. Remove air 10) Using spanner wrench, slightly rotate right side camshaft sprocket
cleaner assembly. Disconnect electric cooling fan wiring connectors. COUNTERCLOCKWISE to relieve tension on timing belt. See Fig. 7.
Remove upper radiator supports, and remove radiator and cooling fan Remove timing belt.
assembly. Inspection – 1) Inspect timing belt for damaged teeth, cracking or oil
3) Remove serpentine drive belt by turning drive belt tensioner pulley contamination. Replace timing belt if damaged or contaminated. Check
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND idler pulleys for smooth rotation and oil seal leakage. Replace idler
threads. pulleys if defective.
4) Remove power steering pump assembly with hoses attached, and
position out of way. Remove generator. Remove A/C compressor from CAUTION: Never hold timing belt tensioner with push rod facing
engine with hoses attached. Move A/C compressor out of way. DOWN.
NOTE: Note size and location of idler pulley bolts for reassembly
reference. NOTE: Timing belt tensioner may weep a small amount of oil on
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. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
Remove serpentine drive belt tensioner. Remove No. 1 drive belt idler belt tensioner if there are excessive oil leaks.
pulley. 3) Hold timing belt tensioner body with push rod facing UPWARD. Press
6) Using Pulley Holder (09213-70011) and Handle (09330-00021), push rod against solid surface. Replace timing belt tensioner if push rod
remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller moves. Measure timing belt tensioner push rod protrusion from end of
Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt rod to edge of housing. See Fig. 8. Replace timing belt tensioner if
cover. See Fig. 2. Noting installed direction for reassembly reference, distance is not .374-.413″ (9.50-10.50 mm). Inspect water pump for
remove timing belt guide (Crankshaft Position (CKP) sensor plate) from
leaks or worn bearing, and replace as necessary.
end of crankshaft.
468 LEXUS
4.3L V8 – SC 430 (Cont.)

LEXUS 469
4.3L V8 – SC 430 (Cont.)
Fig. 2: Exploded View Of Timing Belt & Idler Pulleys
Fig. 6: Aligning Crankshaft Sprocket For Timing Belt Removal

470 LEXUS
4.3L V8 – SC 430 (Cont.)

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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
sprocket CLOCKWISE one tooth. See Fig. 10. Turn crankshaft CLOCK-
WISE to align timing marks of crankshaft sprocket and oil pump body. Fig. 9: Aligning Camshaft Sprocket Timing Marks
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
Ensure timing belt tensioner is held with push rod facing UPWARD. Courtesy of Toyota Motor Sales, U.S.A., Inc.
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 Fig. 10: Positioning Camshaft Sprockets For Timing Belt
hold rod in retracted position. See Fig. 12. Release press. Install dust Installation
boot on timing belt tensioner. Install timing belt tensioner. Alternately
tighten bolts to specification. See TORQUE SPECIFICATIONS.

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 Fig. 11: Aligning Crankshaft Sprocket Timing Marks
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 speci-
fication. See TORQUE SPECIFICATIONS. Fill cooling system, and
check for leaks. See COOLING SYSTEM BLEEDING.


LEXUS 471
4.3L V8 – SC 430 (Cont.)

A/C Compressor
Bolt ........................................................................................................................... 36 (49)
Nut ........................................................................................................................... 21 (29)
Generator Pivot & Lock Bolt ..................................................................................... 29 (39)
No. 1 Drive Belt Idler Pulley Bolts
12-mm Head ............................................................................................................ 12 (16)
14-mm Head ............................................................................................................ 24 (32)
Fig. 13: Installing Timing Belt Guide 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)
Water Pump Bolt ....................................................................................................... 13 (18)
INCH Lbs. (N.m)
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
– Apply Loctite 242 or equivalent to No. 1 idler pulley bolt threads.
Fig. 14: Installing No. 2 Timing Belt Cover Sub-Assembly
472 LEXUS & TOYOTA
3.3L V6 – 2004
Application Labor Time Belt CAUTION: If timing belt is disengaged, having crankshaft pulley at
Part No. wrong angle can cause piston and valve to come in contact with
3.3L V6 – 3MZ-FE each other when you remove crankshaft or camshaft pulleys,
Camry causing damage. Always set crankshaft pulley at correct angle.
2004 ........................................................... 3.0 Hours ... ..... T257
Camry Solara 8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
2004 ........................................................... 3.0 Hours ... ..... T257 boot. DO NOT hold tensioner with push rod facing DOWN. Remove
ES 330 timing belt in the following sequence:
2004 ........................................................... 3.0 Hours ... ..... T257 a) No. 1 idler pulley
Highlander b) Right camshaft sprocket (firewall side)
2004 ........................................................... 2.5 Hours ... ..... T257 c) No. 2 idler pulley
RX 330
d) Left camshaft sprocket (front of vehicle side)
2004 ........................................................... 4.4 Hours ... ..... T257
Sienna e) Water pump pulley
2004 ........................................................... 4.0 Hours ... ..... T257 f) Crankshaft sprocket

or 72 months.


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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Remove accessory drive belts. Lower vehicle. Disconnect engine cool-
ant reservoir hose from water outlet. Disconnect ground strap connec- Fig. 1: Exploded View Of Timing Belt & Components
tors.
2) Remove engine moving control rod and engine mounting bracket Inspection (Camry, Camry Solara & ES 330) – 1) Inspect timing belt
No. 2 (right side), located near timing belt cover. Remove generator-to- for damaged teeth, cracking or oil contamination. Ensure idler pulleys
engine bracket for access to timing belt covers. rotate freely and are not leaking oil. Replace damaged components.
3) Using Pulley Holder (09213-54015) or equivalent and Handle Check water pump for leaks or worn out bearing.
(09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft
pulley bolt. Using puller and crankshaft pulley bolt, remove crankshaft CAUTION: Never hold timing belt tensioner with push rod facing
pulley. Remove No. 2 timing belt cover and gasket. See Fig. 1. Remove DOWN.
right side engine mounting bracket. Note direction of timing belt guide 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
installation for reassembly reference. Remove timing belt guide. belt tensioner if oil leakage exists. Hold timing belt tensioner body with
NOTE: Always turn crankshaft clockwise, as viewed from timing push rod facing UP. Press rod against solid surface. Replace timing belt
belt side of engine. tensioner if push rod moves.
4) Temporarily install crankshaft pulley bolt and washer in crankshaft. NOTE: Engine should be cold when installing timing belt.
Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing
mark on crankshaft sprocket aligns with timing mark on oil pump body. Installation (Camry, Camry Solara & ES 330) – 1) Install No. 1 and
See Fig. 2. No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads
5) Ensure timing marks on camshaft sprockets are aligned with timing with Loctite 242 or equivalent. Install and tighten bolts to specification.
mark on No. 3 timing belt rear cover. See Fig. 2. If timing marks are not See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and
aligned, rotate crankshaft CLOCKWISE one full revolution (360 rotate smoothly.
degrees). Remove crankshaft pulley bolt. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,
6) If reusing old belt, ensure there are 3 installation marks and front use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE
arrow marked on belt. See Fig. 3. If not, place mating mark on belt where until timing mark on crankshaft sprocket is about 60 degrees BTDC. See
timing belt contacts crankshaft and camshaft sprockets. Also, mark belt Fig. 4.
with arrow showing direction of rotation.
7) Turning crankshaft pulley, set cylinder No. 1 to 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.
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)
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
Courtesy of Toyota Motor Sales, U.S.A., Inc. housing and push rod hole to secure push rod. Release press and install
Fig. 2: Aligning Crankshaft & Camshaft Timing Marks dust boot on timing belt tensioner.
6) Install timing belt tensioner. Install and alternately tighten bolts to
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 specifica-
tion.
Ensure there are no gaps in gasket. Cut off any excess gasket. Install
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.
Courtesy of Toyota Motor Sales, U.S.A., Inc. 13) To install remaining components, reverse removal procedure.
Fig. 3: Identifying Timing Belt Reference Marks & Front Mark
Connect engine ground strap. Adjust drive belts to proper tension.
Fig. 4: Aligning Crankshaft For Removal/Installation Of

Timing Belt Courtesy of Toyota Motor Sales, U.S.A., Inc.

474 LEXUS & TOYOTA
3.3L V6 – 2004 (Cont.)
Removal (Highlander, Sienna & RX 330) – 1) Remove windshield 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,
wiper arms, cowl top ventilator louver sub-assembly and windshield use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE
wiper link assembly. Remove cowl top panel outer sub-assembly. See until timing mark on crankshaft sprocket is about 60 degrees BTDC. See
Fig. 6. Fig. 4.
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 each other when you remove crankshaft or camshaft pulleys,
No. 2 (right side), located near timing belt cover. Remove generator-to- causing damage. Always set crankshaft pulley at correct angle.
engine bracket for access to timing belt covers.
4) Using Pulley Holder (09213-54015) or equivalent, and Handle 3) Using spanner wrench, rotate each camshaft sprocket so timing mark
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft on camshaft sprocket aligns with timing mark on No. 3 timing belt rear
pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 cover. See Fig. 2.
timing belt covers and gaskets. See Fig. 1. On RX330, remove nut and NOTE: Engine should be cold when installing timing belt.
separate engine mounting insulator. Place wooden block on jack and
jack up engine enough to remove right side engine mounting bracket. 4) Install timing belt in following order:
On Highlander and Sienna, lifting engine is not required. On all models, • Crankshaft sprocket
• Water pump pulley
Remove engine mounting bracket. Note direction of timing belt guide
• Left camshaft sprocket (front of vehicle side)
installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing • Right camshaft sprocket (firewall side)
belt side of engine. • No. 1 idler pulley
If reusing old belt, ensure belt installation marks align with camshaft and
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crank- crankshaft sprocket marks. Ensure front (or rotation direction mark)
shaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on points in correct direction.
crankshaft sprocket aligns with timing mark on oil pump body. See 5) Using press, SLOWLY apply about 200-2200 lbs. of pressure on push
Fig. 2. rod of timing belt tension until rod is retracted and holes in rod and
6) Ensure timing marks on camshaft sprockets are aligned with timing housing are aligned. See Fig. 5. Align holes in housing and push rod.
mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not Install 1.5 mm hexagon wrench through housing and push rod hole to
aligned, rotate crankshaft CLOCKWISE one full revolution (360 secure push rod. Release press and install dust boot on timing belt
degrees). Remove crankshaft pulley bolt. tensioner.
7) If reusing old belt, ensure there are 3 installation marks and front 6) Install timing belt tensioner. Install and alternately tighten bolts to
arrow marked on belt. See Fig. 3. If not, place mating mark on belt where specification. See TORQUE SPECIFICATIONS.
7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly
it contacts the crankshaft and camshaft sprockets. Also, mark belt with
rotate crankshaft CLOCKWISE 2 revolutions until timing mark on
crankshaft sprocket aligns with timing mark on oil pump body.
8) Turning crankshaft pulley COUNTERCLOCKWISE, set cylinder No. 1
to about 60 degrees BTDC. See Fig. 4.
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
each other when you remove crankshaft or camshaft pulleys,
block on jack and jack up engine enough to install right side engine
causing damage. Always set crankshaft pulley at correct angle.
mounting bracket. On all models, Install engine mounting bracket on
9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust front of cylinder block. Install nut on engine mounting insulator. Install
boot. DO NOT hold tensioner with push rod facing DOWN. Remove and tighten bolts and nut to specification. See TORQUE SPECIFICA-
timing belt in following sequence: TIONS.
a) No. 1 idler pulley 10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure
b) Right camshaft sprocket (firewall side) there are no gaps in gasket. Cut off excess gasket. Install and tighten
bolts to specification.
c) No. 2 idler pulley
d) Left camshaft sprocket (front of vehicle side)
e) Water pump pulley
tion.
f) Crankshaft sprocket
12) Install generator bracket. Connect engine ground strap. Install
Inspection (Highlander, Sienna & RX 330) – 1) Inspect timing belt for engine mounting bracket No. 2 (right side) and engine moving control
damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate rod. Install cruise control actuator (if equipped).
freely and are not leaking oil. Replace damaged components. Inspect 13) To install remaining components, reverse removal procedure.
water pump for leaks or worn out bearing. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
CAUTION: Never hold timing belt tensioner with push rod facing
downward.
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.
LEXUS & TOYOTA 475
3.3L V6 – 2004 (Cont.)
Fig. 6: Exploded View Of Outer Cowl Top Panel (Highlander & RX-330)
476 LEXUS & TOYOTA
3.3L V6 – 2004 (Cont.)
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 Bracket-To-Engine Bolts .......................................................................... 21 (28)
Generator Pivot Bolt .................................................................................................. 43 (58)
Power Steering Pump Bracket-To-Cylinder Head Bolt ............................................ 32 (43)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Pivot Bolt ................................................................................. 1 25 (34)
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
LEXUS & TOYOTA 477
4.7L V8 – Except GX 470 & 4Runner

Application Labor Time Belt CAUTION: If the timing belt is disengaged with the crankshaft
Part No. pulley at the wrong angle, this can cause the piston head and valve
4.7L V8 head to come into contact with each other when you remove the
Land Cruiser camshaft timing pulley, causing damage. Always set the crank-
1998-04 ..................................................... 4.5 Hours ... ..... T298 shaft pulley at the correct angle.
LX 470
8) On 1998-2002 models only, using crankshaft pulley bolt, rotate
1998-04 ..................................................... 4.5 Hours ... ..... T298
Sequoia crankshaft CLOCKWISE (viewed from front of engine) about 50 degrees
2001-03 ..................................................... 3.6 Hours ... ..... T298 ATDC. This will align crankshaft pulley groove with centerline of
Tundra crankshaft pulley bolt and No. 2 idler pulley bolt. See Fig. 4. This
2000-03 ..................................................... 3.6 Hours ... ..... T298 prevents valves from contacting pistons. On all models, remove crank-
shaft pulley bolt.
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED the camshaft timing pulleys.
SCHEDULED MAINTENANCE NOTE: When replacing timing belt tensioner only: To maintain
The manufacturer recommends the belt be replaced at 90,000 miles or meshing of the timing pulley and timing belt, secure one of them
72 months. with string. Place matchmarks on the timing belt and passenger’s
side camshaft timing pulley.
9) Alternately loosen bolts, and remove timing belt tensioner and dust
REMOVAL & INSTALLATION boot. Using spanner wrench in holes in camshaft sprocket, slightly rotate
passenger’s side camshaft sprocket CLOCKWISE to release timing belt
CAUTION: This application is an interference engine. Do not rotate tension. Remove timing belt from camshaft sprockets.
camshaft or crankshaft when timing belt is removed, or engine 10) Remove serpentine drive belt tensioner. See Fig. 1. Remove
damage may occur. 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
TIMING BELT
(Crankshaft Position (CKP) sensor plate) and timing belt cover spacer.
Remove timing belt.
battery cable at least 90 seconds before working on vehicle. CAUTION: DO NOT use solvent to clean crankshaft or camshaft
sprockets. Wipe clean only.
Removal (Land Cruiser & LX 470) – 1) Raise and support vehicle.
Remove oil pan protector. Remove lower engine cover. Drain cooling
Inspection (Land Cruiser & LX 470) – 1) Inspect timing belt for
system. Remove battery clamp cover. Remove “V” bank cover located
damaged teeth, cracking or oil contamination. Replace timing belt if
on top of engine. Remove air cleaner assembly with air intake hose that damaged or contaminated. Check idler pulleys for smooth rotation.
goes to throttle body. Replace idler pulleys if defective. Inspect timing belt tensioner for signs
2) Loosen 4 bolts/nuts holding fluid coupling to cooling fan bracket. See of oil leakage. Replace timing belt tensioner if oil leakage exists.
Fig. 1. Remove serpentine drive belt, cooling fan fluid coupling assem-
bly, and fan pulley. NOTE: Timing belt tensioner may weep a small amount of oil on
3) Remove radiator assembly. Remove pulley bolt, cover plate and drive rod seal under normal conditions. If excessive amount of oil exists,
belt idler pulley. Remove No. 3 timing belt cover from front of passen- replace timing belt tensioner. NEVER hold timing belt tensioner
ger’s side camshaft. with push rod facing DOWN.
4) Disconnect engine wiring harness clamps for access to No. 3 timing 2) Hold timing belt tensioner body and press rod against solid surface.
belt cover at front of driver’s side camshaft. Disconnect electrical Replace timing belt tensioner if rod moves.
connectors from Camshaft Position (CMP) sensor on No. 3 timing belt 3) Measure timing belt tensioner rod protrusion from end of rod to edge
cover. Remove No. 3 timing belt cover. See Fig. 1. of housing. See Fig. 5. Replace timing belt tensioner if distance is not
5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C 0.413-0.453″ (10.5-11.5 mm). Inspect water pump for leaks or bearing
compressor with hoses attached, and set aside. Remove cooling fan failure.
bracket.
NOTE: Install timing belt with engine cold.
CAUTION: If reusing timing belt, ensure installation mark exists at
Installation (Land Cruiser & LX 470) – 1) If No. 1 idler pulley was
crankshaft and camshaft sprockets. If installation mark does not removed, apply Loctite 242 or equivalent to bolt threads. Ensure pulley
exist, place mating marks on timing belt and crankshaft sprocket. bracket moves freely.
See Fig. 3. Also, place arrow on belt indicating direction of rotation. 2) Install timing belt on crankshaft sprocket. If reusing old belt, ensure
6) Using Pulley Holder (09213-70010 or 09213-70010) and Handle match marks made on removal are properly aligned.
(09330-00021), hold crankshaft pulley. Loosen crankshaft pulley bolt. 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
7) Rotate crankshaft CLOCKWISE (viewed from front of engine) so
facing out away from crankshaft sprocket.
crankshaft pulley groove aligns with “0” timing mark on No. 1 (lower)
4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with
timing belt cover. See Fig. 2. Ensure timing marks on camshaft
key in crankshaft. Tap crankshaft pulley until seated on crankshaft.
sprockets align with marks on the timing belt rear plates. See Fig. 3. If
5) Install serpentine drive belt tensioner. Install generator. Tighten all
timing marks are not aligned, rotate crankshaft CLOCKWISE one full fasteners to specification. See TORQUE SPECIFICATIONS. Ensure
revolution. Realign crankshaft pulley groove with “0” timing mark on timing mark on crankshaft pulley aligns with timing mark “0” of No. 1
No. 1 (lower) timing belt cover. (lower) timing belt cover. See Fig. 4.
478 LEXUS & TOYOTA
4.7L V8 – Except GX 470 & 4Runner (Cont.)
Fig. 3: Locating Timing Belt Alignment Marks

LEXUS & TOYOTA 479
Fig. 4: Positioning Crankshaft Pulley

Fig. 6: Installing Timing Belt On Camshaft Sprocket
6) Ensure timing mark on driver’s side camshaft sprocket is correctly
aligned. See Fig. 6. Install timing belt on driver’s side camshaft sprocket.
If reusing old belt, ensure matching marks are aligned. Rotate driver’s
side camshaft sprocket COUNTERCLOCKWISE until tension exists on
timing belt between crankshaft sprocket and driver’s side camshaft
sprocket.
7) Ensure passenger’s side camshaft sprocket timing mark is still
aligned. Install timing belt on passenger’s 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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
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. Removal (Except Land Cruiser & LX 470) – 1) Raise and support
vehicle. Remove engine undercover. Drain cooling system. Remove
CAUTION: When checking valve timing, only rotate crankshaft radiator assembly. Remove throttle body cover. Remove intake air
CLOCKWISE as viewed from front of engine. DO NOT rotate connector assembly.
crankshaft COUNTERCLOCKWISE. 2) Loosen 4 bolts holding fluid coupling to cooling fan bracket. See
Fig. 1. Remove serpentine drive belt, cooling fan fluid coupling assem-
10) Remove 1.27 mm hexagon wrench from timing belt tensioner. To
bly, and fan pulley.
check valve timing, rotate crankshaft pulley CLOCKWISE 2 full revolu-
3) Remove power steering pump from engine with hoses attached, and
tions from TDC to TDC. Crankshaft pulley groove must align with “0”
secure out of way. Remove serpentine drive belt idler pulley. Remove
timing mark on No. 1 (lower) timing belt cover.
No. 3 timing belt cover from front of passenger’s side camshaft.
11) With crankshaft at TDC position, ensure camshaft sprockets align
4) Disconnect engine wiring harness clamps for access to No. 3 timing
with timing marks on rear plates. If installing old belt, ensure belt
belt cover at front of driver’s side camshaft. Disconnect electrical
matching marks are aligned with camshaft sprockets. If timing marks are
connectors from camshaft position sensor on No. 3 timing belt cover.
not aligned, timing belt will have to be removed and repositioned.
Remove No. 3 timing belt cover. See Fig. 1.
5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C
SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install
compressor with hoses attached, and set aside. Remove cooling fan
No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install
bracket.
radiator. Install cooling fan assembly.
Fill and bleed air from cooling system. See COOLING SYSTEM
BLEEDING.
480 LEXUS & TOYOTA
3) Place timing belt around No. 1 and No. 2 idler pulleys. Install gasket
CAUTION: If reusing timing belt, ensure installation marks exist at and timing belt cover spacer. Install timing belt guide with cupped side
crankshaft and camshaft sprockets on timing belt. If installation away from crankshaft sprocket.
marks do not exist, place matching marks on timing belt before 4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with
removing timing belt. See Fig. 3. Also, place arrow on belt indicat- key in crankshaft. Using Crankshaft Front Oil Seal Replacer (SST
ing direction of rotation. 09223-46011) and a hammer, tap crankshaft pulley until seated on
crankshaft.
6) Using Pulley Holder (09213-70011) and Handle (09330-00021), hold 5) Install serpentine drive belt tensioner. Install generator. Tighten all
crankshaft pulley. Loosen crankshaft pulley bolt. fasteners to specification. See TORQUE SPECIFICATIONS. Ensure the
7) Rotate crankshaft CLOCKWISE (viewed from front of engine) so crankshaft pulley groove aligns with “0” timing mark on No. 1 timing belt
crankshaft pulley groove aligns with “0” timing mark on No. 1 (lower) cover. See Fig. 2.
timing belt cover. See Fig. 2. 6) Ensure timing mark on driver’s side camshaft sprocket is correctly
8) Ensure timing marks on camshaft sprockets align with marks on the aligned. See Fig. 6. Install timing belt on driver’s side camshaft sprocket.
timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate If reusing old belt, ensure matching marks are aligned. Rotate driver’s
crankshaft CLOCKWISE one full revolution. Realign crankshaft pulley side camshaft sprocket COUNTERCLOCKWISE until tension exists on
groove with “0” timing mark on No. 1 (lower) timing belt cover). Remove timing belt between crankshaft sprocket and driver’s side camshaft
crankshaft pulley bolt. sprocket.
7) Ensure passenger’s side camshaft sprocket timing mark is still
NOTE: When re-using timing belt: If the installation marks have aligned. Install timing belt on passenger’s side camshaft sprocket. If
disappeared, before removal of the timing belt, place 2 new reusing old belt, ensure installation marks are aligned. See Fig. 6.
installation marks on the timing belt to match the timing marks of 8) Using press, SLOWLY apply about 220-2200 lbs. (100-1000 kg) of
the camshaft timing pulleys. 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
NOTE: When replacing timing belt tensioner only: To maintain position.
meshing of the timing pulley and timing belt, secure one of them 9) Release press and install dust boot on timing belt tensioner. Install
with string. Place matchmarks on the timing belt and passenger’s timing belt tensioner on engine. Install and alternately tighten bolts to
side camshaft timing pulley. specification.
9) Remove generator. Alternately loosen bolts, and remove timing belt CAUTION: When checking valve timing, only rotate crankshaft
tensioner and dust boot. Using spanner wrench in holes in camshaft CLOCKWISE as viewed from front of engine. DO NOT rotate
sprocket, slightly rotate passenger’s side camshaft sprocket CLOCK- crankshaft COUNTERCLOCKWISE.
WISE to release timing belt tension. Remove timing belt from camshaft
sprockets. 10) Remove 1.27 mm hexagon wrench from timing belt tensioner. To
10) Remove serpentine drive belt tensioner. See Fig. 1. Without letting check valve timing, rotate crankshaft pulley CLOCKWISE 2 full revolu-
crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1 tions from TDC to TDC. Crankshaft pulley groove must align with “0”
timing belt cover. Noting direction of timing belt guide for installation timing mark on No. 1 (lower) timing belt cover.
reference, remove timing belt guide (crankshaft position sensor plate) 11) With crankshaft at TDC position, ensure camshaft sprockets align
and timing belt cover spacer. Remove timing belt. with timing marks on rear plates. If installing old belt, ensure belt
installation marks are aligned with camshaft sprockets. If installation
CAUTION: DO NOT use solvent to clean crankshaft or camshaft marks are not aligned, timing belt will have to be removed and
sprockets. Wipe clean only. repositioned.
Inspection (Except Land Cruiser & LX 470) – 1) Inspect timing belt for
SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install
damaged teeth, cracking or oil contamination. Replace timing belt if
No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install
damaged or contaminated. Check idler pulleys for smooth rotation.
radiator. Install cooling fan assembly.
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.
Fill and bleed air from cooling system. See COOLING SYSTEM
NOTE: Timing belt tensioner may weep a small amount of oil on BLEEDING.
replace timing belt tensioner. NEVER hold timing belt tensioner COOLING SYSTEM BLEEDING
with push rod facing DOWN. 1) Fill cooling system. Install radiator cap. Move heater control to
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.
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 SPECIFICA-
TIONS. 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 crank-
shaft pulley.
LEXUS & TOYOTA 481

A/C Compressor-To-Mount Bolt ................................................................................ 36 (49)
Cooling Fan Bracket
12-mm Head ............................................................................................................ 12 (16)
14-mm Head ............................................................................................................ 24 (32)
Cooling Fan Fluid Coupling-To-Cooling Fan Bracket
Except Sequoia ....................................................................................................... 16 (21)
Sequoia .................................................................................................................... 21 (29)
Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37)
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)
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.
482 LEXUS & TOYOTA
4.7L V8 – GX 470 & 4Runner
Application Labor Time Belt CAUTION: If the timing belt is disengaged with the crankshaft
Part No. sprocket at the wrong angle, this can cause the piston head and
4.7L V8 valve head to come into contact with each other when you remove
GX 470 the camshaft sprocket, causing damage. Always set the crankshaft
2003-04 ..................................................... 3.5 Hours ... ..... T298 sprocket at the correct angle.
4Runner
2003-04 ..................................................... 3.5 Hours ... ..... T298 9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCK-
WISE about 50 degrees. See Fig. 5. Alternately loosen 2 bolts, and
NOTE: For information about tensioners and/or pulleys (when remove timing belt tensioner and dust boot. DO NOT hold timing belt
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED Remove timing belt.
The manufacturer recommends the belt be replaced at 90,000 miles or
72 months.
idler pulleys for smooth rotation and oil seal leakage. Replace idler
pulleys if defective.
REMOVAL & INSTALLATION CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
NOTE: Timing belt tensioner may weep a small amount of oil on
damage may occur.
TIMING BELT
belt tensioner if there are excessive oil leaks.
Remove air cleaner hose assembly. Remove “V” bank cover from top of
3) Hold timing belt tensioner body with push rod facing UP. Press push
engine. Remove 11 clips, and remove upper radiator support seal.
2) Remove serpentine drive belt by turning drive belt tensioner pulley rod against solid surface. Replace timing belt tensioner if push rod
bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND moves. Measure timing belt tensioner push rod protrusion from end of
threads. rod to edge of housing. See Fig. 7. Replace timing belt tensioner if
3) Remove 2 oil cooler hoses from fan shroud. Remove 3 bolts, and distance is not .440-.480″ (11.20-12.20 mm). Inspect water pump for
separate fan shroud from radiator. Remove 4 nuts, and separate fan leaks or worn bearing, and replace as necessary.
w/fluid coupling from engine. Remove fan shroud and fan w/fluid Installation – 1) Turn camshaft and set No. 1 cylinder to TDC. Timing
coupling assembly from vehicle. marks on camshaft sprockets must align with timing marks on timing belt
4) Remove power steering pump assembly with hoses attached, and rear plates. See Fig. 8. To ease installation of timing belt, turn left
position out of way. Remove generator. Remove A/C compressor from camshaft sprocket CLOCKWISE 1/2 tooth and turn right camshaft
engine with hoses attached. Move A/C compressor out of way. sprocket CLOCKWISE one tooth. See Fig. 9. Turn crankshaft CLOCK-
WISE to align timing marks of crankshaft sprocket and oil pump body.
NOTE: Note size and location of idler pulley bolts for reassembly
See Fig. 10.
reference.
2) Face the front mark (arrow) on timing belt forward. While aligning
5) Remove No. 2 idler pulley. See Fig. 1. Remove oil cooler pipe. installation marks on timing belt with mark on appropriate sprocket,
Disconnect Camshaft Position (CMP) sensor connector and wires, and install timing belt in the following sequence:
remove No. 3 left side timing belt cover. Remove No. 3 right side timing a) Crankshaft timing sprocket
belt cover. Remove No. 2 timing belt cover. Remove serpentine drive b) Idler pulley No. 2
belt tensioner. Remove cooling fan bracket assembly. c) Left camshaft sprocket
6) Using Pulley Holder (09213-70011) and Handle (09330-00021), d) Water pump pulley
remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller e) Right camshaft sprocket
Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt f) Idler pulley No. 1
cover. See Fig. 1. Noting installed direction for reassembly reference, See Fig. 2.
remove timing belt guide from end of crankshaft. 3) Using press, slowly apply about 220-2205 lbs. (100-1000 kg) of
CAUTION: If reusing timing belt, check that there are 3 mating Ensure timing belt tensioner is held with push rod facing upward. Holes
marks on belt to show installed position on crankshaft and cam- in push rod and housing must be aligned. See Fig. 11.
shaft timing sprockets. See Fig. 2. If marks are missing, place 4) Install 1.27 mm hexagon wrench through holes in housing and rod to
installation mating marks on timing belt and camshaft and crank- hold rod in retracted position. See Fig. 11. Release press. Install dust
shaft sprockets. Also, mark belt with arrow to indicate original boot on timing belt tensioner. Install timing belt tensioner. Alternately
direction of rotation. tighten bolts to specification. See TORQUE SPECIFICATIONS.
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. 5) Remove hexagon wrench from timing belt tensioner. Slowly rotate
8) Turning hexagon wrench head portion of camshaft, align timing marks crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. Ensure all
on camshaft sprockets with timing marks on timing belt rear plates. See timing marks are aligned. See Figs. 3 and 4. If timing marks are not
Fig. 4. If timing marks are not aligned, rotate crankshaft CLOCKWISE aligned, remove timing belt and reinstall. Remove crankshaft damper
one complete revolution. bolt. Install timing belt guide. See Fig. 12.
LEXUS & TOYOTA 483
4.7L V8 – GX 470 & 4Runner (Cont.)
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

484 LEXUS & TOYOTA
Courtesy of Toyota Motor Sales, U.S.A., Inc. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Fig. 6: Removing Timing Belt Fig. 9: Positioning Camshaft Sprockets for

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. Fig. 10: Aligning Crankshaft Sprocket Timing Marks
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.

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

A/C Compressor
Bolt ........................................................................................................................... 34 (47)
Nut ........................................................................................................................... 18 (25)
Cooling Fan Bracket Bolt
12-mm ...................................................................................................................... 12 (16)
14-mm ...................................................................................................................... 24 (32)
Fan W/Fluid Coupling Nut ........................................................................................ 21 (29)
Generator
Courtesy of Toyota Motor Sales, U.S.A., Inc. Bolt ........................................................................................................................... 29 (39)
Fig. 13: Installing No. 2 Timing Belt Cover M8 Nut ..................................................................................................................... 11 (16)
M10 Nut ................................................................................................................... 29 (39)
Power Steering Pump Bolt/Nut ................................................................................. 32 (43)
Timing Belt Idler Pulley Bolt ................................................................................... 1 25 (35)
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.
486 MAZDA
1.5L 4-Cylinder
1
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
.2 hours.
NOTE: A timing belt component kit is available for this application. Courtesy of Mazda Motors Corp.
NOTE: For information about tensioners and/or pulleys (when Installation – 1) Position notch on crankshaft sprocket to 12 o’clock
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED Working in a counterclockwise direction, route belt around pulleys and
camshaft sprocket.
SCHEDULED MAINTENANCE 2) Loosen timing belt tensioner lock bolt, and allow spring to apply
The manufacturer suggests the belt be replaced at 60,000 mile intervals tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete
for vehicles sold outside of California and Massachusetts. For vehicles turns in direction of normal engine rotation. Ensure timing marks align.
sold in California and Massachusetts, inspect timing belt at 60,000 3) Letter “Z” on camshaft pulley and pin on crankshaft pulley boss
and 90,000 miles, and replace timing belt at 105,000 miles. 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
REMOVAL & INSTALLATION belt. See Fig. 3. Ensure timing belt deflection is .28-.35″ (7.0-9.0 mm).
TIMING BELT 5) Ensure grooves on valve cover are free of oil, water, and dirt. Using
Removal – 1) Disconnect negative battery cable. Raise and support new valve cover gasket, install valve cover. Tighten valve cover bolts in
vehicle. Remove right front wheel. Remove right side cover and sequence. See Fig. 1. To complete installation, reverse removal proce-
undercover. dure.
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 Courtesy of Mazda Motors Corp.
expanded. Remove timing belt.
Crankshaft Pulley-To-Pulley Boss Bolt ......................................... ................... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167)
Wheel Lug Nuts ...................................................................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Adjuster Bolt .................................................................................. 71-97 (8-11)
Courtesy of Mazda Motors Corp. Timing Cover Bolt ............................................................................................. 71-97 (8-11)
Valve Cover Bolt ............................................................................................... 62-97 (7-11)
Fig. 1: Identifying Valve Cover Bolt Tightening Sequence
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.
MAZDA 487

Part No.
Protege
1
1999-01 .................................................... 2.7 Hours .. ..... T308
1

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 Hamp-
shire, 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 0°F
(-18°C). Under this condition, replace timing belt at 60,000 miles.

TIMING BELT
Removal – 1) Disconnect negative battery cable. Remove camshaft Courtesy of Mazda Motors Corp.
position sensor from left side (exhaust) of engine. Remove ignition coils.
Remove valve cover. Fig. 1: Exploded View Of Timing Belt & Components
2) Remove accessory drive belts and water pump pulley. Align crank-
shaft 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 Courtesy of Mazda Motors Corp.
pulley boss.
7) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner Fig. 2: Aligning Crankshaft & Camshaft Timing Marks
away from belt with spring fully expanded. Remove timing belt. sprocket timing marks are correctly aligned. See Fig. 2. If timing marks
Inspection – Check timing belt for cracks, peeling, abrasion or other are not aligned, remove belt, realign all timing marks, and repeat
damage. Check tensioner bearing for looseness or roughness of installation procedure.
rotation. Inspect tensioner spring for stretching. Tensioner spring free 7) Check timing belt deflection with 22 lbs. (10 kg) of downward pressure
length should be 2.43″ (61.8 mm). Replace parts as necessary. applied to belt, midway between camshaft sprockets. Timing belt
Installation – 1) Install tensioner spring with damper rubber closing face deflection should be 0.24-0.29″ (6.0-7.5 mm). If not, readjust timing belt
on side away from tensioner. See Fig. 3. tension.
2) Ensure camshaft and crankshaft timing marks are still aligned. See 8) To complete installation, reverse removal procedure. When installing
Fig. 2. Temporarily secure tensioner with spring fully extended. Install valve cover, tighten valve cover bolts in correct sequence. See Fig. 5.
belt around crankshaft sprocket, idler pulley, exhaust camshaft, intake 9) Adjust air gap between crankshaft plate and Crankshaft Position
camshaft, then tensioner. (CKP) sensor. With a plate tooth directly centered over CKP sensor, air
3) Temporarily install crankshaft pulley boss and bolt. Loosen timing belt gap should be 0.020-0.059″ (0.5-1.54 mm). Adjust accessory drive belts
tensioner lock bolt, and allow spring to apply tension on belt. Rotate to proper tension.
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.
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
488 MAZDA
Engine Mount Nut/Bolt .................................................................. ................. 44-59 (59-80)
Engine Mount-To-Engine Bolt ....................................................... ................. 50-68 (67-93)
INCH Lbs. (N.m)
Camshaft Position Sensor Bolt ......................................................................... 69-95 (8-11)
Crankshaft Position Sensor Bolt ....................................................................... 69-95 (8-11)
Crankshaft Pulley-To-Pulley Boss Bolt ......................................... ....... 109-151 (12.3-17.1)
Courtesy of Mazda Motors Corp. Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
Fig. 3: Installing Timing Belt Tensioner Spring
Fig. 4: Aligning Timing Belt At Tensioner Set Mark

MAZDA 489
1.6L & 1.8L 4-Cylinder – 1986-95

Kit No. Part No.
MX-3
1
1994-95 ................................ 2.9 Hrs .... .. TCK179 .. ..... T179
MX-5 Miata
1
1990-93 ............................ ... 3.0 Hrs. ... .. TCK179 .. ..... T179
323
1
1988-89 ............................ ... 2.8 Hrs. ... ...... ..... ...... ..... T149
MX-3
1
1992-93 ............................ ... 2.0 Hrs. ... .. TCK185 .. ..... T185
323
1
1986 ................................. ... 2.0 Hrs. ... ...... ..... ...... ..... T123
1
1987-89 ............................ ... 2.0 Hrs. ... .. TCK141 .. ..... T141
1
1990-94 ............................ ... 2.0 Hrs. ... .. TCK185 .. ..... T185
Protege
1
1990-94 ............................ ... 2.8 Hrs. ... .. TCK179 .. ..... T179
Protege
1
1990-94 ............................ ... 2.0 Hrs. ... .. TCK185 .. ..... T185 Courtesy of Mazda Motors Corp.
1
– With Air Conditioning add .2 hours. Fig. 1: Exploded View Of Timing Belt & Components (MX-5 Miata)


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.

Fig. 2: Aligning Camshaft Timing Marks (DOHC Engines)
TIMING BELT
Inspection (All Models) – Check timing belt for cracks, peeling,
Removal (MX-5 Miata) – 1) Disconnect negative battery cable. Drain
abrasion or other damage. Check tensioner bearing for looseness or
cooling system. Remove radiator hose and by-pass hoses from thermo-
roughness of rotation. Inspect tensioner spring for stretching. Replace
stat housing. Remove air cleaner intake duct assembly from throttle
parts as necessary.
body to air cleaner filter housing. Remove splash shield.
Installation (All Models) – 1) Position notch on crankshaft sprocket to
2) Remove drive belt(s) and water pump pulley. See Fig. 1. Align
12 o’clock position (aligned with mark on oil pump). Align timing marks
crankshaft pulley timing mark with cylinder No. 1 at TDC of compression
on camshaft sprocket(s). See Figs. 2 and 6. Ensure crankshaft timing
stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley
mark is at TDC. Install belt around crankshaft sprocket, then working in
bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.
a counterclockwise direction, route belt around camshaft sprocket(s).
3) Remove cylinder head cover. Remove upper, center and lower timing
2) Loosen timing belt tensioner lock bolt, and allow spring to apply
belt cover. If timing belt is to be reused, mark timing belt rotation
tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete
direction. Ensure timing marks on camshaft sprockets are aligned. See
turns in direction of normal engine rotation. Ensure timing marks align.
Fig. 2. Loosen timing belt tensioner lock bolt, and move tensioner away
If timing marks are not aligned, remove belt, realign all timing marks, and
from belt with spring fully expanded. Remove timing belt.
repeat installation procedure.
Removal (MX-3, Protege & 323) – 1) Disconnect negative battery 3) On all engines, check timing belt deflection with 22 lbs. (10 kg) of
cable. Raise and support vehicle. Remove right front wheel. Remove pressure applied to belt. See Fig. 7. Ensure timing belt deflection is
right splash panels. within specification. See TIMING BELT DEFLECTION table. Adjust drive
2) Remove drive belts and water pump pulley. See Fig. 3, 4 or 5. Align belts to proper tension.
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.
490 MAZDA
1.6L & 1.8L 4-Cylinder – 1986-95 (Cont.)
TIMING BELT DEFLECTION
1
Application Deflection – In. (mm)
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.

(DOHC Except MX-5 Miata)

(1989 SOHC)
Fig. 6: Aligning Camshaft Timing Marks (SOHC Engines)

(1990 & Later SOHC)
MAZDA 491
1.6L & 1.8L 4-Cylinder – 1986-95 (Cont.)

A/C Compressor Bracket
MX-5 Miata .................................................................................................... 11-16 (15-22)
MX-3, Protege & 323 .................................................................. ................. 17-26 (23-35)
Alternator Top Bolt ........................................................................ ................. 27-38 (37-52)
Crankshaft/Timing Belt Sprocket Bolt
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)
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)

492 MAZDA
1.8L 4-Cylinder – BP Engine
TIMING BELT APPLICATION 10) Install pulley boss on crankshaft to temporarily tighten with pulley
Application Labor Time Component Belt lock bolt. Ensure timing marks on camshaft sprockets and crankshaft
Kit No. Part No. sprockets are aligned. See Fig. 3.
1.8L 4-Cyl. – DOHC 11) Loosen timing belt tensioner lock bolt. Move tensioner away from
MX-5 Miata belt with spring fully expanded, and tighten lock bolt. Remove timing
1 belt.
1994-97 ............................ ... 2.6 Hrs. ... .. TCK179 .. ..... T179
1
1999-00 ............................ ... 2.5 Hrs. ... .. TCK179 .. ..... T179
1
2001-04 ............................ ... 2.7 Hrs. ... .. TCK179 .. ..... T179
Protege
1
1995-98 ............................ ... 2.4 Hrs. ... .. TCK179 .. ..... T179
1

NOTE: Engine identification code is on machined pad at left rear

end of engine, at transmission mating flange.

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.
replaced at 60,000 mile intervals for vehicles sold outside of California Courtesy of Mazda Motors Corp.
and Massachusetts. For vehicles sold in California and Massachusetts,
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt (1994-00 MX-5 Miata)
at 105,000 miles.
For 1999-00 vehicles, the replacement interval is 60,000 miles except Removal (Protege) – 1) Disconnect negative battery cable. Raise and
for vehicles registered in California, Connecticut, Delaware, Maine, support vehicle. Remove right front wheel. Remove right splash shield
Maryland, Massachusetts, New Hampshire, New Jersey, New York, from wheelwell.
Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. 2) Remove drive belts and water pump pulley. Align crankshaft pulley
For these states, inspect timing belt at 60,000 and 90,000 miles, and timing mark with cylinder No. 1 at TDC of compression stroke. Hold
replace timing belt at 105,000 miles. crankshaft stationary, and remove crankshaft pulley from crankshaft
pulley boss. See Fig. 4.
For 2001-04 MX-5 Miata, the replacement interval is 60,000 miles.
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.
REMOVAL & INSTALLATION 4) Support engine from above, and remove engine mount bracket from
TIMING BELT timing belt end of engine. Remove middle and lower timing belt covers.
Removal (MX-5 Miata) – 1) Disconnect negative battery cable. Drain 5) Holding crankshaft stationary, remove crankshaft pulley boss. Align
cooling system. Remove front strut bar and strut brackets, if equipped. timing marks on crankshaft and camshaft sprocket(s). See Fig. 3.
2) Disconnect Intake Air Temperature (IAT) sensor harness connector. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner
Remove air cleaner cover and necessary air hoses or pipes. Remove away from belt with spring fully expanded. Remove timing belt.
drive belt(s). Inspection (All Models) – 1) Check timing belt for cracks, peeling,
3) Remove Camshaft Position (CMP) sensor, if equipped. Remove abrasion or other damage. Check tensioner and idler pulley bearing for
Crankshaft Position (CKP) sensor. looseness or roughness of rotation. Replace parts as necessary.
4) Remove high tension leads and ignition coil(s). Remove spark plugs. 2) Inspect tensioner spring for stretching. Replace tensioner spring if
5) Remove upper radiator hose and by-pass hoses from thermostat free length is not greater than 2.33″ (59.2 mm). Free length is measured
housing. See Fig. 1 or 2. between inside edges of hooked portions of spring.
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 crank-
shaft 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.
MAZDA 493
1.8L 4-Cylinder – BP Engine (Cont.)
Fig. 2: Exploded View Of Timing Belt & Components (2001-04 MX-5 Miata)

494 MAZDA
Fig. 4: Exploded View Of Timing Belt & Components (Protege)

MAZDA 495

Installation (All Models) – 1) Position notch on crankshaft sprocket to
12 o’clock 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. Fig. 6: Aligning Timing Belt At Tensioner Set Mark
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 connec-
tion 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.

Fig. 9: Identifying OCV Case Bolts Tightening Sequence
Fig. 5: Installing Timing Belt Tensioner Spring (MX-5 Miata)
496 MAZDA
Alternator Pivot Bolt ...................................................................... ................. 28-38 (38-51)
Alternator Top Bolt ........................................................................ ................. 14-18 (19-25)
Crankshaft Pulley-To-Pulley Boss ................................................. ................... 9-13 (12-18)
Engine Mount Bracket Nuts (Protege) ......................................... ............... 55-77 (75-104)
Ignition Coil Mounting Bolt (1999-00) ........................................... ................. 14-18 (19-24)
Spark Plugs ..................................................................................................... 11-16 (15-22)
Fig. 10: Installing OCV Filter (MX-5 Miata) Strut Bar Bolt ................................................................................. ................. 12-16 (16-22)
Strut Bar Bracket Nut .................................................................... ................. 22-27 (30-37)
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)
Valve Cover Bolt
Except 2001-03 MX-5 Miata ....................................................... ..................... 43-78 (5-9)
2001-03 MX-5 Miata ....................................................................................... 71-97 (8-11)
Fig. 11: Identifying Top Oil Pipe Bolt Tightening Sequence

(MX-5 Miata)
Fig. 12: Identifying Side Oil Pipe Bolt Tightening Sequence

(MX-5 Miata)
MAZDA 497
1.8L 4-Cylinder – FP Engine

Application Labor Time Belt CAUTION: Crankshaft position sensor rotor is on rear of crank-
Part No. shaft pulley. DO NOT damage rotor when removing crankshaft
1.8L 4-Cyl. – DOHC pulley.
Protege 3) Remove crankshaft pulley and guide plate (large washer). Loosen
1
1999-00 .................................................... 2.4 Hours .. ..... T316
valve cover bolts in 2-3 steps. See Fig. 2. Remove valve cover and
1
– With Air Conditioning, add .2 hours. gasket.
4) Remove dipstick tube. Remove upper and lower timing belt covers.
NOTE: Engine code is stamped on machined pad on lower left end Support engine from above. Remove engine mount at timing belt end of
of engine, on transaxle mating flange. engine.
5) If reusing timing belt, mark arrow on belt to indicate direction of
NOTE: For information about tensioners and/or pulleys (when rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft
available), see ALPHABETICAL MODEL LISTING. sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of
engine) until cylinder No. 1 piston is at TDC of compression stroke and
MANUFACTURER’S SUGGESTED 6) Turn tensioner clockwise with a hex wrench to relieve spring tension,
SCHEDULED MAINTENANCE and then disconnect spring. Remove timing belt. Remove tensioner and
The replacement is 60,000 miles except for vehicles registered in idler pulley (if necessary).
California, Connecticut, Delaware, Maine, Maryland, Massachusetts, Inspection – Check timing belt for cracks, peeling, abrasion or other
New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, damage. Check tensioner bearing for looseness or roughness of
Vermont, and Washington D.C. For these states, inspect timing belt at rotation. Inspect tensioner spring for stretching. Tensioner spring free
60,000 and 90,000 miles, and replace timing belt at 105,000 miles. length should be 1.44″ (36.6 mm). Replace parts as necessary.
Installation – 1) Install tensioner, and idler pulley (if removed). Tempo-
rarily tighten tensioner with spring fully retracted. Ensure camshaft and
REMOVAL & INSTALLATION crankshaft timing marks are aligned. See Fig. 3.
TIMING BELT 2) Install timing belt around crankshaft sprocket, water pump sprocket,
Removal – 1) Disconnect negative battery cable. Remove Crankshaft idler pulley, and camshaft sprockets. Ensure slack does not exist on idler
Position (CKP) and Camshaft Position (CMP) sensors from front of side of timing belt.
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.

498 MAZDA
1.8L 4-Cylinder – FP Engine (Cont.)
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.
Fig. 2: Identifying Valve Cover Bolt Loosening Sequence
Courtesy of Mazda Motors Corp. Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52)
3) Complete timing belt installation on slack (tensioner) side. Allow INCH Lbs. (N.m)
tensioner to ride against timing belt. Turn crankshaft 2 revolutions in CKP & CMP Sensor Bolts ................................................................................ 71-97 (8-11)
normal direction of rotation. Ensure camshaft and crankshaft timing Timing Belt Covers ........................................................................ ................... 61-87 (7-10)
marks are still correctly aligned. If not, timing belt will have to be Valve Cover Bolts .......................................................................... ................... 62-89 (7-10)
removed and repositioned. Water Pump Pulley Bolts .................................................................................. 71-97 (8-11)
4) If all timing marks are okay, turn tensioner clockwise by using a hex
wrench. Connect tensioner spring to pin on engine block. Turn crank-
shaft 2 revolutions. Ensure camshaft and crankshaft timing marks are
still aligned.
MAZDA 499
1.8L V6
1.8L V6 Removal – 1) Disconnect negative battery cable. Drain coolant. Raise
MX-3 and support vehicle, and remove right front wheel. Remove lower
1
1992-93 .................................................... 3.8 Hours .. ..... T214 engine covers. Remove accessory drive belts. Remove water pump
MX-3 (Canadian) pulley. Remove drive belt idler pulley bracket. See Fig. 1. Disconnect
1
1995 .......................................................... 3.8 Hours .. ..... T214 necessary clamps and power steering pressure switch connector to
1
– With Air Conditioning, add .2 hours. remove power steering reservoir. Remove retaining bolts and power
With Power Steering, add .2 hours. steering reservoir with hoses attached, and secure reservoir aside.
2) Remove retaining nut and power steering pump pulley. Remove
NOTE: For information about tensioners and/or pulleys (when retaining bolts and power steering pump with hoses attached, and
available), see ALPHABETICAL MODEL LISTING. secure pump aside. Remove crankshaft pulley retaining bolt. Using
puller, remove crankshaft pulley.
MANUFACTURER’S SUGGESTED CAUTION: DO NOT damage crank angle sensor rotor on rear of
SCHEDULED MAINTENANCE crankshaft pulley during crankshaft pulley removal.
For 1992 model year, the manufacturer recommends the belt be 3) Unplug crank angle sensor, and unclip wires from oil dipstick tube.
replaced every 60,000 miles. For 1993-95 model years, the manufac- Remove oil dipstick and oil dipstick tube. Remove crank angle sensor
turer recommends the belt be replaced at 60,000 mile intervals for harness bracket. Remove engine wiring harness, located along top of
vehicles sold outside of California. For vehicles sold in California, timing belt cover. Support engine using hoist or floor jack. Remove right
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt front wheel. Remove through-bolt, retaining nuts and right (timing belt
at 105,000 miles. side) engine mount. Remove retaining bolts, timing belt covers and
gaskets. See Fig. 1.

500 MAZDA
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 CAUTION: If reusing timing belt, ensure timing belt is installed in
crankshaft sprocket aligns with indicator on oil pump body. See Fig. 2. original direction of rotation.
5) If reusing timing belt, place reference mark on timing belt to indicate 3) Push outward at bottom of timing belt tensioner, and install lower
direction of rotation. Hold timing belt tensioner and remove lower retaining bolt in timing belt tensioner. Tighten both timing belt tensioner
retaining bolt first, then remove upper bolt. Remove timing belt ten- retaining bolts to specification. Remove pin from timing belt tensioner,
sioner. Remove No. 2 timing belt pulley and timing belt. Remove No. 1 allowing tension to be applied on timing belt. Rotate crankshaft 2 full
idler pulley and tensioner pulley (if necessary). 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
Courtesy of Mazda Motors Corp. Fig. 4: Retracting Timing Belt Tensioner Rod
contamination. Ensure idler pulleys No. 1 and No. 2 and tensioner pulley
rotate freely. Replace damaged components. Inspect timing belt ten-
sioner 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).
Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion Courtesy of Mazda Motors Corp.
Installation – 1) Place timing belt tensioner in a press using a flat Fig. 5: Measuring Timing Belt Deflection
washer to prevent damage to timing belt tensioner. See Fig. 4. Com-
press tensioner rod until holes in rod and housing are aligned and install
.06″ (1.5 mm) diameter pin through holes in housing and rod to hold rod
in retracted position. See Fig. 4.
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.
MAZDA 501
1.8L V6 (Cont.)
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)
Water Pump Bolt ........................................................................... ................. 14-19 (19-26)
INCH Lbs. (N.m)
Crank Angle Sensor Bracket Bolt ..................................................................... 69-95 (8-11)
Cylinder Block Valley Cover Bolt ...................................................................... 69-95 (8-11)
Valve Cover Bolt 2 ......................................................................... ..................... 43-78 (5-9)
Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
1
– Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs. (31-46 N.m.). Tighten lower
bolt on front of bracket to 14-19 ft. lbs. (19-26 N.m). Tighten rear bracket-to-cylinder
block bolt to 24-33 ft. lbs. (32-45 N.m).
2
– Tighten bolts to specification in sequence. See Fig. 6.
Fig. 6: Identifying Valve Cover Bolt Installation Sequence

502 MAZDA
1
Part No.
626
1984-85
Camshaft ................................................ 1.9 Hours ... ..... T103
Injection Pump ....................................... 1.0 Hours ... ..... T102
1

miles.

damage may occur.

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 Fig. 1: Aligning Front Camshaft & Crankshaft Pulley
as far back as it will go. Snug tensioner lock bolt. Timing Marks
2) Remove torque bracket from right fender apron. If reusing timing belt, 3) Install rear timing belt on injection pump pulley, around tensioner, and
mark an arrow on timing to indicate direction of travel, then remove then on camshaft pulley. Remove bolts securing injection pump pulley.
timing belt. Check belt for premature wear, missing teeth, or cracks.
Loosen tensioner lock nut until tension is applied on belt. Turn crank-
Check turning smoothness of belt tensioner.
shaft in a clockwise direction for 2 complete revolutions.
Installation – 1) Ensure that timing mark on camshaft pulley is aligned
4) Check timing marks on rear camshaft and injection pump pulleys. See
with mark on front seal plate. Make sure that notch on crankshaft pulley
Fig. 2. Tighten tensioner lock nut. Check timing belt deflection using 22
is aligned with timing mark on oil pump housing. See Fig. 1.
2) If tensioner was removed, install tensioner, lock bolt, and spring. Push lbs. (10 kg) of force between injection pump and camshaft pulleys.
tensioner as far left as it will go. Snug tensioner lock bolt. Install timing Deflection should be 0.375″ (9.53 mm). Install rear timing belt cover.
belt. Release tensioner lock bolt, and allow tensioner to contact belt. Adjust drive belts to proper tension.
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.
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 Fig. 2: Aligning Rear Camshaft & Injection Pump Pulley
this time. Remove bolts after installing timing belt. Timing Marks
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.
MAZDA 503

Fuel Injection Pump Pulley Bolts ................................................. ................. 43-51 (58-69)
Timing Belt (Front) Pulley Bolt ............................................................... 116-123 (157-167)
Front ............................................................................................. ................. 23-34 (31-46)
Rear ............................................................................................. ................. 15-20 (20-27)
Water Pump Bolts ......................................................................... ................. 23-34 (31-46)
INCH Lbs. (N.m)
Rear Cover Bolts ........................................................................... ..................... 60-84 (7-9)
504 MAZDA
2.0L 4-Cylinder – DOHC – Except Tribute
TIMING BELT APPLICATION For 1997-98 gasoline engine model years, the manufacturer suggests
Application Labor Time Component Belt the belt be replaced at 60,000 mile intervals for vehicles sold outside of
Kit No. Part No. California and Massachusetts. For vehicles sold in California and
2.0L 4-Cyl. – DOHC Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and
MX-6 replace timing belt at 105,000 miles.
1
1993-97 ............................ ... 2.5 Hrs. ... .. TCK228 .. ..... T228 For 1999-00 gasoline engine model years, the manufacturer recom-
Protege mends the belt be replaced at 60,000 mile intervals except for vehicles
1
2001-03 ............................ ... 2.4 Hrs. ... .. TCK228 .. ..... T228 registered in California, Connecticut, Delaware, Maine, Maryland, Mas-
Protege5 sachusetts, New Hampshire, New Jersey, New York, Pennsylvania,
1
2002-03 ............................ ... 2.4 Hrs. ... .. TCK228 .. ..... T228 Rhode Island, Vermont, Virginia and Washington D.C. For these states,
626
1 inspect timing belt at 60,000 and 90,000 miles, and replace timing belt
1993-02 ............................ ... 2.5 Hrs. ... .. TCK228 .. ..... T228
at 105,000 miles.
1
For 2001-03 gasoline engine models, the manufacturer recommendsin-
With Power Steering, add .2 hours
specting the belt at 60,000 miles and replaced at 105,000 miles,
NOTE: A timing belt component kit is available for this application. UNLESS the vehicle is operated in temperatures under 0°F (-18°C).
See page A1 for information on component kits. Under this condition, replace belt at 60,000 miles.
NOTE: For information about tensioners and/or pulleys (when REMOVAL & INSTALLATION
TIMING BELT
Removal – 1) Disconnect negative battery cable. Remove Crankshaft
MANUFACTURER’S SUGGESTED Position (CKP) and Camshaft Position (CMP) sensors from front of
SCHEDULED MAINTENANCE engine (if equipped). See Fig. 1. Remove spark plugs.
For 1993 model year, the manufacturer recommends the belt be 2) Remove accessory drive belts. Leaving hoses attached, remove
replaced at 60,000 miles. power steering pump and position aside. Remove the water pump
For 1994-96 gasoline engine model years, the manufacturer recom- pulley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on TDC of
mends the belt be replaced at 60,000 mile intervals for vehicles sold compression stroke.
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.
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
7) Turn tensioner clockwise using a Allen wrench to relieve spring
tension, and then disconnect spring from the hook pin. See Fig. 6. Courtesy of Mazda Motors Corp.
Remove timing belt. Remove crankshaft sprocket, tensioner and idler
pulley (if necessary).
Fig. 2: Removing Engine Front Components

506 MAZDA
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
Fig. 4: Identifying Valve Cover Bolt Loosening Sequence 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.
Fig. 5: Aligning Camshaft & Crankshaft Timing Marks Courtesy of Mazda Motors Corp.
Fig. 7: Inspecting Timing Belt
Courtesy of Mazda Motors Corp. Courtesy of Mazda Motors Corp.
Fig. 6: Removing Tensioner Spring 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.
damage. See Fig. 7. Check tensioner bearing for looseness or rough-
ness 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 Courtesy of Mazda Motors Corp.
pulley side of timing belt. Fig. 9: Checking Timing Belt Tensioner
MAZDA 507
Fig. 14: Measuring Crankshaft Position Sensor-To-Crankshaft

Pulley Air Gap
Courtesy of Mazda Motors Corp. Application Ft. Lbs. (N.m)
Fig. 11: Installing Tensioner Spring To Hook Pin Camshaft Pulley Bolt ..................................................................... ................. 37-44 (50-60)
Engine Mount Nut ......................................................................... ............... 55-77 (75-104)
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)
Fig. 12: Identifying Sealant Locations

508 MAZDA
2.0L 4-Cylinder – DOHC – Tribute
Kit No. Part No.
Tribute
2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294


MANUFACTURER’S SUGGESTED Courtesy of Ford Motor Co.
SCHEDULED MAINTENANCE Fig. 1: Removing Valve Cover


TIMING BELT
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. Courtesy of Ford Motor Co.
Remove stud and install Crankshaft TDC Timing Peg (303-574). See
Fig. 2: Aligning Crankshaft Timing Marks Before TDC
Fig. 3.
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. Fig. 3: Removing Stud For Installation Of Crankshaft TDC
Timing Peg (303-574)
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.
CAUTION: DO NOT reuse old timing belt. Replace with a NEW belt.
Installation – 1) Slide crankshaft pulley onto crankshaft. Ensure crank-
shaft 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. Fig. 4: Removing Lower Timing Belt Cover
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
MAZDA 509
2.0L 4-Cylinder – DOHC – Tribute (Cont.)

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
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.
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.
Fig. 6: Removing Engine Mount Upper Bracket
Fig. 7: Removing Upper Timing Belt Cover
Fig. 8: Installing Camshaft Alignment Tool (303-465)

510 MAZDA
2.0L 4-Cylinder – DOHC – Tribute (Cont.)
Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45)
Coolant Tube Attachments ........................................................................................ 15 (20)
Engine Mount Lower Bracket Nuts .......................................................................... 37 (50)
Engine Mount Upper Bracket
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)
Fig. 12: Adjusting Timing Belt Tensioner Upper Timing Belt Cover Studs ................................................................................ 25 (34)
INCH Lbs. (N.m)
Lower Timing Belt Cover Bolts ................................................................................... 62 (7)
Splash Shield Bolts ..................................................................................................... 80 (9)
Upper Timing Belt Cover Bolts ................................................................................... 71 (8)
Valve Cover Bolts ........................................................................................................ 80 (9)
MAZDA 511

TIMING BELT APPLICATION arrow on timing belt to indicate direction of travel. Remove tensioner
Application 1
Labor Time Component Belt lock bolt, tensioner and spring. Remove timing belt. On 2.2L engines,
Kit No. Part No. measure free length of tensioner spring. Replace spring if free length is
2.0L 4-Cyl. – SOHC not 2.48″ (63 mm). See Fig. 3.
B2000
NOTE: Never twist, turn inside out, or bend timing belt.
1986
Thru: Chassis
No. 568707 ........................ 2.6 Hrs. ... ...... ..... ............ T113
From: Chassis
No. 568708 ........................ 2.6 Hrs. ... ...... ..... ............ T117
1987 ....................................... 2.6 Hrs. ... .. TCK117 ........ T117
626
1983 ....................................... 1.6 Hrs. ... ...... ..... ...... ..... T088
626 Coupe
1984-85
Thru: VIN
2
JM1GC221E1617 .............. 1.6 Hrs. ... ...... ..... ...... ... T088
From: VIN
3
JM1GC221E16176 ............ 1.6 Hrs. ... ...... ..... ...... ... T113
626 Hatchback
1984-85
2
Thru: VIN JM1GC241E1 ..... 1.6 Hrs. ... ...... ..... ...... ... T088
3
From: VIN JM1GC241E1 .... 1.6 Hrs. ... ...... ..... ...... ... T113
626 Sedan
1984-85
Thru: VIN
2
JM1GC221E1635511 ......... 1.6 Hrs. ... ...... ..... ...... ... T088
From: VIN
JM1GC221E1635511 ......... 1.6 Hrs. ... ...... ..... ...... ... 3 T113
1986-87 .................................. 1.6 Hrs. ... .. TCK117 ........ T117
2.2L 4-Cyl. – Non-Turbo & Turbo
B2200
1987-93 .................................. 2.6 Hrs. ... .. TCK134 .. ..... T134
MX-6
1988-92 .................................. 2.3 Hrs. ... .. TCK134 .. ..... T134
626
1988-92 .................................. 2.3 Hrs. ... .. TCK134 .. ..... T134
1
2
– With square tooth sprocket.
3
– With round tooth sprocket.
NOTE: A timing belt component kit is available for this application. Fig. 1: Timing Belt Reference Marks & Deflection (2.0L)


damage may occur.
Fig. 2: Aligning Timing Marks (2.2L)

TIMING BELT
Removal – 1) Disconnect negative battery cable. On B2200 models, Installation – 1) Align camshaft pulley with front housing timing mark.
drain cooling system. Radiator removal may be required. Remove Align crankshaft pulley with pointer on oil pump body. See Fig. 1 or 2.
cooling fan and shroud. Remove distributor from front housing. Remove Install tensioner, lock bolt and tensioner spring. Position timing belt
cooling fan pulley and bracket. Remove secondary air pipe assembly tensioner to its limit of travel toward the intake manifold side, and
(carbureted engines). partially tighten lock bolt.
2) On all models, remove all accessory drive belts. Remove crankshaft 2) Install timing belt onto crankshaft pulley and then camshaft pulley.
pulley. Remove timing belt covers. Remove baffle plate located in front Install timing belt from tension side (right side, as viewed from engine
of crankshaft sprocket. Note direction of baffle plate installation. Align front). If timing belt is being reused, ensure that arrow is pointing in
camshaft pulley with front housing timing mark. See Fig. 1 or 2. Mark an direction of travel.
512 MAZDA
TORQUE SPECIFICATIONS (2.0L)
Courtesy of Mazda Motors Corp. Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52)
Torque Stopper Bolts .................................................................... ................. 45-56 (61-76)
Fig. 3: Measuring Free Length of Tensioner Spring
INCH Lbs. (N.m)
3) Loosen tensioner lock bolt to apply tension. To apply equal tension to Timing Belt Covers ........................................................................ ................... 61-87 (7-10)
each side of timing belt, turn crankshaft 2 revolutions in direction of Valve Cover ................................................................................... ..................... 26-35 (3-4)
travel. Tighten tensioner lock bolt. Check for proper alignment of timing
marks. TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo)
4) Check for proper belt tension by measuring amount of deflection Application Ft. Lbs. (N.m)
midway between idler pulley and camshaft sprocket. Belt deflection Coolant Inlet Pipe Bolt .................................................................. ................. 14-19 (19-26)
should be .30-.33″ (7.6-8.4 mm) when force of 22 lbs. (10 kg) is applied. Crankshaft Sprocket Bolt ........................................................................ 116-123 (157-167)
See Fig. 1 or 2. Repeat adjustment if deflection is not within specifica- Timing Belt Idler Pulley ................................................................. ................. 27-38 (37-52)
tion. Timing Belt Tensioner Lock Bolt ................................................... ................. 27-38 (37-52)
5) Reverse removal procedure to complete installation. Adjust drive Water Pump Bolt ........................................................................... ................. 14-19 (19-26)
belts to proper tension. 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
Kit No. Part No.
2.3L 4-Cyl.
B2300
1
1994 ................................... 1.7 Hours .. .. TCK210 .. ..... T210
1
1995-97 .............................. 1.7 Hours .. .. TCK276 .. ..... T276
1



TIMING BELT
Removal – 1) Disconnect negative battery cable. Ensure crankshaft is CAUTION: Always rotate engine in direction of normal rotation
set at TDC and camshaft sprocket timing mark is aligned with cover (clockwise as viewed from front of engine).
pointer. See Fig. 1. Disconnect negative battery cable.
2) Drain cooling system and remove upper radiator hose. Remove Installation – 1) Ensure crankshaft is set at TDC and camshaft sprocket
alternator. Loosen water pump pulley bolts. Remove accessory drive timing mark is aligned with cover pointer. See Fig. 1. Install belt guide
belt(s). Remove spark plugs to ensure belt does not jump time during with flat side toward the camshaft sprocket. See Fig. 2.
2) Install timing belt. Loosen tensioner bolt, allowing tensioner to apply
rotation.
pressure on belt. Tighten tensioner bolt. Rotate crankshaft clockwise 2
3) Remove cooling fan and water pump pulley. Remove crankshaft
complete turns to remove slack from belt.
pulley, hub and belt guide. Remove crankshaft position sensor. Remove
3) Loosen tensioner bolt. Apply additional pressure to tensioner, as
dipstick and pipe. Remove timing belt cover retaining bolt. Release 8
spring pressure is insufficient. Retighten tensioner lock bolt. To complete
cover interlocking tabs. Remove timing belt cover. Loosen timing belt installation, reverse removal procedure. Fill and bleed cooling system.
tensioner pulley bolt. See Fig. 2. Pry tensioner away from timing belt, Adjust drive belts to proper tension.
and tighten bolt to hold tensioner in place. Remove timing belt.
Crankshaft Damper Bolt ................................................................ ......... 103-133 (140-180)
Water Pump Bolt 1 ......................................................................... ................. 14-21 (19-29)
INCH Lbs. (N.m)
Valve Cover Bolt ............................................................................................... 62-97 (7-11)
1
– Apply sealant to bolt threads.

514 MAZDA
2.3L V6
TIMING BELT APPLICATION 4) Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft
Application Labor Time Belt so No. 1 cylinder is at TDC on compression stroke. The crankshaft and
Part No. camshaft timing marks should align. See Fig. 2.
2.3L V6 5) If reusing timing belt, place reference mark on timing belt to indicate
Millenia direction of rotation. Hold timing belt tensioner and remove lower
1
1995-02 .................................................... 4.5 Hours .. ..... T267 retaining bolt first, then remove upper bolt. Remove timing belt ten-
1
– With Air Conditioning, add .2 hours. sioner. Remove timing belt.
With Power Steering, add .2 hours. Inspection – 1) Inspect timing belt for damaged teeth, cracking and oil
contamination. Inspect timing belt auto tensioner for signs of oil leakage.
NOTE: For information about tensioners and/or pulleys (when 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
MANUFACTURER’S SUGGESTED .563-.594″ (14.3-15.1 mm).
SCHEDULED MAINTENANCE NOTE: The following information on repairing the front engine oil
For 1995-96 vehicles, the manufacturer suggests the belt be replaced at leaks is from Mazda technical service bulletin MT0596-07; May,
60,000 mile intervals for vehicles sold outside of California. For vehicles 1996.
sold in California, inspect timing belt at 60,000 and 90,000 miles, and
replace timing belt at 105,000 miles. 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
For 1997-98 vehicles, the manufacturer suggests the belt be replaced at
oil leak, remove No. 3 engine mount bracket. Remove mounting stud
60,000 mile intervals for vehicles sold outside of California and Massa-
chusetts. For vehicles sold in California and Massachusetts, inspect from engine. Clean all threads thoroughly. Apply Loctite PST Pipe
timing belt at 60,000 and 90,000 miles, and replace timing belt at Sealant with Teflon (No. 565) to stud threads. Install stud on engine
105,000 miles. block.
Installation – 1) Place timing belt auto tensioner in a press using a flat
For 1999-00 vehicles, the replacement is 60,000 miles except for
vehicles registered in California, Connecticut, Delaware, Maine, Mary- washer to prevent damage to timing belt tensioner. See Fig. 5. Using no
land, Massachusetts, New Hampshire, New Jersey, New York, Penn- more than 2200 lbs. of pressure, compress tensioner rod until holes in
sylvania, Rhode Island, Vermont, and Washington D.C. For these rod and housing are aligned. Install a .055-.063″ (1.4-1.6 mm) diameter
states, inspect timing belt at 60,000 and 90,000 miles, and replace pin through holes in housing and rod to hold rod in retracted position.
timing belt at 105,000 miles. See Fig. 5.
For 2001-02 vehicles, the replacement interval is 60,000 miles. 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
REMOVAL & INSTALLATION bolts to specification. See TORQUE SPECIFICATIONS. Ensure all
TIMING BELT 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 CAUTION: If reusing timing belt, ensure timing belt is installed in
covers. Remove accessory drive belts. original direction of rotation.
CAUTION: DO NOT damage crank angle sensor rotor on rear of 3) Remove pin from timing belt tensioner, allowing tension to be applied
crankshaft pulley during crankshaft pulley removal. on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC
to TDC. Ensure timing marks on camshaft sprockets and crankshaft
2) Remove crankshaft pulley retaining bolt. Using puller, remove crank- sprockets are properly aligned. See Fig. 2. If timing marks are not
shaft pulley. Remove power steering pump pulley. Remove water pump aligned, remove and repeat entire timing belt installation procedure.
pulley. Remove generator drive belt auto tensioner. See Fig. 1. Remove 4) Install timing belt covers using NEW gaskets. Tighten retaining bolts
camshaft position sensor from right hand camshaft.
to specification. See TORQUE SPECIFICATIONS. Install dipstick tube
3) Remove engine oil dipstick and pipe. Remove vacuum pipe. Remove
with new “O” ring.
upper radiator hose. Support engine using hoist. Remove No. 3 engine
mount and brackets from timing belt end of engine. Remove retaining
fasteners to specification. See TORQUE SPECIFICATIONS. Check
bolts, timing belt covers and gaskets. Remove power steering belt auto
tensioner. See Fig. 1. ignition timing. Adjust drive belts to proper tension.
MAZDA 515
2.3L V6 (Cont.)

516 MAZDA
2.3L V6 (Cont.)
Courtesy of Mazda Motors Corp. 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)
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)
Fig. 4: Locating Engine Mount Bracket Stud

MAZDA 517
2.5L 4-Cylinder
Kit No. Part No.
2.5L 4-Cyl.
B2500
1
1998-00 .............................. 1.7 Hours .. .. TCK276 .. ..... T276
1


The manufacturer recommends the belt be inspected at 120,000 miles
and replaced if necessary.
TIMING BELT Fig. 2: Exploded View Of Timing Belt & Components

Removal – 1) Disconnect negative battery cable. Remove exhaust side
spark plugs. Rotate crankshaft clockwise so No. 1 piston is at TDC of CAUTION: Always rotate engine in direction of normal rotation
compression stroke. (clockwise as viewed from front of engine). Reverse rotation may
2) Remove fan shroud. Loosen fan clutch-to-pulley bolts. Remove cause timing belt to jump time, causing engine damage.
accessory drive belt. Remove fan clutch and pulley. Remove crankshaft
Installation – 1) Ensure crankshaft is set at TDC and camshaft sprocket
center bolt, and remove crankshaft pulley.
timing mark and oil pump sprocket timing mark are aligned with inner
3) Using recycling equipment, recover refrigerant from air conditioning
cover timing marks. See Fig. 1.
system (if equipped). Disconnect A/C clutch connector from A/C clutch.
2) Install timing belt on crankshaft sprocket. Working clockwise, install
Remove A/C compressor from mounting bracket. Remove A/C compres-
belt over oil pump sprocket, camshaft sprocket, and tensioner pulley.
sor mounting bracket with hoses attached, and position out of way.
3) Loosen tensioner bolt and allow tensioner to adjust itself. Rotate
4) Remove timing belt outer cover retaining bolt. Release 7 cover
crankshaft clockwise 2 complete revolutions to remove slack from belt.
interlocking tabs. Remove timing belt cover. Ensure crankshaft and
Recheck timing mark alignment. Readjust as necessary. Tighten timing
camshaft timing marks are aligned. See Fig. 1.
belt tensioner bolts.
5) Holding timing belt tensioner with Camshaft Belt Tension Adjuster
4) Install timing belt cover. Install crankshaft pulley. Install A/C compres-
(T74P-6254-A) or equivalent, loosen adjusting bolt and slowly release
sor bracket with power steering pump. Install A/C compressor and
tension. See Fig. 2. Pry tensioner away from timing belt, and tighten bolt
recharge system (if equipped).
to hold tensioner in place.
6) If reusing old timing belt, mark belt with arrow to indicate direction of
rotation. Remove timing belt.
A/C Compressor Bracket Mount Bolts
M8 Bolt .................................................................................................................... 18 (25)
M10 Bolt .................................................................................................................. 35 (48)
A/C Compressor-To-Bracket Bolt .................................................. ................. 16-20 (21-28)
Cooling Fan-To-Pulley Bolts .......................................................... ................. 13-16 (17-23)
Crankshaft Damper Bolt ................................................................ ........... 92-122 (125-165)
Timing Belt Tensioner Pivot Bolt .................................................. ................. 29-41 (40-55)
INCH Lbs. (N.m)
Spark Plug ....................................................................................................... 80-115 (9-13)

518 MAZDA
2.5L V6
TIMING BELT APPLICATION For 1999 626 models and 1999-00 Millenia models, the manufacturer
Application Labor Time Component Belt recommends the belt be replaced at 60,000 mile intervals except for
Kit No. Part No. vehicles registered in California, Connecticut, Delaware, Maine, Mary-
2.5L V6 land, Massachusetts, New Hampshire, New Jersey, New York, Penn-
Millenia sylvania, Rhode Island, Vermont, Virginia and Washington D.C. For
1 these states, inspect timing belt at 60,000 and 90,000 miles, and replace
1995-02 .............................. 3.4 Hours .. .. TCK214 .. ..... T214
MX-6 timing belt at 105,000 miles.
1
1993-97 .............................. 4.0 Hours .. .. TCK214 .. ..... T214 For 2000 626 models, the manufacturer recommends the belt be
626 replaced at 60,000 mile intervals except for vehicles registered in
1
1993-02 .............................. 4.0 Hours .. .. TCK214 .. ..... T214 California, Maine, Massachusetts and Vermont. For these states,
1
– With Air Conditioning, add .2 hours. inspect timing belt at 60,000 and 90,000 miles, and replace timing belt
With Power Steering, add .2 hours. at 105,000 miles.
NOTE: A timing belt component kit is available for this application. For 2001-02 model year, inspect timing belt at 60,000 and replace timing
See page A1 for information on component kits. belt at 105,000 miles, UNLESS the vehicle is operated in temperatures
that are under 0°F (-18°C). In this case, replace timing belt at 60,000
miles.
MANUFACTURER’S SUGGESTED TIMING BELT
Removal – 1) Disconnect negative battery cable. On Millenia, raise and
SCHEDULED MAINTENANCE support vehicle. Remove right front wheel. Remove lower engine
For 1993 model year, the manufacturer recommends the belt be covers.
replaced at 60,000 miles. 2) On all models, remove accessory drive belts. Remove water pump
For 1994-96 model years, the manufacturer recommends the belt be pulley. Remove drive belt idler pulley bracket. Remove retaining bolts
replaced at 60,000 mile intervals for vehicles sold outside of California. and power steering pump with hoses attached, and secure pump out of
For vehicles sold in California, inspect timing belt at 60,000 and 90,000 way. Remove spark plugs.
CAUTION: DO NOT damage crankshaft position sensor rotor on
For 1997-98 model years, the manufacturer suggests the belt be
rear of crankshaft pulley during crankshaft pulley removal.
replaced at 60,000 mile intervals for vehicles sold outside of California
and Massachusetts. For vehicles sold in California and Massachusetts, 3) Holding crankshaft stationary, remove the crankshaft pulley retaining
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt bolt. Using gear puller, remove crankshaft pulley.
at 105,000 miles.

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.
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

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
Courtesy of Mazda Motors Corp. belt end of engine) from TDC to TDC. Ensure timing marks on camshaft
Fig. 2: Aligning Camshaft & Crankshaft Timing Marks sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If
timing marks are not aligned, remove and repeat entire timing belt
Inspection – 1) Inspect timing belt for damaged teeth, cracking and oil installation procedure.
contamination. Ensure idler pulleys (No. 1 and No. 2) and tensioner 6) Install right (timing belt side) engine mount. Install timing belt covers
pulley rotate freely. Replace damaged components. using NEW gaskets. Tighten retaining bolts to specification. See
2) Inspect timing belt tensioner for signs of oil leakage. Replace timing TORQUE SPECIFICATIONS.
belt tensioner if oil leakage exists. Measure timing belt tensioner rod 7) Install dipstick tube with new “O” ring. To install remaining compo-
protrusion from end of rod to edge of housing. See Fig. 3. There are 2 nents, reverse removal procedure. Tighten fasteners to specification.
types of tensioners used on this engine. See Fig. 4. Replace timing belt See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
tensioner if rod protrusion distance is not as specified. See TIMING 8) Check crankshaft position sensor air gap. Gap between center of
BELT TENSIONER ROD PROTRUSION table. 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.
TIMING BELT TENSIONER ROD PROTRUSION
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)


520 MAZDA
2.5L V6 (Cont.)
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)
Nut (All Models) .......................................................................... ............... 55-75 (74-102)
Courtesy of Mazda Motors Corp. Through-Bolt (626) ...................................................................................... 63-86 (86-116)
Fig. 6: Installing Timing Belt Tensioner Pulley Bolt .................................................................... ................. 28-32 (38-44)
Water Pump Bolt ........................................................................... ................. 14-18 (19-25)
Wheel Lug Nut
Millenia ......................................................................................... ............... 66-94 (89-127)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bracket Bolt ......................................................... 69-95 (8-11)
1
– Tighten 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 2) Remove drive belts. Remove A/C and P/S idler pulleys (if equipped).
Application 1
Labor Time Component Belt Remove crankshaft pulley, baffle plate (if equipped), and sensor rotor (if
Kit No. Part No. equipped). DO NOT damage sensor rotor. Remove coolant by-pass and
3.0L V6 – DOHC upper radiator hoses.
929 3) Remove distributor. Remove timing belt covers and gasket. See
1990-91 ............................... 3.9 Hours .... TCK183A . ..... T183 Fig. 1. Turn crankshaft to align pulley match marks. See Fig. 2. Remove
1992-95 ............................... 3.9 Hours ... .. TCK183 .. ..... T183 timing belt upper idler pulley. If reusing timing belt, mark rotation
Serenia (Canadian) direction. Remove timing belt and timing belt automatic tensioner.
1992-95 ............................... 3.9 Hours ... ...... ..... ...... ..... T183 Inspection – Check automatic tensioner rod projection. Rod should
1
– With Air Conditioning, add .2 hours. project .47-.55″ (12-14 mm) from tensioner body. Replace tensioner if
With Power Steering, add .2 hours. projection is not within specification.
Installation – 1) Using flat washer to prevent damage to tensioner body
NOTE: A timing belt component kit is available for this application. plug, place automatic tensioner in vise or arbor press. Compress
See page A1 for information on component kits. tensioner rod until a pin can be inserted into tensioner rod through hole
in tensioner body. Install tensioner with pin installed.
available), see ALPHABETICAL MODEL LISTING. CAUTION: DO NOT exceed 2200 lbs (1000 kg) pressure on ten-
sioner rod.
MANUFACTURER’S SUGGESTED 2) Ensure match marks on pulleys align with marks on heads. See
SCHEDULED MAINTENANCE Fig. 2. With upper idler pulley removed, install timing belt on pulleys.
Keep slack toward automatic tensioner side. Install upper idler pulley.
The manufacturer recommends the belt be replaced every 60,000 miles Rotate crankshaft twice in direction of rotation, and ensure match marks
for Federal vehicles, and 105,000 miles on California vehicles. still align. Remove automatic tensioner pin, and repeat steps to confirm
REMOVAL & INSTALLATION match marks are still in alignment.
3) Check timing belt deflection between right cam pulley and lower idler.
CAUTION: This application is an interference engine. Do not rotate Deflection should be .20-.28″ (5-7 mm) at 22 lbs. (10 kg). If deflection is
camshaft or crankshaft when timing belt is removed, or engine not correct, repeat installation procedure. If deflection is still not correct,
damage may occur. check for faulty automatic tensioner or stretched timing belt.
4) To complete installation, reverse removal procedure. Tighten fasten-
TIMING BELT ers to specification. See TORQUE SPECIFICATIONS. Adjust the drive
Removal – 1) Disconnect negative battery cable. Drain engine coolant. belts to proper tension.
Remove spark plug cables and spark plugs. Remove air intake hose.
Remove cooling fan and fan shroud.

522 MAZDA
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)
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)
Courtesy of Mazda Motors Corp. Timing Belt Upper Idler Bolt ......................................................... ................. 27-38 (37-52)
Water Pump Bolt/Nut .................................................................... ................. 14-18 (19-25)
Fig. 2: Aligning Timing Belt Match Marks
INCH Lbs. (N.m)
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
1
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


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
replaced at 60,000 mile intervals for vehicles sold outside of California
and Massachusetts. For vehicles sold in California and Massachusetts, Courtesy of Mazda Motors Corp.
inspect timing belt at 60,000 and 90,000 miles, and replace timing belt
at 105,000 miles. Fig. 1: Exploded View Of Timing Belt & Components

damage may occur.
TIMING BELT
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 Courtesy of Mazda Motors Corp.
all timing marks. See Fig. 2.
2) If reusing timing belt, place reference mark on timing belt to indicate Fig. 2: Aligning Timing Marks
direction of timing belt rotation. Remove upper idler pulley. See Fig. 1.
Remove timing belt. Remove timing belt tensioner, tensioner pulley and CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure
lower idler pulley (if necessary). on timing belt tensioner rod.
Inspection – 1) Measure timing belt tensioner rod protrusion from end
of rod to edge of timing belt tensioner housing. Replace timing belt 2) Place timing belt tensioner in press with flat washer to prevent
tensioner if distance is not .47-.55″ (12.0-14.0 mm). damage to timing belt tensioner plug. See Fig. 3. Apply pressure on rod
2) Inspect timing belt for damaged teeth, cracking or oil contamination. of timing belt tensioner until rod is retracted and holes in rod and housing
Ensure idler pulleys and tensioner pulley rotate freely. Inspect timing belt are aligned. See Fig. 3. Install pin through holes in housing and rod to
tensioner for signs of oil leakage. Replace worn components. hold rod in retracted position. Release press and remove timing belt
tensioner.
NOTE: The following information on tensioner pulley inspection is
from Mazda technical service bulletin 002/00R; March 9, 2000. CAUTION: If reusing timing belt, ensure timing belt is installed in
3) During the 60,000 mile inspection or timing belt replacement on MPV, original direction of rotation.
inspect tensioner pulley pivot bushing for a bronze color (wear) on the 3) Install timing belt tensioner on cylinder block with pin installed.
Teflon coating. If the bushing is worn, the tensioner pulley and spacer Tighten retaining bolts to specification. See TORQUE SPECIFICA-
must be replaced with the timing belt. This is to prevent a torn or jumped
TIONS. Rotate camshafts and crankshaft to ensure all timing marks are
timing belt.
aligned. See Fig. 2. With upper idler pulley removed, install timing belt
Installation – 1) Install tensioner pulley and lower idler pulley (if
on crankshaft sprocket, lower idler pulley, left camshaft sprocket, right
removed). Install retaining bolts, and tighten to specification. See
camshaft sprocket and tensioner pulley in sequence.
TORQUE SPECIFICATIONS. Ensure all pulleys are clean and rotate
smoothly.
524 MAZDA
4) Install upper idler pulley. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clock-
wise from TDC to TDC. Ensure all timing marks are aligned. See Fig. 2. TORQUE SPECIFICATIONS
If timing marks are not aligned, remove timing belt and reinstall. Application Ft. Lbs. (N.m)
5) Remove pin from timing belt tensioner, allowing pressure to be A/C Compressor Bolt .................................................................... ................. 13-20 (18-27)
applied to timing belt. Rotate crankshaft 2 full revolutions clockwise from A/C Compressor Bracket-To-Cylinder Block Bolt ......................... ................. 27-38 (37-52)
TDC to TDC. Ensure all timing marks are aligned. Check timing belt Camshaft Sprocket Bolt ................................................................ ................. 52-59 (71-80)
deflection by applying 22 lbs. (10 kg) of force at midpoint between right Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167)
camshaft sprocket and tensioner pulley. Timing belt deflection should be Lower Idler Pulley Bolt .................................................................. ................. 27-38 (37-52)
.20-.28″ (5.0-7.0 mm). Power Steering Pump Bolt ........................................................... ................. 23-34 (31-46)
6) If timing belt deflection is not within specification, repeat installation
procedure. To install remaining components, reverse removal proce- Timing Belt Cover Bolt
dure. Tighten fasteners to specification. See TORQUE SPECIFICA- 6 mm Bolt .................................................................................... ..................................... 1
TIONS. Fill and bleed cooling system. Adjust drive belts to proper 10 mm Bolt .................................................................................. ................. 27-38 (37-52)
tension. 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

MITSUBISHI 525

1
Kit No. Part No.
1.5L 4-Cyl.
Mirage
1985 ................................. .... 2.4 Hrs. .... .. TCK073 .. ..... T073
1986
Before 5/31/86 ............... .... 2.4 Hrs. .... .. TCK073 .. ..... T073
After 6/1/86 .................... .... 2.4 Hrs. .... ...... ..... ...... ..... T073
1987-90 ............................ .... 2.4 Hrs. .... .. TCK128 .. ..... T128
1991-96 ............................ .... 2.4 Hrs. .... .. TCK191 .. ..... T191
1997-99 ............................ .... 2.4 Hrs. .... .. TCK289 .. ..... T289
2000-02 ............................ .... 2.4 Hrs. .... ...... ..... ...... ..... T289
Precis
1987-89 ............................ .... 2.2 Hrs. .... .. TCK073 .. ..... T073
1990-94 ............................ .... 2.2 Hrs. .... .. TCK128 .. ..... T128
1

Inspection (1985-96) – Inspect belt teeth for cracks, damage, or oil
contamination. Inspect all sprockets for damage. Examine belt tensioner
MANUFACTURER’S SUGGESTED for grease leakage and roughness when pulley is rotated. Replace
SCHEDULED MAINTENANCE components if defective.
For 1985-93 models, the manufacturer recommends the belt be Installation (1985-96) – 1) Ensure crankshaft and camshaft timing
replaced at 60,000 miles. marks are aligned. See Fig. 1. Install timing belt onto crankshaft and
For 1994-96 models, the manufacturer recommends the belt be camshaft sprockets. Ensure tension side is tight and all timing marks are
replaced every 60,000 miles except in California. In California, timing aligned when camshaft sprocket is rotated. Install crankshaft pulley.
belt replacement is recommended, but not required, at 60,000 miles. In Loosen tensioner mounting bolts. See Fig. 2. Ensure timing belt is not
California, replace timing belt at 100,000 miles, unless previously out of position and has not jumped a sprocket tooth. Tighten tensioner
changed. bolts.
CAUTION: If pivot bolt is tightened before side bolt, belt tensioner
may rotate, causing belt to be overtightened.
belt replacement is recommended, but not required, at 60,000 miles. In 2) Rotate crankshaft one full revolution clockwise, until crankshaft
these states, replace timing belt at 100,000 miles, unless previously sprocket timing mark aligns with TDC position. Recheck belt tension. To
changed. check belt tension, hold belt tensioner and timing belt together. Apply
slight thumb pressure at center point of belt tensioner. See Fig. 3. A
REMOVAL & INSTALLATION tension gauge can also be used to check belt tension. See Fig. 4.
CAUTION: This application is an interference engine. Do not rotate belts to proper tension.
damage may occur.
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.

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 Courtesy of Mitsubishi Motor Sales of America.
water pump. Temporarily tighten bolt in slot side of tensioner. Remove
timing belt from camshaft sprocket. Remove crankshaft pulley, and Fig. 2: Installing Timing Belt Tensioner (1985-96)
timing belt.
526 MITSUBISHI

Fig. 4: Checking Timing Belt Tension (1985-96)

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.

reference mark on timing belt to indicate direction of rotation Fig. 6: Aligning Timing Marks (1997-02)
before removing.
2) Install timing belt onto crankshaft sprocket, camshaft sprocket, and
2) Place jack under engine. Support engine so there is no weight on tensioner pulley. Ensure tension side is tight and all timing marks are
engine mount bracket (timing belt end of engine). On vehicles equipped aligned. See Fig. 6.
with A/C, move A/C relay box and drier assembly (hoses attached) out 3) After installing timing belt, ensure timing belt is tensioned between
of way to remove engine mount bracket. On all vehicles, remove engine crankshaft and camshaft sprockets. Check that all timing marks are still
mount bracket-to-engine bolt and nut. Remove engine mount bracket- aligned.
4) Loosen tensioner adjusting bolt. Rotate crankshaft two full revolutions
to-body through-bolt. Remove engine mount bracket.
clockwise, until crankshaft sprocket timing mark aligns with TDC posi-
3) Remove water pump pulley. Remove power steering pump and
tion. Tighten tensioner adjusting bolt.
bracket with hoses attached, and secure out of way. Remove oil dipstick
5) Ensure timing belt teeth are fully seated in camshaft sprocket. Install
tube. Remove timing belt upper and lower covers. See Fig. 5.
timing belt covers. Install crankshaft pulley. Tighten bolt to specification.
4) Rotate crankshaft clockwise to align timing mark on camshaft See TORQUE SPECIFICATIONS.
sprocket with mark on cylinder head. Ensure crankshaft sprocket timing 6) To complete installation, reverse removal procedure. Adjust drive
marks are aligned. See Fig. 6. belts to proper tension.
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.
MITSUBISHI 527

TORQUE SPECIFICATIONS (1985-96 MIRAGE)
1985-91 ........................................................................................ ................. 47-54 (65-75)
1992-96 ........................................................................................ ............... 52-74 (70-100)
1991-96 .......................................................................................................... 10-11 (14-15)
1985 ............................................................................................. ................. 37-43 (50-58)
1986-96 ........................................................................................ ............... 52-74 (70-100)
Front Cover Bolt
1985-88 ........................................................................................ ................... 9-10 (12-14)
Rocker Arm Adjuster Lock Nut
1989-96 ........................................................................................ ................. 10-13 (14-18)
1985-96 ........................................................................................ ................. 14-20 (19-27)
INCH Lbs. (N.m)
Front Cover Bolt ............................................................................ ................. 84-132 (9-15)
Fuel Rail Bolt
1992-96 ........................................................................................ ................. 84-108 (9-12)
Rocker Cover Bolt ......................................................................... ............... 13-17 (1.5-1.9)
Water Pump Pulley Bolt
1985-88 ........................................................................................ ............. 108-120 (12-14)
1989-96 ........................................................................................ ..................... 72-84 (8-9)
TORQUE SPECIFICATIONS (1991-94 PRECIS)
Fig. 7: Installing Timing Belt Tensioner (1997-02)
Camshaft Thrust Case Bolt .......................................................... ................. 14-20 (19-27)
Crankshaft Sprocket Bolt .............................................................. ............... 52-74 (70-100)
Front Cover Bolt .............................................................................................. 10-11 (14-15)
INCH Lbs. (N.m)
Camshaft Rear Cover Bolts .......................................................... ................... 70-86 (7-10)
Rocker Cover Bolt ......................................................................... ............... 13-18 (1.5-2.0)
TORQUE SPECIFICATIONS (1997-02)

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)
1
– Apply engine oil to bolt thread before installation.
2
– Final tighten with full weight of engine on bolt.
528 MITSUBISHI
Part No.
Mirage
1
1985-88 .................................................... 2.8 Hours .. ..... T093
1


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.
from timing belt end of engine). If reusing timing belt, place Fig. 2: Aligning Camshaft Timing Marks
reference mark on timing belt to indicate direction of rotation Installation – 1) If crankshaft sprocket was removed, ensure flange and
before removing. spacer are correctly installed. See Fig. 3. If timing belt tensioner was
4) Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of removed, ensure end of tensioner spring is seated under water pump
compression stroke. Ensure camshaft sprocket timing mark aligns with housing. See Fig. 4. Move tensioner towards water pump, and tempo-
mark on under upper cover. See Fig. 2. Holding crankshaft stationary, rarily tighten mounting bolt and nut.
remove crankshaft pulley. Remove lower timing belt cover. 2) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 2.
5) Loosen timing belt tensioner adjusting bolt and nut. Move tensioner Install timing belt onto crankshaft sprocket, and keeping tension tight,
inward toward water pump. Temporarily tighten tensioner adjusting bolt. install timing belt on camshaft sprocket.
Remove timing belt. 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 revolu-
tion.
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

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.
MITSUBISHI 529
Fig. 3: Installing Crankshaft Sprocket, Flange & Spacer
Fig. 6: Checking Timing Belt Tension Adjustment
Fig. 4: Installing Tensioner Spring
Fig. 7: Identifying Timing Belt Cover Bolt Length
Crankshaft Pulley Center Bolt ...................................................... ........... 1 80-96 (110-130)
Engine Mount
Courtesy of Mitsubishi Motor Sales of America. To-Engine Bracket Bolt/Nut ......................................................... ................. 37-50 (50-65)
Bracket-To-Body Through-Bolt .................................................................... 66-81 (90-110)
Fig. 5: Camshaft Sprocket Position For Tension Adjustment 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)
1
– Apply engine oil to bolt thread before installation.
530 MITSUBISHI
TIMING BELT APPLICATION 3) Remove plug on left side of cylinder block. Insert a screwdriver to
Application Labor Time Component Belt keep left silent shaft in position. See Fig. 1. Remove oil pump sprocket.
Kit No. Part No. Loosen right silent shaft sprocket mounting bolt until it can be turned by
1.8L 4-Cyl. hand. Remove belt tensioner “B” and timing belt “B”.
Cordia & Tredia
1983-84
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T090
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... T089
1985-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... T089
1987-88
2.0L 4-Cyl.
Cordia & Tredia
1984
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T090
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... T089
1985-86
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... T089
1987-88
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T159
Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... T158
Galant
1989-92
Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK155 .. ..... T155 Fig. 1: Aligning Camshaft Timing Marks (16-Valve Engine)
1993
Balance Shaft ............... .......... 1 .......... .. TCK232 .. ..... T168 Inspection (1983-88) – Inspect back of belt for hardness, non-elasticity
Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK232 .. ..... T232 and glossy surface. If no mark is produced when fingernail is forced into
Pickup it, replace belt. Check for rounded sides on belt, flaking, peeling,
1983-86 cracking and separating rubber. Cracks are most evident at base of
Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T090 tooth.
Camshaft ....................... ... 2 2.3 Hrs. ... ...... ..... ...... ..... T089 Installation (1983-88) – 1) Install timing belt “B” ensuring tension side
1987-89 has no slack. Install tensioner “B” so only light pressure is on belt.
Balance Shaft ............... .......... 1 ........... TCK158A . ..... T159 Ensure flange on tensioner is mounted away from engine and finger-
Camshaft ....................... ... 2 2.3 Hrs. .... TCK158A . ..... T158
tighten bolt. Lift tensioner with finger tip until slack is removed from
1
– Balance Shaft Belt labor time included in tension side of belt. Tighten tensioner bolt, being careful to prevent
Camshaft Belt labor time. turning shaft. Ensure timing marks are in alignment. Tighten right silent
2
– With Air Conditioning, add .4 hours. shaft bolt.
With Power Steering, add .3 hours. 2) Check belt tension by pressing center of tension side inward, using
3
index finger and measuring belt deflection. Deflection should be .20-.30″
NOTE: A timing belt component kit is available for this application. (5.0-7.0 mm). Readjust if not within specification. Align camshaft timing
See page A1 for information on component kits. 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
MANUFACTURER’S SUGGESTED tensioner secured fully toward water pump, install timing belt in order of
crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure
SCHEDULED MAINTENANCE tension side of belt has no slack. Loosen tensioner mounting bolt and
The manufacturer recommends the belt be replaced every 60,000 miles. nut to allow only tensioner spring pressure to tighten belt.
4) Check belt to ensure each tooth is in proper mesh with camshaft
REMOVAL & INSTALLATION 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
TIMING BELT correct alignment. Remove screwdriver and install plug in block. Turn
Removal (1983-88) – 1) Disconnect negative battery cable. On models crankshaft, clockwise only, one revolution. Loosen mounting nut and
equipped with A/C, remove upper radiator shroud and cooling fan/clutch bolt to allow tensioner to readjust and tighten slot-side bolt, then tighten
assembly. On models equipped with power steering, remove power nut.
steering pump and pulley. On all models, position No. 1 cylinder at TDC 5) Hold belt and seal line of undercover, between thumb and forefinger,
of compression stroke. Loosen pulley bolts. Remove drive belts. at center of tension side. Measure clearance between belt and seal line.
2) Remove crankshaft, water pump and power steering pulleys. Remove Clearance should be .55″ (14.0 mm). Reverse removal procedure to
upper and lower front timing belt covers. Relieve camshaft timing belt complete reassembly. Adjust drive belts to proper tension.
tensioner pressure and secure tensioner toward water pump. If cam- Removal (1989-93) – 1) Disconnect negative battery cable. Remove
shaft timing belt is to be reused, mark belt with an arrow indicating A/C and power steering hose mounting bracket or oxygen sensor
direction of rotation and remove belt. Remove camshaft and crankshaft connector bracket from upper engine mount at timing belt cover. Support
sprocket bolts. Remove camshaft sprocket, crankshaft sprocket and engine, and remove upper engine mount. Remove all drive belts and
crankshaft flange. drive pulleys from crankshaft and water pump.
MITSUBISHI 531

3) DO NOT remove screwdriver until timing belt is installed. Install
camshaft sprocket. Tighten bolts to specification. See TORQUE SPECI-
FICATIONS. 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

(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 TORQUE SPECIFICATIONS
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 Application Ft. Lbs. (N.m)
cover for clearance. A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27)
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
from timing belt end of engine). If timing belt is to be reused, mark Crankshaft Pulley Bolt
direction of rotation before removing. 1983-85 .......................................................................................................... 11-15 (15-20)
1986-93 ........................................................................................ ................. 15-21 (20-29)
3) Rotate crankshaft clockwise (as viewed from timing belt end of Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127)
engine) until cylinder No. 1 is at TDC of compression stroke. Align timing Damper Pulley Bolt ......................................................................................... 11-13 (15-18)
mark on camshaft sprocket with timing mark on cylinder head. See Front Cover Bolts
M8 X 30 Bolt ............................................................................... ................. 20-26 (27-35)
Fig. 2 or 3. Loosen timing belt tensioner adjustment bolt, and move
Except M8 X 30 Bolt .................................................................. ................. 14-20 (19-27)
tensioner toward water pump. Tighten bolt to secure tensioner. Remove
front timing belt and camshaft sprocket. Rear Timing Belt Tensioner ............................................................................ 11-16 (15-22)
4) If oil pump sprocket removal is necessary, remove left silent shaft Silent Shaft Sprocket Bolt
access plug from cylinder block. Insert .31″ (8.0 mm) diameter Phillips .08″ (2.0 mm) Washer ................................................................ ................. 25-29 (34-39)
screwdriver to block left silent shaft. Remove oil pump sprocket nut and .10″ (2.5 mm) Washer ................................................................ ................. 31-35 (42-47)
sprocket. Remove front crankshaft sprocket and flange. Note direction Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27)
and order of installation. Remove rear timing belt tensioner assembly. Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54)
Remove rear timing belt. Timing Belt Cover Bolt
Inspection (1989-93) – Check belt teeth for cracks, damage and Left Lower Rear Cover ............................................................... ................. 22-30 (30-41)
contamination. Inspect sprockets for damage. Check belt tensioner for All Others ..................................................................................... ..................................... 1
leakage or roughness in rotation. Replace components as necessary. Timing Belt Tensioner Nut
Installation (1989-93) – 1) If reusing rear timing belt, install in original 1983-85 ........................................................................................ ................. 16-21 (22-28)
1986-93 ........................................................................................ ................. 32-39 (42-53)
direction of rotation. Ensure timing marks are aligned. See Fig. 4. Install
Water Pump Bolt
rear timing belt tensioner. Hold tensioner tightly against belt while Except 8 X 65 mm .......................................................................................... 9-11 (12-15)
tightening bolts. Depress belt between sprockets to ensure deflection is 8 X 65 mm .................................................................................. ................. 15-19 (20-26)
.20-28″ (5-7 mm). Adjust as necessary.
2) Install crankshaft front sprocket. Install oil pump sprocket. Hold left INCH Lbs. (N.m)
silent shaft using a .31″ (8.0 mm) diameter Phillips screwdriver through
All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12)
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
1
mm), and rotate oil pump sprocket one revolution. Align timing mark. – All except Left Lower Rear Cover Bolt tighten to 84-108 INCH lbs. (9-12 N.m).
Insert screwdriver, and ensure it can be inserted at least 2.36″ (59.9
mm).
532 MITSUBISHI
Application Labor Time Belt Inspection – 1) Inspect timing belt for wear on edges of drive teeth.
Part No. Inspect belt for signs of oil contamination, cracks, separation, worn or
2.0L 4-Cyl. – DOHC missing teeth, or hardened black surface. Replace belt if worn, damaged
Lancer Evolution Turbo or contaminated. Inspect belt tensioner pulleys for smooth rotation.
2003-04 Replace if defective.
Balance Shaft ...................................... .......... 1 .......... ..... T168 2) Remove timing belt tensioner adjuster. Check timing belt tensioner
Camshaft ............................................. ... 2 3.1 Hrs. ... ..... T167 adjuster for leaks. Hold timing belt tensioner adjuster upright. Measure
1
– With Air Conditioning, add .2 hour. rod extension length above edge of housing. See Fig. 9. Length should
With Power Steering, add .2 hour. 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.
SCHEDULED MAINTENANCE CAUTION: When tightening balancer belt tensioner bolt, ensure
tensioner does not rotate with the bolt. Allowing it to rotate can
Manufacturer recommends the belt be replaced every 60,000 miles cause excessive belt tension.
except in California, Massachusetts and Vermont. In California, Massa-
chusetts and Vermont, timing belt replacement is recommended, but not 3) Apply 22-30 INCH lbs. (2.6-4.4 N.m) to balancer belt, then tighten
required, at 60,000 miles. In these states, replace timing belt at 100,000 balancer belt tensioner bolt to specification. See TORQUE SPECIFICA-
miles, unless previously changed. TIONS.
4) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing
marks are aligned. See Fig. 8.
REMOVAL & INSTALLATION 5) Apply about 22 lbs. (10 kg.) of pressure at center (arrow area)
between sprockets as shown. See Fig. 12. Ensure belt deflection is
TIMING BELT .20-.27″ (5.0-7.0 mm).
Removal – 1) Remove undercover and side cover. Remove accessory 6) Clean front of crankshaft. Clean and install crankshaft angle sensing
drive belt. Remove crankshaft pulley bolts. Remove crankshaft pulley. blade and crankshaft timing belt sprocket. Apply engine oil to crankshaft
Remove crossmember bar for access to front exhaust pipe. center bolt threads and both sides of washer. Install crankshaft center
2) Remove front exhaust pipe. Remove timing belt upper cover. See bolt.
Figs. 1 and 2. Remove water pump pulley. Remove idler pulley. 7) Using Special Spanner (MB991367) and Pins (MB991385) to hold
crankshaft timing belt sprocket, tighten crankshaft center bolt to speci-
3) Remove auto-tensioner. Remove timing belt lower cover. Raise
fication. See TORQUE SPECIFICATIONS.
engine and transaxle assembly until its weight is not supported by front
8) If timing belt tensioner adjuster was removed and rod is fully
engine mount. Remove front engine mount.
extended, slowly compress timing belt tensioner adjuster rod with a vise
4) Rotate crankshaft clockwise to align each timing mark and to set
or press to align timing belt tensioner adjuster rod set hole “A” with
cylinder No. 1 at TDC of compression stroke. See Fig. 3. timing belt tensioner adjuster cylinder set hole “B”.
5) Remove timing belt under cover rubber plug. See Fig. 4. Screw in 9) Insert a suitable pin or wire into set hole. Install timing belt tensioner
Adjusting Bolt (MD998738) until it comes in contact with timing belt adjuster, and tighten bolts to specification. Install idler pulley, and tighten
tensioner arm. See Fig. 5. bolt to specification. See TORQUE SPECIFICATIONS.
10) Ensure timing marks are aligned. See Fig. 3. To ensure oil
CAUTION: Adjusting Bolt will bend if it is screwed in too fast. pump/balancer shaft is properly aligned, remove cylinder block plug,
6) Gradually screw in adjusting bolt at a rate of 30 degrees per second and insert a phillips screwdriver as shown. See Fig. 13.
to align timing belt tensioner adjuster rod set hole “A” with timing belt 11) If screwdriver cannot be inserted 2.36″ (60.0 mm) or more, remove
tensioner adjuster cylinder set hole “B”. See Fig. 6. screwdriver and rotate oil pump/balancer shaft one revolution. Ensure
7) Insert a suitable pin or wire into set hole, and remove adjusting bolt. screwdriver can be inserted 2.36″ (60.0 mm) or more. Do not remove
screwdriver until timing belt is installed.
If timing belt is to be reused, mark rotation direction on belt. Loosen
12) Install timing belt on crankshaft timing belt sprocket, oil pump/
timing belt tensioner pulley mounting bolt, and remove timing belt. See
balancer shaft sprocket, and idler pulley in that order. Install timing belt
Fig. 7.
on exhaust camshaft sprocket. Secure timing belt to exhaust camshaft
8) Disconnect power steering pressure switch connector. Remove
sprocket with paper clamp.
power steering pump heat shield. Remove power steering pump with 13) Use 2 wrenches on camshaft sprocket bolts to align timing marks on
hoses attached, and secure aside. Remove power steering pump camshaft sprockets with timing marks on valve cover. Install timing belt
bracket. Remove timing belt idler pulley. on intake camshaft sprocket. Secure timing belt to intake camshaft
9) Remove crankshaft position sensor. Using Special Spanner sprocket with paper clamp.
(MB991367) and Pins (MB991385) to hold crankshaft timing belt 14) Pass timing belt around timing belt tensioner pulley. Apply counter-
sprocket, remove crankshaft center bolt. clockwise pressure to intake camshaft. Ensure timing marks are aligned
10) Using Crankshaft Sprocket Puller (MD998778), remove crankshaft while tension side of belt is tight. Remove paper clamps.
timing belt sprocket. Remove crankshaft angle sensing blade. If bal- 15) Using Tensioner Wrench (MD998767), turn timing belt tensioner in
ancer belt is to be reused, mark rotation direction on belt. direction shown to apply tension to timing belt. See Fig. 14. Pre-tighten
11) Ensure balancer timing marks are aligned. See Fig. 8. Loosen timing belt tensioner pulley bolt.
balancer belt tensioner bolt. Remove balancer belt tensioner. Remove 16) Ensure timing marks are still aligned. Remove Phillips screwdriver
balancer belt. installed in step 10). Install cylinder block plug, and tighten to specifica-
MITSUBISHI 533
Fig. 1: Exploded View Of Timing Belt Components (1 Of 2)
Fig. 2: Exploded View Of Timing Belt Components (2 Of 2)

534 MITSUBISHI
Fig. 6: Retracting Timing Belt Tensioner Adjuster
Fig. 7: Identifying Timing Belt Tensioner Pulley Mounting Bolt
Fig. 4: Locating Timing Belt Under Cover Hole

Fig. 8: Aligning Balancer Timing Marks
Fig. 9: Measuring Tensioner Adjuster Rod Extension Length

Fig. 5: Inserting Adjusting Bolt

MITSUBISHI 535

Fig. 12: Checking Balancer Belt Deflection
Fig. 10: Measuring Timing Belt Tensioner Adjuster Retraction
CAUTION: When crankshaft is rotated counterclockwise, crank-

shaft 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 tim-

ing 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
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. Courtesy of Mitsubishi Motor Sales of America.
When tightening engine mount bolts, ensure weight of engine is on
Fig. 13: Aligning Oil Pump/Balancer Shaft
vehicle body. See TORQUE SPECIFICATIONS.
Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.
Fig. 11: Installing Balancer Belt Tensioner Fig. 14: Tightening Timing Belt
536 MITSUBISHI
Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84)
Balancer Belt Tensioner Bolt ........................................................ ................. 12-16 (16-22)
Crankshaft Center Bolt 1 ....................................................................................... 123 (167)
Crossmember Bar Bolt .................................................................. ................. 30-47 (39-59)
Cylinder Block Plug ....................................................................... ................. 21-25 (28-33)
Drive Belt Auto-Tensioner
Center Bolt .................................................................................. ................. 26-40 (34-54)
Fig. 15: Checking Timing Belt Tension 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)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ................................................... ............... 69-87 (7.8-9.8)
Exhaust Pipe Hanger Bolt ............................................................................ 89-133 (11-15)
Water Pump Pulley Bolt ................................................................ ............... 69-87 (7.8-9.8)
1
– Before installing, apply engine oil to threads and bolt flange.
2
– Tighten with full weight of engine on vehicle body.
MITSUBISHI 537
2.0L 4-Cylinder – DOHC – Eclipse & Galant

TIMING BELT APPLICATION For 1995-97 vehicles, the manufacturer recommends the belt be
Application Labor Time Component Belt replaced every 60,000 miles, except in California. In California, timing
Kit No. Part No. belt replacement is recommended but not required at 60,000 miles. In
2.0L 4-Cyl. – DOHC (4G6) California, replace belt at 100,000 miles, unless previously changed.
Eclipse Turbo & Non-Turbo For 1998-99 vehicles, the manufacturer recommends the belt be
1990-94 replaced every 60,000 miles, except in California, Connecticut and
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... T168 Massachusetts. In California, Connecticut and Massachusetts, timing
Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK167 .. ..... T167 belt replacement is recommended but not required at 60,000 miles. In
Eclipse Turbo California, replace belt at 100,000 miles, unless previously changed.
1995-99
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... T168
Camshaft Belt ............... ... 2 3.0 Hrs. .......... .... ....... ..... T167 REMOVAL & INSTALLATION
Galant
1989-92 CAUTION: This application is an interference engine. Do not rotate
Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... T168 camshaft or crankshaft when timing belt is removed, or engine
Camshaft Belt ............... ... 3 3.6 Hrs. ... .. TCK167 .. ..... T167 damage may occur.
1993
Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK232 .. ..... T232 TIMING BELT & BALANCE SHAFT BELT
1
– Balance Shaft labor time included in Camshaft labor time. Removal – 1) Disconnect negative battery cable. Remove engine
2
– With Air Conditioning, add .7 hours. undercover. Place wooden block between jack and oil pan, and raise
With Power Steering, add .2 hours. engine slightly. Remove engine mount assembly near timing belt cover.
3 2) Remove clamp for power steering return hose near timing belt cover.
Remove all drive belts and tensioner pulley bracket. See Fig. 1. Remove
NOTE: A timing belt component kit is available for this application. power steering and water pump pulleys. Rotate crankshaft clockwise so
See page A1 for information on component kits. that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft
pulley.
available), see ALPHABETICAL MODEL LISTING. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
timing marks are aligned. If reusing timing belts, mark timing belts
for direction of rotation.
MANUFACTURER’S SUGGESTED 3) Remove upper timing belt cover and gasket. Remove stub bolt of
SCHEDULED MAINTENANCE engine support bracket, and remove center timing belt cover. Remove
For 1989-94 vehicles, the manufacturer recommends the belt be lower timing belt cover.

538 MITSUBISHI
2.0L 4-Cylinder – DOHC – Eclipse & Galant (Cont.)
Fig. 2: Aligning Timing Belt “A” Marks (1990-93 Models)
NOTE: Camshaft sprocket dowel pins will be in 12 o’clock 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. Courtesy of Mitsubishi Motor Sales of America.
Ensure belts are not contaminated with oil. Check tensioners for free
rotation and grease leakage. Replace components if damaged or if Fig. 3: Aligning Timing Belt “A” Timing Marks (1994-99 Models)
grease leakage exists. Installation – 1) Retract rod into auto tensioner housing by placing auto
tensioner assembly in a soft-jawed vise. Close vise SLOWLY to push
NOTE: The following revised information for timing belt tensioner
rod back into auto tensioner housing. When pin hole in cylinder aligns
inspection is from Mitsubishi technical service bulletin 96-11-006;
with pin hole in rod, insert set pin. Replace tensioner assembly if rod can
June, 1996.
be retracted easily into housing. Install auto tensioner on engine with set
2) Check timing belt auto tensioner for leaks. Hold timing belt auto pin in place.
tensioner upright. Measure rod protrusion above edge of housing. See 2) Align balance shaft and crankshaft timing marks with rear cover. See
Fig. 6. Length should be .47″ (12 mm). Apply 22-44 lbs. (10-20 kg) of Fig. 7 or 8. Install timing belt “B” on sprockets. If using old belt, install belt
force to end of rod. If auto tensioner rod moves more than 0.39″ (1 mm), in original direction of rotation. Ensure there is no slack in tension side
replace the auto tensioner. of belt.
MITSUBISHI 539
CAUTION: Install crankshaft sensing blade and crankshaft sprock-

ets 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 crank-
shaft sprocket “A”. Apply light coat of engine oil to crankshaft sprocket
bolt threads, and tighten bolt to specification. See TORQUE SPECIFI-
CATIONS. 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
Courtesy of Mitsubishi Motor Sales of America. up. On intake camshaft sprocket, use timing mark on the left, with
Fig. 4: Holding Balance Shaft Stationary 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).
Fig. 5: Timing Belt “B” (Balance Shaft Belt) Components
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.
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.
540 MITSUBISHI


Fig. 10: Installing Crankshaft Sprocket &
Crankshaft Sensing Blade Fig. 13: Installing Set Screw On Tensioner Pulley
Fig. 11: Installing Timing Belt On Intake Sprockets

2) Remove screwdriver from balance shaft hole in side of engine block.
Install plug. Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion
3) Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft 3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or
1/4 clockwise until timing marks are aligned again. No. 1 cylinder should equivalent to tensioner eccentric. Install torque wrench on adapter. See
be at TDC of compression stroke. Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH
4) Attach Adapter (MD998767) to tensioner pulley eccentric. Attach lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley.
torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in 4) Hold tensioner pulley at specified torque, and tighten tensioner center
a clockwise direction. See Fig. 12. With torque applied to eccentric, bolt to specification. DO NOT let tensioner pulley turn with bolt. See
tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). TORQUE SPECIFICATIONS.
5) Insert Set Screw (MD998738) through inner timing belt cover until it 5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are
contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin aligned. Allow engine to stand for 15 minutes without turning crankshaft.
can be removed. Remove set screw from engine. Distance between top of auto tensioner housing and tensioner arm
6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes should be .15-.18″ (3.8-4.5 mm). If distance is incorrect, repeat tension-
without turning crankshaft. Measure distance between top of auto ing procedure until distance is correct. Go to FINAL ASSEMBLY.
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 Courtesy of Mitsubishi Motor Sales of America.
tension timing belt, rotate crankshaft about 1/4 turn counterclockwise,
then 1/4 turn clockwise until all timing marks align. Fig. 15: Adjusting Timing Belt Tension (1993-99)
MITSUBISHI 541

Final Assembly – To install remaining components, reverse removal TORQUE SPECIFICATIONS
procedure. Ensure proper length bolts are installed in timing belt covers.
See TIMING COVER BOLT LENGTH & TORQUE table. See Fig. 16. TORQUE SPECIFICATIONS
Adjust the drive belts to proper tension. Application Ft. Lbs. (N.m)
TIMING COVER BOLT LENGTH & TORQUE Auto Tensioner Bolt ................................................................................................... 17 (24)
Balance Shaft Sprocket Bolt ..................................................................................... 33 (46)
Bolt Length INCH Lbs. (N.m)
“A”: 6 x 16 Flange Bolt ................................................................................ 89-106 (10-12) Crankshaft Pulley Bolt ............................................................................................... 18 (25)
“B”: 6 x 18 Flange Bolt ................................................................................ 89-106 (10-12) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (108-127)
“C”: 6 x 25 Loose Washer Bolt .................... .......................................................... 58 (6.5) Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26)
“D”: 6 x 25 Flange Bolt ................................................................................ 89-106 (10-12) Engine Mount-To-Engine Bolt/Nut (1990-92) ................................ ................. 36-47 (50-65)
“E”: 6 x 45 Flange Bolt ................................................................................ 89-106 (10-12) 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)
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)

542 MITSUBISHI
2.0L 4-Cyl. – SOHC camshaft or crankshaft when timing belt is removed, or engine
Lancer damage may occur.
2002-04 ..................................................... 3.1 Hours ... ..... T201
1
TIMING BELT
Removal – 1) Remove left undercover. Raise engine and transaxle
NOTE: For information about tensioners and/or pulleys (when assembly until its weight is off front engine mount, and support securely.
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED crankshaft pulley.
SCHEDULED MAINTENANCE 3) Remove generator belt tension adjustment bracket, power steering
pump bracket support and engine support bracket. See Fig. 1.
Manufacturer recommends the belt be replaced every 60,000 miles
4) Disconnect crankshaft position sensor electrical connector. Remove
except in California, Massachusetts and Vermont. In California, Massa-
upper and lower timing belt covers.
chusetts 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.

MITSUBISHI 543

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. Application Ft. Lbs. (N.m)
6) If timing belt is to be reused, mark rotation direction on belt. Loosen Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98)
Crankshaft Pulley Bolt 1 ................................................................ ......... 131-137 (178-186)
tensioner bolt. Insert a Phillips screwdriver into tensioner arm hole, and
Engine Mount Bracket-To-Engine Mount Bolt .............................. ............... 49-75 (67-101)
pry tensioner away from timing belt. Temporarily tighten tensioner bolt. Engine Mount Bracket-To-Engine Support Bracket Nut 2 ............ ................. 45-55 (60-74)
Remove flange and timing belt. Engine Mount-To-Body Bolt 2 ........................................................ ................. 26-40 (34-54)
Inspection – Inspect timing belt rubber backing for hardening or surface Engine Support Bracket Bolt ........................................................ ................. 32-40 (44-54)
cracks. Check for cracks or peeling of canvas, cracks on belt sides or Generator Belt Tension Adjustment Bracket Bolt ......................... ................. 16-18 (21-25)
bottom of teeth. Check for abnormal wear on belt sides and teeth. Check Power Steering Pump Bracket Support Bolt ................................ ................. 32-40 (44-54)
for missing teeth. Check tensioner pulley for smooth rotation without Timing Belt Tensioner Bolt ............................................................ ................. 15-19 (21-25)
noise or play. INCH Lbs. (N.m)
Installation – 1) Ensure timing marks are aligned. See Fig. 2. Install Timing Belt Cover Bolt .................................................................. ................. 72-106 (8-12)
timing belt on crankshaft sprocket, water pump sprocket, camshaft 1
sprocket, then tensioner. 2
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
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.

544 MITSUBISHI
Kit No. Part No.
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.
2
– With Air Conditioning, add .4 hour.
With Power Steering, add .3 hour.


except in California. In California, timing belt replacement is recom-
mended, but not required, at 60,000 miles. In California, replace timing Fig. 1: Aligning Timing Marks
belt at 100,000 miles, unless previously changed.

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 Courtesy of Mitsubishi Motor Sales of America.
bracket. Remove pulleys from crankshaft, water pump and power Fig. 2: Exploded View Of Timing Belt & Components
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 neces-
sary). 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 Courtesy of Mitsubishi Motor Sales of America.
block left silent shaft. See Fig. 3. Remove oil pump sprocket nut and
sprocket. Fig. 3: Holding Silent Shaft In Stationary Position
6) Remove bolt, washer, crankshaft sprocket and flange. Note direction
of flange installation. Remove rear timing belt tensioner assembly.
Remove rear timing belt.
MITSUBISHI 545

Inspection – 1) Check belt teeth for damage and oil contamination. position for about 15 minutes. Measure distance between tensioner arm
Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is and automatic tensioner body. Distance should be .15-.18″ (3.8-4.5
not cracked, separated or showing canvas fiber. Inspect all sprockets for mm). See Fig. 8, Dimension “A”.
damage. Check tensioner pulley and idler pulley for grease leakage and 12) If distance cannot be measured due to lack of clearance, use
roughness in rotation. Replace components if damaged. alternate method. Install set screw until it contacts tensioner arm. Rotate
2) Inspect automatic tensioner for leaks. Check rod end of automatic set screw inward while counting number of turns until tensioner arm
tensioner for wear. Measure distance from tensioner rod end to ten- contacts automatic tensioner housing. Number of turns should be 2
sioner housing. Distance should be .47″ (11.9 mm). 1/2-3 if belt tension is correct. Remove set screw. Install rubber plug in
3) Retract rod into tensioner housing by placing automatic tensioner rear timing belt cover.
assembly in a soft-jawed vise. Close vise to push rod back into 13) To complete installation, reverse removal procedure. Apply sealant
tensioner. Replace automatic tensioner assembly if rod can be easily to contact areas on semi-circular packing and rocker cover before
pushed into automatic tensioner. 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. Fig. 4: Retracting Automatic Tensioner Rod
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 compen-
sated 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 screw- Courtesy of Mitsubishi Motor Sales of America.
driver. Leave screwdriver in place until timing belt is installed. Install
Fig. 5: Installing Timing Belt On Camshaft Sprockets
timing belt on intake camshaft sprocket. Use spring clip to hold belt on
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 Fig. 6: Adjusting Timing Belt Tensioner Pulley
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 crank-
shaft clockwise 2 complete revolutions, and allow to remain in this
546 MITSUBISHI
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)
Fig. 7: Measuring Timing Belt Adjustment Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41)
Rear Tensioner Retaining Bolt ........................................................................ 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................................................................. 10 (14)
8 X 65 mm .................................................................................. ................. 15-19 (20-26)
INCH Lbs. (N.m)
Crankshaft Position Sensor Nut ................................................... ................. 84-108 (9-12)
Valve Cover Bolt ........................................................................... ..................... 24-36 (3-4)
Fig. 8: Measuring Automatic Tensioner Protrusion
Fig. 9: Installing Crankshaft Sprockets

MITSUBISHI 547
2.4L 4-Cylinder – Lancer & Outlander

TIMING BELT APPLICATION 2) Remove power steering oil pressure hose clamps. See Fig. 6.
Application Labor Time Belt Disconnect Crankshaft Position (CKP) sensor connector. Remove upper
Part No. timing belt cover and water pump pulley. Remove drive belt idler pulley.
2.4L 4-Cyl. – SOHC, VIN G Remove end cap and drive belt auto-tensioner. Remove lower timing
Lancer belt cover. Raise engine and transaxle assembly until its weight is off
2004 ........................................................... 3.1 Hours ... ..... T332 front engine mount, and support securely. Remove engine front mount-
Outlander ing bracket. See Fig. 7. Turn crankshaft clockwise, and align each timing
2003-04 mark to set No. 1 cylinder to TDC of its compression stroke. See Fig. 8.
Balance Shaft Belt .............................. .......... 1 .......... ..... T168
Camshaft Belt (2003) ............................. 2.7 Hours ... ..... T232 CAUTION: Adjusting Bolt (MD998738) can be gradually installed at
Camshaft Belt (2004) ............................. 2.7 Hours ... ..... T332 a rate of a 30-degree turn per second. If Adjusting Bolt (MD998738)
1
– Balance shaft belt labor time included in is screwed in all at once, timing belt tensioner adjuster rod will not
camshaft belt labor time. easily retract and adjusting bolt may bend.
1
– Balance shaft belt labor time included in 3) Remove timing belt under cover rubber plug and install Adjusting Bolt
(MD998738). See Fig. 9. Screw in Adjusting Bolt (MD998738) until it
NOTE: For information about tensioners and/or pulleys (when comes in contact with timing belt tensioner arm. See Fig. 10.
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED holes. See Fig. 12. Remove Adjusting Bolt (MD998738). Loosen timing
SCHEDULED MAINTENANCE belt tensioner pulley mounting bolt, and remove timing belt.
Manufacturer recommends replacing timing belt at 60,000 miles except Inspection (Timing Belt) – Inspect timing belt for the following condi-
in California, Vermont and Maine. In these states, manufacturer recom- tions:
mends replacing timing belt at 100,000 miles. If timing belt was already • Hardening of rubber backing (rubber backing will be glossy without
replaced at 60,000 miles, it is not required to be replaced at 100,000 resilience and leave no indentation when pressing with fingernail).
miles. • Cracks on rubber back.
• Cracks or peeling of canvas.
REMOVAL & INSTALLATION • Cracks on bottom of ribs.
• Cracks on belt sides.
CAUTION: This application is an interference engine. Do not rotate If any of these conditions are present, replace timing belt.
camshaft or crankshaft when timing belt is removed, or engine Inspection (Timing Belt Tensioner Adjuster) – 1) Check for oil leak
damage may occur. 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.
TIMING BELT Replace as necessary.
3) Hold timing belt tensioner adjuster by hand, and press top end of rod
CAUTION: Do not remove tape securing Crankshaft Position (CKP) onto metal (e.g., cylinder block) under a pressure of 22-44 lbs. (10-20
sensor harness connector and control wiring harness, since con- kg) to measure movement of rod. Movement should be within 0.039″
trol wiring harness may contact power steering pump pulley. See (1.00 mm) of length when it is free (not pressed) and length when it is
Fig. 1. 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 (counter-

clockwise rotation) pressure to camshaft sprocket. Recheck to see
that each timing mark is in proper location while belt is tight.
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
Courtesy of Mitsubishi Motor Sales of America. pump balancer shaft. DO NOT remove bolt until timing belt is
assembled.
Fig. 1: Identifying Crankshaft Position Sensor Connector 3) Place timing belt on timing belt tensioner pulley and crankshaft drive
Securing Tape 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
NOTE: If reusing timing belt, draw an arrow indicating rotating your other hand. Place timing belt on timing belt idler pulley. Place timing
direction (clockwise) on back of belt using chalk. belt on camshaft sprocket.
4) Turn timing belt tensioner in direction shown using Tensioner Wrench
NOTE: Crankshaft drive sprocket may also be referred to as crank- (MD998767) to apply tension to timing belt. See Fig. 16. Pre-tighten
shaft camshaft sprocket. timing belt tensioner pulley. Ensure timing marks are aligned. Remove
bolt installed in step 2). Reinstall cylinder block plug and tighten to
Removal – 1) Remove right side under cover (Outlander shown, Lancer specification. See TORQUE SPECIFICATIONS. Adjust timing belt ten-
is similar). See Fig. 2. Using 1/2″ drive ratchet, turn drive belt auto- sion.
tensioner counterclockwise until it hits stopper. Align hole “A” and hole 5) Install Adjusting Bolt (MD998738) used when removing timing belt.
“B” of drive belt auto-tensioner. See Fig. 3. Insert an L-shaped hexago- See Fig. 9. Gradually screw in Adjusting Bolt (MD998738) until wire or
nal wrench through holes. See Fig. 4. This will fix drive belt auto- pin inserted in timing belt tensioner adjuster slightly moves.
tensioner in place to allow drive belt removal. Remove crankshaft pulley.
See Fig. 5.
548 MITSUBISHI
2.4L 4-Cylinder – Lancer & Outlander (Cont.)
Fig. 2: Removing Under Covers (Outlander)
Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Aligning Drive Belt Auto-Tensioner Holes Fig. 4: Locking Drive Belt Auto-Tensioner Into Place
MITSUBISHI 549

6) Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft in clock-
wise 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. Allow-
ing it to rotate with bolts can cause deficient tension of belt.
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 ten-
sioner. 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
Courtesy of Mitsubishi Motor Sales of America. tension.

550 MITSUBISHI
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 instal-
lation, reverse removal procedures. Tighten nuts and bolts to specifica-
Fig. 9: Installing Adjusting Bolt
Fig. 10: Applying Pressure With Adjusting Bolt Against

Fig. 7: Removing Engine Front Mounting Bracket
Fig. 11: Aligning Timing Belt Tensioner Adjuster Rod With Cylinder

Fig. 8: Identifying Timing Belt Aligning Marks
Fig. 12: Identifying Timing Belt Tensioner Adjuster Wire Or Pin
MITSUBISHI 551

Fig. 16: Pre-Tightening Timing Belt Tensioner Pulley
Fig. 13: Checking Timing Belt Tensioner Rod Movement
Fig. 17: Tightening Timing Belt Tensioner Pulley Bolt

Fig. 14: Identifying Oil Pump Balancer Shaft Cylinder Block Plug
Fig. 18: Checking Timing Belt Tensioner Adjuster Rod Projection

552 MITSUBISHI
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 crank-

shaft 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 com- Courtesy of Mitsubishi Motor Sales of America.
pressor connector clamp. With hose connected, remove power steering
pump assembly from bracket. Remove power steering pump bracket. Fig. 20: Holding Crankshaft Drive Sprocket With Special Spanner
Remove CKP sensor harness connector bracket and CKP sensor. (MB991367 Or MB991367-01) & Pins (MB991385 Or
2) Hold crankshaft drive sprocket using Special Spanner (MB991367 or MIT217213)
MB991367-01) and 2 Pins (MB991385 or MIT217213). See Fig. 20. • Cracks on belt sides.
Loosen crankshaft pulley center bolt, and remove crankshaft drive If any of these conditions are present, replace timing belt.
sprocket. It may be necessary to use Crankshaft Sprocket Puller Installation (Without Scan Tool) – 1) Ensure crankshaft balancer drive
(MD998778). See Fig. 21. sprocket and balancershaft sprocket timing marks are aligned. See
3) Remove crankshaft angle sensing ring. Fig. 22.
4) Loosen center bolt on balancer timing belt tensioner pulley. Remove 2) Install balancer timing belt on crankshaft balancer drive sprocket and
balancer timing belt tensioner pulley. Remove balancer timing belt. balancershaft sprocket. There should be no slack on tension side.
Inspection – Inspect balancer belt for the following conditions: 3) Loosely install balancer timing belt tensioner so that it is at top left
• Hardening of rubber backing (rubber backing will be glossy without from center of assembling bolt. Ensure pulley flange is at front side of
resilience and leave no indentation when pressing with fingernail). engine.
• Cracks on rubber back. 4) Using your fingers, lift balancer timing belt tensioner in direction of
• Cracks or peeling of canvas. arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to
• Cracks on bottom of ribs. specification. See TORQUE SPECIFICATIONS.
MITSUBISHI 553

Fig. 24: Checking Balancer Belt Deflection
Fig. 21: Removing Crankshaft Sprocket With Crankshaft 5) Connect Belt Tension Meter Set (MB991668) to Scan Tool
Sprocket Puller (MD998778)
(MB991502). Connect Battery Harness (MB991704) to scan tool. See
Fig. 25.
Fig. 22: Aligning Balancer Timing Marks
Fig. 25: Identifying Scan Tool & Balancer Timing Belt Deflection
Courtesy of Mitsubishi Motor Sales of America. Measuring Components (MB991668, MB991502 &
MB991704)
Fig. 23: Installing Balancer Belt Tensioner
marks are aligned.
marks are aligned.
7) Select BELT TENSION on menu screen of scan tool.
6) Apply about 22 lbs. (10 kg) of pressure at center (arrow area)
8) Hold Belt Tension Meter Set (MB991668) to middle of balancer timing
between sprockets as shown. See Fig. 24. Ensure belt deflection is
belt between sprockets (at place indicated by arrow), about 0.40-0.78″
.20-.27″ (5-7 mm).
(10-20 mm) away from rear surface of belt so that it is perpendicular to
7) If not within specification, readjust balancer timing belt tension. If
belt (within an angle of 15 degrees). See Fig. 26.
measurement is within specification, go to CRANKSHAFT ANGLE
9) While performing rest of test, ensure the following conditions are met:
SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET.
• Temperature of belt should be as close to normal as possible.
Installation (With Scan Tool) – 1) Ensure crankshaft balancer drive
sprocket and balancershaft sprocket timing marks are aligned. See • Do not allow contaminants such as water or oil to get into micro-
Fig. 22. phone.
2) Install balancer timing belt on crankshaft balancer drive sprocket and • If gusts of wind blow against microphone or if there are any loud
balancershaft sprocket. There should be no slack on tension side. sources of noise nearby, values measured by microphone may not
3) Loosely install balancer timing belt tensioner so that it is at top left correspond to actual values.
from center of assembling bolt. Ensure pulley flange is at front side of • If microphone is touching belt while measurement is being made,
engine. values measured by microphone may not correspond to actual
4) Using your fingers, lift balancer timing belt tensioner in direction of values.
arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to 10) Gently tap middle of balancer timing belt between sprockets (place
specification. See TORQUE SPECIFICATIONS. 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
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.
Fig. 26: Measuring Balancer Timing Belt Deflection With
Belt Tension Meter Set (MB991668)
Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84)
11) If measurement is not with 76-92 Hz, readjust balancer timing belt. Balancer Timing Belt Tensioner Bolt ............................................ ................. 12-16 (16-22)
If measurement is within specification, go to CRANKSHAFT ANGLE Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98)
SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET. Crankshaft Center Bolt 1 ......................................................................... 117-123 (157-167)
Cylinder Block Plug ....................................................................... ................. 21-25 (28-33)
CRANKSHAFT ANGLE SENSING BLADE OR Drive Belt Auto-Tensioner (Center Bolt)
CRANKSHAFT DRIVE SPROCKET Center Bolt .................................................................................. ................. 26-40 (34-54)
Installation – 1) Degrease and clean crankshaft angle sensing blade Except Center Bolt ...................................................................... ................. 13-18 (18-24)
and crankshaft drive sprocket. Engine Mount-To-Body Bolt/Nut 2 ................................................. ................. 26-40 (34-54)
Engine Mount-To-Engine Mounting Bracket Nut .......................... ................. 49-55 (66-74)
2) Degrease and clean crankshaft drive sprocket on installation side of
Power Steering Pump Bracket Mounting Bolt ............................. ................. 29-43 (40-58)
crankshaft. Power Steering Pump Mounting Bolt ........................................... ................. 13-19 (18-20)
3) Install crankshaft angle sensing blade and crankshaft drive sprocket Timing Belt Idler Pulley Mounting Bolt ......................................... ................. 22-30 (29-41)
in direction shown. See Fig. 27. Timing Belt Tensioner Adjuster Mounting Bolt ............................. ................. 15-19 (20-26)
Timing Belt Tensioner Arm Mounting Bolt .................................... ................. 14-18 (17-24)
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)
Water Pump Pulley Bolt ................................................................ ............... 69-87 (7.8-9.8)
Wiring Harness Mounting Bolt ...................................................... ............. 107-124 (13-15)
1
2
Fig. 27: Preparing & Installing Crankshaft Angle Sensing Blade

Or Crankshaft Drive Sprocket
MITSUBISHI 555
2.4L 4-Cylinder – SOHC – 1985-90 Galant & Van

Kit No. Part No.
Galant
1985-87
Camshaft Belt ............... ... 2 2.7 Hrs. ... .. TCK124 .. ..... T124
Van
1987-90
Camshaft Belt ............... ... 2 3.2 Hrs. ... .. TCK124 .. ..... T124
1
2
– With Air Conditioning, add .4 hours on Galant. With Air
Conditioning, add .7 hours on Van. With Power Steering, add .4
hours. Courtesy of Mitsubishi Motor Sales of America.
NOTE: A timing belt component kit is available for this application. Fig. 2: Holding Silent Shaft In Stationary Position
See page A1 for information on component kits. Installation – 1) Lightly oil right silent shaft spacer and insert spacer
with chamfered end toward seal. Install right silent shaft sprocket (if
NOTE: For information about tensioners and/or pulleys (when removed) and finger-tighten bolt. Align crankshaft sprocket and silent
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED tensioner “B” so only light pressure is on belt. Ensure flange on
tensioner is mounted away from engine, and finger-tighten bolt.
SCHEDULED MAINTENANCE 3) Lift tensioner with finger tip until slack is removed from tension side of
The manufacturer recommends the belt be replaced every 60,000 miles. 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
REMOVAL & INSTALLATION index finger and measuring belt deflection. Deflection should be .20-.30″
(5.0-7.0 mm). Readjust if not within specification.
TIMING BELT 5) Align camshaft timing belt sprockets with corresponding timing marks.
Removal – 1) Disconnect negative battery cable. Position No. 1 cylinder See Fig. 6. To ensure oil pump sprocket is in correct alignment, insert
at TDC of compression stroke. Remove crankshaft and water pump screwdriver shaft in hole on left side of block. See Figs. 1 and 2.
pulleys. Remove upper and lower front timing belt covers Relieve 6) If screwdriver cannot be inserted at least 2.4″ (60.0 mm), turn oil
camshaft timing belt tensioner pressure, and secure tensioner toward pump sprocket one revolution and realign marks. Insert screwdriver.
water pump. Leave screwdriver inserted until timing belt installation is complete.
2) If camshaft timing belt is to be reused, mark belt with an arrow Install crankshaft sprocket. See Fig. 7 or 8.
indicating direction of rotation and remove belt. Remove camshaft and 7) With tensioner secured fully toward water pump, install timing belt in
crankshaft sprocket bolts. Remove camshaft sprocket, crankshaft order of crankshaft sprocket, oil pump sprocket and camshaft sprocket.
sprocket and crankshaft flange. Remove plug on left side of cylinder Ensure tension side of belt has no slack. Loosen tensioner mounting bolt
and nut to allow only tensioner spring pressure to tighten belt. Check
block. Insert a screwdriver to keep left silent shaft in position. See Figs. 1
belt to ensure each tooth is in proper mesh with camshaft sprocket.
and 2.
8) Tighten slot-side bolt before tightening nut. Otherwise, tension
3) Remove oil pump sprocket. Loosen right silent shaft sprocket
bracket will turn and belt will be over-tensioned. Ensure all timing marks
mounting bolt until it can be turned by hand. Remove belt tensioner “B”
are in correct alignment. Remove screwdriver and install plug in block.
and timing belt “B”. See Fig. 3. 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.
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 replace-
ment.
556 MITSUBISHI
2.4L 4-Cylinder – SOHC – 1985-90 Galant & Van (Cont.)
Fig. 5: Aligning Rear Timing Belt
Fig. 4: Aligning Timing Marks For Timing Belt “B”

MITSUBISHI 557
2.4L 4-Cylinder – SOHC – 1985-90 Galant & Van (Cont.)
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)
Courtesy of Mitsubishi Motor Sales of America. 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)
Valve Cover Bolt ........................................................................... ................. 84-108 (9-12)
Fig. 7: Installing Crankshaft Sprockets (Galant) Water Pump Pulley Bolt ................................................................ ..................... 48-60 (5-7)
Fig. 8: Installing Crankshaft Sprockets (Van)

558 MITSUBISHI
2.4L 4-Cylinder
SOHC, VIN G – Except Outlander & Lancer
Part No.
2.4L 4-Cyl. – SOHC For 1994-96 and 2001 models, the manufacturer recommends the belt
Eclipse be replaced every 60,000 miles except in California. In California, timing
1996-99 belt replacement is recommended, but not required, at 60,000 miles. In
Balance Shaft Belt .............................. .......... 1 .......... ..... T168 California, replace timing belt at 100,000 miles, unless previously
Camshaft Belt ....................................... 2 3.0 Hours .. ..... T230 changed.
2000-03 For 1997-00 models, the manufacturer recommends the belt be
Camshaft Belt ....................................... 2 2.7 Hours .. ..... T232
2004
Balance Shaft Belt .............................. .......... 1 .......... ..... T168 belt replacement is recommended, but not required, at 60,000 miles. In
Camshaft Belt ....................................... 2 2.7 Hours .. ..... T332 these states, replace timing belt at 100,000 miles.
Galant For 2002-04 models, the manufacturer recommends the belt be
1994-98 replaced every 60,000 miles except in California, Massachusetts, Maine
Balance Shaft Belt .............................. .......... 1 .......... ..... T168 and Vermont. In California, Massachusetts, Maine and Vermont, timing
Camshaft Belt ....................................... 2 2.7 Hours .. ..... T230 belt replacement is recommended, but not required, at 60,000 miles. In
1999-03 these states, replace timing belt at 100,000 miles.
2004 REMOVAL & INSTALLATION
Camshaft Belt ........................................ 3.1 Hours ... ..... T332 CAUTION: This application is an interference engine. Do not rotate
Montero Sport camshaft or crankshaft when timing belt is removed, or engine
1997-99 damage may occur.
Camshaft Belt ....................................... 2 2.2 Hours .. ..... T230
1
TIMING BELT
camshaft belt labor time. Removal (Eclipse & Galant) – 1) Raise and support vehicle. Remove
2
– With Air Conditioning, add .4 hour for 1994-98 Galant and engine splash shield from right side wheelwell.
1997-99 Montero Sport. With Air Conditioning, add .1 hour for 2) Lower vehicle. Support weight of engine with floor jack. If necessary,
1996-99 Eclipse. With Power Steering, add .3 hour for 1994-98 remove coolant reservoir. Remove upper engine mount located near
Galant. timing belt cover. Remove all drive belts. If necessary, remove drive belt
tensioner pulley bracket and power steering pump pulley. See Fig. 1.
NOTE: Engine VIN is eighth character of vehicle VIN. Remove water pump pulley.
3) Remove crankshaft pulley. Noting bolt lengths and locations, remove
NOTE: For information about tensioners and/or pulleys (when upper and lower timing belt cover with gasket.
Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Eclipse & Galant)
MITSUBISHI 559
2.4L 4-Cylinder
SOHC, VIN G – Except Outlander & Lancer (Cont.)
Installation (Eclipse & Galant) – 1) Align crankshaft rear sprocket and
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed balance shaft sprocket timing marks. See Fig. 4. Install balance shaft
from timing belt end of engine). If timing belt is to be reused, mark timing belt. Ensure there is no slack in belt. If reusing old belt, install in
direction of rotation before removing. original direction of rotation.
2) Install crankshaft sensing blade in correct direction. See Fig. 6. Install
4) Rotate crankshaft clockwise (as viewed from timing belt end of
crankshaft sprocket. Apply engine oil to threads of crankshaft sprocket
engine) until cylinder No. 1 is at TDC of compression stroke. Align timing
bolt. Install and tighten bolt to specification. See TORQUE SPECIFICA-
mark on camshaft sprocket with timing mark on cylinder head. See
TIONS.
Fig. 2.
3) Move the balance shaft tensioner pulley so that the center of the
5) Loosen timing belt tensioner center bolt, and move tensioner pulley
toward water pump. Tighten center bolt to secure tensioner. Remove
center bolt. See Fig. 5. The tensioner pulley flange should face toward
front timing belt. Remove tensioner pulley and timing belt auto tensioner.
the front of the engine.
6) To remove balance shaft belt, remove left balance shaft access plug
from cylinder block. Insert .31″ (8.0 mm) diameter Phillips screwdriver to CAUTION: When tightening balance shaft tensioner pulley center
block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at bolt, ensure tensioner pulley shaft does not rotate with bolt. This
least 2.36″ (59.9 mm). Remove screwdriver if it cannot be inserted at will place excessive tension on bolt.
least 2.36″ (59.9 mm). Rotate balance shaft one revolution and realign
timing mark. 4) Using your hand, place pressure on balance shaft tensioner pulley in
7) If reusing old balance shaft timing belt, mark belt with arrow to direction of balance shaft timing belt. Loosen balance shaft tensioner
indicate rotation direction. Holding crankshaft stationary, remove front pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and
crankshaft sprocket bolt. Use gear puller to remove crankshaft sprocket tighten balance shaft tensioner pulley center bolt.
from crankshaft. 5) Press balance shaft belt on side opposite tensioner to check belt
8) Noting direction of installation, remove crankshaft sensing blade. deflection. See Fig. 4. Balance shaft belt deflection should be .20-.28″
Loosen balance shaft tensioner pulley center bolt. Remove balance (5.0-7.0 mm). Adjust as necessary.
shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION.
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.
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.
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.
Courtesy of Mitsubishi Motor Sales of America. 10) Remove Phillips screwdriver from engine block and install plug. To
adjust timing belt tension, turn crankshaft 1/4 revolution counterclock-
Fig. 2: Aligning Front Timing Belt Marks wise. 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
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
Fig. 3: Locking Balance Shaft pulley.
560 MITSUBISHI
2.4L 4-Cylinder

Fig. 4: Aligning Balance Shaft Timing Marks
Fig. 5: Adjusting Balance Shaft Timing Belt Tensioner
Fig. 9: Timing Belt Cover Bolt Installation Locations

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.
Courtesy of Mitsubishi Motor Sales of America. 6) Remove timing belt lower cover. Align timing mark on camshaft
sprocket with timing mark on cylinder head. See Fig. 2.
Fig. 6: Installing Crankshaft Sensing Blade (Eclipse & Galant) 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 screw-
driver 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
Fig. 7: Installing Set Screw On Tensioner Pulley balance shaft sprocket timing marks. See Fig. 4. Install balance shaft
timing belt. If reusing old belt, install in original direction of rotation.
CAUTION: Never rotate crankshaft counterclockwise. 2) Move the balance shaft tensioner pulley so that the center of the
2) Rotate crankshaft clockwise so that No. 1 piston is at TDC of center bolt. See Fig. 5. The tensioner pulley flange should face toward
compression stroke. Leaving secondary wires attached, remove dis- the front of the engine.
tributor cap and set aside. 3) Using your hand, place pressure on balance shaft tensioner pulley in
3) Note installed position of distributor and distributor rotor. Unplug direction of balance shaft timing belt. Loosen balance shaft tensioner
distributor electrical connector. Remove distributor housing and set pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and
aside. tighten balance shaft tensioner pulley center bolt.
MITSUBISHI 561
2.4L 4-Cylinder
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.

(Montero Sport) Courtesy of Mitsubishi Motor Sales of America.

NOTE: When tightening balance shaft tensioner pulley center bolt, TIMING BELT INSPECTION
ensure tensioner pulley shaft does not rotate with bolt. This will
1) Inspect back of belt for being hard, non-elastic and having a glossy
place excessive tension on belt.
surface. Check for rounded sides on belt. Sides of belt should be straight
4) Press balance shaft belt on side opposite tensioner to check belt and clear-cut. Flaking, peeling, cracking rubber from canvas also
deflection. See Fig. 4. Balance shaft belt deflection should be .20-.28″ indicates that belt should be replaced. Cracks are most evident at base
(5.0-7.0 mm). Adjust as necessary. of tooth.
5) Using a soft-jawed vise, SLOWLY compress the timing belt auto 2) Abnormal wear most often occurs on load side of tooth. Fluffy canvas,
tensioner push rod until rod pin hole aligns with pin hole in tensioner unclear canvas texture, belt color changed to White from rubber
missing, reduced tooth width or a missing tooth warrant belt replace-
body. Insert a locking pin through tensioner body and tensioner push rod
ment.
pin holes to lock auto tensioner in position. Install auto tensioner on
3) Check timing belt and balance shaft belt tensioner pulleys for worn
engine with locking pin in place.
bearings. Replace as necessary.
on engine. If reusing old timing belt, ensure belt is installed in original tensioner upright. Measure rod protrusion above edge of housing. See
direction of rotation. Make sure there is no slack in timing belt between Fig. 12. Length should be .47″ (12 mm). Apply 22-44 lbs. (20 kg) of force
sprockets. to end of rod. If auto tensioner rod moves more than 0.39″ (1 mm),
replace the auto tensioner.
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed.
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. Fig. 12: Inspecting Timing Belt Auto Tensioner
9) Remove Phillips screwdriver from engine block and install plug. To
adjust timing belt tension, turn crankshaft 1/4 revolution counterclock-
wise. 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.
562 MITSUBISHI
2.4L 4-Cylinder
TORQUE SPECIFICATIONS (ECLIPSE & GALANT) TORQUE SPECIFICATIONS (MONTERO SPORT)
Auto Tensioner Bolt ................................................................................................... 18 (24) Auto Tensioner Bolt ................................................................................................... 18 (24)
Camshaft Sprocket Bolt ............................................................................................ 65 (88) Camshaft Sprocket Bolt ............................................................................................ 65 (90)
Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24) Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24)
Crankshaft Sprocket Bolt .............................................................. ........... 1 80-94 (108-127) Distributor Bracket Bolt
Drive Belt Tensioner Pulley Bracket Bolt ..................................... ................. 17-20 (23-26) Except M6 x 18 mm ................................................................... ..................................... 1
Engine Upper Mount M6 x 18 mm ............................................................................................................ 17 (24)
Mount-To-Engine Bracket Nut/Bolt Tensioner Pulley Center Bolt
Eclipse (2000-03) ...................................................................... ................. 56-72 (74-98) Balance Shaft Belt Pulley ....................................................................................... 14 (19)
Galant (1999-03) ................................................................................................... 63 (86) Camshaft Belt Pulley ............................................................................................... 35 (48)
All Other Models ................................................................................................... 49 (67) Water Pump Bolt ....................................................................................................... 10 (14)
Mount-To-Body Through-Bolt
INCH Lbs. (N.m)
Eclipse (2000-03) ...................................................................... ................. 51-69 (69-93)
Galant (1999-03) ................................................................................................... 60 (81) Cooling Fan Clutch-To-Stud Nut ................................................... ............... 89-106 (10-12)
All Other Models ....................................................................................... 71-85 (98-118) Distributor Housing Hold-Down Bolt ............................................. .......................... 115 (13)
Power Steering Pump Pulley Bolt ............................................................................ 45 (61) Timing Belt Cover
Tensioner Pulley Center Bolt Lower Cover Bolt ................................................................................................... 78 (8.8)
Balance Shaft Belt Pulley ....................................................................................... 14 (19) Upper Cover Bolt .................................................................................................... 97 (11)
Camshaft Belt Pulley ............................................................................................... 35 (48) Water Pump Pulley Bolt .......................................................................................... 117 (13)
Water Pump Bolt ....................................................................................................... 10 (14) 1
– Tighten bolt to 97 INCH lbs. (11 N.m).
INCH Lbs. (N.m)
6-mm (Except Flange Bolts) .................................................................................. 78 (8.8)
6-mm (Flange Bolt) ..................................................................... ............... 89-106 (10-12)
8-mm Bolt .............................................................................................................. 120 (14)
1
MITSUBISHI 563
3.0L V6 – SOHC, 12-Valve Engine

Kit No. Part No.
3.0L V6 – SOHC
Diamante
1
1992-96 ............................ ... 3.8 Hrs. ... .. TCK139 .. ..... T139
Galant Sigma
1
1988-90 ............................ ... 3.8 Hrs. ... .. TCK139 .. ..... T139
Montero (12-Valve Engine)
2
1989-91 ............................ ... 3.5 Hrs. ... .. TCK139 .. ..... T139
1
1992-94 ............................ ... 3.5 Hrs. ... .. TCK139 .. ..... T139
Pickup (4WD)
1
1990-94 ............................ ... 3.5 Hrs. ... .. TCK139 .. ..... T139
Sigma
1
1989-90 ............................ ... 3.8 Hrs. ... .. TCK139 .. ..... T139
3000GT
1
1997-99 ............................ ... 3.5 Hrs. ... .. TCK139 .. ..... T139
1
2


SCHEDULED MAINTENANCE Courtesy of Mitsubishi Motor Sales of America.
Fig. 1: Removing & Installing Engine Support Bracket
changed.
changed.

TIMING BELT REMOVAL
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 Courtesy of Mitsubishi Motor Sales of America.
pulley. Remove timing belt covers. Remove flange from crankshaft. See
Fig. 2. Rotate crankshaft to align all timing marks. See Figs. 3 and 4. Fig. 2: Exploded View of Timing Belt & Components
Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to
Removal (Galant) – 1) Disconnect negative battery cable. Remove all
release belt tension.
accessory drive belts. Disconnect connector and pressure hoses at
4) If reusing timing belt, mark belt to indicate direction of belt rotation.
Loosen tensioner bolt. Pry tensioner counterclockwise to relieve belt power steering pump. Remove power steering pump with return hose
tension. While holding tensioner, tighten tensioner bolt. Remove timing connected. Remove through-bolt from front engine mount.
belt.
564 MITSUBISHI
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.
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.
2) Remove A/C tensioner pulley and mounting bracket. Remove timing
Fig. 3: Locating Timing Belt & Sprocket 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.
Courtesy of Mitsubishi Motor Sales of America. 3) Place floor jack under engine to support weight of engine. Remove
engine-to-body mount from timing belt end of engine.
Fig. 4: Aligning Timing Marks 4) Unplug power steering pump pressure switch electrical connector.
Remove power steering pump with hoses attached, and set out of way.
CAUTION: Apply spray lubricant on reamer bolt during removal, as
CAUTION: Reamer bolt may be heat-seized to engine support
bolt is sometimes seized in engine support.
bracket. Reamer bolt has “R” marking on bolt head.
2) Support engine and remove front engine mount. Remove engine 5) Remove engine support bracket bolts, in specified sequence, from
mount bracket bolts in sequence. Lubricate reamer bolt with penetrating front of engine. See Fig. 1. Note position of reamer bolt for reassembly
oil before and during removal. See Fig. 1. reference.
3) Remove A/C tensioner pulley and mounting bracket. Remove No. 1 6) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove
upper outer cover and gaskets. See Fig. 2. Remove engine support crankshaft pulley.
bracket bolts in proper sequence. See Fig. 1. Remove engine support 7) Remove all timing belt covers. Noting position for reassembly
bracket. reference, remove front flange from crankshaft. See Fig. 5.
4) Remove cover cap and No. 2 upper outer cover and gaskets. Remove 8) Rotate crankshaft to align all timing marks. See Figs. 3 and 4. Loosen
under cover. Using Holder (MB990767-01) and Adapter Bolts belt tensioner bolt. Rotate belt tensioner pulley counterclockwise to
(MD998719) or equivalent, remove crankshaft pulley. relieve belt tension. Tighten tensioner pulley bolt.
5) Remove lower outer cover, gaskets and flange. See Fig. 2. Rotate 9) If reusing timing belt, place arrow on belt to indicate belt running
crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt direction. Remove timing belt.
tensioner bolt, and rotate belt tensioner counterclockwise to release belt
tension.
TIMING BELT INSPECTION
of belt rotation. Remove timing belt and belt tensioner. All Models – Inspect timing belt for wear on edges of drive teeth.
Removal (Montero & Pickup) – 1) Disconnect negative battery cable. Inspect belt for signs of oil contamination, cracks, separation, worn or
Drain cooling system. Disconnect upper radiator hose. Remove upper missing teeth, or hardened black surface. Replace belt if worn, damaged
radiator shroud. Remove cooling fan and fan clutch assembly. Remove or contaminated. Inspect belt tensioner for smooth rotation. Replace
cooling fan pulley. Remove all accessory drive belts. Remove power parts, if defective.
steering pump with pressure and return hoses connected and set aside.
2) Remove power steering pump brackets. Remove A/C tensioner pulley TIMING BELT INSTALLATION
and mounting bracket. Remove A/C compressor with hoses connected Installation (Diamante) – 1) Install timing belt onto crankshaft sprocket,
and mounting bracket. Remove cooling fan bracket assembly. Remove then around left camshaft sprocket, with all slack removed from tension
timing belt No. 1 upper outer cover and gaskets. See Fig. 2. side of belt. Route timing belt onto water pump pulley, right camshaft
MITSUBISHI 565

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 crank-
shaft 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.
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
Installation (Montero & Pickup) – 1) Install belt tensioner and spring.
Ensure spring is secured on pin of water pump and engaged in hole of
Courtesy of Mitsubishi Motor Sales of America. belt tensioner with hook of spring pointing away from cylinder block.
(3000GT – SOHC) temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC
of compression stroke. See Figs. 3 and 4.
sprocket, and tensioner. Apply torque to rear camshaft pulley to tighten 3) Install timing belt on crankshaft sprocket and then left camshaft
belt. Ensure all timing marks are aligned. sprocket with all slack removed from tension side of belt. Route timing
2) Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and
belt onto water pump pulley, right camshaft sprocket and tensioner.
allow tensioner to apply belt tension. Using Crankshaft Socket
Remove any slack from belt by rotating left and then right camshaft
(MD998716-01) or equivalent, rotate crankshaft 2 revolutions clockwise.
sprockets counterclockwise. Ensure all timing marks are aligned. Install
DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt
flange on crankshaft. Loosen belt tensioner bolts slightly, and allow
tensioner bolts to specification. See TORQUE SPECIFICATIONS. Using
belt tension gauge, measure belt tension halfway between crankshaft tensioner to apply belt tension.
sprocket and camshaft sprocket on side opposite belt tensioner. Belt 4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions
tension should be 44-66 lbs. (20-30 kg). clockwise. DO NOT rotate counterclockwise. Realign all timing marks.
3) Install proper length bolts in timing belt covers. See Fig. 6. Tighten all Tighten belt tensioner bolts to specification. See TORQUE SPECIFICA-
bolts and nuts to specification. See TORQUE SPECIFICATIONS. TIONS. Using belt tension gauge, measure belt tension halfway
between crankshaft sprocket and camshaft sprocket on side opposite
NOTE: Engine support bracket reamer bolt must be tightened belt tensioner.
slowly while spraying lubricant on bolt. 5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining
4) Install engine support bracket and tighten bolts in sequence. See components, reverse removal procedure. Install proper length bolts in
Fig. 1. Tighten bolts to specification. See TORQUE SPECIFICATIONS. timing belt covers. See Fig. 7. Tighten bolts to specification. See
To install remaining components, reverse removal procedure. Adjust 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.
Courtesy of DaimlerChrysler Corp. 2) Rotate belt tensioner counterclockwise as far as possible, and
Fig. 6: Identifying Timing Belt Cover Bolt Lengths temporarily tighten bolt. Align all timing marks with No.1 cylinder at TDC
(Diamante, Galant & Sigma) of compression stroke. See Figs. 3 and 4.
3) Install timing belt on crankshaft sprocket, rear head camshaft
Installation (Galant) – 1) Install belt tensioner and spring. Ensure
sprocket, water pump pulley, front head sprocket and timing belt
spring is secured on pin of water pump and engaged in hole of belt
tensioner. Ensure belt is installed in original direction of rotation and all
tensioner with hook of spring pointing away from cylinder block.
timing marks are aligned on crankshaft. Loosen belt tensioner bolts
temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC slightly, and allow tensioner to apply belt tension.
of compression stroke. See Figs. 3 and 4.
566 MITSUBISHI
Fig. 8: Identifying Timing Belt Cover Bolt Lengths (3000GT)
TORQUE SPECIFICATIONS (DIAMANTE)
Fig. 7: Identifying Timing Belt Cover Bolt Lengths
(Montero & Pickup) Application Ft. Lbs. (N.m)
4) Using Crankshaft Socket (MD998716) or equivalent, rotate crank- Camshaft Sprocket Bolt ............................................................................................ 66 (90)
shaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign Crankshaft Pulley Bolt
all timing marks. Tighten belt tensioner bolts to specification. See 1991 ....................................................................................................... 108-116 (146-157)
TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt 1992-96 ................................................................................................................ 136 (185)
tension halfway between crankshaft sprocket and camshaft sprocket on Engine Support Bracket Bolt
side opposite belt tensioner. 10 X 40 mm ................................................................................ ................. 47-54 (64-73)
Except 10 X 40 mm .................................................................................. 76-83 (103-113)
Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42)
components, reverse removal procedure. Install proper length bolts in Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49)
timing belt covers. See Fig. 6. Water Pump Bolt ....................................................................................................... 17 (23)
NOTE: Engine support bracket reamer bolt must be tightened INCH Lbs. (N.m)
slowly while spraying lubricant on bolt. Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
6) Install engine support bracket. Tighten bolts in sequence to specifi- TORQUE SPECIFICATIONS (GALANT)
cation. See Fig. 1. See TORQUE SPECIFICATIONS. Adjust drive belts
to proper tension.
Installation (3000GT) – 1) Ensure all timing belt marks are aligned. See Crankshaft Pulley Bolt ............................................................................. 108-116 (146-157)
Figs. 3 and 4. If not already done, loosen tensioner center bolt. Turn Engine Support Bracket Bolt
tensioner counterclockwise. Temporarily tighten tensioner center bolt. 10 X 40 mm ................................................................................ ................. 25-36 (34-49)
2) Install timing belt on crankshaft sprocket, left hand camshaft sprocket 10 X 53 mm ................................................................................ ................. 47-54 (64-73)
(side away from tensioner pulley), water pump pulley, right hand 12 X 56 mm .............................................................................................. 76-83 (103-113)
camshaft sprocket, and timing belt tensioner. Apply counterclockwise Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29)
force to right hand camshaft sprocket (camshaft closest to firewall) to Water Pump Bolt ........................................................................... ................. 14-19 (19-26)
remove any belt slack. Ensure all timing marks are still aligned. INCH Lbs. (N.m)
3) Install front flange on crankshaft. Loosen timing belt tensioner pulley Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
center bolt. Allow the tensioner spring force to tension timing belt. Turn Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)
crankshaft 2 revolutions clockwise. DO NOT turn counterclockwise.
4) Align all timing belt marks. Final tighten tensioner pulley center bolt. TORQUE SPECIFICATIONS (MONTERO & PICKUP)
Using a belt tension gauge, measure timing belt tension midway Application Ft. Lbs. (N.m)
between crankshaft sprocket and left hand camshaft sprocket (side Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98)
opposite belt tensioner pulley). Belt tension should be 46.3-68.3 lbs. Crankshaft Pulley Bolt
(21-31 kg). Montero .................................................................................................. 108-116 (146-157)
5) Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and Pickup .......................................................................................... ......... 130-137 (176-186)
allow tensioner to apply belt tension. Left Engine Support Bracket Bolt ................................................. ................. 15-21 (20-30)
Rear Engine Support Bracket Bolt ............................................... ................. 13-18 (18-25)
6) Install timing belt covers. Install timing belt cover bolts in correct
Right Engine Support Bracket Bolt
locations. See Fig. 8. 10 X 22 mm ................................................................................ ................. 25-36 (34-49)
10 X 40 mm ................................................................................ ................. 25-36 (34-49)
NOTE: When installing engine support bracket reamer bolt, tighten 12 X 22 mm ................................................................................ ................. 47-61 (64-83)
it slowly while spraying lubricant on reamer bolt. Reamer bolt has 12 X 32 mm ................................................................................ ................. 47-61 (64-83)
“R” marking on bolt head. Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29)
Water Pump Bolt ........................................................................... ................. 14-20 (19-27)
7) Install crankshaft pulley. Tighten crankshaft pulley bolt to specifica-
tion. See TORQUE SPECIFICATIONS. Install engine support bracket INCH Lbs. (N.m)
on engine block. Install bolts in correct location, and tighten in sequence. Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
See Fig. 1. Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)
8) To install remaining components, reverse removal procedure. Adjust
MITSUBISHI 567

TORQUE SPECIFICATIONS (SIGMA) TORQUE SPECIFICATIONS (3000GT)
Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Camshaft Sprocket Bolt ............................................................................................ 66 (90)
Crankshaft Pulley Bolt ............................................................................. 110-118 (150-160) Crankshaft Pulley Bolt ............................................................................. 108-116 (150-160)
Engine Mount Bracket Nut ............................................................ ................. 44-57 (60-77) Engine Mount
Engine Support Bracket Bolt To-Body Through-Bolt .............................................................................................. 51 (70)
10 X 40 mm ................................................................................ ................. 25-36 (34-49) To-Engine Support Bracket ......................................................... ............. 72-87 (100-120)
10 X 53 mm ................................................................................ ................. 47-54 (64-73) Engine Support Bracket-To-Engine Bolt 1
12 X 56 mm M10 Bolt .................................................................................................................. 51 (70)
1989 ......................................................................................................... 76-83 (103-113) M12 Bolt ................................................................................................................ 80 (110)
1990 ........................................................................................... ................. 47-61 (65-85) Generator/Power Steering Tensioner Pulley Bracket Bolt ....................................... 30 (42)
Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29) Power Steering Pump Mount Bolt
Water Pump Bolt ........................................................................... ................. 14-20 (19-27) Short Bolt ................................................................................................................. 29 (40)
Long, Shoulder Bolt ................................................................................................ 16 (22)
INCH Lbs. (N.m)
Timing Belt Tensioner Pulley Center Bolt .................................... ................. 16-22 (22-30)
Timing Belt Cover Bolt .................................................................. ............... 90-102 (10-12) Water Pump Bolt ....................................................................................................... 17 (23)
INCH Lbs. (N.m)
1
– Spray lubricant on reamer bolt while tightening.
568 MITSUBISHI
3.0L V6 – SOHC, 24-Valve Engine
TIMING BELT APPLICATION 4) Remove power steering pump belt tensioner. See Fig. 1. Remove
Application Labor Time Component Belt upper and lower timing belt covers. Remove engine support bracket
Kit No. Part No. from front of engine.
3.0L V6 – SOHC
Eclipse CAUTION: Always turn crankshaft in clockwise direction (as
1 viewed from front of engine).
2000-04 .............................. 3.0 Hours .. .. TCK259 .. ..... T259
Galant
1999-03 .............................. 1
3.0 Hours .. .. TCK259 .. ..... T259 5) If timing belt is to be reused, place arrow on belt to indicate direction
Montero (24-Valve Engine) of belt rotation. Turn crankshaft clockwise to align camshaft and
2 crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt
1995-96 .............................. 3.4 Hours .. .. TCK259 .. ..... T259
Montero Sport tensioner pulley, and remove timing belt. Remove timing belt auto-
1
1997-02 .............................. 2.8 Hours .. .. TCK259 .. ..... T259 tensioner from engine block.
1
2003 ................................... 2.8 Hours .. ...... ..... ...... ..... T259
1
– With Air Conditioning, add .3 hours for Montero Sport.
2
– With Air Conditioning, add .4 hours for Montero.


For 1995-96 and 2001 Eclipse and Galant models, the manufacturer
recommends the belt be replaced every 60,000 miles except in Califor-
nia. 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.
changed.
For 2002-04 Eclipse and 2002-03 Galant models, the manufacturer
recommends the belt be replaced every 60,000 miles except in Califor- Fig. 1: Exploded View Of Timing Belt & Components
nia, Massachusetts, Maine and Vermont. In California, Massachusetts, (Eclipse & Galant)
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.

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 Courtesy of Mitsubishi Motor Sales of America.
tube from front of engine. Remove generator with wires attached, and
secure out of way. Remove power steering pump drive belt. Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner)
3) Lower vehicle. Support weight of engine with jack. Remove engine
Removal (Montero & Montero Sport) – 1) Disconnect negative battery
mount from timing belt end of engine. Using Tensioner Wrench
cable. Drain cooling system. Disconnect upper radiator hose from
(MB990767) and Crankshaft Pulley Holder Pin (MD998715), hold crank-
engine. Remove upper radiator shroud. Loosen cooling fan clutch-to-
shaft pulley stationary and remove crankshaft pulley bolt. Remove
pulley nuts. Relieve tension on accessory drive belts.
crankshaft pulley.
MITSUBISHI 569

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.
of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.

(Montero & Montero Sport)
Courtesy of Mitsubishi Motor Sales of America. Fig. 5: Checking Timing Belt Auto-Tensioner Movement
Fig. 3: Exploded View Of Accessory Mount Assembly
(Montero & Montero Sport) WARNING: Right bank camshaft can turn easily due to applied
spring force, so keep fingers out of the way.
Inspection (All Models) – 1) Inspect timing belt for wear on edges of
drive teeth. Inspect belt for signs of oil contamination, cracks, separa- 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt
tion, worn or missing teeth, or hardened black surface. Replace belt if on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water
worn, damaged or contaminated. Inspect belt tensioner pulley for pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all
smooth rotation. Replace if defective. slack out of timing belt.
2) Check timing belt auto-tensioner for leaks. Hold timing belt auto- 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
tensioner upright. Measure rod protrusion above edge of housing. See Socket Wrench (MD998767), rotate tensioner pulley against timing belt.
Fig. 5. Length should be .47″ (12 mm). Apply 22-44 lbs. (98-196 N) of Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
force to end of rod. If auto tensioner rod moves more than 0.39″ (1 mm), Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
replace the auto-tensioner. crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still
Installation (Eclipse & Galant) – 1) Place auto-tensioner in soft-jawed aligned.
vise to SLOWLY compress the push rod. If there is a plug at the base of 5) For 1999-00 models, loosen tensioner pulley center bolt. Position
the auto-tensioner body, place flat washer around plug so it will not tensioner pin holes at BOTTOM of tensioner. Install Tensioner Pulley
contact vise jaw. Socket Wrench (MD998767) on tensioner pulley. See Fig. 6. Use a
torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque (counterclock-
CAUTION: Never compress the auto-tensioner too fast, or the push wise direction) to tensioner pulley. Tighten tensioner center bolt to
rod will be damaged. specification while holding tensioner stationary. See TORQUE SPECI-
FICATIONS.
2) Slowly compress auto-tensioner push rod until holes in push rod and
6) For 2001 and later models, loosen tensioner pulley center bolt.
auto-tensioner housing are aligned. Insert a locking pin into the align-
Position tensioner pin holes at TOP of tensioner. Install Tensioner Pulley
ment holes. Install auto-tensioner on engine.
Socket Wrench (MD998767) on tensioner pulley. See Fig. 7. Use a
570 MITSUBISHI
torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque (clockwise Installation (Montero & Montero Sport) – 1) Place auto-tensioner in
direction) to tensioner pulley. Tighten tensioner center bolt to specifica- soft-jawed vise to SLOWLY compress the push rod. If there is a plug at
tion while holding tensioner stationary. See TORQUE SPECIFICA- the base of the auto-tensioner body, place flat washer around plug so it
TIONS. will not contact vise jaw.
7) On all models, remove locking pin from auto-tensioner. Turn crank-
CAUTION: Never compress the auto-tensioner too fast, or the push
shaft 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 2) SLOWLY compress auto-tensioner push rod until holes in push rod
protrusion. To check push rod protrusion, measure clearance between and auto-tensioner housing are aligned. Insert a locking pin into the
body of auto-tensioner and bottom of tensioner pulley bracket arm. alignment holes. Install auto-tensioner on engine.
Clearance should be 0.15-0.20″ (3.8-5.0 mm). If protrusion is not
correct, repeat timing belt tensioning procedure. WARNING: Right bank camshaft can turn easily due to applied
9) Install engine support bracket on engine block. Tighten top bolt first, spring force, so keep fingers out of the way.
then working in a counterclockwise direction, tighten the remaining 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt
bolts. See Fig. 8. Install timing belt covers. Install crankshaft pulley. on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water
Apply engine oil to crankshaft pulley bolt, then tighten bolt to specifica- pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all
tion. See TORQUE SPECIFICATIONS. slack out of timing belt.
10) To install remaining components, reverse removal procedure. Adjust 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
drive belts to proper tension. 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.
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 revolu-
Courtesy of Mitsubishi Motor Sales of America. wise.
7) Wait for at least 5 minutes, then check auto-tensioner push rod
Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse & Galant; protrusion. To check push rod protrusion, measure clearance between
1995-03 Montero & Montero Sport)
body of auto-tensioner and bottom of tensioner pulley bracket arm.
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. 9) Before refilling cooling system, remove air bleed bolt on top of
thermostat housing. Refill cooling system with 50/50 mix of water and
Fig. 7: Adjusting Timing Belt Tension (2001-04 Eclipse & coolant until it overflows from air bleed bolt hole. Install air bleed bolt
2001-03 Galant)
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.
Fig. 8: Identifying Engine Support Bracket Tightening Sequence

(Eclipse & Galant)
MITSUBISHI 571

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (MONTERO & MONTERO SPORT)
TORQUE SPECIFICATIONS (ECLIPSE & GALANT)
Accessory Mount Assembly Bolt
Application Ft. Lbs. (N.m) 12 x 100 Bolt ........................................................................................................... 54 (74)
Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24) All Other Bolts ......................................................................................................... 33 (44)
Camshaft Sprocket Bolt ............................................................................................ 65 (88) Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24)
Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (177-186) Camshaft Sprocket Bolt ............................................................................................ 65 (88)
Dipstick Tube Bolt ..................................................................................................... 10 (14) Crankshaft Pulley Bolt ......................................................................................... 1 134 (181)
Engine Mount Generator ................................................................................................................... 16 (22)
To-Engine Support Bracket Nut/Bolt ....................................................................... 63 (86) M8 Bolt .................................................................................................................... 15 (21)
To-Body Through-Bolt ............................................................................................ 2 61 (83) M10 Bolt .................................................................................................................. 30 (51)
Engine Support Bracket-To-Engine Bolt ................................................................... 33 (44) Power Steering Pump Bolt
Generator Pivot Bolt .................................................................................................. 33 (44) 1995-96 ........................................................................................ ................. 29-33 (39-44)
Generator Top Bolt .................................................................................................... 15 (21) 1997-03 .................................................................................................................... 17 (24)
Power Steering Pump Belt Tensioner Bolt ............................................................... 33 (44) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Timing Belt Tensioner Center Bolt ............................................................................ 35 (48) Timing Belt Tensioner Center Bolt ............................................................................ 35 (48)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Water Pump Bolt ....................................................................................................... 18 (24)
Water Pump Bolt INCH Lbs. (N.m)
M8 Bolt .................................................................................................................... 17 (23)
M10 Bolt .................................................................................................................. 30 (41) Cooling Fan Clutch-to-Pulley Nut ................................................. ............... 89-106 (10-12)
Power Steering Pump Cover Bolt .............................................................................. 43 (5)
INCH Lbs. (N.m) Radiator Shroud Bolt ................................................................................................... 43 (5)
Timing Belt Cover Bolt ............................................................................................ 106 (12) Timing Belt Cover Bolt
1 M6 Bolt .................................................................................................................... 97 (11)
– Apply engine oil to bolt threads before installation. M8 Bolt .................................................................................................................. 117 (13)
2
– Final tighten bolt with full weight of engine on mount. Timing Indicator Bracket Bolt .................................................................................... 97 (11)
1
572 MITSUBISHI
3.5L V6 – DOHC
Part No.
3.5L V6
Montero
1
1994-96 .................................................... 4.4 Hours .. ..... T253
1

The manufacturer requires the belt be replaced every 60,000 miles,
except in California. In California, belt replacement is recommended, but
not required. In California, replace belt at 100,000 miles, unless previ-
ously changed.

Fig. 1: Exploded View Of Accessory Mount Components
damage may occur.
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. Courtesy of Mitsubishi Motor Sales of America.
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 Fig. 2: Exploded View Of Timing Belt & Components
belt tensioner center bolt. Remove timing belt and timing belt automatic
tensioner. CAUTION: Turning camshaft sprockets while No. 1 piston is at TDC
may damage valve and piston. Use care when aligning timing
NOTE: Revised auto-tensioner procedure is from Mitsubishi tech- marks.
nical service bulletin 96-11-006; June, 1996.
3) To lower No. 1 piston from TDC and prevent valve and piston contact,
Inspection – 1) Inspect timing belt for wear on edges of drive teeth. turn crankshaft back 3 sprocket teeth (measured at timing mark). See
Inspect belt for signs of oil contamination, cracks, separation, worn or
Fig. 4.
missing teeth, or hardened black surface. Replace belt if worn, damaged
4) Starting with left (driver’s side) bank of cylinders, verify intake and
or contaminated. Inspect belt tensioner pulley for smooth rotation.
exhaust camshaft timing marks are correctly aligned with marks on rear
2) Check timing belt automatic tensioner for leaks. Hold timing belt
timing belt cover. See Fig. 3. Rotate either camshaft sprocket clockwise
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 to align timing marks.
kg) of force to end of rod. If automatic tensioner rod moves more than
WARNING: Use care when aligning timing marks. Camshaft is
0.39″ (1 mm), replace the automatic tensioner.
under valve spring pressure and may rotate suddenly, pinching
Installation – 1) Place automatic tensioner assembly in a soft-jawed
hand between sprockets.
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 5) Align camshaft timing marks on right (passenger’s side) camshaft
or drill bit through both holes. sprockets. See Fig. 3. Using box end wrenches, hold camshaft sprocket
2) Remove automatic tensioner from vise, and install assembly on center bolts to prevent sprockets from turning. With right bank camshaft
engine with wire in place. Install crankshaft sprocket (if removed). Align
timing marks on crankshaft and camshaft sprockets. See Fig. 3.
MITSUBISHI 573

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
Fig. 3: Aligning Timing Marks Courtesy of Mitsubishi Motor Sales of America.
sprocket timing marks aligned with marks on rear timing belt cover, Fig. 4: Positioning Crankshaft For Timing Belt Installation
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 tempo-
rarily 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 Courtesy of Mitsubishi Motor Sales of America.
clockwise direction. Holding tensioner pulley to prevent it from turning,
final tighten center bolt to 35 ft. lbs. (48 N.m). Ensure tensioner pulley Fig. 5: Securing Timing Belt With Spring Clips
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 Courtesy of Mitsubishi Motor Sales of America.
pump and A/C compressor. Install cooling fan. Install accessory drive Fig. 6: Adjusting Timing Belt Tension
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).
574 MITSUBISHI
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)
Crankshaft Pulley Center Bolt ...................................................... ......... 130-137 (177-186)
Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
INCH Lbs. (N.m)

Coolant Air Bleed Bolt ....................................................................................... 80-97 (9-11)
Cooling Fan-To-Pulley Bolt ........................................................... ............... 89-106 (10-12)
Fig. 7: Measuring Push Rod Protrusion Crankshaft Position Sensor ........................................................................................ 80 (9)
Radiator Mounting Bolt/Nut ......................................................................................... 62 (7)
MITSUBISHI 575
3.5L V6 – SOHC
Kit No. Part No.
3.5L V6 – SOHC
Diamante
1997-02 .............................. 1 3.4 Hours .. .. TCK287 .. ..... T287
2003-04 .............................. 1 3.4 Hours .. ...... ..... ...... ..... T287
Montero
1997-00 .............................. 1 3.4 Hours .. .. TCK287 .. ..... T287
2001-02 ............................... 3.9 Hours ... ...... ..... ...... ..... T320
Montero Sport
1999-00 .............................. 1 2.8 Hours .. ...... ..... ...... ..... T287
2001-02 .............................. 1 2.8 Hours .. .. TCK287 .. ..... T287
2003-04 .............................. 1 2.8 Hours .. ...... ..... ...... ..... T287
1
– With Air Conditioning, add .4 hour for Montero. With Air
Conditioning, add .3 hour for Montero Sport.


For 1997-00 models and 2002-04 models, the manufacturer recom-
mends the belt be replaced every 60,000 miles except in California,
Connecticut, and Massachusetts. In California, Connecticut, and Mas-
sachusetts, timing belt replacement is recommended, but not required,
at 60,000 miles. In these states, replace timing belt at 100,000 miles,
unless previously changed.
For 2001 models, the manufacturer recommends the belt be replaced
every 60,000 miles except in California, Massachusetts and Vermont. In
California, Massachusetts and Vermont, timing belt replacement is
recommended, but not required, at 60,000 miles. In these states,

Fig. 1: Exploded View Of Timing Belt & Components (Diamante)
damage may occur.
TIMING BELT
NOTE: Replacement procedure for Diamante includes revised
information from Mitsubishi technical service bulletin
No. 00-11-005; April, 2000.
accessory drive belts. Remove generator with wires attached, and
secure out of way.
2) Holding crankshaft pulley stationary, remove crankshaft pulley bolt.
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.

of belt rotation. Turn crankshaft clockwise to align camshaft and
crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt Fig. 2: Aligning Timing Marks
tensioner pulley, and remove timing belt. Remove timing belt auto-
tensioner from engine block. Inspect timing belt. See TIMING BELT
INSPECTION.
576 MITSUBISHI
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.


timing belt.
3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt Courtesy of Mitsubishi Motor Sales of America.
pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all Fig. 4: Engine Support Bracket Tightening Sequence (Diamante)
slack out of timing belt. 3) Remove cover and power steering pump with hoses connected, and
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley set aside. Remove A/C compressor from bracket (hoses connected),
Wrench (MD998767), rotate tensioner pulley against timing belt. Tem- and set aside. Remove A/C compressor bracket. On Montero Sport,
porarily tighten tensioner pulley center bolt. Using Crankshaft Pulley remove timing mark indicator plate from front of engine. On all models,
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
remove accessory mount assembly. See Fig. 5.
4) Remove upper timing belt cover. See Fig. 6. Using Crankshaft Pulley
aligned.
Holder Pin (MD998715) and End Yoke Holder (MB990767), hold crank-
shaft pulley stationary and remove crankshaft pulley bolt. Remove
bottom of tensioner. Install Tensioner Pulley Wrench (MD998767)) on
tensioner pulley. See Fig. 3. Using torque wrench, apply 39 INCH lbs. crankshaft pulley.
(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 revolu- 5) Remove lower timing belt cover. Turn crankshaft clockwise to align
tions clockwise and align all timing marks. DO NOT rotate counterclock- camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner
wise. pulley center bolt.
7) Wait for at least 5 minutes, then check auto-tensioner push rod 6) If timing belt is to be reused, place arrow on belt to indicate direction
protrusion. To check push rod protrusion, measure clearance between of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.
body of auto-tensioner and bottom of tensioner pulley bracket arm. For Inspect timing belt. See TIMING BELT INSPECTION.
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 specifica-
9) To install remaining components, reverse removal procedure. Adjust

Fig. 3: Adjusting Timing Belt Tension (Except 2001-02 Montero) (1997-00 Montero & 1999-04 Montero Sport)
Removal (1997-00 Montero & 1999-04 Montero Sport) – 1) Discon- Installation (1997-00 Montero & 1999-04 Montero Sport) – 1) Place
nect negative battery cable. Drain cooling system. Remove upper auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If
radiator hose. Remove radiator shroud. Loosen cooling fan clutch-to- there is a plug at the base of the auto-tensioner body, place flat washer
pulley nuts. Relieve tension on accessory drive belts. around plug so it will not contact vise jaw.
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.
MITSUBISHI 577

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
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
Fig. 6: Exploded View Of Timing Belt & Components from bracket (hoses connected), and set aside. Remove A/C compres-
(1997-00 Montero & 1999-04 Montero Sport) sor bracket. Remove cooling fan bracket assembly. Remove accessory
mount assembly.
CAUTION: Never compress the auto-tensioner too fast, or the push 5) Remove upper timing belt cover. See Fig. 10. Using Pulley Holder
rod will be damaged. (MB991800) and Pin “B” (MD991802), hold crankshaft pulley stationary
and remove crankshaft pulley bolt. Remove crankshaft pulley.
auto-tensioner housing are aligned. Insert a locking pin into the align- CAUTION: Always turn crankshaft in clockwise direction (as
ment holes. Install auto-tensioner on engine. 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
timing belt. compression TDC. See Fig. 11. Loosen belt tensioner pulley center bolt.
3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt 7) If timing belt is to be reused, place arrow on belt to indicate direction
on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water of belt rotation. Remove timing belt. Inspect timing belt. See TIMING
pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all BELT INSPECTION.
slack out of timing belt. 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
4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
the auto-tensioner body, place flat washer around plug so it will not
Wrench (MD998767), rotate tensioner pulley against timing belt. Tem-
contact vise jaw.
porarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn CAUTION: Never compress the auto-tensioner too fast, or the push
crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still rod will be damaged.
aligned.
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. WARNING: Right bank camshaft can easily turn from applied
Tighten tensioner center bolt to specification while holding tensioner spring pressure. Be careful not to pinch fingers when installing
pulley stationary. See TORQUE SPECIFICATIONS. timing belt.
wise. pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all
7) Wait for at least 5 minutes, then check auto-tensioner push rod slack out of timing belt.
protrusion. To check push rod protrusion, measure clearance between 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley
body of auto-tensioner and bottom of tensioner pulley bracket arm. Wrench (MD998767), rotate tensioner pulley against timing belt. Tem-
Clearance should be 0.15-0.20″ (3.8-5.0 mm). If protrusion is not porarily tighten tensioner pulley center bolt. Using Crankshaft Pulley
correct, repeat timing belt tensioning procedure. Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn
aligned.
578 MITSUBISHI
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.
wise.
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 SPECIFI-
CATIONS. Install accessory mount assembly on front of engine. See
Fig. 13. See TORQUE SPECIFICATIONS. To install remaining compo-
nents, 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, separa-
tion, worn or missing teeth, or hardened black surface. Replace belt if Courtesy of Mitsubishi Motor Sales of America.
worn, damaged or contaminated. Inspect belt tensioner pulley for
Fig. 7: Exploded View Of Air Cleaner Assembly (2001-02 Montero)
smooth rotation. Replace if defective.
2) Check timing belt auto-tensioner for leaks. Hold timing belt auto-
tensioner 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.
MITSUBISHI 579
Fig. 8: Exploded View Of Drive Belt Components (2001-02 Montero)
Fig. 9: Removing Drive Belt Auto Tensioner (2001-02 Montero)

580 MITSUBISHI
Fig. 10: Exploded View Of Timing Belt Components (2001-02 Montero)
Fig. 11: Aligning Timing Marks (2001-02 Montero)

MITSUBISHI 581

TORQUE SPECIFICATIONS (1997-00 MONTERO & 1999-04 MONTERO SPORT)
Accessory Mount Assembly Bolt
12 x 100 Bolt ........................................................................................................... 54 (74)
All Other Bolts ......................................................................................................... 33 (44)
Auto-Tensioner Bolt ................................................................................................... 18 (24)
Generator Bottom Bolt .............................................................................................. 16 (22)
Generator Pivot (Upper) Bolt .................................................................................... 38 (52)
Courtesy of Mitsubishi Motor Sales of America. Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Fig. 12: Adjusting Timing Belt Tensioner (2001-02 Montero) 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 Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1
TORQUE SPECIFICATIONS (2001-02 MONTERO)

Fig. 13: Installing Accessory Mount Assembly Bolts Accessory Mount Assembly Bolt
(2001-02 Montero) 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)
Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186)
Courtesy of Mitsubishi Motor Sales of America. Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54)
Fig. 14: Checking Timing Belt Auto-Tensioner Movement INCH Lbs. (N.m)
Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 88-104 (10-12)
TORQUE SPECIFICATIONS Radiator Shroud Bolt ..................................................................... ..................... 35-53 (4-6)
TORQUE SPECIFICATIONS (DIAMANTE) Timing Mark Indicator Plate Bolt .................................................. ............... 88-104 (10-12)
Application Ft. Lbs. (N.m) Water Pump Pulley Nuts .............................................................. ............... 88-104 (10-12)
1
Auto-Tensioner Bolt ................................................................................................... 17 (23) – Apply engine oil to bolt threads before installation.
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 Tensioner Arm Pivot Bolt ....................................................................... 33 (44)
Water Pump Bolt
M8 Bolt .................................................................................................................... 17 (23)
M10 Bolt .................................................................................................................. 30 (41)
INCH Lbs. (N.m)
Timing Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1
2
– Arrow on engine mount plates must face toward front of vehicle.
582 MITSUBISHI
3.8L V6 – SOHC – Endeavor & Galant
TIMING BELT APPLICATION Inspection – 1) Inspect timing belt for wear on edges of drive teeth.
Application Labor Time Belt Inspect belt for signs of oil contamination, cracks, separation, worn or
Part No. missing teeth, or hardened back surface. Replace belt if worn, damaged
3.8L V6 – SOHC or contaminated. Inspect belt tensioner pulley for smooth rotation.
Endeavor & Galant Replace if defective.
2004 ........................................................... 3.0 Hours ... ..... T287 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
NOTE: For information about tensioners and/or pulleys (when protrusion above edge of housing. See Fig. 4. Apply 22-44 lbs. (98-196
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED compress the push rod. If there is a plug at the base of the auto-
SCHEDULED MAINTENANCE tensioner body, place flat washer around plug so it will not contact vise
jaw.
except in California, Massachusetts and Vermont. In California, Massa- CAUTION: Never compress the auto-tensioner too fast, or the push
chusetts and Vermont, timing belt replacement is recommended, but not rod will be damaged.
required, at 60,000 miles. In these states, replace timing belt at 100,000 2) Slowly compress auto-tensioner push rod until holes in push rod and
miles, unless previously changed. auto-tensioner housing are aligned. Insert a locking pin into the align-
REMOVAL & INSTALLATION on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water
CAUTION: This application is an interference engine. Do not rotate slack out of timing belt.
camshaft or crankshaft when timing belt is removed, or engine 4) Loosen the tensioner pulley center bolt. Rotate tensioner pulley
damage may occur. against timing belt. Temporarily tighten tensioner pulley center bolt. Turn
crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clock-
wise. Ensure all timing belt marks are still aligned.
TIMING BELT 5) Loosen tensioner pulley center bolt. Position tensioner pin holes at
Removal – 1) On Galant, remove engine cover. On all models, remove bottom of tensioner. Install Adapter (MD998767) on tensioner pulley.
skid plate and under cover. Remove accessory drive belts. Using Pulley See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque
Holder (MB991800) and Pins “B” (MB001802), remove crankshaft (counterclockwise direction) to tensioner pulley. Tighten tensioner cen-
pulley. ter bolt to specification while holding tensioner pulley stationary. See
2) Disconnect harness connectors on connector bracket. See Fig. 1 or 2. TORQUE SPECIFICATIONS.
Remove connector bracket. Remove engine mount support bracket. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolu-
Remove both upper timing belt covers. tions clockwise and align all timing marks. DO NOT rotate counterclock-
3) Remove tensioner pulley and tensioner bracket. Remove crankshaft wise.
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 Clearance should be 0.19-0.24″ (4.8-6.0 mm). If protrusion is not
viewed from front of engine). correct, repeat timing belt tensioning procedure.
8) Install timing belt covers. Install crankshaft pulley. Using Pulley Holder
4) Turn crankshaft clockwise to align camshaft and crankshaft timing (MB991800) and Pins “B” (MB001802), tighten crankshaft pulley bolt to
marks. See Fig. 3. If timing belt is to be reused, place arrow on belt to specification. See TORQUE SPECIFICATIONS. To complete installa-
indicate direction of belt rotation. tion, reverse removal procedure.
5) Loosen belt tensioner pulley center bolt. Remove timing belt. Remove
timing belt auto-tensioner.
MITSUBISHI 583
3.8L V6 – SOHC – Endeavor & Galant (Cont.)
Fig. 1: Exploded View Of Timing Belt Components (Endeavor)

584 MITSUBISHI
Fig. 2: Exploded View Of Timing Belt Components (Galant)

MITSUBISHI 585

Crankshaft Pulley Bolt ................................................................... ....... 1 134-140 (180-190)
Engine Mount Bracket-To-Engine Bolt .......................................... ................. 31-37 (42-48)
INCH Lbs. (N.m)
1
Fig. 4: Checking Timing Belt Auto-Tensioner Movement

586 MITSUBISHI
3.8L V6 – SOHC – Montero
TIMING BELT APPLICATION 2) Remove accessory drive belt. Remove cooling fan and pulley.
Application Labor Time Belt Remove drive belt auto tensioner. Remove accessory mount support.
Part No. See Fig. 1.
3.8L V6 – SOHC 3) Remove power steering pump with hoses connected, and set aside.
Montero Remove A/C compressor from bracket (hoses connected), and set
2003-04 ..................................................... 3.9 Hours ... ..... T320 aside. Remove A/C compressor bracket. Remove cooling fan bracket.
Remove accessory mount assembly.
NOTE: For information about tensioners and/or pulleys (when 4) Remove upper timing belt cover. See Fig. 2. Using Pulley Holder
available), see ALPHABETICAL MODEL LISTING. (MB991800 or MB991800-01) and Pin (MB991802 or MB991802-01) to
hold crankshaft pulley stationary, remove crankshaft pulley bolt.
SCHEDULED MAINTENANCE CAUTION: Always turn crankshaft in clockwise direction (as
except in California, Massachusetts and Vermont. In California, Massa- 5) Remove timing belt indicator bracket. Remove lower timing belt cover.
chusetts and Vermont, timing belt replacement is recommended, but not Turn crankshaft clockwise to align camshaft and crankshaft timing
required, at 60,000 miles. In these states, replace timing belt at 100,000 marks. See Fig. 3.
miles, unless previously changed. 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
REMOVAL & INSTALLATION belt. Remove timing belt auto-tensioner.
Inspection – 1) Inspect timing belt for wear on edges of drive teeth.
CAUTION: This application is an interference engine. Do not rotate Inspect belt for signs of oil contamination, cracks, separation, worn or
camshaft or crankshaft when timing belt is removed, or engine missing teeth, or hardened back surface. Replace belt if worn, damaged
damage may occur. or contaminated. Inspect belt tensioner pulley for smooth rotation.
Replace if defective.
2) Check timing belt auto-tensioner for leaks. Hold timing belt auto-
TIMING BELT tensioner upright. Measure rod protrusion above edge of housing. See
Removal – 1) Remove skid plate and under cover. Drain engine coolant. Fig. 4. Length should be .461-.484″ (11.7-12.3 mm). Apply 22-44 lbs.
Remove battery and battery tray. Remove air cleaner and intake air (98-196 N) of force to end of rod. If auto tensioner rod moves more than
duct. Remove upper radiator hose. Remove radiator shroud. Loosen 0.39″ (1 mm), replace the auto-tensioner.
cooling fan clutch-to-pulley nuts.

MITSUBISHI 587
3.8L V6 – SOHC – Montero (Cont.)
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 auto-
tensioner body, place flat washer around plug so it will not contact vise
jaw.

slack out of timing belt.
Courtesy of Mitsubishi Motor Sales of America. 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 clock-
wise. Ensure all timing belt marks are still aligned.
588 MITSUBISHI
3.8L V6 – SOHC – Montero (Cont.)
5) Loosen tensioner pulley center bolt. Position tensioner pin holes at TORQUE SPECIFICATIONS
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 TORQUE SPECIFICATIONS
(counterclockwise direction) to tensioner pulley. Tighten tensioner cen- Application Ft. Lbs. (N.m)
ter bolt to specification while holding tensioner pulley stationary. See Accessory Mount Assembly Bolt 1
TORQUE SPECIFICATIONS. Bolt “A” (10 x 100 mm) .............................................................. ................. 24-36 (33-49)
6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolu- Bolt “B” (10 x 30 mm) ................................................................ ................. 24-36 (33-49)
tions clockwise and align all timing marks. DO NOT rotate counterclock- Bolt “C” (10 x 100 mm) .............................................................. ................. 26-40 (34-54)
wise. Bolt “D” (12 x 100 mm) .............................................................. ................. 47-61 (65-83)
7) Wait for at least 5 minutes, then check auto-tensioner push rod Bolt “E” (8 x 30 mm) .................................................................. ................. 15-19 (20-26)
Bolt “F” (10 x 100 mm) ............................................................... ................. 32-40 (44-54)
body of auto-tensioner and bottom of tensioner pulley bracket arm. Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98)
Clearance should be 0.15-0.20″ (3.8-5.0 mm). If protrusion is not Cooling Fan Bracket Bolt .............................................................. ................. 24-36 (33-49)
correct, repeat timing belt tensioning procedure. Crankshaft Pulley Bolt ................................................................... ....... 2 134-140 (180-190)
8) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft Power Steering Pump Bolt ........................................................... ................. 13-19 (18-26)
pulley bolt to specification. See TORQUE SPECIFICATIONS. Install Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49)
accessory mount assembly on front of engine. Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54)
9) To complete installation, reverse removal procedure. When filling
cooling system, use 50/50 mix of coolant and water. Open bleed screw INCH Lbs. (N.m)
on top of thermostat housing. Slowly fill cooling system until coolant Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 89-106 (10-12)
flows out of bleed hole. Install bleed screw. Start engine and run to Timing Belt Cover Bolt .............................................................................................. 97 (11)
normal operating temperature. Race engine to 3000 RPM several times. 1
– For bolt identification and locations, see Fig. 6.
Stop engine. After engine cools, refill radiator and coolant reservoir tank. 2
Fig. 6: Identifying Accessory Mount Assembly Bolts

NISSAN 589

1
Kit No. Part No.
Sentra
1982-83 ............................ .... 2.8 Hrs. .... .. TCK077 .. ..... T077
Pulsar NX (Includes Canadian)
1983-84 ............................ .... 3.0 Hrs. .... .. TCK077 .. ..... T077
310
1982 ................................. .... 5.8 Hrs. .... .. TCK077 .. ..... T077
Pulsar & Pulsar NX
1983-88 ............................ .... 2.3 Hrs. .... .. TCK077 .. ..... T077
Sentra
1983-88 ............................ .... 2.8 Hrs. .... .. TCK077 .. ..... T077
1


MANUFACTURER’S SUGGESTED Courtesy of Nissan Motor Co., U.S.A.
SCHEDULED MAINTENANCE Fig. 1: Exploded View of Timing Belt & Components

On 1982-85 models, although the manufacturer does not recommend a
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.

damage may occur.
TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshaft separately with
timing belt removed. Valves will contact piston and may cause Fig. 2: Aligning Timing Marks
damage.
Removal – 1) Disconnect negative battery cable. Place crankshaft on
TDC of compression stroke. Remove spark plugs. Remove right front TORQUE SPECIFICATIONS (1.5L)
under engine cover and splash cover. Remove accessory drive belts. Application Ft. Lbs. (N.m)
Remove water pump pulley and crankshaft pulley. On 1988 models, Camshaft Sprocket Bolt ................................................................ ................. 29-35 (39-48)
support engine with a jack under oil pan and remove right side engine Crankshaft Pulley Bolt ................................................................... ......... 108-145 (147-197)
mount. Crankshaft Pulley Damper Bolt .................................................... ............. 90-98 (123-132)
2) On all models, remove upper and lower timing belt cover. See Fig. 1.
INCH Lbs. (N.m)
Check timing mark alignment. See Fig. 2. Mark timing belt rotation
direction for installation reference. Loosen timing belt tensioner and Camshaft Lockplate ....................................................................... ..................... 35-43 (4-5)
retain tensioner away from timing belt. Remove timing belt. Remove Timing Belt Tensioner .................................................................... ..................... 52-70 (6-8)
tensioner and spring (if necessary). See Fig. 1.
TORQUE SPECIFICATIONS (1.6L)
CAUTION: Camshaft sprockets have 2 marks on them. Ensure the Application Ft. Lbs. (N.m)
correct mark is aligned. See Fig. 2. Crankshaft Pulley Bolt ................................................................................ 80-94 (108-127)
Installation – 1) Ensure camshaft and crankshaft sprocket timing marks Timing Belt Tensioner Lock Nut .................... ................................................. 12-15 (16-21)
are aligned at TDC on compression stroke. See Fig. 2. Install timing belt INCH Lbs. (N.m)
tensioner so no tension will be applied to belt during installation (if Camshaft Sprocket Bolt ................................. ........................................... 78-104 (8.8-11.8)
removed). If installing removed belt, properly position rotation direction Jackshaft Sprocket Bolt ................................. ........................................... 78-104 (8.8-11.8)
mark made at removal. Timing Belt Cover ......................................................................................... 46-58 (5.2-6.6)
2) Install timing belt, keeping belt tight on jackshaft and camshaft Valve Cover Bolt
sprockets side. Loosen tensioner and allow tension to be applied to 1st Step ....................................................................................................... 17-35 (1.9-4.0)
timing belt. Rotate camshaft sprocket 20 degrees (2 cogs) clockwise. 2nd Step ..................................................................................................... 35-52 (4.0-5.9)
3) Using a screwdriver, prevent tensioner from turning and tighten Water Pump Bolt .......................................................................................... 46-58 (5.2-6.6)
tensioner lock nut. Recheck timing mark alignment. Ensure ignition rotor Water Pump Pulley Bolt ............................................................................. 74-96 (8.4-10.9)
is firing No. 1 cylinder. To complete installation, reverse removal
590 NISSAN
1.6L & 1.8L 4-Cylinder – DOHC
1
Part No.
Pulsar
1987 ........................................................... 3.8 Hours ... ..... T137
Pulsar NX
1988-89 ..................................................... 3.8 Hours ... ..... T137
1

REMOVAL & INSTALLATION Courtesy of Nissan Motor Co., U.S.A.

damage may occur.
TIMING BELT
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. Fig. 2: Aligning Timing Marks
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 specifi-
cation. See TORQUE SPECIFICATIONS. Ensure all marks are aligned.
Install timing belt covers. Courtesy of Nissan Motor Co., U.S.A.
4) Install crankshaft pulley and washer. Install engine mount. Install
crank angle sensor and water pump pulley. Ensure reference marks on Fig. 3: Removing Camshaft Sprocket
crank angle sensor are aligned. Tighten bolts to specification. See
5) Install accessory drive belts. Adjust drive belts to proper tension.
Install upper radiator hose and refill cooling system.
NISSAN 591
1.6L & 1.8L 4-Cylinder – DOHC (Cont.)

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)
592 NISSAN
Part No.
Sentra (Includes Canadian)
1983-87
Camshaft ................................................ 4.0 Hours ... ..... T096
1

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.
Fig. 1: Installing Camshaft Timing Belt

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. Courtesy of Nissan Motor Co., U.S.A.
Fig. 2: Installing Injection Timing Belt

INJECTION PUMP BELT
Removal – Disconnect negative battery cable. Remove timing belt TORQUE SPECIFICATIONS
cover from rear of engine. Loosen injection timing belt tensioner.
Remove injection timing belt.
Installation – Install injection timing belt. Ensure reference marks are Application Ft. Lbs. (N.m)
23 cogs apart. See Fig. 2. Rotate crankshaft 2 revolutions in normal Camshaft Pulley Bolt ..................................................................... ................. 68-75 (18-22)
direction of rotation. Tighten tensioner bolt while holding it to keep it from Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132)
Front Tensioner Bolt ...................................................................... ................. 27-33 (36-34)
rotating. To complete installation, reverse removal procedure.
Rear Tensioner Bolt ...................................................................... ................. 12-15 (16-21)
INCH Lbs. (N.m)
NISSAN 593

Kit No. Part No.
1
1984-87 .............................. 2.0 Hours .. ...... ..... ...... ..... T100
2.0L 4-Cyl.
Stanza & Stanza Wagon
1
1982-89 .............................. 4.4 Hours .. .. TCK078 .. ..... T078
1
1984-87 .............................. 2.0 Hours ... TCK078A . ..... T078
1
1988 ................................... 2.0 Hours .. .. TCK078 .. ..... T078
1

available), see ALPHABETICAL MODEL LISTING. Courtesy of Nissan Motor Co., U.S.A.
Fig. 1: Timing Belt Alignment Procedure

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.

CAUTION: The 2.0L is an interference engine. Do not rotate cam-
shaft 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 Fig. 2: Adjusting Timing Belt Tension
crankshaft until No. 1 cylinder is at TDC on compression stroke.
Remove cooling fan, radiator shroud and accessory drive belts. TORQUE SPECIFICATIONS
NOTE: After timing belt is removed, do not rotate crankshaft or TORQUE SPECIFICATIONS (1982-88)
camshaft. Application Ft. Lbs. (N.m)
2) Remove upper and lower dust cover mount bolts. Remove upper and Camshaft Pulley Bolt ..................................................................... ................. 10-14 (14-19)
lower covers and gaskets. Remove timing belt tensioner, bracket, and
Engine Mount Bolt ......................................................................... ................. 29-40 (39-54)
timing belt. Idler Nut ......................................................................................... ................. 23-31 (31-42)
Removal (1989) – 1) Disconnect negative battery cable. Raise and Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30)
support vehicle. Remove right front wheel. Remove exhaust side spark Water Pump Bolt ........................................................................... ................. 12-14 (16-19)
plugs. Turn crankshaft until No. 1 cylinder is at TDC on compression INCH Lbs. (N.m)
stroke. Remove dust cover and undercovers. Remove belts.
2) Support engine with a chain hoist. Remove right side engine mount
Front Cover Bolts .......................................................................... ..................... 27-43 (3-5)
and bracket. Remove upper and lower timing belt covers and gaskets. Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8)
Remove timing belt tensioner, bracket and timing belt.
Installation (All Models) – 1) Do not tighten tensioner bolts to final TORQUE SPECIFICATIONS (1989)
specification before drive belt is installed. Install timing belt. Align belt Application Ft. Lbs. (N.m)
mark to camshaft and crankshaft sprocket marks. See Fig. 1.
Camshaft Lock Plate Bolt ............................................................. ................. 58-65 (78-88)
2) Tighten belt tensioner and assemble spring. To set spring, hook one Camshaft Sprocket Bolt ................................................................ ................. 58-65 (78-88)
end on bolt “B” side and hook the other end on tensioner bracket pawl. Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132)
Tighten bolt “B”, and then bolt “A”. See Fig. 2. Engine Mount Bolt ......................................................................... ................. 29-40 (39-54)
3) Belt tension will automatically be at the specified value. Install lower Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30)
front cover with gaskets, and tighten mount bolts. Install plate and front INCH Lbs. (N.m)
pulley damper. Complete installation by reversing removal procedure.
Adjust drive belts to proper tension. Front Cover Bolts .......................................................................... ..................... 27-43 (3-5)
Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8)
594 NISSAN
3.0L V6 – DOHC
TIMING BELT APPLICATION 2) Lock flywheel/flexplate to prevent crankshaft from rotating. Remove
Application 1
Labor Time Belt crankshaft pulley bolt and pulley. Remove water inlet and outlet hoses.
Part No. Remove timing belt front covers. Remove spark plugs.
3.0L V6 – DOHC 3) Install a stopper bolt (M6 x 16) into timing belt tensioner arm to
300ZX maintain tensioner position. See Fig. 1. Set cylinder No. 1 at TDC of
1990-93 ..................................................... 4.6 Hours ... ..... T180 compression stroke by rotating crankshaft until timing marks align.
1994-96 ..................................................... 4.6 Hours ... ..... T251 Remove timing belt tensioner and timing belt.
1
– With Air Conditioning, add .3 hours. Inspection – Replace timing belt if cracked, worn or saturated with oil or
With Power Steering, add .3 hours. coolant. Replace tensioner if it leaks oil.
Installation – 1) Ensure cylinder No. 1 is at TDC of compression stroke.
NOTE: For information about tensioners and/or pulleys (when See Fig. 1. Measure clearance between tensioner arm and tensioner
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 2) Remove tensioner. Remove stopper bolt. Using a vise, adjust
SCHEDULED MAINTENANCE clearance until it is as specified. Install stopper bolt in tensioner to
For 1990-92 models, the manufacturer recommends the belt be maintain clearance. Install tensioner. Hand-tighten tensioner nut and
replaced every 60,000 miles. On 1993 convertible models, the manu- bolts.
facturer recommends the belt be replaced every 60,000 miles. On 1993 3) Install timing belt with arrow on timing belt facing front of engine. Align
non-convertible models, the manufacturer recommends the belt be White lines on timing belt with marks on camshaft sprockets and
replaced every 105,000 miles. On 1994-96 turbocharged models, the crankshaft sprocket. White lines ensure correct number of teeth exist
manufacturer recommends the belt be replaced every 60,000 miles. On between timing marks on sprockets.
1994-96 non-turbocharged models, the manufacturer recommends the 4) Push tensioner gently toward timing belt to prevent belt from slipping
belt be replaced every 105,000 miles. (excessive pressure will overtighten belt). Maintain light pressure on
tensioner.
5) Turn crankshaft clockwise 10 degrees. Tighten tensioner bolts and
REMOVAL & INSTALLATION nut. See TORQUE SPECIFICATIONS. Turn crankshaft counterclock-
wise 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
damage may occur.
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
TIMING BELT tensioner nut and bolts.
Removal – 1) Disconnect negative battery cable. Remove engine 7) Turn crankshaft 120 degrees clockwise, then turn it 120 degrees
undercover. Drain coolant from radiator and cylinder block. Remove counterclockwise to TDC. Fabricate a small steel plate. See Fig. 3. Set
radiator. Remove accessory drive belts. Remove cooling fan and plate at each position shown (“A”, “B”, “C” and “D”).
coupling. Remove starter.
Fig. 1: Installing Timing Belt & Tensioner

NISSAN 595

8) Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Measure and TORQUE SPECIFICATIONS
record timing belt deflection in each position. Divide sum of measure-
ments (“A” + “B” + “C” + “D”) by 4 to obtain average. TORQUE SPECIFICATIONS
9) Average timing belt deflection should be .24-.28″ (6-7 mm). If Application Ft. Lbs. (N.m)
deflection is not as specified, repeat steps 4)-8). If timing belt deflection Camshaft Sprocket Bolts
is excessive, change amount of pushing force applied in step 6). Exhaust ........................................................................................ ................. 10-14 (14-19)
10) Remove tensioner stopper bolt. After 5 minutes, ensure clearance Intake ........................................................................................... ............. 90-98 (122-133)
between pusher rod and tensioner arm is .138-.205″ (3.5-5.2 mm). Crankshaft Pulley Bolt ................................................................... ......... 159-174 (216-236)
Check for slippage or misplacement of timing belt at each sprocket. Timing Belt Idler Pulley Nut .......................................................... ................. 32-43 (43-58)
Install timing belt covers. To complete installation, reverse removal Timing Belt Tensioner Lock Nut ................................................... ................. 12-15 (16-20)
Water Pump Bolt ........................................................................... ................. 12-15 (16-20)
INCH Lbs. (N.m)

596 NISSAN
3.0L V6 – SOHC
Kit No. Part No.
3.0L V6 – SOHC
Maxima
1985-88 ............................ ... 1 6.0 Hrs. ... .. TCK104 .. ..... T104
1989-91 ............................ .... 5.7 Hrs. .... .. TCK104 .. ..... T104
1992-94
With Round Tooth
Sprocket .................... .... 5.7 Hrs. .... .. TCK249 .. ..... T249
With Square Tooth
Pathfinder & Pickup
1986-92 ............................ .... 4.5 Hrs. .... .. TCK104 .. ..... T104
1993-94
With Round Tooth
With Square Tooth
1995-96 ............................ .... 4.5 Hrs. .... .. TCK249 .. ..... T249 Courtesy of Nissan Motor Co., U.S.A.
Quest
1993-94 Fig. 1: Exploded View Of Timing Belt & Components
With Round Tooth
2) Turn tensioner clockwise and temporarily tighten lock nut. Install
With Square Tooth timing belt. Align White lines on timing belt with punch mark on camshaft
Sprocket .................... .... 3.6 Hrs. .... .. TCK104 .. ..... T104 pulleys and crankshaft pulley. Arrow on timing belt must be pointing
1995-98 ............................ .... 3.6 Hrs. .... .. TCK249 .. ..... T249 toward front belt covers.
200SX 3) Using Allen wrench, slowly turn tensioner clockwise and counter-
1987-88 ............................ .... 4.8 Hrs. .... .. TCK104 .. ..... T104 clockwise 2 or 3 times. When camshafts and crankshaft marks are
300ZX aligned, tighten tensioner lock nut. See Fig. 2. Ensure that camshaft
1984-89 ............................ .... 6.0 Hrs. .... .. TCK104 .. ..... T104 lobes are correctly positioned. Tighten rocker shaft bolts in 2 stages.
1
– With Air Conditioning add .3 hours. 4) Refill and bleed air from cooling system. To complete installation,
With Power Steering, add .3 hours. reverse removal procedures. Adjust drive belts to proper tension.

specific scheduled maintenance interval, belt manufacturers suggest Courtesy of Nissan Motor Co., U.S.A.
the belt be replaced at 60,000 mile intervals. On 1986 and later models, Fig. 2: Adjusting Timing Belt
the manufacturer recommends the belt be replaced every 60,000 miles.
Removal (Maxima & Quest) – 1) Disconnect negative battery cable.
REMOVAL & INSTALLATION Raise and support vehicle. Remove covers from below engine. Drain
cooling system. Remove right front wheel and engine side cover.
CAUTION: This application is an interference engine. Do not rotate Remove accessory drive belts. Remove crankshaft pulley bolt and
camshaft or crankshaft when timing belt is removed, or engine pulley.
damage may occur. 2) Remove upper radiator hose and water inlet hose. Remove A/C
compressor idler pulley and bracket. Remove water pump pulley.
TIMING BELT Remove upper and lower timing belt front covers. See Fig. 1.
Removal (200SX & 300ZX) – 1) Disconnect negative battery cable. 3) Temporarily install crankshaft pulley bolt so crankshaft can be rotated.
Release fuel pressure from system. Raise and support vehicle. Remove Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft
right wheel and engine side cover (if necessary). Drain cooling system. until marks on camshaft sprockets align with marks on timing belt upper
Remove cooling fan duct. Remove engine coolant reservoir. Remove rear cover, and mark on crankshaft sprocket aligns with mark on front
actuator and remove radiator hoses. Do not allow coolant to contact cover housing. See Fig. 3.
drive belts. 4) Loosen timing belt tensioner nut. Release tension on belt. Remove
2) Remove front upper and lower belt covers. See Fig. 1. Remove drive timing belt. Check timing belt tensioner, spring and timing belt.
belts and set No. 1 cylinder at TDC of compression stroke. Remove idler
Installation (Maxima & Quest) – 1) Ensure cylinder No. 1 is at TDC of
bracket of compressor drive belt and crankshaft pulley. Remove timing
compression stroke. See Fig. 3. Install tensioner and return spring if
belt by removing timing belt tensioner and return spring.
removed. If return spring stud was removed, apply thread lock sealant to
Inspection (200SX & 300ZX) – Visually inspect condition of timing belt.
threads before installing stud. Insert an Allen wrench into hole in
Inspect for cracks, wear, breaks, and oil/coolant saturation.
Installation (200SX & 300ZX) – 1) Ensure that piston No. 1 is at TDC tensioner, turn tensioner fully clockwise, and temporarily tighten lock
of compression stroke. Remove valve covers and loosen all rocker shaft nut.
bolts. Do not bend timing belt. Install tensioner and return spring.
NISSAN 597

wise 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.
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;
Courtesy of Nissan Motor Co., U.S.A. valves will contact pistons, resulting in bent valves.
Fig. 3: Installing Timing Belt & Sprocket Removal (Pathfinder & Pickup) – 1) Remove covers from below
2) Install timing belt with arrow on timing belt facing front of engine. Align engine. Drain and remove radiator. Remove cooling fan and water pump
White lines on timing belt with marks on camshaft sprockets and pulley. Remove accessory drive belts. Remove spark plugs. Remove
crankshaft sprocket. White lines ensure correct number of teeth exist distributor protector. Remove A/C compressor idler pulley and bracket.
between timing marks on sprockets. 2) Remove fresh air tube from cylinder head cover. Remove thermostat
3) Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by housing coolant hose. Remove crankshaft pulley bolt and pulley.
turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock Remove upper and lower timing belt front covers. See Fig. 4. Tempo-
nut. Rotate crankshaft clockwise at least 2 revolutions. rarily install crankshaft pulley bolt to rotate crankshaft.
4) Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull 3) Set cylinder No. 1 at TDC of compression stroke by aligning marks on
Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to camshaft sprockets with marks on timing belt upper rear cover, and
timing belt between right camshaft sprocket and tensioner. Hold ten- mark on crankshaft sprocket with mark on front cover housing. See
sioner in position with Allen wrench, and loosen tensioner lock nut. Fig. 5. Loosen timing belt tensioner. Remove timing belt. Check timing
5) Place a .0138″ (.351 mm) feeler gauge at tensioner pulley and timing belt tensioner, spring and timing belt.
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.

598 NISSAN
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. Fig. 5: Installing Timing Belt & Sprocket
wise at least 2 revolutions until cylinder No. 1 is at TDC of compression TORQUE SPECIFICATIONS
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. Application Ft. Lbs. (N.m)
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)
OPTIMA 599

Kit No. Part No.
1.6L 4-Cyl.
Optima (Canadian)
1
1988-91 .............................. 2.9 Hours .. ...... ..... ...... ..... T148
2.0L 4-Cyl.
Optima (Canadian)
1
1988-89 .............................. 2.9 Hours .. ...... ..... ...... ..... T081
1
1990-91 .............................. 2.9 Hours .. .. TCK163 .. ..... T163
1


maintenance interval, belt manufacturers suggest the belt be replaced at Fig. 1: Exploded View Of Timing Belt & Components (2.0L)
60,000 mile intervals. 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
REMOVAL & INSTALLATION (J-33039-A) or equivalent to rotate water pump eccentric until tensioner
TIMING BELT touches stop. Slightly tighten water pump attaching bolts.
2) Rotate crankshaft clockwise 2 revolutions. Rotate water pump
Removal (1.6L) – Disconnect negative battery cable. Remove acces-
eccentric counterclockwise until hole in tensioner arm is in line with hole
sory drive belts. Remove power steering pump. Remove timing belt in base. Tighten water pump attaching bolts and make sure tensioner
cover. Remove air cleaner. Mark all hoses for installation reference and holes are still aligned. To complete installation, reverse removal proce-
disconnect hoses from valve cover. Remove valve cover. Remove dure. Adjust drive belt to proper tension.
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. TORQUE SPECIFICATIONS
Removal (2.0L) – 1) Disconnect negative battery cable. Remove drive Application Ft. Lbs. (N.m)
belt. Remove power steering pump and bracket. Remove serpentine Water Pump Bolts ..................................................................................................... 18 (24)
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.
600 PEUGEOT
1.9L 4-Cylinder
Part No.
1.9L 4-Cyl.
405
1989-91
DOHC ...................................................... 4.0 Hours ... ..... T188
SOHC ...................................................... 4.0 Hours ... ..... T189


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 compart-
ment.
2) Remove alternator drive belt, then alternator. Support engine.
Courtesy of Peugeot Motors of America, Inc.
Remove upper engine mount and two upper cover bolts. Tilt engine and
transmission assembly as far as possible. Disconnect wiring harnesses Fig. 1: Installing Camshaft & Crankshaft Sprocket Locking Pins
from relay box, then pull up on clip and lift upper cover upward. (DOHC)
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 crank-
shaft 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 Fig. 2: Installing Timing Belt & Tensioning Tool (DOHC)
pins. Install lower cover. Lock flywheel in position with Peugeot Lock
Tool (J-36358) or equivalent. Install crankshaft pulley. Removal (SOHC) – 1) Disconnect negative battery cable. Remove right
6) To complete installation, reverse removal procedure. Adjust drive mud shield. Remove A/C compressor and alternator drive belts.
belts to proper tension. Remove upper timing belt cover. Rotate crankshaft using pulley bolt,
PEUGEOT 601

aligning holes in camshaft sprocket and crankshaft pulley for pin Installation (SOHC) – 1) Position crankshaft pulley and key to crank-
installation. Insert Peugeot Locking Pin Tool (No. 0-0163), or equivalent, shaft, then loosely install crankshaft pulley retaining bolt. Insert Peugeot
through camshaft sprocket and crankshaft pulley locking pin holes. See Locking Pin Tool (No. 0-0163), or equivalent, through camshaft sprocket
Figs. 3 and 4. and crankshaft pulley locking pin holes. See Figs. 3 and 4.
2) Remove locking pins. Remove lower flywheel cover. Using Flywheel 2) Remove crankshaft retaining bolt and pulley. Install timing belt over
Stop Tool (No. 91-86) or equivalent, lock flywheel in position. Remove camshaft sprocket, crankshaft sprocket and water pump sprocket, then
crankshaft pulley retaining bolt and crankshaft pulley. Remove stop tool position timing belt on tensioner pulley. Ensure timing belt is properly
that was used to lock flywheel in position. seated on sprockets. Loosen tensioner nut, then turn tensioner square
3) Remove upper portion of timing belt lower cover. Remove lower to release spring.
3) Remove locking pins, then tighten tensioner retaining nuts. Rotate
portion of timing belt lower cover. Loosen three timing belt tensioner
crankshaft 2 turns in direction of engine rotation, and bring No. 1 cylinder
nuts. Do not remove timing belt tensioner nuts. Push timing belt
to TDC of compression stroke. Loosen timing belt tensioner retaining
tensioner away from timing belt to relieve tension. Tighten tensioner
nuts to tension timing belt. After timing belt has tensioned, tighten
retaining bolt next to pulley to hold tensioner in position.
tensioner retaining bolts. Position crankshaft pulley and key to crank-
4) Remove timing belt from sprockets. shaft, 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.
Crankshaft Pulley Bolts
DOHC ...................................................................................................................... 18 (25)
SOHC ........................................................................................... .......................... 81 (111)
Timing Belt Tensioner Nut/Bolt
DOHC (4 Bolts) ....................................................................................................... 18 (26)
Fig. 3: Installing Camshaft Sprocket Timing Pin (SOHC) SOHC ....................................................................................................................... 12 (16)
Upper Engine Mount
DOHC ...................................................................................................................... 33 (45)
Fig. 4: Installing Crankshaft Sprocket Timing Pin (SOHC)

602 PEUGEOT
2.2L 4-Cylinder
Part No.
2.2L 4-Cyl.
505
1986-91 ..................................................... 2.7 Hours ... ..... T140


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. Fig. 1: Aligning Timing Marks
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. TORQUE SPECIFICATIONS
3) To complete installation, reverse removal procedures. Crankshaft
pulley bolt must be reinstalled using Loctite. Adjust drive belts to proper
tension. Crankshaft Pulley Bolts ........................................................................................... 98 (133)
Timing Belt Tensioner Nut/Bolt ................................................................................. 18 (26)
PORSCHE 603
2.0L 4-Cylinder
924 damage may occur.
1977-82 ............................... 1.0 Hours ... .. TCK017 .. ..... T017
NOTE: A timing belt component kit is available for this application. TIMING BELT
See page A1 for information on component kits. 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.
MANUFACTURER’S SUGGESTED Installation – To install components, reverse removal procedure. Belt
must be tightened until belt can be turned 90 degrees with thumb and
SCHEDULED MAINTENANCE index finger at a point midway between crankshaft and camshaft. Adjust
The manufacturer recommends that under normal operating conditions, drive belts to proper tension.
check tension at 2,000 miles, then every 15,000 miles. Replace belt
every 45,000 miles. TORQUE SPECIFICATIONS
Crankshaft Pulley .................................................................................................. 180 (245)
Tensioner Pulley ........................................................................................................ 29 (39)
INCH Lbs. (N.m)
Camshaft Sprocket Cover ......................................................................................... 84 (10)
604 PORSCHE
2.5L, 2.7L & 3.0L 4-Cylinder
TIMING BELT APPLICATION 2) Turn crankshaft clockwise to align camshaft sprocket TDC mark with
Application 1
Labor Time Belt mark in distributor cap console. See Fig. 2. Ensure mark on upper and
Part No. lower balance shaft sprockets align with mark on rear timing belt cover.
2.5L 4-Cyl. See Fig. 3.
924 3) The flywheel mark for No. 1 cylinder must also align with cast boss on
1987-88 clutch housing. On 1986 and earlier models, release belt tension. On
Balance Shaft ......................................... 3.2 Hours ... ..... T293 1987 and later models, mechanical belt tensioner must be removed.
Camshaft ................................................ 3.2 Hours ... ..... T107 See Fig. 4. Remove balance shaft drive belt. Loosen camshaft belt
944 tensioning sprocket lock nut and then sprocket by turning it clockwise.
1983-86 Remove camshaft timing belt.
Balance Shaft ......................................... 2.4 Hours ... ..... T293
Camshaft ................................................ 2.4 Hours ... ..... T107
1987-88
Camshaft ................................................ 3.2 Hours ... ..... T107
1989
Camshaft ................................................ 3.5 Hours ... ..... T107
944S
1987-88
Camshaft ................................................ 3.5 Hours ... ..... T152
2.7L 4-Cyl.
944
1989
Camshaft ................................................ 3.5 Hours ... ..... T107
Courtesy of Porsche of North America, Inc.
3.0L 4-Cyl.
944 Fig. 1: Loosening Pressure Rod
1989-91
Camshaft ................................................ 3.5 Hours ... ..... T152
968
1992-95
Camshaft .................................................. 3.4 Hours ... ..... T152
1


Fig. 2: Aligning Camshaft Sprocket Timing Mark
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 sys-
tem (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 Fig. 3: Aligning Upper Balance Shaft Timing Mark
lock nuts. See Fig. 1. Remove accessory drive belts.
PORSCHE 605
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 adjust-
ment 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 Courtesy of Porsche of North America, Inc.
mark on camshaft sprocket with mark on rear drive belt cover. Install Fig. 5: Identifying Drive Belt Positioning
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 Fig. 6: Installing Balance Shaft Drive Belt
nut. Install and adjust poly-rib belt.
606 PORSCHE
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

Part No.
4.5L V8
928
1978-82 ..................................................... 4.6 Hours ... ..... T196
4.7L V8
928
1983-84 ..................................................... 4.6 Hours ... ..... T196
5.0L V8
928
1985-86 ..................................................... 5.8 Hours ... ..... T196
1987-91 ..................................................... 6.5 Hours ... ..... T196
5.4L V8
928
1993-95 ..................................................... 6.5 Hours ... ..... T196


camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Identifying Camshaft Sprocket & Timing Belt Types
damage may occur.
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.
intake hoses. Remove accessory drive belts. Disconnect cables for Courtesy of Porsche of North America, Inc.
throttle, cruise control and automatic transaxle. Remove retainers and
clamp on console, and position cable aside. Remove clutch slave Fig. 2: Installing Camshaft Drive Belt
cylinder. clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until
timing marks (notches) on camshaft sprockets align with marks cast on
CAUTION: NEVER operate clutch pedal when slave cylinder is
camshaft bearing caps.
removed.
2) On 4.5L V8, align TDC mark on vibration damper with red indicator on NOTE: Manufacturer indicates sufficient clearance exists so pis-
cover. On 4.7L, 5.0L and 5.4L V8, align mark for 45 degrees BTDC on tons and valves will not collide when crankshaft is turned with
vibration damper with Red needle. Turn crankshaft clockwise. See camshaft timing belt removed.
Fig. 2. On 4.5L V8, rotate crankshaft clockwise until timing marks
2) Preload belt by hand and install belt on sprockets in order of
(notches) on camshaft sprockets align with marks cast on camshaft
crankshaft, oil pump, left camshaft, water pump, right camshaft and
bearing caps.
3) On 4.7L, 5.0L and 5.4L V8, lock crankshaft by installing Porsche Tool tension roller. See Fig. 2. Ensure belt and camshaft sprocket teeth
(9161/1) or equivalent. Secure tool with slave cylinder mounting bolts. match. If necessary, rotate camshaft counterclockwise until teeth match.
4) Remove crankshaft pulley mounting bolt, both pulleys, vibration Tighten timing belt to specification. Rotate engine 2 revolutions and align
damper and collar. Remove oil dipstick tube. Remove alternator. cylinder No. 1 at TDC of compression stroke.
Remove left upper and center timing belt covers. Loosen timing belt 3) Check camshaft timing marks for proper alignment and retighten
tensioner. Loosen tensioning roller. Remove timing belt. camshaft drive belt. Ensure tester is not turned or pushed during tension
Installation – 1) On 4.5L V8, align TDC mark on vibration damper with measurement. Recheck belt adjustment at least once. Adjust drive belts
Red indicator on cover. On 4.7L, 5.0L and 5.4L V8, align mark for 45 to proper tension.
degrees BTDC on vibration damper with Red needle. Turn crankshaft
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 Courtesy of Porsche of North America, Inc.
necessary. See TIMING BELT TENSION table. Adjustment screw is Fig. 3: Using Drive Belt Tension Tester
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.
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 Fig. 4: Exploded View of Timing Belt & Components
are open.
2) To fill, remove the larger oil filler and open Allen head bleeder screws TORQUE SPECIFICATIONS
on tensioner housing. Using an oil can, slowly pour oil into filler hole until TORQUE SPECIFICATIONS
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 Camshaft Housing Mounting Bolt ............................................................................. 14 (20)
Camshaft Pulley Mounting Bolt ................................................................................ 33 (45)
filler bolt. If oil can be seen, level is okay. If not, add oil as necessary.
Front Pulley Mounting Nut ............................................................ ......... 181-188 (250-260)
RENAULT 609
1.7L 4-Cylinder
1
Part No.
1.7L 4-Cyl.
Alliance & Encore
1985-87 ..................................................... 2.3 Hours ......... T119
1

Fig. 1: Identifying Camshaft Sprocket Alignment Marks
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 ten-
sioner 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. Fig. 2: Installing Timing Belt
NOTE: The intermediate shaft sprocket does not have a timing TORQUE SPECIFICATIONS
mark.
4) There should be 66 timing belt teeth (cogs) between camshaft
sprocket timing mark and crankshaft sprocket timing mark. See Fig. 2. Application Ft. Lbs. (N.m)
Remove TDC tool and install plug into cylinder block. Check timing belt Tensioner Pulley Lock Nut ........................................................................................ 30 (41)
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 counter-
clockwise 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.
610 RENAULT
2.2L 4-Cylinder
TIMING BELT APPLICATION Installation & Adjustment – 1) Position camshaft sprocket timing index
Application Labor Time Belt in line with static timing mark. See Fig. 1. Position crankshaft so No. 1
Part No. piston is at TDC of compression stroke. Remove plug in cylinder block
2.2L 4-Cyl. and insert TDC Rod (Mot. 861), or equivalent, into TDC hole in
Fuego crankshaft. Install timing belt. See Fig. 2.
1984-85 ..................................................... 2.2 Hours ... ..... T140 2) Position timing belt cover over sprockets and check camshaft timing
Sportwagon mark with index on cover. See Fig. 3. Remove TDC rod and install plug
1984-86 ..................................................... 2.0 Hours ... ..... T140 in cylinder block. Rotate crankshaft clockwise 2 complete revolutions.
DO NOT rotate counterclockwise. Remove timing belt cover and loosen
NOTE: For information about tensioners and/or pulleys (when timing belt tensioner bolts a maximum of 1/4 turn.
available), see ALPHABETICAL MODEL LISTING. 3) Spring loaded timing belt tensioner will automatically adjust to correct
position. Ensure clearance between timing belt tensioner and interme-
MANUFACTURER’S SUGGESTED diate shaft cover is .004″ (.10 mm). See Fig. 4. Tighten bottom timing
belt tensioner bolt. Tighten top bolt. Test belt tension with Tension Gauge
SCHEDULED MAINTENANCE (Ele. 343) or equivalent. See Fig. 5. Deflection should be .216-.276″
Although the manufacturer does not recommend a specific scheduled (5.5-7.0 mm). Install timing belt cover. To complete installation, reverse
maintenance interval, manufacturers suggest the belt be replaced at removal procedure. Adjust drive belts to proper tension.

TIMING BELT
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.
Fig. 1: Aligning Camshaft & Crankshaft Sprockets

RENAULT 611
Fig. 3: Identifying Timing Belt Cover TDC Marks
Fig. 4: Adjusting Intermediate Shaft Cover Clearance

612 SAAB
2.5L & 3.0L V6 – 1994-97
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


Courtesy of Saab-Scania of America, Inc.

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 Courtesy of Saab-Scania of America, Inc.
of way. Remove the timing belt cover. Remove the 6 outer bolts from the Fig. 2: Installing Camshaft Belt Holders
crankshaft pulley, NOT the center bolt.
4) Turn crankshaft so No. 1 cylinder is at TDC of compression stroke. TORQUE SPECIFICATIONS
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. Application Ft. Lbs. (N.m)
5) If belt is to be reused, mark belt with direction of rotation. Remove Camshaft Sprocket Bolt ............................................................................................ 37 (50)
timing belt from engine. Crankshaft Pulley Bolt ............................................................................................... 15 (20)
INCH Lbs. (N.m)
NOTE: Use the marks on each side of the direction of rotation
Valve Cover Nuts ...................................................................................................... 86 (10)
arrows to line up the left (driver’s 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.
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 installa-
tion, reverse removal procedure.
SAAB 613
3.0L V6 – DOHC – 1999-03

Part No.
9-5
1999-03 ....................................................... 2.4 Hours ... ..... T285
1

Manufacturer recommends belt be replaced every 90,000 miles.

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 Courtesy of Saab-Scania of America, Inc.
Fig. 3.
Fig. 2: Locating Mass Air Flow Sensor & Power Steering Hose
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.
Fig. 3: Removing Right Engine Attachment With Bracket & Mount

Inspection – Inspect timing belt for wear on rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if it is
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
Courtesy of Saab-Scania of America, Inc. tension. See Fig. 7.
Fig. 1: Removing Lower Spoiler Sections

614 SAAB
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 specifica-
tion. See TORQUE SPECIFICATIONS. Use Adjusting Wrench (83 94
983) as a counterstay. Check belt tension again and adjust as neces-
sary.
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 specifica- Courtesy of Saab-Scania of America, Inc.
tion. See TORQUE SPECIFICATIONS. Fig. 5: Releasing Timing Belt Tension
5) Remove Locking Tool for camshaft sprockets No. 1 and 2. Install
Adjustment Tool (KM-800-20). Adjust upper adjusting roller counter-
clockwise 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
6) Remove Adjustment Tool (KM-800-20) and other locking tools.
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
9) Install timing cover and tighten bolts to specification. See TORQUE
SPECIFICATIONS. Courtesy of Saab-Scania of America, Inc.
10) Install belt tensioner and generator air intake. Install coolant pump Fig. 6: Locking Camshaft & Crankshaft Sprockets
pulley and power steering pump pulley. Use Loctite. Do NOT tighten
bolts.
11) Install timing belt. Tighten retaining bolts on pulleys to specification.
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.

SAAB 615
3.0L V6 – DOHC – 1999-03 (Cont.)

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)
Fig. 8: Measuring Tension Roller Position

616 SATURN
3.0L V6 DOHC – L-Series After VIN 578512 & Vue
Application Labor Time Belt CAUTION: DO NOT remove Camshaft Holders (J-42069) with timing
Part No. belt removed.
3.0L V6 DOHC – VIN B
Vue CAUTION: DO NOT rotate crankshaft unless camshafts are prop-
2002-03 ..................................................... 3.0 Hours ... ..... T285
erly locked in place, or valves may contact pistons.
3.0L V6 DOHC – VIN R (After S/N 578512)
L300
2002-04 ..................................................... 3.2 Hours ... ..... T285 CAUTION: DO NOT rotate camshafts unless crankshaft in at 60°
LW300 BTDC, or valves may contact pistons.
2002-03 ..................................................... 3.2 Hours ... ..... T285

intervals.

camshaft or crankshaft when timing belt is removed, or engine Courtesy of General Motors Corp.
damage may occur.
Fig. 1: Positioning Crankshaft At 60° BTDC
TIMING BELT
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 Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks
necessary.
8) Rotate crankshaft clockwise to 60 degrees Before Top Dead Center Inspection – Check timing belt for excessive wear, cracks, missing
(BTDC). See Fig. 1. teeth, oil contamination or damage. Inspect timing belt tensioner and
9) Install Crankshaft Locking Tool (J-42069-10). Rotate the crankshaft in idler pulleys for grease leaks or worn bearings. Replace as necessary.
the engine rotational direction, clockwise, using the Crank Hub TORX
CAUTION: DO NOT kink belt or a NEW belt will be required.
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. Installation – 1) Remove crankshaft holder. This will ease installation of
the timing belt.
NOTE: Ensure timing marks are not 180 degrees from TDC. Cam-
shaft timing marks should be aligned with marks on rear cover. See NOTE: With the camshaft locks installed, verify the distance
Fig. 2. between the camshaft sprockets with the Green test belt located in
the Timing Belt Alignment Kit (J-42069).
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 2) Starting at the No. 1 and No. 2 camshaft sprockets, route the belt
loosen timing belt idler pulley and turn eccentric until holder can be around the No. 1 and No. 2 sprockets while aligning the belt marks to the
inserted. marks on the sprockets and the rear cover. See Fig. 2. Keeping slack out
11) Loosen timing belt tensioner. Remove timing belt. 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.

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
Fig. 3: Installing Crankshaft Holder after aligning idler pulley. Tighten idler pulley bolt to specification. See
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. Fig. 6: Setting Timing Belt Tension Setting
CAUTION: If TDC is passed while rotating crankshaft, DO NOT turn
crankshaft counterclockwise. This will take out correct timing belt
NOTE: Use the marks on each side of the direction of rotation
tension between timing belt tensioner and crankshaft sprocket. To
arrows to line up the left (driver’s side) camshaft sprockets. For correct for this, rotate crankshaft 2 additional turns.
this design (idler pulley located above crankshaft) engine, use the
remaining 3 White marks on the timing belt. Correct belt marks 9) Remove camshaft holders from camshaft sprockets. Remove crank-
MUST be used. shaft locking tool. Rotate crankshaft 1-3/4 turns clockwise, install
crankshaft locking tool and then stop rotating crankshaft at TDC. Secure
3) Route the belt around the No. 3 and the No. 4 camshaft sprockets crankshaft locking tool arm to water pump pulley flange.
while aligning the belt marks to the marks on the sprockets and the rear 10) Install Checking Gauge (J-42069-20) to left hand (driver’s side)
cover. Route the belt around the crankshaft hub sprockets while aligning camshafts. See Fig. 7. Verify marks are within 0.08″ (2.0 mm) of each
the marks on the belt to the marks on the sprockets and the rear cover. other. Adjust timing belt tensioner so center alignment mark is approxi-
See Fig. 5. Hold timing belt in place against crankshaft sprocket using mately 1/8″ (3.0 mm) above mark on spring loaded idler pulley. Tighten
Plastic Wedge (J-42069-30). 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
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
13) Raise vehicle. Install splash shield. Install wheel. Lower vehicle and
install air cleaner assembly.

618 SATURN
3.0L V6 DOHC – L-Series After VIN 578512 & Vue (Cont.)
TORQUE SPECIFICATIONS (L-SERIES)
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60°
Step 3 ........................................................................................................... Additional 15°
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45°
Step 3 ........................................................................................................... Additional 15°
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)
Courtesy of General Motors Corp. Timing Belt Idler Pulley Torx Bolt ............................................................................. 30 (40)
Fig. 7: Positioning Timing Belt On Left Hand Camshafts Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40)
Water Pump Bolt ....................................................................................................... 18 (25)
Wheel Lug Nut ........................................................................................................ 92 (125)
INCH Lbs. (N.m)
Timing Belt Front Cover Bolt ...................................................................................... 71 (8)
TORQUE SPECIFICATIONS (VUE)

Accessory Drive Belt Idler Pulley ............................................................................. 15 (20)
Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60°
Step 3 ........................................................................................................... Additional 15°
Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45°
Step 3 ........................................................................................................... Additional 15°
Engine Mount-To-Bracket 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)
Water Pump Bolt ....................................................................................................... 18 (25)
Wheel Lug Nut ........................................................................................................ 92 (125)
INCH Lbs. (N.m)
Timing Belt Front Cover Bolt ...................................................................................... 71 (8)
SATURN 619
3.0L V6 DOHC – L-Series Before VIN 578511

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

SCHEDULED MAINTENANCE Courtesy of General Motors Corp.
intervals. Fig. 1: Positioning Crankshaft At 60° BTDC

damage may occur.
TIMING BELT
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. Courtesy of General Motors Corp.
Remove engine mount bracket from engine block. Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks
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 clock-
wise 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 Courtesy of General Motors Corp.
idler pulley and turn eccentric until holder can be inserted.
11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing Fig. 3: Installing Crankshaft Holder
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.
620 SATURN
3.0L V6 DOHC – L-Series Before VIN 578511 (Cont.)

5) Install upper idler pulley. Tighten mounting bolt just enough so that the
pulley will rotate with slight resistance. Install Timing Belt Holder
NOTE: Upper timing belt idler pulley uses a narrow .20″ (5 mm)
(J42069-30) or equivalent to crankshaft. Tighten lever arm to water
thick spacer and a Black bolt. The lower timing belt idler pulley
pump pulley flange.
uses a .40″ (11 mm) thick spacer and a Silver bolt.
6) Ensure timing belt tension is taut (no slack). Loosen timing belt
Installation – 1) To install timing belt, remove crankshaft holder. Using tensioner lock nut. Turn tensioner eccentric until center alignment mark
a felt pen, mark the face of the upper and lower timing belt idler pulleys. is about .118″ (3 mm) above alignment mark on spring loaded idler
The mark should line up with point farthest away from the Torx head pulley. See Fig. 7. Remove plastic wedge holding timing belt against
mounting bolt. See Fig. 5. The idler pulleys provide adjustment by crankshaft sprocket. Tighten timing belt tensioner lock nut until snug.
rotating on an eccentric circle around the mounting bolt. Lock nut will be final tightened after final adjustments are made.
Fig. 7: Setting Timing Belt Tension Setting

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 o’clock).
See Fig. 5. Temporarily tighten Torx mounting bolt.
Fig. 5: Positioning Timing Belt Idler Pulleys 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 o’clock).
2) Loosen lower idler pulley mounting bolt just enough so that pulley will
See Fig. 5. Temporarily tighten Torx mounting bolt.
rotate with slight resistance. Remove upper timing belt pulley.
9) Remove camshaft holders from camshaft sprockets. Install Checking
NOTE: Use the marks on each side of the direction of rotation Gauge (J42069-20) to left hand (driver’s side) camshafts. See Fig. 8.
arrows to line up the left (driver’s side) camshaft sprockets. For Pull timing belt between timing belt tensioner and crankshaft sprocket to
this design (idler pulley located above crankshaft) engine, use the take up slack between left hand camshaft sprocket and lower idler
remaining 3 White marks on the timing belt. Correct belt marks pulley.
MUST be used. 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
3) Install timing belt onto left hand camshafts (as viewed from rear of Fig. 8. If they are not, turn lower idler pulley clockwise to allow retard of
engine), matching marks on timing belt with corresponding marks on left hand camshafts. Pull timing belt between timing belt tensioner and
camshaft sprockets. See Fig. 2. Keeping slack out of belt, route timing crankshaft sprocket to take up slack between left hand camshaft
belt around lower idler pulley and around crankshaft sprocket. Ensure sprocket and lower idler pulley.
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.
SATURN 621
3.0L V6 DOHC – L-Series Before VIN 578511 (Cont.)

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 acces-
sory 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
Courtesy of General Motors Corp. install air cleaner assembly.
Fig. 8: Positioning Timing Belt On Left Hand Camshafts
CAUTION: If TDC is passed while rotating crankshaft, DO NOT turn TORQUE SPECIFICATIONS
crankshaft counterclockwise. This will take out correct timing belt Application Ft. Lbs. (N.m)
tension between timing belt tensioner and crankshaft sprocket. To Camshaft Sprocket Bolt
correct for this, rotate crankshaft 2 additional turns. Step 1 ...................................................................................................................... 37 (50)
Step 2 ........................................................................................................... Additional 60°
11) Remove Crankshaft Holder (J42069-10). Rotate crankshaft clock- Step 3 ........................................................................................................... Additional 15°
wise 1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to crank- Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20)
shaft flange, and then stop at TDC. Tighten lever arm to water pump Crankshaft Sprocket Center Bolt
pulley flange. Step 1 .................................................................................................................. 184 (250)
Step 2 ........................................................................................................... Additional 45°
NOTE: Alignment marks on timing belt will no longer align with Step 3 ........................................................................................................... Additional 15°
camshaft sprocket marks after one or more crankshaft revolutions. Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55)
Timing marks on timing belt are used for initial installation only. Engine Mount-To-Bracket Bolt .................................................................................. 41 (55)
Generator Bolt ........................................................................................................... 30 (40)
12) Rotate lower timing belt idler pulley counterclockwise until the left Power Steering Pump Pulley Bolt ............................................................................ 15 (20)
hand camshaft timing marks on the sprockets are lined up with marks on Serpentine Drive Belt Tensioner Unit Bolt ............................................................... 30 (40)
the Checking Gauge (J42069-20). While holding lower idler pulley in this Timing Belt Idler Pulley Torx Bolt ............................................................................. 15 (20)
Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40)
position, tighten lower idler pulley Torx mounting bolt to 15 ft. lbs. (20
N.m). Water Pump Bolt ....................................................................................................... 18 (25)
13) Remove Crankshaft Holder (J42069-10). Rotate crankshaft 1 3/4 Wheel Lug Nut ........................................................................................................ 92 (125)
turns clockwise. DO NOT rotate crankshaft counterclockwise. Install
INCH Lbs. (N.m)
Crankshaft Holder (J42069-10) to crankshaft flange, and then stop at
TDC. Tighten lever arm to water pump pulley flange. Timing Belt Front Cover Bolt ...................................................................................... 71 (8)
14) Inspect left hand camshaft timing marks for alignment. Sprocket Water Pump Pulley Bolt .............................................................................................. 71 (8)
timing marks should align with marks on rear cover. Realign, if neces-
sary.
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 Crank-
shaft Holder (J42069-10) to crankshaft flange, and then stop at TDC.
Tighten lever arm to water pump pulley flange.
622 SATURN
3.5L V6
TIMING BELT APPLICATION Installation – 1) Clean the belt pulleys and covers. Rotate the crank-
Application Labor Time Belt shaft and align the Top Dead Center (TDC) mark on the sprocket with
Part No. the pointer on the oil pump housing. See Fig. 2.
3.5L V6 2) Rotate the left camshaft sprocket to TDC by aligning the mark on the
Vue sprocket with the pointer on the cover. See Fig. 3.
2004 ........................................................... 3.0 Hours ... ..... T329 3) Rotate the right camshaft sprocket to TDC by aligning the mark on the
sprocket with the pointer on the cover. See Fig. 4.
NOTE: For information about tensioners and/or pulleys (when 4) Install the Timing Belt Tensioner Pulley Retaining Bolt (EN-46331).
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED sequence starting with the tensioner pulley. See Fig. 6.
SCHEDULED MAINTENANCE 6) Tighten the idler pulley bolt to specifications. See TORQUE SPECI-
FICATIONS. Remove the Timing Belt Tensioner Retaining Pin
The manufacturer recommends the belt be replaced at 100,000 mile (EN-46330) and timing belt tensioner pulley retaining bolt.
intervals. 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
REMOVAL & INSTALLATION the timing belt on the sprockets.
8) Align the mark on the sprocket with the pointer on the oil pump
CAUTION: This application is an interference engine. Do not rotate housing. See Fig. 2. Inspect the left camshaft sprocket for proper
camshaft or crankshaft when timing belt is removed, or engine alignment. The TDC mark on the sprocket should align with the pointer
damage may occur. 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.
TIMING BELT 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 condi-
tions:
• The crankshaft position (CKP) sensor is removed for replace-
ment or during disassembly.
• The timing belt is removed for replacement or during disassem-
bly.
• 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.
Fig. 2: Identifying Crankshaft Timing Marks
Fig. 1: Identifying Idler Pulley Bolt

SATURN 623
3.5L V6 (Cont.)
Fig. 5: Identifying Timing Belt Tensioner Pulley Retainer Bolt

Fig. 3: Identifying Left Camshaft Sprocket Timing Mark
Fig. 6: Identifying Timing Belt Alignment
Fig. 4: Identifying Right Camshaft Sprocket Timing Mark
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) Courtesy of General Motors Corp.
Timing Belt Auto-Tensioner Bolts ............................................................................ 106 (12)
Fig. 7: Identifying Balancer Components
Timing Belt Front Cover Bolts ................................................................................ 106 (12)
624 STERLING
2.5L & 2.7L V6
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



damage may occur.
TIMING BELT
Removal – 1) Remove negative battery cable. Turn crankshaft clock-
wise 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 Fig. 1: Adjusting Timing Belt
pump and secure out of way. Remove upper timing belt pulley covers.
Remove crankshaft pulley. Remove timing belt lower cover. Loosen TORQUE SPECIFICATIONS
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. Application Ft. Lbs. (N.m)
Installation – 1) Remove spark plugs. Turn crankshaft clockwise to A/C Compressor Bolts .............................................................................................. 16 (22)
bring No. 1 cylinder to TDC of compression stroke. Advance crankshaft A/C Compressor Bracket Bolts ................................................................................. 33 (45)
an additional 15 degrees from TDC position. Rotate camshaft pulleys to Alternator Bracket Bolts ............................................................................................ 33 (45)
compression stroke (TDC position) of No. 1 cylinder. See Fig. 1. Return Alternator Mount Bolts .............................................................................................. 16 (22)
crankshaft pulley 15 degrees to TDC position.
2) Push timing belt tensioner to full release position and snug adjuster
Engine Mount Bolts ................................................................................................... 40 (54)
bolt. Install timing belt over crankshaft pulley, front camshaft pulley, Power Steering Pump Mount Bolt ............................................................................ 33 (45)
water pump pulley, tensioner and then over rear camshaft pulley. See Timing Belt Tensioner Bolt ........................................................................................ 33 (45)
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 INCH Lbs. (N.m)
ride in. Loosen timing belt tensioner bolt. To complete installation, Timing Belt Cover Bolts ............................................................................................ 86 (10)
reverse removal procedure. Adjust drive belts to proper tension. Valve Cover Bolts .................................................................................................... 106 (12)
Water Pump Bolts ................................................................................................... 106 (12)
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 sev-

eral times to ensure valves DO NOT contact pistons.
STERLING 625
2.5L & 2.7L V6 (Cont.)

626 SUBARU
1.2L 3-Cylinder
1
Part No.
1.2L 3-Cyl.
Justy
1987-95 ..................................................... 1.4 Hours ... ..... T135
1


TIMING BELT
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 fender-
well housing.
2) Remove outer timing belt cover. Loosen tensioner retaining bolts.
Move tensioner toward outside of engine. Tighten bolts to hold ten-
sioner. See Fig. 1. Mark timing belt for direction of rotation. Remove Courtesy of Subaru of America, Inc.
crankshaft belt drive sprocket plate and timing belt.
Inspection – Inspect timing belt for wear on rounded edges of drive Fig. 1: Exploded View Of Timing Belt Components
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
Crankshaft Pulley Bolt ................................................................... ................. 58-72 (78-98) Courtesy of Subaru of America, Inc.
INCH Lbs. (N.m) Fig. 2: Aligning Timing Marks

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)
SUBARU 627
1.8L & 2.2L 4-Cylinder – Impreza & Legacy

Application Labor Time Component Belt CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992
Kit No. Part No. kg). DO NOT release pressure until stopper pin is completely
1.8L 4-Cyl. installed.
Impreza Installation – 1) Ensure timing marks are aligned. Using a press, align
1 2
1993 ................................... 2.2 Hours .. . TCK172 . ..... T172
holes in belt tension adjuster rod and adjuster body, and push rod into
1 2
1994-95 .............................. 2.2 Hours .. . TCK254 . ..... T254
1 2 body. DO NOT allow press pressure to exceed 2205 lbs. (992 kg). Install
1996-97 .............................. 2.8 Hours .. . TCK254 . ..... T254
2.2L 4-Cyl. a stopper pin with a diameter of .059″ (1.5 mm) through holes in adjuster
Impreza body and rod. See Fig. 2.
1995-96 .............................. 1
2.8 Hours .. . 2 TCK254 . ..... T254 2) Temporarily tighten mount bolts while tension adjuster is pushed
1997 ................................... 1
2.8 Hours .. ...... ..... ...... ..... T254 completely right. Install belt tensioner. Ensure belt direction of rotation is
1
1998 ................................... 2.3 Hours .. ...... ..... ...... ..... T254 correct.
Legacy 3) Install timing belt, being careful not to move sprockets. Install belt idler
1
1990-93 .............................. 2.8 Hours .. . 2 TCK172 . ..... T172 No. 2 and belt idler. Loosen tension adjuster mount bolts and push
1
1994-95 .............................. 2.8 Hours .. . 2 TCK254 . ..... T254 tension adjuster completely left. Tighten adjuster mount bolts.
1
1996 ................................... 2.3 Hours .. . 2 TCK254 . ..... T254 4) Ensure the marks on timing belt and sprockets align. See Fig. 1.
1
1997-98 .............................. 2.3 Hours .. ...... ..... ...... ..... T254 Remove stopper from tension adjuster. Remove rocker covers and
1
– With Air Conditioning, add .4 hours. ensure valve lash adjuster does not contain air. To complete installation,
With Power Steering, add .2 hours. reverse removal procedure. Adjust drive belts to proper tension.
2
– Does not include camshaft tensioner hydraulic assembly.


For 1990-94 model years, the manufacturer recommends belt be
replaced every 60,000 miles. For 1995-97 model years, the manufac-
turer recommends belt be replaced at 60,000 miles on Federal vehicles,
Courtesy of Subaru of America, Inc.
and 105,000 miles on California vehicles.

TIMING BELT
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 Courtesy of Subaru of America, Inc.
Stopper (498497000) or equivalent for A/T models.
2) Remove front, left and right timing belt covers. If timing belt is to be Fig. 2: Installing Tension Adjuster Rod Stopper Pin
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 TORQUE SPECIFICATIONS
notches on timing cover and engine block. See Fig. 1. Use White paint Application Ft. Lbs. (N.m)
to mark timing belt in relation to sprocket timing marks. Loosen tensioner
adjuster mounting bolts. Remove belt idler. Remove belt idler No. 2. Camshaft Support Bolt .............................................................................................. 12 (16)
Remove timing belt. Crankshaft Pulley Bolt ................................................................... ............... 69-76 (93-103)
Inspection – 1) Inspect timing belt for wear on rounded edges of drive Timing Belt Idler Bolt .................................................................... ................. 26-32 (35-43)
teeth. Inspect belt for signs of oil contamination. Replace belt if it is Timing Belt Tension Adjuster Bolt ................................................. ................. 17-20 (23-27)
damaged or contaminated. Inspect belt tension adjuster oil seals for Timing Belt Tensioner Bracket Bolt .............................................. ................. 17-20 (23-27)
leaks. Inspect rod ends for abnormal wear and scratches. Timing belt INCH Lbs. (N.m)
bend diameter must be greater than 2.36″ (60.0 mm). Rocker Cover Bolt .................................................................................................... 44 (5.0)
2) Slight trace of oil at rod oil seal does not indicate a problem. While Rocker Shaft Support Bolt
holding tensioner using both hands, push rod section against floor or Long .................................................................................................................... 108 (12.2)
wall using a force of 33-110 lbs. (15-50 kg) to ensure rod section does Short ....................................................................................................................... 44 (5.0)
not move. Timing Belt Cover Bolt ............................................................................................. 44 (5.0)
3) If rod section moves, replace tension adjuster. Measure extension of Water Pump Bolt ........................................................................... ......... 89-124 (10.0-14.0)
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.
628 SUBARU
1.8L 4-Cylinder – Except Impreza & Legacy
TIMING BELT APPLICATION by hand to ensure smooth operation and movement of tensioner. Using
Application 1
Labor Time Component Belt Belt Tensioner Wrench (499437000) or equivalent, apply 17-19 ft. lbs.
Kit No. Part No. (23-26 N.m) of torque to camshaft sprocket in a counterclockwise
1.8L 4-Cyl. direction.
DL, GL & RX (Coupe, Sedan & Station Wagon) 4) While applying torque, tighten tensioner bolts. Ensure all timing marks
1985-89 are aligned. See Figs. 3, 4 and 5.
Left Side ........................ .... 2.7 Hrs. .... .. TCK299 .. ..... T299
Right Side ..................... .... 2.7 Hrs. .... .. TCK299 .. ..... T300 NOTE: After installing left side timing belt, crankshaft is rotated
Loyale one full turn (360 degrees). This will be the position for installing
1990-94 the right side camshaft belt. The camshaft timing mark for the left
Left Side ........................ .... 2.7 Hrs. .... .. TCK299 .. ..... T299 side timing belt will now be pointing straight down (6 o’clock
Right Side ..................... .... 2.7 Hrs. .... .. TCK299 .. ..... T300 position). See Fig. 6.
XT
1985-91 5) To install right (outer) timing belt, rotate crankshaft clockwise 360
Left Side ........................ .... 2.7 Hrs. .... .. TCK299 .. ..... T299 degrees and align center line on flywheel with timing mark on flywheel
Right Side ..................... .... 2.7 Hrs. .... .. TCK299 .. ..... T300 housing. Align camshaft sprocket timing mark with notch in housing. See
1 Figs. 4 and 5.
– Both Belts. With Air Conditioning, add .4 hours.
With Power Steering, add .2 hours. 6) Install right timing belt over crankshaft and camshaft sprockets,
keeping slack out of side opposite tensioner. Ensure reused belt is
NOTE: A timing belt component kit is available for this application. installed in original direction of rotation. Loosen inner tensioner bolt and
See page A1 for information on component kits. allow tensioner to apply belt tension. While turning camshaft sprocket
counterclockwise, apply 17-19 ft. lbs. (23-26 N.m) of torque using Belt
NOTE: For information about tensioners and/or pulleys (when Tension Wrench (499437000) or equivalent.
available), see ALPHABETICAL MODEL LISTING. NOTE: When timing belts are properly installed, left side camshaft
sprocket timing mark will be pointing DOWN and right side cam-
MANUFACTURER’S SUGGESTED shaft sprocket timing mark will be pointing UP. Engine timing
marks for both camshafts are located on TOP side of rear timing
SCHEDULED MAINTENANCE 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 compo-
REMOVAL & INSTALLATION nents, reverse removal procedure. Adjust drive belts to proper tension.
TIMING BELT
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

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. Courtesy of Subaru of America, Inc.
Inspection – Inspect timing belt for wear and rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace belt if it is Fig. 1: Identifying Timing Belts & Engine Components
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
SUBARU 629
1.8L 4-Cylinder – Except Impreza & Legacy (Cont.)
Fig. 2: Measuring Tensioner Squareness Courtesy of Subaru of America, Inc.
Fig. 5: Identifying Camshaft Position For Installing Timing Belts

(Right Camshaft Sprocket)
Fig. 3: Aligning Flywheel Timing Marks
Fig. 6: Identifying Final Installed Position Of Left Timing Belt

Sprocket
Belt Idler Bolt ................................................................................. ................. 29-35 (39-47)
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)
Camshaft Sprocket Bolt ................................................................ ................... 80-89 (9-10)
Courtesy of Subaru of America, Inc. Camshaft Support Bolt .................................................................. ..................... 53-62 (6-7)
Timing Belt Cover Bolt .................................................................. ..................... 35-44 (4-5)
Fig. 4: Identifying Camshaft Position For Installing Timing Belts
Valve Cover Bolt ........................................................................... ..................... 35-44 (4-5)
(Left Camshaft Sprocket)
1
– Coat bolt threads with oil before installation.
630 SUBARU
Part No.
2.0L 4-Cylinder – DOHC (Turbocharged)
Impreza
2002-04 ..................................................... 2.4 Hours ... ..... T328

SCHEDULED MAINTENANCE Courtesy of Subaru of America, Inc.
Fig. 1: Removing Drive Belt Cover
miles.

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 Fig. 2: Identifying Crank Pulley Wrench (499977400 Shown)
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 rein-
stalled in same position. See INSTALLATION MARK MEASUREMENT
SPECIFICATIONS table. For location of measurement points, refer to
illustration. See Fig. 7. Courtesy of Subaru of America, Inc.
CAUTION: After timing belt has been removed, NEVER rotate Fig. 3: Removing Timing Belt Covers & Bolts
intake and exhaust camshaft sprockets. If camshaft sprocket is
rotated, intake and exhaust valve heads will strike together and
valve stems will bend.
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

Inspection – 1) Inspect timing belt teeth for breaks, cracks or wear.
Inspect belt for signs of oil contamination. When inspecting timing belt, Fig. 4: Identifying Crankshaft Socket (499987500)
do not bend less than a radius of 2.36″ (6.0 mm). Replace belt if any fault 3) Measure extension of adjuster rod beyond tensioner body. Holding
is present. tensioner with adjuster rod facing up, adjuster rod extension should be
2) Inspect automatic belt tension adjuster oil seal for leaks. Slight trace .204-.244″ (5.2-6.2 mm). See Fig. 10. Replace automatic timing belt
of oil at adjuster rod oil seal does not indicate a problem. Inspect tensioner assembly if adjuster rod extension is not as specified.
adjuster rod end for abnormal wear and scratches.
SUBARU 631
Fig. 6: Identifying Timing & Directional Arrow Marks On

Timing Belt & Sprockets
Fig. 7: Identifying Tooth Measurement Locations On Timing Belt
Fig. 5: Identifying Location of Timing Belt Guides Courtesy of Subaru of America, Inc.
Fig. 8: Identifying Timing Belt Idler Pulley Location

632 SUBARU
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. Courtesy of Subaru of America, Inc.
4) Place automatic belt tension adjuster assembly in a press with Fig. 11: Identifying DOHC Valve Position In Cylinder Head
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.
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. Courtesy of Subaru of America, Inc.
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 Fig. 12: Rotating Camshafts To Align Timing Marks
corresponding valves down. Under this condition, these valves are held 3) Align single mark on right hand intake camshaft sprocket with notch
lifted. Right-side camshafts are held so that their cams do not push on belt cover. Ensure double line marks on intake and exhaust camshaft
valves down. sprockets are aligned.
4) Left-hand camshafts must be rotated from “Zero Lift” position where 4) Align single line mark “A” on left hand exhaust camshaft sprocket with
timing belt is to be installed at as small an angle as possible, in order to notch “B” on belt cover by turning sprocket counterclockwise (as viewed
prevent mutual interference of intake and exhaust valve heads. from front of engine). See Fig. 13.
5) Do not allow camshafts to rotate in direction shown in figure, as this 5) Align single line mark “A” on left hand intake camshaft sprocket with
causes both intake and exhaust valves to lift simultaneously, resulting in notch “B” on belt cover by turning sprocket clockwise (as viewed from
interference with their heads. See Fig. 12. front of engine). Ensure double line marks “C” on intake and exhaust
Installation – 1) Align mark on crankshaft sprocket with mark on oil camshaft sprockets are aligned. See Fig. 14.
pump cover at cylinder block. See Fig. 6.
2) Align single mark on right hand exhaust camshaft sprocket with notch
on belt cover.
SUBARU 633
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 Courtesy of Subaru of America, Inc.
it through stopper pin hole in cylinder and adjuster rod to secure adjuster
rod. See Fig. 15. Fig. 13: Aligning Left Exhaust Camshaft
8) Install automatic belt tension adjuster assembly on engine with
stopper pin in place. Install idler pulleys. Tighten bolts to specification.
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 crank-
shaft 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 Courtesy of Subaru of America, Inc.
over crankshaft pulley and at corners by camshaft pulleys. See Fig. 5.
Fig. 14: Aligning Left Intake Camshaft
Adjust clearance between all belt guides and timing belt to .020-.058”
(.5-1.5 mm). See Fig. 17.
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 Courtesy of Subaru of America, Inc.
12) Install accessory drive belts. To complete installation, reverse Fig. 15: Installing Adjuster Rod Stopper Pin
634 SUBARU
Fig. 16: Identifying Order For Installing Timing Belt
Fig. 17: Checking Clearance Between Timing Belt Guides & Timing Belt
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (Cont.)

INCH Lbs. (N.m)
Crankshaft Pulley Bolt ............................................................................................. 94 (127) Timing Belt Cover Bolt ................................................................................................ 44 (5)
Idler Pulley Bolt ......................................................................................................... 29 (39) 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

Part No.
2.2L 4-Cyl.
Impreza
1999-01 ..................................................... 2.3 Hours ... ..... T304
Legacy
1999 ........................................................... 2.3 Hours ... ..... T304
2.5L 4-Cyl.
Baja
2003-04 ..................................................... 2.3 Hours ... ..... T307
Forester
1999-04 ..................................................... 2.3 Hours ... ..... T304
Impreza
1999-04 ..................................................... 2.3 Hours ... ..... T304
Legacy & Outback
2000-04 ..................................................... 2.3 Hours ... ..... T307

miles.

damage may occur.
TIMING BELT Courtesy of Subaru of America, Inc.

Removal – 1) Disconnect negative battery cable. Raise and support Fig. 2: Aligning Camshaft & Crankshaft Timing Marks
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. 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.
CAUTION: Always use a vertical type pressing tool to compress
Fig. 1: Identifying Timing Belt Routing & Timing Marks automatic tensioner rod. DO NOT use a bench vise to compress
6) On all models, if reusing old belt, use White paint to mark timing belt rod. It may take more than 3 minutes to compress the automatic
in relation to sprocket timing marks. Also mark timing belt direction of tensioner rod.
rotation.
4) Place automatic tensioner in a press with tensioner rod facing up.
7) Remove No. 2 timing belt idler pulley. See Fig. 3. Remove timing belt.
Apply 66 lbs. (294 N) of pressure on rod. If rod moves down easily,
Remove timing belt automatic tensioner with rod facing up.
replace automatic tensioner.
5) Inspect automatic tensioner and idler pulleys for worn bearings or
lubricant leaks. Replace as necessary.
636 SUBARU
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.
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 Courtesy of Subaru of America, Inc.
idler pulleys (if removed). Fig. 6: Identifying Timing Belt Direction Of Rotation (New Belt)
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.
CAUTION: If tightening angle of crankshaft pulley bolt is less than

65 degrees, bolt is damaged. Bolt must be replaced. Courtesy of Subaru of America, Inc.
5) On all models, install timing belt covers. Clean crankshaft pulley bolt Fig. 7: Checking Timing Belt Guide Clearance
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 SPECIFICA- TORQUE SPECIFICATIONS
TIONS.
6) Install accessory drive belts. Install radiator fan assembly. To com-
plete installation, reverse removal procedures. Adjust drive belts to
proper tension. 2.2L ........................................................................................................................ 94 (127)
2.5L ...................................................................................................................... 130 (177)
INCH Lbs. (N.m)
Timing Belt Guide Bolt (M/T) .................................................................................... 89 (10)
Valve Cover Bolt ......................................................................................................... 44 (5)
Water Pump Bolt ........................................................................... ............... 89-124 (10-14)
Fig. 5: Installing Automatic Tensioner Pin

SUBARU 637

TIMING BELT APPLICATION 6) Check mating surfaces of timing belt and contact point of tension
Application Labor Time Component Belt adjuster rod for abnormal wear or scratches. Replace belt tensioner if
Kit No. Part No. faulty. Check spacer and tensioner bushing for wear. Check tensioner
2.5L 4-Cyl. – DOHC for smooth rotation. Replace if noise or excessive play is noted. Check
Forester tensioner for grease leakage.
1998 .................................... 2.3 Hours ... ...... ..... ...... ..... T277
Impreza
1998 ................................... 1 2.8 Hours .. .. TCK277 .. ..... T277
Legacy & Outback
1996-99 .............................. 1 2.8 Hours .. .. TCK277 .. ..... T277
1


on 1996-97 Federal vehicles. Replace belt at 105,000 miles on all
1998-99 vehicles.

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. Fig. 1: Placing Alignment &/Or Rotation Marks On Timing Belt
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. Courtesy of Subaru of America, Inc.
Inspection – 1) Check timing belt teeth for breaks, cracks, and wear. If Fig. 2: Removing Drive Belt Cover
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 Courtesy of Subaru of America, Inc.
maintain a projectionally acting force and should not sink within 8.5
Fig. 3: Removing Crankshaft Pulley Bolt
seconds.
638 SUBARU
7) Check idler for smooth rotation. Replace if noise or excessive play is Installation – 1) Ensure crankshaft and camshaft timing marks are still
noted. Check outer contacting surfaces of idler pulley for abnormal wear aligned. Place automatic adjuster in a press with rod facing up. Apply
and scratches. Check idler for grease leakage. pressure to end of rod. SLOWLY (taking more than 3 minutes) compress
rod into housing until rod and housing holes are aligned. Insert locking
CAUTION: Do not allow press pressure to exceed 2205 lbs (1000 pin through holes. See Fig. 8.
kg,). Do not release press pressure until stopper pin is completely 2) Install automatic tensioner on engine with locking pin in place. Install
inserted. Push tension adjuster rod vertically. Press-in the push idler pulleys (if removed). Install timing belt in correct routing order.
rod gradually, taking 3 minutes or more. 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
Fig. 4: Removing & Installing Front Belt Cover
Fig. 5: Exploded View Of Timing Belt & Related Components

SUBARU 639
Fig. 6: Aligning Timing Marks & Sprocket Alignment Marks
Fig. 7: Measuring Belt Tensioner Rod Extension (2.5L Engine)

640 SUBARU
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)
Fig. 8: Installing Belt Tensioner Stopper Pin

MOTORES CHECK
SUBARU 641
2.7L 6-Cylinder
1
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.

MANUFACTURER’S SUGGESTED Courtesy of Subaru of America, Inc.
SCHEDULED MAINTENANCE Fig. 2: Loosening Right Hand Timing Belt Tension


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 Courtesy of Subaru of America, Inc.
from front of engine. See Fig. 1. Remove center, left and right timing belt
covers. Fig. 3: Removing Left Timing Belt Idler Pulley
4) Loosen right (passenger side) hand timing belt tensioner bolts 1/2 Inspection – Inspect timing belt for wear on rounded edges of drive
turn. Rotate tensioner to release belt tension and retighten bolts. See teeth. Inspect belt for signs of oil contamination. Replace belt if
Fig. 2. If right (passenger side) timing belt is to be reused, place arrow damaged or contaminated. Inspect idler pulleys and tensioners for
on belt to indicate direction of belt rotation. Remove timing belt. smooth rotation. Check belt tensioner roller for squareness. See Fig. 8.
5) Remove crankshaft outer sprocket. To remove left (driver side) timing Replace tensioner in out-of-square exceeds .020″ (.51 mm).
belt, remove idler pulley. See Fig. 3. Remove rubber plug and retaining Installation – 1) If not already done, remove Phillips screw from bottom
bolt located below belt tension adjuster in rear timing cover. See Figs. 4 of belt tension adjuster. Insert a standard slot screwdriver into hole in
and 5. bottom of belt tension adjuster. Turn screw clockwise to compress
6) Remove Phillips screw from bottom of belt tension adjuster. See rubber boot. Install belt adjuster stopper on top of belt tension adjuster.
Fig. 6. Insert slot screwdriver in bottom of belt tension adjuster and 2) Using syringe, add engine oil through vent hole on top of rubber boot.
rotate screw clockwise to release belt tension. Install Belt Adjuster Add oil until it overflows. Install Phillips screw and new gasket.
3) Install belt tension adjuster on engine. Keep belt adjuster stopper in
Stopper (13082AA000) or equivalent, on tension adjuster. See Fig. 7.
place. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
7) Remove left hand timing belt tensioner. If timing belt is to be reused,
4) Install rubber plug and retaining bolt on engine. Install left timing belt
place arrow on belt to indicate direction of belt rotation. Remove timing
idler pulley. Tighten bolt to specification. See TORQUE SPECIFICA-
belt. Remove belt tension adjuster.
TIONS.
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 ten-

sion adjuster and all timing marks align.
Fig. 1: Removing Oil Level Gauge Guide

642 SUBARU
Fig. 5: Removing Rubber Plug & Retaining Bolt
Fig. 6: Removing Phillips Screw From Belt Tension Adjuster
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 o’clock position). See Fig. 10.
7) To install right (passenger side) timing belt, rotate crankshaft clock-
wise 360 degrees. Align flywheel or drive plate timing marks with mark
on housing. Align camshaft sprocket timing mark with notch in rear
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 Courtesy of Subaru of America, Inc.
Fig. 7: Installing Belt Adjuster Stopper
10) Loosen right hand tensioner bolts, and allow tensioner to apply belt
tension. Install Belt Tension Wrench (499437100) on right camshaft
sprocket.
SUBARU 643
Fig. 8: Checking Belt Tensioner Roller Squareness Courtesy of Subaru of America, Inc.
11) Using torque wrench and belt tension wrench, apply 17-18 ft. lbs. Fig. 10: Identifying Final Installed Position Of Left (Driver Side)
(24-25 N.m) of torque in a counterclockwise direction to right camshaft Camshaft Sprocket
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 TORQUE SPECIFICATIONS
belt tension is correct, tighten tensioner bolt closest to the tensioner
pulley, and then the tensioner pivot bolt to specification. See TORQUE
Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27)
SPECIFICATIONS. Ensure all timing marks are still aligned. Crankshaft Pulley Center Bolt 1 .................................................... ............... 66-79 (90-107)
NOTE: When timing belts are properly installed, left camshaft Left Hand Tensioner .................................................................... ................. 29-35 (39-47)
sprocket timing mark will be pointing DOWN and right camshaft Right Hand Tensioner ................................................................. ................. 17-20 (23-27)
sprocket timing mark will be pointing UP. Engine timing mark
INCH Lbs. (N.m)
notches for both camshafts are located on TOP side of rear timing
belt covers. See Figs. 9 and 10. Camshaft Sprocket Bolt ................................................................................ 97-108 (11-13)
Oil Level Guide Bolt ...................................................................... ..................... 40-48 (4-5)
13) Install rubber plug and retaining bolt below belt tension adjuster. Timing Belt Cover Bolt .................................................................. ..................... 40-48 (4-5)
Install timing belt covers. Install crankshaft pulley. Apply engine oil to Water Pump Pulley Bolt ................................................................ ................... 80-92 (9-10)
crankshaft pulley bolt threads. Holding crankshaft pulley stationary, 1
install and tighten center bolt to specification.
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.

644 SUBARU
3.3L 6-Cylinder
TIMING BELT APPLICATION Installation – 1) If tension adjuster was removed or replaced, use a
Application Labor Time Belt press to push adjuster rod down far enough to install a stopper pin. See
Part No. Fig. 2. Turn sprockets to align timing marks with marks on rear timing
3.3L 6-Cyl. belt covers and oil pump. See Fig. 1.
SVX 2) While aligning marks on timing belt with marks on sprockets, position
1 timing belt properly. Ensure belt rotating direction is correct. Install idler
1992-97 .................................................... 2.6 Hours .. ..... T209
1 pulleys. Loosen tension adjuster attaching bolts and move adjuster fully
With Power Steering, add .2 hours. left.
NOTE: For information about tensioners and/or pulleys (when CAUTION: Readjust new alternator belt after 5 minutes of opera-
available), see ALPHABETICAL MODEL LISTING. tion.
3) Tighten adjuster bolts. Once all timing marks are aligned, remove
stopper pin from tension adjuster. Install front timing belt covers. To
MANUFACTURER’S SUGGESTED complete installation, reverse removal procedure. Tighten all nuts and
SCHEDULED MAINTENANCE bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive
For 1992-94 model years, the manufacturer recommends belt be belts to proper tension.
turer recommends belt be replaced at 60,000 miles on Federal vehicles,
and 105,000 miles on California vehicles.

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 char-
coal 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 crank-
shaft, 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
Belt Idler Bolt ................................................................................. ................. 26-32 (35-43)
Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27)
Crankshaft Pulley Bolt 1 ................................................................ ......... 108-123 (147-167)
Tensioner Bolt ................................................................................ ................. 26-32 (35-43)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................................................. ............... 35-44 (4.0-5.0)
Valve Cover Bolt ........................................................................... ................. 5-44 (4.0-5.0)
Water Pump Pulley Bolt ................................................................ ......... 84-120 (10.0-14.0)
1
Fig. 1: View Of Timing Belt Components
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.
SUZUKI 645

TIMING BELT APPLICATION Installation – 1) Align timing marks. Bolts with flanged nuts may be
Application Labor Time Belt wedged between cam sprocket teeth to hold camshaft on timing mark
Part No. during belt installation (if necessary). See Figs. 2 and 3.
CAUTION: While aligning timing marks, DO NOT turn camshaft
Swift
1 sprockets more than 20 degrees in either direction from aligned
1989-94 .................................................... 2.6 Hours .. ..... T171
1
position. DO NOT turn crankshaft more than 90 degrees in either
– With Air Conditioning, add .4 hours. direction from aligned position.
NOTE: For information about tensioners and/or pulleys (when 2) Install timing belt so no slack exists on drive side of belt. Adjust
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 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
SCHEDULED MAINTENANCE and tighten to specification. See TORQUE SPECIFICATIONS. To
For 1989-92 model years, although the manufacturer does not recom- complete installation, reverse removal procedure. Tighten bolts to
mend a specific scheduled maintenance interval, belt manufacturers specification. Adjust drive belts to proper tension.
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.

damage may occur.
TIMING BELT
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 Courtesy of Suzuki of America Corp.
Fig. 1. Move timing belt tensioner up and secure. Mark timing belt for
Fig. 2: Securing Intake & Exhaust Camshaft Sprocket For
direction of rotation if it is to be reused. Remove timing belt from Timing Belt Installation
sprockets.
Courtesy of Suzuki of America Corp.

646 SUZUKI
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28)
Alternator Pulley Bolts
1992-94 ........................................................................................ ............... 70-96 (95-130)
INCH Lbs. (N.m)
Alternator Pulley Bolt
1989-91 ........................................................................................ ............... 90-108 (10-13)
Timing Belt Outer Cover Bolt ....................................................... ................. 80-106 (9-12)
Timing Belt Tensioner Stud Nut .................................................... ................. 80-106 (9-12)
Water Pump Mounting Bolt ........................................................... ................. 80-106 (9-12)
Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)
Fig. 3: Identifying Sprocket Movement Limits

SUZUKI 647

Kit No. Part No.
Samurai
1
1985 ................................... 3.0 Hours .. ...... ..... ...... ..... T095
1
1986-93 .............................. 3.0 Hours .. .. TCK095 .. ..... T095
1
1994 ................................... 3.0 Hours .. .. TCK095 .. ... 2 T095
1
1994 ................................... 3.0 Hours .. ...... ..... ...... ... 3 T243
1
1995 ................................... 3.0 Hours .. ...... ..... ...... ..... T243
Sidekick
1989
1
8-Valve ............................. 3.6 Hours .. .. TCK095 .. ..... T095
1
16-Valve ........................... 4.0 Hours .. .. TCK095 .. ..... T095
Swift
1
1989-93 .............................. 2.6 Hours .. .. TCK095 .. ..... T095
1
1994 ................................... 2.6 Hours .. ...... ..... ...... ..... T243
1
1995-97 .............................. 2.6 Hours .. .. TCK272 .. ..... T272
1
1998-01 .............................. 2.6 Hours ... TCK194A . ..... T194
1
2
– For VIN R4100375 and earlier.
3
– For VIN R4100376 and later.

See page A1 for information on component kits. Courtesy of Suzuki of America Corp.
Fig. 1: Adjusting Valve Clearance

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
MANUFACTURER’S SUGGESTED aligned with arrow mark on oil pump housing. With timing marks aligned,
install timing belt. Ensure direction arrow mark on timing belt is pointed
SCHEDULED MAINTENANCE in direction of crankshaft rotation. Ensure drive side of belt is free of
For 1985-92 model years, although the manufacturer does not recom- slack.
mend a specific scheduled maintenance interval, belt manufacturers 3) Move tensioner plate up with finger pressure, and loosely secure
suggest the belt be replaced at 60,000 mile intervals. For 1993-01 model tensioner bolt. Turn crankshaft 2 revolutions clockwise to remove all
years, the manufacturer recommends the belt be replaced at 60,000 slack from belt. Tighten tensioner nut and then tensioner bolt to
mile intervals. specification. See TORQUE SPECIFICATIONS.
4) Ensure timing marks are aligned. Install timing belt outer cover and
ADJUSTMENTS tighten to specification. See TORQUE SPECIFICATIONS. Reverse
removal procedure to complete installation. Adjust valve clearance. See
VALVE CLEARANCE SPECIFICATIONS VALVE CLEARANCE SPECIFICATIONS under ADJUSTMENTS. Adjust
VALVE CLEARANCE SPECIFICATIONS drive belts to proper tension.
Valve Cold – In. (mm) Hot – In. (mm) Removal (Swift) – 1) Disconnect negative battery cable. Raise and
support vehicle. Remove right side fender apron extension by pushing
Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28)
Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28) 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.
REMOVAL & INSTALLATION Remove engine mount from timing belt end of engine. Loosen water
pump pulley bolts. Remove accessory drive belts. Remove water pump
TIMING BELT pulley.
Removal (Samurai & Sidekick) – 1) Disconnect negative battery cable. 3) Remove crankshaft pulley-to-crankshaft bolts. Remove crankshaft
Remove cooling fan and fan shroud. Discharge A/C system using pulley. It is NOT necessary to remove crankshaft center bolt.
approved refrigerant recovery/recycling equipment and disconnect com- 4) Remove resonator and timing belt cover. Rotate crankshaft clockwise
pressor flexible suction hose from suction pipe (if equipped). Remove to align camshaft and crankshaft timing marks. See Fig. 3. Camshaft
A/C compressor belt (if equipped). sprocket mark should align with “V” mark on rear cover. Punch mark on
2) Loosen alternator, and remove water pump pulley and belt. Remove crankshaft sprocket should align with mark on oil pump case.
crankshaft pulley. Remove timing belt cover. Loosen timing belt ten- 5) If reusing timing belt, mark belt with an arrow indicating direction of
sioner bolt and move away from timing belt. Secure timing belt ten- rotation for installation reference.
sioner. 6) Loosen timing belt tensioner eccentric bolt and stud nut. Move
3) Mark belt with an arrow indicating direction of rotation for installation tensioner away from belt and snug bolt and nut. Remove timing belt.
reference. Remove timing belt from camshaft and crankshaft sprockets.
CAUTION: With timing belt removed, DO NOT turn camshaft
CAUTION: With timing belt removed, DO NOT turn camshaft sprocket more than 20 degrees in either direction from aligned
sprocket more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either
position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Doing so could damage piston(s)
direction from aligned position. Doing so could damage piston(s) and/or valve(s) by interference. Also, DO NOT bend timing belt.
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Installation (Samurai & Sidekick) – 1) Loosen all valve adjusting contamination. Check timing belt tensioner for worn bearing. Replace
screws fully before installing timing belt. Allow camshaft to rotate freely damaged components.
648 SUZUKI
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 clock-
wise to remove all slack from belt. Ensure timing marks are aligned.
Tighten tensioner stud nut and then tensioner bolt to specification. See
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
Fig. 4: Releasing Timing Belt Tensioner
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28)
Crankshaft Pulley-To-Crankshaft Bolt ........................................... ................... 7-10 (10-13)
Except 2000-01 Swift ................................................................................ 77-85 (105-115)
2000-01 Swift ........................................................................................................ 94 (130)
Engine Mount Bolt (Swift) ......................................................................................... 40 (55)
INCH Lbs. (N.m)
Courtesy of Suzuki of America Corp. Timing Belt Tensioner Stud Nut .................................................... ................. 80-106 (9-12)
Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)
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.
SUZUKI 649
1.6L 4-Cylinder
Application Labor Time Component Belt CAUTION: With timing belt removed, DO NOT turn camshaft or
Kit No. Part No. crankshaft sprocket more than 90 degrees in either direction from
1.6L 4-Cyl. – SOHC aligned position. Doing so could damage pistons and valves.
Esteem
1
1995-99 .............................. 2.3 Hours .. .. TCK212 .. ..... T212
Esteem (Canadian)
1
2000-02 .............................. 2.3 Hours .. .. TCK212 .. ..... T212
Sidekick (8-Valve)
1
1989-95 .............................. 3.6 Hours .. .. TCK164 .. ..... T164
1
1996-98 .............................. 3.6 Hours .. ...... ..... ...... ..... T212
Sidekick (16-Valve)
1
1989-91 .............................. 4.0 Hours .. .. TCK164 .. ..... T164
1
1992-98 .............................. 4.0 Hours .. .. TCK212 .. ..... T212
Vitara (Includes Canadian)
1
1999-02 .............................. 4.0 Hours .. .. TCK212 .. ..... T212
X-90
1
1996-98 .............................. 4.0 Hours .. .. TCK212 .. ..... T212
1
– With Air Conditioning, add .4 hours, except Esteem. For
Esteem, add .2 hours.


For 1989-92 model years, although the manufacturer does not recom- Courtesy of Suzuki of America Corp.
mend a specific scheduled maintenance interval, belt manufacturers
years, the manufacturer recommends the belt be replaced at 60,000 Removal (Sidekick, Vitara & X-90) – 1) Disconnect negative battery
mile intervals. 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.
ADJUSTMENTS 2) Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is
VALVE CLEARANCE SPECIFICATIONS NOT necessary to remove crankshaft center bolt. Remove timing belt
cover. See Fig. 1.
VALVE CLEARANCE SPECIFICATIONS 3) Rotate crankshaft clockwise to align timing marks. See Figs. 2 and 3.
Valve Cold – In. (mm) Hot – In. (mm) Stamped “E” or punch mark on camshaft sprocket must straight up.
Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28) Loosen timing belt tensioner bolt and stud nut. Move tensioner away
Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28) 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
TIMING BELT than 20 degrees in either direction from aligned position. To
Removal (Esteem) – 1) Disconnect negative battery cable. Remove prevent piston and valve damage, DO NOT turn crankshaft more
right side engine under cover. Remove power steering and A/C com- than 90 degrees in either direction from aligned position.
pressor drive belts.
2) Remove A/C compressor and power steering pump with hoses Inspection (All Models) – Inspect timing belt for damaged teeth,
attached, and secure out of way. Support engine from above or with floor cracking and oil contamination. Check timing belt tensioner for worn
jack under oil pan. Remove air cleaner case with air cleaner outlet hose. bearing. Replace damaged components.
3) From timing belt end of engine, remove engine mount and mounting Installation (All Models) – 1) If the tensioner was removed, install
tensioner plate on tensioner. Ensure tensioner plate lug engages hole
bracket. Loosen water pump pulley bolts. Remove water pump drive belt
on rear of tensioner. Install tensioner spring. Tighten tensioner bolt finger
and pulley.
tight to allow movement of tensioner.
4) Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is
2) On 1989-94 Sidekick with 8-valve engine, remove valve cover.
NOT necessary to remove crankshaft center bolt. Remove timing belt
Loosen all valve adjusting screws. On all models, ensure timing marks
cover. See Fig. 1. are still aligned. Install timing belt. If reusing old belt, ensure direction
5) Rotate crankshaft clockwise to align timing marks. See Figs. 2 and 3. arrow mark on timing belt is pointed in direction of crankshaft rotation.
Stamped “E” on camshaft sprocket must point straight up. Loosen timing Ensure drive side of belt is free of slack.
belt tensioner bolt and stud nut. Move tensioner away from belt, and 3) Loosen tensioner bolt and stud nut to place tension on timing belt.
hand tighten bolt and nut. See Fig. 4. Turn crankshaft 2 revolutions clockwise to remove all slack from belt.
6) If reusing old belt, mark belt with an arrow indicating direction of Tighten tensioner stud nut and then tensioner bolt. See TORQUE
rotation for installation reference. Remove timing belt. SPECIFICATIONS.
650 SUZUKI

4) Ensure timing marks are aligned. Install timing belt cover and tighten
bolts to specification. Reverse removal procedure to complete installa-
tion. 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.
Fig. 4: Releasing Timing Belt Tensioner
TORQUE SPECIFICATIONS (Cont.)
TORQUE SPECIFICATIONS Timing Belt Tensioner Bolt ........................................................................................ 18 (25)
Application Ft. Lbs. (N.m) INCH Lbs. (N.m)
A/C Compressor Mounting Bolt (Esteem) ................................................................ 17 (23)
Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28) Crankshaft Pulley-To-Crankshaft Bolt ..................................................................... 106 (12)
Camshaft Sprocket Bolt ............................................................................................ 43 (60) Timing Belt Cover Bolt .............................................................................................. 97 (11)
Crankshaft Sprocket Center Bolt .................................................. .......................... 80 (110) Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11)
Engine Mount Bolt/Nut (Esteem) .............................................................................. 40 (55) Water Pump Pulley Bolt ............................................................................................ 97 (11)
Power Steering Pump Bolt (Esteem) ....................................................................... 25 (35)
SUZUKI 651
2.0L 4-Cylinder
Part No.
2.0L 4-Cylinder
Forenza
2004 ........................................................... 1.6 Hours ... ..... T309

Manufacturer recommends that timing belt be inspected every 30,000
miles and be replaced every 60,000 miles.

TIMING BELT
Removal – 1) Turn ignition off. Disconnect negative battery cable. Courtesy of Suzuki of America Corp.
Disconnect manifold air temperature (MAT) sensor electrical connector. Fig. 2: Installing Engine Support Hardware
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. Courtesy of Suzuki of America Corp.
Turn hex-key tab counterclockwise to relieve belt tension and remove
timing belt. See Fig. 6. Fig. 3: Removing Right Engine Mount Bracket
Fig. 4: Aligning Crankshaft Gear Timing Mark

Fig. 1: Locating Drive Belt Tensioner

652 SUZUKI
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
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
Courtesy of Suzuki of America Corp. belt. Remove socket wrench and belt will tighten itself. Reverse removal
Fig. 5: Aligning Timing Marks On Camshaft Gears procedure to complete installation.
Crankshaft Pulley Bolts ............................................................................................. 15 (20)
Engine Mount Retaining Bolts .................................................................................. 33 (45)
Engine Mount Bracket Retaining Bolts .................................................................... 41 (55)
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)
Fig. 6: Identifying Timing Belt Tensioner Components

TOYOTA 653
1.5L 4-Cylinder – 1A-C & 3A-C

1.5L 4-Cyl.
Corolla Tercel CAUTION: Do not bend or twist timing belt. Keep belt free of oil,
1980-82 water or dust.
A/T ................................. .... 2.6 Hrs. .... .. TCK070 .. ..... T070 Removal – 1) Drain engine coolant. Remove radiator. Remove air
M/T ................................. .... 2.8 Hrs. .... .. TCK070 .. ..... T070
cleaner assembly. Remove accessory drive belts. Remove water pump
Tercel
pulley.
1983-86 ............................ ... 1 2.7 Hrs. ... .. TCK070 .. ..... T070
1987-88 2) If equipped with A/C, remove A/C drive belt idler pulley with bracket.
Wagon Remove PCV valve from valve cover. Remove valve cover.
3A-C ............................. ... 1 2.7 Hrs. ... .. TCK070 .. ..... T070 3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
1 stroke. Timing notch on crankshaft pulley must align with “0” timing mark
on timing belt cover.
NOTE: A timing belt component kit is available for this application. 4) Ensure cylinder No. 1 rocker arms are loose and cylinder No. 4 rocker
See page A1 for information on component kits. arms are tight. If conditions are not as described, rotate crankshaft one
complete revolution.
5) Holding crankshaft stationary, remove crankshaft pulley center bolt.
6) Remove timing belt covers and gaskets. Remove timing belt guide.
See Fig. 1. If reusing old timing belt, mark belt with arrow indicating
MANUFACTURER’S SUGGESTED direction of rotation. Also place mating marks on timing belt and
camshaft timing pulley. Place mating marks on timing belt and crank-
SCHEDULED MAINTENANCE shaft timing pulley.
For 1980-85 model years, although the manufacturer does not recom- 7) Loosen idler pulley retaining bolt. Move idler pulley away from timing
mend a specific scheduled maintenance interval, belt manufacturers belt and tighten retaining bolt. Remove timing belt.
years, the manufacturer recommends the belt be replaced every 60,000
miles under severe service operating conditions.

654 TOYOTA
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.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
crankshaft pulley. Install and tighten crankshaft pulley center bolt to Fig. 5: Checking Timing Belt Tension
7) Install water pump pulley. Install A/C idler pulley (if equipped). Install TORQUE SPECIFICATIONS
accessory drive belts. Adjust drive belts to proper tension.
8) Install valve cover and air cleaner assembly. Install radiator. Fill and
bleed cooling system. Application Ft. Lbs. (N.m)
Idler Pulley Retaining Bolt ........................................................................................ 27 (37)

TOYOTA 655
1.5L 4-Cylinder – 3E
1
1.5L 4-Cyl. – 3E camshaft or crankshaft when timing belt is removed, or engine
Tercel Sedan damage may occur.
1987 ................................. .... 2.3 Hrs. ............. ......... ..... T136
Tercel
1988-94 ............................ .... 2.3 Hrs. .... .. TCK233 .. ..... T233 TIMING BELT
1
CAUTION: On models equipped with air bag, DO NOT start work
NOTE: A timing belt component kit is available for this application. until after 90 seconds from time ignition switch is turned to LOCK
See page A1 for information on component kits. position and negative battery cable is disconnected.
NOTE: For information about tensioners and/or pulleys (when vehicle. Remove right side engine under cover (splash) shield. Lower
available), see ALPHABETICAL MODEL LISTING. vehicle. Remove accessory drive belts.
2) Disconnect accelerator cable. On A/T models, disconnect throttle
MANUFACTURER’S SUGGESTED cable. On all models, disconnect PCV hoses. On 1987-91 models,
remove air cleaner assembly.
SCHEDULED MAINTENANCE 3) On all models, remove bolt, ground strap and vacuum transmitting
The manufacturer recommends the belt be replaced every 60,000 miles valves with bracket on right engine mount. This is mount on timing belt
under severe service operating conditions. end of engine.
Fig. 1: Exploded View Of Timing Belt & Components (1991-94 Shown; 1987-90 Use One-Piece Crankshaft Pulley)
656 TOYOTA
1.5L 4-Cylinder – 3E (Cont.)
4) Using floor jack, support weight of engine from below. Remove right 5) If timing marks do align, tighten No. 1 idler pulley bolt to specification.
engine mount from timing belt end of engine. Remove valve cover. See TORQUE SPECIFICATIONS. Install timing belt guide. Install timing
Remove spark plugs. belt covers.
5) Set No. 1 cylinder at TDC on compression stroke. Turn crankshaft 6) Install crankshaft pulley. Holding crankshaft pulley stationary, tighten
pulley, and align groove on crankshaft with “0” mark on timing belt cover. crankshaft pulley bolt to specification. On 1991-94 models, install
Ensure rocker arms on No. 1 cylinder are loose. If not, turn crankshaft accessory drive pulley.
pulley one complete revolution. 7) On all models, install spark plugs. Install valve cover. Install right
6) On 1991-94 models with A/C and/or power steering, remove acces- engine mount to engine and body. Install vacuum switching valves and
engine ground strap to engine mount (if equipped).
sory drive pulley from crankshaft pulley. See Fig. 1.
8) Connect negative battery cable. To complete installation, reverse
7) Using Holder (09213-14010) or equivalent, hold crankshaft pulley.
Loosen crankshaft pulley center bolt. Remove holder. Remove crank-
shaft 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.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
engines, spring tension should be 18.3 lbs. at 2.157″ (8.3 kg at 54.8
Fig. 3: Aligning Camshaft Knock Pin With Bearing Cap
mm). For 1990-94 engines, spring tension should be 11.3 lbs. at 2.028″
(5.11 kg at 51.5 mm). Replace spring if tension is not as specified.
NOTE: Before installing timing belt, remove any oil or water from
camshaft sprocket, crankshaft sprocket and idler pulleys.
Installation – 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
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.

TOYOTA 657
1.5L 4-Cylinder – 3E (Cont.)

A/C Compressor Bolt ................................................................................................ 18 (24)
A/C Compressor Mounting Bracket Bolt .................................................................. 20 (27)
Accessory Drive Belt Pulley Bolt .............................................................................. 14 (19)
Engine Mount
Mount-To-Cylinder Block Bolt/Nut ........................................................................... 47 (64)
Through-Bolt
1987-90 .................................................................................................................. 47 (64)
1991-94 .................................................................................................................. 54 (73)
Idler Pulley Bracket Bolt
12 mm ..................................................................................................................... 20 (27)
14 mm ..................................................................................................................... 27 (37)
No. 1 Idler Pulley Bolt .............................................................................................. 13 (18)
Power Steering Bracket Bolt ..................................................................................... 32 (43)
Spark Plugs ............................................................................................................... 13 (18)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Timing Belt Idler Mount Bolt ..................................................................................... 27 (37)
Fig. 5: Routing Timing Belt
INCH Lbs. (N.m)
No. 1 Timing Belt Cover Bolt .................................................................................. 66 (7.5)
Valve Cover Nut ....................................................................................................... 61 (6.5)
658 TOYOTA
1.5L 4-Cylinder – 5E-FE
TIMING BELT APPLICATION 2) Measure tension required to extend tension spring to 1.866″ (47.40
Application 1
Labor Time Component Belt mm). Replace tension spring if tension is not 7.3 lbs. (3.3 kg).
Kit No. Part No. Installation – 1) If removed, install crankshaft sprocket with flange
1.5L 4-Cyl. toward engine. Install tension spring and No. 1 idler pulley with bolt
Paseo (Includes Canadian) loosely installed. DO NOT tighten bolt at this time. Move No. 1 idler
1992-95 ............................... 2.5 Hours ... .. TCK208 .. ..... T208 pulley away from timing belt area as far as possible. Temporarily tighten
1996-99 ............................... 3.5 Hours ... .. TCK208 .. ..... T208 No. 1 idler pulley bolt. Ensure all sprockets and idler pulleys are clean.
Tercel (Includes Canadian) Temporarily install crankshaft pulley bolt, and rotate crankshaft so timing
1995-98 ............................... 2.8 Hours ... .. TCK208 .. ..... T208 mark on crankshaft sprocket aligns with timing mark on oil pump body.
1999 .................................... 2.8 Hours ... .. TCK208 .. ..... T208 See Fig. 2 or 3.
1
– With Air Conditioning and Power Steering, add .4 hours.
NOTE: A timing belt component kit is available for this application. belt align with those placed on all sprockets and timing belt is
See page A1 for information on component kits. installed in original direction of rotation.
2) Remove crankshaft pulley bolt. Install timing belt on crankshaft
NOTE: For information about tensioners and/or pulleys (when sprocket, oil pump drive sprocket, No. 1 idler pulley and then No. 2 idler
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED against timing belt. Rotate crankshaft clockwise 2 full turns from TDC to
SCHEDULED MAINTENANCE TDC. Ensure camshaft timing marks are still aligned. If all timing marks
For 1992-97 model years, the manufacturer recommends the belt be are aligned, tighten No. 1 idler pulley bolt to specification. See TORQUE
replaced every 60,000 miles under severe service operating conditions. SPECIFICATIONS.
For 1998 model year, the manufacturer recommends the belt be 4) Install timing belt guide with cupped side away from crankshaft
replaced every 90,000 miles for severe service operating conditions. For sprocket and flat side toward timing belt. Install No. 1 and No. 3 timing
1999 model year, the manufacturer recommends the belt be replaced belt covers and gasket. Align crankshaft pulley key groove with key in
every 90,000 miles or 72 months. crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley
bolt to specification.
REMOVAL & INSTALLATION 5) Install accessory drive belt pulley on front of crankshaft and tighten
bolt to specification. See TORQUE SPECIFICATIONS. Install gasket
TIMING BELT and No. 2 timing belt cover.
Removal – 1) Disconnect negative battery cable. Raise and support 6) To install remaining components, reverse removal procedure. If valve
vehicle. Remove right engine undercover. Remove accessory drive cover was removed, apply sealant at ends of camshafts. See Fig. 4. To
belts. Remove charcoal canister for access to timing belt covers. ensure proper mount alignment, install all right (timing belt side) engine
2) Slightly raise engine to remove weight from right (timing belt side) mount bolts/nuts before tightening to specification. See TORQUE
engine mount. Remove the through-bolt and right engine mount insula- SPECIFICATIONS. Adjust drive belts to proper tension.
tor. 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.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
possible and tighten bolt. Remove timing belt, idler pulley bolt and No. 2
idler pulley (if necessary). Fig. 1: Exploded View Of Timing Belt & Components
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.
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).
TOYOTA 659
1.5L 4-Cylinder – 5E-FE (Cont.)

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)
Engine Mount Right (Timing Belt Side)
Mount-To-Cylinder Block Bolt/Nut ........................................................................... 47 (64)
Through-Bolt ............................................................................................................ 54 (73)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Idler Pulley Bolt
No. 1 Idler Pulley .................................................................................................... 13 (18)
Fig. 2: Aligning Timing Marks No. 2 Idler Pulley .................................................................................................... 20 (27)
Oil Pump Drive Sprocket Nut ................................................................................... 27 (37)
Power Steering Pump Adjusting Bracket Bolt .......................................................... 15 (20)
Lower Bolt ............................................................................................................... 29 (39)
Upper Bolt ............................................................................................................... 32 (43)
Spark Plugs ............................................................................................................... 13 (18)
INCH Lbs. (N.m)
Valve Cover Nut ....................................................................................................... 61 (6.9)
Fig. 4: Cylinder Head Sealant Application Areas

660 TOYOTA
1.6L 4-Cylinder – DOHC, 4A-GE
Kit No. Part No.
Corolla FX-16, GTS & Sport (4A-GE)
1985-88 ............................ .......... 1 .......... .. TCK176 ........ T112
Corolla GTS (4A-GE, 4A-GELC)
1989-91 ............................ .... 1.6 Hrs. .... .. TCK176 .. ..... T176
MR2
1985-88 ............................ ... 2 2.7 Hrs. ... .. TCK176 ........ T112
1989 ................................. ... 2 2.7 Hrs. ... .. TCK176 .. ..... T176
1
– Labor time is 2.2 hours with FWD, or 1.6 hours with RWD.
2

See page A1 for information on component kits. Courtesy of Toyota Motor Sales, U.S.A., Inc.

For 1985 model year, although the manufacturer does not recommend
a specific scheduled maintenance interval, belt manufacturers suggest Courtesy of Toyota Motor Sales, U.S.A., Inc.
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. 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.
REMOVAL & INSTALLATION 3) Loosen tensioner pulley bolt allowing tensioner to apply tension to
belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE
TIMING BELT
2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If
Removal (1985-87 RWD Corolla) – 1) Remove air cleaner intake duct
timing marks align, tighten tensioner pulley bolt to specification. See
above radiator. If equipped with power steering, remove power steering
TORQUE SPECIFICATIONS. Remove crankshaft pulley.
belt. Remove the power steering pump with hoses attached and set
aside. 4) Measure timing belt deflection midway between camshaft sprockets.
2) Loosen water pump pulley bolts. Remove cooling fan belt. Remove See Fig. 3. If deflection is not correct, readjust timing belt tension.
cooling fan assembly. Remove spark plugs. 5) Install timing belt guide on crankshaft. Install timing belt covers. Install
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression crankshaft pulley. Install and tighten center bolt to specification. See
stroke. Crankshaft pulley notch must align with “0” timing mark on lower TORQUE SPECIFICATIONS.
timing belt cover. With valve cover oil filler cap removed, cavity in 6) Install water pump pulley and fan assembly. Install generator drive
camshaft should be visible. If not, turn crankshaft one complete revolu- belt. Install power steering pump pulley and drive belt. Adjust drive belt
tion. to proper tension.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
damage or improper installation. Ensure sprocket teeth are free of
foreign material. Fig. 3: Checking Timing Belt Deflection
3) Check free length of idler pulley tension spring. See Fig. 2. Replace Removal (1985-88 FWD Corolla) – 1) Raise and support vehicle.
spring if free length is not 1.713″ (43.5 mm). Inspect spring tension at Remove right front wheel. Remove engine under cover. Drain engine
installed length. Installed tension is 22 lbs. at 1.976″ (9.97 kg at 50.2 coolant.
mm). Replace spring if not to specification. 2) If equipped with cruise control, disconnect accelerator cable and
Installation (1985-87 RWD Corolla) – 1) If removed, install timing belt cruise control cable from actuator. Disconnect cruise control electrical
idler pulley (tensioner) and spring. Secure pulley as far to the left as connector. Remove cruise control actuator. Remove windshield washer
possible and temporarily tighten bolt. 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 6) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley
out of way. On all models, remove the upper radiator hose. as far left as possible and temporarily tighten bolt. Remove timing belt.
4) Loosen water pump pulley bolts. Remove all accessory drive belts. Inspection (MR2) – 1) Check timing belt teeth for cracks or damage. If
Rotate crankshaft so that No. 1 cylinder is at TDC of compression tooth damage is found, ensure camshaft and crankshaft sprockets are
stroke. Notch on crankshaft pulley must align with “0” timing mark on okay. If wear or cracks on flat side of belt face are found, check for nicks
timing belt cover. Remove oil filler cap from valve cover. Cavity in on idler pulleys. If wear or damage to only one side of belt is found,
camshaft should be visible in hole. If not, turn crankshaft one complete check belt guide and alignment of each pulley and sprocket.
revolution. 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.
sprockets, and on timing belt and crankshaft sprocket. Also place arrow 2) Install timing belt. If reusing old belt, ensure mating marks made on
on belt indicating original direction of rotation. disassembly match crankshaft and camshaft marks. Ensure arrow
7) Support weight of engine with floor jack. Remove engine mount from points in direction of rotation.
timing belt end of engine. 3) Loosen tensioner pulley bolt allowing tensioner to apply tension to
8) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE
as far left as possible and temporarily tighten bolt. Remove timing belt. 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If
Inspection (1985-88 FWD Corolla) – 1) Check timing belt teeth for timing marks align, tighten tensioner pulley bolt to specification. See
cracks or damage. If tooth damage is found, ensure camshaft and TORQUE SPECIFICATIONS. Remove crankshaft pulley.
crankshaft sprockets are okay. If wear or cracks on flat side of belt face 4) Measure timing belt deflection midway between camshaft sprockets.
are found, check for nicks on idler pulleys. If wear or damage to only one See Fig. 3. If deflection is not correct, readjust timing belt tension.
side of belt is found, check belt guide and alignment of each pulley and 5) Install timing belt guide on crankshaft. Install timing belt covers. Install
sprocket. crankshaft pulley. Install and tighten center bolt to specification. See
2) Check free length of idler pulley tension spring. See Fig. 2. Replace TORQUE SPECIFICATIONS.
spring if free length is not 1.713″ (43.5 mm). Inspect spring tension at 6) Install engine mount to timing belt end of engine. Tighten bolts to
installed length. Installed tension is 22 lbs. at 1.976″ (9.97 kg at 50.2 specification. See TORQUE SPECIFICATIONS. Install right front wheel
mm). Replace spring if not to specification. and engine under cover.
Installation (1985-88 FWD Corolla) – 1) If removed, install timing belt 7) Install water pump pulley. Install accessory drive belts. Adjust drive
idler pulley (tensioner) and spring. Secure pulley as far to the left as belts to proper tension.
possible and temporarily tighten bolt.
2) Install timing belt. If reusing old belt, ensure mating marks made on TORQUE SPECIFICATIONS
disassembly match crankshaft and camshaft marks. Ensure arrow
points in direction of rotation. TORQUE SPECIFICATIONS
3) Loosen tensioner pulley bolt allowing tensioner to apply tension to Application Ft. Lbs. (N.m)
belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE Camshaft Sprocket Bolt ............................................................................................ 34 (47)
2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If Crankshaft Pulley Bolt
timing marks align, tighten tensioner pulley bolt to specification. See Corolla (FWD) ..................................................................................................... 101 (137)
TORQUE SPECIFICATIONS. Remove crankshaft pulley. Corolla (RWD) ..................................................................................................... 105 (142)
4) Measure timing belt deflection midway between camshaft sprockets. MR2
See Fig. 3. If deflection is not correct, readjust timing belt tension. 1985-86 ................................................................................................................ 87 (118)
5) Install timing belt guide on crankshaft. Install timing belt covers. Install 1987 ................................................................................................................... 105 (142)
1988-89 .............................................................................................................. 101 (137)
crankshaft pulley. Install and tighten center bolt to specification. See
Engine Mounts (Corolla FWD)
FX-16
6) Install engine mount to timing belt end of engine. Tighten bolts to Through-Bolt .......................................................................................................... 58 (78)
specification. See TORQUE SPECIFICATIONS. Except FX-16
7) Install water pump pulley. Install accessory drive belts. Adjust drive Mount-To-Engine Bracket Nut ............................................................................... 34 (52)
belts to proper tension. Install right front wheel and engine under cover. Through-Bolt .......................................................................................................... 64 (87)
8) Install upper radiator hose. Install windshield washer tank. On FX-16, Engine Mount (MR2)
install ignition coil. On all models, install cruise control actuator (if Through-Bolt
equipped). Fill radiator with coolant and bleed air from system. 1985-87 .................................................................................................................. 58 (78)
Removal (MR2) – 1) Raise and support vehicle. Remove right front 1988-89 .................................................................................................................. 43 (58)
wheel. Remove engine under cover. Power Steering Pump-To-Bracket Bolts ................................................................... 43 (58)
2) Loosen water pump pulley bolts. Remove all accessory drive belts. Power Steering Pump Pulley Bolt (Corolla RWD) ................................................... 29 (39)
Rotate crankshaft so that No. 1 cylinder is at TDC of compression Spark Plug ................................................................................................................. 13 (18)
stroke. Notch on crankshaft pulley must align with timing mark on timing
Water Pump Bolts ..................................................................................................... 11 (15)
belt cover. Remove oil filler cap from valve cover. Cavity in camshaft Wheel Lug Nut ........................................................................................................ 76 (103)
should be visible in hole. If not, turn crankshaft one complete revolution.
3) Support weight of engine with floor jack. Remove engine mount INCH Lbs. (N.m)
through bolt from timing belt end of engine. Valve Cover Bolts ..................................................................................................... 69 (7.8)
sprockets, and on timing belt and crankshaft sprocket. Also place arrow
on belt indicating original direction of rotation.
662 TOYOTA
Kit No. Part No.
Corolla (FWD)
1984-88 .............................. 1 3.1 Hours .. .. TCK070 .. ..... T070
Corolla (RWD)
1983 ................................... 2 2.5 Hours .. .. TCK070 .. ..... T070
1984-87 ............................... 1.6 Hours ... .. TCK070 .. ..... T070
Corolla FX
1987-88 ............................... 2.5 Hours ... .. TCK070 .. ..... T070
Corolla SR5
1985-87 ............................... 1.6 Hours ... .. TCK070 .. ..... T070
1988 (FWD) ........................ 3.1 Hours ... .. TCK036 .. ..... T036
1 Courtesy of Toyota Motor Sales, U.S.A., Inc.
– With Air Conditioning and Power Steering, add .4 hours.
2
– With Air Conditioning, add .2 hours. Fig. 1: Aligning Timing Marks For Timing Belt Installation
3) Measure tension of spring at installed length. Tension should be
NOTE: A timing belt component kit is available for this application. 1.976″ at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if
See page A1 for information on component kits. necessary.

mend a specific scheduled maintenance interval, belt manufacturers Fig. 2: Measuring Tensioner Spring Free Length
suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model Installation (FWD Models) – 1) Insert timing belt between engine
mount and body. Lower engine, and install engine mount through-bolt
mile intervals for severe service operating conditions.
through body and mount insulator. Tighten bolt to specification. See
REMOVAL & INSTALLATION 2) Align camshaft sprocket timing hole with camshaft bearing cap mark.
Align timing marks on oil pump body and crankshaft timing sprocket.
TIMING BELT See Figs. 1 and 3.
Removal (FWD Models) – 1) Raise and support vehicle. Remove right 3) Install idler pulley (tensioner) and spring (if removed). Pry idler pulley
front wheel. Remove right undercover from wheelwell. Drain engine toward left and temporarily tighten bolt. Install timing belt. If installing
coolant. Disconnect upper radiator hose. used belt, ensure mating marks are aligned to camshaft sprocket and
2) Loosen water pump pulley bolts. Remove all accessory drive belts. crankshaft sprocket. See Fig. 4. Ensure arrow on belt points in original
Remove generator with wires attached and set aside. Remove A/C direction of rotation.
compressor from mount with hoses attached, and set aside. Remove 4) Loosen timing belt idler pulley bolt so that pulley applies tension to
water pump pulley. belt. Rotate crankshaft 2 revolutions from TDC to TDC. Recheck
3) Remove upper and center timing belt covers. Turn crankshaft until alignment of sprockets and timing belt. Tighten idler pulley (tensioner)
No. 1 cylinder is at TDC of compression stroke. Crankshaft pulley notch bolt to specification. See TORQUE SPECIFICATIONS.
must align with “0” timing mark on lower timing belt cover. Remove valve 5) Check timing belt deflection. See Fig. 5. If timing belt deflection is not
cover. Camshaft sprocket timing mark must align with mark on bearing correct, readjust timing belt tension.
cap. See Fig. 1. 6) Install timing belt guide on crankshaft. Install timing belt covers. Install
4) Hold crankshaft stationary and remove crankshaft pulley center bolt. crankshaft pulley and tighten bolt to specification.
Remove crankshaft pulley using a gear puller. Remove lower timing belt 7) Install water pump pulley. Install valve cover. Install air cleaner
cover. assembly. Install A/C compressor to engine mount. Install generator.
5) Noting installed position for reassembly reference, remove timing belt Install valve cover. Apply sealant to cylinder head when installing valve
guide from crankshaft. cover.
6) If reusing timing belt, place mating marks on belt and sprockets for 8) Install upper radiator hose. Refill cooling system.
reassembly reference. See Fig. 4. Place arrow on belt to indicate 9) Install right under cover. Install right front wheel. Adjust drive belts to
original direction of rotation. proper tension.
7) Loosen idler pulley bolt. Push idler pulley as far left as possible and Removal (RWD Models) – 1) Remove power steering and A/C com-
temporarily tighten center bolt. pressor drive belts (if equipped). On models with power steering,
8) Support weight of engine from below with a floor jack. Working from remove power steering pump with hoses attached and set aside.
below the vehicle, remove the 4 lower engine mount bolts from the 2) On all models, remove air cleaner assembly. Loosen water pump
engine crossmember. Remove engine mount through-bolt from mount at pulley bolts. Remove cooling fan drive belt. Remove cooling fan.
timing belt end of engine. Raise engine slightly and remove timing belt. Disconnect PCV hose and remove valve cover.
Inspection (FWD Models) – 1) Inspect timing belt for damaged teeth, 3) Hold crankshaft stationary and remove crankshaft pulley center bolt.
cracking and oil contamination. Ensure idler pulley rotates freely. Inspect Remove crankshaft pulley using a gear puller.
all sprockets for damage. Replace damaged components. 4) Remove timing belt covers and gaskets. Noting installed position for
2) Measure free length of tension spring. Free length should be 1.705″ reassembly reference, remove timing belt guide from crankshaft.
(43.3 mm). See Fig. 2. Replace tension spring if free length is not as 5) Rotate crankshaft so that No. 1 cylinder is at TDC on compression
specified. stroke. Align crankshaft and camshaft timing marks. See Figs. 1 and 3.
TOYOTA 663

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
3) Loosen timing belt idler pulley bolt so that pulley applies tension to
Fig. 3: Aligning TDC Marks On Crankshaft Sprocket & Oil Pump belt. Rotate crankshaft 2 revolutions from TDC to TDC. Recheck
Body alignment of sprockets and timing belt. Tighten idler pulley (tensioner)
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.
A/C Compressor-To-Block Bolts (4) .......................................................................... 18 (25)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Camshaft Sprocket Bolt ............................................................................................ 34 (47)
Fig. 4: Installing Timing Belt Engine Mount Through-Bolt (FWD Models) ............................................................. 58 (78)
Engine Mount-To-Crossmember Bolt ........................................................................ 29 (39)
6) If reusing timing belt, place mating marks on belt and sprockets for
reassembly reference. See Fig. 4. Place arrow on belt to indicate Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ..................................................................................................... 69 (7.8)
Fig. 5: Measuring Timing Belt Tension Deflection

664 TOYOTA
Application Labor Time 1 Component Belt
Kit No. Part No.
Celica
1990-92 ............................... 3.1 Hours ... .. TCK036 .. ..... T036
1993 .................................... 3.1 Hours ... ...... ..... ...... ..... T239
Corolla (4A-FE)
1988-92 ............................... 2.6 Hours ... .. TCK036 .. ..... T036
1993-97 ............................... 2.2 Hours ... .. TCK236 .. ..... T236
Celica
1994-97 ............................... 2.8 Hours ... .. TCK235 .. ..... T235
Corolla
1993-97 ............................... 2.2 Hours ... .. TCK235 .. ..... T235
1


intervals for severe service operating conditions. Courtesy of Toyota Motor Sales, U.S.A., Inc.
REMOVAL & INSTALLATION 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
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.
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left Fig. 2: Exploded View Of Timing Belt & Components
as possible, and snug tighten bolt. Remove timing belt. (1993-97 1.6L & 1.8L)
Inspection (Celica) – 1) Check timing belt teeth for cracks or damage. 1.6L engine, timing mark notch on crankshaft sprocket will align with
If tooth damage is found, ensure camshaft and crankshaft sprockets are
timing mark on oil pump housing. See Fig. 1. Crankshaft sprocket on
okay. If wear or cracks on flat side of belt face are found, check for nicks
1.8L engine does not have notch. On 1.6L and 1.8L, hole in camshaft
on idler pulleys. If wear or damage to only one side of belt is found,
sprocket must align with mark on bearing cap.
check belt guide and alignment of each pulley and sprocket.
2) Check free length of idler pulley tension spring. See Fig. 4. Replace NOTE: Loosen idler pulley (tensioner) bolt and allow pulley to
spring if free length is not 1.51″ (38.4 mm) for 1.6L (4A-FE engine), or
move against belt. Install timing belt guide on crankshaft (dished
1.252″ (31.8 mm) for 1.8L (7A-FE engine).
side facing away from belt).
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 2) Ensure idler pulley (tensioner) is pushed as far to the left as possible
at 37.6 mm) for 1.8L (7A-FE engine). If tension is not as specified, and pulley bolt is snug tight. If reusing old timing belt, install belt and
replace spring. align match marks made during removal. Install new timing belt.
Installation (Celica) – 1) Ensure No. 1 cylinder is at TDC on compres-
sion stroke. Crankshaft Woodruff key will be at 12 o’clock position. On
TOYOTA 665
Fig. 3: Placing Mating Marks On Timing Belt & Sprockets

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 crank-
shaft 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 Fig. 6: Identifying Cylinder Head Sealant Application Areas
marks are not aligned, remove and reinstall timing belt. If timing marks
Inspection (1988-92 Corolla) – 1) Check timing belt teeth for cracks or
are aligned, final tighten crankshaft pulley center bolt. See TORQUE
damage. If tooth damage is found, ensure camshaft and crankshaft
SPECIFICATIONS.
6) With idler pulley bolt still loose, measure timing belt deflection at sprockets are okay. If wear or cracks on flat side of belt face are found,
midway point of belt longest run. See Fig. 5. Deflection should be check for nicks on idler pulleys. If wear or damage to only one side of
.20-.24″ with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deflection belt is found, check belt guide and alignment of each pulley and
is not as specified, readjust tension on belt by moving idler pulley sprocket.
(tensioner). 2) Check free length of idler pulley tension spring. See Fig. 4. Replace
7) Tighten idler pulley bolt. Install upper and center timing belt covers. spring if free length is not 1.51″ (38.4 mm). Check tension at installed
When installing valve cover, ensure sealant is apply in correct positions. length. Tension should be 8.8 lbs. at 1.976″ (4 kg at 50.2 mm).
See Fig. 6. Installation (1988-92 Corolla) – 1) Ensure No. 1 cylinder is at TDC on
8) Install water pump pulley. On 1.8L engine, install A/C compressor compression stroke. Crankshaft key will be at 12 o’clock position, and
mount to engine. Install A/C compressor. timing mark notch on crankshaft sprocket will align with timing mark on
9) On 1.6L and 1.8L engines, install all accessory drive belts. Adjust oil pump housing. See Fig. 1. Hole in camshaft sprocket must align with
belts to proper tension. Final tighten water pump pulley bolts. mark on bearing cap.
10) Install engine mount to timing belt end of engine. Install front wheel
and engine under cover. Install cruise control actuator (if equipped). NOTE: Engine should be cold when installing timing belt.
Removal (1988-92 Corolla) – 1) Raise and support vehicle. Remove
2) Ensure idler pulley (tensioner) is pushed as far to the left as possible
right front wheel and engine undercover. Remove washer tank. Loosen
and pulley bolt is snug tight. If reusing old timing belt, install belt and
water pump pulley bolts, then remove all accessory drive belts. Remove
align match marks made during removal. Install new timing belt.
valve cover.
3) Loosen idler pulley (tensioner) bolt and allow pulley to move against
2) Disconnect engine wiring harness from upper timing belt cover.
Rotate crankshaft so that No. 1 cylinder is at TDC of compression belt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC.
stroke. Notch in crankshaft pulley must align with “0” timing mark on 4) Recheck timing mark alignment. If timing marks are not aligned,
timing belt cover. remove and reinstall timing belt.
3) Support weight of engine with a floor jack. Remove engine mount at 5) With idler pulley bolt still loose, measure timing belt deflection at
timing belt end of engine. midway point of belt longest run. See Fig. 5. Deflection should be
4) Remove water pump pulley. Remove crankshaft pulley bolt. Using .20-.24″ with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deflection
gear puller, remove crankshaft pulley. Remove timing belt covers. is not as specified, readjust tension on belt by moving idler pulley
Remove timing belt guide (large washer) from crankshaft sprocket. (tensioner).
5) If reusing timing belt, mark direction of rotation on timing belt. Match 6) Tighten idler pulley bolt to specification. See TORQUE SPECIFICA-
mark timing belt with marks on both sprockets for installation reference. TIONS. Install timing belt guide to crankshaft sprocket.
See Fig. 3. Place arrow on belt to indicate original direction of rotation. 7) Install timing belt covers. Install crankshaft pulley. Tighten center bolt
6) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left to specification. See TORQUE SPECIFICATIONS. When installing
as possible, and snug tighten bolt. Remove timing belt. valve cover, ensure sealant is apply in correct positions. See Fig. 6.
666 TOYOTA
8) Install water pump pulley. Install accessory drive belts. Adjust drive
belts to proper tension. Final tighten water pump pulley bolts. NOTE: Engine should be cold when installing timing belt.
9) Install front wheel and engine undercover. 2) Ensure idler pulley (tensioner) is pushed as far to the left as possible
Removal (1993-97 Corolla) – 1) Raise and support vehicle. Remove and pulley bolt is snug tight. If reusing old timing belt, install belt and
right front wheel and engine undercover. Lower vehicle. align match marks made during removal. Install new timing belt.
2) Remove windshield washer tank. Remove cruise control actuator 3) Loosen idler pulley (tensioner) bolt and allow pulley to move against
from right side of engine compartment. Loosen water pump pulley bolts, belt. Install timing belt guide on crankshaft (dished side facing away from
then remove all accessory drive belts. Remove water pump pulley. belt).
Remove valve cover. 4) Install lower timing belt cover. Install crankshaft pulley. Install crank-
3) On models with A/C, remove A/C compressor from mount bracket shaft pulley center bolt. Rotate crankshaft CLOCKWISE 2 revolutions
with hoses attached, and set aside. Remove A/C compressor mount from TDC to TDC.
bracket from engine. 5) Ensure crankshaft pulley notch aligns with “0” timing mark on lower
4) On all models, disconnect engine wiring harness from upper timing timing belt cover. Ensure camshaft sprocket timing marks align. If timing
belt cover. Rotate crankshaft so that No. 1 cylinder is at TDC of marks are not aligned, remove and reinstall timing belt. If timing marks
compression stroke. Notch in crankshaft pulley must align with “0” timing are aligned, final tighten crankshaft pulley center bolt. See TORQUE
mark on timing belt cover. SPECIFICATIONS.
5) Remove upper timing belt cover. With No. 1 cylinder at TDC, hole in 6) With idler pulley bolt still loose, measure timing belt deflection at
camshaft sprocket must align with mark on bearing cap. See Fig. 1. 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
6) Support weight of engine with a floor jack. Remove engine mount at
is not as specified, readjust tension on belt by moving idler pulley
(tensioner).
7) Remove crankshaft pulley bolt. Using gear puller, remove crankshaft
7) Tighten idler pulley bolt to specification. See TORQUE SPECIFICA-
pulley. Remove center and lower timing belt covers. Remove timing belt
TIONS.
guide (large washer) from crankshaft sprocket. 8) Install upper and center timing belt covers. When installing valve
8) If reusing timing belt, mark direction of rotation on timing belt. Match cover, ensure sealant is apply in correct positions. See Fig. 6.
mark timing belt with marks on both sprockets for installation reference. 9) Install water pump pulley. Install A/C compressor mount to engine.
See Fig. 3. Place arrow on belt to indicate original direction of rotation. Install A/C compressor.
9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left 10) Install all accessory drive belts. Adjust belts to proper tension. Final
as possible, and snug tighten bolt. Remove timing belt. tighten water pump pulley bolts.
Inspection (1993-97 Corolla) – 1) Check timing belt teeth for cracks or 11) Install engine mount to timing belt end of engine. On 1995-97
damage. If tooth damage is found, ensure camshaft and crankshaft models, ensure engine ground strap is connected to ground wire on
sprockets are okay. If wear or cracks on flat side of belt face are found, passenger side shock tower. Install front wheel and engine undercover.
check for nicks on idler pulleys. If wear or damage to only one side of Install cruise control actuator (if equipped).
belt is found, check belt guide and alignment of each pulley and
sprocket. TORQUE SPECIFICATIONS
2) Check free length of idler pulley tension spring. See Fig. 4. See
TENSION SPRING FREE LENGTH (1993-97 COROLLA) table. TORQUE SPECIFICATIONS
Replace spring if free length is not to specification. Application Ft. Lbs. (N.m)
3) Check tension at installed length. See TENSION SPRING A/C Compressor Mount Bracket-To-Engine
INSTALLED TENSION (1993-97 COROLLA) table. Replace spring if Celica (1.8L) ............................................................................................................ 35 (47)
tension is not to specification. A/C Compressor-To-Mount Bolts
Celica (1.8L) ............................................................................................................ 18 (25)
TENSION SPRING FREE LENGTH (1993-97 COROLLA) Camshaft Sprocket Bolt ............................................................................................ 43 (58)
Application Free Length – In (mm) Crankshaft Pulley Bolt ............................................................................................. 87 (118)
1993-94 1.6L ................................................................................................. 1.453 (36.9) Engine Mounts
Celica (1993)
(4A-FE) .............
Mount Bolt ............................................................................................................. 47 (64)
1995-97 1.6L ................................................................................................. 1.717 (43.6)
Mount Nut .............................................................................................................. 38 (52)
(4A-FE) ............. Celica (1994-97) & Corolla (1988-92)
1993-97 1.8L ................................................................................................. 1.252 (31.8) Mount-To-Engine Bracket Bolt .............................................................................. 47 (64)
(7A-FE) ............. Mount-To-Engine Bracket Nut ............................................................................... 38 (52)
Through-Bolt .......................................................................................................... 64 (87)
TENSION SPRING INSTALLED TENSION (1993-97 COROLLA) Corolla (1993-97)
Application Tension At Installed Length – Lbs. At In. (Kg At mm) Mount-To-Body Bolt ............................................................................................... 19 (25)
1993-94 1.6L ............................................................................ 13 at 1.988 (5.9 at 50.5) Mount-To-Engine Bracket Bolt .............................................................................. 47 (64)
(4A-FE) ............. Mount-To-Engine Bracket Nut ............................................................................... 38 (52)
1993-94 1.8L ....................................................................... 26.5 at 1.988 (12.4 at 50.5) Power Steering Pump-To-Bracket Bolts ................................................................... 29 (39)
Spark Plug ................................................................................................................. 13 (18)
(7A-FE) .............
1995-97 1.6L ........................................................................... 8.6 at 1.717 (3.9 at 43.6)
Wheel Lug Nut ........................................................................................................ 76 (103)
(4A-FE) .............
1995-97 1.8L .......................................................................... 11.7 at 1.480 (5.3 at 37.6) INCH Lbs. (N.m)
(7A-FE) ............. Timing Belt Cover Bolt ............................................................................................. 65 (7.4)
Valve Cover Cap Nuts
Installation (1993-97 Corolla) – 1) Ensure No. 1 cylinder is at TDC on
1988-92 1.6L .......................................................................................................... 69 (7.8)
compression stroke. Crankshaft woodruff key will be at 12 o’clock 1993-97 1.6L & 1.8L .............................................................................................. 52 (5.9)
position. On 1.6L engine, timing mark notch on crankshaft sprocket will Water Pump Pulley Bolt ........................................................................................... 82 (9.3)
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.
TOYOTA 667

TIMING BELT APPLICATION Removal (1985-86) – 1) Disconnect negative battery cable. Remove air
Application Labor Time Belt cleaner. Drain engine coolant and remove radiator hoses, washer, and
Part No. radiator reservoir tanks. Remove drive belts, cooling fan and pulley.
1.8L 4-Cyl. – Diesel 2) Remove cruise control actuator (if equipped). Disconnect the accel-
Camry erator and cruise control cables. Disconnect the actuator vacuum hose.
1984-86 ..................................................... 5.0 Hours ... ..... T098 Remove the actuator cover, and the actuator. Disconnect the wiring
Corolla connector.
1984-85 ..................................................... 2.7 Hours ... ..... T098 3) Remove power steering pump with bracket (if equipped). Remove
drive belt and pulley. Remove 3 mounting bolts and power steering
NOTE: For information about tensioners and/or pulleys (when pump with bracket. Place pump aside and suspend it. Remove alterna-
available), see ALPHABETICAL MODEL LISTING. tor 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
MANUFACTURER’S SUGGESTED cylinder head. Using Special Service Socket (09213-14010
SCHEDULED MAINTENANCE and 09330-00020) or equivalent, remove crankshaft pulley. See Fig. 1.
5) Remove No. 1 timing belt cover and belt guide. Jack up engine
The manufacturer recommends the belt be replaced every 60,000 miles. 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,
REMOVAL & INSTALLATION indicating direction of engine rotation. Place match marks on pulleys and
TIMING BELT timing belt at each position.
Inspection (All Models) – 1) Check timing belt for wear, cracks or
Removal (1984) – 1) Disconnect negative battery cable. Remove air
missing teeth. If defective, check if injection pump camshaft is locked or
cleaner. Drain engine coolant and remove radiator hoses, cooling fan there are nicks on belt side of idler pulley lock. Replace belt and
shroud and radiator from vehicle. Remove drive belts, cooling fan and components as needed.
pulley. 2) Inspect belt for excessive wear on one side only. If damaged, check
2) If equipped with A/C, remove compressor pulley from crankshaft the belt guide and the alignment of each sprocket. Before installing new
pulley. Using Pulley Holder and Socket (09213-14010 belt, remove idler pulleys and spring. Check idler pulley bearings for
and 09330-00020) or equivalent, remove crankshaft pulley set bolt and noise or roughness.
washer. 3) Inspect spring for proper free length and tension. Standard free length
3) Using a puller, remove crankshaft pulley. See Fig. 1. If equipped with is 2.045″ (51.93 mm). Replace idler pulley and/or spring as necessary.
A/C, remove idler pulley. Remove timing belt cover mount bolts. 4) Check camshaft, injection pump and crankshaft timing sprockets for
Remove timing belt cover and belt guide. wear or damage. If belt teeth are worn, check timing belt cover gasket
4) Disconnect glow plugs by removing 4 screw grommets and glow plug for damage and proper installation. Replace components as necessary.
connecting nuts. Disconnect current sensor by removing nut, plate Installation (All Models) – 1) Install timing belt tensioner, with larger
washer, insulator and current connector. Remove glow plug connector bolt behind water pump, and loosely fasten mounting bolts. Swing
and glow plugs. tensioner toward the left. Check alignment of timing marks on each
5) Using crankshaft set bolt, rotate engine and align TDC mark on pulley. See Fig. 2.
camshaft timing pulley with top surface of cylinder head on intake NOTE: When tightening idler pulley and timing sprocket mount
manifold side. Using pliers, remove tensioner spring. Loosen tensioner bolts, do not move idler pulley bracket or apply tension to timing
set bolts and remove timing belt. 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 crank-
shaft 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.

668 TOYOTA
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)
Fig. 2: Aligning Camshaft, Crankshaft & Injection Pump Sprocket

Timing Marks
TOYOTA 669
2.0L 4-Cylinder – Except RAV4

1
Kit No. Part No.
2.0L 4-Cyl.
Camry
1983-86 ............................... 3.6 Hours ... .. TCK087 .. ..... T087
1987-91 ............................... 3.0 Hours ... .. TCK199 .. ..... T138
Celica
1986
GTS ................................... 3.2 Hours ... ...... ..... ...... ..... T125
Exc. GTS .......................... 2.8 Hours ... .. TCK087 .. ..... T087
1987-88
GTS ................................... 3.0 Hours ... ...... ..... ...... ..... T125
Exc. GTS .......................... 2.8 Hours ... .. TCK199 .. ..... T138 Fig. 1: Aligning Oil Seal Retainer Mark With
1989 .................................... 3.0 Hours ... .. TCK199 .. ..... T138 Camshaft Sprocket Hole
1990-93 ............................... 4.3 Hours ... ...... ..... ...... ..... T125
MR2
1991-95 ............................... 4.0 Hours ... ...... ..... ...... ..... T125
1


MANUFACTURER’S SUGGESTED Courtesy of Toyota Motor Sales, U.S.A., Inc.
SCHEDULED MAINTENANCE Fig. 2: Positioning Sprocket To BTDC Or ATDC

For 1983-85 model years, although the manufacturer does not recom- retaining bolt 1/2 turn and release spring tension on timing belt. To
mend a specific scheduled maintenance interval, belt manufacturers complete installation, reverse removal procedure. Adjust drive belts to
suggest the belt be replaced at 60,000 mile intervals. For 1986-95 model proper tension.

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 actua-
tor 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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
belt from camshaft timing sprocket.
4) Using Drive Shaft Holding Tool (09278-54011) or equivalent, hold Fig. 3: Installing Crankshaft Sprocket
timing sprocket in place, then remove sprocket retaining bolt and Removal (Celica With 3S-GE Engine) – 1) Disconnect negative battery
sprocket. Remove No. 1 idler pulley and tension spring. Using Crank-
cable. Raise and support vehicle. Remove right front wheel and engine
shaft Pulley and Companion Flange Holding Tools (09213-14010
undercover. Remove radiator reservoir tank. Remove cruise control
and 09330-00020) or equivalents, remove crankshaft pulley retaining
actuator and bracket.
bolt, then pulley.
2) Remove the power steering oil reservoir bolts, and position reservoir
5) Remove No. 1 timing belt cover and gasket assembly. Remove timing
belt and belt guide. Remove No. 2 idler pulley and crankshaft timing aside. Remove accessory drive belts. Remove alternator and bracket.
sprocket. Raise the engine slightly with suitable jack with wooden block between
jack and engine. Remove the right engine mount through-bolt, then
Installation (1983-86 Camry) – 1) Install crankshaft timing sprocket
mount.
over crankshaft key. See Fig. 3. Install No. 2 idler pulley. See Fig. 4.
Tighten idler pulley retaining bolt. Temporarily install timing belt onto 3) Remove the valve cover. Remove spark plugs. Remove No. 2 timing
sprockets. Install timing belt guide. Install No. 1 timing belt cover and belt cover with gasket. Set the cylinder No. 1 to TDC by rotating
gasket assembly. crankshaft pulley until groove is aligned with “0” timing mark. See Fig. 6.
2) Install crankshaft pulley. Pull timing belt upward and align preset mark Ensure alignment marks of camshaft pulleys and No. 3 timing belt cover
on No. 1 timing belt cover with crankshaft pulley groove. See Fig. 5. are aligned. See Fig. 7.
Align camshaft oil seal retainer preset mark with center of small hole on
camshaft timing pulley. Install timing belt. Loosen No. 1 idler pulley
670 TOYOTA
2.0L 4-Cylinder – Except RAV4 (Cont.)

Fig. 4: Installing No. 2 Idler Pulley
Fig. 6: Positioning Crankshaft Pulley At TDC (3S-GE)
Fig. 7: Aligning Camshaft Sprocket Marks With Marks On

No. 3 Timing Belt Cover (3S-GE)
Fig. 5: Aligning Mark On No. 1 Timing Belt Cover With 4) Hang the timing belt on camshaft sprocket pulleys with sprocket “S”
Groove In Crankshaft Pulley
markings facing outward. Align the camshaft sprocket alignment marks
4) Loosen the spring loaded idler pulley attaching bolt. Pry pulley as far with No. 3 timing cover match mark, and install sprockets. See Fig. 7. On
left as possible and temporarily tighten bolt. Remove the timing belt from models equipped with 2-hole camshaft flange, ensure camshaft knock
the camshaft timing pulleys. Hold the camshaft flats with a suitable pin is aligned with sprocket hole.
wrench and remove the camshaft sprocket attaching bolts, sprockets 5) On models equipped with 5-hole camshaft flange, insert knock pin
and pins. Mark the intake and exhaust camshaft sprockets for installa- into any holes in alignment. On 5-hole flange type cams, if knock pin
tion reference before removing. alignment is not exact, camshafts can be rotated slightly to compensate.
5) Remove the crankshaft pulley attaching bolt, then using suitable While holding the camshafts with suitable wrench, install and tighten
puller, remove the crankshaft pulley. Remove No. 1 timing cover, then camshaft sprocket attaching bolts.
the timing belt guide from crankshaft sprocket. Remove the timing belt, 6) Loosen the spring-loaded idler pulley attaching bolt just enough to
spring loaded idler pulley, tension spring and fixed idler pulley from allow pulley to move by itself under spring tension. Allow the pulley to
engine. take up belt tension. Rotate the crankshaft clockwise 2 complete
Installation (Celica With 3S-GE Engine) – 1) Install fixed idler pulley. revolutions. Tighten pulley bolt. Ensure that the timing belt has tension
Pry the idler pulley as far to the left as possible, then temporarily tighten between crankshaft sprocket and intake camshaft sprocket. See Fig. 10.
attaching bolt. Temporarily install the timing belt on crankshaft sprocket, To complete installation, reverse removal procedure. Adjust drive belts
oil pump sprocket, fixed idler pulley and water pump pulleys. to proper tension.
2) Install the timing belt guide on crankshaft sprocket and timing cover
Removal (1987-91 Camry & 1988-89 Celica With 3S-FE Engine) – 1)
No. 1. Install the crankshaft pulley. Ensure crankshaft pulley groove is
Disconnect negative battery cable. Raise and support vehicle. Remove
still aligned with “0” timing mark. This indicates No. 1 cylinder is at TDC
right front wheel. Remove undercover. Remove cruise control actuator
of compression stroke. See Fig. 6.
and bracket (if equipped). Remove accessory drive belts. Remove
3) On models equipped with 2-hole camshaft flanges, use suitable
alternator and bracket.
wrench to align camshaft knock pins and cam lobes as shown. See
Fig. 8. On models equipped with 5-hole camshaft flanges, use suitable CAUTION: Position a wooden block between jack and engine to
wrench to align camshaft alignment marks as shown. See Fig. 9. prevent damage.
2) Use a jack to raise engine slightly. Remove right side engine mount
through-bolt, and then mount.
TOYOTA 671
Fig. 8: Aligning Camshaft Sprocket With 2-Hole Camshaft Flange

(3S-GE)
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
bearing cap No. 1 alignment mark. See Fig. 14.
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
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
with matchmark on crankshaft sprocket. See Fig. 13. Fig. 12: Marking Timing Belt & Camshaft Sprocket For
Installation (1987-91 Camry & 1988-89 Celica With 3S-FE Engine) – Reuse Of Timing Belt (3S-FE)
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.
672 TOYOTA
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.
Fig. 13: Marking Timing Belt & Crankshaft Sprocket For

Reuse Of Timing Belt (3S-FE)

Fig. 15: Aligning Camshaft Sprocket Timing Marks (3S-GTE)
Fig. 14: Camshaft Sprocket Alignment (3S-FE)
Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine) –
1) Temporarily install No. 1 idler pulley and tension spring. See Fig. 16.
NOTE: If reusing timing belt, align matchmarks on timing belt with Install pulley attaching bolt. Do not tighten bolt. Install tension spring,
matchmark on camshaft sprocket. See Fig. 12. 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
2) Install timing belt on camshaft sprocket. Ensure that belt has tension water pump pulley.
between crankshaft sprocket, water pump sprocket and camshaft 2) Install timing belt guide. Install No. 1 timing belt cover and gasket.
sprocket. Loosen spring loaded idler pulley attaching bolt just enough to Make sure camshaft groove is aligned with drilled out mark of No. 1
allow pulley to move under spring tension. Allow pulley to take up belt camshaft bearing cap.
tension. 3) Place No. 1 cylinder at TDC of compression stroke by turning
3) Rotate crankshaft clockwise two complete revolutions, from TDC crankshaft pulley and aligning its groove with “0” mark on No. 1 timing
compression stroke to TDC compression stroke, then tighten spring belt cover. See Fig. 17. Turn camshaft and align marks on camshaft
loaded idler pulley. Ensure that timing belt has tension between water sprockets and cylinder head cover.
pump sprocket and camshaft sprocket. Install upper timing belt cover. To 4) Install timing belt. Ensure that tension between crankshaft and intake
complete installation, reverse removal procedure. Adjust drive belts to camshaft timing sprockets exists. To complete installation, reverse
proper tension. 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 nega-
tive 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.
TOYOTA 673

Camshaft Timing Sprocket Bolt .................................................... ................. 40-43 (54-59)
Engine Mount
Bolt ........................................................................................................................... 65 (88)
Nut ........................................................................................................................... 38 (52)
Through-Bolt ............................................................................................................ 64 (87)
Idler Pulley Bolt
No. 1 ........................................................................................................................ 31 (42)
No. 2 ........................................................................................................................ 31 (42)
Oil Pump Pulley ........................................................................................................ 31 (42)
Fig. 16: Installing Tension Spring & Idler Pulley Valve Cover Nut ........................................................................................................ 17 (23)
INCH Lbs. (N.m)
Timing Cover Attaching Bolts ..................................................................................... 78 (9)
Fig. 17: Identifying Crankshaft Pulley Angle

674 TOYOTA
2.0L 4-Cylinder – RAV4
1
Kit No. Part No.
2.0L 4-Cyl.
RAV4
1996-00
1
With ABS ......................... 5.3 Hours .. .. TCK199 .. ..... T199
1
Without ABS ................... 3.3 Hours .. .. TCK199 .. ..... T199
1

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.

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. 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 compres- Fig. 2: Removing No. 2 Timing Belt Cover
sion stroke by temporarily installing No. 1 timing belt cover and between cylinder head cover and No. 3 timing belt cover. Install No. 2
crankshaft pulley. Align groove with timing mark “0” on No. 1 timing belt timing belt cover. Install engine wire to No. 2 timing belt cover. Install
cover. Ensure that camshaft and timing belt match marks are aligned. engine wire protector to mounting bolts of No. 2 timing belt cover.
Remove crankshaft pulley and timing belt cover. Install timing belt. If
5) Remove crankshaft pulley. Install engine mounting bracket-to-engine
reusing old belt, ensure rotation direction and mating marks are in
bolts and tighten to specification. Install crankshaft pulley, and tighten
correct position.
pulley bolt to specification. See TORQUE SPECIFICATIONS. To com-
2) Install timing belt guide on crankshaft with cup side facing out. Install
plete installation, reverse removal procedure. Adjust drive belts to
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 proper tension.
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
TOYOTA 675
2.0L 4-Cylinder – RAV4 (Cont.)

Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 7: Locating 45 Degree BTDC Mark
Fig. 3: Setting No. 1 Cylinder To TDC
Camshaft Timing Pulley Bolt .................................................................................... 40 (54)
Generator Bracket Bolts ............................................................................................ 31 (42)
Engine Mount Insulator-To-Body Bolts ..................................................................... 38 (52)
Engine Mount Insulator-To-Bracket Nut .................................................................... 27 (37)
No. 1 Idler Pulley Mounting Bolt .............................................................................. 31 (42)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Water Pump Bolts .................................................................................................... 78 (8.8)
Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt
Fig. 5: Aligning Matching Marks Of Timing Belt & Cams

676 TOYOTA
1
Part No.
Pickup
1981 ........................................................... 2.2 Hours ... ..... T079
1982
Up To 5/31 .............................................. 2.2 Hours ... ..... T079
From 6/1 ................................................. 2.2 Hours ... ..... T084
1983 ........................................................... 2.2 Hours ... ..... T084
1

miles.

damage may occur. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Fig. 1: Exploded View Of Cylinder Head & Timing Belt

TIMING BELT pulley bracket is moving. Ensure that each pulley aligns with marks. See
Fig. 3. Tighten timing belt idler pulley bolt. Reverse removal procedure
NOTE: Late model 1982 engines with extra idler pulley use a
to complete installation. Adjust drive belts to proper tension.
different design timing belt. ALL timing pulleys and camshaft
pulleys are also different from early 1982 engines. Timing pulleys
and camshaft pulleys are not interchangeable between engines.
Removal – 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 radia-
tor 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, cam-

shaft pulley, and injection pump pulley, release tension on timing
belt. Do not bend or twist belt, and keep belt free from oil, water or Courtesy of Toyota Motor Sales, U.S.A., Inc.
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
TOYOTA 677

Camshaft-To-Timing Pulley ........................................................... ............... 69-75 (94-102)
Crankshaft Pulley Bolt ................................................................... ............... 69-75 (94-102)
Fig. 3: Realigning Timing Marks

678 TOYOTA
TIMING BELT APPLICATION 9) Using gear puller, remove crankshaft pulley. Remove No. 1 timing belt
Application Labor Time Component Belt cover and gasket. Note direction of timing belt guide installation. See
Kit No. Part No. Fig. 1. Remove timing belt guide.
2.2L 4-Cyl. 10) Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing belt from
Camry crankshaft sprocket. Remove idler pulleys (if necessary).
1992-01 ........................... .. 1 3.0 Hours .. .. TCK199 .. ..... T199
Camry Solara
1999-01 ........................... .. 1 3.0 Hours .. .. TCK199 .. ..... T199
Celica
1990-91 ........................... .. 1 3.1 Hours .. .. TCK199 .. ..... T199
1992-99 ........................... .. 1 2.4 Hours .. .. TCK199 .. ..... T199
Celica GT & GTS
1990-91 ............................ 1, 2 3.1 Hours . .. TCK199 .. ..... T199
1992-93 ............................ 1, 2 3.1 Hours . .. TCK199 .. ..... T138
MR2
1991-95 ........................... .. 1 3.5 Hours .. .. TCK199 .. ..... T199
1
On MR2 with Turbo and Air Conditioning, time is 4.5 hours.
2
– On Celica AWD, add 1.2 hours.


SCHEDULED MAINTENANCE Courtesy of Toyota Motor Sales, U.S.A., Inc.
replaced every 60,000 miles under severe service driving conditions. Fig. 1: Exploded View of Timing Belt & Components

TIMING BELT
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
3) On all models, remove accessory drive belts. Using floor jack, slightly
raise engine to remove weight from right (timing belt side) engine mount Fig. 2: Aligning Camshaft Timing Marks
at timing belt cover. Inspection – 1) Inspect timing belt for damaged teeth, cracking or oil
4) Remove right (timing belt side) engine mount and bracket from front contamination. Ensure idler pulleys rotate freely. Replace components if
of engine. Remove spark plugs. Remove No. 2 timing belt cover and damaged or worn.
gaskets. See Fig. 1.
5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compres- NOTE: For 1992-96 Camry, the timing belt tension spring proce-
sion stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. dure has been revised. See REVISED TIMING BELT TENSION
6) Ensure timing mark on crankshaft pulley aligns with ”0″ mark on No. 1 SPRING PROCEDURE (1992-96 CAMRY).
timing belt cover. Ensure hole in camshaft sprocket aligns with align-
2) Ensure free length of tension spring is within specification. See
ment mark on camshaft bearing cap. See Fig. 2. If hole in camshaft
TENSION SPRING SPECIFICATIONS table. Measure free length
sprocket is not aligned with alignment mark, rotate crankshaft clockwise
between from inside edges of hooked portion of spring. Do not measure
one full revolution.
spring coils. See Fig. 3.
CAUTION: If reusing timing belt, mark direction of timing belt 3) Measure tension needed to extend tension spring to specified
rotation on belt. Place mating marks on timing belt at camshaft installed length. Replace spring if tension is not within specification. See
sprocket and at crankshaft sprocket for reassembly reference. TENSION SPRING SPECIFICATIONS table.
Also place reference mark on timing belt at upper edge of No. 1
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 crank-
shaft pulley. Remove crankshaft pulley bolt.
TOYOTA 679
2.2L 4-Cylinder – Gasoline (Cont.)

TENSION SPRING SPECIFICATIONS
Application Specification CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed
Free Length from timing belt end of engine.
Except 1999-00 Camry ................................ ........................................ 1.811″ (46.00 mm) 9) Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full
1999-00 Camry ............................................ ........................................ 1.654″ (42.00 mm)
revolutions clockwise from TDC to TDC.
Tension At Spring Installed Length 1
Camry (1992-95) 10) Ensure timing mark on crankshaft pulley aligns with ”0″ mark on
Green Spring ............................................. ........................... 7.2-8.3 Lbs. (3.25-3.75 kg) No. 1 timing belt cover, and hole in camshaft sprocket aligns with
Silver Spring ...................................................................... 10.5-11.6 Lbs. (4.75-5.25 kg) alignment mark on camshaft bearing cap. See Fig. 2. If timing marks are
Camry (1996-01) .......................................... ........................... 7.2-8.3 Lbs. (3.25-3.75 kg) not aligned, remove timing belt and reinstall.
Camry Solara ............................................... ........................... 7.2-8.3 Lbs. (3.25-3.75 kg) 11) Rotate crankshaft clockwise 1 and 7/8 revolutions and align crank-
Celica & MR2 .............................................. ........................... 7.2-8.3 Lbs. (3.25-3.75 kg) shaft pulley “0” mark with 45-degree Before Top Dead Center (BTDC)
1
– At 1.988″ (50.50 mm). 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
Fig. 3: Measuring Tensioner Spring Free Length locations. See Fig. 7. Adjust drive belts to proper tension.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
smoothly. Fig. 4: Aligning Crankshaft Sprocket Timing Marks
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 o’clock
position.

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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
5) Install timing belt guide with cupped side away from crankshaft Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC Mark
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
tion.
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
tension exists on timing belt between crankshaft and camshaft sprock-
Fig. 6: Control Rod & Bracket Bolt Installation Sequence (Camry)
ets.
680 TOYOTA
2.2L 4-Cylinder – Gasoline (Cont.)
TORQUE SPECIFICATIONS (CELICA)
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)
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)
Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8)
TORQUE SPECIFICATIONS (MR2)

Left (Flywheel Side) Engine Mount
Through-Bolt ............................................................................................................ 58 (79)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Bracket Bolt ................................................................................. ..................................... 1
Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts (MR2) Support Bracket Bolt/Nut ........................................................................................ 54 (73)
Bracket-To-Cylinder Block Bolt ............................................................................... 45 (61)
TORQUE SPECIFICATIONS Mounting Bracket Nut ............................................................................................. 38 (52)
TORQUE SPECIFICATIONS (CAMRY) Through-Bolt ............................................................................................................ 58 (79)
Idler Pulley Bracket-To-Cylinder Block Bolt
Application Ft. Lbs. (N.m) 12-mm Head ............................................................................................................ 20 (27)
Alternator Bracket Bolt .............................................................................................. 31 (42) 14-mm Head ............................................................................................................ 27 (37)
Camshaft Sprocket Bolt ............................................................................................ 40 (54) Fuel Pulsation Damper ............................................................................................. 25 (34)
Coolant Outlet Bolt .................................................................................................... 11 (15) No. 1 Idler Pulley Bolt .............................................................................................. 31 (42)
Crankshaft Pulley Bolt ............................................................................................. 80 (109) No. 2 Idler Pulley Bolt .............................................................................................. 31 (42)
Engine Mounts & Brackets Spark Plug ................................................................................................................. 13 (18)
Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ............... 38 (52) Valve Cover Nut ........................................................................................................ 17 (23)
No. 1 Idler Pulley Bolt ............................................................................................... 31 (42) Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Oil Pump Sprocket Nut ............................................................................................. 21 (29)
Power Steering Pump Bracket Bolt .......................................................................... 32 (43) No. 3 Timing Belt Cover Bolt .................................................................................. 68 (7.8)
Power Steering Pump-To-Bracket Bolt ..................................................................... 32 (43) Water Pump-To-Cylinder Block Bolt ............................................. ..................................... 2
Spark Plug ................................................................................................................. 13 (18) Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8)
Valve Cover Nut ........................................................................................................ 17 (23) 1
– Tighten bolts to specification. See Fig. 7.
Wheel Lug Nut ........................................................................................................ 76 (103) 2
– Tighten bolts to 78 INCH lbs. (8.8 N.m) in sequence. See Fig. 7. On models without A/C,
INCH Lbs. (N.m) tighten large bracket bolt to 20 ft. lbs. (27 N.m).
Coolant By-Pass Pipe-To-Water Pump Nut ............................................................ 78 (8.8)
No 3 Timing Belt Cover Bolt ................................................................................... 69 (7.8)
Oil Pan Bolt/Nut ....................................................................................................... 48 (5.4)
Oil Pump Body Cover Bolt ...................................................................................... 78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut ............................................................................. 48 (5.4)
Oil Pump-To-Cylinder Block Bolt ............................................................................. 82 (9.3)
Water Pump-To-Water Pump Cover Bolt ................................................................ 82 (9.3)
TOYOTA 681

TIMING BELT APPLICATION 3) Using Puller (09213-60017) or equivalent, remove crankshaft pulley.
Application Labor Time Belt If equipped with A/C, remove idler pulley. On 2L, remove timing belt
Part No. cover mount bolts, timing belt cover, and belt guide. On 2L-T, remove
2.4L 4-Cyl. – Diesel No. 1 turbocharger water pipe, air cleaner pipe, No. 1 air cleaner hose,
Pickup and timing cover. On all models, disconnect glow plugs by removing 4
1984-87 ..................................................... 2.2 Hours ... ..... T084 screw grommets and glow plug connecting nuts. Disconnect current
sensor by removing nut, plate washer, insulator and current connector.
NOTE: For information about tensioners and/or pulleys (when Remove glow plug connector and glow plugs.
available), see ALPHABETICAL MODEL LISTING. 4) Using crankshaft set bolt, rotate engine and align TDC mark on
camshaft timing pulley with top surface of cylinder head. See Fig. 2.
MANUFACTURER’S SUGGESTED Using pliers, remove tensioner spring. Loosen tensioner set bolts, and
SCHEDULED MAINTENANCE remove timing belt. Using Pulley Holder (09278-54011), and a wrench,
remove camshaft pulley set bolt. Using Puller (09950-20015), remove
The manufacturer recommends the belt be replaced every 100,000 camshaft pulley. Using Pulley Holder (09278-54011), and a wrench on
miles. injection pump drive pulley, remove set bolt on pulley.
REMOVAL & INSTALLATION 5) Using Puller (09213-60017), remove injection pump drive pulley.
Remove lower timing belt idler pulley. Using Puller (09213-60017),
CAUTION: This application is an interference engine. Do not rotate remove crankshaft timing belt pulley.
camshaft or crankshaft when timing belt is removed, or engine Inspection – 1) Check timing belt for wear, cracks or missing teeth. If
damage may occur. 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
TIMING BELT needed. Inspect belt for excessive wear on one side only. If damaged,
Removal – 1) Disconnect negative battery cable. Drain engine coolant check belt guide and alignment of each pulley. Before installing new belt,
and radiator hoses, fan shroud, and radiator from vehicle. Remove remove idler pulleys and spring. Check idler pulley bearings for noise or
water pump pulley, drive belts, cooling fan and pulley. See Fig. 1. roughness.
2) If equipped with A/C, remove compressor pulley from crankshaft 2) Inspect spring for proper free length and tension. Standard free length
pulley. Using Crankshaft Pulley Holding Tool (09213-54011) and Com- is 1.563″ (39.70 mm). See Fig. 3. Installed tension is 8.8 lbs. at 2.05″
panion Flange Holding Tool (09330-00020) or equivalent, remove (4.0 kg at 52 mm). Replace idler pulley and/or spring as necessary.
crankshaft pulley set bolt and washer.

682 TOYOTA
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.

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 compo-
nents as necessary.

Installation – 1) Install lower idler pulley. Install timing belt tensioner, Courtesy of Toyota Motor Sales, U.S.A., Inc.
with large bolt behind water pump, and loosely fasten mounting bolts.
Fig. 4: Realigning Timing Marks
Swing tensioner toward the left. Set No. 1 cylinder to TDC of compres-
sion stroke and check alignment of timing marks on each pulley. See TORQUE SPECIFICATIONS
Fig. 2. If using a new timing belt, note that injection pump timing is
normally in the retarded position. TORQUE SPECIFICATIONS
CAUTION: When tightening idler pulley and timing sprocket mount
bolts, DO NOT move idler pulley bracket or apply tension to timing Crankshaft Pulley Bolt ........................................................................................... 101 (137)
belt. Glow Plugs .................................................................................................................. 9 (13)
Injector Pump Drive Pulley Bolt ............................................................................... 47 (64)
2) Install timing belt onto camshaft timing pulley. Ensure timing belt is
securely meshed and not loose. Align marks of injector pump drive Timing Belt Tensioner Pulley Bolts ........................................................................... 14 (19)
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.
TOYOTA 683
2.5L & 3.0L V6 – DOHC – 1988-97

Kit No. Part No. WARNING: To prevent air bag deployment, disconnect negative
2.5L V6 battery cable at least 90 seconds before working on vehicle.
Camry
1988-91 ............................... 3.8 Hours ... .. TCK157 .. ..... T157
3.0L V6 TIMING BELT
Avalon Removal (2.5L & 1992-93 3.0L V6) – 1) Disconnect negative battery
1995-97 ............................... 3.0 Hours ... .. TCK257 .. ..... T257 cable. Remove cruise control actuator and vacuum pump. Remove
Camry power steering reservoir with hoses attached, and secure them aside.
1992-93 ............................... 3.0 Hours ... .. TCK200 .. ..... T200 Raise and support vehicle. Remove right front wheel. Remove right
1994-97 ............................... 3.0 Hours ... .. TCK257 .. ..... T257 lower engine cover. Remove all drive belts.
NOTE: A timing belt component kit is available for this application. 2) Remove top braces on right engine mount at timing belt cover. Slightly
See page A1 for information on component kits. 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

MANUFACTURER’S SUGGESTED belt rotation and location on camshaft sprockets for reassembly
SCHEDULED MAINTENANCE reference. Also place reference mark on timing belt at upper edge
Although the manufacturer does not recommend a specific scheduled of No. 1 timing belt cover.

684 TOYOTA
2.5L & 3.0L V6 – DOHC – 1988-97 (Cont.)
3) Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compres- 5) Temporarily install crankshaft pulley bolt in crankshaft. Using crank-
sion stroke. Ensure timing mark on crankshaft pulley aligns with “0” mark shaft pulley bolt, rotate crankshaft clockwise until timing mark on
on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets crankshaft sprocket aligns with timing mark on oil pump body. See
are aligned with timing marks on No. 3 timing belt cover. See Fig. 2. Fig. 3. Ensure timing marks on camshaft sprockets are aligned with
Remove retaining bolts and timing belt tensioner. timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not
4) Install Camshaft Sprocket Holder (09278-54012) or equivalent, in aligned, rotate crankshaft clockwise one full revolution (360 degrees).
holes on front of right camshaft sprocket. Slightly rotate right camshaft
sprocket clockwise to release tension on timing belt between camshaft CAUTION: If reusing timing belt, ensure 3 reference marks and
sprockets. Remove timing belt from camshaft sprockets. front mark are on timing belt. See Fig. 4. If reference marks or front
5) Using Pulley Holder (09213-54014) or equivalent, and Handle mark are not apparent, place reference mark on timing belt at
(09330-00021), hold crankshaft pulley, and remove retaining bolt. If timing mark area on camshaft sprockets or dot area on crankshaft
timing belt is to be reused, ensure reference mark placed on timing belt sprocket for reassembly reference. Place front mark on timing belt
aligns with upper edge of No. 1 timing belt cover when timing mark on to indicate direction of timing belt installation.
crankshaft pulley is aligned with “0” mark on No. 1 timing belt cover. 6) Remove retaining bolts, timing belt tensioner and dust boot. Remove
6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft to crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder
rotate. Remove No. 1 timing belt cover and gasket. If timing belt is to be (09960-10010) or equivalent, in holes on front of right camshaft
reused, mark direction of belt rotation, and place reference marks on sprocket. Slightly rotate right camshaft sprocket clockwise to release
timing belt and crankshaft sprocket for reassembly reference. Note tension on timing belt between camshaft sprockets. Remove timing belt
direction of timing belt guide installation for reassembly reference. See from camshaft sprockets. Remove idler pulleys (if necessary).
Fig. 1. Remove timing belt guide and timing belt. Remove idler pulleys 7) If removing camshaft sprocket, use Camshaft Sprocket Holder
(if necessary). (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 (09213–60017), remove crankshaft
sprocket.
Fig. 3: Aligning Timing Marks (1994-97 3.0L)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Inspection (2.5L & 3.0L V6) – 1) Inspect timing belt for damaged teeth,
cracking or oil contamination. Ensure idler pulleys rotate freely. Replace
Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L) damaged components. Inspect timing belt tensioner for signs of oil
Removal (1994-97 3.0L V6) – 1) Disconnect negative battery cable. leakage. Replace timing belt tensioner if oil leakage exists. Hold timing
Remove coolant reservoir. Raise and support vehicle. Remove right side belt tensioner body. Press rod against solid surface. Replace timing belt
front wheel. Remove right lower engine cover. Remove accessory drive tensioner if rod moves.
belts. 2) Measure timing belt tensioner rod protrusion from end of rod to edge
2) Remove engine stabilizer rod, engine mounting bracket and right of timing belt tensioner housing. See Fig. 5. On 2.5L engines, replace
engine mount brace, located near timing belt cover. Remove the timing belt tensioner if distance is not .413-.453″ (10.5-11.5 mm). On
alternator bracket for access to timing belt covers. Remove No. 2 timing 3.0L engines, replace timing belt tensioner if distance is not .394-.413″
belt cover. See Fig. 1. (10.01-10.49 mm).
3) Use Pulley Holder (09213-54015) or equivalent and Holder (09330– Installation (2.5L & 1992-93 3.0L V6) – 1) Install No. 1 idler pulley (if
00021) to hold crankshaft pulley. Remove crankshaft pulley bolt. Using removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining
puller, remove crankshaft pulley. Remove No. 1 timing belt cover. bolt. Install and tighten retaining bolt to specification. See TORQUE
4) Remove engine mounting bracket. Note direction of timing belt guide SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates
installation for reassembly reference. Remove timing belt guide. 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
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.
shaft 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.

Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L)

2) Install timing belt on crankshaft sprocket with installation mark on
timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2. Fig. 6: Retracting Timing Belt Tensioner Rod
Install timing belt guide with cupped side away from crankshaft sprocket. Installation (1994-97 3.0L V6) – 1) Install No. 1 and No. 2 idler pulleys
Install No. 1 timing belt cover and gasket. Align crankshaft key with key (if removed). Install and tighten bolts to specification. See TORQUE
groove of crankshaft pulley and install crankshaft pulley. Tighten retain- SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly.
ing bolt to specification. 2) If installing crankshaft sprocket, align crankshaft sprocket with key in
crankshaft. Using hammer and Sprocket Installer (09223-46011), install
CAUTION: If reusing timing belt, ensure timing mark on crankshaft crankshaft sprocket with flange toward cylinder block.
sprocket is aligned with reference mark placed on timing belt, and 3) Install timing belt plate. Install and tighten bolt to specification. See
timing belt is installed in original direction of rotation. TORQUE SPECIFICATIONS. Install No. 1 and 2 idler pulleys (if
removed). Install and tighten bolts to specification. Ensure idler pulleys
3) Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure
are clean and rotate smoothly.
idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on 4) If installing camshaft sprockets, ensure camshaft sprockets are
crankshaft pulley aligns with “0” mark on No. 1 timing belt cover. Rotate installed with flange in correct direction. Right camshaft sprocket must
left camshaft so timing mark on camshaft sprocket aligns with timing be installed with flange outward (away from cylinder head), while left
mark on No. 3 timing belt cover. See Fig. 2. camshaft sprocket must be installed with flange inward (against cylinder
4) Rotate right camshaft so knock pin hole in camshaft aligns with timing head). See Fig. 1.
mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure 5) Align hole in camshaft sprocket with pin in camshaft and install
reference mark placed on timing belt aligns with upper edge of No. 1 sprocket. Install and tighten camshaft sprocket bolt to specification. See
timing belt cover when timing mark on crankshaft pulley is aligned with TORQUE SPECIFICATIONS.
“0” mark on No. 1 timing belt cover. 6) Temporarily install crankshaft pulley bolt in crankshaft. Using crank-
5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket shaft pulley bolt, rotate crankshaft clockwise until timing mark on
clockwise, and install timing belt on camshaft sprocket. Ensure refer- crankshaft sprocket aligns with timing mark on oil pump body. See
ence mark on timing belt aligns with timing mark on camshaft sprocket. Fig. 3.
6) Using camshaft sprocket holder, slightly rotate left camshaft sprocket, 7) Using camshaft sprocket holder, rotate each camshaft sprocket so
and align timing mark on camshaft sprocket with timing mark on No. 3 timing mark on camshaft sprocket aligns with timing mark on No. 3
timing belt cover. Ensure tension exists on timing belt between crank- timing belt cover. See Fig. 3. Align reference marks on timing belt with
shaft sprocket and left camshaft reference mark on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. See
timing mark on right camshaft sprocket. Install right camshaft sprocket Fig. 4. Ensure front mark is pointing toward timing belt end of engine.
on camshaft with flange side toward cylinder head. Ensure timing mark 8) Install timing belt on crankshaft sprocket, water pump pulley, left
on right camshaft sprocket aligns with timing mark on No. 3 timing belt camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then
cover. See Fig. 2. 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 TORQUE SPECIFICATIONS
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 TORQUE SPECIFICATIONS (2.5L V6)
retracted position. See Fig. 6. Release press and install dust boot on Application Ft. Lbs. (N.m)
timing belt tensioner. Install timing belt tensioner. Install and alternately Camshaft Sprocket Bolt .......................................................................................... 80 (109)
tighten bolts to specification. See TORQUE SPECIFICATIONS. Crankshaft Pulley Bolt ........................................................................................... 181 (245)
10) Remove 1.27 mm hexagon wrench from timing belt tensioner. Engine Crossmember-To-Body Bolt .......................................................................... 29 (39)
Rotate crankshaft clockwise until timing mark on crankshaft sprocket Engine Mount Through-Bolt ...................................................................................... 64 (87)
aligns with timing mark on oil pump body. See Fig. 3. Ensure timing mark Engine Mount-To-Engine Crossmember Bolt ........................................................... 54 (73)
on each camshaft sprocket is aligned with timing mark on No. 3 timing Idler Pulley Bolt
No. 1 Idler Pulley .................................................................................................... 25 (34)
belt cover. See Fig. 3. If all timing marks are not aligned, remove timing
No. 2 Idler Pulley .................................................................................................... 29 (39)
belt and reinstall. Remove crankshaft pulley bolt. Idler Pulley Support Bolt ........................................................................................... 13 (18)
11) Install timing belt guide with cupped side away from crankshaft Right (Timing Belt Side) Engine Mount
sprocket. Install engine mounting bracket on front of cylinder block. Bolt ........................................................................................................................... 47 (64)
Install and tighten bolts to specification. Nut
12) Ensure No. 1 and No. 2 timing belt cover gaskets do not have any Bracket Side .......................................................................................................... 38 (52)
cracks, peeling or damage. Install No. 1 and No. 2 timing belt covers. Body Side .............................................................................................................. 65 (88)
Install and tighten bolts to specification. See TORQUE SPECIFICA-
Water Pump Bolt ....................................................................................................... 14 (19)
TIONS. Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
tion using Pulley Holder (09213-54015) and Holding Tool (09330– No. 3 Timing Belt Cover Bolt ..................................................................................... 65 (7)
00021) or equivalent. To complete installation, reverse removal proce- Valve Cover Nut .......................................................................................................... 52 (6)
dures. Tighten all fasteners to specification. See TORQUE
TORQUE SPECIFICATIONS (3.0L V6)
Front Engine Mount-To-Crossmember Bolt
Toyota Motor Corporation Bolt ................................................................................ 59 (80)
Toyota Motor Manufacturing Bolt ............................................................................ 49 (66)
Front Engine Mount-To-Cylinder Block Bolt ............................................................. 47 (64)
Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43)
Right Engine Mount Brace Bolt ................................................................................ 23 (31)
Stabilizer Bar Link-To Lower Control Arm Nut ......................................................... 29 (39)
Wheel Lug Nut ........................................................................................................ 76 (103)
INCH Lbs. (N.m)
Timing Belt Plate Bolt .............................................................................................. 71 (8.0)
Valve Cover Bolt ...................................................................................................... 71 (8.0)
Water Pump Bolt/Nut ............................................................................................... 71 (8.0)
TOYOTA 687
2.8L 6-Cylinder
Kit No. Part No.
2.8L 6-Cyl.
Celica Supra
1982-83
A/T .................................... 3.5 Hours ... ...... ..... ...... ..... T074
M/T .................................... 3.3 Hours ... ...... ..... ...... ..... T074
1984-85
A/T .................................... 3.5 Hours ... .. TCK101 .. ..... T101
M/T .................................... 3.3 Hours ... .. TCK101 .. ..... T101
Cressida
1983 .................................... 3.1 Hours ... ...... ..... ...... ..... T074
1984-88 ............................... 3.1 Hours ... .. TCK101 .. ..... T101
Supra
1986 .................................... 3.4 Hours ... .. TCK101 .. ..... T101


mend a specific scheduled maintenance interval, belt manufacturers
years, the manufacturer recommends the belt be replaced at 60,000 Fig. 1: Camshaft Pulley Match Marks

TIMING BELT
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
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 CAUTION: Ensure camshaft timing pulleys are installed in original
possible. Using Pulley Installer (09214-60010), install crankshaft timing location. Guide on exhaust side must be toward No. 2 timing cover
pulley. Install timing belt on crankshaft pulley. If used belt is installed, and intake side guide facing away from No. 2 timing cover. See
ensure belt is installed in proper direction of rotation. Install No. 1 timing Fig. 2.
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 align-
ment of match marks.
4) Install timing belt cover and crankshaft pulley. To complete installa-
tion, reverse removal procedure. See Figs. 6, 7 and 8. Adjust drive belts
to proper tension.
688 TOYOTA

Fig. 6: Camshaft Housing Bolt Tightening Sequence
Fig. 3: Identifying Pulley Holding Tool

Fig. 4: Identifying Crankshaft Sprocket Puller
Fig. 7: Aligning Camshaft Match Hole
TORQUE SPECIFICATIONS Courtesy of Toyota Motor Sales, U.S.A., Inc.
Application Ft. Lbs. (N.m) Fig. 8: Aligning Camshaft & Pulley

Camshaft Housing Bolt ........................................................................................... 1 16 (22)
Camshaft Timing Pulley Bolt .................................................................................... 51 (69)
Oil Pump Drive Pulley Bolt ....................................................................................... 16 (22)
Rear Timing Cover Bolt ............................................................................................ 36 (49)
Timing Belt Case Bolt
8 mm ....................................................................................................................... 13 (18)
10 mm ..................................................................................................................... 27 (37)
INCH Lbs. (N.m)
No. 2 Timing Belt Cover ......................................................................................... 108 (12)
1
– Tighten in 3 steps in proper sequence. See Fig. 6.
TOYOTA 689
3.0L 6-Cylinder – 2JZ, 1993-97

Part No.
3.0L 6-Cyl. – 2JZ
Supra
1
1993-97 .................................................... 2.7 Hours .. ..... T215
1
– With Turbo, add .9 hours.

or 96 months for severe operating conditions.

TIMING BELT
WARNING: To prevent air bag deployment which may cause per-
sonal injury, disconnect negative battery cable at least 90 seconds
before working on vehicle.
Removal – 1) Disconnect negative battery cable. Remove battery, and Courtesy of Toyota Motor Sales, U.S.A., Inc.
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.
No. 4 timing belt cover. See Fig. 2. If conditions are not as described,
rotate crankshaft clockwise one complete revolution.
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.
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
NOTE: Timing belt tensioner may have a small amount of oil on rod Fig. 2: Aligning Camshaft & Crankshaft Timing Marks
seal under normal conditions. If excessive amount of oil exists,
2) Hold timing belt tensioner body, and press rod against solid surface.
Replace timing belt tensioner if rod moves. Measure timing belt ten-
sioner 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).
Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to
specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is Courtesy of Toyota Motor Sales, U.S.A., Inc.
clean and rotates smoothly, and idler pulley bracket moves freely.
on crankshaft sprocket with timing mark on oil pump body. See Fig. 2. timing belt cover. Align crankshaft pulley key groove with crankshaft key.
Install timing belt on crankshaft sprocket. Install crankshaft pulley, and tighten pulley bolt to specification. See
3) Install timing belt guide with cupped side away from crankshaft TORQUE SPECIFICATIONS.
sprocket and flat side against timing belt. Install gaskets and No. 1
690 TOYOTA
3.0L 6-Cylinder – 2JZ, 1993-97 (Cont.)
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.
7) Install hexagon wrench through holes in housing and rod to hold rod Courtesy of Toyota Motor Sales, U.S.A., Inc.
in retracted position. See Fig. 4. Release press. Install dust boot on Fig. 4: Retracting Timing Belt Tensioner Rod
timing belt tensioner bolts to specification. See TORQUE SPECIFICA- TORQUE SPECIFICATIONS
TIONS.
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate Application Ft. Lbs. (N.m)
crankshaft counterclockwise. A/C Compressor Bolt/Nut .......................................................................................... 38 (52)
8) Remove hexagon wrench from timing belt tensioner. Rotate crank- Camshaft Sprocket Bolt ............................................................................................ 59 (80)
shaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate Crankshaft Pulley Bolt ........................................................................................... 239 (324)
crankshaft counterclockwise. Drive Belt Tensioner Bolt .......................................................................................... 15 (20)
9) Ensure timing marks on camshaft sprockets align with timing marks Fan Clutch-To-Water Pump Nut ............................................................................... 12 (16)
on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns Idler Pulley Bolt ......................................................................................................... 25 (34)
with “0” mark on timing belt cover. See Fig. 2. If timing marks are not Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
Water Pump Bolt ....................................................................................................... 15 (20)
10) To install remaining components, reverse removal procedure. Use INCH Lbs. (N.m)
care when installing drive belt tensioner bolts to avoid dropping bolts into No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8)
timing belt cover. Valve Cover Bolt/Nut ................................................................................................ 73 (8.3)
11) Tighten fasteners to specification. See TORQUE SPECIFICA-
TIONS. Adjust fluid levels and check ignition timing. Adjust drive belts to
proper tension.
TOYOTA 691
3.0L 6-Cylinder – 2JZ, 1998

Part No.
3.0L 6-Cyl. – 2JZ-GE & 2JZ-GTE
Supra
1
1998 .......................................................... 2.7 Hours .. ..... T215
1
– With Turbo, add .9 hours.

The manufacturer recommends the belt be replaced every 90,000 miles Courtesy of Toyota Motor Sales, U.S.A., Inc.
or 72 months for severe operating conditions.
Fig. 1: Aligning Camshaft Timing Marks (Non-Turbo)
Inspection (Non-Turbo) – 1) Inspect timing belt for damaged teeth,
REMOVAL & INSTALLATION cracking or oil contamination. Replace timing belt if damaged or
contaminated. Check idler pulley and drive belt tensioner for smooth
TIMING BELT 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
Removal (Non-Turbo) – 1) Remove battery and battery tray. Raise and
seal under normal conditions. If excessive amount of oil exists,
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. 2) Hold timing belt tensioner body, and press rod against solid surface.
Remove drive belt. Replace timing belt tensioner if rod moves. Measure timing belt ten-
3) Place reference mating marks on fan clutch, water pump pulley, and sioner rod protrusion from end of rod to edge of housing. See Fig. 4.
water pump stud for reassembly reference. Remove cooling fan, fan Replace timing belt tensioner if distance is not .315-.346″ (8.00-8.80
clutch, and water pump pulley. mm).
4) Remove power steering pump with hoses attached, and hang out of Installation (Non-Turbo) – 1) Install idler pulley and plate washer (if
way. Remove power steering pump front bracket. Remove No. 2 and removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt.
No. 3 timing belt covers and gaskets. Remove drive belt tensioner. Install and tighten bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure idler pulley is clean and rotates smoothly, and idler
pulley bracket moves freely.
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
No. 4 timing belt cover. See Fig. 1. If not, rotate crankshaft clockwise belt on crankshaft sprocket and around idler pulley.
CAUTION: Crankshaft must be correctly positioned by aligning belt and crankshaft sprocket align, and timing belt is installed in
sub-timing mark with “0” mark on timing belt cover to prevent original direction of rotation.
valves from contacting pistons.
7) Rotate crankshaft pulley 60 degrees counterclockwise. Align sub- sprocket and flat side against timing belt. Install gaskets and No. 1
timing mark with “0” mark on timing belt cover. Perform STEP 1. See timing belt cover. Align crankshaft pulley key groove with crankshaft key.
Fig. 2. Ensure dot marks of camshaft sprockets are aligned with timing Install crankshaft pulley.
marks of No. 4 timing belt cover. See Fig. 2, STEP 2. 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
CAUTION: If reusing timing belt, place arrow on timing belt to 4. Temporarily install crankshaft pulley bolt.
and each camshaft sprocket for reassembly reference. CAUTION: If reusing timing belt, ensure reference marks on timing
8) Using Handle (09330-00021) and Pulley Holder (09213-70010) or original direction of rotation.
equivalent to hold crankshaft pulley, remove crankshaft pulley bolt. DO
5) If necessary, use spanner wrench to rotate camshaft sprockets so
NOT allow the crankshaft pulley to rotate.
timing marks on camshaft sprockets align with timing marks on No. 4
timing belt cover. See Fig. 1. Install timing belt on camshaft sprockets.
belt tensioner, and dust boot. See Fig. 3. Remove timing belt from Ensure tension exists on timing belt between camshaft sprockets.
camshaft sprockets. 6) Using press, apply pressure on rod of timing belt tensioner until rod is
10) Remove crankshaft pulley using gear puller. Remove No. 1 timing retracted and holes in rod and housing are aligned. See Fig. 6.
belt cover and gaskets. Note direction of timing belt guide installation for 7) Install hexagon wrench through holes in housing and rod to hold rod
reassembly reference (flat side toward timing belt). See Fig. 3. Remove in retracted position. See Fig. 6. Release press. Install dust boot on
timing belt guide. If reusing timing belt, place mating reference marks on timing belt tensioner. Install timing belt tensioner. Alternately tighten
timing belt and crankshaft sprocket. Remove timing belt. timing belt tensioner bolts to specification. See TORQUE SPECIFICA-
TIONS.
692 TOYOTA
3.0L 6-Cylinder – 2JZ, 1998 (Cont.)
Fig. 3: Exploded View Of Typical Timing Belt & Components

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
Courtesy of Toyota Motor Sales, U.S.A., Inc. timing belt covers. To install remaining components, reverse removal
Fig. 2: Aligning Sub-Timing Marks (Non-Turbo) 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.
shaft clockwise 2 full revolutions from TDC to TDC.
TOYOTA 693

No. 4 timing belt cover. See Fig. 7. If not, rotate crankshaft clockwise
CAUTION: It reusing timing belt, place arrow on timing belt to

and each camshaft sprocket for reassembly reference.
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 crank-
shaft 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.
Fig. 7: Aligning Camshaft Timing Marks (Turbo)

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
Courtesy of Toyota Motor Sales, U.S.A., Inc. 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
WARNING: To prevent air bag deployment, disconnect negative seal under normal conditions. If excessive amount of oil exists,
battery cable at least 90 seconds before working on vehicle. replace timing belt tensioner.
Removal (Turbo) – 1) Disconnect the negative battery cable. Remove 2) Hold timing belt tensioner body, and press rod against solid surface.
battery and battery tray. Raise and support vehicle. Remove lower Replace timing belt tensioner if rod moves. Measure timing belt ten-
engine cover. Drain cooling system. sioner rod protrusion from end of rod to edge of housing. See Fig. 4.
2) Remove No. 2 air tube located below radiator. Remove air intake Replace timing belt tensioner if distance is not .315-.346″ (8.00-8.80
hose to air intake chamber for access to timing belt covers. Remove air mm).
cleaner duct located above radiator. Remove lower fan shroud and 3) Compress and extend drive belt tensioner damper. Make sure there
radiator assembly. is no abnormal resistance or unusual operation sounds. Replace if
3) On manual transmission models, remove drive belt tensioner damper defective.
(located between drive belt tensioner and stud on front of engine). See
CAUTION: Before discarding drive belt tensioner damper, gas
Fig. 3. Rotate drive belt tensioner clockwise. Remove drive belt.
must be released from damper. Fully extend damper. Drill small
4) On all models, place reference mating marks on fan clutch, water
hole in damper, just above lower mounting stud hole. Use care, as
pump pulley, and water pump stud for reassembly reference. Remove
gas will force metal chips to fly out while drilling hole.
cooling fan, fan clutch, and water pump pulley.
5) Remove front bracket for power steering pump for access to timing Installation (Turbo) – 1) Install idler pulley and plate washer (if
belt covers. It may be necessary to remove pump pulley. Remove oil removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt.
filler cap and No. 3 timing belt cover. See Fig. 3. Remove No. 2 timing Install and tighten bolt to specification. See TORQUE SPECIFICA-
belt cover and gasket. Remove drive belt tensioner. TIONS. Ensure idler pulley is clean and rotates smoothly, and idler
pulley bracket moves freely.
CAUTION: DO NOT rotate crankshaft counterclockwise. Rotate
crankshaft clockwise (as viewed from front of engine).
on crankshaft sprocket with timing mark on oil pump body. See Fig. 5.
6) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at Install timing belt on crankshaft sprocket.
694 TOYOTA
belt and crankshaft sprocket align, and timing belt is installed in TORQUE SPECIFICATIONS
original direction of rotation. Application Ft. Lbs. (N.m)
3) Install timing belt guide with cupped side away from crankshaft Camshaft Sprocket Bolt ............................................................................................ 60 (81)
sprocket and flat side against timing belt. Install gaskets and No. 1
timing belt cover. Align crankshaft pulley key groove with crankshaft key. Drive Belt Tensioner Damper Bolt ............................................................................ 15 (21)
Install crankshaft pulley, and tighten pulley bolt to specification while Fan Clutch-To-Water Pump Nut ............................................................................... 12 (16)
holding crankshaft. See TORQUE SPECIFICATIONS. Idler Pulley Bolt 1 ....................................................................................................... 26 (35)
4) On automatic transmission models, reinstall clamps for oil cooler lines Power Steering Pump Pulley Bolt (Turbo) ............................................................... 32 (43)
near crankshaft pulley. Power Steering Pump-To-Front Bracket (Non-Turbo)
5) On all models, rotate crankshaft clockwise so cylinder No. 1 (front Right Side Bolt 2 ...................................................................................................... 29 (39)
cylinder) is at TDC on compression stroke. Ensure timing mark on Left Side Bolt 2 ........................................................................................................ 42 (58)
crankshaft pulley aligns with “0” mark on timing belt cover.
Water Pump Bolt ....................................................................................................... 15 (21)
6) Using spanner wrench, rotate camshaft sprockets so timing marks on
camshaft sprockets align with timing marks on No. 4 timing belt cover. INCH Lbs. (N.m)
See Fig. 7. Clean oil or water off of crankshaft sprocket and install timing Fan-To-Fan Clutch Nuts ........................................................................................... 65 (7.5)
belt on camshaft sprockets. Ensure tension exists on timing belt No. 1 & No. 2 Timing Belt Cover Bolt ....................................................................... 71 (8)
between camshaft sprockets. No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8)
1
2
CAUTION: If reusing timing belt, ensure reference marks on timing – Right and left side as viewed from rear of engine.
timing belt tensioner bolts to specification. See TORQUE SPECIFICA-
TIONS.

shaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate
with “0” mark on timing belt cover. See Fig. 7. If timing marks are not
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.
TOYOTA 695
3.0L 6-Cylinder – 7M-GE & 7M-GTE

Part No.
3.0L 6-Cyl. – 7M-GE
Cressida
1989-91 ..................................................... 3.1 Hours ... ..... T126
1992 ........................................................... 3.1 Hours ... ..... T237
Supra – 7M-GE
1986-90 ..................................................... 3.4 Hours ... ..... T126
1991-92 ..................................................... 3.4 Hours ... ..... T237
Supra – 7M-GTE
1987-90 ..................................................... 3.8 Hours ... ..... T126
1991-92 ..................................................... 3.8 Hours ... ..... T237

for severe service operating conditions.

TIMING BELT
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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
on No. 4 timing belt cover. See Fig. 2. If timing marks are not aligned,
rotate crankshaft 360 degrees and recheck alignment. Fig. 1: Exploded View Of Timing Belt & Components
5) Remove power steering belt pulley. Using Pulley Holder
(09213-58011) and Handle (09330-00021), or equivalent, hold crank-
shaft 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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
contamination. Replace timing belt if damaged or contaminated. Inspect
idler pulleys and fan for smooth rotation. Replace component if defec- Fig. 2: Aligning Timing Marks
tive.
2) Inspect tension spring for damage, and measure spring free length. CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
Replace tension spring if damaged or free length is not 2.216″ (56.274 crankshaft counterclockwise.
mm).
Installation – 1) Install No. 1 idler pulley as far to the left as possible 4) Ensure all timing marks are properly aligned. See Figs. 2 and 3.
(away from timing belt), and temporarily tighten retaining bolt. Align Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37 N.m). Check
timing marks on camshaft sprockets with timing mark on No. 4 timing timing belt deflection.
belt cover. See Fig. 2. Install timing belt. 5) To remove slack in timing belt, rotate intake and exhaust camshaft
2) Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pulley as far to timing pulleys inward by applying a turning torque of 14 ft. lbs. (19 N.m).
the right as possible (toward timing belt), and temporarily tighten See Fig. 4.
retaining bolt. Install tension spring. Loosen No. 1 idler pulley retaining 6) Remove crankshaft pulley retaining bolt. Install timing belt guide with
bolt until idler pulley moves with spring force of tension spring. cupped side toward front of engine.
3) Temporarily install crankshaft pulley retaining bolt. Using crankshaft
pulley retaining bolt, rotate crankshaft clockwise (viewed from front of
engine) 2 full revolutions.
696 TOYOTA
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. TORQUE SPECIFICATIONS
7) To install remaining components, reverse removal procedure. Apply Application Ft. Lbs. (N.m)
sealant to coolant outlet before installing. Tighten bolts and nuts to Camshaft Sprocket Bolt .......................................................................................... 80 (109)
Coolant By-Pass Outlet Bolt ..................................................................................... 13 (18)
Coolant Inlet Nut ....................................................................................................... 14 (19)
proper tension. Crankshaft Pulley Bolt ........................................................................................... 181 (245)
Fan Bracket Bolt ....................................................................................................... 30 (41)
Idler Pulley Bolt
No. 1 Pulley ............................................................................................................. 27 (37)
No. 2 Pulley ............................................................................................................. 13 (18)
Spark Plug ................................................................................................................. 13 (18)
Tension Spring Bracket Bolt ..................................................................................... 13 (18)
INCH Lbs. (N.m)
Fan Retaining Nut ....................................................................................................... 48 (5)
No. 1 & 2 Covers ...................................................................................................... 48 (5)
Courtesy of Toyota Motor Sales, U.S.A., Inc. No. 3 & 4 Covers ...................................................................................................... 74 (8)

MOTORES CHECK
TOYOTA 697
3.0L V6 – DOHC – 1998-04

3.0L V6 – 1MZ-FE
Avalon WARNING: To prevent air bag deployment, disconnect negative
1998-04 ............................... 3.0 Hours ... .. TCK257 .. ..... T257 battery cable at least 90 seconds before working on vehicle.
Camry
1998-02 ............................... 3.0 Hours ... .. TCK257 .. ..... T257 CAUTION: This application is an interference engine. Do not rotate
2003-04 ............................... 3.0 Hours ... ...... ..... ...... ..... T257 camshaft or crankshaft when timing belt is removed, or engine
Camry Solara damage may occur.
1999-03 ............................... 3.0 Hours ... .. TCK257 .. ..... T257
Highlander Removal (Avalon, Camry – 1998-01 & Camry Solara) – 1) Raise and
2001-03 ............................... 2.5 Hours ... .. TCK257 .. ..... T257 support vehicle. Remove right side front wheel. Remove right fender
Sienna apron seal. Remove accessory drive belts. Lower vehicle.
1998-00 ............................... 3.8 Hours ... .. TCK257 .. ..... T257 2) Disconnect engine coolant reservoir hose from water outlet. Discon-
2001-03 ............................... 4.0 Hours ... .. TCK257 .. ..... T257 nect 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.
NOTE: For information about tensioners and/or pulleys (when 4) Using Pulley Holder (09213-54015) or equivalent, and Handle
available), see ALPHABETICAL MODEL LISTING. (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
MANUFACTURER’S SUGGESTED mounting bracket from front (timing belt end) of engine. Note direction of
SCHEDULED MAINTENANCE timing belt guide installation for reassembly reference. Remove timing
The manufacturer recommends the belt be replaced every 90,000 miles belt guide.
or 72 months.

698 TOYOTA
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 crank-
shaft 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
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.
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 compo-
nents. Check water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing
DOWN.
belt tensioner if oil leakage exists. Hold timing belt tensioner body with Fig. 4: Identifying Timing Belt Reference Marks & Front Mark
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).

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 Courtesy of Toyota Motor Sales, U.S.A., Inc.
specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion
clean and rotate smoothly.
2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, 3) Using spanner wrench, rotate each camshaft sprocket so timing mark
use crankshaft pulley bolt to rotate crankshaft CLOCKWISE until timing on camshaft sprocket aligns with appropriate timing mark on No. 3
mark on crankshaft sprocket aligns with timing mark on oil pump body. timing belt rear cover. See Fig. 2 or 3.
See Fig. 2 or 3.
TOYOTA 699
3.0L V6 – DOHC – 1998-04 (Cont.)

4) Using gear puller and crankshaft pulley bolt, remove crankshaft
CAUTION: Clean timing belt sprockets before installing timing belt. pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1.
Wipe off any oil or water with rag. DO NOT use any cleaning Remove engine mounting bracket from front of engine. Note direction of
solvents. timing belt guide installation for reassembly reference. Remove timing
belt guide. See Fig. 4.
4) Install timing belt in following order:
a) Crankshaft sprocket NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing
b) Water pump pulley belt side of engine.
c) Left camshaft sprocket (front of vehicle side)
d) No. 2 idler pulley 5) Temporarily install crankshaft pulley bolt in crankshaft. Using crank-
e) Right camshaft sprocket (firewall side) shaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on
f) No. 1 idler pulley crankshaft sprocket aligns with timing mark on oil pump body. See
If reusing old belt, ensure belt installation marks align with camshaft Fig. 3.
and crankshaft sprocket marks. Ensure front (or rotation direction mark) 6) Ensure timing marks on camshaft sprockets are aligned with timing
points in correct direction. mark on No. 3 timing belt rear cover. See Fig. 3. If timing marks are not
5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of aligned, rotate crankshaft CLOCKWISE one full revolution (360
pressure on push rod of timing belt tensioner until rod is retracted and degrees).
holes in rod and housing are aligned. See Fig. 6. Align holes in housing 7) If reusing old belt, ensure there are 3 installation marks and front
and push rod. Install 1.5 mm hexagon wrench through housing and push arrow marked on belt. See Fig. 4. If not, place mating mark on belt where
rod hole to secure push rod. Release press and install dust boot on it contacts the crankshaft and camshaft sprockets. Also, mark belt with
timing belt tensioner. arrow showing direction of rotation.
6) Install timing belt tensioner. Install and alternately tighten bolts to 8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust
specification. See TORQUE SPECIFICATIONS. boot. Do NOT hold tensioner with push rod facing DOWN. Remove
7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly timing belt in following order
rotate crankshaft CLOCKWISE 2 revolutions until timing mark on a) No. 1 idler pulley
crankshaft sprocket aligns with timing mark on oil pump body. b) Right camshaft sprocket (firewall side)
8) Ensure timing mark on each camshaft sprocket is aligned with timing c) No. 2 idler pulley
mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If all timing marks d) Left camshaft sprocket (front of vehicle side)
e) Water pump pulley
are not aligned, remove timing belt and reinstall. Remove crankshaft
f) Crankshaft sprocket
pulley bolt.
Inspection (Camry – 2002-04 & Highlander) – 1) Inspect timing belt for
damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate
sprocket and flat side toward timing belt. Install engine mounting bracket
freely and are not leaking oil. Replace damaged components. Inspect
on front of cylinder block. Install and tighten bolts to specification. See water pump for leaks or worn out bearing.
10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure CAUTION: Never hold timing belt tensioner with push rod facing
there are no gaps in gasket. Cut off any excess gasket. Install and DOWN.
tighten bolts to specification.
11) Align crankshaft key with key groove of crankshaft pulley. Install belt tensioner if oil leakage exists. Hold timing belt tensioner body with
crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica- push rod facing UP. Press rod against solid surface. Replace timing belt
tion. See TORQUE SPECIFICATIONS. To install remaining compo- tensioner if push rod moves.
nents, reverse removal procedure. Tighten fasteners to specification.
Connect engine ground strap. Adjust drive belts to proper tension. 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.
CAUTION: Clean timing belt sprockets before installing timing belt.

Courtesy of Toyota Motor Sales, U.S.A., Inc. Wipe off any oil or water with rag. DO NOT use any cleaning
solvents.
4) Install timing belt in following order:
Removal (Camry – 2002-04 & Highlander) – 1) Raise and support a) Crankshaft sprocket
vehicle. Remove right side front wheel. Remove right fender apron seal. b) Water pump pulley
Remove accessory drive belts. Lower vehicle. c) Left camshaft sprocket (front of vehicle side)
2) Remove control (torque) rod from timing belt end of engine. Remove d) No. 2 idler pulley
engine mount from timing belt end of engine. Remove generator e) Right camshaft sprocket (firewall side)
mounting bracket from engine for access to timing belt covers. f) No. 1 idler pulley
3) Using Pulley Holder (09213-54015) or equivalent, and Handle If reusing old belt, ensure belt installation marks align with camshaft
(09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark)
pulley bolt. 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 CAUTION: Never hold timing belt tensioner with push rod facing
holes in rod and housing are aligned. See Fig. 6. Align holes in housing DOWN.
and push rod. Install 1.5 mm hexagon wrench through housing and push 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing
rod hole to secure push rod. Release press and install dust boot on belt tensioner if oil leakage exists. Hold timing belt tensioner body with
timing belt tensioner. push rod facing UP. Press rod against solid surface. Replace timing belt
6) Install timing belt tensioner. Install and alternately tighten bolts to tensioner if push rod moves.
specification. See TORQUE SPECIFICATIONS. 3) Measure timing belt tensioner push rod protrusion from end of rod to
7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly edge of timing belt tensioner housing. See Fig. 5. Replace timing belt
rotate crankshaft CLOCKWISE 2 revolutions until timing mark on tensioner if distance is not .394-.425″ (10.01-10.8 mm).
crankshaft sprocket aligns with timing mark on oil pump body.
8) Ensure timing mark on each camshaft sprocket is aligned with NOTE: Engine should be cold when installing timing belt.
appropriate timing mark on No. 3 timing belt rear cover. See Fig. 3. If all Installation (Sienna) – 1) Install No. 1 and 2 idler pulleys (if removed).
timing marks are not aligned, remove timing belt and reinstall. Remove On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent.
crankshaft pulley bolt. Install and tighten bolts to specification. See TORQUE SPECIFICA-
9) Install timing belt guide with cupped side away from crankshaft TIONS. Ensure idler pulleys are clean and rotate smoothly.
sprocket and flat side toward timing belt. Install right side engine 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary,
mounting bracket on front of cylinder block. Install and tighten bolts to use crankshaft pulley bolt to rotate crankshaft CLOCKWISE until timing
specification. See TORQUE SPECIFICATIONS. mark on crankshaft sprocket aligns with timing mark on oil pump body.
10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure See Fig. 2 or 3.
there are no gaps in gasket. Cut off excess gasket. Install and tighten 3) Using spanner wrench, rotate each camshaft sprocket so timing mark
bolts to specification. on camshaft sprocket aligns with timing mark on No. 3 timing belt rear
cover. See Fig. 2 or 3.
11) Install generator bracket. Install crankshaft pulley. Install and tighten
crankshaft pulley bolt. See TORQUE SPECIFICATIONS. CAUTION: Clean timing belt sprockets before installing timing belt.
12) Install engine mounting stay and engine moving control rod to Wipe off any oil or water with rag. DO NOT use any cleaning
engine and body. Connect engine ground strap. solvents.
13) Install accessory drive belts. Adjust drive belts to proper tension.
4) Install timing belt on crankshaft sprocket, water pump pulley, left (front
Install right fender apron seal. Install right front wheel.
of vehicle side) camshaft sprocket, No. 2 idler pulley, right (firewall side)
Removal (Sienna) – 1) Remove the outer cowl top panel along with the
camshaft sprocket, and then on No. 1 idler pulley. If reusing old belt,
ventilation louvers and windshield wiper arm assembly. See Fig. 7.
ensure belt installation marks align with camshaft and crankshaft
Raise and support vehicle. sprocket marks. Ensure front (or rotation direction mark) points in
2) Remove right side front wheel. Remove right fender apron seal. correct direction.
Remove accessory drive belts. Lower vehicle. Disconnect Data Link 5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of
Connector 1 (DLC-1) from right side engine mounting bracket. pressure on push rod of timing belt tensioner until rod is retracted and
3) Disconnect engine coolant reservoir hose from water outlet. Discon- holes in rod and housing are aligned. See Fig. 6. Align holes in housing
nect ground strap connectors. and push rod. Install hexagon wrench through housing and push rod
4) Remove engine stabilizer rod, engine mounting stay and engine hole to secure push rod. Release press and install dust boot on timing
mounting bracket, located near timing belt cover. Remove generator-to- belt tensioner.
engine bracket for access to timing belt covers. 6) Install timing belt tensioner. Install and alternately tighten bolts to
5) Using Pulley Holder (09213-54015) or equivalent, and Handle specification. See TORQUE SPECIFICATIONS.
(09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft 7) Remove hexagon wrench from timing belt tensioner. Slowly rotate
pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft
timing belt covers and gaskets. See Fig. 1. Remove engine mounting sprocket aligns with timing mark on oil pump body.
bracket from front of engine. Note direction of timing belt guide instal- 8) Ensure timing mark on each camshaft sprocket is aligned with timing
lation for reassembly reference. Remove timing belt guide. 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
NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing pulley bolt.
belt side of engine. 9) Install timing belt guide with cupped side away from crankshaft
6) Temporarily install crankshaft pulley bolt in crankshaft. Using crank- sprocket and flat side toward timing belt. Install engine mounting bracket
shaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on on front of cylinder block. Install and tighten bolts to specification. See
crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 TORQUE SPECIFICATIONS.
or 3. 10) Using new gaskets, install No. 1 and 2 timing belt covers. Ensure
7) Ensure timing marks on camshaft sprockets are aligned with timing there are no gaps in gasket. Cut off excess gasket. Install and tighten
mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If timing marks are bolts to specification.
not aligned, rotate crankshaft CLOCKWISE one full revolution (360 11) Align crankshaft key with key groove of crankshaft pulley. Install
degrees). crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica-
8) If reusing old belt, ensure there are 3 installation marks and front tion.
arrow marked on belt. See Fig. 4. If not, place mating mark on belt where 12) Install generator bracket. Install engine stabilizer rod and engine
it contacts the crankshaft and camshaft sprockets. Also, mark belt with mounting bracket, located near timing belt cover. Connect engine
arrow showing direction of rotation. ground strap.
9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust 13) To install remaining components, reverse removal procedure.
boot. Do NOT hold tensioner with push rod facing DOWN. Remove Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
timing belt. Adjust drive belts to proper tension.
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.
TOYOTA 701
3.0L V6 – DOHC – 1998-04 (Cont.)

Camshaft Sprocket Bolt (Except Highlander)
Left Hand (Front End of Vehicle Side) ................................................................. 92 (125)
Right Hand (Firewall Side of Vehicle) .................................................................... 65 (88)
Camshaft Sprocket Bolt (Highlander) ..................................................................... 92 (125)
Engine Mount Bracket-to-Engine Bolt ...................................................................... 21 (28)
Engine Mounting Stay ............................................................................................... 23 (32)
Engine Moving Control Rod Bolts ............................................................................ 47 (64)
Generator Bracket No. 2 ........................................................................................... 21 (28)
Generator Pivot Bolt
Avalon ...................................................................................................................... 41 (56)
Except Avalon .......................................................................................................... 38 (52)
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)
No. 1 Idler Pulley Bolt 1 .......................................................................................... 25 (34)
Fig. 7: Exploded View Of Outer Cowl Top Panel (Sienna) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43)
Wheel Lug Nut ........................................................................................................ 76 (103)
Wiper Arm Nuts
Sienna ...................................................................................................................... 15 (20)
INCH Lbs. (N.m)
Timing Belt Plate Bolt .............................................................................................. 71 (8.0)
Water Pump Bolt/Nut
Except Sienna ........................................................................................................ 71 (8.0)
Sienna ..................................................................................................................... 69 (7.8)
1
702 TOYOTA
3.0L V6 – SOHC
TIMING BELT APPLICATION 7) Install Camshaft Sprocket Holder (09278-54012), or equivalent, in
Application Labor Time Component Belt holes on front of right camshaft sprocket. Slightly rotate right camshaft
Kit No. Part No. sprocket clockwise to release tension on timing belt between camshaft
3.0L V6 sprockets.
Pickup 8) Remove timing belt from camshaft sprockets. Remove power steering
1 2 belt pulley. Using Pulley Holder (09213-58012) and Handle
1988-91 .............................. 4.1 Hours .. . TCK240 . ..... T154
1992 (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft
1
8/92 & Earlier .................. 4.1 Hours .. . 2 TCK240 . ..... T154 pulley bolt.
1
9/92 & Later .................... 4.1 Hours ... TCK240A . ..... T240
1 NOTE: If reusing timing belt, ensure reference mark placed on
1993-95 .............................. 4.1 Hours ... TCK240A . ..... T240
T100 timing belt aligns with upper edge of No. 1 timing belt cover when
1
1993-94 .............................. 4.1 Hours ... TCK240A . ..... T240 timing mark on crankshaft pulley aligns with “0” mark on No. 1
4Runner timing belt cover.
1 2
1988-91 .............................. 4.1 Hours .. . TCK240 . ..... T154
1992 9) Using puller, remove crankshaft pulley. Remove bolts, No. 1 timing
8/92 & Earlier .................. 1 2
4.1 Hours .. . TCK240 . ..... T154 belt cover and gasket. Note direction of timing belt guide installation for
1
9/92 & Later .................... 4.1 Hours ... TCK240A . ..... T240 reassembly reference. Remove timing belt guide.
1
1993-95 .............................. 4.1 Hours ... TCK240A . ..... T240 10) If reusing timing belt, mark direction of timing belt rotation. Ensure
1
– With Air Conditioning, add .5 hours. reference mark exists on timing belt at reference mark (dot) on crank-
2
– Timing belt component kit does not include camshaft shaft sprocket. See Fig. 3.
tensioner hydraulic assembly. 11) If reference mark does not exist, install reference mark on timing belt
in alignment with timing mark (dot) on crankshaft sprocket for reassem-
NOTE: A timing belt component kit is available for this application. bly reference. See Fig. 3.
See page A1 for information on component kits. 12) Remove timing belt. Remove bolt, No. 1 idler pulley and plate
washer (if necessary). See Fig. 1 or 2.
for severe operating conditions.

TIMING BELT
Remove lower engine covers. Remove radiator. Remove all accessory
drive belts. Courtesy of Toyota Motor Sales, U.S.A., Inc.
2) Remove power steering pump with hoses attached, and secure aside
(if equipped). Remove spark plugs. Disconnect hoses from air pipe. Fig. 1: Exploded View of Timing Belt & Components
(1988-92 Models)
NOTE: If separating fluid coupling from fan bracket, place refer- Inspection – 1) Inspect timing belt for damaged teeth, cracking or oil
ence mark on fluid coupling and fan bracket for reassembly contamination. Replace timing belt if damaged or contaminated.
reference. 2) On 1988-92 models, go to step 4). On 1993-95 models, inspect timing
3) Remove coolant outlet. See Fig. 1 or 2. Remove fan. Remove spark belt tensioner for oil leakage. Replace timing belt tensioner if oil leakage
plug wire clamps across front of No. 2 timing belt cover. If necessary, exists. Hold timing belt tensioner housing and press rod against solid
remove studs for coolant outlet from mount. Remove bolts, No. 2 timing surface. Replace timing belt tensioner if rod moves.
belt cover and gaskets. 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
CAUTION: If reusing timing belt, mark direction of timing belt tensioner if distance is not .394-.413″ (10.00-10.50 mm).
rotation and ensure reference marks are on timing belt. See Fig. 3. 4) Inspect No. 1 and No. 2 idler pulleys and fan for smooth rotation.
If reference marks are not apparent, place reference mark on timing Replace component if defective.
belt and all sprockets for reassembly reference. Also place refer-
ence 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.
sion 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.
on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned,
rotate crankshaft clockwise one complete revolution and recheck align-
ment.
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.
TOYOTA 703
Fig. 2: Exploded View Of Timing Belt & Components (1993-95 Models)
Fig. 3: Identifying Timing Belt Reference Marks

704 TOYOTA
Installation – 1) Install plate washer and No. 1 idler pulley (if removed). 12) Install hexagon wrench through holes in housing and rod to hold rod
See Fig. 1 or 2. Install and tighten bolt to specification. See TORQUE in retracted position. Release press. Install dust boot on end of timing
SPECIFICATIONS. Ensure No. 1 idler pulley is clean and rotates belt tensioner. Install timing belt tensioner. Install and alternately tighten
smoothly. bolts. See TORQUE SPECIFICATIONS.
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 13) On 1993-95 models, remove hexagon wrench from timing belt
timing belt aligned with reference mark (dot) on crankshaft sprocket. tensioner. On 1988-92 models, loosen No. 1 idler pulley retaining bolt.
See Fig. 3. Install timing belt on water pump. 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
CAUTION: If reusing timing belt, ensure timing belt is installed in bolt until pulley moves with spring force tension. Tighten idler pulley bolt.
original direction of rotation and reference mark on timing belt On all models, rotate crankshaft 2 full revolutions clockwise from TDC to
aligns with reference mark (dot) on crankshaft sprocket. TDC. Ensure crankshaft pulley timing mark aligns with “0” mark on No. 1
timing belt cover.
4) Install timing belt guide with cupped side away from crankshaft 14) Ensure timing marks on camshaft sprockets align with timing marks
sprocket and flat side against timing belt. Install No. 1 timing belt cover on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned,
and gasket. Align groove of crankshaft pulley with crankshaft key. Install remove timing belt and reinstall using proper procedure.
crankshaft pulley. Install and tighten crankshaft pulley bolt to specifica- 15) Install No. 2 idler pulley gasket. See Fig. 1 or 2. Install No. 2 timing
tion. See TORQUE SPECIFICATIONS. Install power steering belt pulley belt cover and gaskets. Install crankshaft pulley.
on crankshaft pulley. 16) To install remaining components, reverse removal procedure. Apply
5) Rotate crankshaft so cylinder No. 1 is at TDC on compression stroke. sealant on coolant outlet before installing. Tighten all bolts/nuts to
Ensure timing mark on crankshaft pulley aligns with “0” mark on timing specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling
belt cover. system. Adjust drive belts to proper tension.
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. Courtesy of Toyota Motor Sales, U.S.A., Inc.
9) Using camshaft sprocket holder, slightly rotate left camshaft sprocket
and align timing mark on camshaft sprocket with timing mark on No. 3 Fig. 6: Retracting Timing Belt Tensioner Rod
timing belt cover. See Fig. 4. Ensure tension exists on timing belt TORQUE SPECIFICATIONS
between crankshaft sprocket and left camshaft sprocket.
10) Align reference mark on timing belt with timing mark on right TORQUE SPECIFICATIONS
camshaft sprocket. See Fig. 3. Ensure timing mark on right camshaft Application Ft. Lbs. (N.m)
sprocket aligns with timing mark on No. 3 timing belt cover. Alternator Bracket-To-Cylinder Head Bolt ................................................................. 27 (37)
11) Using new gasket, install fan bracket. Install and tighten bolt/nuts to Camshaft Sprocket Bolt .......................................................................................... 80 (109)
specification. See TORQUE SPECIFICATIONS. On 1988-92 models, go Crankshaft Pulley Bolt ........................................................................................... 181 (245)
to step 13). On 1993-95 models, use press to apply pressure on rod of No. 1 Idler Pulley Bolt .................................................................. ................. 25-27 (34-37)
timing belt tensioner until rod is retracted and holes in rod and housing Spark Plug ................................................................................................................. 13 (18)
are aligned. See Fig. 6. Timing Belt Tensioner Bolt ........................................................................................ 20 (27)
INCH Lbs. (N.m)
Camshaft Housing Rear Cover Bolt ........................................................................ 43 (4.9)
Fan Retaining Nut .................................................................................................... 48 (5.4)
Valve Cover Bolt ...................................................................................................... 48 (5.4)
TOYOTA 705
3.4L V6
TIMING BELT APPLICATION 8) If reusing timing belt, check that there are 3 installation marks and a
Application Labor Time Component Belt front mark on belt. See Fig. 3. If marks are missing, place 3 NEW marks
Kit No. Part No. on belt to match position of belt on camshaft and crankshaft pulleys.
3.4L V6 Also place front facing arrow on belt.
Tacoma 9) Alternately loosening the bolts, remove timing belt tensioner and dust
1995-04 .............................. 1 2.7 Hours .. .. TCK271 .. ..... T271 boot. DO NOT hold tensioner with push rod facing DOWN. Remove
Tundra timing belt.
2000-04 10) On Tundra and T100, loosen right camshaft timing pulley bolt using
Automatic ........................ 2 2.9 Hours .. .. TCK271 .. ..... T271 Pulley Holder (09960-10010) or equivalent to hold pulley. Remove bolt,
Manual ............................. 2 2.7 Hours .. .. TCK271 .. ..... T271 knock pin and camshaft timing pulley.
T100 Inspection (All Models) – 1) Inspect idler pulleys for oil leakage at seal
1995-98 .............................. 1 2.7 Hours .. .. TCK271 .. ..... T271 area. Inspect idler pulley bearings for smoothness. Replace if defective.
4Runner
1996-00 .............................. 1 2.7 Hours .. .. TCK271 .. ..... T271 CAUTION: DO NOT hold tensioner with push rod facing DOWN.
2001-02 ............................... 3.2 Hours ... .. TCK271 .. ..... T271
1 2) Inspect timing belt tensioner for oil leakage. Hold tensioner (push rod
2 facing upward) with both hands and push the push rod against a hard
surface. If push rod moves, replace tensioner. Measure protrusion of
NOTE: A timing belt component kit is available for this application. push rod. If protrusion is not .394-.425″ (10.0-10.8 mm), replace
See page A1 for information on component kits. tensioner. See Fig. 4.
NOTE: Only wipe timing belt pulleys and sprockets clean. Do NOT
NOTE: For information about tensioners and/or pulleys (when use any cleaning agents or solvents.
NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or
MANUFACTURER’S SUGGESTED equivalent to 2 or 3 threads of pivot bolt.
SCHEDULED MAINTENANCE Installation (Tacoma & 4Runner) – 1) Ensure No. 1 cylinder is at TDC
For 1990-97 model years, the manufacturer recommends the belt be of compression stroke by aligning crankshaft sprocket with mark on oil
replaced every 60,000 miles under severe driving conditions. For pump body. See Fig. 5. Ensure camshaft sprockets are still aligned at
1998-04 model years, the manufacturer recommends the belt be TDC positions. See Fig. 6.
replaced every 90,000 miles. 2) Install timing belt in following order:
a) Left (driver’s side) camshaft pulley
REMOVAL & INSTALLATION b) No. 2 idler pulley
c) Right (passenger’s side) camshaft pulley
d) Water pump pulley
e) Crankshaft pulley
damage may occur.
f) No. 1 idler pulley
TIMING BELT If reusing old belt, ensure all reference marks are aligned.
3) Using a press, SLOWLY press in tensioner push rod with pressure of
Removal (All Models) – 1) Remove lower engine cover (if equipped).
200-2205 lbs. (100-1000 kg). Align holes of push rod and housing, and
Drain cooling system. Disconnect upper radiator hose. Remove acces-
insert a 1.27 mm hexagon wrench. Release pressure on push rod. See
sory drive belts. Disconnect 2 power steering hoses from the air intake
Fig. 7.
chamber and resonator. Remove power steering pump drive belt.
4) Install dust boot on tensioner. Install tensioner and alternately tighten
Remove power steering pump with hoses attached, and hang out of
2 bolts to specification. See TORQUE SPECIFICATIONS. Remove
way. Remove A/C compressor with hoses attached, and hang out of
hexagon wrench from tensioner.
way.
5) Ensure timing marks of crankshaft timing pulley and oil pump body
2) Loosen cooling fan with fluid coupling and fan pulleys. Remove lower
are aligned, and check camshaft timing marks. See Fig. 2. If timing
fan shroud. Remove fan and fan pulleys.
marks do not align, remove timing belt and reinstall it. Remove crank-
3) Remove A/C compressor bracket from engine. On Tacoma and
shaft pulley bolt, if necessary.
4Runner, remove engine oil dipstick and tube. On all models, disconnect
electrical connectors and clamps from upper timing belt cover. Remove
sprocket and flat side toward timing belt. Install starter wire bracket and
upper timing belt cover. See Fig. 1. Remove power steering pump
lower timing belt cover with NEW gaskets. Install crankshaft pulley.
adjusting strut. Remove fan bracket.
Install crankshaft pulley bolt and tighten to specification.
NOTE: Always turn crankshaft CLOCKWISE as viewed from timing 7) Turn crankshaft CLOCKWISE 2 revolutions from TDC to TDC. Ensure
belt end of engine. “V” notch (TDC mark) on crankshaft pulley aligns with “0” mark on lower
timing belt cover. Ensure camshaft timing marks are still aligned with
4) Ensure No. 1 cylinder is set at TDC of compression stroke (crankshaft marks on rear cover.
pulley groove aligned with zero mark on lower timing belt cover, and 8) Install fan bracket. Install power steering adjusting strut. Install upper
camshaft sprocket timing marks are aligned with marks on back cover). timing belt cover with NEW gasket. Connect electrical connectors and
Use Pulley Holder (09213-54015) or equivalent to hold crankshaft install clamps on timing belt cover. Using a NEW “O” ring with an
pulley. Remove crankshaft pulley bolt. Use gear puller to remove application of soapy water, install oil dipstick tube. Install A/C compres-
crankshaft pulley. sor bracket and A/C compressor. Install power steering pump. Connect
5) Remove starter wire bracket and lower timing belt cover. Noting 2 power steering hoses to air intake chamber and resonator. Install fan
installed position for reassembly reference, remove timing belt guide. and lower fan shroud. Install accessory drive belts. Install engine
6) Check that the crankshaft sprocket timing mark is aligned with mark undercover.
on oil pump body. Check that camshaft sprocket timing marks are 9) To complete installation, reverse removal procedure. Tighten all nuts
aligned with timing marks on back cover. See Fig. 2. and bolts to specification. See TORQUE SPECIFICATIONS. Fill cooling
7) If marks are not aligned, temporarily install crankshaft pulley bolt. system and bleed air from system. Adjust drive belts to proper tension.
Turn crankshaft CLOCKWISE one revolution (360 degrees). Recheck
alignment of timing marks. Remove crankshaft pulley bolt.
706 TOYOTA
3.4L V6 (Cont.)

TOYOTA 707
3.4L V6 (Cont.)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 6: Aligning Camshaft Sprocket Timing Marks
Courtesy of Toyota Motor Sales, U.S.A., Inc. NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or
Fig. 3: Locating Timing Belt Installation Marks 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.
Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion 3) Install lower timing belt cover and starter wire bracket, and tighten
bolts to specification. See TORQUE SPECIFICATIONS. Install crank-
shaft 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
Courtesy of Toyota Motor Sales, U.S.A., Inc. crankshaft pulley and left camshaft pulley. Align installation mark on
timing belt with timing mark on right camshaft pulley, and install timing
Fig. 5: Aligning Crankshaft Sprocket Timing Mark 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.
708 TOYOTA
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 BLEED-
ING. Check for leaks. Adjust drive belts to proper tension.
Fig. 11: Aligning Installation Mark On Timing Belt With Timing

Mark On Right Camshaft Pulley (Tundra & T100)
Fig. 8: Aligning Timing Belt Installation Mark With Drilled Mark

On Crankshaft Timing Pulley (Tundra & T100)
Fig. 12: Installing Camshaft Timing Pulley Knock Pin

(Tundra & T100)
Fig. 9: Aligning Camshafts For Timing Belt Installation
(Tundra & T100)
Fig. 10: Aligning Installation Mark On Timing Belt With Timing

Mark On Left Camshaft Pulley (Tundra & T100)
TOYOTA 709
3.4L V6 (Cont.)
A/C Compressor Bracket-To-Engine ......................................................................... 35 (47)
A/C Compressor-To-Bracket ..................................................................................... 18 (25)
Camshaft Pulley Bolt ............................................................................................... 81 (110)
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)
Power Steering Pump Bolt/Nut ................................................................................. 31 (43)
Spark Plug ................................................................................................................. 13 (18)
Water Pump Bolt ....................................................................................................... 14 (20)
INCH Lbs. (N.m)
Fan Retaining Nut .................................................................................................... 48 (5.4)
Oil Dipstick Tube ......................................................................................................... 71 (8)
1
– Apply Loctite 242 or equivalent to 2 or 3 threads of pivot bolt
710 VOLKSWAGEN
1.5L & 1.6L 4-Cylinder – Diesel & Turbo Diesel
Part No.
Dasher
1979-80 ..................................................... 2.8 Hours ... ..... T043
Rabbit
1977-80 ..................................................... 1.5 Hours ... ..... T043
Rabbit Pickup
1980 ........................................................... 2.8 Hours ... ..... T043
1.6L 4-Cyl. – Diesel & Turbo Diesel
Dasher
1981 ........................................................... 2.8 Hours ... ..... T043
Golf
1985-87 ..................................................... 2.8 Hours ... ..... T043 Courtesy of Volkswagen United States, Inc.
1988-92 (Canadian) .................................. 2.2 Hours ... ..... T043
Jetta Fig. 1: Installing Camshaft Setting Bar
1981-86 ..................................................... 2.8 Hours ... ..... T043 belt so there is no slack between camshaft sprocket and injection pump,
1986 (Canadian) ....................................... 2.8 Hours ... ..... T043 and between injection pump and crankshaft sprocket.
1989-92 ..................................................... 2.2 Hours ... ..... T043 2) Tighten tension adjuster to keep belt firmly in place. Remove injection
1988-92 (Canadian) .................................. 2.2 Hours ... ..... T043
pump locking pin. Adjust belt tension by turning tensioner until scale
Quantum
reads 12-13 on Tension Gauge (210) or equivalent. See Fig. 2. Tighten
1982-85 ..................................................... 2.8 Hours ... ..... T043
Rabbit camshaft sprocket bolt and tensioner adjuster lock nut. Remove lock
1981-84 ..................................................... 1.5 Hours ... ..... T043 from camshaft.
Rabbit Pickup 3) Turn crankshaft 2 revolutions in direction of engine rotation. Using a
1981-83 ..................................................... 2.8 Hours ... ..... T043 rubber hammer, strike belt once between camshaft sprocket and
Vanagon injection pump sprocket. Recheck belt tension and install remaining
1982 ........................................................... 2.8 Hours ... ..... T043 components in reverse order of removal. Check injection pump timing.

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 Fig. 2: Installing Timing Belt Tension Gauge
cylinder to TDC. Check that TDC mark on flywheel is aligned with
reference. TORQUE SPECIFICATIONS
2) Using Setting Bar (2065A for Vanagon, 2065 for other models) or TORQUE SPECIFICATIONS
equivalent, lock camshaft in position. See Fig. 1. Align tool by turning
camshaft until one end of tool touches cylinder head. Measure gap at Application Ft. Lbs. (N.m)
other end with feeler gauge. Insert feeler gauges of 1/2 thickness Camshaft Sprocket Bolt ............................................................................................ 33 (45)
measured between tool and cylinder head at each end of tool. Crankshaft Pulley Bolts ............................................................................................. 15 (20)
3) Lock injection pump sprocket at TDC with Special Pin (2064) or Crankshaft Sprocket Bolt
equivalent. Loosen belt tensioner and remove timing belt from sprock- Except Vanagon .................................................................................................... 81 (110)
Vanagon ............................................................................................................... 110 (150)
ets.
Intermediate Sprocket Bolt ........................................................................................ 33 (45)
Timing Belt Tensioner Lock Nut ............................................................................... 33 (45)
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
VOLKSWAGEN 711
1.5L, 1.6L & 1.7L 4-Cylinder – Gasoline

TIMING BELT APPLICATION 3) Reverse removal procedure for remaining components. Adjust drive
Application Labor Time Component Belt belts to proper tension.
Kit No. Part No.
1.5L 4-Cyl.
Dasher
1974-75 ............................ .... 1.3 Hrs. .... .. TCK017 .. ..... T017
Rabbit
1975-79 ............................ .... 1.5 Hrs. .... .. TCK017 .. ..... T017
Scirocco
1978 ................................. .... 1.8 Hrs. .... .. TCK017 .. ..... T017
1.6L 4-Cyl.
Dasher
1976-80 ............................ .... 1.5 Hrs. .... .. TCK017 .. ..... T017
Jetta
1980 ................................. .... 1.8 Hrs. .... .. TCK017 .. ..... T017
Pickup
1980 ................................. .... 1.8 Hrs. .... .. TCK017 .. ..... T017
Rabbit
1980 ................................. .... 1.5 Hrs. .... .. TCK017 .. ..... T017
Scirocco
1976-80 ............................ .... 1.8 Hrs. .... .. TCK017 .. ..... T017
1.7L 4-Cyl.
Jetta
1981-84 ............................ .... 1.8 Hrs. .... .. TCK017 .. ..... T017 Courtesy of Volkswagen United States, Inc.
Quantum
1982-83 ............................ ... 1 1.8 Hrs. ... .. TCK017 .. ..... T017 Fig. 1: Aligning Crankshaft & Intermediate Sprockets
Rabbit
1981 ................................. .... 1.5 Hrs. .... .. TCK017 .. ..... T017
1982-84 ............................ .... 1.8 Hrs. .... .. TCK017 .. ..... T017
Rabbit Pickup
1981-83 ............................ .... 1.8 Hrs. .... .. TCK017 .. ..... T017
Scirocco
1981-83 ............................ .... 1.8 Hrs. .... .. TCK017 .. ..... T017
1
With Radiator removal, labor time is 3.9 hours.


60,000 mile intervals. Fig. 2: Aligning Camshaft With Cylinder Head Flange

camshaft or crankshaft when timing belt is removed, or engine Application Ft. Lbs. (N.m)
damage may occur. Crankshaft Pulley Bolts ............................................................................................. 15 (20)
Crankshaft Sprocket Bolt .......................................................................................... 59 (80)
Intermediate Sprocket Bolt 1 ..................................................................................... 59 (80)
TIMING BELT Timing Belt Tensioner Lock Nut ............................................................................... 33 (45)
Removal – Disconnect negative battery cable. Remove alternator belt, Water Pump Bolts ..................................................................................................... 15 (20)
water pump pulley, and upper and lower drive belt covers. If equipped, Water Pump Pulley Bolts .......................................................................................... 15 (20)
remove air conditioning compressor drive belt. Remove timing belt 1
– Use Loctite.
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.
712 VOLKSWAGEN
1.8L 4-Cylinder
Golf, GTI & Jetta – AWD, AWP & AWW Engines
1.8L 4-Cylinder Turbo (AWD, AWP & AWW Engines) camshaft or crankshaft when timing belt is removed, or engine
Golf damage may occur.
2000-01 ..................................................... 2.9 Hours ... ..... T306
GTI & Jetta
2000-04 ..................................................... 2.9 Hours ... ..... T306 TIMING BELT
NOTE: Engine code is located on machined pad on bellhousing NOTE: To identify engine, check engine code located on a pad on
flange, where engine connects to transaxle. engine block near bellhousing of transmission.
Removal – 1) Working under hood, remove engine cover. Working
NOTE: For information about tensioners and/or pulleys (when under vehicle, remove insulation tray.
available), see ALPHABETICAL MODEL LISTING. 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.
intervals.
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.
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 Fig. 3: Setting Crankshaft To TDC (Automatic Transmission)
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.
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 Courtesy of Volkswagen United States, Inc.
pulley. It is NOT necessary to remove crankshaft pulley center bolt.
11) Remove lower and middle timing belt covers. See Fig. 5. Remove Fig. 4: Setting Crankshaft To TDC (Manual Transmission)
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.
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.
14) Remove timing belt. Turn crankshaft back just slightly to ensure that
crankshaft is not at TDC for any cylinder in case camshaft moves.

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.
Fig. 2: Releasing Belt Tensioner
714 VOLKSWAGEN
1.8L 4-Cylinder
Golf, GTI & Jetta – AWD, AWP & AWW Engines (Cont.)

Courtesy of Volkswagen United States, Inc. Fig. 8: Aligning Timing Marks
Fig. 6: Locating Engine Bracket-To-Block Bolts

NOTE: Before installing engine mount, insert bolts into engine Fig. 9: Locating Right-Hand Engine Support Arm
mount.
2) Install timing belt around crankshaft sprocket. If installing used belt,
ensure it is installed in original direction of rotation. Install engine mount TORQUE SPECIFICATIONS
bracket to block. Install lower timing belt guard. Use Locking Fluid (D Application Ft. Lbs. (N.m)
000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley, Crankshaft Pulley-To-Crankshaft Sprocket ............................................................... 18 (25)
and tighten bolt to specification. See TORQUE SPECIFICATIONS. Engine Mount-To-Body 1
3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 8. Place timing belt Step 1 ...................................................................................................................... 30 (40)
on water pump, tensioner pulley and camshaft sprocket. Step 2 ................................................................................................... Additional 1/4 Turn
4) Compress tensioner and remove locking pin or drill bit from timing belt Engine Mount-To-Engine Bracket 1
Step 1 ...................................................................................................................... 44 (60)
tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft
2 complete revolutions in normal direction of rotation. Align camshaft Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
and crankshaft timing marks. Install crankshaft pulley. Timing Belt Tensioner
5) Install center and upper timing belt covers. Install engine right-hand Bottom Bolt .............................................................................................................. 11 (15)
engine support arm and console using NEW bolts. Adjust engine Top Bolt ................................................................................................................... 15 (20)
console and right-hand engine support arm so clearance is about .50″ Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27)
(13 mm). See Fig. 9. Water Pump Bolt ....................................................................................................... 11 (15)
6) Remove Engine Support Bracket (10-222) or floor jack from under INCH Lbs. (N.m)
vehicle. Install serpentine belt tensioner and serpentine belt. Timing Belt Cover Bolt .............................................................................................. 89 (10)
7) Install coolant expansion tank and power steering reservoir. Install 1
– Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.
vacuum line between fuel evaporative canister and throttle body. To
install remaining components, reverse removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS.
VOLKSWAGEN 715
1.8L 4-Cylinder – New Beetle – APH, AWP & AWV Engines

Application Labor Time Belt CAUTION: Engine mount assembly is secured by torque-to-yield
Part No. bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt.
1.8L 4-Cylinder – DOHC (APH, AWP & AWV Engines) These bolts MUST be replaced if they are loosened or removed.
New Beetle
1999-04 ..................................................... 2.9 Hours ... ..... T306 8) Remove bolts from engine mount assembly at timing belt end of
engine. Remove engine mount.
NOTE: For information about tensioners and/or pulleys (when 9) Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED timing belt with arrow to indicate original direction of rotation.
SCHEDULED MAINTENANCE 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.
The manufacturer suggests the timing belt AND tensioner be replaced at
Compress tensioner just enough so that Locking Pin (T40011) or drill bit
can be inserted through the tensioner body, locking the tensioner in
REMOVAL & INSTALLATION place.
CAUTION: When turning camshaft, crankshaft must not be at TDC,

damage may occur.
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.
Fig. 2: Releasing Serpentine Drive Belt Tension (1 Of 2)
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 Courtesy of Volkswagen United States, Inc.
stroke. Ensure that TDC marks on flywheel and bellhousing are aligned.
See Fig. 4 or 5. Fig. 3: Releasing Serpentine Drive Belt Tension (2 Of 2)
5) Remove coolant expansion tank and set aside. Label all vacuum
hoses for reassembly reference, and disconnect vacuum hoses from Installation – 1) Ensure camshaft is still at TDC of compression stroke
fuel evaporative canister. Disconnect vacuum hoses at throttle body. for No. 1 cylinder. Align timing marks on camshaft sprocket with mark on
6) Remove upper timing belt cover. See Fig. 6. cylinder head cover. See Fig. 9.
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.
716 VOLKSWAGEN
1.8L 4-Cylinder – New Beetle – APH, AWP & AWV Engines (Cont.)
Fig. 4: Setting Crankshaft to TDC (Automatic Transmission)
Fig. 7: Locating Engine Bracket-To-Block Bolts
Fig. 5: Setting Crankshaft to TDC (Manual Transmission)
Fig. 8: Installing Timing Belt Tensioner Locking Pin

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 crank-
shaft marks align properly. See Fig. 9.
6) Install middle and upper timing belt covers. Tighten bolts to specifi-
cation. 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
9) To complete installation, reverse remaining removal procedure.
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,
3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 9. Place timing belt
on water pump, tensioner pulley and camshaft sprocket.
VOLKSWAGEN 717
1.8L 4-Cylinder – New Beetle – APH, AWP & AWV Engines (Cont.)
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°)
Courtesy of Audi of America, Inc. Timing Belt Tensioner Mount Bolt ................................................ ............................ 11 (15)
Fig. 9: Aligning Camshaft & Crankshaft Timing Marks Water Pump Bolt ....................................................................................................... 11 (15)
1
– Replace bolts if loosened or removed.
Fig. 10: Adjusting Engine Mount Clearance

718 VOLKSWAGEN
1.8L 4-Cylinder – Passat – AEB & ATW Engines
Part No.
1.8L 4-Cylinder – DOHC (AEB & ATW Engines)
Passat
1998-00

For 1998-99 model years, the manufacturer suggests the belt be
replaced at 90,000 mile intervals. For 2000 model year, the manufac-
turer suggests the belt AND tensioner be replaced at 105,000 mile
intervals.

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
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 driver’s 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. Courtesy of Volkswagen United States, Inc.
5) Remove accessory drive belt tensioner pulley and lever. Turn Fig. 2: Exploded View Of Lock Carrier Assembly
crankshaft to TDC of compression stroke on No. 1 cylinder. See Fig. 4.
6) Remove crankshaft pulley. It is NOT necessary to remove center 3) Tighten tensioner pulley bolt to specification. See TORQUE SPECI-
crankshaft pulley center bolt. Remove upper and lower timing belt FICATIONS. Rotate crankshaft 2 revolutions. Make sure camshaft and
covers. Loosen timing belt tensioner lever bolt. crankshaft timing marks are aligned.
7) If reusing timing belt, mark belt with arrow to indicate direction of 4) Belt tension is correct if edge of tensioner lever aligns with piston
rotation. Remove timing belt. 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
CAUTION: When turning camshaft, crankshaft must not be at TDC dimension is not correct.
or there is a potential for valves to contact pistons. Install timing 5) Remove crankshaft pulley. Install lower and upper timing belt covers.
belt when engine is cold or lukewarm. Install crankshaft pulley. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Install accessory drive belt tensioner. Install acces-
Installation – 1) Align timing marks on camshaft sprocket with mark on sory drive belt. Install the A/C compressor drive belt (if equipped).
cylinder head cover. See Fig. 4. Ensure crankshaft is still at TDC Ensure used belts are installed in original direction of rotation.
position. Install timing belt around crankshaft sprocket. Temporarily 6) Install lock carrier in original location. Install bumper and bumper
install crankshaft pulley to ensure crankshaft is still at TDC of compres- cover.
sion 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.
VOLKSWAGEN 719
1.8L 4-Cylinder – Passat – AEB & ATW Engines (Cont.)

Fig. 3: Removing Timing Belt TORQUE SPECIFICATIONS
Accessory Drive Belt Tensioner Bolt ........................................................................ 18 (25)
A/C Drive Belt Tensioner Bolt ................................................................................... 22 (30)
Bumper Carrier-To-Impact Damper Vertical Bolt ...................................................... 15 (20)
Impact Damper-To-Lock Carrier Bolt ........................................................................ 68 (50)
Lock Carrier
Front Support Bolt ................................................................................................... 37 (50)
INCH Lbs. (N.m)
Bumper Guide-To-Side Panel Bolt .............................................................................. 18 (2)
Lock Carrier-To-Side Panel Bolt ................................................................................. 71 (8)

720 VOLKSWAGEN
1.8L 4-Cylinder – Passat – AUG & AWM Engines
Application Labor Time Belt NOTE: If necessary, align pressure piston using needle nose pliers
Part No. or a thin wire (hole in piston and hole in housing must align).
1.8L 4-Cylinder – DOHC (AUG & AWM Engines) 6) On vehicles built through July 2000, align holes in timing belt
Passat tensioner piston rod and housing. Insert Tensioning Bolt (T10092) into
2000-04 ..................................................... 3.6 Hours ... ..... T306 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.
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
SCHEDULED MAINTENANCE on tensioner and push pulley counter-clockwise in direction of arrow with
The manufacturer suggests the timing belt AND tensioner be replaced at a socket head wrench using even but not excessive application of force
105,000 mile intervals. 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
REMOVAL & INSTALLATION Wrench (3387). Ensure tab on Pin Wrench is not bent. Loosen nut in
center of tensioner, and rotate clockwise using Pin Wrench.
CAUTION: This application is an interference engine. Do not rotate 9) On all models, remove timing belt. Turn crankshaft back just slightly
to ensure that crankshaft is not at TDC for any cylinder.
damage may occur. CAUTION: When turning camshaft, crankshaft must not be at TDC,
TIMING BELT
Installation – 1) Align timing marks on camshaft sprocket with mark on
NOTE: Lock carrier is slid forward onto alignment tools. This will cylinder head cover. Ensure crankshaft sprocket is still aligned with
allow servicing of front engine components. Lock carrier can be timing mark. See Fig. 6.
removed at technicians discretion. 2) Install timing belt around crankshaft sprocket. Install lower timing belt
cover. Install NEW vibration damper bolts, and tighten to specification.
Removal – 1) For vehicles manufactured up to September, 2000, See TORQUE SPECIFICATIONS.
disconnect front turn signal light assembly wiring harnesses. Separate 3) Set crankshaft pulley to TDC No. 1 cylinder. Place timing belt on water
hood release lever from bumper cover. Remove front bumper cover. See pump, tensioner pulley and camshaft sprocket. For models built through
Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner July 2000, go to next step. For models built after July 2000, go to step 5).
housing. Remove support bolts from lock carrier assembly. See Fig. 2.
Install Support Tool (3369) through lock carrier to body. Remove oil NOTE: Engine must be cool (not more than lukewarm) when
cooler from lock carrier assembly. Move lock carrier forward on support tensioning timing belt.
tools. 4) On models built through July 2000, remove Locking Pin (T40011) and
2) For vehicles manufactured from October, 2000, remove bumper unscrew Tensioning Bolt (T10092). See Fig. 7.
cover from bumper carrier. See Fig. 3. Remove noise insulation panel
from under engine compartment. Remove air intake duct at lock carrier. CAUTION: If tensioner is fully extended at any time, it must be
Remove bolts from front of bumper carrier. See Fig. 4. Install guide rods pressed back into compressed position using tensioner assembly
and Pin Wrench. Excessive force during this compression proce-
on right and left sides. Pull lock carrier forward about 4″ (10 cm) on guide
dure can damage tensioner assembly.
rods into service position.
5) On models built after July 2000, rotate tensioner counterclockwise
CAUTION: DO NOT hang condenser or oil cooler from their lines. using Pin Wrench (3387), removing all tension until Locking Plate
(T10008) can be removed without force. After removing Locking Plate,
3) On all vehicles, loosen bolts for air conditioning drive belt and remove
rotate tensioner clockwise using Pin Wrench until a 5/16″ (8 mm) drill bit
belt. Remove serpentine drive belt. Remove serpentine drive belt
can be inserted between tensioner lever and housing through underside
tensioner.
of tensioner. While holding tensioner in this position, tighten tensioner
NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior 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 prop-
destroy it.
erly. See Fig. 6.
4) Remove upper timing belt cover. See Fig. 5. Rotate crankshaft to TDC 7) On models built after July 2000, using a drill bit check dimension
No. 1 cylinder. See Fig. 6. between tightening lever and housing of tightening device. Specified
value .236-.393″ (6-10 mm). If dimension is not as specified, repeat
CAUTION: Vibration damper outer bolts and center bolt are torque- timing belt tensioning procedure.
to-yield type. If loosened or removed, bolts must be replaced. 8) To finish installation, reverse remaining removal procedure. Tighten
all fasteners to specification. See TORQUE SPECIFICATIONS.
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).
VOLKSWAGEN 721
1.8L 4-Cylinder – Passat – AUG & AWM Engines (Cont.)
Fig. 1: Removing Front Bumper Cover (Up To September, 2000)

Fig. 3: Removing Front Bumper Cover (From October, 2000)

Courtesy of Volkswagen United States, Inc. Fig. 4: Moving Lock Carrier To Service Position
Fig. 2: Moving Lock Carrier To Service Position (From October, 2000)
(Up To September, 2000)
722 VOLKSWAGEN
Fig. 7: Compressing Timing Belt Tensioner (Up To July, 2000)


VOLKSWAGEN 723

Bumper Carrier-To-Impact Absorber Vertical Bolt .................................................... 15 (20)
Crankshaft Pulley Center Bolt 1
Step 1 ...................................................................................................................... 66 (90)
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90°)
Impact Damper-To-Lock Carrier Bolt (From Oct. 2000) .......................................... 68 (50)
Lock Carrier
Front Support Bolt ................................................................................................... 37 (50)
Water Pump Bolt ....................................................................................................... 11 (15)
INCH Lbs. (N.m)
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.
724 VOLKSWAGEN
Kit No. Part No.
Cabriolet
1985-93 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017
Corrado
1990-92 ........................... ... 1.8 Hours ... .. TCK017 .. ..... T017
Fox
1987-93 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017
Golf
1985-92 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017
Golf (Canadian)
1993-95 ........................... ... 1.8 Hours ... .. TCK017 .. ..... T017
GTI
1984-87 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017
1988-89 ........................... ... 1.9 Hours ... .. TCK017 .. ..... T017
1990-92 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017
Jetta
1984-92 ........................... ... 1.8 Hours ... .. TCK017 .. ..... T017
Jetta (Canadian)
1993-95 ........................... ... 1.8 Hours ... .. TCK017 .. ..... T017 Courtesy of Audi of America, Inc.
Passat (Canadian)
1992-94 ........................... ... 1.8 Hours ... .. TCK017 .. ..... T017 Fig. 1: Removing Timing Belt
Quantum
3) Rotate tensioner clockwise to tighten belt and install lock nut. Proper
1985 ................................ .. 1 1.8 Hours .. .. TCK017 .. ..... T017
Rabbit deflection is achieved when longest span of belt between sprockets can
1983-84 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017 be twisted 90 degrees. See Fig. 4.
Scirocco 4) By hand, rotate crankshaft 2 turns and check timing mark alignment.
1983-88 ............................ 1, 2 1.8 Hours . .. TCK017 .. ..... T017 To complete installation, reverse removal procedure. Adjust drive belts
1 to proper tension.
With Radiator removal, labor time is 3.9 hours.
2
Without Radiator removal, labor time is 3.6 hours.




TIMING BELT
damage may occur.
Removal – Disconnect negative battery cable. Match mark all compo-
nents to ensure reassembly in original position. See Fig. 1. DO NOT turn
crankshaft with belt removed. Valve 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. Courtesy of Volkswagen United States, Inc.
Installation – 1) Align flywheel/flexplate “0” mark with pointer. This is
TDC. Remove distributor cap and check position of ignition rotor. Rotate Fig. 3: Aligning 1.8L Timing Marks (8-Valve)
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.
VOLKSWAGEN 725

A/C Bracket-To-Engine Bolt ...................................................................................... 22 (30)
Crankshaft Timing Sprocket Bolt .............................................................................. 66 (90)
Lower Pulley Bolt ...................................................................................................... 15 (20)
INCH Lbs. (N.m)
Valve Cover Retaining Nut ....................................................................................... 89 (10)
Water Pump-To-Housing ........................................................................................... 89 (10)
Fig. 4: Checking 1.8L Timing Belt Tension (8-Valve)

726 VOLKSWAGEN
TIMING BELT APPLICATION noting offset holes. If valve cover is installed, mark on front of camshaft
Application Labor Time Belt sprocket must align with mark on valve cover. If valve cover is removed,
Part No. place camshaft sprocket mark even with valve cover surface. See Fig. 3.
1.8L 4-Cyl. – DOHC 2) Align crankshaft sprocket mark with mark on lower timing belt cover.
GTI See Fig. 3. Install timing belt around camshaft sprocket. Rotate ten-
1987-89 ..................................................... 1.9 Hours ... ..... T292 sioner clockwise until Timing Belt Tension Scale (VW 210), or equiva-
Jetta lent, reads 13-14.
1987-89 ..................................................... 1.9 Hours ... ..... T292 3) Rotate crankshaft 2 revolutions and check timing mark alignment. To
Scirocco (Canadian)
1988-89 ..................................................... 1.8 Hours ... ..... T292
Scirocco proper tension.
1987-88 ..................................................... 1.9 Hours ... ..... T292
GTI
1990-92 ..................................................... 1.9 Hours ... ..... T292
Jetta
1990-92 ..................................................... 1.9 Hours ... ..... T292
Passat
1990-92 ..................................................... 1.9 Hours ... ..... T292


damage may occur.
TIMING BELT
Removal – 1) Disconnect negative battery cable. Match mark all
components to ensure reassembly to original position. Remove acces-
sory drive belts.
stroke. Remove fan belt and water pump pulleys. See Fig. 1. Remove
timing belt covers. Remove tensioner pulley. Remove timing belt.
Fig. 3: Timing Mark Alignment

Installation – 1) Install timing belt around crankshaft and intermediate
shaft sprockets. Install lower timing belt cover. Install vibration damper, Fig. 4: Proper Timing Belt Tension
VOLKSWAGEN 727

Crankshaft Pulley Nut ............................................................................................... 15 (20)
16-Valve ............................................................................................................... 148 (200)
Intermediate Shaft Sprocket Bolt
16-Valve ................................................................................................................... 48 (65)
Water Pump Pulley ................................................................................................... 15 (20)
INCH Lbs. (N.m)
Upper & Lower Timing Belt Cover Bolt ..................................................................... 53 (6)
Water Pump-To-Housing ........................................................................................... 84 (10)
728 VOLKSWAGEN
1.9L 4-Cylinder – Turbo Diesel – AAZ, AHU & 1Z Engines
Part No.
1.9L 4-Cylinder Turbo Diesel (AAZ, AHU & 1Z Engines)
Golf & Golf III 1
1993-95 ..................................................... 2.8 Hours ... ..... T242
1996-97 ..................................................... 2.8 Hours ... ..... T242
Jetta & Jetta III 1
1993-95 ..................................................... 2.8 Hours ... ..... T242
1996-98 ..................................................... 2.8 Hours ... ..... T242
Passat (USA) 1
1996-97 ..................................................... 2.8 Hours ... ..... T242
Passat (Canada) 1
1993-98 ..................................................... 2.2 Hours ... ..... T242
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.


Fig. 1: Removing Serpentine Belt
The manufacturer recommends the belt AND tensioner be replaced at CAUTION: Use spanner wrench to hold camshaft sprocket while
60,000 mile intervals. 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
CAUTION: This application is an interference engine. Do not rotate sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft
camshaft or crankshaft when timing belt is removed, or engine sprocket on camshaft taper.
damage may occur. 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
TIMING BELT (2064) from injection pump sprocket.
Removal (Golf, Jetta & Passat w/AAZ Engine, Up To Sept., 1994) – 4) On models without semiautomatic timing belt tensioner, apply tension
1) On models with tensioner, install Tensioner Tool (3299) and rotate to timing belt using Tension Pin Wrench (Matra V159). See Fig. 6. Turn
clockwise. Mark serpentine belt with arrow to indicate rotation direction, tensioner clockwise to tension belt. Install Tension Tool (VW210) set to
and remove belt. See Fig. 1. Remove tensioner pulley. On models 12 to 13. Measure tension midway between camshaft sprocket and
without serpentine belts, remove accessory drive belts. injection pump sprocket. Tighten lock nut on timing belt tensioner to 33
2) On all models, remove upper timing belt cover. See Fig. 2. Remove ft. lbs. (45 N.m).
valve cover. 5) On models with semiautomatic timing belt tensioner, install idler
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin
stroke. Flywheel TDC mark must be aligned to mark on transmission Wrench (Matra V159), turn tensioner clockwise until notch aligns with
mating flange. See Fig. 3. raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15
4) Lock camshaft in place with Setting Bar (2065A) installed on rear of ft. lbs. (20 N.m).
camshaft. See Fig. 4. Center setting bar by turning camshaft so one side 6) On all models, tighten camshaft sprocket bolt. See TORQUE SPECI-
of setting bar contacts cylinder head. Using feeler gauge, measure FICATIONS. Remove setting bar from camshaft.
distance between other end of setting bar and cylinder head. 7) Turn crankshaft 2 revolutions in normal direction of rotation. Recheck
5) Divide this feeler gauge dimension in half. Place a feeler gauge timing belt tension.
corresponding to half the bar-to-cylinder head dimension between 8) On models with semiautomatic tensioner, apply thumb pressure to
setting bar and one side of cylinder head. timing belt. Notched and raised portions of timing belt tensioner must
6) Turn camshaft until setting bar contacts feeler gauge. Place second move apart. Release thumb pressure on belt. Tensioner must back to its
feeler gauge of same dimension between other end of bar and cylinder original position (raised and notched portions aligned). If not, replace
head. tensioner.
7) Lock injection pump in place using Lock Pin (2064). See Fig. 5. 9) On all models, install timing belt covers. Install vibration damper and
Loosen timing belt tensioner. Remove crankshaft vibration damper. belt pulleys (if removed). Install accessory drive belts. To prevent
Remove the lower timing belt cover. See Fig. 3. damage to serpentine belt, install in original direction of rotation.
8) If reusing old timing belt, mark belt with arrow to indication original 10) Install valve cover. On engine code AAZ, check fuel injection
direction of rotation. Move timing belt tensioner, and remove timing belt. delivery. Consult service information for procedure.
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.)

11) For Passat with 1Z engine, check injection pump start of delivery.
CAUTION: Timing belt replacement for Passat (1Z engine) requires Consult service information for procedure using VAG 1551/1552 factory
using factory scan tool VAG 1551/1552 to check injection pump scan tool.
start of delivery after timing belt is installed.
CAUTION: Timing belt replacement for 1998 Passat (AHH engine)
Removal (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ Engine, requires using factory scan tool VAG 1551/1552 to check injection
From October 1994) – 1) On models with tensioner, install Tensioner pump start of delivery after timing belt is installed.
Tool (3299) and rotate clockwise. Mark serpentine belt with arrow to Removal (1998 Passat, w/AHH Engine) – 1) Disconnect front turn
indicate rotation direction, and remove belt. See Fig. 1. Remove signal light assembly wiring harnesses. Separate hood release lever
tensioner pulley. On models without serpentine belts, remove accessory from bumper cover. Remove front bumper cover. See Fig. 9. Remove
drive belts. bumper beam.
2) On all models, remove upper timing belt cover. See Fig. 2. Remove 2) Remove air intake duct from air cleaner housing. Remove support
valve cover. bolts from lock carrier assembly. See Fig. 10. Install Support Tool (3369)
3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression through lock carrier to body. Remove oil cooler from lock carrier
stroke. Flywheel TDC mark must be aligned to mark on transmission assembly. Move lock carrier forward on support tools.
mating flange. 3) Mark serpentine drive belt with arrow to indicate direction of rotation.
4) Lock camshaft in place with Setting Bar (2065A) installed on rear of Rotate tensioner counterclockwise, and remove serpentine drive belt.
camshaft. See Fig. 4. Center setting bar by turning camshaft so one side Remove upper timing belt cover. See Fig. 3.
of setting bar contacts cylinder head. Using feeler gauge, measure 4) Lock camshaft in place with Setting Bar (2065A) installed on rear of
distance between other end of setting bar and cylinder head. camshaft. See Fig. 4. Center setting bar by turning camshaft so one side
5) Divide this feeler gauge dimension in half. Place a feeler gauge of setting bar contacts cylinder head. Using feeler gauge, measure
corresponding to half the bar-to-cylinder head dimension between distance between other end of setting bar and cylinder head.
setting bar and one side of cylinder head. 5) Divide this feeler gauge dimension in half. Place a feeler gauge
6) Lock injection pump in place using lock pin. See Figs. 5and 8. Loosen corresponding to half the bar-to-cylinder head dimension between
injection pump sprocket mounting bolt(s). setting bar and one side of cylinder head.
7) Loosen timing belt tensioner. On Passat with 1Z engine, remove 6) Remove timing belt tensioner. Lock injection pump in place using lock
water pump pulley and power steering pump pulley. pin. See Fig. 8. Loosen injection pump sprocket mounting bolts.
8) On all models, remove crankshaft vibration damper. Remove the 7) Remove crankshaft vibration damper. Remove lower timing belt
lower timing belt cover. See Fig. 2. cover. See Fig. 2.
9) If reusing old timing belt, mark belt with arrow to indication original 8) If reusing old timing belt, mark belt with arrow to indication original
direction of rotation. Move timing belt tensioner, and remove timing belt. direction of rotation. Move timing belt tensioner, and remove timing belt.
Installation (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ Installation (1998 Passat w/AHH Engine) – 1) Ensure TDC mark on
Engine, From Oct., 1994) – 1) Ensure TDC mark on flywheel and flywheel and transmission mating flange are still aligned. See Fig. 3.
transmission mating flange are still aligned. See Fig. 3.
CAUTION: Use spanner wrench to hold camshaft sprocket while
CAUTION: Use spanner wrench to hold camshaft sprocket while loosening center bolt. Do not use camshaft setting bar to hold
loosening center bolt. Do not use camshaft setting bar to hold camshaft sprocket.
camshaft sprocket.
2) Holding camshaft stationary, loosen camshaft sprocket bolt 1/2 turn.
2) Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch Place drift punch through rear timing belt cover and LIGHTLY tap
through hole in rear of timing belt cover until it contacts rear of camshaft camshaft sprocket loose from tapered end of camshaft.
sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft 3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and
sprocket on camshaft taper. crankshaft at TDC, install timing belt on engine. If reusing old belt,
3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and ensure belt is installed in original direction of rotation.
crankshaft at TDC, install timing belt on engine. If reusing old belt, 4) Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using
ensure belt is installed in original direction of rotation. Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch
4) Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock
Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch nut to 15 ft. lbs. (20 N.m).
aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock 5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS.
nut to 15 ft. lbs. (20 N.m). Tighten injection pump sprocket mounting bolts.
5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. 6) Remove setting bar from camshaft. Remove lock pin from injection
Tighten injection pump sprocket mounting bolt(s). pump.
6) Remove setting bar from camshaft. Remove lock pin from injection 7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set
pump No. 1 cylinder to TDC of compression stroke.
7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set 8) Apply thumb pressure to timing belt. Notched and raised portions of
No. 1 cylinder to TDC of compression stroke. timing belt tensioner must move apart. Release thumb pressure on belt.
8) On models with semiautomatic tensioner, apply thumb pressure to Tensioner must back to its original position (raised and notched portions
timing belt. Notched and raised portions of timing belt tensioner must aligned). If not, replace tensioner.
move apart. Release thumb pressure on belt. Tensioner must back to its 9) Ensure injection pump sprocket can be locked using Lock Pin (3359).
original position (raised and notched portions aligned). If not, replace See Fig. 8. If injection pump cannot be locked using correct lock pin,
tensioner. loosen injection pump sprocket mounting bolt(s), and turn sprocket until
9) On engine codes AHU and 1Z, ensure injection pump sprocket can be lock pin can be inserted in place. Tighten mounting bolts.
locked using Lock Pin (2064). See Fig. 5. On engine code AAZ, ensure 10) Install timing belt covers. Install vibration damper. Install valve cover.
injection pump sprocket can be locked using Lock Pin (3359). See To prevent damage to serpentine belt, install in original direction of
Fig. 8. If injection pump cannot be locked using correct lock pin, loosen rotation.
injection pump sprocket mounting bolt(s), and turn sprocket until lock pin 11) Place lock carrier in original position on body. Install front bumper
can be inserted in place. Tighten mounting bolt(s). assembly.
10) Install timing belt covers. Install vibration damper and belt pulleys (if 12) Check injection pump start of delivery. Consult service information
removed). Install valve cover. Install accessory drive belts. To prevent for procedure using VAG 1551/1552 factory scan tool.
damage to serpentine belt, install in original direction of rotation.
730 VOLKSWAGEN
Fig. 4: Locking Camshaft With Setting Bar (2065A)
Fig. 3: Locating TDC Mark on Flywheel/Flexplate

Fig. 5: Locking Diesel Fuel Injection Pump Sprocket (AHU & 1Z

Engines; AAZ Engines Up To September 1994)
VOLKSWAGEN 731
Fig. 6: Tensioning Timing Belt (AAZ Engines Up To October

1994, Without Semi-Automatic Tensioner)
Fig. 9: Exploded View of Bumper Assembly (1998 Passat)
Fig. 7: Adjusting Timing Belt Tension (Semi-Automatic

Timing Belt Tensioner)
Fig. 10: Exploded View Of Lock Carrier Assembly (1998 Passat)
Fig. 8: Locking Diesel Fuel Injection Pump Sprocket

(AHH Engine & AAZ Engines From October 1994)
732 VOLKSWAGEN
TORQUE SPECIFICATIONS TECHNICAL SERVICE BULLETIN
TORQUE SPECIFICATIONS (GOLF & JETTA) TIMING BELT RUNS TOWARD OUTSIDE, WEARS OUT,
Application Ft. Lbs. (N.m) JUMPS OFF SPROCKET OR CRACKS
Camshaft Sprocket Bolt ............................................................................................ 33 (45) 1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines) – 1) If this condition
Crankshaft Pulley Bolt ............................................................................................... 18 (25) exists, replace timing belt and semiautomatic tensioner (Part No. 028
Crankshaft Sprocket Center Bolt 109 243F).
Step 1 ...................................................................................................................... 66 (90) 2) BEFORE installing new timing belt, clean all timing belt sprockets.
Step 2 .......................................................................................... ........ Plus 1/4 Turn (90°) Install new belt. Before installing vibration damper, start and run engine
Injection Pump Sprocket Mounting Bolt at idle for a few seconds. Turn off engine.
Center Mounting Bolt .............................................................................................. 33 (45) 3) Belt must not protrude past edge of crankshaft sprocket. If it does,
Three Mounting Bolts .............................................................................................. 18 (25) 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
Timing Belt Tensioner Pulley Lock Nut
“A” and lifting mount at “B”. See Fig. 11.
With Semi-Automatic Tensioner .............................................................................. 15 (20)
Without Semi-Automatic Tensioner ......................................................................... 33 (45) 4) Start and run engine at idle for a few seconds. Turn off engine. Belt
must not protrude past edge of crankshaft sprocket.
INCH Lbs. (N.m)
Lower Timing Belt Cover Bolt ................................................................................... 89 (10) NOTE: This information is from Volkswagen technical service
Valve Cover Nut ........................................................................................................ 89 (10) bulletin Group 15, No. 97-01; June 4, 1997.
1
– ALWAYS replace if loosened or removed.
TORQUE SPECIFICATIONS (PASSAT)

Bumper Beam-To-Impact Absorber Bolt (1998) ....................................................... 15 (20)
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°)
Timing Belt Tensioner Pulley Lock Nut .................................................................... 18 (25)
INCH. Lbs. (N.m)
Bumper Cover Bolt (1998) .......................................................................................... 18 (2) Courtesy of Volkswagen United States, Inc.
Lower Timing Belt Cover Bolt ................................................................................... 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10) Fig. 11: Injection Pump Mounting Bracket (1994-97 Golf, Jetta &
1 Passat w/AAZ & 1Z Engines)
– ALWAYS replace if loosened or removed.
VOLKSWAGEN 733
1.9L 4-Cylinder – Turbo Diesel – ALH Engine

TIMING BELT APPLICATION 3) If serpentine belt is to be reused, mark rotational direction of belt.
Application Labor Time Belt Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise
Part No. to relieve belt tension, and remove serpentine belt. Remove serpentine
1.9L 4-Cylinder Turbo Diesel (ALH Engine) belt tensioner.
Golf 1
1999 ........................................................... 4.0 Hours ... ..... T301 CAUTION: The valve cover has an integrated, vulcanized gasket. If
Or T321 gasket is damaged or leaking, replace the valve cover.
2000-01
Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... T301 4) Remove brake booster vacuum pump. Remove upper timing belt
After Eng. No. 500,001 .......................... 4.4 Hours ... ..... T321 cover. Remove engine valve cover using care not to damage gasket.
2002-04 ..................................................... 4.4 Hours ... ..... T321 5) Rotate crankshaft so that No. 1 cylinder is at TDC of compression
Jetta 1 stroke. TDC mark can be viewed through access hole in engine-to-
1999 ........................................................... 4.0 Hours ... ..... T301 transmission mating flange. See Fig. 1.
Or T321 6) Lock camshaft in place with Camshaft Setting Bar (3418) installed on
2001-00 rear of camshaft. See Fig. 2. Center setting bar by turning camshaft so
Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... T301
one side of setting bar contacts cylinder head. Using feeler gauge,
After Eng. No. 500,001 .......................... 4.4 Hours ... ..... T321
2002-04 ..................................................... 4.4 Hours ... ..... T321 measure distance between other end of setting bar and cylinder head.
New Beetle 1 Divide this dimension in half. Place a feeler gauge corresponding to half
1998 ........................................................... 4.4 Hours ... ..... T301 the bar-to-cylinder head dimension between setting bar and cylinder
1999 ........................................................... 4.4 Hours ... ..... T301 head. Turn camshaft until setting bar contacts feeler gauge. Place
Or T321 second feeler gauge of same dimension between other end of bar and
2000-01 cylinder head.
Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... T301
After Eng. No. 500,001 .......................... 4.4 Hours ... ..... T321
2002-04 ..................................................... 4.4 Hours ... ..... T321
1

SCHEDULED MAINTENANCE INTERVAL
1
Model Year Interval
1998-99 .......................................................... ............................................................ 60,000
2000 ............................................................... ............................................................ 40,000
2001 2 ............................................................. ............................................................ 40,000
2001 3 ............................................................. ............................................................ 60,000
2002 ............................................................... ............................................................ 80,000
2003-04 .......................................................... .......................................................... 100,000
1
– Replace timing belt and tensioner together.
2
– Models equipped with automatic transmissions.
3
– Models equipped with manual transmission.

damage may occur.

TIMING BELT
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. 7) Lock injection pump in place using Lock Pin (3359). See Fig. 3.
Removal (Golf & Jetta) – 1) Working under hood, remove fuel supply CAUTION: DO NOT loosen diesel injection pump center hub nut.
and return lines from fuel filter. Seal fuel lines to prevent contamination This will alter injection pump basic setting.
of fuel system. Remove upper and lower right headlight assembly
8) Loosen, but do not remove, the 3 diesel injection pump sprocket
mounting screws. Disconnect harness connectors and remove right
mounting bolts. Replace these bolts with NEW bolts during installation.
headlight assembly.
Attach Engine Support (10-222A) with legs (10-222A/1) or equivalent.
2) Remove pipe between charge air cooler (intercooler) and intake
Remove coolant reservoir bottle and power steering reservoir, and
manifold. Remove upper engine cover. Remove right sound damper
leaving hoses attached set aside.
cover.
734 VOLKSWAGEN
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. NOTE: The 3 diesel injection pump bolts are torque-to-yield type.
Fig. 2: Locking Camshaft With Setting Bar Manufacturer recommends replacing bolts during final assembly.
8) Loosen, but do not remove, the 3 diesel injection pump sprocket
CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt. mounting bolts. Manufacturer recommends replacing these torque-to-
This bolt MUST be replaced if loosened or removed. yield bolts during final assembly. Support engine weight from above or
below with floor jack.
9) Remove engine mount from timing belt end of engine. Remove 4
crankshaft pulley socket-head bolts and remove crankshaft pulley (it is NOTE: On New Beetle, engine mount bolts are torque-to-yield type.
not necessary to remove center bolt). Remove middle and lower timing Manufacturer recommends replacing bolts if they are loosened or
belt covers. Remove engine mount bracket. removed.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt 9) Remove engine mount from timing belt end of engine.
removed.
CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt.
10) If reusing old timing belt, mark belt with arrow to indicate original This bolt MUST be replaced if loosened or removed.
direction of rotation. Loosen timing belt tensioner lock nut. Turn ten-
sioner to release belt and remove timing belt. 10) Remove 4 crankshaft pulley socket-head bolts, and remove crank-
shaft pulley (it is not necessary to remove center bolt). Remove timing
belt covers.

removed.
direction of rotation. Loosen timing belt tensioner lock nut. Turn ten-
sioner 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.
2) Using Spanner Wrench (3036) counter-hold camshaft and loosen
Fig. 3: Locking Diesel Fuel Injection Pump Sprocket camshaft sprocket bolt 1/2 turn. See Fig. 4. On New Beetle, place drift
punch through rear timing belt cover and LIGHTLY tap camshaft
Removal (New Beetle) – 1) Remove tube between charge air cooler
sprocket loose from tapered end of camshaft. On Golf and Jetta, use a
and air intake pipe. Disconnect and plug fuel supply and return lines at
fuel filter. Remove fuel filter from bracket. Two Arm Puller (T40001) to remove sprocket. Remove camshaft
sprocket.
CAUTION: The valve cover has an integrated, vulcanized gasket. If 3) Install timing belt onto crankshaft sprocket, idler pulley, water pump,
gasket is damaged or leaking, replace the valve cover. injection pump sprocket, and tensioner pulley. Adjust injection pump
sprocket on mount so mounting slots are centered. If installing old belt,
2) Remove upper timing belt cover. Remove valve cover. Remove brake
booster vacuum pump. Remove pipe between charge air cooler and note direction of rotation mark.
turbocharger. 4) Install camshaft sprocket together with timing belt. Install camshaft
3) If serpentine belt is to be reused, mark rotational direction of belt. sprocket bolt finger tight. Camshaft sprocket should still be free to turn.
Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise 5) On Golf and Jetta with automatic transaxle, use an Allen wrench to
to relieve belt tension, and remove serpentine belt. Remove serpentine turn timing belt tensioner clockwise until notch and pointer align. See
belt tensioner. Fig. 5. If tensioner is turned too far and correct tension is exceeded,
4) Rotate crankshaft so that No. 1 cylinder is at TDC of compression tension must be fully released, and then readjusted. Tighten center lock
stroke. TDC mark can be viewed through access hole in engine-to- nut on tensioner pulley to specification. See TORQUE SPECIFICA-
transmission mating flange. See Fig. 1. TIONS.
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 SPECIFI-
CATIONS.
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 Courtesy of Volkswagen United States, Inc.
procedure (dynamic timing) using factory scan tester (VAG 1551/1552).
Fig. 6: Adjusting Timing Belt Tension (Golf & Jetta With
After performing start of injection procedure, tighten injection pump Manual Transaxle, & New Beetle)
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.
engine mount, install mounting bolts in holes on bracket before attempt-
ing to fit bracket to engine block. Tighten nuts and bolts to specification.
See TORQUE SPECIFICATIONS. Check fuel lines for leaks. Adjust
12) Using scan tester (VAG 1551/1552), check Diesel injection pump
start of delivery. Courtesy of Volkswagen United States, Inc.
TORQUE SPECIFICATIONS (GOLF & JETTA)
Diesel Injection Pump Sprocket Bolts 1 ......................................................... 15 (20) + 90°
Serpentine Drive Belt Tensioner ............................................................................... 18 (25)
Vacuum Pump Bolt ................................................................................................... 15 (20)
Water Pump Bolts ..................................................................................................... 16 (22)
INCH. Lbs. (N.m)
Courtesy of Volkswagen United States, Inc. Timing Belt Cover Bolt .............................................................................................. 89 (10)
Valve Cover Nut ........................................................................................................ 89 (10)
Fig. 4: Securing Camshaft Sprocket 1
– Replace with new torque-to-yield bolts on installation.
TORQUE SPECIFICATIONS (NEW BEETLE)

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°
Water Pump Bolts ..................................................................................................... 11 (15)
INCH Lbs. (N.m)
Valve Cover Nut ........................................................................................................ 89 (10)
1
– Replace with new torque-to-yield bolts on installation.
Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With

Automatic Transaxle)
736 VOLKSWAGEN
1.9L 4-Cylinder – Turbo Diesel, BEW Engine
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

The manufacturer suggests the belt be replaced at 90,000 mile intervals.

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 appro- Courtesy of Volkswagen United States, Inc.
priate sized drift pushed through hole in tensioner. Remove poly V-belt
Fig. 1: Attaching Engine Support & Removing Engine Mount
tensioner.
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 com-
plete mounting assembly.
6) Raise engine slightly with the support device, and unbolt engine
mounting bracket-to-cylinder block bolts (arrows) and remove. See Courtesy of Volkswagen United States, Inc.
Fig. 2.
Fig. 2: Removing Engine Mount From Engine Block
CAUTION: Engine mount assembly is secured by torque-to-yield push Crankshaft Stop from face side of timing belt pulley into pulley
bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These teeth. The marks on the crankshaft pulley and the Crankshaft Stop must
bolts MUST be replaced if they are loosened or removed. align. At the same time, the pin of the Crankshaft Stop must engage in
7) Remove 4 crankshaft/vibration damper pulley socket-head bolts, and hole in the sealing flange.
crankshaft/vibration damper pulley. It is NOT necessary to remove
crankshaft pulley center bolt.
removed.
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 10) If reusing old timing belt, mark belt with arrow to indicate original
at the top and the arrow on the rear timing belt guard aligns with the lugs direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but
on the sender wheel of the hub. See Fig. 3. do not remove, camshaft pulley securing bolts (1) until camshaft pulley
9) Lock camshaft pulley with Locking Pin (3359). See Fig. 3. To do this, can be moved within elongated holes. See Fig. 4.
slide locking pin through free elongated hole on left side of cylinder
head. Lock crankshaft pulley with Crankshaft Stop (T10050). To do this,
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.

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 com-
plete 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. bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These
bolts MUST be replaced if they are loosened or removed.
Fig. 3: Locating TDC Position; Locking Cam & Crankshafts Into
Position 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.

removed.
direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but
Fig. 4: Loosening Camshaft Pulley Securing Bolts do not remove, camshaft pulley securing bolts (1) until camshaft pulley
can be moved within elongated holes. See Fig. 4.
Removal (New Beetle) – 1) Working under hood, remove engine cover. 12) Turn Pin Wrench (3387) counterclockwise (opposite direction of
Pull front of engine cover abruptly upward and then pull forward out of arrow on tensioner) until timing belt tensioner can be locked in position
rear securing elements. using Locking Pin (T10115). See Fig. 5. Turn pin wrench clockwise (in
2) Remove upper charge air line and connecting hose. Carefully cover direction of arrow on tensioner) until stop and tighten securing nut
or close open ends of charge air line. If poly V-belt is to be reused, mark hand-tight. Remove timing belt first from coolant pump and then from
rotational direction of belt. Using appropriate wrench, rotatep poly V-belt remaining pulleys.
738 VOLKSWAGEN
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.
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. Courtesy of Volkswagen United States, Inc.
3) Ensure that tab on tensioning roller seats correctly in rear timing belt
guard. Loosen tensioning roller securing nut. Relieve tension on ten- Fig. 8: Positioning Crankshaft Gear With Crankshaft Stop Pin
(T10050)
sioning roller by turning pin wrench and remove locking pin from
tensioning roller. 7) Turn crankshaft two rotations in engine direction of rotation until
4) Carefully turn tensioning roller with Pin Wrench (3387) in direction of crankshaft is set to TDC No. 1 cylinder again. With engine at TDC No. 1
arrow (on tensioner) until indicator is in middle of gap in base plate cylinder, the shaft of the Crankshaft Stop (T10050) must be able to
(arrow). See Fig. 7. Hold tensioning roller in this position, and tighten engage in the sealing flange from direction of engine rotation. If the
tensioning roller securing nut to 15 ft. lbs. (20 N.m) plus an additional 45° crankshaft is turned past TDC No. 1 cylinder and the Crankshaft Stop
(1/8 turn). Counter-hold camshaft pulley, and tighten securing bolts to 18 could not engage in the sealing flange, turn the crankshaft back 1/4 turn
ft. lbs. (25 N.m). Remove Locking Pin and Crankshaft Stop. 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
crankshaft two rotations in direction of engine rotation and set again to
normal direction of rotation when turning to ensure the Crankshaft Stop
TDC No. 1 cylinder.
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.

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
engine mount, install mounting bolts in holes on bracket before attempt-
ing to fit bracket to engine block. Tighten nuts and bolts to specification.

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

TORQUE SPECIFICATIONS (GOLF & JETTA) TORQUE SPECIFICATIONS (NEW BEETLE)
Camshaft Sprocket Bolt .......................................................................................... 74 (100) Camshaft Sprocket Bolt .......................................................................................... 74 (100)
Crankshaft Gear Bolt 1 .................................................................. ..................................... 2 Crankshaft Gear Bolt 1 .................................................................. ..................................... 2
Engine Mount-To-Engine Bolts ................................................................................. 33 (45) Engine Mount-To-Engine Bolts ................................................................................. 33 (45)
Engine Mounting Bracket-To-Engine Bolt ............................................................... 74 (100) Engine Mount-To-Engine Bracket Bolt .................................................................... 74 (100)
Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3 Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3
Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25) Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25)
Poly V-Belt Tensioner ................................................................................................ 18 (25) Poly V-Belt Tensioner ................................................................................................ 18 (25)
Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4 Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4
INCH. Lbs. (N.m) INCH. Lbs. (N.m)
1 5
Crankshaft Pulley Bolts ............................................................... ..................................... Crankshaft Pulley Bolts ............................................................... ..................................... 5
1
Timing Belt Cover Bolts ............................................................................................ 89 (10) Timing Belt Cover Bolts ............................................................................................ 89 (10)
1 1
– Replace with new torque-to-yield bolts on installation. – Replace with new torque-to-yield bolts on installation.
2 2
– Tighten to 89 ft. lbs. (120 N.m) plus an additional 90° (1/4 turn). – Tighten to 89 ft. lbs. (120 N.m) plus an additional 90° (1/4 turn).
3 3
4 4
5 5
– Tighten to 89 INCH lbs. (10 N.m) plus an additional 90° (1/4 turn). – Tighten to 89 INCH lbs. (10 N.m) plus an additional 90° (1/4 turn).
740 VOLKSWAGEN
2.0L 4-Cylinder – ABA Engine
Application Labor Time Component Belt CAUTION: To prevent valves from contacting piston, DO NOT
Kit No. Part No. rotate camshaft or crankshaft with timing belt removed. Valve
2.0L 4-Cyl. (ABA Engine) damage may result.
Cabrio 4) If reusing timing belt, mark belt with arrow to indicate original direction
1995-02 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262 of rotation.
Golf
5) Place crankshaft at TDC by aligning flywheel (M/T) or drive plate (A/T)
1993-99 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262
Golf (Canadian) TDC marks. See Fig. 5. Ensure camshaft timing mark is aligned with
1995 ................................ ... 1.9 Hours ... .. TCK262 .. ..... T262 mark on belt guard. See Fig. 6. Loosen belt tensioner. Remove timing
GTI belt.
1996-99 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262
GTI (Canadian)
1993-95 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262
Jetta
1993-99 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262
Passat
1993-96 ........................... ... 1.9 Hours ... .. TCK262 .. ..... T262


maintenance interval, belt manufacturers suggest the belt be replaced at Courtesy of Volkswagen United States, Inc.
Fig. 2: Removing & Installing Ribbed (Accessory) Drive Belts
NOTE: Engine code (ABA) is stamped into machined pad on front (Without A/C)
of cylinder block above crankcase breather, near cylinder head
mating surface. See Fig. 1.
Fig. 1: Locating Engine Identification Code (2.0L – ABA)

Fig. 3: Removing & Installing Ribbed (Accessory) Drive Belts
(With A/C)
damage may occur.
NOTE: Disregard marking on intermediate shaft drive belt

TIMING BELT sprocket.
Removal (Standard Tensioner – Up To 1997) – 1) Remove accessory
Installation (Standard Tensioner – Up To 1997) – 1) Ensure crank-
drive belts. See Fig. 2 or 3. Remove accessory drive belt tensioner
shaft is still at TDC position. See Fig. 5. Remove distributor cap. Rotate
bracket. See Fig. 4. intermediate shaft counterclockwise until rotor is pointed at No. 1
2) Remove crankshaft pulley bolts and pulley (it is NOT necessary to cylinder mark. See Fig. 5. Ensure camshaft timing mark is still aligned
remove center bolt). with mark on belt guard. See Fig. 6.
3) Remove water pump pulley. Remove upper and lower timing belt 2) Install timing belt around crankshaft, intermediate shaft, tensioner,
covers. and camshaft sprockets.
VOLKSWAGEN 741
2.0L 4-Cylinder – ABA Engine (Cont.)
Courtesy of Volkswagen United States, Inc. Fig. 6: Aligning Camshaft Timing Marks
Fig. 4: Exploded View Of Timing Belt & Components (With
Standard Tensioner)
CAUTION: To prevent valves from contacting piston, DO NOT

rotate camshaft or crankshaft with timing belt removed. Valve
damage may result.
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 (acces-
sory) belt tensioner using Ribbed Belt Installation Tool (3299) and
Courtesy of Volkswagen United States, Inc. remove ribbed belt at generator. Remove ribbed belt tension roller and
Fig. 5: Aligning Crankshaft & Distributor Timing Marks upper timing belt guard. Remove lower V-belt cover. Hold hydraulic
(P/S) pump pulley using (VAG1590) or mandrel, and remove fasteners
3) Loosen timing belt tensioner center nut. Using spanner wrench, rotate for coolant pump pulley. Remove coolant pump pulley and V-belt.
tensioner pulley clockwise to tension belt. Belt tension is correct when it Remove vibration damper/pulley. See Figs. 2 and 3.
is possible to rotate belt 90 degrees with thumb and forefinger, half-way 3) Turn drive plate (A/T) or flywheel (M/T) to align mark (arrows in
between camshaft and intermediate shaft sprockets. See Fig. 7. illustration) and place No. 1 cylinder at TDC. See Fig. 5. Remove lower
4) While holding tensioner pulley stationary, tighten tensioner pulley timing belt guard.
center nut to specification. Rotate crankshaft 2 revolutions and recheck 4) Mark the running direction on the timing belt. Remove fastener for
check belt tension. Adjust tension as necessary. Recheck all timing timing belt thermo tension roller. Remove belt and roller. Remove timing
marks again. belt thermo tensioner. See Fig. 8.
5) Install timing belt covers. Install drive belt tensioner bracket. To
complete installation, reverse removal procedure. Adjust drive belts to CAUTION: DO NOT turn the camshaft while any piston is at TDC
proper tension. 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
742 VOLKSWAGEN
2.0L 4-Cylinder – ABA Engine (Cont.)

(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 Courtesy of Volkswagen United States, Inc.
bracket (arrows in illustration) until tensioner piston No. 1 is driven all the
Fig. 10: Installing & Adjusting Thermo Tensioner Roller
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 TORQUE SPECIFICATIONS
revolutions in running direction. Counter-hold thermo tension roller with
two-pin spanner, and tighten mounting bolt to specification. See TORQUE SPECIFICATIONS (STANDARD TENSIONER – UP TO 1997)
TORQUE SPECIFICATIONS. Install lower timing belt guard. Install Application Ft. Lbs. (N.m)
vibration damper/pulley. Camshaft Sprocket Bolt ............................................................................................ 59 (80)
4) Install ribbed belt tension roller. Using Ribbed Belt Installation Tool Crankshaft Pulley Bolt ............................................................................................... 18 (25)
(3299), adjust tension on ribbed belt tensioner and position belt. Position Crankshaft Sprocket Center Bolt ................................................................. 1 66 (90) + 90°
V-belt, and bolt coolant pump pulley to coolant pump. Install upper Drive Belt Tensioner Bracket Bolt ............................................................................. 15 (20)
timing belt guard. Install air cleaner with pre-heated air hose and intake
Timing Belt Tensioner Center Nut ............................................................................ 33 (45)
air duct. Water Pump Pulley Bolt ............................................................................................ 18 (25)
INCH Lbs. (N.m)
Timing Belt Cover Nut .............................................................................................. 89 (10)
1
– Replace torque-to-yield bolt on installation.
TORQUE SPECIFICATIONS (THERMO TENSIONER – 1997 & UP)

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)
Fig. 9: Identifying Thermo Tensioner Roller Assembly

VOLKSWAGEN 743
2.0L 4-Cylinder – AEG, AVH, AZG, BDC & BEV Engines

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


SCHEDULED MAINTENANCE Courtesy of Volkswagen United States, Inc.
For 1998-00 model years, although the manufacturer does not recom- Fig. 2: Locating Engine Identification Code
mend a specific scheduled maintenance interval, belt manufacturers (AVH, AZG, BDC & BEV)
mile intervals.
NOTE: For 2004, manufacturer does not provide a timing belt

replacement interval.

damage may occur.
NOTE: Engine code AEG is stamped into machined pad on front of

cylinder block above crankcase breather, near cylinder head mat-
ing 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 Courtesy of Volkswagen United States, Inc.
data plate and on a sticker on the timing belt cover.
Fig. 3: Releasing Serpentine Belt Tensioner
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
Courtesy of Volkswagen United States, Inc. that must be replaced if removed).
5) Remove timing belt covers. Remove engine support from front of
Fig. 1: Locating Engine Identification Code (AEG) engine. See Fig. 4.
CAUTION: To prevent valves from contacting piston, DO NOT

TIMING BELT 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 6) If reusing old belt, mark belt with arrow to indicate original direction of
cover. Rotate serpentine belt tensioner clockwise to relieve belt tension. rotation. Loosen timing belt tensioner nut and rotate timing belt tensioner
Remove serpentine belt. See Fig. 3. Lock in place using Mandrel away from belt to remove timing belt. See Fig. 8.
(T10060) or a drift.
744 VOLKSWAGEN
2.0L 4-Cylinder – AEG, AVH, AZG, BDC & BEV Engines (Cont.)

(AEG, AVH, AZG, BDC & BEV Engine Codes)
Fig. 6: Locating TDC Mark on Transaxle
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.)
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)
Courtesy of Volkswagen United States, Inc. Timing Belt Tensioner Center Nut ............................................................................ 15 (20)
Water Pump Bolt ....................................................................................................... 11 (15)
Fig. 8: Releasing/Adjusting Timing Belt Tension
INCH Lbs. (N.m)
Installation (AEG, AVH, AZG, BDC & BEV Engine Codes) – 1) Ensure
crankshaft and camshaft timing marks are still aligned. See Figs. 5
and 6.
1
2) Install timing belt around crankshaft and water pump sprockets. Install – Replace torque-to-yield bolt on installation.
2
engine support on front of engine block. Tighten mounting bolts to – First tighten to (40 N.m), then tighten bolts an additional 90° (1/4 turn).
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.
746 VOLKSWAGEN
2.0L 4-Cylinder – BBW Engines
TIMING BELT APPLICATION 2) Remove upper intake manifold as follows. Turn ignition off. Check
Application Labor Time Component Belt whether a coded radio is installed, and obtain radio code as necessary.
Kit No. Part No. Disconnect battery ground strap.
2.0L 4-Cyl. (BBW Engine) 3) Open cap on coolant expansion tank. Clamp off hose (3). See Fig. 3.
Golf Disconnect hoses (1), (2) and (3). Disconnect harness connector (1) and
2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296 pull off hoses (4), (5), (6) and (7). See Fig. 4.
Jetta
2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296


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

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.
Fig. 3: Removing & Installing Upper Intake Manifold (1 Of 2)
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 compart-
ment. Rotate serpentine belt tensioner clockwise to relieve belt tension.
Remove serpentine belt. See Fig. 2. Lock tensioner in place using Fig. 4: Removing & Installing Upper Intake Manifold (2 Of 2)
Mandrel (T10060) or a appropriate sized drift. Remove serpentine belt
tensioner.
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.
Fig. 6: Removing Vibration Damper & Engine Mount Bracket
Fig. 7: Identifying Adjustment Bar (2065A)
NOTE: When starting installation of timing belt pistons must not be

positioned at TDC.
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.
Courtesy of Volkswagen United States, Inc. 2) Clean oil from camshaft sprocket with a cloth. Counter-holding
camshaft with Counter Bracket (T10172) with Pins (T10172/3) or
Fig. 5: Attaching Engine Support & Removing Engine Mount
equivalent, remove camshaft pulley bolt. See Fig. 9. DO NOT rotate
camshaft, if possible. Remove camshaft sprocket from camshaft and
clean it.
748 VOLKSWAGEN
Courtesy of Volkswagen United States, Inc. Courtesy of Volkswagen United States, Inc.
Fig. 8: Removing & Installing Camshaft Sealing Plug Fig. 10: Identifying Crankshaft Alignment Marks

Courtesy of Volkswagen United States, Inc. Fig. 11: Tensioning Timing Belt
Fig. 9: Removing & Installing Camshaft Pulley
NOTE: At this point, manufacturer recommends replacing cam-

shaft 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 Courtesy of Volkswagen United States, Inc.
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 Fig. 12: Counter-Holding & Torquing Camshaft Sprocket Bolt
(T10004) onto limit stop. Release tension on toothed belt until notch (1) 7) Turn crankshaft two rotations in direction of engine rotation until
and indicator (2) align (use mirror). Tighten tensioner securing nut to 15 Adjustment Bar can be inserted. It is essential that the last 45° (1/8 turn)
ft. lbs. (20 N.m). Verify that crankshaft is at TDC, correcting if necessary. is performed without stopping. If the crankshaft has been turned to far,
6) Using Counter Bracket hold camshaft sprocket and tighten camshaft turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1
bolt to 30 ft. lbs. (40 N.m). See Fig. 12. Remove Adjustment Bar from cylinder again (insert the Adjustment Bar).
rear of camshaft. Counter-hold camshaft sprocket and tighten camshaft 8) Check that crankshaft is at TDC. Notch (2) on vibration damper/belt
bolt to 96 ft. lbs. (130 N.m). 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

9) If the crankshaft positioned as specified, verify timing belt tension, TORQUE SPECIFICATIONS
indicator and notch align, adjusting as necessary.
10) Install sealing plug (1) with NEW O-ring to camshaft pulley. See TORQUE SPECIFICATIONS
Fig. 8. Tightening sealing plug to 18 ft. lbs. (25 N.m). Install engine Application Ft. Lbs. (N.m)
mounting to cylinder block. Tighten to bolts specification. See TORQUE Camshaft Sprocket Bolt .......................................................................................... 74 (100)
SPECIFICATIONS. Insert bolts into engine bracket before installing Camshaft Sprocket Bolt
engine bracket. Tighten all bolts of the engine bracket to specification, Step 1 1 .................................................................................................................... 30 (40)
before installing the engine mounting. Step 2 1 .................................................................................................................. 96 (130)
11) Remaining installation is performed in reverse order to removal. Camshaft Sprocket Sealing Plug .............................................................................. 18 (25)
Replace all “O” ring seals or gaskets that were disturbed during removal. Crankshaft Pulley Socket-Head Bolts ....................................................................... 18 (25)
Crankshaft Sprocket Center Bolt ......................................................................... 2, 3 66 (90)
Engine Mounting Bolts
Check and top off engine oil level as necessary. Note the following Engine Support-To-Engine Block ............................................................................ 33 (45)
concerning intake manifold installation: Mounting Bracket-To-Body (Small Bolt) .................................................................. 18 (25)
• Considering installed position, replace intake manifold lower part Mounting Bracket-To-Body Bolts (Large Bolts) 2 ........................ ..................................... 3
seal. Mount-To-Body ....................................................................................................... 74 (100)
Intake Manifold
• After connecting battery cables, turn ignition on engine off, for 10
Lower Part ............................................................................................................... 15 (20)
seconds before starting engine.
Upper Part-To-Lower Part ........................................................... ..................................... 4
• Adapt (match) ECM to throttle valve control module. Generate Upper Part-To-Bracket Bolt ..................................................................................... 18 (25)
readiness code again if DTC memory has been erased or ECM was Serpentine Belt Tensioner Bolt ................................................................................. 18 (25)
disconnected from battery voltage. See appropriate service informa- Timing Belt Tensioner Center Nut ............................................................................ 15 (20)
tion. Water Pump Bolt ....................................................................................................... 11 (15)
INCH Lbs. (N.m)
1
– 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.
2
– Replace torque-to-yield bolt on installation.
3
– First tighten to (40 N.m), then tighten bolts an additional 90° (1/4 turn).
4
– Tighten to 89 INCH lbs. (10 N.m).
750 VOLKSWAGEN
2.5L 5-Cylinder
TIMING BELT APPLICATION 2) For ALL engines, place timing belt on crankshaft sprocket, relay roller
Application Labor Time Belt or tensioning roller and coolant pump (note direction of rotation).
Part No. 3) For vehicles build up to July, 1995, install lower timing belt cover
2.5L 5-Cylinder and install mounting bolt M8 for coolant pump. If tensioning roller is
Eurovan installed, tighten to 15 ft. lbs. (20 N.m).
1992-96 ..................................................... 2.3 Hours ... ....... N/A 4) For ALL engines, torque vibration damper to crankshaft timing belt
Transporter (Canadian) sprocket (4 M8 bolts):
1992-96 ..................................................... 2.3 Hours ... ....... N/A V- Belt Pulley – 15 ft. lbs. (20 N.m).
Serpentine Belt Pulley – 15 ft. lbs. (20 N.m), pull another 1/4 turn (90
NOTE: For information about tensioners and/or pulleys (when degrees further).
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED timing belt sprocket center bolt to 118 ft. lbs. (160 N.m), plus 180 degree
SCHEDULED MAINTENANCE (1/2) additional turn. The additional 1/2 turn can be completed in several
Although the manufacturer does not recommend a specific scheduled stages.
maintenance interval, aftermarket belt manufacturers suggest the belt Vehicles With Short Center Bolt (65 mm) – Coat threads and bolt
be replaced at 60,000 mile intervals. head contact surface of center bolt with (AMV 188 001 02), or equiva-
lent. Insert Counter-Hold Tool (3419). See Fig. 6. Tighten center bolt to
REMOVAL & INSTALLATION 340 ft. lbs. (460 N.m).
6) For ALL engines, Set camshaft sprocket to marking TDC Cyl. 1. The
CAUTION: This application is an interference engine. Do not rotate marking on the camshaft sprocket must align with the mark on the rear
camshaft or crankshaft when timing belt is removed, or engine timing belt cover. See Fig. 7.
damage may occur.
NOTE: Adjust timing belt tension with engine cold.
8) For vehicles WITH tensioning roller built up to July, 1995, loosen
TIMING BELT nut (1) and check that tensioning roller moves freely, then place timing
Removal – Remove lower sound dampening pan. belt on camshaft sprocket (note direction of rotation). See Fig. 9. Tighten
1) Removing V-belt or serpentine belt. tensioning roller mounting bolt hand tight. Turn engine about 2 turns until
2) Remove timing belt upper cover. just before TDC. To tension timing belt, turn crankshaft slowly to TDC
3) Fit counter Hold Tool (3419) and loosen vibration damper and position (crankshaft must not jump back). Tighten tensioning roller nut to
crankshaft sprocket. See Fig. 1. 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.
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
Fig. 1: Removing/Installing Crankshaft Vibration Damper between camshaft and intermediate shaft sprockets. See Fig. 12.
Tighten coolant pump mounting bolts to 15 ft. lbs. (20 N.m). See Fig. 11.
4) Remove vibration damper center bolt.
Go to step 11).
5) Remove the 4 x M8 crankshaft vibration damper/timing belt pulley
11) On ALL engines, rotate crankshaft two full turns and check adjust-
mounting bolts.
ment. Install upper timing belt cover
6) Remove vibration damper.
12) Install serpentine belt. See Figs. 13-15. Check ignition timing and
7) Remove timing belt lower cover.
adjust, if necessary.
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.
VOLKSWAGEN 751
Fig. 2: Identifying Timing Belt & Components (2.5L, Up To July, 1995)
Fig. 3: Identifying Timing Belt & Components (2.5L, From August, 1995 & Up)
752 VOLKSWAGEN
Fig. 4: Identifying Crankshaft Vibration Damper & Components (2.5L)
Fig. 5: Setting Up & Installing Tensioning Roller (Vehicles Built

From August, 1995 & Up)
VOLKSWAGEN 753

Fig. 6: Removing/Installing Crankshaft Vibration Damper Fig. 9: Tensioning Timing Belt (Vehicles Built Up To July, 1995)

Fig. 10: Tensioning Timing Belt (Vehicles Built From
Fig. 7: Setting Camshaft Sprocket To TDC Cylinder No. 1. August, 1995 & Up)

Fig. 8: Setting Crankshaft To TDC Cylinder No. 1.
Fig. 11: Tensioning Timing Belt Vehicles Without
Tensioning Roller
754 VOLKSWAGEN
Fig. 15: Serpentine Drive Belt Routing (2.5L – Without A/C)
Courtesy of Volkswagen United States, Inc. TORQUE SPECIFICATIONS

Fig. 12: Adjustment Timing Belt Tension TORQUE SPECIFICATIONS
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)
Transmission Mount-To-Sub Frame .......................................................................... 33 (45)
Vibration Damper Center Bolt ....................................................... ..................................... 1
INCH Lbs. (N.m)
Radiator Mounting Bolt ............................................................................................. 89 (10)
Courtesy of Volkswagen United States, Inc. Sound Dampening Pan Hex Nut ................................................................................ 80 (9)
Timing Belt Covers (M6 Short) ............................................................................... 2 89 (10)
Fig. 13: Serpentine Drive Belt Routing (2.5L – Basic) Timing Belt Covers (M8 Long) ............................................................................. 2 177 (20)
Timing Belt Inner Covers .............................................................. ..................................... 2
Thermostat Housing .................................................................................................. 89 (10)
Valve Cover ............................................................................................................... 89 (10)
1
– For torque specifications, see Fig. 4.
2
– For torque specifications related to timing belt components, refer to appropriate
illustration. See Figs. 2 and 3.
Fig. 14: Serpentine Drive Belt Routing (2.5L – With A/C)

VOLKSWAGEN 755
2.8L V6 – Passat – AHA & ATQ Engines

TIMING BELT APPLICATION 9) Remove serpentine belt tensioner. Remove center and left timing belt
Application Labor Time Belt covers.
Part No. 10) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner
2.8L V6 (AHA & ATQ Engines) pulley clockwise to compress timing belt tensioner. See Fig. 9. Com-
Passat press timing belt tensioner just enough so a 2-mm pin can be inserted
1998-04 ..................................................... 4.4 Hours ... ..... T297 through the holes in top of tensioner body and push rod. This will hold
the tensioner in the compressed position.
available), see ALPHABETICAL MODEL LISTING. 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.
MANUFACTURER’S SUGGESTED 11) Remove crankshaft vibration damper from crankshaft. It is NOT
SCHEDULED MAINTENANCE necessary to remove center bolt. If center bolt is removed, manufacturer
recommends using NEW bolt on reassembly. Remove serpentine belt
SCHEDULED REPLACEMENT INTERVAL
idler pulley.
Model Year Interval 12) Remove fan retainer and belt pulley toothed belt protection. Remove
1998 ............................................................... ............................................................ 90,000 timing belt.
1999 ............................................................... ............................................................ 75,000 Installation – 1) Install Camshaft Locator Bar (3391) into locking plates
2000-04 .......................................................... .......................................................... 105,000 of camshafts. See Fig. 10. Loosen camshaft sprocket bolts about 5
turns. Remove locator bar.
REMOVAL & INSTALLATION 2) Leaving camshaft sprocket bolts in place, use gear puller to loosen
camshaft sprockets on camshaft taper.
camshaft or crankshaft when timing belt is removed, or engine NOTE: Camshaft sprockets must be loose enough to rotate on
damage may occur. camshaft, but not loose enough to tilt.
3) Ensure all timing marks are still aligned. Install timing belt on engine.
TIMING BELT 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.
CAUTION: Obtain the radio anti-theft code before disconnecting 4) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner
the battery. so that 2-mm pin can be removed from tensioner.
5) Pre-load timing belt tension, using 8-mm hex socket and torque
NOTE: Lock carrier is slid forward onto alignment tools. This will wrench on timing belt tensioner pulley, apply 11 ft. lbs. (15 N.m) to
allow servicing of front engine components. Lock carrier can be tensioner in direction of tension (clockwise).
removed at technicians discretion. 6) Tighten camshaft sprocket bolts to specification. See TORQUE
SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft
Removal – 1) Disconnect negative battery cable. Remove engine top holder. Install sealing plug.
cover. Remove noise insulation panel from under front of vehicle. 7) Install timing belt cover. Install crankshaft pulley. Install serpentine
2) For vehicles manufactured up to September, 2000, disconnect front drive belt.
turn signal light assembly wiring harnesses. Separate hood release 8) To complete installation, reverse remaining removal procedure. When
lever from bumper cover. Remove front bumper cover. See Fig. 1. installing crankshaft pulley, ensure notches in pulley are aligned with
Remove bumper beam. Remove air intake duct from air cleaner locating lugs in crankshaft. Tighten all fasteners to specification. See
housing. Remove support bolts from lock carrier assembly. See Fig. 2. TORQUE SPECIFICATIONS.
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. Courtesy of Volkswagen United States, Inc.
8) Remove sealing plug from left side of engine block. See Fig. 8. TDC Fig. 1: Removing Front Bumper Cover (Up To September, 2000)
mark on crankshaft must be visible or be felt through sealing hole. Install
Crankshaft Holding Tool (Audi 3242) into sealing plug hole.
756 VOLKSWAGEN
2.8L V6 – Passat – AHA & ATQ Engines (Cont.)

(From October, 2000)

(Up To September, 2000)
Fig. 5: Removing & Installing Viscous Fan
Fig. 3: Removing Front Bumper Cover (From October, 2000)

VOLKSWAGEN 757
2.8L V6 – Passat – AHA & ATQ Engines (Cont.)
Fig. 7: Aligning Camshaft Sprocket Holes
Fig. 10: Installing Camshaft Locator Bar
Fig. 8: Installing Crankshaft Holding Tool

Crankshaft Pulley Center Bolt ......................................................................... 1, 2 148 (200)
Crankshaft Pulley-To-Crankshaft Hex Bolt ............................................................... 18 (25)
Lock Carrier-To-Body Bolts ....................................................................................... 37 (50)
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
– If removed, manufacturer recommends using NEW bolt.
2
– Tighten to initial specification than an additional 180° (1/2 turn).

758 VOLVO
1.9L 4-Cylinder – Turbo – 2000-01
TIMING BELT APPLICATION 5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn
Application Labor Time Belt tensioner counterclockwise until tensioner indicator passes marked
Part No. position. See Fig. 8.
1.9L 4-Cyl. – Turbo 6) Turn tensioner eccentric back so that indicator’s position is in center
S40 & V40 of window. See Fig. 8. Holding eccentric in this position, tighten bolt “B”
2000-01 to 15 ft. lbs (20 N.m) without moving tensioner.
Up To VIN 1219110 ................................ 3.1 Hours ... ..... T252 7) Recheck adjustment by pressing pin “A” clockwise and counterclock-
From Engine Vin 1219111 ..................... 3.1 Hours ......... T311 wise to check. Rotate crankshaft two complete revolutions, and check
that markings on crankshaft pulley and timing gears align with marks on
NOTE: For information about tensioners and/or pulleys (when timing gear cover. Ensure indicator pin “A” is in middle. Readjust if
available), see ALPHABETICAL MODEL LISTING. necessary. See Fig. 12. After readjustment, always turn crankshaft 2
complete revolutions to check if tensioner indicator returns to correct
MANUFACTURER’S SUGGESTED position.
SCHEDULED MAINTENANCE NOTE: Timing belt tensioner indicator will be in different positions
depending on engine temperature. At very low or high tempera-
For 2000-01 model years, the manufacturer recommends the timing belt
tures, tensioner indicator will be to the left or right of center. See
and belt tensioner be replaced every 105,000 miles.
Fig. 13.
REMOVAL & INSTALLATION 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.
damage may occur. 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.
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 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
Courtesy of Volvo Cars of North America.
wrench. Remove timing belt from tensioner pulley, camshaft sprockets
and water pump. Fig. 1: Removing Accessory Drive Belt
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 68°F (20°C) 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.
VOLVO 759
1.9L 4-Cylinder – Turbo – 2000-01 (Cont.)
Fig. 2: Removing Timing Gear Covers Courtesy of Volvo Cars of North America.
Fig. 5: Removing Lower Timing Gear Cover
Fig. 3: Locating Engine Mount (2000)
Fig. 6: Locating Engine Bracket Bolts
Fig. 4: Locating Engine Mount (2001)
Fig. 7: Locating Upper Rear Timing Belt Cover

760 VOLVO
Fig. 10: Installing New Tensioner
Fig. 9: Locating Snow Cap & Bolts

VOLVO 761

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)
Water Pump Bolt ....................................................................................................... 13 (17)
Wheel Lug Nut ........................................................................................................ 81 (110)
INCH Lbs. (N.m)
Power Steering Hose Bolt ........................................................................................ 89 (10)
Snow Cap Bolt .......................................................................................................... 89 (10)
Timing Belt Cover
Front ....................................................................................................................... 106 (12)
Upper ....................................................................................................................... 89 (10)
Fig. 11: Installing New Timing Belt
Fig. 13: Identifying Timing Belt Tension Positions

762 VOLVO
1.9L 4-Cylinder – Turbo – 2002-04
TIMING BELT APPLICATION 5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn
Application Labor Time Belt tensioner counterclockwise until tensioner indicator passes marked
Part No. position. See Fig. 5.
1.9L 4-Cyl. – Turbo 6) Turn tensioner eccentric back so that indicator’s position is in center
S40 & V40 of window. See Fig. 5. Holding eccentric in this position, tighten bolt “B”
2002-04 ..................................................... 3.1 Hours ......... T311 to 15 ft. lbs (20 N.m) without moving tensioner.
7) Recheck adjustment by pressing pin “A” clockwise and counterclock-
NOTE: For information about tensioners and/or pulleys (when wise to check. See Fig. 10. Install upper timing cover. Rotate crankshaft
available), see ALPHABETICAL MODEL LISTING. 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
MANUFACTURER’S SUGGESTED turn crankshaft 2 complete revolutions to check if tensioner indicator
SCHEDULED MAINTENANCE returns to correct position.
The manufacturer recommends the timing belt and belt tensioner be
NOTE: Timing belt tensioner indicator will be in different positions
depending on engine temperature. At very low or high tempera-
tures, tensioner indicator will be to left or right of center. See Fig. 9.
8) Install timing covers. Install engine mount. Tighten bolts on engine
CAUTION: This application is an interference engine. Do not rotate side to specification. See TORQUE SPECIFICATIONS. Tighten bolts on
camshaft or crankshaft when timing belt is removed, or engine body side to specification. Install power steering reservoir.
damage may occur.
NOTE: Close lid in side cover and move wheels to straight-ahead
position.
TIMING BELT
9) Remove engine lifting tool. Install metal bracket for power steering
CAUTION: DO NOT turn crankshaft or camshafts while belt is hose on rotation protection for serpentine drive belt. Install right front
removed. wheel. Install serpentine drive belt. Install right hand engine cover and
cover over right headlight unit. Tighten all fasteners to specification. See
Removal – 1) Remove right engine compartment cover and cover TORQUE SPECIFICATIONS.
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 protec-
tion 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 crank-
shaft 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 o’clock 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. Courtesy of Volvo Cars of North America.
Inspection – Spin idler pulley and tensioner pulley, and listen for noise.
Ensure pulley surfaces in contact with belt are clean and smooth. Fig. 1: Removing Accessory Drive Belt
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 o’clock.
3) Install timing belt in correct sequence shown in Fig. 8.

is cold. Around 68°F (20°C) 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.
VOLVO 763
Courtesy of Volvo Cars of North America. Courtesy of Volvo Cars of North America.
Fig. 2: Aligning Camshaft & Crankshaft Timing Marks Fig. 5: Adjusting Timing Belt Tension
Courtesy of Volvo Cars of North America. Fig. 6: Removing Splash Guards

Fig. 3: Removing Power Steering Hose Metal Bracket
Fig. 7: Removing Snow Cap & Bolts

Fig. 4: Removing Engine Mount

764 VOLVO
Engine Mount
To-Body Nut ............................................................................................................. 37 (50)
To-Engine Bolt ......................................................................................................... 50 (67)
Wheel Lug Nut 1 ...................................................................................................... 81 (110)
INCH Lbs. (N.m)
Timing Belt Cover
Front ....................................................................................................................... 106 (12)
Upper ......................................................................................................................... 71 (8)
Fig. 8: Installing Timing Belt 1
– Use anti-corrosion agent (Volvo P/N 1161038-3 or equivalent).

VOLVO 765
2.1L & 2.3L 4-Cylinder – B21 & B23

1
2.1L 4-Cyl. – B21 camshaft or crankshaft when timing belt is removed, or engine
242, 244 & 245 damage may occur.
1976-79 ............................ .... 1.3 Hrs. .... .. TCK032 .. ..... T032
DL & GL
1980-83 ............................ .... 1.3 Hrs. .... .. TCK032 .. ..... T032 TIMING BELT
DL (Canadian) Removal – Disconnect negative battery cable. Remove fan shroud and
1983 ................................. .... 1.3 Hrs. .... .. TCK032 .. ..... T032 accessory drive belts. Remove timing belt cover. Rotate crankshaft until
GLT timing marks are aligned. See Fig. 1. Loosen belt tensioner and pull belt
1981-83 ............................ .... 1.3 Hrs. .... .. TCK032 .. ..... T032 outward until tensioner spring is compressed. Tighten tensioner nut.
GT Turbo
Remove timing belt.
1984-85 ............................ .... 1.3 Hrs. .... .. TCK032 .. ..... T032
Installation – 1) Ensure that timing marks are still aligned. See Fig. 1.
2.3L 4-Cyl. – B23
DL & GL Install belt around crankshaft and intermediate shaft so that lines on belt
1982-85 ............................ .... 1.3 Hrs. .... .. TCK032 .. ..... T032 are aligned with timing mark on crankshaft. Install belt over camshaft
GLE (Canadian) pulley and tensioner roller. Loosen tensioner nut to release spring
1984 ................................. .... 1.3 Hrs. .... .. TCK032 .. ..... T032 tension. Tighten tensioner nut.
GLT (Canadian) 2) To complete installation, reverse removal procedure. Adjust drive
1983 ................................. .... 1.3 Hrs. .... .. TCK032 .. ..... T032 belts to proper tension.
760 GLE
1984 ................................. .... 1.3 Hrs. .... .. TCK032 .. ..... T032
1


SCHEDULED MAINTENANCE Fig. 1: Locating Timing Marks for Crankshaft, Intermediate Shaft
& Camshaft
On 1976-85 engines, the manufacturer recommends the belt be
replaced every 40,000 miles. On 1986-88 engines, the manufacturer TORQUE SPECIFICATIONS
recommends the belt be replaced every 50,000 miles.
Camshaft Sprocket .................................................................................................... 37 (50)
Crankshaft Sprocket ................................................................................................ 22 (166)
Drive Belt Tensioner Nut ........................................................................................... 37 (50)
Fan Bolt ..................................................................................................................... 33 (45)
Intermediate Shaft Sprocket ..................................................................................... 37 (50)
766 VOLVO
2.3L & 2.4L 5-Cylinder – 1998-01
TIMING BELT APPLICATION 4) Turn crankshaft clockwise (as viewed from timing belt end of engine)
Application Labor Time Belt to align the timing marks on the crankshaft pulley and camshaft
Part No. sprockets. See Fig. 2. Turn crankshaft an additional 1/4 turn clockwise,
2.3L 5-Cyl. – Turbo and then back again until the timing marks align.
C70, S70 & V70 5) Loosen timing belt tensioner pulley center bolt. Holding center bolt,
1998-01, Up To VIN 1266127 ................... 2.4 Hours ... ..... T252 turn the tensioner eccentric clockwise with a 6-mm Allen wrench. Turn
1998-01, From VIN 1266128 .................... 1.8 Hours ......... T311 eccentric until the hole for the Allen wrench is at the 10 o’clock position.
S60
2001, Up To VIN 1266127 ........................ 2.2 Hours ... ..... T252 CAUTION: Vibration damper pulley bolts are torque-to-yield type. If
2001, From VIN 1266128 ......................... 2.2 Hours ......... T311 vibration damper pulley bolts are removed so that Counterhold
2.4L 5-Cyl.
(999 5433) or equivalent can be installed, pulley bolts MUST be
C70, S70 & V70
1998-01, Up To VIN 1266127 ................... 2.4 Hours ... ..... T252 replaced.
1998-01, From VIN 1266128 .................... 1.8 Hours ......... T311 6) Raise and support vehicle. Holding vibration damper stationary with
S60
Counterhold (999 5433) or equivalent, remove vibration damper center
2001, Up To VIN 1266127 ........................ 2.2 Hours ... ..... T252
2001, From VIN 1266128 ......................... 2.2 Hours ......... T311 bolt. Remove vibration damper. Lower vehicle. Remove timing belt.

For 1998 model year, the manufacturer recommends the belt be
turer recommends the belt be replaced every 105,000 miles. In addition,
manufacturer recommends replacing timing belt tensioner on 2001 C70.

damage may occur.
TIMING BELT
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 noise. Ensure pulley surfaces in contact with belt are clean and smooth.
brace between the front shock towers. 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 68°F (20°C) is the best temperature.
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.
Courtesy of Volvo Cars of North America. 6) Turn tensioner eccentric back until the needle reaches the marked
position corresponding to engine temperature. At 68°F (20°C), the
Fig. 1: Removing Accessory Drive (Serpentine) Belt & needle must be centered in the window.
Drive Belt Routing
7) Holding the timing belt tensioner eccentric steady, tighten the center
2) On all models, remove upper timing belt cover. Remove power bolt to 15 ft. lbs. (20 N.m). Ensure tensioner needle is still in correct
steering pump reservoir with hoses attached, and set aside. Remove position. Press timing belt to see if the indicator on the tensioner moves
coolant reservoir and set aside. Remove accessory drive belt. easily.
3) Remove front timing belt cover. Raise and support vehicle. Remove 8) Turn crankshaft clockwise 2 turns. Align camshaft and crankshaft
right front wheel. Remove nut from fender liner cover. Remove upper timing marks. Ensure the timing belt tensioner indicator is within the
timing belt cover. correct area.
VOLVO 767
2.3L & 2.4L 5-Cylinder – 1998-01 (Cont.)

9) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure TORQUE SPECIFICATIONS
camshaft and crankshaft sprocket timing marks are still aligned. Ensure
timing belt tensioner indicator is in the correct position for engine TORQUE SPECIFICATIONS
temperature. Application Ft. Lbs. (N.m)
10) Install front and upper timing belt covers. Install accessory drive belt. Shock Tower Brace (S60)
Install power steering reservoir. Check power steering fluid level. Refill, Engine Bracket Bolt ................................................................................................ 37 (50)
if necessary. Shock Tower Bolt .................................................................................................... 59 (80)
11) Install coolant reservoir. Install fender liner cover. Install front wheel. Timing Belt Idler Pulley Bolt ......................................................... ................. 17-18 (24-25)
On S60, install shock tower brace. 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)
1
– Always replace bolts if loosened or removed.

768 VOLVO
2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder – 1992-98
TIMING BELT APPLICATION Removal (6-Cylinder) – 1) Remove auxiliary drive belt, front transmis-
Application Labor Time Belt sion cover splash guard under engine, vibration damper guard, and
Part No. ignition coil cover.
2.3L 5-Cyl. – Turbo 2) Turn crankshaft clockwise until timing marks on camshaft pulleys/
850 transmission plate and crankshaft pulley/oil pump housing are aligned.
1
1994 .......................................................... 2.4 Hours .. ... 2 T217 See Fig. 1. Remove upper transmission cover.
1
1994 .......................................................... 2.4 Hours .. ... 3 T252 3) Remove tensioner upper mounting bolt, and loosen lower mounting
1
1995-97 .................................................... 2.4 Hours .. ..... T252 bolt. Twist tensioner to free plunger/pulley. If reusing old timing belt,
850 (Canadian) mark belt with arrow to indicate rotation direction. Remove lower bolt,
1
1996 .......................................................... 2.4 Hours .. ..... T252 tensioner, and timing belt.
2.4L 5-Cyl.
850 CAUTION: DO NOT turn crankshaft or camshafts while belt is
1
1993 .......................................................... 2.4 Hours .. ... 2 T217 removed.
1
1993 .......................................................... 2.4 Hours .. ... 3 T252
1994-97 .................................................... 1
2.4 Hours .. ..... T252 Inspection – Spin tensioner and idler pulleys and listen for bearing
850 (Canadian) noise. See Fig. 2. Ensure pulley surfaces in contact with belt are clean
1 2
1995 .......................................................... 2.4 Hours .. ... T217 and smooth. Check tensioner pulley arm and idler pulley mountings, and
1 3
1995 .......................................................... 2.4 Hours .. ... T269 tighten bolts as necessary. See TORQUE SPECIFICATIONS. Check
2.9L 6-Cyl. tensioner for signs of leakage, no resistance when depressed, or a
S90 & V90 plunger that cannot be depressed.
1
1997-98 .................................................... 2.2 Hours .. ..... T270 Installation – 1) Compress tensioner and tighten center nut. Wait until
960 compression has taken place and insert a 2-mm locking pin in plunger.
1
1992-93 .................................................... 2.2 Hours .. ..... T217 Install tensioner and tighten mounting bolts to specification. See
1
1994 .......................................................... 2.2 Hours .. ..... T252
1 TORQUE SPECIFICATIONS.
1995-97 .................................................... 2.2 Hours .. ..... T270
2) Place timing belt around crankshaft pulley and right idler. Place belt
1
– With Air Conditioning, add .5 hours. over camshaft pulleys. Position belt around water pump and press over
With shimmed Air Conditioning belt, add .5 hours. tensioner pulley.
2
– Through engine number 131034. 3) Remove tensioner locking pin. To complete installation, reverse
3
– From engine number 131035.
removal procedure. Turn crankshaft 2 revolutions to ensure timing
marks on crankshaft and camshaft pulleys are aligned. See Fig. 1.
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.

CAUTION: This application is an interference engine. Do not rotate Courtesy of Volvo Cars of North America.
camshaft or crankshaft when timing belt is removed, or engine Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
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.
VOLVO 769
2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder – 1992-98 (Cont.)

Camshaft Cover Bolt ................................................................................................. 13 (17)
Spark Plug ................................................................................................................. 18 (25)
Timing Belt Pulley Bolt .............................................................................................. 30 (40)
Vibration Damper Center Nut
5-Cylinder ............................................................................................................. 133 (180)
6-Cylinder ............................................................................................................. 221 (300)
Vibration Damper-To-Crankshaft Bolt
5-Cylinder
Step 1 .................................................................................................................... 18 (25)
Step 2 ......................................................................................................... Plus 30° Turn
6-Cylinder
Courtesy of Volvo Cars of North America. Step 1 .................................................................................................................... 26 (35)
Fig. 2: Checking Tensioner & Idler Pulleys Step 2 ......................................................................................................... Plus 50° Turn
Water Pump Bolt ....................................................................................................... 13 (17)
Wheel Lug Nut ........................................................................................................ 81 (110)
770 VOLVO
2.3L 4-Cylinder – B230, B230F & B230FT
Application 1
Labor Time Component Belt NOTE: If reusing timing belt, mark direction of rotation for instal-
Kit No. Part No. lation reference.
2.3L 4-Cyl. – SOHC 4) Place mark on timing belt to indicate direction of belt rotation. Loosen
Coupe belt tensioner nut one turn. Pull on timing belt to compress belt tensioner
1991 ................................. .... 2.7 Hrs. .... .. TCK032 .. ..... T032 spring. Tighten belt tensioner nut.
240 Series
5) Install a 3-mm drill bit through hole of belt tensioner bolt to lock belt
1986 ................................... 2, 3 2.0 Hrs. .. .. TCK032 .. ..... T032
1987-92 ............................ ... 3 2.0 Hrs. ... .. TCK032 .. ..... T032 tensioner spring in place. Remove timing belt from camshaft sprocket.
1993 ................................. ... 3 2.0 Hrs. ... .. TCK234 .. ..... T234
740 Series
1986-92 ............................ .... 2.2 Hrs. .... .. TCK032 .. ..... T032
760 Series
1985-90 ............................ .... 2.2 Hrs. .... .. TCK032 .. ..... T032
780 Series
1989-90 ............................ .... 2.7 Hrs. .... .. TCK032 .. ..... T032
940 Series
1991-92 ............................ .... 2.2 Hrs. .... .. TCK032 .. ..... T032
1993-95 ............................ .... 2.2 Hrs. .... .. TCK234 .. ..... T234
1
2
– On Diesel engines, Front Belt labor time is 3.6 hours. On Diesel
engines, Rear Belt labor time is 1.9 hours.
3
– On 240 model, with Shimmed Air Conditioning Belt, add, .5
hours.

NOTE: For information about tensioners and/or pulleys (when Courtesy of Volvo Cars of North America.
Inspection – Check belt teeth for cracks, damage or oil contamination.
MANUFACTURER’S SUGGESTED Inspect all sprockets for damage. Check belt tensioner for roughness in
SCHEDULED MAINTENANCE rotation. Replace components if damaged.
Installation – 1) Install belt tensioner if previously removed. Ensure all
timing marks align. See Fig. 1Fig. 1.
except for 1994 and later B230FT engines with EGR. On these engines, 2) Outer side of timing belt has 2 lines, which should fit toward
the manufacturer recommends the timing belt be replaced at 100,000 crankshaft marks. Install belt over crankshaft sprocket first, then over
mile intervals. 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
REMOVAL & INSTALLATION belt. Tighten belt tensioner nut. Ensure timing marks align. To install
remaining components, reverse removal procedure.
camshaft or crankshaft when timing belt is removed, or engine CAUTION: Readjust timing belt when engine reaches normal oper-
damage may occur. ating temperature.
4) Warm engine to normal operating temperature. Remove plug from
front timing belt cover. Loosen belt tensioner bolt one turn, and allow for
TIMING BELT
belt tensioner spring to apply pressure on timing belt. This readjusts
timing belt to allow for belt stretch. Tighten belt tensioner nut. Install
CAUTION: Ensure timing marks align before removing timing belt.
rubber plug. Adjust drive belts to proper tension.
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 TORQUE SPECIFICATIONS
hose (below fan shroud) and fan shroud. Application Ft. Lbs. (N.m)
2) Using center bolt on crankshaft, rotate crankshaft so mark on Camshaft Sprocket Bolt ............................................................................................ 37 (50)
camshaft pulley aligns with timing mark on inner timing belt cover, and Crankshaft Pulley Bolt 1
crankshaft pulley mark aligns with TDC mark on timing belt cover. Step 1 ...................................................................................................................... 44 (60)
Step 2 ........................................................................................................... Additional 60°
3) Remove nut and washer from belt tensioner. Install Crankshaft Holder
(5284), or equivalent, on crankshaft pulley and belt tensioner stud.
1
Install nut on stud. Remove crankshaft center bolt, crankshaft pulley and – Apply light coat of oil to bolts before installation.
lower timing belt cover. Ensure timing marks are aligned. See Fig. 1.
VOLVO 771
2.3L 4-Cylinder – B234

1
Part No.
2.3L 4-Cyl. – B234
1986-88
Balance Shaft ...................................... .......... 2 .......... ..... T174
Camshaft ................................................ 2.8 Hours ... ..... T173
1989 (With Automatic Tensioner)
Balance Shaft ...................................... .......... 2 .......... ..... T174
Camshaft ................................................ 2.8 Hours ... ..... T198
1989 (With Manual Tensioner)
Balance Shaft ...................................... .......... 2 .......... ..... T174
Camshaft ................................................ 2.8 Hours ... ..... T173
1990
Balance Shaft ...................................... .......... 2 .......... ..... T174
Camshaft ................................................ 2.8 Hours ... ..... T173
1991-92
Balance Shaft ...................................... .......... 2 .......... ..... T174
Camshaft ................................................ 2.8 Hours ... ..... T198
1
– With Air Conditioning, add .5 hours. Fig. 1: Aligning Camshaft & Crankshaft Markings
2
– Balance shaft belt labor time is included in


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 compres-
sor 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. Courtesy of Volvo Cars of North America.
Remove balance shaft belt idler pulley. Loosen lock nut and remove
balance shaft belt. See Fig. 2. Fig. 2: Removing Balance Shaft Belt
Installation – 1) Check that balance shaft marking aligns with markings 3) Tighten balance shaft belt tensioner using an Allen key inserted in
on transmission mounting plate. See Fig. 3. Ensure that crankshaft adjusting hole in tensioner. See Fig. 5. Carefully rotate crankshaft a few
marking is opposite TDC marking on cylinder head. Install balance shaft degrees on either side of TDC position to ensure that balance shaft belt
belt under crankshaft pulley assembly. Ensure that blue dot (marking B) engages properly in pulleys. Return crankshaft to TDC position.
is opposite bottom TDC marking on belt guide plate at bottom of 4) Ensure that adjusting hole in balance shaft belt tensioner is below 3
crankshaft. See Fig. 4. o’clock position when tightening locking bolt. Torque locking bolt to 29.5
2) Install balance shaft belt around left (upper) balance shaft with ft. lbs. (40.5 N.m) using an Allen key inserted in adjusting hole as
marking “C” opposite marking on pulley. See Fig. 4. Install balance shaft counter hold. See Fig. 5. Check balance shaft belt tension using Volvo
belt on right (lower) balance shaft with marking “A” opposite marking on Gauge Tool (No. 998 8500) or equivalent.
pulley. Install balance shaft belt around tensioner. Ensure that markings
are still aligned.
772 VOLVO
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 Courtesy of Volvo Cars of North America.
equivalent, between exhaust camshaft pulley and idler. Belt tension
Fig. 4: Installing Balance Shaft Belt
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
Fig. 5: Adjusting Tensioner
Fig. 3: Aligning Balance Shaft & Crankshaft Markings

VOLVO 773
Fig. 6: Checking Balance Shaft Belt Tension

Fig. 8: Rotating Crankshaft
Fig. 9: Checking Belt Tension

774 VOLVO
Tensioner Locking Bolt ........................................................................................... 29.5 (40)
Tensioner Lock Nut ................................................................................................ 37.0 (49)
Fig. 10: Adjusting Belt Tension

VOLVO 775
2.3L, 2.4L & 2.5L 5-Cylinder – 2002-04

Part No.
C70, S60 & V70
2002-04 ..................................................... 2.2 Hours ... ..... T252
2.4L 5-Cyl. – Non-Turbo
S60 & V70
2002-04 ..................................................... 2.2 Hours ... ..... T252
C70, S60 & V70
2002-04 ..................................................... 2.2 Hours ... ..... T331
XC90
2003-04 ..................................................... 2.3 Hours ... ..... T331

MANUFACTURER’S SUGGESTED Courtesy of Volvo Cars of North America.
SCHEDULED MAINTENANCE 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.

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 Fig. 2: Identifying Timing Belt Tensioner
C70, remove cross brace between front shock towers. 2) Place timing belt around crankshaft pulley. Install vibration damper.
Install vibration damper center bolt. Hold vibration damper stationary
WARNING: DO NOT spill power steering fluid. It is extremely
with Counterhold (999 5433) or equivalent, and tighten center bolt to
flammable.
specification. See TORQUE SPECIFICATIONS. Remove Counterhold
2) On all models, remove upper timing belt cover. Remove power and install NEW screws. Tighten to specification. See TORQUE SPECI-
steering pump reservoir with hoses attached, and set aside. Remove FICATIONS.
coolant reservoir and set aside. If necessary, use a small screwdriver 3) Place timing belt around idler pulley, intake camshaft pulley, exhaust
and remove plastic cover on accessory belt tensioner. Use a wrench and camshaft pulley, water pump and timing belt tensioner. See Fig. 3.
turn accessory belt tensioner clockwise to release tension and remove
accessory drive belt. NOTE: Timing belt tension MUST be adjusted when engine is cold.
3) Remove front timing belt cover. Raise and support vehicle. Remove Around 68°F (20°C) is best temperature.
right front wheel. Remove nut from fender liner cover.
4) Install upper timing belt cover. Turn crankshaft clockwise (as viewed 4) Slowly turn crankshaft clockwise (as viewed from timing belt end of
from timing belt end of engine) to align timing marks on timing belt cover, engine) until timing belt is tensioned. Belt should be tight between intake
crankshaft pulley and camshaft sprockets. See Fig. 1. Turn crankshaft camshaft sprocket, idler pulley and crankshaft sprocket.
an additional 1/4 turn clockwise, and then back again until timing marks 5) Hold timing belt tensioner pulley bolt secure, and turn tensioner
align. eccentric counterclockwise until tensioner needle passes to right of
5) Remove upper timing belt cover. Loosen timing belt tensioner pulley center position. See Fig. 4.
center bolt slightly. Holding center bolt, turn tensioner eccentric clock- 6) Turn tensioner eccentric back until needle reaches marked position
wise with a 6-mm Allen wrench. Turn eccentric until hole for Allen wrench corresponding to engine temperature. At 68°F (20°C), needle must be
is at 10 o’clock position. See Fig. 2. centered in window.
6) Remove timing belt from tension pulley, camshaft pulley and water 7) Holding timing belt tensioner eccentric steady, tighten center bolt to
pump. 15 ft. lbs. (20 N.m). Ensure tensioner needle is still in correct position.
7) Holding vibration damper stationary with Counterhold (999 5433) or Press timing belt to see if indicator on tensioner moves easily.
equivalent, work vibration damper loose. Remove timing belt. 8) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure
Inspection – Spin tensioner and idler pulleys, and listen for bearing camshaft and crankshaft sprocket timing marks are still aligned. Ensure
noise. Ensure pulley surfaces in contact with belt are clean and smooth. timing belt tensioner indicator is in correct position for engine tempera-
Installation – 1) If timing belt tensioner was removed, ensure tensioner ture.
fork is installed with fork centered over rib on engine block.
776 VOLVO
2.3L, 2.4L & 2.5L 5-Cylinder – 2002-04 (Cont.)
9) Install front timing belt cover. Install upper timing belt cover. Tighten TORQUE SPECIFICATIONS
bolts to specification. See TORQUE SPECIFICATIONS. Install acces-
sory drive belt. Install power steering reservoir. Check power steering TORQUE SPECIFICATIONS
fluid level. Refill, if necessary. Application Ft. Lbs. (N.m)
10) Install coolant reservoir. Install fender liner cover. Install front wheel. Idler Pulley ................................................................................................................. 17 (24)
On all models except C70, install cross brace between shock towers. Shock Tower Brace
Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Brace-To-Bracket Bolt ............................................................................................. 37 (50)
Bracket-To-Shock Tower Bolt .................................................................................. 59 (80)
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)
1

VOLVO 777
2.4L & 2.5L 5-Cylinder – Turbo – 2004 1/2

Part No.
S40
2004 1/2 ................................................. ........ N/A ........ ..... T331
S40
2004 1/2 ................................................. ........ N/A ........ ..... T331

Manufacturer recommends timing belt, tensioner and idler pulley
replacement every 120,000 miles.

camshaft or crankshaft when timing belt is removed, or engine Courtesy of Volvo Cars of North America.
damage may occur.
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.
Fig. 3: Disconnecting Power Steering Pressure Line From Pump
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 Courtesy of Volvo Cars of North America.
crankshaft center nut to counter. Use Counterhold (999-5433) to hold
Fig. 4: Using Counterhold To Remove Vibration Damper
damper and remove crankshaft center nut. See Fig. 4. Remove Coun-
terhold and work vibration damper loose. 9) Loosen belt tensioner center bolt slightly. Hold center bolt and turn
8) Turn crankshaft clockwise until crankshaft and camshaft timing marks eccentric clockwise using a 6mm Allen key. Turn to 10 o’clock position
align. See Fig. 5. Lower engine so that belt tensioner bolts are and remove timing belt from pulleys.
accessible from underneath.
778 VOLVO
2.4L & 2.5L 5-Cylinder – Turbo – 2004 1/2 (Cont.)
Courtesy of Volvo Cars of North America. Courtesy of Volvo Cars of North America.
Fig. 5: Aligning Crankshaft & Camshaft Timing Marks Fig. 7: Adjusting Timing Belt Tensioner
6) Ensure tensioner indicator is within marked area. If not, adjust belt
NOTE: Tensioner and idler pulley will not be reused. tension again. If so, go to next step.
7) Install vibration damper. Use Counterhold (999-5433) to tighten
10) Remove belt tensioner and idler pulley. Discard both. crankshaft center nut. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
NOTE: Timing belt tensioner and idler pulley MUST be replaced
8) Install outer accessory drive belt. Connect pressure hose to power
with timing belt. steering pump. Do not forget to remove seals from pipe and pump
Installation – 1) Fit new tensioner with center bolt. Ensure tensioner openings.
fork is centered over rib in engine block. Ensure Allen key hole on 9) Install fender liner and front wheel. Tighten wheel lugs to specifica-
eccentric is at 10 o’clock position. Install new idler pulley and tighten tion. See TORQUE SPECIFICATIONS.
bolts to specification. See TORQUE SPECIFICATIONS. 10) Lower vehicle. Install front transmission covers. Install engine mount
2) Ensure timing marks are aligned. Install timing belt in the following and limiter. Remove Lifting Beam. Fit coolant expansion tank.
order: 11) Fit all remaining components. Start engine and check function.
• Crankshaft.
• Idler pulley.
• Intake camshaft.
• Exhaust camshaft.
• Water pump.
• Tensioner.
NOTE: Engine MUST be cold to accurately adjust timing belt

tension. Approximately 20°C (68°F) 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.

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 revolu-
tions and ensure crankshaft and camshaft timing marks align.
VOLVO 779
2.4L & 2.5L 5-Cylinder – Turbo – 2004 1/2 (Cont.)

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)
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
780 VOLVO
Part No.
DL
1982
Camshaft ............................................... 1 3.6 Hours .. ..... T083
GL
1982-84
Camshaft ............................................... 1 3.6 Hours .. ..... T083
740 Series
1985-86
Camshaft ............................................... 1 3.6 Hours .. ..... T083
760 GLE
1983-84
Camshaft ............................................... 1 3.9 Hours .. ..... T083 Fig. 1: Camshaft Timing & Injection Timing At TDC
760 Series
1985
Camshaft ............................................... 1 3.9 Hours .. ..... T083
1


damage may occur.
TIMING BELT
Removal – 1) Disconnect negative battery cable. Remove splash guard, Courtesy of Volvo Cars of North America.
cooling fan, spacer, and pulley. Remove fan and power steering pump
Fig. 2: Using Camshaft Gear Retaining Wrench
belts, power steering pump and expansion tank cap. Drain and remove
radiator. Disconnect battery ground cable. Installation – 1) Check that No. 1 cylinder is at TDC, timing mark on
2) Remove valve cover and front and rear timing belt covers. Using a 1 flywheel is at “0”, and camshaft lobes for No. 1 cylinder are facing up
1/16″ (27 mm) socket on damper pulley bolt, set No. 1 cylinder at TDC with equally large angles in comparison with cylinder head. See Fig. 1.
(timing mark on flywheel at 0°). Loosen water pump and idler pulley bolts Place Camshaft Lock Gauge Tool (5190) or equivalent in camshaft
to remove timing belt from camshaft gear. See Fig. 1. groove at rear of cylinder head.
3) Using Damper Pulley Wrench (5187) or equivalent, and Damper
Pulley Bolt Tool (5188) or equivalent, remove damper pulley bolt. Using NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool
a 6-mm socket, remove 4 screws from damper pulley and pulley (it may (5190) or equivalent is to compensate for timing gear clearance.
be necessary to tap pulley from shaft). Remove lower belt shield and
timing gear belt. 2) Place a .008″ (.2 mm) feeler gauge under left side of Camshaft
4) Remove center bolt from idler pulley. Using Idler Pulley Removal Tool Locking Gauge Tool (5190) or equivalent. See Fig. 3. Install timing gear
(5202) or equivalent, remove idler pulley. Replace and tap new idler belt and damper pulley. Replace 4 damper pulley bolts, and torque to 15
pulley into position. Using Spanner Wrench Tool (5199) or equivalent, ft. lbs. (20 N.m).
hold front camshaft drive gear in place and remove center retaining bolt. 3) Using Damper Pulley Wrench Tools (5187 and 5188) or equivalent,
See Fig. 2. 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
CAUTION: Idler pulley must be replaced when replacing timing and camshaft timing gear (ensuring camshaft does not turn). Torque to
gear belt. Use Puller (5202) to remove pulley.
33 ft. lbs. (45 N.m) after setting timing marks.
4) Remove Camshaft Gauge Locking Tool (5190) and feeler gauge from
CAUTION: Camshaft MUST NOT rotate, or damage to valves and rear of camshaft. Install rear camshaft gear and injection pump belt. Set
pistons may result. injection pump timing. See Fig. 4.
5) Tap gear loose from camshaft tapered end. Remove injection pump 5) Position Belt Tension Gauge Tool (5197) or equivalent on timing and
drive belt by loosening retaining bracket bolts. Tighten one screw to hold injection pump belt, set gauge to .50″ (12.5 mm). Place tension on belt
pump in upper position. Use Spanner Wrench Tool (5199) or equivalent until mark on plunger is flush with gauge sleeve, and tighten bolts.
to hold rear camshaft sprocket, and Wrench (5201) or equivalent to
remove center retaining bolt. Tap gear loose from camshaft. See Fig. 2.
VOLVO 781

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.
Fig. 4: Locating Injection Pump Alignment Marks
Camshaft Gear Bolt
Front ......................................................................................................................... 33 (45)
Courtesy of Volvo Cars of North America. Rear ....................................................................................................................... 74 (100)
Crankshaft Pulley Nut ........................................................................................... 258 (350)
Fig. 3: Setting Timing Using Camshaft Locking Gauge Injector Pump Gear ................................................................................................... 33 (45)
782 VOLVO
TIMING BELT APPLICATION 4) Remove air duct, cover, surround and control module box. Remove
Application Labor Time Belt hose between thermostat housing and expansion tank. Remove front
Part No. timing belt cover.
2.8L 6-Cyl. – Turbo 5) Seal hose between expansion tank and radiator. Disconnect hose at
S80 expansion tank. Lift expansion tank and place on top of engine.
1999 ........................................................... 4.4 Hours ... ..... T270 6) Raise and support vehicle. Remove right front wheel. Remove plastic
2000-01 ..................................................... 3.5 Hours ... ..... T319 nuts from cover in fender liner. Install upper timing belt cover.
2.9L 6-Cyl. – Turbo 7) Rotate crankshaft clockwise until timing marks are aligned. See
S80 Fig. 2. Rotate crankshaft further 1/4 turn clockwise, then rotate coun-
2002-03 ..................................................... 3.5 Hours ... ..... T319 terclockwise until marks are aligned.
XC90 8) Remove upper timing belt cover. Remove 4 vibration damper screws.
2003-04 ..................................................... 3.5 Hours ... ..... T319 Remove vibration damper. Remove accessory drive belt. On models
2.9L 6-Cyl. – Non-Turbo
with hydraulic timing belt tensioner, go to next step. On models without
S80
hydraulic timing belt tensioner, go to step 11).
1999 ......................................................... 2.7 Hours ... ..... T270
2000-03 ................................................... 3.6 Hours ... ..... T319 9) Install Counterhold (999 5433), and remove crankshaft center nut.
See Fig. 3. Remove counterhold and accessory drive belt pulley.
NOTE: For information about tensioners and/or pulleys (when 10) Remove timing belt tensioner/hydraulic unit upper screw, then
available), see ALPHABETICAL MODEL LISTING. loosen lower screw. Turn tensioner/hydraulic unit so that cylinder comes
free. Remove lower screw. Remove tensioner/hydraulic unit. Remove
timing belt.
MANUFACTURER’S SUGGESTED 11) Remove belt cover behind crankshaft pulley for accessory drive belt.
SCHEDULED MAINTENANCE Spray universal oil around rubber sleeve on underside of oil pump.
Remove rubber sleeve.
For S80 models, manufacturer recommends the timing belt and belt
12) Slightly loosen timing belt tensioner center screw. Hold screw from
tensioner be replaced every 105,000 miles.
turning. Using a 6-mm hex wrench in eccentric, turn tensioner counter-
For 2003-04 XC90 models, manufacturer recommends the timing belt clockwise until eccentric is at 10 o’clock position. See Fig. 4. Remove
and belt tensioner be replaced every 120,000 miles. timing belt.

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 Courtesy of Volvo Cars of North America.
clockwise to relieve tension on belt. See Fig. 1. Lift off accessory drive
belt. Remove upper timing belt cover. Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Fig. 3: Removing Crankshaft Center Nut
Fig. 1: Identifying Accessory Drive (Serpentine) Belt Routing
VOLVO 783

11) To complete installation, reverse removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS. Fill coolant
and power steering fluid.

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. 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 SPECIFI-
CATIONS.
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.

is cold. Around 68°F (20°C) 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 indicator’s 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 Courtesy of Volvo Cars of North America.
and tensioner indicator is in correct position. Fig. 6: Identifying Timing Belt Installation Order
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.
784 VOLVO
Crankshaft Center Nut .......................................................................................... 221 (300)
Engine Stabilizer Brace
To-Body Bolt ............................................................................................................ 37 (50)
To-Engine Bracket Bolt ........................................................................................... 59 (80)
Courtesy of Volvo Cars of North America. Idler Pulley Bolt ......................................................................................................... 18 (24)
Center Screw (Except Hydraulic Tensioner) .......................................................... 18 (24)
(Mechanical Tensioner)
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.

MOTORES CHECK
YUGO 785

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

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.

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 Courtesy of Yugo America, Inc.
crankshaft pulley. Remove timing belt covers. Fig. 1: Identifying Camshaft-To-Crankshaft Alignment
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.
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.
Courtesy of Yugo America, Inc.
TORQUE SPECIFICATIONS Fig. 2: Exploded View Of Timing Belt &

Related Components
Camshaft Housing Bolts ........................................................................................... 14 (19)
Camshaft Pulley Nut ............................................................................................. 101 (137)
Tensioner Pulley Support Nut ................................................................................... 33 (45)
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 custom-
er 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 Gates Competitive Gates Competitive Gates Competitive Gates Competitive Gates
No. No. No. No. No. No. No. No. No. No.
ACDELCO ACDELCO - Cont. ACDELCO - Cont. ACDELCO - Cont. ACDELCO - Cont.

Timing Belts Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belt Tensioners
TB013................. T013 - Cont.
TB138................. T138 TB216................. T216 TB298................. T298
TB014................. T014 TB139................. T139 TB217................. T217 TB299................. T299 T41043............... T41043
TB017................. T017 TB140................. T140 TB218................. T218 TB300................. T300 T41044............... T41044
TB018................. T018 TB141................. T141 TB219................. T219 TB301................. T301 T41045............... T41045
TB020................. T020 TB142................. T142 TB220................. T220 TB302................. T302 T41046............... T41046
TB028................. T028 TB143................. T143 TB221................. T221 TB303................. T303 T41047............... T41047
TB032................. T032 TB144................. T144 TB222................. T222 TB304................. T304 T41048............... T41048
TB036................. T036 TB145................. T145 TB223................. T223 TB305................. T305 T41049............... T41049
TB037................. T037 TB146................. T146 TB224................. T224 TB306................. T306 T41050............... T41050
TB039................. T039 TB147................. T147 TB225................. T225 TB307................. T307 T41051............... T41051
TB041................. T041 TB148................. T148 TB226................. T226 TB308................. T308 T41052............... T41052
TB043................. T043 TB149................. T149 TB227................. T227 TB309................. T309 T41053............... T41053
TB061................. T061 TB150................. T150 TB228................. T228 TB310................. T310 T41054............... T41054
TB062................. T062 TB151................. T151 TB229................. T229 TB311................. T311 T41055............... T41055
TB064................. T064 TB152................. T152 TB230................. T230 TB312................. T312 T41056............... T41056
TB065................. T065 TB153................. T153 TB232................. T232 TB313................. T313 T41057............... T41057
TB067................. T067 TB154................. T154 TB233................. T233 TB314................. T314 T41058............... T41058
TB068................. T068 TB155................. T155 TB234................. T234 TB315................. T315 T41059............... T41059
TB069................. T069 TB157................. T157 TB235................. T235 TB316................. T316 T41060............... T41060
TB070................. T070 TB158................. T158 TB236................. T236 TB317................. T317 T41061............... T41061
TB071................. T071 TB159................. T159 TB237................. T237 TB318................. T318 T41062............... T41062
TB073................. T073 TB160................. T160 TB239................. T239 TB319................. T319 T41063............... T41063
TB074................. T074 TB161................. T161 TB240................. T240 TB320................. T320 T41064............... T41064
TB075................. T075 TB162................. T162 TB241................. T241 TB321................. T321 T41065............... T41065
TB076................. T076 TB163................. T163 TB242................. T242 TB322................. T322 T41066............... T41066
TB077................. T077 TB164................. T164 TB243................. T243 TB323................. T323 T41067............... T41067
TB078................. T078 TB165................. T165 TB244................. T244 TB324................. T324 T41068............... T41068
TB079................. T079 TB166................. T166 TB245................. T245 TB326................. T326 T41069............... T41069
TB081................. T081 TB167................. T167 TB246................. T246 TB327................. T327 T41070............... T41070
TB082................. T082 TB168................. T168 TB247................. T247 TB329................. T329 T41071............... T41071
TB083................. T083 TB169................. T169 TB248................. T248 T41072............... T41072
TB084................. T084 Timing Belt Tensioners
TB170................. T170 TB249................. T249 T41073............... T41073
TB087................. T087 TB171................. T171 TB251................. T251 T41000............... T41000 T41074............... T41074
TB088................. T088 TB172................. T172 TB252................. T252 T41001............... T41001 T41075............... T41075
TB089................. T089 TB173................. T173 TB253................. T253 T41002............... T41002 T41076............... T41076
TB090................. T090 TB174................. T174 TB254................. T254 T41003............... T41003 T41077............... T41077
TB091................. T091 TB176................. T176 TB255................. T255 T41004............... T41004 T41078............... T41078
TB092................. T092 TB177................. T177 TB256................. T256 T41005............... T41005 T41079............... T41079
TB093................. T093 TB178................. T178 TB257................. T257 T41006............... T41006 T41080............... T41080
TB094................. T094 TB179................. T179 TB258................. T258 T41007............... T41007 T41081............... T41081
TB095................. T095 TB180................. T180 TB259................. T259 T41008............... T41008 T41083............... T41083
TB096................. T096 TB181................. T181 TB260................. T260 T41009............... T41009 T41084............... T41084
TB097................. T097 TB182................. T182 TB262................. T262 T41010............... T41010 T41085............... T41085
TB098................. T098 TB183................. T183 TB263................. T263 T41011............... T41011 T41087............... T41087
TB099................. T099 TB184................. T184 TB264................. T264 T41012............... T41012 T41088............... T41088
TB100................. T100 TB185................. T185 TB265................. T265 T41013............... T41013 T41089............... T41089
TB101................. T101 TB186................. T186 TB266................. T266 T41014............... T41014 T41090............... T41090
TB102................. T102 TB187................. T187 TB267................. T267 T41015............... T41015 T41091............... T41091
TB103................. T103 TB188................. T188 TB269................. T269 T41016............... T41016 T41092............... T41092
TB104................. T104 TB189................. T189 TB270................. T270 T41017............... T41017 T43001............... T43001
TB106................. T106 TB190................. T190 TB271................. T271 T41018............... T41018 T43002............... T43002
TB107................. T107 TB191................. T191 TB272................. T272 T41019............... T41019 T43003............... T43003
TB112................. T112 TB192................. T192 TB273................. T273 T41020............... T41020 T43004............... T43004
TB113................. T113 TB193................. T193 TB276................. T276 T41021............... T41021 T43005............... T43005
TB114................. T114 TB194................. T194 TB277................. T277 T41022............... T41022 T43006............... T43006
TB117................. T117 TB195................. T195 TB278................. T278 T41023............... T41023 T43007............... T43007
TB118................. T118 TB196................. T196 TB279................. T279 T41024............... T41024 T43008............... T43008
TB119................. T119 TB197................. T197 TB280................. T280 T41025............... T41025 T43010............... T43010
TB120................. T120 TB198................. T198 TB281................. T281 T41026............... T41026
TB121................. T121 TB199................. T199 TB282................. T282 T41027............... T41027 Timing Belt Pulleys
TB122................. T122 TB200................. T200 TB283................. T283 T41028............... T41028 T42001............... T42001
TB123................. T123 TB201................. T201 TB284................. T284 T41029............... T41029 T42002............... T42002
TB124................. T124 TB203................. T203 TB285................. T285 T41030............... T41030 T42003............... T42003
TB125................. T125 TB204................. T204 TB286................. T286 T41031............... T41031 T42004............... T42004
TB126................. T126 TB205................. T205 TB287................. T287 T41032............... T41032 T42005............... T42005
TB127................. T127 TB206................. T206 TB288................. T288 T41033............... T41033 T42006............... T42006
TB128................. T128 TB207................. T207 TB289................. T289 T41034............... T41034 T42007............... T42007
TB129................. T129 TB208................. T208 TB290................. T290 T41035............... T41035 T42008............... T42008
TB130................. T130 TB209................. T209 TB291................. T291 T41036............... T41036 T42009............... T42009
TB131................. T131 TB210................. T210 TB292................. T292 T41037............... T41037 T42010............... T42010
TB132................. T132 TB211................. T211 TB293................. T293 T41038............... T41038 T42011............... T42011
TB134................. T134 TB212................. T212 TB294................. T294 T41039............... T41039 T42012............... T42012
TB135................. T135 TB213................. T213 TB295................. T295 T41040............... T41040 T42013............... T42013
TB136................. T136 TB214................. T214 TB296................. T296 T41041............... T41041 T42014............... T42014
TB137................. T137 TB215................. T215 TB297................. T297 T41042............... T41042 T42015............... T42015
Changeover Listing - PowerGrip™ Timing System Products 787
ACDELCO - Cont. ATLAS (CANADA) - Cont. AUTO VALUE - Cont. BALKAMP - Cont. BECK ARNLEY - Cont.
Timing Belt Pulleys - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont.
T42016............... T42016 TB1058............... T163 R089................... T089 9-074.................. T074 026-0184............ T077
T42017............... T42017 TB1059............... T164 R090................... T090 9-075.................. T075 026-0185............ T089
T42018............... T42018 TB1060............... T165 R091................... T091 9-076.................. T076 026-0186............ T090
T42020............... T42020 TB1061............... T166 R092................... T092 9-077.................. T077 026-0187............ T092
T42021............... T42021 TB1062............... T169 R093................... T093 9-078.................. T078 026-0188............ T091
T42022............... T42022 TB1063............... T167 R094................... T094 9-079.................. T079 026-0189............ T084
T42023............... T42023 TB1064............... T168 R095................... T095 9-081.................. T081 026-0190............ T074
T42024............... T42024 TB6401............... T014 R096................... T096 9-082.................. T082 026-0191............ T087
T42025............... T42025 TB6402............... T013 R098................... T098 9-083.................. T083 026-0192............ T079
T42026............... T42026 TB6403............... T037 R099................... T099 9-084.................. T084 026-0193............ T076
T42027............... T42027 TB6404............... T017 AUTOZONE (See GOOD- 9-087.................. T087 026-0194............ T075
T42028............... T42028 TB6406............... T018 YEAR) 9-088.................. T088 026-0195............ T107
T42029............... T42029 TB6408............... T020 9-089.................. T089 026-0196............ T093
T42030............... T42030 TB6409............... T039 AVON AUTO 9-090.................. T090 026-0197............ T096
T42031............... T42031 TB6410............... T032 Timing Belts 9-091.................. T091 026-0198............ T106
T42032............... T42032 TB6411............... T041 9-092.................. T092 026-0199............ T140
T42033............... T42033 TB6412............... T062 B0100................. T100 9-093.................. T093 026-0201............ T196
T42034............... T42034 TB6415............... T028 B0101................. T101 9-094.................. T094 026-0202............ T100
T42035............... T42035 TB6416............... T064 B0102................. T102 9-095.................. T095 026-0205............ T097
T42036............... T42036 TB6417............... T065 B0103................. T103 9-096.................. T096 026-0206............ T101
T42037............... T42037 TB6418............... T061 B0104................. T104 9-098.................. T098 026-0207............ T095
T42038............... T42038 TB6419............... T073 B0114................. T114 9-099.................. T099 026-0208............ T161
TB6424............... T069 B0118................. T162 9-100.................. T100 026-0209............ T160
AQUA POWER B013................... T013 026-0210............ T120
TB6425............... T070 9-101.................. T101
Timing Belts TB6426............... T068 B014................... T014 026-0212............ T300
B017................... T017 BANDO 026-0213............ T299
1221 ................... T032 TB6427............... T071
TB6428............... T067 B018................... T018 Timing Belts 026-0215............ T158
ATLAS TB6429............... T076 B020................... T020 026-0216............ T104
B028................... T028 100ZA19............. T061
Timing Belts TB6430............... T075 109ZA19............. T088 026-0217............ T112
TB6431............... T078 B032................... T032 026-0218............ T293
689900 ............... T067 B036................... T036 111ZA19............. T121
TB6432............... T077 113ZA19............. T065 026-0219............ T119
689901 ............... T071 B037................... T037 026-0220............ T138
689902 ............... T014 TB6433............... T043 B039................... T039 118ZA19............. T069
TB6434............... T074 121ZA19............. T017 026-0221............ T071
689903 ............... T061 B041................... T041 026-0222............ T162
689904 ............... T017 TB6435............... T081 B043................... T043 124ZA25............. T071
TB6436............... T088 135ZA25............. T043 026-0223............ T113
689905 ............... T081 B061................... T061 026-0224............ T117
689906 ............... T070 TB6437............... T087 B062................... T062 142ZA25............. T074
TB6438............... T093 206AL050........... T062 026-0225............ T149
689907 ............... T089 B063................... T073 026-0226............ T141
689908 ............... T077 TB6439............... T094 B064................... T064 315AL075........... T028
TB6440............... T104 326AHL125 ........ T075 026-0228............ T122
689909 ............... T094 B065................... T065 026-0229............ T124
TB6442............... T100 B067................... T067 330AL075........... T070
ATLAS (CANADA) TB6443............... T084 345AL075........... T073 026-0230............ T128
B068................... T068 026-0231............ T134
Timing Belts TB6444............... T099 B069................... T069 398AL075........... T077
TB6446............... T082 458AL075........... T013 026-0232............ T129
TB1001............... T121 B070................... T070 026-0233............ T139
TB6447............... T083 B071................... T071 89ZA19............... T095
TB1002............... T127 TB6448............... T095 94ZA19............... T036 026-0234............ T146
TB1003............... T128 B074................... T074 026-0235............ T148
TB6450............... T176 B075................... T075 97ZA25............... T067
TB1004............... T101 TB6451............... T089 99ZA15............... T037 026-0236............ T292
TB1005............... T125 B076................... T076 026-0237............ T170
TB6452............... T118 B077................... T077 99ZA19............... T039
TB1006............... T126 TB6453............... T079 026-0238............ T143
TB1007............... T130 B078................... T078 BAP-GEON 026-0239............ T131
TB1008............... T129 TB6454............... T122 B079................... T079 026-0240............ T144
B081................... T081 Timing Belts
TB1010............... T114 AUTO VALUE 026-0242............ T142
TB1011............... T300 B082................... T082 54-70301............ T062 026-0243............ T135
Timing Belts B083................... T083 54-70302............ T073
TB1012............... T299 026-0244............ T179
TB1013............... T091 R0100................. T100 B084................... T084 54-70303............ T064 026-0245............ T147
TB1014............... T092 R0101................. T101 B087................... T087 54-70901............ T041 026-0246............ T126
TB1015............... T117 R0102................. T102 B088................... T088 54-70902............ T028 026-0247............ T136
TB1016............... T119 R0103................. T103 B089................... T089 54-70904............ T073 026-0248............ T125
TB1017............... T292 R0104................. T104 B090................... T090 54-71501............ T070 026-0249............ T164
TB1018............... T134 R013................... T013 B091................... T091 54-72001............ T017 026-0250............ T166
TB1020............... T136 R014................... T014 B092................... T092 54-72100............ T065 026-0251............ T165
TB1021............... T137 R017................... T017 B093................... T093 54-76000............ T020 026-0252............ T130
TB1022............... T138 R018................... T018 B094................... T094 54-76300............ T069 026-0253............ T121
TB1023............... T139 R020................... T020 B095................... T095 54-76301............ T018 026-0255............ T167
TB1024............... T140 R028................... T028 B096................... T096 54-77801............ T014 026-0256............ T043
TB1026............... T141 R032................... T032 B099................... T099 54-77802............ T067 026-0258............ T197
TB1027............... T123 R036................... T036 BALKAMP 54-79800............ T013 026-0259............ T137
TB1028............... T090 R037................... T037 BECK ARNLEY 026-0260............ T171
TB1031............... T113 R039................... T039 Timing Belts 026-0261............ T177
TB1032............... T132 R041................... T041 9-013.................. T013 Timing Belts 026-0262............ T179
TB1033............... T142 R042................... T068 9-014.................. T014 026-0018............ T028 026-0263............ T103
TB1034............... T143 R043................... T043 9-017.................. T017 026-0026............ T020 026-0264............ T102
TB1035............... T144 R061................... T061 9-018.................. T018 026-0034............ T020 026-0265............ T157
TB1036............... T145 R062................... T062 9-020.................. T020 026-0042............ T018 026-0266............ T159
TB1037............... T146 R063................... T073 9-028.................. T028 026-0067............ T036 026-0267............ T151
TB1038............... T147 R064................... T064 9-032.................. T032 026-0075............ T041 026-0268............ T182
TB1039............... T148 R065................... T065 9-036.................. T036 026-0083............ T013 026-0269............ T184
TB1040............... T149 R067................... T067 9-037.................. T037 026-0091............ T014 026-0270............ T181
TB1041............... T150 R069................... T069 9-039.................. T039 026-0109............ T032 026-0271............ T155
TB1042............... T151 R070................... T070 9-041.................. T041 026-0117............ T065 026-0272............ T144
TB1044............... T102 R071................... T071 9-043.................. T043 026-0125............ T068 026-0273............ T178
TB1045............... T103 R073................... T073 9-061.................. T061 026-0133............ T062 026-0274............ T104
TB1047............... T124 R074................... T074 9-062.................. T062 026-0158............ T064 026-0275............ T150
TB1048............... T154 R075................... T075 9-063.................. T073 026-0174............ T069 026-0276............ T187
TB1049............... T155 R076................... T076 9-064.................. T064 026-0175............ T070 026-0277............ T180
TB1051............... T157 R077................... T077 9-065.................. T065 026-0176............ T017 026-0278............ T186
TB1052............... T158 R078................... T078 9-067.................. T067 026-0177............ T043 026-0279............ T176
TB1053............... T159 R079................... T079 9-068.................. T068 026-0178............ T083 026-0280............ T191
TB1054............... T160 R081................... T081 9-069.................. T069 026-0179............ T073 026-0281............ T174
TB1055............... T161 R084................... T084 9-070.................. T070 026-0180............ T082 026-0282............ T183
TB1056............... T162 R087................... T087 9-071.................. T071 026-0182............ T088 026-0283............ T154
TB1057............... T153 R088................... T088 9-073.................. T073 026-0183............ T078 026-0284............ T168
788 Changeover Listing - PowerGrip™ Timing System Products
BECK ARNLEY - Cont. BECK ARNLEY - Cont. BORG WARNER - Cont. BORG WARNER - Cont. BRYCO - Cont.
Timing Belts - Cont. Timing Belt Tensioners Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont.
026-0285............ T173 LER80038 .......... T41037 TB041................. T041 TB166................. T166 B113................... T113
026-0286............ T172 LER88893 .......... T41041 TB042................. T068 TB167................. T167 B114................... T114
026-0287............ T207 024-0953............ T41055 TB043................. T043 TB168................. T168 B115................... T299
026-0288............ T152 024-0954............ T41042 TB061................. T061 TB169................. T169 B116................... T300
026-0289............ T189 024-0955............ T41057 TB062................. T062 TB170................. T170 B117................... T117
026-0290............ T188 024-0963............ T41079 TB063................. T073 TB171................. T171 B118................... T118
026-0293............ T198 024-0964............ T41045 TB064................. T064 TB172................. T172 B121................... T121
026-0294............ T208 024-0966............ T41043 TB065................. T065 TB177................. T177 B122................... T122
026-0295............ T211 024-0976............ T41035 TB067................. T067 TB178................. T178 B123................... T123
026-0296............ T201 024-0981............ T41058 TB068................. T068 TB179................. T179 B124................... T124
026-0297............ T204 024-0982............ T41088 TB069................. T069 TB183................. T183 B126................... T126
026-0298............ T218 024-0985............ T41080 TB070................. T070 TB184................. T184 B127................... T127
026-0299............ T216 024-0986............ T41081 TB071................. T071 TB185................. T185 B128................... T128
026-0300............ T203 024-0987............ T41083 TB073................. T073 TB186................. T186 B130................... T130
026-0301............ T212 024-0991............ T41012 TB074................. T074 TB187................. T187 B132................... T132
026-0302............ T193 024-0992............ T41017 TB075................. T075 TB191................. T191 B133................... T292
026-0303............ T185 024-1008............ T41062 TB076................. T076 TB192................. T192 B134................... T134
026-0304............ T221 024-1012............ T41005 TB077................. T077 TB194................. T194 B136................... T136
026-0305............ T220 024-1028............ T41069 TB078................. T078 TB195................. T195 B137................... T137
026-0306............ T194 024-1046............ T41061 TB079................. T079 TB199................. T199 B138................... T138
026-0307............ T224 024-1050............ T41064 TB081................. T081 TB200................. T200 B139................... T139
026-0308............ T226 024-1074............ T41059 TB082................. T082 TB201................. T201 B141................... T141
026-0309............ T223 024-1076............ T41011 TB083................. T083 TB202................. T248 B142................... T142
026-0310............ T227 024-1077............ T41003 TB084................. T084 TB204................. T204 B143................... T143
026-0311............ T214 024-1079............ T41076 TB087................. T087 TB206................. T206 B144................... T144
026-0312............ T209 024-1081............ T41067 TB088................. T088 TB208................. T208 B145................... T145
026-0314............ T229 024-1083............ T41073 TB089................. T089 TB210................. T210 B146................... T146
026-0316............ T230 024-1086............ T41074 TB090................. T090 TB214................. T214 B147................... T147
026-0317............ T232 024-1087............ T41066 TB091................. T091 TB228................. T228 B149................... T149
026-0318............ T217 024-1088............ T41025 TB092................. T092 TB233................. T233 B153................... T153
026-0319............ T195 024-1089............ T41029 TB093................. T093 TB235................. T235 B154................... T154
026-0320............ T234 024-1090............ T41056 TB094................. T094 TB236................. T236 B155................... T155
026-0322............ T235 024-1091............ T41060 TB095................. T095 TB237................. T237 B157................... T157
026-0323............ T252 024-1106............ T41026 TB096................. T096 T219................... T219 B158................... T158
026-0324............ T241 024-1118............ T41075 TB098................. T098 B159................... T159
026-0325............ T236 024-1119............ T41015 TB099................. T099 BOSCH
B160................... T160
026-0326............ T262 024-1144............ T41013 TB100................. T100 Timing Belts B161................... T161
026-0327............ T228 024-1145............ T41014 TB101................. T101 B162................... T162
026-0329............ T252 024-1147............ T41052 TB102................. T102 914416094 ......... T036
024-1151............ T41018 9144161055 ....... T062 B164................... T164
026-0330............ T281 TB103................. T103 B165................... T165
026-0331............ T253 024-1152............ T41053 TB104................. T104 9144161084 ....... T088
024-1153............ T41016 9144161092 ....... T073 B167................... T167
026-0332............ T247 TB106................. T106 B168................... T168
026-0334............ T249 024-1154............ T41020 TB107................. T107 9144161095 ....... T041
024-1155............ T41021 9144161113 ....... T065 B169................... T169
026-0335............ T263 TB110................. T196 B176................... T176
026-0336............ T259 024-1156............ T41030 TB112................. T112 9144161116 ....... T018
024-1160............ T41044 9144161118 ....... T069 B177................... T177
026-0338............ T120 TB113................. T113 B179................... T179
026-0339............ T244 024-1162............ T41031 TB114................. T114 9144161121 ....... T017
024-1164............ T41051 9144161122 ....... T013 B182................... T182
026-0340............ T243 TB115................. T299 B184................... T184
026-0341............ T264 024-1165............ T41034 TB116................. T300 9144161146 ....... T020
026-0344............ T271 024-1166............ T41009 TB117................. T117 9144161148 ....... T068 B185................... T185
026-0345............ T316 024-1167............ T41033 TB118................. T118 9144165075 ....... T082 B186................... T186
026-1000............ T158 024-1168............ T41039 TB119................. T119 9144165119 ....... T083 B187................... T187
026-1001............ T196 024-1172............ T41072 TB121................. T121 9144165135 ....... T043 B191................... T191
026-1002............ T161 024-1177............ T41078 TB122................. T122 B194................... T194
BRYCO B195................... T195
026-1003............ T160 024-1187............ T41071 TB123................. T123
026-1004............ T199 024-1193............ T41048 TB124................. T124 Timing Belts B199................... T199
026-1005............ T159 024-1195............ T41063 TB125................. T125 B013................... T013 B201................... T201
026-1006............ T254 024-1197............ T41027 TB126................. T126 B014................... T014 B204................... T204
026-1007............ T242 024-1199............ T41023 TB127................. T127 B017................... T017 B208................... T208
026-1008............ T262 024-1204............ T41065 TB128................. T128 B028................... T028 B210................... T210
026-1009............ T276 024-1206............ T41054 TB129................. T129 B036................... T036 B223................... T223
026-1010............ T272 TB130................. T130 B041................... T041 B224................... T224
Timing Belt Pulleys B227................... T227
026-1011............ T200 TB131................. T131 B043................... T043
026-1012............ T266 024-1006............ T42025 TB132................. T132 B062................... T062 B228................... T228
026-1013............ T190 024-1082............ T42028 TB133................. T292 B064................... T064 B229................... T229
026-1014............ T240 024-1092............ T42011 TB134................. T134 B067................... T067 B230................... T230
026-1015............ T267 024-1148............ T42009 TB135................. T135 B070................... T070 B235................... T235
026-1016............ T215 024-1149............ T42010 TB136................. T136 B071................... T071 B236................... T236
026-1017............ T126 024-1150............ T42001 TB137................. T137 B073................... T073 B237................... T237
026-1018............ T257 024-1157............ T42013 TB138................. T138 B074................... T074 B258................... T258
026-1021............ T246 024-1163............ T42005 TB139................. T139 B075................... T075 T115................... T299
026-1022............ T287 024-1174............ T42008 TB140................. T140 B076................... T076 54700 ................. T095
026-1023............ T284 024-1176............ T42030 TB141................. T141 B077................... T077 54742 ................. T075
026-1024............ T286 024-1178............ T42031 TB142................. T142 B078................... T078 54754 ................. T112
026-1025............ T277 024-1180............ T42021 TB143................. T143 B079................... T079 54755 ................. T176
026-1026............ T278 024-1184............ T42020 TB144................. T144 B087................... T087 54788 ................. T076
026-1027............ T282 024-1190............ T42029 TB145................. T145 B088................... T088 CARQUEST
026-1028............ T279 024-1203............ T42012 TB146................. T146 B089................... T089
026-1029............ T270 TB147................. T147 B090................... T090 Timing Belts
BORG WARNER
026-1030............ T205 TB148................. T148 B091................... T091 T013................... T013
026-1031............ T207 Timing Belts TB153................. T153 B092................... T092 T014................... T014
026-1033............ T297 TB013................. T013 TB154................. T154 B093................... T093 T096................... T096
026-1034............ T296 TB014................. T014 TB155................. T155 B094................... T094 T097................... T097
026-1035............ T302 TB017................. T017 TB157................. T157 B095................... T095 T098................... T098
026-1037............ T298 TB018................. T018 TB158................. T158 B096................... T096 T099................... T099
026-1038............ T288 TB020................. T020 TB159................. T159 B099................... T099 T100................... T100
026-1039............ T303 TB028................. T028 TB160................. T160 B100................... T100 T101................... T101
026-1040............ T308 TB029................. T104 TB161................. T161 B101................... T101 T102................... T102
026-1042............ T310 TB032................. T032 TB162................. T162 B102................... T102 T103................... T103
026-1043............ T309 TB036................. T036 TB163................. T163 B103................... T103 T104................... T104
026-1044............ T305 TB037................. T037 TB164................. T164 B104................... T104 T106................... T106
026-1045............ T311 TB039................. T039 TB165................. T165 B112................... T112 T107................... T107
CARQUEST - Cont. CARQUEST - Cont. CLEVELAND MOTIVE CLEVITE ENGINE PARTS CLEVITE ENGINE PARTS
Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. - Cont.
B013................... T013 Timing Belts - Cont. Timing Belts - Cont.
T112................... T112 T210................... T210
T113................... T113 T211................... T211 B014................... T014 TB-184 ............... T184 TB-292 ............... T292
T114................... T114 T212................... T212 B037................... T037 TB-185 ............... T185 TB-296 ............... T296
T117................... T117 T213................... T213 B043................... T043 TB-186 ............... T186 TB-297 ............... T297
T118................... T118 T214................... T214 B068................... T068 TB-187 ............... T187 TB-298 ............... T298
T119................... T119 T215................... T215 B074................... T074 TB-188 ............... T188 TB-300 ............... T300
T120................... T120 B075................... T075 TB-189 ............... T189 TB-302 ............... T302
T216................... T216 B076................... T076
T121................... T121 T217................... T217 TB-190 ............... T190 TB-303 ............... T303
T122................... T122 B077................... T077 TB-191 ............... T191 TB-308 ............... T308
T218................... T218 B078................... T078
T123................... T123 T219................... T219 TB-192 ............... T192 TB-309 ............... T309
T124................... T124 B081................... T081 TB-193 ............... T193 TB-310 ............... T310
T220................... T220
T125................... T125 T221................... T221 CLEVITE ENGINE PARTS TB-194 ............... T194 TB-32 ................. T032
T126................... T126 T222................... T222 TB-195 ............... T195 TB-36 ................. T036
T127................... T127 Timing Belts TB-196 ............... T196
T223................... T223 TB-37 ................. T037
T128................... T128 TB-100 ............... T100 TB-197 ............... T197 TB-39 ................. T039
T129................... T129 T224................... T224 TB-101 ............... T101
T225................... T225 TB-198 ............... T198 TB-41 ................. T041
T130................... T130 TB-102 ............... T102 TB-199 ............... T199 TB-43 ................. T043
T131................... T131 T226................... T226 TB-103 ............... T103 TB-20 ................. T020
T227................... T227 TB-61 ................. T061
T132................... T132 TB-104 ............... T104 TB-200 ............... T200 TB-62 ................. T062
T134................... T134 T228................... T228 TB-106 ............... T106 TB-201 ............... T201 TB-64 ................. T064
T135................... T135 T229................... T229 TB-107 ............... T107 TB-203 ............... T203 TB-65 ................. T065
T136................... T136 T230................... T230 TB-112 ............... T112 TB-204 ............... T204 TB-67 ................. T067
T137................... T137 T232................... T232 TB-113 ............... T113 TB-205 ............... T205 TB-69 ................. T069
T138................... T138 T233................... T233 TB-114 ............... T114 TB-206 ............... T206 TB-70 ................. T070
T139................... T139 T234................... T234 TB-117 ............... T117 TB-208 ............... T208 TB-71 ................. T071
T140................... T140 T235................... T235 TB-118 ............... T118 TB-209 ............... T209 TB-73 ................. T073
T141................... T141 T236................... T236 TB-119 ............... T119 TB-210 ............... T210 TB-74 ................. T074
T142................... T142 T237................... T237 TB-120 ............... T120 TB-211 ............... T211 TB-75 ................. T075
T143................... T143 T239................... T239 TB-121 ............... T121 TB-212 ............... T212 TB-76 ................. T076
T144................... T144 T240................... T240 TB-122 ............... T122 TB-214 ............... T214 TB-77 ................. T077
T145................... T145 T241................... T241 TB-123 ............... T123 TB-215 ............... T215 TB-78 ................. T078
T146................... T146 T242................... T242 TB-124 ............... T124 TB-216 ............... T216 TB-79 ................. T079
T147................... T147 T243................... T243 TB-125 ............... T125 TB-217 ............... T217 TB-81 ................. T081
T148................... T148 T244................... T244 TB-126 ............... T126 TB-218 ............... T218 TB-82 ................. T082
T149................... T149 T245................... T245 TB-127 ............... T127 TB-219 ............... T219 TB-83 ................. T083
T150................... T150 T246................... T246 TB-128 ............... T128 TB-220 ............... T220 TB-84 ................. T084
T151................... T151 T247................... T247 TB-129 ............... T129 TB-221 ............... T221 TB-87 ................. T087
T152................... T152 T248................... T248 TB-13 ................. T013 TB-222 ............... T222 TB-88 ................. T088
T153................... T153 T249................... T249 TB-130 ............... T130 TB-223 ............... T223 TB-89 ................. T089
T154................... T154 T251................... T251 TB-131 ............... T131 TB-224 ............... T224 TB-90 ................. T090
T155................... T155 T252................... T252 TB-132 ............... T132 TB-226 ............... T226 TB-91 ................. T091
T157................... T157 TB-134 ............... T134 TB-227 ............... T227 TB-92 ................. T092
T158................... T158 T253................... T253 TB-135 ............... T135 TB-228 ............... T228
T254................... T254 TB-93 ................. T093
T159................... T159 TB-136 ............... T136 TB-229 ............... T229 TB-94 ................. T094
T160................... T160 T255................... T255 TB-137 ............... T137 TB-230 ............... T230
T161................... T161 T256................... T256 TB-138 ............... T138 TB-232 ............... T232 TB-95 ................. T095
T162................... T162 T257................... T257 TB-139 ............... T139 TB-233 ............... T233 TB-96 ................. T096
T163................... T163 T258................... T258 TB-14 ................. T014 TB-234 ............... T234 TB-97 ................. T097
T164................... T164 T259................... T259 TB-140 ............... T140 TB-235 ............... T235 TB-98 ................. T098
T165................... T165 T260................... T260 TB-141 ............... T141 TB-236 ............... T236 TB-99 ................. T099
T166................... T166 T262................... T262 TB-142 ............... T142 TB-237 ............... T237 CLOYES GEAR
T167................... T167 T263................... T263 TB-143 ............... T143 TB-239 ............... T239 Timing Belts
T168................... T168 T264................... T264 TB-144 ............... T144 TB-240 ............... T240
T169................... T169 T265................... T265 TB-145 ............... T145 TB-241 ............... T241 B013................... T013
T170................... T170 T266................... T266 TB-146 ............... T146 TB-242 ............... T242 B014................... T014
T171................... T171 T267................... T267 TB-147 ............... T147 TB-243 ............... T243 B017................... T017
T172................... T172 T269................... T269 TB-148 ............... T148 TB-244 ............... T244 B018................... T018
T173................... T173 T271................... T271 TB-149 ............... T149 TB-245 ............... T245 B020................... T020
T174................... T174 T272................... T272 TB-150 ............... T150 TB-246 ............... T246 B028................... T028
T176................... T176 T273................... T273 TB-151 ............... T151 TB-247 ............... T247 B032................... T032
T177................... T177 T276................... T276 TB-152 ............... T152 TB-248 ............... T248 B036................... T036
T178................... T178 T277................... T277 TB-153 ............... T153 TB-249 ............... T249 B037................... T037
T179................... T179 T278................... T278 TB-154 ............... T154 TB-251 ............... T251 B039................... T039
T180................... T180 T279................... T279 TB-155 ............... T155 TB-252 ............... T252 B041................... T041
T181................... T181 T280................... T280 TB-157 ............... T157 TB-253 ............... T253 B043................... T043
T182................... T182 T281................... T281 TB-158 ............... T158 TB-254 ............... T254 B061................... T061
T183................... T183 T282................... T282 TB-159 ............... T159 TB-255 ............... T255 B062................... T062
T184................... T184 T283................... T283 TB-160 ............... T160 TB-256 ............... T256 B063................... T073
T185................... T185 T284................... T284 TB-161 ............... T161 TB-257 ............... T257 B064................... T064
T186................... T186 T285................... T285 TB-162 ............... T162 TB-258 ............... T258 B065................... T065
T187................... T187 T286................... T286 TB-163 ............... T163 TB-259 ............... T259 B067................... T067
T188................... T188 T287................... T287 TB-164 ............... T164 TB-262 ............... T262 B068................... T068
T189................... T189 T288................... T288 TB-165 ............... T165 TB-263 ............... T263 B069................... T069
T190................... T190 T289................... T289 TB-166 ............... T166 TB-264 ............... T264 B070................... T070
T191................... T191 TB-167 ............... T167 TB-265 ............... T265 B071................... T071
T192................... T192 T290................... T290 TB-168 ............... T168 TB-266 ............... T266 B073................... T073
T193................... T193 T291................... T291 TB-169 ............... T169 TB-267 ............... T267 B074................... T074
T194................... T194 T292................... T292 TB-17 ................. T017 TB-271 ............... T271 B075................... T075
T195................... T195 T293................... T293 TB-170 ............... T170 TB-273 ............... T273 B076................... T076
T196................... T196 T294................... T294 TB-171 ............... T171 TB-276 ............... T276 B077................... T077
T197................... T197 T295................... T295 TB-172 ............... T172 TB-277 ............... T277 B078................... T078
T198................... T198 T296................... T296 TB-173 ............... T173 TB-278 ............... T278 B079................... T079
T199................... T199 T297................... T297 TB-174 ............... T174 TB-279 ............... T279 B081................... T081
T200................... T200 T298................... T298 TB-176 ............... T176 TB-28 ................. T028 B082................... T082
T201................... T201 T299................... T299 TB-177 ............... T177 TB-281 ............... T281 B083................... T083
T203................... T203 T300................... T300 TB-178 ............... T178 TB-282 ............... T282 B084................... T084
T204................... T204 T301................... T301 TB-179 ............... T179 TB-284 ............... T284 B087................... T087
T205................... T205 T302................... T302 TB-18 ................. T018 TB-285 ............... T285 B088................... T088
T206................... T206 T303................... T303 TB-180 ............... T180 TB-286 ............... T286 B089................... T089
T207................... T207 T304................... T304 TB-181 ............... T181 TB-287 ............... T287 B090................... T090
T208................... T208 T305................... T305 TB-182 ............... T182 TB-288 ............... T288 B091................... T091
T209................... T209 T306................... T306 TB-183 ............... T183 TB-291 ............... T291 B092................... T092
CLOYES GEAR - Cont. CLOYES GEAR - Cont. CLOYES GEAR - Cont. CONTINENTAL - Cont. CONTITECH - Cont.
Timing Belts - Cont. Timing Belts - Cont. Timing Belt Tensioners Timing Belts - Cont. Timing Belts - Cont.
B093................... T093 B194................... T194 9-5011................ T41005 6585910 ............. T013 TB122................. T122
B094................... T094 B195................... T195 9-5032................ T41055 6585911 ............. T082 TB123................. T123
B095................... T095 B196................... T196 9-5033................ T41042 6585912 ............. T083 TB124................. T124
B096................... T096 B199................... T199 9-5038................ T41057 6585913 ............. T032 TB125................. T125
B097................... T097 B200................... T200 9-5066................ T41066 6585914 ............. T043 TB126................. T126
B098................... T098 B201................... T201 9-5075................ T41058 6585916 ............. T018 TB127................. T127
B099................... T099 B203................... T203 9-5089................ T41080 6585918 ............. T020 TB128................. T128
B100................... T100 B204................... T204 9-5091................ T41000 6585921 ............. T068 TB129................. T129
B101................... T101 B205................... T205 9-5096................ T41069 6585924 ............. T078 TB130................. T130
B102................... T102 B206................... T206 9-5097................ T41068 6585929 ............. T064 TB131................. T131
B103................... T103 B208................... T208 9-5104................ T41070 6585933 ............. T062 TB133................. T292
B104................... T104 B209................... T209 9-5105................ T41043 6585934 ............. T073 TB134................. T134
B106................... T106 B210................... T210 9-5106................ T41053 6585935 ............. T077 TB135................. T135
B107................... T107 B211................... T211 9-5107................ T41050 6585939 ............. T028 TB136................. T136
B108................... T293 B212................... T212 9-5108................ T41049 6585943 ............. T041 TB137................. T137
B112................... T112 B214................... T214 9-5114................ T41006 6585945 ............. T069 TB138................. T138
B113................... T113 B216................... T216 9-5117................ T41077 6585949 ............. T070 TB139................. T139
B114................... T114 B219................... T219 9-5124................ T41059 6589089 ............. T131 TB140................. T140
B115................... T299 B220................... T220 9-5126................ T41017 6589092 ............. T084 TB141................. T141
B116................... T300 B221................... T221 9-5135................ T41074 6589095 ............. T107 TB142................. T142
B117................... T117 B223................... T223 9-5148................ T41079 6589100 ............. T081 TB143................. T143
B118................... T118 B224................... T224 9-5154................ T41061 6589103 ............. T106 TB144................. T144
B119................... T119 B225................... T225 9-5155................ T41062 6598500 ............. T062 TB145................. T145
B121................... T121 B226................... T226 9-5156................ T41081 6598506 ............. T028 TB146................. T146
B122................... T122 B227................... T227 9-5160................ T41056 6598512 ............. T073 TB147................. T147
B123................... T123 B228................... T228 9-5161................ T41045 6598513 ............. T041 TB148................. T148
B124................... T124 B229................... T229 9-5162................ T41011 6598519 ............. T077 TB150................. T150
B125................... T125 B230................... T230 9-5163................ T41012 6598521 ............. T088 TB151................. T151
B126................... T126 B232................... T232 9-5164................ T41030 6598523 ............. T069 TB152................. T152
B127................... T127 B233................... T233 9-5165................ T41035 6598530 ............. T087 TB154................. T154
B128................... T128 B234................... T234 9-5166................ T41029 6598534 ............. T075 TB155................. T155
B129................... T129 B235................... T235 9-5182................ T41064 6598550 ............. T094 TB157................. T157
B130................... T130 B236................... T236 9-5183................ T41026 6598551 ............. T293 TB158................. T158
B131................... T131 B237................... T237 9-5192................ T41001 6598554 ............. T196 TB159................. T159
B132................... T132 B239................... T239 9-5194................ T41046 TB160................. T160
B133................... T292 9-5195................ T41048 CONTITECH TB162................. T162
B240................... T240
B134................... T134 B241................... T241 9-5196................ T41044 Timing Belts TB163................. T163
B135................... T135 B243................... T243 9-5197................ T41047 TB164................. T164
B136................... T136 9-5198................ T41015 TB014................. T014 TB165................. T165
B244................... T244 TB017................. T017
B137................... T137 B245................... T245 9-5202................ T41019 TB166................. T166
B138................... T138 9-5203................ T41014 TB018................. T018 TB167................. T167
B246................... T246 9-5204................ T41013 TB032................. T032
B139................... T139 B247................... T247 TB168................. T168
B140................... T140 9-5206................ T41076 TB036................. T036 TB169................. T169
B248................... T248 9-5209................ T41073 TB041................. T041
B141................... T141 B249................... T249 TB170................. T170
B142................... T142 9-5213................ T41031 TB043................. T043 TB171................. T171
B251................... T251 9-5221................ T41010 TB061................. T061
B143................... T143 B252................... T252 TB172................. T172
B144................... T144 9-5224................ T41051 TB063................. T073 TB173................. T173
B253................... T253 9-5226................ T41020 TB064................. T064
B145................... T145 B254................... T254 TB174................. T174
B146................... T146 9-5262................ T41016 TB065................. T065 TB176................. T176
B255................... T255 9-5263................ T41025 TB068................. T068
B147................... T147 B256................... T256 TB177................. T177
B148................... T148 9-5269................ T41003 TB069................. T069 TB178................. T178
B149................... T149 B257................... T257 9-5270................ T41004 TB070................. T070 TB179................. T179
B150................... T150 B258................... T258 9-5271................ T41039 TB074................. T074 TB180................. T180
B151................... T151 B259................... T259 9-5272................ T41052 TB075................. T075 TB181................. T181
B152................... T152 B262................... T262 9-5275................ T41060 TB076................. T076 TB182................. T182
B153................... T153 B263................... T263 9-5282................ T41065 TB077................. T077 TB183................. T183
B154................... T154 B264................... T264 9-5292................ T41036 TB078................. T078 TB184................. T184
B155................... T155 B265................... T265 9-5293................ T41033 TB079................. T079 TB185................. T185
B157................... T157 B266................... T266 9-5299................ T41071 TB081................. T081 TB186................. T186
B158................... T158 B267................... T267 9-5301................ T41067 TB082................. T082 TB187................. T187
B159................... T159 B271................... T271 9-5342................ T41072 TB083................. T083 TB188................. T188
B160................... T160 B272................... T272 9-5343................ T41009 TB084................. T084 TB189................. T189
B161................... T161 B273................... T273 9-5350................ T41007 TB087................. T087 TB190................. T190
B162................... T162 B276................... T276 9-5354................ T41018 TB088................. T088 TB191................. T191
B163................... T163 B277................... T277 9-5357................ T41002 TB089................. T089 TB193................. T193
B164................... T164 B278................... T278 9-5390................ T41008 TB090................. T090 TB195................. T195
B165................... T165 B279................... T279 9-9228................ T41021 TB091................. T091 TB196................. T196
B166................... T166 B280................... T280 TB092................. T092 TB197................. T197
B281................... T281 Timing Belt Pulleys
B167................... T167 TB093................. T093 TB198................. T198
B168................... T168 B282................... T282 S675................... T42022 TB094................. T094 TB199................. T199
B169................... T169 B283................... T283 9-5110................ T42026 TB095................. T095 TB200................. T200
B170................... T170 B284................... T284 9-5118................ T42027 TB096................. T096 TB201................. T201
B171................... T171 B285................... T285 9-5184................ T42001 TB097................. T097 TB203................. T203
B172................... T172 B286................... T286 9-5207................ T42028 TB098................. T098 TB204................. T204
B174................... T174 B287................... T287 9-5214................ T42005 TB099................. T099 TB205................. T205
B176................... T176 B288................... T288 9-5215................ T42003 TB100................. T100 TB208................. T208
B177................... T177 B289................... T289 9-5216................ T42011 TB101................. T101 TB209................. T209
B178................... T178 B291................... T291 9-5222................ T42006 TB102................. T102 TB210................. T210
B179................... T179 B292................... T292 9-5223................ T42007 TB103................. T103 TB211................. T211
B180................... T180 B294................... T294 9-5225................ T42017 TB104................. T104 TB212................. T212
B181................... T181 B295................... T295 9-5244................ T42020 TB106................. T106 TB213................. T213
B182................... T182 B296................... T296 9-5283................ T42021 TB107................. T107 TB214................. T214
B183................... T183 B297................... T297 9-5300................ T42029 TB108................. T293 TB215................. T215
B184................... T184 B298................... T298 9-5302................ T42025 TB110................. T196 TB216................. T216
B185................... T185 B299................... T299 9-5303................ T42030 TB112................. T112 TB217................. T217
B186................... T186 B300................... T300 9-5325................ T42010 TB113................. T113 TB218................. T218
B187................... T187 B301................... T301 9-5326................ T42009 TB115................. T299 TB220................. T220
B189................... T189 B302................... T302 CONTINENTAL TB116................. T300 TB221................. T221
B190................... T190 B303................... T303 TB117................. T117 TB222................. T222
B191................... T191 B304................... T304 Timing Belts TB118................. T118 TB224................. T224
B192................... T192 B305................... T305 6585901 ............. T065 TB119................. T119 TB225................. T225
B193................... T193 B308................... T308 6585902 ............. T017 TB121................. T121 TB227................. T227
CONTITECH - Cont. DAYCO - Cont. DAYCO - Cont. DAYCO - Cont. DURKEE-ATWOOD - Cont.
Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont.
TB228................. T228 95064 ................. T064 95166 ................. T166 95277 ................. T277 88102 ................. T102
TB229................. T229 95065 ................. T065 95167 ................. T167 95278 ................. T278 88104 ................. T104
TB230................. T230 95067 ................. T067 95168 ................. T168 95281 ................. T281 88106 ................. T106
TB232................. T232 95068 ................. T068 95169 ................. T169 95283 ................. T283 88107 ................. T107
TB233................. T233 95069 ................. T069 95170 ................. T170 95284 ................. T284 88112 ................. T112
TB235................. T235 95070 ................. T070 95171 ................. T171 95286 ................. T286 88113 ................. T113
TB236................. T236 95071 ................. T071 95172 ................. T172 95287 ................. T287 88114 ................. T114
TB239................. T239 95073 ................. T073 95173 ................. T173 95288 ................. T288 88115 ................. T299
TB240................. T240 95074 ................. T074 95174 ................. T174 95289 ................. T289 88116 ................. T300
TB241................. T241 95075 ................. T075 95176 ................. T176 95291 ................. T291 88117 ................. T117
TB252................. T252 95076 ................. T076 95177 ................. T177 95292 ................. T292 88118 ................. T118
CY-LENT 95077 ................. T077 95178 ................. T178 95293 ................. T293 88121 ................. T121
95078 ................. T078 95179 ................. T179 95294 ................. T294 88122 ................. T122
Timing Belts 95079 ................. T079 95180 ................. T180 95295 ................. T295 88124 ................. T124
C013................... T013 95081 ................. T081 95181 ................. T181 95296 ................. T296 88125 ................. T125
C014................... T014 95082 ................. T082 95182 ................. T182 95298 ................. T298 88126 ................. T126
C017................... T017 95083 ................. T083 95183 ................. T183 95299 ................. T299 88127 ................. T127
C018................... T018 95084 ................. T084 95184 ................. T184 95300 ................. T300 88130 ................. T130
C020................... T020 95087 ................. T087 95185 ................. T185 95302 ................. T302 88131 ................. T131
C028................... T028 95088 ................. T088 95186 ................. T186 95303 ................. T303 88132 ................. T132
C032................... T032 95089 ................. T089 95187 ................. T187 95304 ................. T304 88133 ................. T292
C037................... T037 95090 ................. T090 95188 ................. T188 95308 ................. T308 88134 ................. T134
C039................... T039 95091 ................. T091 95190 ................. T190 95311 ................. T311 88136 ................. T136
C041................... T041 95092 ................. T092 95191 ................. T191 DAYCO EUROPE 88138 ................. T138
C043................... T043 95093 ................. T093 95192 ................. T192 88141 ................. T141
C061................... T061 95094 ................. T094 95193 ................. T193 Timing Belts 88143 ................. T143
C062................... T062 95095 ................. T095 95194 ................. T194 19084 ................. T028 88144 ................. T144
C063................... T073 95096 ................. T096 95195 ................. T195 19113 ................. T065 88146 ................. T146
C064................... T064 95097 ................. T097 95196 ................. T196 19116 ................. T018 88153 ................. T153
C065................... T065 95098 ................. T098 95197 ................. T197 19121 ................. T017 88157 ................. T157
C067................... T067 95099 ................. T099 95198 ................. T198 19122 ................. T013 88158 ................. T158
C069................... T069 95100 ................. T100 95199 ................. T199 19123 ................. T032 88159 ................. T159
C070................... T070 95101 ................. T101 95200 ................. T200 19146 ................. T020 88160 ................. T160
C071................... T071 95102 ................. T102 95201 ................. T201 88161 ................. T161
95103 ................. T103 95202 ................. T248 DURKEE-ATWOOD 88162 ................. T162
C073................... T073 95104 ................. T104 95203 ................. T203
C075................... T075 Timing Belts 88163 ................. T163
95106 ................. T106 95204 ................. T204 88165 ................. T165
C076................... T076 95107 ................. T107 95205 ................. T205 24-436PD........... T018
C077................... T077 88170 ................. T170
95108 ................. T293 95206 ................. T206 24-457PD........... T017
C078................... T078 95110 ................. T196 95207 ................. T207 24-542PD........... T020 DYNAFLEX (See DAYCO)
C081................... T081 95112 ................. T112 95208 ................. T208 28-457PD........... T013 DYNAGEAR
DAYCO 95113 ................. T113 95210 ................. T210 28-487PD........... T014
95114 ................. T114 95211 ................. T211 88013 ................. T013 Timing Belts
Timing Belts 95115 ................. T299 95212 ................. T212 88014 ................. T014 B013................... T013
A206L050........... T062 95116 ................. T300 95214 ................. T214 88017 ................. T017 B014................... T014
A234L075........... T073 95117 ................. T117 95215 ................. T215 88018 ................. T018 B017................... T017
A315L075........... T028 95118 ................. T118 95216 ................. T216 88020 ................. T020 B018................... T018
A356L075........... T041 95119 ................. T119 95217 ................. T217 88028 ................. T028 B020................... T020
A371L059........... T037 95120 ................. T120 95218 ................. T218 88032 ................. T032 B028................... T028
A375L075........... T061 95121 ................. T121 95219 ................. T219 88037 ................. T037 B032................... T032
A450L075........... T064 95122 ................. T122 95220 ................. T220 88039 ................. T039 B037................... T037
A453L075........... T017 95123 ................. T123 95221 ................. T221 88041 ................. T041 B039................... T039
A457L075........... T013 95124 ................. T124 95223 ................. T223 88042 ................. T068 B041................... T041
A484L088........... T014 95125 ................. T125 95224 ................. T224 88043 ................. T043 B043................... T043
A547L075........... T020 95126 ................. T126 95225 ................. T225 88046 ................. T013 B061................... T061
94011 ................. T092 95127 ................. T127 95226 ................. T226 88047 ................. T014 B062................... T062
94075 ................. T070 95128 ................. T128 95227 ................. T227 88050 ................. T018 B063................... T073
94078 ................. T203 95129 ................. T129 95228 ................. T228 88052 ................. T020 B064................... T064
94080 ................. T203 95130 ................. T130 95229 ................. T229 88057 ................. T037 B065................... T065
94098 ................. T089 95131 ................. T131 95230 ................. T230 88058 ................. T039 B067................... T067
94100 ................. T090 95132 ................. T132 95232 ................. T232 88060 ................. T017 B068................... T068
94123 ................. T117 95133 ................. T292 95233 ................. T233 88061 ................. T061 B069................... T069
94133 ................. T128 95134 ................. T134 95234 ................. T234 88062 ................. T062 B070................... T070
94165 ................. T146 95135 ................. T135 95235 ................. T235 88063 ................. T073 B071................... T071
94169 ................. T148 95136 ................. T136 95236 ................. T236 88064 ................. T064 B074................... T074
94185 ................. T163 95137 ................. T137 95237 ................. T237 88065 ................. T065 B075................... T075
94266 ................. T091 95138 ................. T138 95240 ................. T240 88067 ................. T067 B076................... T076
94283 ................. T124 95139 ................. T139 95241 ................. T241 88069 ................. T069 B077................... T077
94284 ................. T185 95140 ................. T140 95244 ................. T244 88070 ................. T070 B078................... T078
94293 ................. T165 95141 ................. T141 95245 ................. T245 88071 ................. T071 B081................... T081
94294 ................. T179 95142 ................. T142 95246 ................. T246 88074 ................. T074 B087................... T087
94340 ................. T155 95143 ................. T143 95247 ................. T247 88075 ................. T075 B088................... T088
94341 ................. T139 95144 ................. T144 95248 ................. T248 88076 ................. T076 B093................... T093
94350 ................. T167 95145 ................. T145 95249 ................. T249 88077 ................. T077 B094................... T094
94351 ................. T168 95146 ................. T146 95251 ................. T251 88078 ................. T078 B095................... T095
94430 ................. T155 95147 ................. T147 95252 ................. T252 88079 ................. T079 B099................... T099
95013 ................. T013 95148 ................. T148 95253 ................. T253 88081 ................. T081 B104................... T104
95014 ................. T014 95150 ................. T150 95254 ................. T254 88082 ................. T082 B112................... T112
95017 ................. T017 95151 ................. T151 95255 ................. T255 88083 ................. T083 TB013................. T013
95018 ................. T018 95152 ................. T152 95257 ................. T257 88084 ................. T084 TB014................. T014
95020 ................. T020 95153 ................. T153 95258 ................. T258 88087 ................. T087 TB017................. T017
95028 ................. T028 95154 ................. T154 95259 ................. T259 88088 ................. T088 TB018................. T018
95032 ................. T032 95155 ................. T155 95262 ................. T262 88089 ................. T089 TB020................. T020
95036 ................. T036 95157 ................. T157 95263 ................. T263 88090 ................. T090 TB028................. T028
95037 ................. T037 95158 ................. T158 95264 ................. T264 88091 ................. T091 TB029................. T104
95039 ................. T039 95159 ................. T159 95265 ................. T265 88092 ................. T092 TB032................. T032
95041 ................. T041 95160 ................. T160 95266 ................. T266 88093 ................. T093 TB036................. T036
95042 ................. T068 95161 ................. T161 95269 ................. T269 88094 ................. T094 TB037................. T037
95043 ................. T043 95162 ................. T162 95271 ................. T271 88095 ................. T095 TB039................. T039
95061 ................. T061 95163 ................. T163 95272 ................. T272 88099 ................. T099 TB041................. T041
95062 ................. T062 95164 ................. T164 95273 ................. T273 88100 ................. T100 TB043................. T043
95063 ................. T073 95165 ................. T165 95276 ................. T276 88101 ................. T101 TB061................. T061
DYNAGEAR - Cont. DYNAGEAR - Cont. DYNAGEAR - Cont. FEDERAL MOGUL - Cont. GENERAL CHAIN - Cont.
Timing Belts - Cont. Timing Belts - Cont. Timing Belt Pulleys - Cont. Timing Belts - Cont. Timing Belts - Cont.
TB062................. T062 TB165................. T165 9325 ................... T42010 LB125................. T125 B4511................. T078
TB063................. T073 TB166................. T166 9326 ................... T42009 LB126................. T237 B4512................. T079
TB064................. T064 TB167................. T167 ELGIN MACH. LB128................. T128 B4513................. T087
TB065................. T065 TB168................. T168 LB129................. T129 B4514................. T084
TB067................. T067 TB169................. T169 Timing Belts LB130................. T130 B4515................. T101
TB068................. T068 Timing Belt Tensioners LB-013................ T013 LB131................. T131 B4516................. T070
TB069................. T069 LB-014................ T014 LB132................. T132 B4518................. T112
TB070................. T070 7206 ................... T41076 LB-017................ T017 LB133................. T292 B4519................. T084
TB071................. T071 7209 ................... T41073 LB-018................ T018 LB134................. T134 B4540................. T127
TB073................. T073 9011 ................... T41005 LB-020................ T020 LB135................. T135 B4550................. T089
TB074................. T074 9032 ................... T41055 LB-028................ T028 LB136................. T233 B4551................. T090
TB075................. T075 9033 ................... T41042 LB-032................ T032 LB138................. T199 B4580................. T094
TB076................. T076 9038 ................... T41057 LB-036................ T036 LB139................. T139 B4590................. T082
TB077................. T077 9066 ................... T41066 LB-037................ T037 LB141................. T141
9075 ................... T41058 LB142................. T142 GMB
TB078................. T078 LB-039................ T039
TB079................. T079 9089 ................... T41080 LB-041................ T041 LB143................. T143 Timing Belt Tensioners
TB081................. T081 9091 ................... T41000 LB-043................ T043 LB144................. T144 GT10010 ............ T41042
TB082................. T082 9096 ................... T41069 LB-061................ T061 LB145................. T145 GT10022 ............ T41037
TB083................. T083 9097 ................... T41068 LB-062................ T062 LB146................. T146 GT10031 ............ T41043
TB084................. T084 9104 ................... T41070 LB-063................ T073 LB147................. T147 GT10032 ............ T41044
TB087................. T087 9105 ................... T41043 LB-064................ T064 LB148................. T148 GT10040 ............ T41045
TB088................. T088 9106 ................... T41053 LB-065................ T065 LB149................. T149 GT10060 ............ T41046
TB089................. T089 9107 ................... T41050 LB-067................ T067 LB152................. T152 GT10070 ............ T41047
TB090................. T090 9108 ................... T41049 LB-068................ T068 LB153................. T153 GT10072 ............ T41038
TB091................. T091 9114 ................... T41006 LB-069................ T069 LB154................. T154 GT10080 ............ T41048
TB092................. T092 9117 ................... T41077 LB-070................ T070 LB155................. T155 GT10100 ............ T41039
TB093................. T093 9124 ................... T41059 LB-071................ T071 LB157................. T157 GT10130 ............ T41049
TB094................. T094 9126 ................... T41017 LB-073................ T073 LB158................. T158 GT10140 ............ T41050
TB095................. T095 9135 ................... T41074 LB-074................ T074 LB159................. T159 GT10150 ............ T41041
TB096................. T096 9148 ................... T41079 LB-075................ T075 LB160................. T160 GT20010 ............ T41029
TB098................. T098 9154 ................... T41061 LB161................. T161
TB099................. T099 LB-076................ T076 LB162................. T162 GT20040 ............ T41030
9155 ................... T41062 LB-077................ T077 GT20050 ............ T41031
TB100................. T100 9156 ................... T41081 LB163................. T163
TB101................. T101 LB-078................ T078 LB164................. T164 GT40010 ............ T41003
9160 ................... T41056 LB-081................ T081 GT80010 ............ T41066
TB102................. T102 9161 ................... T41045 LB165................. T165
TB103................. T103 LB-088................ T088 LB166................. T166 GT80020 ............ T41067
9162 ................... T41011 LB-093................ T093 GT80050 ............ T41060
TB104................. T104 9163 ................... T41012 LB167................. T167
TB106................. T106 FEDERAL MOGUL LB168................. T168 GT80070 ............ T41079
9164 ................... T41030 GT80090 ............ T41051
TB107................. T107 9165 ................... T41035 Timing Belts LB169................. T169
TB108................. T293 LB170................. T170 GT80100 ............ T41011
9166 ................... T41029 GT80110 ............ T41058
TB110................. T196 9182 ................... T41064 LB013................. T013 LB172................. T254
TB112................. T112 9183 ................... T41026 LB014................. T014 LB176................. T176 GT80140 ............ T41068
TB113................. T113 9192 ................... T41001 LB020................. T020 LB177................. T177 GT80170 ............ T41012
TB114................. T114 9194 ................... T41046 LB028................. T028 LB179................. T179 GT80250 ............ T41025
TB115................. T299 9195 ................... T41048 LB032................. T032 LB180................. T180 GT80280 ............ T41080
TB116................. T300 9196 ................... T41044 LB036................. T036 LB183................. T183 GT80310 ............ T41009
TB117................. T117 9197 ................... T41047 LB037................. T037 LB184................. T184 GT80320 ............ T41064
TB118................. T118 9198 ................... T41015 LB039................. T039 LB185................. T185 GT80340 ............ T41059
TB119................. T119 9202 ................... T41019 LB041................. T041 LB186................. T186 GT80360 ............ T41069
TB121................. T121 9203 ................... T41014 LB043................. T043 LB187................. T187 GT80370 ............ T41070
TB122................. T122 9204 ................... T41013 LB061................. T061 LB193................. T193 GT80390 ............ T41013
TB123................. T123 9213 ................... T41031 LB062................. T062 LB194................. T194 GT80400 ............ T41052
TB124................. T124 9221 ................... T41010 LB064................. T064 LB202................. T248 GT80410 ............ T41004
TB125................. T125 9224 ................... T41051 LB065................. T065 LB210................. T210 GT80420 ............ T41071
TB126................. T126 9226 ................... T41020 LB067................. T067 GT80430 ............ T41072
FIRESTONE GT80440 ............ T41014
TB127................. T127 9262 ................... T41016 LB069................. T069
TB128................. T128 9263 ................... T41025 LB070................. T070 Timing Belts GT80480 ............ T41053
TB129................. T129 9268 ................... T41021 LB071................. T071 51309510 ........... T017 GT80490 ............ T41005
TB130................. T130 9269 ................... T41003 LB073................. T073 51309618 ........... T061 GT80500 ............ T41006
TB131................. T131 9270 ................... T41004 LB074................. T074 51309677 ........... T067 GT80550 ............ T41015
TB132................. T132 9271 ................... T41039 LB075................. T075 51309693 ........... T071 GT80560 ............ T41061
TB133................. T292 9272 ................... T41052 LB076................. T076 51309766 ........... T081 GT80570 ............ T41062
TB134................. T134 9275 ................... T41060 LB077................. T077 GT80580 ............ T41016
TB135................. T135 9276 ................... T41027 LB078................. T078 FRESHSTART (See GOOD- GT80590 ............ T41017
TB136................. T136 9282 ................... T41065 LB081................. T081 YEAR) GT80600 ............ T41073
TB137................. T137 9292 ................... T41036 LB082................. T082 GENERAL CHAIN GT80610 ............ T41018
TB138................. T138 9293 ................... T41033 LB083................. T083 GT80620 ............ T41026
TB139................. T139 LB087................. T087 Timing Belts GT80630 ............ T41074
9299 ................... T41071
TB140................. T140 9301 ................... T41067 LB088................. T088 B4013................. T013 GT80640 ............ T41065
TB141................. T141 9343 ................... T41009 LB089................. T089 B4014................. T014 GT80650 ............ T41019
TB142................. T142 9900 ................... T41007 LB090................. T090 B4017................. T017 GT80660 ............ T41033
TB143................. T143 9903 ................... T41018 LB093................. T093 B4018................. T018 GT80670 ............ T41034
TB144................. T144 9904 ................... T41072 LB094................. T094 B4020................. T020 GT80680 ............ T41075
TB145................. T145 LB095................. T095 B4028................. T028 GT80700 ............ T41076
TB146................. T146 Timing Belt Pulleys LB099................. T099 B4032................. T032 GT80710 ............ T41077
TB147................. T147 S675................... T42022 LB101................. T101 B4036................. T036 GT80800 ............ T41054
TB148................. T148 7184 ................... T42001 LB102................. T102 B4037................. T037 GT80820 ............ T41000
TB149................. T149 7207 ................... T42028 LB103................. T103 B4039................. T039 GT80830 ............ T41001
TB150................. T150 7214 ................... T42005 LB104................. T104 B4041................. T041 GT80860 ............ T41021
TB151................. T151 7215 ................... T42003 LB107................. T107 B4042................. T068 GT80890 ............ T41055
TB152................. T152 7216 ................... T42011 LB108................. T293 B4043................. T043 GT80900 ............ T41056
TB153................. T153 7222 ................... T42006 LB110................. T196 B4061................. T061 GT80940 ............ T41010
TB154................. T154 7223 ................... T42007 LB112................. T112 B4065................. T065 GT80950 ............ T41057
TB155................. T155 7227 ................... T42018 LB113................. T113 B4067................. T067 GT80970 ............ T41035
TB157................. T157 7244 ................... T42020 LB114................. T114 B4070................. T070 420-8820............ T41000
TB158................. T158 7274 ................... T42017 LB115................. T299 B4071................. T071 420-8830............ T41001
TB159................. T159 7283 ................... T42021 LB116................. T300 B4073................. T073 420-9010............ T41002
TB160................. T160 7300 ................... T42029 LB117................. T117 B4075................. T075 422-4010............ T41003
TB161................. T161 7302 ................... T42025 LB118................. T162 B4076................. T076 422-8410............ T41004
TB162................. T162 7303 ................... T42030 LB119................. T119 B4501................. T196 425-8490............ T41005
TB163................. T163 9110 ................... T42026 LB122................. T122 B4507................. T100 425-8500............ T41006
TB164................. T164 9118 ................... T42027 LB124................. T124 B4510................. T077 425-8960............ T41007
GMB - Cont. GMB - Cont. GOODYEAR - Cont. GOODYEAR - Cont. GOODYEAR - Cont.
Timing Belt Tensioners Timing Belt Pulleys - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont.
- Cont.
GT80350 ............ T42028 CD-154............... T154 CD-247............... T247 40036 ................. T036
425-9000............ T41008 GT80380 ............ T42029 CD-155............... T155 CD-248............... T248 40037 ................. T037
430-8310............ T41009 GT80510 ............ T42009 CD-157............... T157 CD-249............... T249 40039 ................. T039
430-8940............ T41010 GT80520 ............ T42010 CD-158............... T158 CD-251............... T251 40041 ................. T041
435-8100............ T41011 GT80530 ............ T42011 CD-159............... T159 CD-252............... T252 40042 ................. T068
435-8170............ T41012 GT80540 ............ T42030 CD-160............... T160 CD-253............... T253 40043 ................. T043
435-8390............ T41013 GT80690 ............ T42022 CD-161............... T161 CD-254............... T254 40046 ................. T013
435-8440............ T41014 GT80870 ............ T42012 CD-162............... T162 CD-255............... T255 40047 ................. T014
435-8550............ T41015 GT80880 ............ T42013 CD-163............... T163 CD-256............... T256 40050 ................. T018
435-8580............ T41016 GT80910 ............ T42021 CD-164............... T164 CD-257............... T257 40052 ................. T020
435-8590............ T41017 GT80930 ............ T42020 CD-165............... T165 CD-258............... T258 40057 ................. T037
435-8610............ T41018 425-9350............ T42033 CD-166............... T166 CD-259............... T259 40058 ................. T039
435-8650............ T41019 425-9360............ T42032 CD-167............... T167 CD-260............... T260 40060 ................. T017
435-8850............ T41020 425-9390............ T42034 CD-168............... T168 CD-262............... T262 40061 ................. T061
435-8860............ T41021 425-9400............ T42035 CD-169............... T169 CD-263............... T263 40062 ................. T062
435-9030............ T41022 440-8840............ T42001 CD-17................. T017 CD-264............... T264 40063 ................. T073
435-9040............ T41023 440-9060............ T42002 CD-170............... T170 CD-265............... T265 40064 ................. T064
435-9120............ T41024 445-2020............ T42003 CD-171............... T171 CD-266............... T266 40065 ................. T065
440-8250............ T41025 445-2030............ T42004 CD-172............... T172 CD-267............... T267 40067 ................. T067
440-8620............ T41026 445-2060............ T42005 CD-173............... T173 CD-269............... T269 40068 ................. T068
440-9070............ T41027 445-2090............ T42006 CD-174............... T174 CD-271............... T271 40069 ................. T069
440-9110............ T41028 445-2100............ T42007 CD-176............... T176 CD-272............... T272 40070 ................. T070
445-2010............ T41029 445-8040............ T42008 CD-177............... T177 CD-273............... T273 40071 ................. T071
445-2040............ T41030 445-8510............ T42009 CD-178............... T178 CD-276............... T276 40073 ................. T073
445-2050............ T41031 445-8520............ T42010 CD-179............... T179 CD-277............... T277 40074 ................. T074
445-2140............ T41032 445-8530............ T42011 CD-18................. T018 CD-278............... T278 40075 ................. T075
445-8660............ T41033 445-8870............ T42012 CD-180............... T180 CD-279............... T279 40076 ................. T076
445-8670............ T41034 445-8880............ T42013 CD-181............... T181 CD-28................. T028 40077 ................. T077
445-8970............ T41035 446-1111............ T42014 CD-182............... T182 CD-280............... T280 40078 ................. T078
445-9100............ T41036 446-1160............ T42015 CD-183............... T183 CD-281............... T281 40079 ................. T079
446-1022............ T41037 446-1170............ T42016 CD-184............... T184 CD-282............... T282 40081 ................. T081
446-1061............ T41087 448-1050............ T42017 CD-185............... T185 CD-283............... T283 40082 ................. T082
446-1072............ T41038 448-1110............ T42018 CD-186............... T186 CD-284............... T284 40083 ................. T083
446-1100............ T41039 450-8920............ T42020 CD-187............... T187 CD-285............... T285 40084 ................. T084
446-1101............ T41040 450-8930............ T42021 CD-188............... T188 CD-286............... T286 40087 ................. T087
446-1150............ T41041 460-8690............ T42022 CD-189............... T189 CD-287............... T287 40088 ................. T088
448-1010............ T41042 460-9020............ T42023 CD-190............... T190 CD-288............... T288 40089 ................. T089
448-1031............ T41043 460-9130............ T42024 CD-191............... T191 CD-289............... T289 40090 ................. T090
448-1032............ T41044 470-8030............ T42025 CD-192............... T192 CD-290............... T290 40091 ................. T091
448-1040............ T41045 470-8150............ T42026 CD-193............... T193 CD-291............... T291 40092 ................. T092
448-1060............ T41046 470-8330............ T42027 CD-194............... T194 CD-292............... T292 40093 ................. T093
448-1070............ T41047 470-8350............ T42028 CD-195............... T195 CD-293............... T293 40094 ................. T094
448-1080............ T41048 470-8380............ T42029 CD-196............... T196 CD-294............... T294 40095 ................. T095
448-1130............ T41049 470-8540............ T42030 CD-197............... T197 CD-295............... T295 40096 ................. T096
448-1140............ T41050 470-9050............ T42031 CD-198............... T198 CD-296............... T296 40097 ................. T097
448-8090............ T41051 CD-199............... T199 CD-297............... T297 40098 ................. T098
448-8400............ T41052 GOODYEAR CD-20................. T020 CD-298............... T298 40099 ................. T099
448-8480............ T41053 Timing Belts CD-200............... T200 CD-299............... T299 40100 ................. T100
448-8800............ T41054 CD-201............... T201 CD-300............... T300 40101 ................. T101
448-8890............ T41055 CD-100............... T100 CD-202............... T248 CD-301............... T301 40102 ................. T102
448-8900............ T41056 CD-101............... T101 CD-203............... T203 CD-302............... T302 40103 ................. T103
448-8950............ T41057 CD-104............... T104 CD-204............... T204 CD-303............... T303 40104 ................. T104
450-8110............ T41058 CD-106............... T106 CD-205............... T205 CD-304............... T304 40106 ................. T106
450-8340............ T41059 CD-112............... T112 CD-206............... T206 CD-305............... T305 40107 ................. T107
450-8910............ T41085 CD-113............... T113 CD-207............... T207 CD-306............... T306 40112 ................. T176
460-8050............ T41060 CD-114............... T114 CD-208............... T208 CD-32................. T032 40113 ................. T113
460-8560............ T41061 CD-115............... T299 CD-209............... T209 CD-36................. T036 40114 ................. T114
460-8570............ T41062 CD-116............... T300 CD-210............... T210 CD-37................. T037 40115 ................. T299
460-9080............ T41063 CD-117............... T117 CD-211............... T211 CD-39................. T039 40116 ................. T300
465-8320............ T41064 CD-118............... T118 CD-212............... T212 CD-41................. T041 40117 ................. T117
465-8640............ T41065 CD-122............... T122 CD-213............... T213 CD-42................. T068 40118 ................. T118
470-8010............ T41066 CD-124............... T124 CD-214............... T214 CD-43................. T043 40119 ................. T119
470-8020............ T41067 CD-125............... T125 CD-215............... T215 CD-61................. T061 40121 ................. T121
470-8140............ T41068 CD-126............... T126 CD-216............... T216 CD-62................. T062 40122 ................. T122
470-8360............ T41069 CD-127............... T127 CD-217............... T217 CD-63................. T073 40123 ................. T123
470-8370............ T41070 CD-128............... T128 CD-218............... T218 CD-64................. T064 40124 ................. T124
470-8420............ T41071 CD-129............... T129 CD-219............... T219 CD-65................. T065 40125 ................. T125
470-8430............ T41072 CD-13................. T013 CD-220............... T220 CD-67................. T067 40126 ................. T126
470-8600............ T41073 CD-130............... T130 CD-221............... T221 CD-69................. T069 40127 ................. T127
470-8630............ T41074 CD-131............... T131 CD-222............... T222 CD-70................. T070 40128 ................. T128
470-8680............ T41075 CD-132............... T132 CD-223............... T223 CD-71................. T071 40129 ................. T129
470-8700............ T41076 CD-133............... T292 CD-224............... T224 CD-74................. T074 40130 ................. T130
470-8710............ T41077 CD-134............... T134 CD-225............... T225 CD-77................. T077 40131 ................. T131
470-9090............ T41078 CD-136............... T136 CD-226............... T226 CD-78................. T078 40132 ................. T132
480-8070............ T41079 CD-137............... T137 CD-227............... T227 CD-81................. T081 40133 ................. T292
480-8280............ T41080 CD-138............... T138 CD-228............... T228 CD-87................. T087 40134 ................. T134
490-9143............ T41081 CD-139............... T139 CD-229............... T229 CD-88................. T088 40135 ................. T135
CD-14................. T014 CD-230............... T230 CD-89................. T089 40136 ................. T136
Timing Belt Pulleys CD-140............... T140 CD-232............... T232 CD-90................. T090 40137 ................. T137
GT10050 ............ T42017 CD-141............... T141 CD-233............... T233 CD-91................. T091 40138 ................. T138
GT10110 ............ T42018 CD-142............... T142 CD-234............... T234 CD-92................. T092 40139 ................. T139
GT10160 ............ T42015 CD-143............... T143 CD-235............... T235 CD-93................. T093 40140 ................. T140
GT10170 ............ T42016 CD-144............... T144 CD-236............... T236 CD-94................. T094 40141 ................. T141
GT20020 ............ T42003 CD-145............... T145 CD-237............... T237 CD-95................. T095 40142 ................. T142
GT20030 ............ T42004 CD-146............... T146 CD-239............... T239 CD-99................. T099 40143 ................. T143
GT20060 ............ T42005 CD-147............... T147 CD-240............... T240 40013 ................. T013 40144 ................. T144
GT20090 ............ T42006 CD-148............... T148 CD-241............... T241 40014 ................. T014 40145 ................. T145
GT20100 ............ T42007 CD-149............... T149 CD-242............... T242 40017 ................. T017 40146 ................. T146
GT80030 ............ T42025 CD-150............... T150 CD-243............... T243 40018 ................. T018 40147 ................. T147
GT80040 ............ T42008 CD-151............... T151 CD-244............... T244 40020 ................. T020 40148 ................. T148
GT80150 ............ T42026 CD-152............... T152 CD-245............... T245 40028 ................. T028 40149 ................. T149
GT80330 ............ T42027 CD-153............... T153 CD-246............... T246 40032 ................. T032 40151 ................. T151
GOODYEAR - Cont. GOODYEAR - Cont. HOOF PRODUCTS - Cont. LAZORLITE - Cont. MBL THREE STARS - Cont.
40152 ................. T152 40248 ................. T248 HB032 ................ T032 L55-4618............ T141 129ZA22............. T014
40153 ................. T153 40249 ................. T249 HB036 ................ T036 L55-4626............ T117 134ZA30............. T076
40154 ................. T154 40251 ................. T251 HB037 ................ T037 L55-4634............ T134 134ZB301........... T076
40155 ................. T155 40252 ................. T252 HB039 ................ T039 L55-4642............ T128 135ZB25............. T043
40157 ................. T157 40253 ................. T253 HB041 ................ T041 L55-4650............ T124 139ZA25............. T087
40158 ................. T158 40254 ................. T254 HB042 ................ T068 L55-4669............ T139 142ZA25............. T074
40159 ................. T159 40255 ................. T255 HB043 ................ T043 L55-4677............ T103 146ZA19............. T020
40160 ................. T160 40256 ................. T256 HB061 ................ T061 L55-4685............ T135 148ZA19............. T068
40161 ................. T161 40257 ................. T257 HB062 ................ T062 L55-4693............ T136 55ZA13............... T062
40162 ................. T162 40258 ................. T258 HB063 ................ T073 L55-4707............ T126 84ZA19............... T028
40163 ................. T163 40259 ................. T259 HB064 ................ T064 L55-4715............ T098 87ZA34............... T075
40164 ................. T164 40260 ................. T260 HB065 ................ T065 L55-4723............ T138 87ZB34............... T075
40165 ................. T165 40262 ................. T262 HB067 ................ T067 L55-4731............ T130 88ZA19............... T070
40166 ................. T166 40263 ................. T263 HB069 ................ T069 L55-4740............ T129 92ZA19............... T073
40167 ................. T167 40264 ................. T264 HB070 ................ T070 L55-4758............ T145 95ZA19............... T041
40168 ................. T168 40265 ................. T265 HB071 ................ T071 L55-4766............ T122 97ZA25............... T067
40169 ................. T169 40266 ................. T266 HB073 ................ T073 L55-4774............ T121 98ZA19............... T078
40170 ................. T170 40267 ................. T267 HB074 ................ T074 L55-4782............ T148 99ZA15............... T037
40171 ................. T171 40269 ................. T269 HB075 ................ T075 L55-4790............ T138 99ZA19............... T039
40172 ................. T172 40271 ................. T271 HB076 ................ T076 L55-4812............ T146
40173 ................. T173 40272 ................. T272 L55-4820............ T159 MCQUAY-NORRIS
HB077 ................ T077
40174 ................. T174 40273 ................. T273 HB078 ................ T078 L55-4839............ T168 Timing Belts
40176 ................. T176 40274 ................. T274 HB079 ................ T079 L55-4847............ T144 TC013 ................ T013
40177 ................. T177 40275 ................. T275 HB081 ................ T081 L55-4855............ T142 TC014 ................ T014
40178 ................. T178 40276 ................. T276 HB082 ................ T082 L55-4863............ T143 TC017 ................ T017
40179 ................. T179 40277 ................. T277 HB083 ................ T083 L55-4880............ T167
40278 ................. T278 L55-4898............ T165 TC018 ................ T018
40180 ................. T180 HB084 ................ T084 TC020 ................ T020
40181 ................. T181 40279 ................. T279 HB087 ................ T087 L55-4901............ T164
40280 ................. T280 L55-4910............ T150 TC028 ................ T028
40182 ................. T182 HB088 ................ T088 TC032 ................ T032
40183 ................. T183 40281 ................. T281 HB089 ................ T089 L55-4928............ T151
40282 ................. T282 L55-4936............ T166 TC036 ................ T036
40184 ................. T184 HB090 ................ T090 TC037 ................ T037
40185 ................. T185 40283 ................. T283 HB091 ................ T091 L55-4944............ T113
40186 ................. T186 40284 ................. T284 L55-4952............ T157 TC039 ................ T039
HB092 ................ T092 TC041 ................ T041
40187 ................. T187 40285 ................. T285 HB093 ................ T093 L55-4960............ T154
40188 ................. T188 40286 ................. T286 L55-4979............ T125 TC042 ................ T068
HB094 ................ T094 TC043 ................ T043
40189 ................. T189 40287 ................. T287 HB095 ................ T095 U55-4359 ........... T069
40190 ................. T190 40288 ................. T288 U55-4367 ........... T018 TC061 ................ T061
HB096 ................ T096 TC062 ................ T062
40191 ................. T191 40289 ................. T289 HB099 ................ T099 U55-4375 ........... T068
40192 ................. T192 40290 ................. T290 U55-4383 ........... T020 TC063 ................ T073
40291 ................. T291 HB100 ................ T100 U55-4405 ........... T017 TC064 ................ T064
40193 ................. T193 HB102 ................ T102
40194 ................. T194 40292 ................. T292 U55-4413 ........... T065 TC065 ................ T065
40293 ................. T293 HB103 ................ T103 U55-4421 ........... T127 TC067 ................ T067
40195 ................. T195 HB104 ................ T104
40196 ................. T196 40294 ................. T294 U55-4430 ........... T083 TC068 ................ T068
40295 ................. T295 HB114 ................ T114 U55-4448 ........... T032 TC069 ................ T069
40197 ................. T197 HB115 ................ T299
40198 ................. T198 40296 ................. T296 U55-4456 ........... T082 TC070 ................ T070
40297 ................. T297 HB116 ................ T300 U55-4464 ........... T043 TC071 ................ T071
40199 ................. T199 HB118 ................ T118
40200 ................. T200 40298 ................. T298 U55-4545 ........... T082 TC074 ................ T074
40299 ................. T299 HB121 ................ T121 U55-4553 ........... T083 TC075 ................ T075
40201 ................. T201 HB122 ................ T122
40202 ................. T248 40300 ................. T300 U55-4561 ........... T293 TC076 ................ T076
40203 ................. T203 40301 ................. T301 HB127 ................ T127 U55-4570 ........... T107 TC077 ................ T077
40204 ................. T204 40302 ................. T302 HB128 ................ T128 U55-4588 ........... T119 TC078 ................ T078
40205 ................. T205 40303 ................. T303 LAZORLITE U55-4871 ........... T292 TC081 ................ T081
40206 ................. T206 40304 ................. T304 TC087 ................ T087
Timing Belts LEMPCO TC088 ................ T088
40207 ................. T207 40305 ................. T305
40208 ................. T208 40306 ................. T306 L55-4014............ T013 Timing Belts TC089 ................ T089
40209 ................. T209 40307 ................. T307 L55-4022............ T062 TB013................. T013 MELLING AUTOMOTIVE
40210 ................. T210 40308 ................. T308 L55-4030............ T064 TB014................. T014
40211 ................. T211 40309 ................. T309 L55-4049............ T028 Timing Belts
TB017................. T017
40212 ................. T212 40310 ................. T310 L55-4057............ T041 TB018................. T018 B0100................. T100
40213 ................. T213 40311 ................. T311 L55-4065............ T041 TB028................. T028 B0101................. T101
40214 ................. T214 40312 ................. T312 L55-4081............ T073 TB037................. T037 B0102................. T102
40215 ................. T215 40313 ................. T313 L55-4103............ T078 TB039................. T039 B0103................. T103
40216 ................. T216 40314 ................. T314 L55-4111............ T077 TB041................. T041 B0104................. T104
40217 ................. T217 40315 ................. T315 L55-4120............ T074 TB063................. T073 B0106................. T106
40218 ................. T218 40316 ................. T316 L55-4138............ T079 TB064................. T064 B0107................. T107
40219 ................. T219 40317 ................. T317 L55-4154............ T088 TB071................. T071 B0108................. T293
40220 ................. T220 40318 ................. T318 L55-4162............ T089 TB112................. T112 B0112................. T176
40221 ................. T221 40319 ................. T319 L55-4170............ T090 B0113................. T113
40222 ................. T222 40320 ................. T320 L55-4189............ T092 LINK-BELT B0114................. T114
40223 ................. T223 40321 ................. T321 L55-4200............ T070 Timing Belts B0115................. T299
40224 ................. T224 40322 ................. T322 L55-4219............ T075 B0116................. T300
40323 ................. T323 B013................... T013
40225 ................. T225 L55-4227............ T076 B014................... T014 B0117................. T117
40226 ................. T226 40324 ................. T324 L55-4235............ T117 B0118................. T162
40325 ................. T325 B037................... T037
40227 ................. T227 L55-4243............ T093 B0119................. T119
40228 ................. T228 Timing Belt Tensioners L55-4251............ T091 LITENS AUTOMOTIVE B0121................. T121
40229 ................. T229 L55-4260............ T095 Timing Belt Tensioners B0122................. T122
40230 ................. T230 48001 ................. T43005 L55-4286............ T104 B0123................. T123
40232 ................. T232 48002 ................. T43002 L55-4294............ T101 979002 ............... T43004 B0124................. T124
40233 ................. T233 48003 ................. T43003 L55-4308............ T084 MBL THREE STARS B0125................. T125
40234 ................. T234 48004 ................. T43008 L55-4316............ T087 B0126................. T126
40235 ................. T235 48005 ................. T43004 L55-4324............ T094 Timing Belts B0127................. T127
40236 ................. T236 48007 ................. T43001 L55-4332............ T099 100ZA19............. T061 B0128................. T128
40237 ................. T237 48008 ................. T43007 L55-4405............ T017 106ZA19............. T077 B0129................. T129
40239 ................. T239 HOOF PRODUCTS L55-4472............ T300 109ZA19............. T088 B013................... T013
40240 ................. T240 L55-4480............ T299 113ZA19............. T065 B0130................. T130
40241 ................. T241 Timing Belts L55-4499............ T112 116ZA19............. T018 B0131................. T131
40242 ................. T242 HB013 ................ T013 L55-4502............ T161 118ZA19............. T069 B0132................. T132
40243 ................. T243 HB014 ................ T014 L55-4510............ T118 120ZA19............. T064 B0133................. T292
40244 ................. T244 HB017 ................ T017 L55-4529............ T104 121ZA19............. T017 B0134................. T134
40245 ................. T245 HB018 ................ T018 L55-4537............ T137 122ZA19............. T013 B0135................. T135
40246 ................. T246 HB020 ................ T020 L55-4596............ T149 123ZA19............. T032 B0136................. T136
40247 ................. T247 HB028 ................ T028 L55-4600............ T141 124ZA25............. T071 B0137................. T137
MELLING AUTOMOTIVE MELLING AUTOMOTIVE MIGHTY - Cont. MOTORCRAFT - Cont. NAPA - Cont.
- Cont. - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont.
Timing Belts - Cont. Timing Belts - Cont.
CD186................ T186 CET257.............. T257 25-90177............ T177
B0138................. T138 B069................... T069 CD187................ T187 CET262.............. T262 25-90178............ T178
B0139................. T139 B070................... T070 CD191................ T191 CET263.............. T263 25-90179............ T179
B014................... T014 B071................... T071 CD20.................. T020 CET264.............. T264 25-90180............ T018
B0140................. T140 B074................... T074 CD208................ T208 CET265.............. T265 25-90181............ T181
B0141................. T141 B075................... T075 CD210................ T210 CET271.............. T271 25-90182............ T182
B0142................. T142 B076................... T076 CD28.................. T028 CET272.............. T272 25-90183............ T183
B0143................. T143 B077................... T077 CD32.................. T032 CET273.............. T273 25-90184............ T184
B0144................. T144 B078................... T078 CD36.................. T036 CET277.............. T277 25-90185............ T185
B0145................. T145 B079................... T079 CD37.................. T037 CET278.............. T278 25-90186............ T186
B0146................. T146 B081................... T081 CD39.................. T039 CET279.............. T279 25-90187............ T187
B0147................. T147 B082................... T082 CD41.................. T041 CET28................ T028 25-90188............ T188
B0148................. T148 B083................... T083 CD42.................. T068 CET280.............. T280 25-90189............ T189
B0149................. T149 B084................... T084 CD43.................. T043 CET281.............. T281 25-90191............ T191
B0150................. T150 B087................... T087 CD61.................. T061 CET282.............. T282 25-90192............ T192
B0151................. T151 B088................... T088 CD62.................. T062 CET284.............. T284 25-90193............ T193
B0152................. T152 B089................... T089 CD63.................. T073 CET285.............. T285 25-90194............ T194
B0153................. T153 B090................... T090 CD64.................. T064 CET286.............. T286 25-90195............ T195
B0154................. T154 B091................... T091 CD65.................. T065 CET287.............. T287 25-90196............ T196
B0155................. T155 B092................... T092 CD67.................. T067 CET288.............. T288 25-90197............ T197
B0157................. T157 B093................... T093 CD69.................. T069 CET289.............. T289 25-90198............ T198
B0158................. T158 B094................... T094 CD70.................. T070 CET290.............. T290 25-90199............ T199
B0159................. T159 B095................... T095 CD71.................. T071 CET291.............. T291 25-90200............ T020
B0160................. T160 B096................... T096 CD74.................. T074 CET37................ T037 25-90201............ T201
B0161................. T161 B097................... T097 CD75.................. T075 CET39................ T039 25-90202............ T248
B0162................. T162 B098................... T098 CD76.................. T076 CET41................ T041 25-90203............ T203
B0163................. T163 B099................... T099 CD77.................. T077 CET61................ T061 25-90204............ T204
B0164................. T164 CD78.................. T078 CET67................ T067 25-90205............ T205
B0165................. T165 MIGHTY CD79.................. T079 CET70................ T070 25-90206............ T206
B0166................. T166 Timing Belts CD81.................. T081 CET71................ T071 25-90207............ T207
B0167................. T167 CD100................ T100 CD82.................. T082 CET94................ T094 25-90208............ T208
B0168................. T168 CD83.................. T083 25-90209............ T209
B0169................. T169 CD101................ T101 MOTORCRAFT CANADA 25-90210............ T039
CD102................ T102 CD84.................. T084
B017................... T017 CD87.................. T087 Timing Belts 25-90211............ T211
B0170................. T170 CD103................ T103 25-90212............ T212
CD104................ T104 CD88.................. T088 CET13................ T013
B0171................. T171 CD89.................. T089 25-90213............ T213
B0172................. T172 CD111................ T140 CET135.............. T135 25-90214............ T214
CD112................ T176 CD90.................. T090 CET14................ T014
B0174................. T174 CD91.................. T091 25-90215............ T215
B0176................. T176 CD113................ T113 CET17................ T017 25-90216............ T216
CD114................ T114 CD92.................. T092 CET207.............. T207
B0177................. T177 CD93.................. T093 25-90217............ T217
B0178................. T178 CD115................ T299 CD94.................. T094 CET230.............. T230 25-90218............ T218
B0179................. T179 CD116................ T300 CD95.................. T095 CET257.............. T257 25-90219............ T219
B018................... T018 CD117................ T117 CD99.................. T099 CET262.............. T262 25-90220............ T062
B0180................. T180 CD118................ T118 CET263.............. T263 25-90221............ T221
B0181................. T181 CD119................ T119 MITSUBOSHI CET264.............. T264 25-90222............ T222
B0182................. T182 CD121................ T121 Timing Belts CET265.............. T265 25-90223............ T223
B0183................. T183 CD122................ T122 CET271.............. T271 25-90224............ T224
CD123................ T123 106ZA19............. T077 CET272.............. T272
B0184................. T184 111ZA19............. T121 25-90225............ T225
B0185................. T185 CD124................ T124 CET273.............. T273 25-90226............ T226
CD125................ T125 116ZA19............. T018 CET277.............. T277
B0186................. T186 120ZA19............. T064 25-90227............ T227
B0187................. T187 CD126................ T126 CET278.............. T278 25-90228............ T228
CD127................ T127 122ZA19............. T013 CET279.............. T279
B0189................. T189 123ZA19............. T032 25-90229............ T229
B0191................. T191 CD128................ T128 CET28................ T028 25-90232............ T232
CD129................ T129 127ZA25............. T079 CET280.............. T280
B0192................. T192 129ZA22............. T014 25-90233............ T233
B0193................. T193 CD13.................. T013 CET281.............. T281 25-90234............ T234
CD130................ T130 134ZB30............. T076 CET282.............. T282
B0194................. T194 139ZA25............. T087 25-90235............ T235
B0195................. T195 CD131................ T131 CET284.............. T284 25-90236............ T236
CD132................ T132 146ZA19............. T020 CET285.............. T285
B0199................. T199 148ZA19............. T068 25-90237............ T237
B020................... T020 CD133................ T292 CET286.............. T286 25-90239............ T239
CD134................ T134 55ZA13............... T062 CET287.............. T287
B0202................. T248 55ZB13............... T090 25-90250............ T028
B0203................. T203 CD135................ T135 CET288.............. T288 25-90260............ T061
CD136................ T136 83ZB19............... T092 CET289.............. T289
B0204................. T204 84ZA19............... T028 25-90270............ T064
B0205................. T205 CD137................ T137 CET290.............. T290 25-90280............ T065
87ZB34............... T075 CET291.............. T291
B0208................. T208 CD138................ T138 88ZA19............... T070 25-90290............ T073
B0210................. T210 CD139................ T139 CET37................ T037 25-90310............ T069
89ZA19............... T095 CET39................ T039
B0216................. T216 CD14.................. T014 92ZA19............... T073 25-90320............ T036
B0219................. T219 CD141................ T141 CET41................ T041 25-90330............ T070
94ZA19............... T036 CET61................ T061
B0223................. T223 CD142................ T142 95ZA19............... T041 25-90340............ T068
B0224................. T224 CD143................ T143 CET67................ T067 25-90350............ T071
98ZA19............... T078 CET70................ T070
B0226................. T226 CD144................ T144 25-90360............ T067
B0228................. T228 CD145................ T145 MOPAR CET71................ T071 25-90370............ T037
B0229................. T229 CD146................ T146 CET94................ T094 25-90380............ T076
Timing Belts
B0230................. T230 CD147................ T147 NAPA 25-90390............ T075
B0232................. T232 CD148................ T148 BTC-13............... T013 25-90400............ T078
B0233................. T233 CD153................ T153 BTC-14............... T014 Timing Belts 25-90410............ T077
B0237................. T237 CD154................ T154 BTC-37............... T037 25-90073............ T073 25-90420............ T043
B0239................. T239 CD155................ T155 BTC-39............... T020 25-90096............ T096 25-90430............ T074
B028................... T028 CD157................ T157 B0040013........... T013 25-90097............ T097 25-90440............ T081
B029................... T104 CD158................ T158 B0040017........... T017 25-90130............ T013 25-90450............ T088
B032................... T032 CD159................ T159 B0040062........... T062 25-90140............ T014 25-90460............ T087
B036................... T036 CD160................ T160 B0040063........... T073 25-90150............ T032 25-90470............ T093
B037................... T037 CD161................ T161 B0040064........... T064 25-90160............ T041 25-90480............ T094
B039................... T039 CD162................ T162 B0040071........... T071 25-90166............ T166 25-90490............ T104
B041................... T041 CD163................ T163 MOTORCRAFT 25-90167............ T167 25-90510............ T100
B042................... T068 CD164................ T164 25-90168............ T168 25-90520............ T084
B043................... T043 CD165................ T165 Timing Belts 25-90169............ T169 25-90530............ T099
B061................... T061 CD166................ T166 CET13................ T013 25-90170............ T017 25-90540............ T098
B062................... T062 CD167................ T167 CET135.............. T135 25-90171............ T171 25-90550............ T082
B063................... T073 CD17.................. T017 CET14................ T014 25-90172............ T172 25-90560............ T083
B064................... T064 CD176................ T176 CET17................ T017 25-90173............ T173 25-90570............ T095
B065................... T065 CD18.................. T018 CET207.............. T207 25-90174............ T174 25-90590............ T112
B067................... T067 CD185................ T185 CET230.............. T230 25-90176............ T176 25-90600............ T089
NAPA - Cont. NAPA - Cont. NAPA - Cont. NAPA - Cont. PAREX TRANS. PARTS
Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. - Cont.
Timing Belts - Cont.
25-90610............ T118 250074 ............... T074 250174 ............... T174 250272 ............... T272
25-90620............ T079 250075 ............... T075 250176 ............... T176 250273 ............... T273 087 ..................... T087
25-90630............ T122 250076 ............... T076 250177 ............... T177 250274 ............... T274 088 ..................... T088
25-90640............ T121 250077 ............... T077 250178 ............... T178 250275 ............... T275 093 ..................... T093
25-90650............ T127 250078 ............... T078 250179 ............... T179 250276 ............... T276 094 ..................... T094
25-90670............ T101 250079 ............... T079 250180 ............... T180 250277 ............... T277 095 ..................... T095
25-90680............ T125 250081 ............... T081 250181 ............... T181 250278 ............... T278 099 ..................... T099
25-90690............ T126 250082 ............... T082 250182 ............... T182 250279 ............... T279 104 ..................... T104
25-90700............ T130 250083 ............... T083 250183 ............... T183 250280 ............... T280 PEP BOYS (See DAYCO)
25-90710............ T129 250084 ............... T084 250184 ............... T184 250281 ............... T281
25-90720............ T106 250087 ............... T087 250185 ............... T185 250282 ............... T282 PERFECT CIRCLE
25-90730............ T114 250088 ............... T088 250186 ............... T186 250283 ............... T283 Timing Belts
25-90740............ T300 250089 ............... T089 250187 ............... T187 250284 ............... T284
25-90750............ T299 250090 ............... T090 250188 ............... T188 250285 ............... T285 9-100.................. T100
25-90760............ T091 250091 ............... T091 250189 ............... T189 250286 ............... T286 9-101.................. T101
25-90770............ T092 250092 ............... T092 250190 ............... T190 250287 ............... T287 9-102.................. T102
25-90780............ T117 250093 ............... T093 250191 ............... T191 250288 ............... T288 9-103.................. T103
25-90790............ T119 250094 ............... T094 250192 ............... T192 250289 ............... T289 9-104.................. T104
25-90800............ T292 250095 ............... T095 250193 ............... T193 250290 ............... T290 9-13.................... T013
25-90810............ T134 250096 ............... T096 250194 ............... T194 250291 ............... T291 9-14.................... T014
25-90820............ T135 250097 ............... T097 250195 ............... T195 250292 ............... T292 9-17.................... T017
25-90830............ T136 250098 ............... T098 250196 ............... T196 250293 ............... T293 9-18.................... T018
25-90840............ T137 250099 ............... T099 250197 ............... T197 250294 ............... T294 9-20.................... T020
25-90850............ T138 250100 ............... T100 250198 ............... T198 250295 ............... T295 9-28.................... T028
25-90860............ T139 250101 ............... T101 250199 ............... T199 250296 ............... T296 9-32.................... T032
25-90870............ T140 250102 ............... T102 250200 ............... T200 250297 ............... T297 9-36.................... T036
25-90880............ T131 250103 ............... T103 250201 ............... T201 250298 ............... T298 9-37.................... T037
25-90890............ T141 250104 ............... T104 250202 ............... T248 250299 ............... T299 9-39.................... T039
25-90900............ T123 250106 ............... T106 250203 ............... T203 250300 ............... T300 9-41.................... T041
25-90910............ T090 250107 ............... T107 250204 ............... T204 250301 ............... T301 9-43.................... T043
25-90920............ T293 250108 ............... T293 250205 ............... T205 250302 ............... T302 9-61.................... T061
25-90930............ T196 250112 ............... T112 250206 ............... T206 250303 ............... T303 9-62.................... T062
25-90940............ T113 250113 ............... T113 250207 ............... T207 250304 ............... T304 9-63.................... T073
25-90950............ T132 250114 ............... T114 250208 ............... T208 250305 ............... T305 9-64.................... T064
25-90960............ T142 250115 ............... T299 250209 ............... T209 250306 ............... T306 9-65.................... T065
25-90970............ T143 250116 ............... T300 250210 ............... T210 250307 ............... T307 9-67.................... T067
25-90980............ T144 250117 ............... T117 250211 ............... T211 250308 ............... T308 9-69.................... T069
25-90990............ T145 250118 ............... T118 250212 ............... T212 250309 ............... T309 9-70.................... T070
25-91000............ T146 250119 ............... T119 250213 ............... T213 250310 ............... T310 9-71.................... T071
25-91001............ T147 250120 ............... T120 250214 ............... T214 250311 ............... T311 9-74.................... T074
25-91002............ T148 250121 ............... T121 250215 ............... T215 250312 ............... T312 9-75.................... T075
25-91003............ T149 250122 ............... T122 250216 ............... T216 250313 ............... T313 9-76.................... T076
25-91004............ T150 250123 ............... T123 250217 ............... T217 250314 ............... T314 9-77.................... T077
25-91005............ T151 250124 ............... T124 250218 ............... T218 250315 ............... T315 9-78.................... T078
25-91006............ T152 250125 ............... T125 250219 ............... T219 250316 ............... T316 9-79.................... T079
25-91007............ T102 250126 ............... T126 250220 ............... T220 250317 ............... T317 9-81.................... T081
25-91008............ T103 250127 ............... T127 250221 ............... T221 250318 ............... T318 9-84.................... T084
25-91009............ T107 250128 ............... T128 250222 ............... T222 250319 ............... T319 9-87.................... T087
25-91010............ T124 250129 ............... T129 250223 ............... T223 250320 ............... T320 9-88.................... T088
25-91011............ T154 250130 ............... T130 250224 ............... T224 250321 ............... T321 9-89.................... T089
25-91012............ T155 250131 ............... T131 250225 ............... T225 250322 ............... T322 9-90.................... T090
25-91014............ T157 250132 ............... T132 250226 ............... T226 250323 ............... T323 9-91.................... T091
25-91015............ T158 250133 ............... T292 250227 ............... T227 250324 ............... T324 9-92.................... T092
25-91016............ T159 250134 ............... T134 250228 ............... T228 250325 ............... T325 9-93.................... T093
25-91017............ T160 250135 ............... T135 250229 ............... T229 250326 ............... T326 9-94.................... T094
25-91018............ T161 250136 ............... T136 250230 ............... T230 250327 ............... T327 9-96.................... T096
25-91019............ T162 250137 ............... T137 250232 ............... T232 250329 ............... T329 9-98.................... T098
25-91020............ T163 250138 ............... T138 250233 ............... T233 9-99.................... T099
Timing Belt Tensioners
25-91021............ T164 250139 ............... T139 250234 ............... T234 PERFECTION AM
25-91022............ T165 250140 ............... T140 250235 ............... T235 T43001............... T43001
25-91023............ T153 250141 ............... T141 250236 ............... T236 T43002............... T43002 Timing Belts
25-91120............ T120 250142 ............... T142 250237 ............... T237 T43003............... T43003 B0101................. T101
25-91170............ T170 250143 ............... T143 250239 ............... T239 T43004............... T43004 B0102................. T102
25-91180............ T180 250144 ............... T144 250240 ............... T240 T43005............... T43005 B0103................. T103
25-91190............ T190 250145 ............... T145 250241 ............... T241 T43006............... T43006 B0104................. T104
25-91200............ T200 250146 ............... T146 250242 ............... T242 T43007............... T43007 B0114................. T114
25-91210............ T210 250147 ............... T147 250243 ............... T243 T43008............... T43008 B0118................. T162
25-91220............ T220 250148 ............... T148 250244 ............... T244 T43010............... T43010 B013................... T013
25-91230............ T230 250149 ............... T149 250245 ............... T245 PAREX TRANS. PARTS B014................... T014
25-91240............ T240 250150 ............... T150 250246 ............... T246 B017................... T017
250013 ............... T013 250151 ............... T151 250247 ............... T247 Timing Belts B018................... T018
250014 ............... T014 250152 ............... T152 250248 ............... T248 013 ..................... T013 B020................... T020
250017 ............... T017 250153 ............... T153 250249 ............... T249 018 ..................... T018 B028................... T028
250018 ............... T018 250154 ............... T154 250251 ............... T251 020 ..................... T020 B032................... T032
250020 ............... T020 250155 ............... T155 250252 ............... T252 028 ..................... T028 B036................... T036
250028 ............... T028 250157 ............... T157 250253 ............... T253 032 ..................... T032 B037................... T037
250032 ............... T032 250158 ............... T158 250254 ............... T254 037 ..................... T037 B039................... T039
250036 ............... T036 250159 ............... T159 250255 ............... T255 041 ..................... T041 B041................... T041
250037 ............... T037 250160 ............... T160 250256 ............... T256 043 ..................... T043 B043................... T043
250039 ............... T039 250161 ............... T161 250257 ............... T257 062 ..................... T062 B061................... T061
250041 ............... T041 250162 ............... T162 250258 ............... T258 065 ..................... T065 B062................... T062
250043 ............... T043 250163 ............... T163 250259 ............... T259 067 ..................... T067 B063................... T073
250061 ............... T061 250164 ............... T164 250260 ............... T260 068 ..................... T068 B064................... T064
250062 ............... T062 250165 ............... T165 250262 ............... T262 069 ..................... T069 B065................... T065
250064 ............... T064 250166 ............... T166 250263 ............... T263 070 ..................... T070 B067................... T067
250065 ............... T065 250167 ............... T167 250264 ............... T264 071 ..................... T071 B069................... T069
250067 ............... T067 250168 ............... T168 250265 ............... T265 074 ..................... T074 B070................... T070
250068 ............... T068 250169 ............... T169 250266 ............... T266 075 ..................... T075 B071................... T071
250069 ............... T069 250170 ............... T170 250267 ............... T267 076 ..................... T076 B074................... T074
250070 ............... T070 250171 ............... T171 250269 ............... T269 077 ..................... T077 B075................... T075
250071 ............... T071 250172 ............... T172 250270 ............... T270 078 ..................... T078 B076................... T076
250073 ............... T073 250173 ............... T173 250271 ............... T271 081 ..................... T081 B077................... T077
PERFECTION AM - Cont. PIRELLI - Cont. PIRELLI - Cont. PROVEN VALU - Cont. REPUBLIC
Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belts
B078................... T078 TB134................. T134 88075 ................. T075 TB-079 ............... T079 R0112................. T176
B081................... T081 TB135................. T135 88076 ................. T076 TB-081 ............... T081 R0113................. T113
B082................... T082 TB136................. T233 88077 ................. T077 R0114................. T114
TB-082 ............... T082 R0115................. T299
B083................... T083 TB138................. T199 88078 ................. T078 TB-083 ............... T083
B087................... T087 TB139................. T139 88081 ................. T081 R0116................. T300
TB-084 ............... T084 R0117................. T117
B088................... T088 TB141................. T141 88082 ................. T082 TB-087 ............... T087
B089................... T089 TB142................. T142 88083 ................. T083 R0118................. T162
TB-088 ............... T088 R0119................. T119
B090................... T090 TB143................. T143 88087 ................. T087 TB-089 ............... T089
B093................... T093 TB144................. T144 88088 ................. T088 R0122................. T122
B094................... T094 TB145................. T145 88089 ................. T158 TB-090 ............... T090 R0124................. T124
B095................... T095 TB146................. T146 88090 ................. T159 TB-091 ............... T091 R0125................. T125
B099................... T099 TB147................. T147 88093 ................. T093 TB-092 ............... T092 R0126................. T126
013 ..................... T013 TB148................. T148 88094 ................. T160 TB-093 ............... T093 R0127................. T127
014 ..................... T014 TB153................. T153 88095 ................. T095 TB-094 ............... T094 R0128................. T128
017 ..................... T017 TB154................. T154 88099 ................. T161 TB-095 ............... T095 R0129................. T129
018 ..................... T020 TB155................. T155 88101 ................. T101 TB-096 ............... T096 R0130................. T130
037 ..................... T037 TB157................. T157 88102 ................. T102 TB-098 ............... T098 R0132................. T132
039 ..................... T039 TB158................. T158 88104 ................. T104 TB-099 ............... T099 R0133................. T292
TB159................. T159 88112 ................. T176 TB-100 ............... T100 R0134................. T134
PETRO-CANADA TB-101 ............... T101 R0135................. T135
TB160................. T160 88113 ................. T113
Timing Belts TB161................. T161 88114 ................. T114 TB-102 ............... T102 R0136................. T233
TB162................. T162 88115 ................. T299 TB-103 ............... T103 R0138................. T138
742-P014............ T014 R0139................. T139
742-P017............ T017 TB163................. T163 88116 ................. T300 TB-104 ............... T104
TB164................. T164 88117 ................. T117 TB-112 ............... T112 R0141................. T141
742-P028............ T028 R0142................. T142
742-P061............ T061 TB165................. T165 88118 ................. T162 TB-113 ............... T113
TB166................. T166 88122 ................. T122 R0143................. T143
742-P067............ T067 TB-114 ............... T114 R0144................. T144
742-P071............ T071 TB167................. T167 88124 ................. T124 TB-115 ............... T299
TB168................. T168 88125 ................. T125 R0145................. T145
PIRELLI TB-116 ............... T300 R0146................. T146
TB169................. T169 88126 ................. T237 TB-117 ............... T117
TB170................. T170 88130 ................. T130 R0147................. T147
Timing Belts TB-118 ............... T118 R0148................. T148
TB172................. T254 88131 ................. T131
TB013................. T013 TB176................. T176 TB-119 ............... T119 R0153................. T153
TB014................. T014 88132 ................. T132 TB-121 ............... T121 R0154................. T154
TB177................. T177 88134 ................. T134
TB017................. T017 TB179................. T179 TB-122 ............... T122 R0157................. T157
TB018................. T018 88136 ................. T233 TB-123 ............... T123 R0158................. T158
TB180................. T180 88138 ................. T199
TB020................. T020 TB183................. T183 TB-125 ............... T125 R0159................. T159
TB028................. T028 88141 ................. T141 R0160................. T160
TB184................. T184 88143 ................. T143 TB-126 ............... T126
TB032................. T032 TB185................. T185 TB-127 ............... T127 R0161................. T161
TB036................. T036 88144 ................. T144 R0162................. T162
TB186................. T186 88146 ................. T146 TB-128 ............... T128
TB037................. T037 TB187................. T187 TB-129 ............... T129 R0163................. T163
TB039................. T039 88153 ................. T153 R0164................. T164
TB190................. T190 88157 ................. T157 TB-130 ............... T130
TB041................. T041 TB191................. T191 TB-134 ............... T134 R0166................. T166
TB042................. T068 88158 ................. T158 R0167................. T167
TB192................. T192 88159 ................. T159 TB-139 ............... T139
TB043................. T043 TB193................. T193 R0168................. T168
TB061................. T061 88160 ................. T160 REPCOPARTS R0169................. T169
TB194................. T194 88161 ................. T161
TB062................. T062 TB199................. T199 Timing Belts R0170................. T170
88162 ................. T162 R0176................. T176
TB063................. T073 TB201................. T201 88163 ................. T163
TB064................. T064 TB202................. T248 4013 ................... T013 R0177................. T177
88165 ................. T165 4014 ................... T014 R0179................. T179
TB065................. T065 TB205................. T205 88170 ................. T170
TB067................. T067 TB210................. T210 4017 ................... T017 R0184................. T184
TB069................. T069 80013 ................. T013 PRO-1 4018 ................... T018 R0185................. T185
TB070................. T070 80014 ................. T014 4020 ................... T020 R0186................. T186
Timing Belts R0187................. T187
TB071................. T071 80017 ................. T017 4028 ................... T028
TB074................. T074 80018 ................. T018 013 ..................... T013 4029 ................... T104 R082................... T082
TB075................. T075 80020 ................. T020 014 ..................... T014 4032 ................... T032 R083................... T083
TB076................. T076 80028 ................. T028 017 ..................... T017 4036 ................... T036 REPUBLIC PARTS
TB077................. T077 80032 ................. T032 037 ..................... T037 4037 ................... T037
TB078................. T078 80037 ................. T037 039 ..................... T039 Timing Belts
061 ..................... T061 4039 ................... T039
TB081................. T081 80039 ................. T039 4041 ................... T041 R-0100 ............... T100
TB082................. T082 80041 ................. T041 067 ..................... T067 R-0101 ............... T101
081 ..................... T081 4042 ................... T068
TB083................. T083 80042 ................. T068 4043 ................... T043 R-0102 ............... T102
TB087................. T087 80043 ................. T043 PROVEN VALU 4061 ................... T061 R-0103 ............... T103
TB088................. T088 80061 ................. T061 R-0104 ............... T104
TB089................. T158 80062 ................. T062 Timing Belts 4065 ................... T065 R-0112 ............... T112
TB090................. T159 80064 ................. T064 TB-013 ............... T013 4070 ................... T070 R-013 ................. T013
TB093................. T093 80065 ................. T065 TB-014 ............... T014 4071 ................... T071 R-014 ................. T014
TB094................. T160 80067 ................. T067 TB-017 ............... T017 4073 ................... T073 R-017 ................. T017
TB095................. T095 80069 ................. T069 TB-018 ............... T018 4074 ................... T074 R-018 ................. T018
TB099................. T161 80070 ................. T070 TB-020 ............... T020 4077 ................... T077 R-020 ................. T020
TB101................. T101 80071 ................. T071 TB-028 ............... T028 4078 ................... T078 R-028 ................. T028
TB102................. T102 88013 ................. T013 TB-032 ............... T032 4079 ................... T079 R-032 ................. T032
TB103................. T103 88014 ................. T014 TB-036 ............... T036 4081 ................... T081 R-036 ................. T036
TB104................. T104 88017 ................. T017 TB-037 ............... T037 4082 ................... T082 R-037 ................. T037
TB112................. T176 88018 ................. T018 TB-039 ............... T039 4083 ................... T083 R-039 ................. T039
TB113................. T113 88020 ................. T020 TB-041 ............... T041 4084 ................... T084 R-041 ................. T041
TB114................. T114 88028 ................. T028 TB-043 ............... T043 4089 ................... T089 R-042 ................. T068
TB115................. T299 88032 ................. T032 TB-061 ............... T061 4091 ................... T091 R-043 ................. T043
TB116................. T300 88037 ................. T037 TB-062 ............... T062 4092 ................... T092 R-061 ................. T061
TB117................. T117 88039 ................. T039 TB-063 ............... T073 4093 ................... T093 R-062 ................. T062
TB118................. T162 88041 ................. T041 TB-064 ............... T064 4094 ................... T094 R-063 ................. T073
TB119................. T119 88042 ................. T068 TB-065 ............... T065 R-064 ................. T064
TB122................. T122 88043 ................. T043 TB-067 ............... T067 4095 ................... T095 R-065 ................. T065
TB124................. T124 88061 ................. T061 TB-068 ............... T068 4096 ................... T096 R-067 ................. T067
TB125................. T125 88062 ................. T062 TB-069 ............... T069 4097 ................... T097 R-068 ................. T068
TB126................. T237 88063 ................. T073 TB-070 ............... T070 4098 ................... T098 R-069 ................. T069
TB127................. T127 88064 ................. T064 TB-071 ............... T071 4099 ................... T099 R-070 ................. T070
TB128................. T128 88065 ................. T065 TB-073 ............... T073 4100 ................... T100 R-071 ................. T071
TB129................. T129 88067 ................. T067 TB-074 ............... T074 4101 ................... T101 R-073 ................. T073
TB130................. T130 88069 ................. T069 TB-075 ............... T075 4102 ................... T102 R-074 ................. T074
TB131................. T131 88070 ................. T070 TB-076 ............... T076 4103 ................... T103 R-075 ................. T075
TB132................. T132 88071 ................. T071 TB-077 ............... T077 4104 ................... T104 R-076 ................. T075
TB133................. T292 88074 ................. T074 TB-078 ............... T078 4106 ................... T106 R-077 ................. T077
REPUBLIC PARTS - Cont. SEALED POWER - Cont. SEALED POWER - Cont. SKF - Cont. SUNOCO - Cont.
Timing Belts - Cont. Timing Belts - Cont. Timing Belts - Cont. Timing Belt Tensioners Timing Belts - Cont.
- Cont.
R-078 ................. T078 222-65................ T065 222115 ............... T299 T1071................. T071
R-079 ................. T079 222-67................ T067 222116 ............... T300 VKM74005 ......... T41036 T1081................. T081
R-081 ................. T081 222-69................ T069 222117 ............... T117 VKM74007 ......... T41033 T.R.W.
R-084 ................. T084 222-70................ T070 222118 ............... T162 VKM74200 ......... T41030
R-087 ................. T087 222-71................ T071 222119 ............... T119 VKM74201 ......... T41031 Timing Belts
R-088 ................. T088 222-73................ T073 222122 ............... T122 VKM74600 ......... T41029 LB042................. T068
R-089 ................. T089 222-74................ T074 222124 ............... T124 VKM75000 ......... T41039 LB074................. T074
R-090 ................. T090 222-75................ T075 222125 ............... T125 VKM75001 ......... T41051 LB075................. T075
R-091 ................. T091 222-76................ T076 222126 ............... T237 VKM75002 ......... T41052 LB077................. T077
R-092 ................. T092 222-77................ T077 222128 ............... T128 VKM75004 ......... T41048 LB078................. T078
R-093 ................. T093 222-78................ T078 222129 ............... T129 VKM75006 ......... T41037 LB079................. T079
R-094 ................. T094 222-81................ T081 222130 ............... T130 VKM75008 ......... T41045 LB081................. T081
R-095 ................. T095 222-87................ T087 222131 ............... T131 VKM75033 ......... T41044 LB082................. T082
R-096 ................. T096 222-88................ T088 222132 ............... T132 VKM75044 ......... T41047 LB083................. T083
R-098 ................. T098 222-89................ T089 222133 ............... T292 VKM75064 ......... T41054 LB084................. T084
R-099 ................. T099 222-90................ T090 222134 ............... T134 VKM75100 ......... T41042 LB087................. T087
222-91................ T091 222135 ............... T135 VKM75101 ......... T41055 LB088................. T088
ROCKHILL VKM75108 ......... T41056
222-92................ T092 222136 ............... T233 LB090................. T090
Timing Belts 222-93................ T093 222138 ............... T199 VKM75113 ......... T41053 LB091................. T091
TB-100 ............... T100 222-94................ T094 222139 ............... T139 VKM75119 ......... T41057 LB092................. T092
TB-101 ............... T101 222-95................ T095 222141 ............... T141 VKM75130 ......... T41043 LB093................. T093
TB-102 ............... T102 222-99................ T161 222142 ............... T142 VKM75144 ......... T41046 LB094................. T094
TB-103 ............... T103 222B160............. T160 222143 ............... T143 VKM75601 ......... T41050 LB095................. T095
TB-104 ............... T104 222B161............. T161 222144 ............... T144 VKM75612 ......... T41049 LB100................. T100
TB-112 ............... T176 222B162............. T162 222145 ............... T145 VKM75613 ......... T41038 LB101................. T101
222B163............. T163 222146 ............... T146 VKM76001 ......... T41065
TB-118 ............... T118 VKM76200 ......... T41010 LB102................. T102
TB-13 ................. T013 222B164............. T164 222147 ............... T147 LB103................. T103
222B165............. T165 222148 ............... T148 VKM76202 ......... T41064
TB-14 ................. T014 VKM76203 ......... T41009 LB104................. T104
TB-17 ................. T017 222B166............. T166 222152 ............... T152 LB112................. T112
222B167............. T167 222153 ............... T153 VKM77300 ......... T41003
TB-18 ................. T018 VKM77500 ......... T41004 LB113................. T113
TB-20 ................. T020 222B168............. T168 222154 ............... T154 LB114................. T114
222B169............. T169 222155 ............... T155 VKM78000 ......... T41063
TB-28 ................. T028 222B170............. T170 VKM78001 ......... T41062 LB115................. T299
TB-32 ................. T032 222157 ............... T157 LB116................. T300
222B172............. T254 222158 ............... T158 VKM78002 ......... T41061
TB-36 ................. T036 222B177............. T177 VKM78003 ......... T41092 LB117................. T117
TB-37 ................. T037 222159 ............... T159 LB118................. T162
222B179............. T179 VKM78105 ......... T41060
TB-39 ................. T039 222B180............. T180 SIERRA VKM79000 ......... T41026 LB119................. T119
TB-41 ................. T041 222B183............. T183 VKM79001 ......... T41025 LB121................. T121
TB-43 ................. T043 Timing Belts LB122................. T122
222B184............. T184 VKM79007 ......... T41028
TB-61 ................. T061 222B185............. T185 18-4029.............. T032 LB123................. T123
TB-62 ................. T062 Timing Belt Pulleys LB124................. T124
222B186............. T186 SKF
TB-63 ................. T073 222B187............. T187 VKM64001 ......... T42032 LB125................. T125
TB-64 ................. T064 Timing Belt Tensioners VKM64002 ......... T42033 LB126................. T237
222B193............. T193
TB-65 ................. T065 222B194............. T194 VKM11000 ......... T41079 VKM64003 ......... T42034 LB128................. T128
TB-67 ................. T067 222B202............. T248 VKM11010 ......... T41080 VKM64004 ......... T42035 LB129................. T129
TB-68 ................. T068 222B210............. T210 VKM11113 ......... T43010 VKM64005 ......... T42036 LB13................... T013
TB-69 ................. T069 222013 ............... T013 VKM16300 ......... T41081 VKM81000 ......... T42030 LB130................. T130
TB-77 ................. T077 222036 ............... T036 VKM54003 ......... T43003 VKM81400 ......... T42029 LB14................... T014
SEALED POWER 222078 ............... T078 VKM72000 ......... T41058 VKM88000 ......... T42023 LB164................. T164
222082 ............... T082 VKM72004 ......... T41059 VKM88001 ......... T42024 LB165................. T165
Timing Belts 222083 ............... T083 VKM72200 ......... T41088 VKM88002 ......... T42022 LB166................. T166
222-100.............. T100 222087 ............... T087 VKM72300 ......... T41089 VKM89000 ......... T42002 LB167................. T167
222-13................ T013 222088 ............... T088 VKM73000 ......... T41011 SUNOCO LB168................. T168
222-14................ T014 222089 ............... T158 VKM73001 ......... T41015 LB169................. T169
222-17................ T017 222090 ............... T159 VKM73002 ......... T41019 Timing Belts LB17................... T017
222-18................ T018 222093 ............... T093 VKM73003 ......... T41018 TB063................. T073 LB18................... T018
222-20................ T020 222094 ............... T160 VKM73004 ......... T41021 TB070................. T070 LB20................... T020
222-28................ T028 222095 ............... T095 VKM73005 ......... T41023 TB077................. T077 LB28................... T028
222-32................ T032 222099 ............... T161 VKM73006 ......... T41024 TB401................. T014 LB32................... T032
222-36................ T036 222101 ............... T101 VKM73007 ......... T41022 TB402................. T013 LB36................... T036
222-37................ T037 222102 ............... T102 VKM73011 ......... T41013 TB403................. T037 LB37................... T037
222-39................ T039 222103 ............... T103 VKM73101 ......... T41017 TB404................. T017 LB39................... T039
222-41................ T041 222104 ............... T104 VKM73200 ......... T41012 TB409................. T039 LB41................... T041
222-42................ T068 222107 ............... T107 VKM73201 ......... T41016 TB411................. T041 LB43................... T043
222-43................ T043 222108 ............... T293 VKM73600 ......... T41014 TB415................. T028 LB61................... T061
222-61................ T061 222110 ............... T196 VKM73605 ......... T41090 TB418................. T061 LB62................... T062
222-62................ T062 222112 ............... T176 VKM74000 ......... T41034 TB428................. T067 LB63................... T073
222-63................ T073 222113 ............... T113 VKM74001 ......... T41035 T1043................. T043 LB64................... T064
222-64................ T064 222114 ............... T114 VKM74002 ......... T41091 T1064................. T064 LB65................... T065
T.R.W. - Cont. ULTRALAST - Cont. UNIROYAL - Cont. VERA - Cont. WOLVERINE - Cont.
LB67................... T067 B145................... T145 A416L075R ........ T081 45-01283............ T088 TB063................. T073
LB68................... T068 B146................... T146 A423L075........... T065 45-01291............ T087 TB064................. T064
LB69................... T069 B147................... T147 A435L075........... T018 45-01325............ T104 TB067................. T067
LB70................... T070 B148................... T148 A442L075........... T069 45-01341............ T099 TB069................. T069
LB71................... T071 B153................... T153 A443L075........... T069 45-01366............ T094 TB070................. T070
LB73................... T073 B154................... T154 A450L075........... T064 45-01382............ T093 TB071................. T071
LB74................... T074 B155................... T155 A450L075S ........ T093 45-01408............ T062 TB073................. T073
LB75................... T075 B157................... T157 A453L075........... T017 45-01424............ T100 TB077................. T077
LB76................... T076 B158................... T158 A457L075........... T013 45-01440............ T103 TB078................. T078
LB77................... T077 B159................... T159 A457L075S ........ T158 45-01481............ T090 TB081................. T081
LB78................... T078 B160................... T160 A461L075........... T032 45-01499............ T092 TB095................. T095
LB79................... T079 B161................... T161 A465L100........... T071 45-01580............ T127 WORLD PARTS
LB81................... T081 B162................... T162 A483L087........... T014 45-01614............ T293
LB82................... T082 B163................... T163 A484L088........... T014 45-01622............ T292 Timing Belts
LB83................... T083 B164................... T164 A502L118B ........ T076 45-01630............ T118 W11-600............. T018
LB84................... T084 B166................... T166 A506L100B ........ T043 45-01648............ T095 W11-601............. T020
LB87................... T087 B167................... T167 A521L100........... T087 45-01655............ T137 W11-631............. T075
LB88................... T088 B168................... T168 A532L100........... T074 45-01663............ T300 W11-636............. T013
LB89................... T158 B172................... T172 A547L075........... T020 45-01671............ T299 W11-639............. T013
LB90................... T159 B177................... T177 A555L075........... T068 45-01689............ T131 W11-640............. T076
LB91................... T091 B179................... T179 UNOCAL 45-01697............ T135 W11-643............. T017
LB92................... T092 B184................... T184 45-01705............ T136 W11-645............. T020
LB93................... T093 B185................... T185 Timing Belts 45-01713............ T176 W11-651............. T028
LB94................... T160 B186................... T186 TB063................. T073 45-01721............ T126 W11-654............. T041
LB95................... T095 B187................... T187 TB070................. T070 45-01739............ T101 W11-655............. T014
LB96................... T096 B191................... T191 TB077................. T077 45-01754............ T138 W11-657............. T036
LB98................... T098 B194................... T194 TB401................. T014 45-01762............ T129 W11-658............. T032
LB99................... T161 B199................... T199 TB402................. T013 45-01770............ T071 W11-659............. T043
B233................... T233 TB403................. T037 45-01788............ T122 W11-660............. T064
TEXACO W11-661............. T062
B236................... T236 TB404................. T017 45-01796............ T141
Timing Belts B32..................... T032 TB409................. T039 45-01804............ T134 W11-665............. T070
TB401................. T014 TB063................. T073 TB411................. T041 45-01812............ T113 W11-669............. T073
TB402................. T013 TB070................. T070 TB415................. T028 45-01820............ T117 W11-670............. T065
TB403................. T037 TB077................. T077 TB418................. T061 45-01838............ T124 W11-673............. T068
TB404................. T017 TB401................. T014 TB428................. T067 45-01853............ T121 W16-801............. T079
TB409................. T039 TB402................. T013 T013................... T013 45-01861............ T140 W16-802............. T084
TB411................. T041 TB403................. T037 T014................... T014 45-01879............ T147 W16-803............. T078
TB404................. T017 45-01887............ T102 W16-804............. T087
TB415................. T028 T017................... T017 W16-805............. T101
TB409................. T039 T028................... T028 45-01895............ T119
ULTRALAST TB411................. T041 45-01911............ T152 W16-807............. T090
T032................... T032 W16-808............. T158
Timing Belts TB415................. T028 T037................... T037 45-01945............ T187
TB418................. T061 45-01952............ T186 W16-811............. T083
B013................... T013 T039................... T039 W16-812............. T082
B014................... T014 TB428................. T067 T041................... T041 45-01960............ T143
T013................... T013 45-01978............ T145 W16-814............. T299
B017................... T017 T043................... T043 W16-815............. T094
T014................... T014 T061................... T061 45-01986............ T144
B028................... T028 T017................... T017 45-01994............ T142 W16-816............. T300
B032................... T032 T063................... T073
T028................... T028 T064................... T064 45-02009............ T124
B036................... T036 T032................... T032 45-02017............ T169
B037................... T037 T067................... T067
T037................... T037 T070................... T070 45-02025............ T149
B039................... T039 T039................... T039 45-02033............ T146
B041................... T041 T071................... T071
T041................... T041 T073................... T073 45-02041............ T155
B043................... T043 T043................... T043 45-02066............ T167
B061................... T061 T077................... T077
T061................... T061 T081................... T081 45-02074............ T168
B064................... T064 45-02082............ T139
B067................... T067 T063................... T073 T094................... T094
T064................... T064 T1043................. T043 45-02090............ T300
B070................... T070 45-02108............ T299
B071................... T071 T067................... T067 T1064................. T064
T070................... T070 T1071................. T071 45-02116............ T164
B073................... T073 45-02124............ T157
B074................... T074 T071................... T071 T1081................. T081
T073................... T073 45-02140............ T199
B077................... T077 VERA 45-02157............ T154
B078................... T078 T077................... T077
T081................... T081 Timing Belts 45-02199............ T127
B081................... T081 45-02215............ T128
B087................... T087 T087................... T087 A326L134B ........ T075
T089................... T089 45-05074............ T168
B088................... T088 45-00070............ T062
B089................... T089 T092................... T092 45-00096............ T062 WESTERN AUTO
B090................... T090 T094................... T094 45-00724............ T028
T099................... T099 Timing Belts
B094................... T094 45-00732............ T036
B095................... T095 T1043................. T043 45-00740............ T020 74-2736-2........... T067
B099................... T099 T1064................. T064 45-00773............ T032 74-2737-0........... T061
B101................... T101 T1071................. T071 45-00781............ T018 74-2738-8........... T039
B104................... T104 T1081................. T081 45-00799............ T014 74-2739-6........... T037
B112................... T112 T115................... T299 45-00807............ T013 74-2741-2........... T013
B113................... T113 T203................... T203 45-00815............ T043 74-2742-0........... T014
B114................... T114 T210................... T210 45-00823............ T017 74-2743-8........... T017
B116................... T300 T228................... T228 45-00849............ T065 74-2744-6........... T071
B117................... T117 UNIROYAL 45-00856............ T069 WOLVERINE
B118................... T118 45-00864............ T070
B122................... T122 Timing Belts 45-00930............ T073 Timing Belts
B124................... T124 A206L050........... T062 45-00948............ T064 TB013................. T013
B125................... T125 A206L050S ........ T090 45-00955............ T041 TB014................. T014
B126................... T126 A315L075........... T028 45-01051............ T082 TB017................. T017
B128................... T128 A326L134B ........ T075 45-01069............ T083 TB018................. T018
B129................... T129 A330L075........... T070 45-01127............ T076 TB020................. T020
B130................... T130 A345L075........... T073 45-01135............ T075 TB028................. T028
B132................... T132 A356L075........... T041 45-01150............ T078 TB032................. T032
B134................... T134 A363L100........... T067 45-01168............ T077 TB036................. T036
B136................... T136 A367L075........... T078 45-01176............ T074 TB037................. T037
B138................... T138 A371L060........... T037 45-01200............ T107 TB039................. T039
B139................... T139 A371L075........... T039 45-01226............ T158 TB041................. T041
B141................... T141 A375L075........... T061 45-01234............ T091 TB043................. T043
B142................... T142 A397L075........... T077 45-01267............ T106 TB061................. T061
B143................... T143 A408L075........... T088 45-01275............ T196 TB062................. T062
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. Gates Mfr. Gates Mfr. Gates Mfr. Gates Mfr. Gates
Part No. No. Part No. No. Part No. No. Part No. No. Part No. No.
ADO41407 .......... T090 FE0212205.......... T088 JE2612740 .......... T42007 MD110709........... T124 OHC064 .............. T064
AD041407 ........... T090 FE0312205.......... T113 JE2612740A........ T42007 MD111427........... T139 OHC065 .............. T065
A405RU100......... T264 FE03122050........ T113 JE2612750 .......... T41036 MD113561........... T064 OHC067 .............. T067
BNP2955............. T028 FE0412205.......... T113 JE4812730 .......... T42012 MD113562........... T013 OHC068 .............. T068
BPY112205 ......... T185 FE04122050........ T113 JE4812740 .......... T42013 MD113563........... T073 OHC069 .............. T069
BP0112205 ......... T185 FE0612205.......... T117 JF0112205 .......... T146 MD113564........... T128 OHC070 .............. T070
BP0112205A ....... T185 FE0812205.......... T117 JF0112205A........ T146 MD113790........... T158 OHC071 .............. T071
BP0112205B ....... T185 FE08122050........ T113 JF0112205D........ T146 MD115976........... T41047 OHC073 .............. T073
BP0212205 ......... T185 FE0912205.......... T117 JF0112730 .......... T42011 MD115977........... T168 OHC074 .............. T074
BP0212205A ....... T185 FE09122050........ T113 JF0112730A........ T42011 MD120487........... T155 OHC075 .............. T075
B10112205A ....... T141 FE1H12205A....... T264 JF0112750 .......... T41033 MD121993........... T42017 OHC076 .............. T076
B59712205.......... T179 FE1H12700A....... T41029 J0856351 ............ T140 MD128765........... T41045 OHC077 .............. T077
B6S712205A ....... T179 FE1H12730 ......... T42003 KJ0112205 .......... T267 MD129033........... T41044 OHC078 .............. T078
B6S712205B ....... T179 FE1H12730A....... T42003 KLY212SJ0 ......... T41034 MD129355........... T41046 OHC079 .............. T079
B6S712205C Kia T179 FE1J12205.......... T264 KL0112205.......... T214 MD133115........... T167 OHC081 .............. T081
B6S712205C Ma FE3N12730 ......... T42004 KL0112730.......... T42010 MD133116........... T165 OHC082 .............. T082
zda .................... T179 FE7912205.......... T113 KL0112730A ....... T42010 MD134377........... T091 OHC083 .............. T083
B6S712205D....... T179 FE7915205.......... T113 KL0112740.......... T42009 MD13805............. T093 OHC084 .............. T084
B6Y212205 ......... T141 FP0112205A ....... T316 KL0112750.......... T41034 MD140070........... T195 OHC087 .............. T087
B63012205.......... T141 FSY112205 ......... T228 KL0212750.......... T41034 MD140071........... T41039 OHC088 .............. T088
B63012205A ....... T123 FS0112205A ....... T228 KL0212750A ....... T41034 MD140227........... T155 OHC089 .............. T089
B63012205B ....... T123 FS0112700A ....... T41091 K0AA352700 ....... T248 MD140228........... T158 OHC090 .............. T090
B63012205C ....... T123 FS0112700B ....... T41091 K0BA352700 ....... T248 MD140229........... T124 OHC091 .............. T091
B63012205D ....... T141 FS0112730A ....... T42008 LHN100420L ....... T326 MD145713........... T167 OHC092 .............. T092
B63012205E ....... T141 FS0212205.......... T228 LNH100410L ....... T327 MD145714........... T165 OHC093 .............. T093
B63012700C ....... T41030 F0BZ 6268 A ...... T185 MBP0112205B K MD145716........... T168 OHC094 .............. T094
B63012700D ....... T41030 F0CZ 6K 254A.... T41007 ia ....................... ✩T185 MD145813........... T191 OHC095 .............. T095
B63012700E ....... T41030 F0EE 6K 254AA . T41007 MBP0112205B M MD146186........... T41051 OHC096 .............. T096
B63212205.......... T141 F1ZZ 6268 A ...... T210 itsubishi ............. T185 MD151447........... T42018 OHC097 .............. T097
B632122050........ T141 F17E 6268 AA .... T210 MB6S712205C.... T179 MD152243........... T159 OHC098 .............. T098
B66012205.......... T149 F2CE 6268 AA ... T194 MD008960........... T013 MD152622........... T092 OHC099 .............. T099
B66012205B ....... T149 F2Y112205.......... T134 MD008961........... T062 MD154243........... T204 OHC100 .............. T100
B66012205C ....... T149 F20212205 .......... T134 MD008965........... T41055 MD156604........... T42017 OHC101 .............. T101
B66012700D ....... T41031 F20312205 .......... T134 MD008968........... T013 MD160103........... T090 OHC102 .............. T102
B66012700E ....... T41031 F21012205 .......... T134 MD008969........... T062 MD161427........... T195 OHC103 .............. T103
B66012730A ....... T42005 F3BZ 6268 A ...... T185 MD009277........... T064 MD171748........... T167 OHC104 .............. T104
B66012730B ....... T42005 F3CZ 6268 A ...... T179 MD009352........... T013 MD171749........... T168 OHC106 .............. T106
B66012730C ....... T42005 F3DZ 6268 A ...... T248 MD009650........... T41057 MD175375........... T41052 OHC107 .............. T107
C3905942............ T165 F3XY 6268 A ...... T104 MD009651........... T062 MD176387........... T201 OHC112 .............. T112
DBP4131............. T099 F32Z 6268 A....... T228 MD009666........... T064 MD182195........... T168 OHC113 .............. T113
DBP9289............. T099 F32Z 6268 B....... T214 MD009667........... T064 MD182201........... T165 OHC114 .............. T114
D1FZ 6268 A ...... T013 F37E 6268 AA .... T210 MD011536........... T41043 MD182291........... T167 OHC117 .............. T117
D4FZ 6K 254A.... T41005 F4BZ 6268 A ...... T185 MD013805........... T093 MD182292........... T256 OHC118 .............. T118
D4FZ 6268 A ...... T014 F4XY 6268 A ...... T249 MD015310........... T093 MD182293........... T232 OHC119 .............. T119
D4ZE 6268 AE ... T014 F42Z 6268 A....... T228 MD015311........... T159 MD182294........... T230 OHC120 .............. T120
D42E 6268 AB.... T014 F47E 6268 AA .... T210 MD015701........... T089 MD182295 Chrys OHC121 .............. T121
D8EE 6268 AA ... T014 F47Z 6268 B....... T210 MD030599........... T073 ler ...................... T168 OHC122 .............. T122
D9EE 6268 AA ... T014 F5CE 6268 AA ... T283 MD030600........... T073 MD182295 Mitsu OHC123 .............. T123
ECP244............... T129 F5RZ 6K 254A.... T41008 MD030605........... T41042 bishi................... ✩T168 OHC124 .............. T124
E1EE 6268 DA ... T067 F5RZ 6268 A ...... T258 MD030610........... T073 MD182537........... T41054 OHC125 .............. T125
E1FZ 6268 D ...... T067 F50112700A........ T41091 MD040754........... T41053 MD183005........... T195 OHC126 .............. T126
E2CE 6268 AA ... T194 F50112730A........ T42008 MD040756........... T062 MD183006........... T253 OHC127 .............. T127
E2EE 6268 AA ... T067 F50512700B........ T41091 MD040797........... T062 MD185544........... T41038 OHC128 .............. T128
E3EE 6268 AA ... T067 F57E 6K 254AA.. T41005 MD041390........... T158 MD189522........... T229 OHC129 .............. T129
E3FZ 6268 A ...... T067 F57E 6268 AA .... T276 MD041407........... T159 MD191982........... T288 OHC130 .............. T130
E43Z 6268 B ...... T103 F57E 6268 BB .... T276 MD050119........... T092 MD192068........... T41038 OHC131 .............. T131
E43Z 6268 C ...... T102 F57Z 6K 254A .... T41005 MD050125........... T41049 MD193874........... T195 OHC132 .............. T132
E5EE 6K 254AA . T41006 F57Z 6268 A....... T276 MD050130........... T091 MD193875........... T253 OHC134 .............. T134
E5FZ 6K254 A.... T41006 F7CZ 6268 AA.... T283 MD050135........... T41050 MD199418........... T165 OHC135 .............. T135
E5FZ 6268 A ...... T067 F8CZ 6K 254AA . T43003 MD050175........... T092 MD307487........... T259 OHC136 .............. T136
E5RE 6268 AA ... T014 F8CZ 6268 AA.... T294 MD060461........... T091 MD315265........... T41052 OHC137 .............. T137
E5RE 8286 AA ... T142 F80112205 .......... T077 MD068173........... T124 MD319022........... T42018 OHC138 .............. T138
E5TZ 6268 A ...... T092 F80212205 .......... T077 MD095866........... T093 MD322641........... T287 OHC139 .............. T139
E5TZ 6268 B ...... T091 F80512700 .......... T41035 MD098491........... T089 MD325854........... T289 OHC140 .............. T140
E5ZZ 6268 A ...... T014 F80512700A........ T41035 MD098492........... T124 MD326059........... T167 OHC141 .............. T141
E7GZ 6268 A...... T141 F80512700C ....... T41035 MD098706........... T073 MD336149........... T232 OHC142 .............. T142
E7GZ 6268 B...... T141 F9JY 6268 A....... T179 MD099706........... T073 MD340625........... T289 OHC143 .............. T143
E7GZ 6268 C ..... T141 GC01201200....... T068 MD099707........... T091 MO4667611 ........ T246 OHC144 .............. T144
E80112205.......... T077 GC01201201....... T068 MD099708........... T090 OHC013 .............. T013 OHC145 .............. T145
E9DZ 6268 A...... T248 GTB1208............. T129 MD100103........... T090 OHC014 .............. T014 OHC146 .............. T146
E9JY 6K 254A .... T41031 GTB1237............. T142 MD100619........... T064 OHC017 .............. T017 OHC147 .............. T147
E9JY 6268 A ...... T179 HM8268BA.......... T013 MD100620........... T013 OHC018 .............. T018 OHC148 .............. T148
E92Z 6K 254A .... T41029 JE1512730 .......... T42011 MD100632........... T062 OHC020 .............. T020 OHC149 .............. T149
FC01201202 ....... T020 JE1512730A........ T42011 MD100679........... T139 OHC028 .............. T028 OHC150 .............. T150
FC01201203 ....... T020 JE1512730D ....... T42011 MD100814........... T128 OHC032 .............. T032 OHC151 .............. T151
FDU1464............. T142 JE1512750 .......... T41033 MD102248........... T093 OHC036 .............. T036 OHC152 .............. T152
FEO1122050....... T088 JE1512750A........ T41033 MD102249........... T158 OHC037 .............. T037 OHC153 .............. T153
FEY812205 ......... T113 JE2612205 .......... T183 MD104578........... T41048 OHC039 .............. T039 OHC154 .............. T154
FEY8122050 ....... T113 JE2612205A........ T183 MD106103........... T159 OHC041 .............. T041 OHC155 .............. T155
FEY912205 ......... T113 JE2612205B........ T183 MD109958........... T41056 OHC043 .............. T043 OHC157 .............. T157
FE0112205.......... T088 JE26122050 ........ T183 MD110029........... T167 OHC061 .............. T061 OHC158 .............. T158
FE01122050........ T088 JE2612730A........ T42006 MD110041........... T165 OHC062 .............. T062 OHC159 .............. T159
✩ Interference engine application.

Manufacturers’ Part Numbers - PowerGrip™ Timing System Products 801
OHC160 .............. T160 OHC262 .............. T262 XHM460 .............. T129 1257223 .............. T083 13070KA020 ....... T41060
OHC161 .............. T161 OHC263 .............. T263 XS4Z 6M 250AA. T42036 1257237 .............. T082 13070V5001........ T41059
OHC162 .............. T162 OHC264 .............. T264 XS4Z 6M 250BA. T42034 12581899 ............ T329 1307001M00 ....... T41058
OHC163 .............. T163 OHC265 .............. T265 YF0912205.......... T294 12612650017 ...... T41015 1307016A00........ T41089
OHC164 .............. T164 OHC266 .............. T266 ZZM112205......... T210 12612650044 ...... T129 1307016A02 Nis
OHC165 .............. T165 OHC267 .............. T267 ZZM312205......... T276 1272382 .............. T106 san .................... T41089
OHC166 .............. T166 OHC269 .............. T269 Z50112205 .......... T266 1272384 .............. T106 1307016A02 Sub
OHC167 .............. T167 OHC270 .............. T270 Z50212205 .......... T308 12723842 ............ T106 aru..................... T41089
OHC168 .............. T168 OHC271 .............. T271 0B59712205........ T179 1276150G00 ....... T194 1307016A03........ T41089
OHC169 .............. T169 OHC272 .............. T272 0K24712205........ T302 1276153B00........ T171 1307042L00 ........ T41059
OHC170 .............. T170 OHC273 .............. T273 0K24712700........ T42032 1276153B01........ T171 13071AA001 ....... T41062
OHC171 .............. T171 OHC274 .............. T274 0K30E12205 ....... T318 1276160A00........ T164 13071AA002 ....... T41062
OHC172 .............. T172 OHC275 .............. T275 0K95412205........ T281 1276160B10........ T166 13073AA000 ....... T42022
OHC173 .............. T173 OHC276 .............. T276 0K97212205........ T264 1276160E00........ T241 13073AA080 ....... T42023
OHC174 .............. T174 OHC277 .............. T277 0060562106 ........ T120 1276163B00........ T095 13073AA081 ....... T42023
OHC176 .............. T176 OHC278 .............. T278 026109243 .......... T41079 1276163E00........ T243 13073AA140 ....... T42023
OHC177 .............. T177 OHC279 .............. T279 026109243E........ T41079 1276170C00........ T194 13073AA142 ....... T42023
OHC178 .............. T178 OHC280 .............. T280 026109243L ........ T41079 1276171C00........ T212 13077F6200 ........ T42021
OHC179 .............. T179 OHC281 .............. T281 027109119A........ T292 1276172F00 ........ T272 13077F6510 ........ T42020
OHC180 .............. T180 OHC282 .............. T282 027109119C........ T292 1276173000 ........ T028 13077F6512 ........ T42021
OHC181 .............. T181 OHC283 .............. T283 028109119D........ T242 1276173001 ........ T028 1307745V00........ T42021
OHC182 .............. T182 OHC284 .............. T284 028109119K........ T242 1276178400 ........ T070 13085AA010 ....... T42024
OHC183 .............. T183 OHC285 .............. T285 028109119M ....... T242 1276180C00........ T243 1320811M00 ....... T077
OHC184 .............. T184 OHC286 .............. T286 028109119P........ T242 1276182000 ........ T095 1326288 .............. T174
OHC185 .............. T185 OHC287 .............. T287 028109243E........ T43006 1276185Z00 ........ T309 13404PT0003...... T41013
OHC186 .............. T186 OHC288 .............. T288 028109243F ........ T43006 1281053B00........ T41010 13404PT0004...... T41013
OHC187 .............. T187 OHC289 .............. T289 034109119 .......... T127 1281053B01........ T41010 13404P13003...... T41022
OHC188 .............. T188 OHC290 .............. T290 034109119A........ T197 1281071C00........ T41065 13405PAAA01..... T186
OHC189 .............. T189 OHC291 .............. T291 03510911 ............ T065 1281071C01........ T41065 13405PAAA02..... T186
OHC190 .............. T190 OHC292 .............. T292 035109119 .......... T065 1281082001 ........ T41064 13405PAAA03..... T186
OHC191 .............. T191 OHC293 .............. T293 037109119C........ T262 1281082002 ........ T41064 13405PTO004..... T186
OHC192 .............. T192 OHC294 .............. T294 038109119 .......... T301 1281082003 ........ T41064 13405PT0004...... T186
OHC193 .............. T193 OHC295 .............. T295 038109119B........ T301 1281086500 ........ T41009 13440P5A004 ..... T280
OHC194 .............. T194 OHC296 .............. T296 038109119D........ T301 1281086501 ........ T41009 1350311010 ........ T42028
OHC195 .............. T195 OHC297 .............. T297 038109119M ....... T321 1286168 .............. T106 1350311011 ........ T42028
OHC196 .............. T196 OHC298 .............. T298 038109243N........ T43007 12861684 ............ T106 1350311020 ........ T42028
OHC197 .............. T197 OHC299 .............. T299 048109119D........ T262 130RG25............. T084 1350311030 ........ T42029
OHC198 .............. T198 OHC300 .............. T300 054109119A........ T197 13028AA010 ....... T300 1350311040 ........ T42029
OHC199 .............. T199 OHC301 .............. T301 054109119E........ T225 13028AA040 ....... T150 1350350010 ........ T42031
OHC200 .............. T200 OHC302 .............. T302 054109119G ....... T197 13028AA072 ....... T277 1350350011 ........ T42031
OHC201 .............. T201 OHC303 .............. T303 054109119H........ T225 13028AA101 ....... T172 1350354010 ........ T42026
OHC203 .............. T203 OHC304 .............. T304 056109119A........ T017 13028AA102 ....... T172 1350354020 ........ T42026
OHC204 .............. T204 OHC305 .............. T305 056109243D........ T41079 13028AA120 ....... T209 1350362010 ........ T42030
OHC205 .............. T205 OHC306 .............. T306 058109119A........ T291 13028AA150 ....... T254 1350362030 ........ T42030
OHC206 .............. T206 OHC307 .............. T307 058109119B........ T317 13028AA170 ....... T300 1350363010 ........ T42025
OHC207 .............. T207 OHC308 .............. T308 058109119C........ ✩T317 13028AA181 ....... T304 1350363011 ........ T42025
OHC208 .............. T208 OHC309 .............. T309 058109119D........ T291 13028AA21A ....... T307 1350363020 ........ T42025
OHC209 .............. T209 OHC310 .............. T310 06A109119C ....... T296 13028D0100........ T100 1350363021 ........ T42025
OHC210 .............. T210 OHC311 .............. T311 06A109479A ....... T43010 13028D1700........ T078 1350364010 ........ T42027
OHC211 .............. T211 OHC312 .............. T312 06A109479B ....... T43010 13028D4200........ T137 1350364020 ........ T42027
OHC212 .............. T212 OHC313 .............. T313 06A109479C ....... T43010 13028D4210........ T137 1350365010 ........ T42037
OHC213 .............. T213 OHC314 .............. T314 06B109119A ....... T306 13028D4211........ T137 1350388360 ........ T42025
OHC214 .............. T214 OHC315 .............. T315 06B109119B ....... T306 13028KA021 ....... T135 1350388380 ........ T42025
OHC215 .............. T215 OHC316 .............. T316 06B109119F........ T306 13028V4000........ T017 1350501010 ........ T41066
OHC216 .............. T216 OHC317 .............. T317 06141PH9305 ..... T070 13028V4310........ T093 1350502020 ........ T41074
OHC217 .............. T217 OHC318 .............. T318 06141679305 ...... T274 13028V5100........ T104 1350511010 ........ T41076
OHC218 .............. T218 OHC319 .............. T319 068109119 .......... T043 13028V5200........ T104 1350511011 ........ T41076
OHC219 .............. T219 OHC320 .............. T320 068109119A........ T043 13028V5201........ T104 1350511020 ........ T41076
OHC220 .............. T220 OHC321 .............. T321 068109119E........ T043 13028V5210........ T104 1350511040 ........ T41071
OHC221 .............. T221 OHC322 .............. T322 068109243F ........ T41080 13028V5220........ T104 1350511050 ........ T41071
OHC222 .............. T222 OHC323 .............. T323 069109119A........ T083 13028V5221........ T104 1350515031 ........ T41066
OHC223 .............. T223 OHC324 .............. T324 069130113A........ T082 130280B700........ T249 1350515040 ........ T41066
OHC224 .............. T224 OHC325 .............. T325 074109119 .......... T170 130280B785........ T249 1350515041 ........ T41066
OHC225 .............. T225 OHC326 .............. T326 075RH200 ........... T082 1302810M00 ....... T077 1350515050 ........ T41072
OHC226 .............. T226 OHC327 .............. T327 075109119B........ T083 1302811M00 ....... T077 1350516020 ........ T41074
OHC227 .............. T227 OHC329 .............. T329 077109119B........ T207 1302811M10 ....... T077 1350516021 ........ T41074
OHC228 .............. T228 OJE2612730A Ki 077109119C........ T297 1302812C00........ T100 1350520010 ........ T41075
OHC229 .............. T229 a ........................ T42006 077109119D........ T207 1302812G00 ....... T104 1350520020 ........ T41075
OHC230 .............. T230 OJE2612730A M 077109119E........ T207 1302816A01........ T096 1350543010 ........ T41069
OHC232 .............. T232 azda .................. T42006 078109119A........ T218 1302816A10........ T096 1350550010 ........ T41078
OHC233 .............. T233 OJE2612740A..... T42007 078109119C........ T297 1302816E00........ T104 1350550011 ........ T41078
OHC234 .............. T234 OJE2612750 Kia. T41036 078109119D........ T218 1302816E10........ T104 1350550021 ........ T41078
OHC235 .............. T235 OJE2612750 Ma 078109119G ....... T297 1302816E85........ T104 1350550022 ........ T41078
OHC236 .............. T236 zda .................... T41036 078109119H........ T297 1302816V00........ T180 1350562031 ........ T41075
OHC237 .............. T237 OK24712700 ....... T41032 081616 ................ T018 1302820R00........ T078 1350562050 ........ T41075
OHC239 .............. T239 OK90012700 ....... T41035 081619 ................ T069 1302845P00........ T251 1350562060 ........ T41075
OHC240 .............. T240 OK93712700A..... T41031 081629 ................ T189 1302851E00........ T137 1350563011 ........ T41070
OHC241 .............. T241 OK93712730 ....... T42005 081632 ................ T140 1302851E10........ T137 1350563021 ........ T41070
OHC242 .............. T242 OK95412730 ....... T42004 081640 ................ T188 1302861A00........ T077 1350564010 ........ T41077
OHC243 .............. T243 OK95512730A..... T42004 088AG19 ............. T070 1302885 .............. T104 1350564011 ........ T41077
OHC244 .............. T244 OK97212205 ....... T264 09128500 ............ ✩T285 1302885E00........ T104 1350564020 ........ T41077
OHC245 .............. T245 OK97212700 ....... T41029 10068553 ............ T163 13029AA010 ....... T299 1350564021 ........ T41077
OHC246 .............. T246 OK97212700A..... T41029 101R24................ T099 13029AA011 ....... T299 1350565020 ........ T41073
OHC247 .............. T247 OK97212730 ....... T42004 10162006 ............ T192 13029AA040 ....... T151 1350565040 ........ T41073
OHC248 .............. T248 OK97312700 ....... T41029 102500 ................ T078 13029AA070 ....... T299 1350574010 ........ T41067
OHC249 .............. T249 RF0312205 ......... T103 108R24................ T094 13029AA080 ....... T299 1350574011 ........ T41067
OHC251 .............. T251 RF03122050 ....... T103 1125360160 ........ T075 13029AA11 ......... T299 1350587102 ........ T41004
OHC252 .............. T252 RF0312206A ....... T102 113R190.............. T065 13069AA034 ....... T41063 1350587702 ........ T41003
OHC253 .............. T253 RF4312205 ......... T103 11311272384 ...... T106 13069AA035 ....... T41063 1351415010 ........ T070
OHC254 .............. T254 RF7112205 ......... T103 11311286168 ...... T106 13069AA036 ....... T41063 1351487711 ........ T178
OHC255 .............. T255 RF7912205 ......... T103 11311711082 ...... T131 13069AA037 ....... T41063 135148771100 .... T178
OHC256 .............. T256 R1463635109...... T140 11311711153 ...... T41083 13069AA063 ....... T41092 1351487711000 .. T178
OHC257 .............. T257 T0718752 ............ T119 11311713361 ...... T131 13070AA00 ......... T41062 1356422021 ........ T126
OHC258 .............. T258 T0718836 ............ T140 119RH250 ........... T083 13070AA000 ....... T41061 135680A010........ T257
OHC259 .............. T259 T0729581 ............ T140 1191303105 ........ T120 13070AA001 ....... T41062 1356803010 ........ T138
OHC260 .............. T260 T830 .................... T264 119130310500 .... T120 13070D0100........ T41088 1356803020 ........ T199

802 Manufacturers’ Part Numbers - PowerGrip™ Timing System Products
1356803021 ........ T199 1356869075 ........ T240 144006570040 .... T036 2431233020 ........ T165 3547459 .............. T174
1356809040 ........ T199 1356869095 ........ T271 144006570042 .... T041 2431233030 ........ T165 35474592 ............ T174
1356809041 ........ T199 1356874010 ........ T138 14400657014 ...... T036 2431233040 ........ T165 360525 ................ T037
1356809050 ........ T257 1356874011 ........ T138 144006570140 .... T036 2431233050 ........ T165 376388 ................ T037
1356809080 ........ T257 1356874012 ........ T199 14400657024 ...... T041 2431233060 ........ T165 376401 ................ T037
1356811030 ........ T136 1356874012B...... T199 144006570240 .... T041 2431233110 ........ T167 414701001 .......... T028
1356811031 ........ T233 1356874013 ........ T199 144006570241 .... T041 2431233120 ........ T167 414705601 .......... T079
1356811032 ........ T233 1356874020 ........ T138 144006570242 .... T041 2431233130 ........ T167 4164869 .............. T020
1356811033 ........ T233 1356874021 ........ T199 1440065704 ........ T036 2431233140 ........ T167 4176840 .............. T018
1356811100 ........ T208 1356879025 ........ T199 14400673004 ...... T073 2431233150 ........ T167 4182426 .............. T020
1356811101 ........ T208 1356879045 ........ T125 144006730040 .... T073 2431233160 ........ T167 4201379 .............. T068
1356811111 ........ T208 1356879095 ........ T199 144006730041 .... T073 2431235000 ........ T139 4201738 .............. T068
1356815010 ........ T070 1356887101 ........ T181 144006730042 .... T073 2431235010 ........ T139 4201739 .............. T068
1356815011 ........ T070 1356887101000 .. T181 14400679003 ...... T274 2431235040 ........ T139 4242396 .............. T069
1356815020 ........ T070 1356887102 ........ T181 144006790040 .... T274 2431237100 ........ ✩T315 4300516 .............. T122
1356815030 ........ T070 1356887102000 .. T181 144006790041 .... T274 2431237400 ........ T315 4302971 .............. T122
1356815040 ........ T036 1356887103 ........ T182 14400679014X.... T274 2431237500 Hyu 4304099 .............. T075
1356815041 ........ T036 1356887103000 .. T182 14401MN5004..... T275 ndai ................... T315 4315705 .............. T41001
1356815042 ........ T239 1356887104 ........ T182 14401MN50040... T275 2431237500 Kia.. T315 4343824 .............. T114
1356815050 ........ T036 1356887104000 .. T182 14401MT3004 ..... T325 2431238210 Hyu 4343946 .............. T071
1356816010 ........ T112 1356887708 ........ T178 14401MT30041 ... T325 ndai ................... T313 43439469 ............ T071
1356816020 ........ T176 1356888360 ........ T125 14450P8AA01 ..... T42038 2431238210 Kia.. T313 4387534 .............. T132
1356816040 ........ T236 1356888361 ........ T125 14510PC6004 ..... T41012 2431238220 ........ T313 4387549 .............. T153
1356816041 ........ T236 1356888380 ........ T125 14510PE0003 ..... T41017 2431239400 ........ T322 4401261 .............. T069
1356816050 ........ T236 1356888381 ........ T125 14510PE0005 ..... T41017 2431239800 Hyu 4401269 .............. T069
1356816051 ........ T236 1356888382 ........ T125 14510PG6013 ..... T41018 ndai ................... T323 4406634 .............. T032
1356816060 ........ T235 139AG25 ............. T087 14510PH1003 ..... T41012 2431239800 Kia.. T323 4420507 .............. T018
1356816061 ........ T235 14001168 ............ T061 14510PH1004 ..... T41012 24410-38001 ....... T41087 4484494 .............. T206
1356816070 ........ T235 14400MG9000 .... T070 14510PH3003 ..... T41019 2441021010 ........ T41042 4504163 .............. T285
1356816071 ........ T235 14400MG90000 .. T070 14510PH7003 ..... T41015 2441022000 ........ T41037 4573347 .............. T41084
1356819045 ........ T236 14400PAAA01..... T244 14510PH7004 ..... T41015 2441022020 ........ T41037 4573348 .............. T41084
1356819046 ........ T236 14400PAAA02..... T244 14510PK1014 ..... T41019 2441023011 ........ T41041 4573944 .............. T219
1356819055 ........ T235 14400PC6004 ..... T160 14510PM3003..... T41011 2441023500 Hyu 460165 ................ T039
1356819056 ........ T235 14400PC60040 ... T094 14510PM7003..... T41011 ndai ................... T41041 4621348 .............. T285
1356819085 ........ T233 14400PC60042 ... T160 14510PM7004..... T41011 2441023500 Kia.. T41041 4621844 .............. T265
1356819086 ........ T233 14400PD2004 ..... T160 14510PR3003 ..... T41016 2441026000 ........ T41037 46337 .................. T032
1356819115 ........ T208 14400PD6004 ..... T160 14510PR3004 ..... T41016 2441032000 ........ T41044 463377 ................ T032
1356819116 ........ T208 14400PE0004 ..... T099 14510PT0003...... T41014 2441032010 ........ T41044 4633772 .............. T032
1356819125 ........ T070 14400PE00040 ... T099 14510PT0004...... T41014 2441032553 ........ T41046 463633 ................ T41081
1356819135 ........ T239 14400PE3004 ..... T099 14510PV0003 ..... T41020 2441035010 ........ T41048 4636338 .............. T41081
1356819145 ........ T112 14400PE30040 ... T161 14510PY3003 ..... T41021 2441035020 ........ T41048 4663515 .............. T41002
1356820010 ........ T257 14400PG6004 ..... T130 14510PY3004 ..... T41021 2441039001 Hyu 4663598 .............. T255
1356820020 ........ T257 14400PG60040 ... T130 14510P08003...... T41023 ndai ................... T41040 4667530 .............. T206
1356829015 ........ T257 14400PG6014 ..... T130 14510P08004...... T41023 2441039001 Kia.. T41039 4667606 .............. T245
1356829025 ........ T257 14400PG6040 ..... T130 14510P13003...... T41024 2445033010 ........ T41046 4667611 .............. T246
1356842010 ........ T126 14400PH7004 ..... T129 14510P30003...... T41016 2445033020 ........ T41046 4667625 .............. T265
1356842011 ........ T237 14400PH70040 ... T129 14510P8AA01 ..... T41090 2445037100 Hyu 4770491 .............. T285
1356842012 ........ T126 14400PH7014 ..... T129 146R190.............. T020 ndai ................... T41040 477393 ................ T41002
1356842020 ........ T126 14400PH70140 ... T129 1649170 .............. T067 2445037100 Kia.. T41040 4781570AB ......... T43008
1356842021 ........ T237 14400PH90040 ... T070 1649171 .............. T067 2445038010 ........ T41087 4792353 .............. T295
1356843010 ........ T074 14400PH90040P. T070 1680616A00........ T097 24502982 ............ T192 484981001 .......... T028
1356843020 ........ T074 14400PK1004 ..... T144 1680616A10........ T097 24503363 ............ T273 4884320AA ......... T43001
1356843030 ........ T101 14400PK10040 ... T144 1711082 .............. T131 248102X700........ T42005 5010371AA ......... T43005
1356843040 ........ T101 14400PK2004 ..... T142 1713361 .............. T131 2481023011 ........ T42015 512430160 .......... T075
1356846020 ........ T215 14400PK20040 ... T142 177RG25............. T098 2481023500 ........ T42015 512536016 .......... T075
1356849015 ........ T237 14400PK3004 ..... T142 2335238010 ........ T314 2481026020 ........ T42016 5125360160 ........ T075
1356849035 ........ T215 14400PLM004..... T312 2335632010 ........ T159 2481033021 ........ T42017 5203401 .............. T071
1356849036 ........ T215 14400PMMA01 ... T312 2335632020 ........ T159 2481033024 ........ T42017 52267904 ............ T163
1356849046 ........ T074 14400PM3004..... T143 2335632030 ........ T159 2481035530 Hyu 52289664 ............ T163
1356849055 ........ T101 14400PM30040... T143 2335633110 ........ T168 ndai ................... T42014 524034 ................ T017
1356850010 ........ T190 14400PM6004..... T145 2335633120 ........ T168 2481035530 Kia.. T42018 5240346 .............. T017
1356850020 ........ T298 14400PM70040... T142 2335633130 ........ T168 2481037100 Hyu 5862021480 ........ T186
1356854010 ........ T079 14400PR3004 ..... T227 2335633140 ........ T168 ndai ................... T42014 5862021620 ........ T187
1356854020 ........ T079 14400PR4A01..... T184 2335633150 ........ T168 2481037100 Kia.. T42014 5862059260 ........ T186
1356854030 ........ T079 14400PR4A01M1 T184 2335633160 ........ T168 2481037120 ........ T42014 5862059340 ........ T244
1356854031 ........ T079 14400PT0004...... T187 2335638000 ........ T314 271705 ................ T217 5985163 .............. T087
1356854038 ........ T079 14400PV1004 ..... T211 2335638010 ........ T314 2717056 .............. T217 60507464 ............ T120
1356854050 ........ T084 14400PY3A010 ... T193 2335638020 ........ T314 271713 ................ T032 60562106 ............ T120
1356854051 ........ T084 14400PY3004 ..... T193 2335732000 ........ T41053 271714 ................ T198 636350 ................ T081
1356859015 ........ T079 14400P0A004 ..... T244 2335732010 ........ T41053 2717148 .............. T198 636359 ................ T081
1356859016 ........ T079 14400P0GA01..... T263 2335732020 ........ T41053 271720 ................ T173 636363 ................ T081
1356859017 ........ T079 14400P0GA010M 2335733120 ........ T41047 271747 ................ T234 636365 ................ T148
1356859025 ........ T084 1 ........................ T263 2335742000 ........ T41050 2717478 .............. T234 636368 ................ T148
1356859026 ........ T084 14400P08004...... T223 2335742010 ........ T41050 271834 ................ T252 636370 ................ T081
1356859027 ........ T084 14400P13004...... T226 2413232010 ........ T089 2718344 .............. T252 636560 ................ T081
1356859045 ........ T190 14400P14004...... T216 2431032010 ........ T41044 271835 ................ T252 636562 ................ T148
1356859095 ........ T298 14400P2E004 ..... T224 243122Y000........ T302 2718351 .............. T269 636565 ................ T081
1356862020 ........ T157 14400P2FA01 ..... T224 2431221040 ........ T073 271856 ................ T252 6842469 .............. T198
1356862030 ........ T200 14400P2T004...... T227 2431222010 ........ T191 2718567 .............. T252 70HM 6268 AB ... T013
1356862030A...... T200 14400P28004...... T224 2431222611 ........ T324 271876 ................ T270 70HM 6268 BA ... T013
1356862040 ........ T157 14400P5A004 ..... T279 2431222612 ........ T324 2718765 .............. T270 7533266 .............. T013
1356862050 ........ T271 14400P7J004 ...... T184 2431223001 ........ T278 271952 ................ T217 7533267 .............. T013
1356863010 ........ T087 14400P72004...... T247 2431223201 ........ T284 2719524 .............. T217 7700618657 ........ T018
1356863020 ........ T087 14400P72014...... T247 2431223202 Hyu 272327 ................ T252 7700663550 ........ T018
1356863022 ........ T087 14400P8AA01 ..... T286 ndai ................... T284 272329 ................ T311 7700666593 ........ T069
1356864010 ........ T098 14400P8AA02 ..... T286 2431223202 Kia.. T284 2723294 .............. T311 7700717284 ........ T140
1356864011 ........ T098 14400RCAA01 .... T329 2431223400 ........ T284 272386 ................ T270 7700718725 ........ T140
1356865010 ........ T154 14400TG6004 ..... T130 2431224000 ........ T128 274184 ................ T319 7700718726 ........ T140
1356865010A...... T154 14400634003 ...... T028 2431224010 ........ T128 2900009150 ........ T305 7700718752 ........ T119
1356865020 ........ T240 14400634004 ...... T028 2431224050 ........ T128 3250141 .............. T017 7700718836 ........ T140
1356869025 ........ T200 14400634005 ...... T028 2431226000 ........ T282 3342103 .............. T119 7700729581 ........ T140
1356869035 ........ T157 144006340050 .... T028 2431226001 ........ T282 3507227 .............. T083 7700853660 ........ T140
1356869045 ........ T087 144006340051 .... T028 2431232610 ........ T124 3507651 .............. T217 7701348801 ........ T018
1356869055 ........ T154 14400634014 ...... T028 2431232620 ........ T124 3507704 .............. T234 8091287220 ........ T305
1356869065 ........ T098 144006340141 .... T028 2431232820 ........ T089 3514323 .............. T173 82317934 ............ T065
1356869066 ........ T098 14400657004 ...... T036 2431233010 ........ T165 3531358 .............. T198 85867058 ............ T096

Manufacturers’ Part Numbers - PowerGrip™ Timing System Products 803
8920639440 ........ T305 8944723490 ........ T41026 91112009 ............ T070 94109626 ............ T118 94854404 ............ T235
894109626 .......... T162 8944723491 ........ T41026 91171175 ............ T272 94158327 ............ T121 94856081 ............ T236
8941096260 ........ T118 8944795230 ........ T162 91172367 ............ T194 94160656 ............ T122 94856082 ............ T235
8941583270 ........ T121 8970163260 ........ T221 91172368 ............ T41010 94215197 ............ T41025 95ZA19................ T100
8941606560 ........ T122 8970270620 ........ T205 91173157 ............ T194 94215254 ............ T121 95951646 ............ T095
8941743060 ........ T147 8970417840 ........ T122 912761 ................ T014 94220922 ............ T076 96051646 ............ T095
894200372A........ T122 8970422680 ........ T147 9128500 .............. T285 94337708 ............ T177 96057945 ............ T164
8942151970 ........ T41025 8971160020 ........ T41028 9128722 .............. T305 94386497 ............ T220 96060050 ............ T166
8942151971 ........ T41025 8971363210 Hon 9135031 .............. T252 9440383 .............. T311 96065049 ............ T41009
8942152540 ........ T121 da ...................... T303 9135450 .............. T173 94410221902 ...... T293 96067809 ............ T095
8942187820 ........ T088 8971363210 Isuz 9135733 .............. T252 94410221904 ...... T293 96068423 ............ T241
894220372A........ T122 u ........................ T303 9151772280 ........ T189 94410513703 ...... T107 96068424 ............ T243
8942209220 ........ T076 90122429 ............ T081 91540557 ............ T188 94410515703 ...... T107 96068591 ............ T212
8942220922 ........ T076 90231883 ............ T148 9154055780 ........ T188 94410515704 ...... T107
8942353620 ........ T088 90234902 ............ T081 91541318 ............ T188 94410515706 ...... T152 96144976 ............ T148
8942372420 ........ T121 90324698 ............ T148 9180954 .............. T252 94410532300 ...... T152 96183352 Daewo
894337708 .......... T177 90324699 ............ T148 92029834 ............ T075 94410532301 ...... T152 o Int................... T310
8943377080 ........ T177 90325576 ............ T081 92063917 ............ T309 94410532302 ...... T152 96183352 Gener
8943624350 ........ T41027 90325578 ............ T081 92066312 ............ T309 94429486 ............ T169 al Motors........... T309
8943648160 ........ T41028 90353179 ............ T203 928M 6K254 AC . T41008 94452094 ............ T118 96414718702 ...... T222
8943648161 ........ T41028 90353211 ............ T081 928M 6M250 BC T42036 94479523 ............ T162 97016326 ............ T221
8943864881 ........ T42002 90354783 ............ T148 928M 6M250 DC T42032 94840054 ............ T070 97027062 ............ T205
8943864882 ........ T42002 90409900 ............ T081 928M 6268 AB.... T258 94844702 ............ T112 97041784 ............ T122
8943864883 ........ T42002 90410014 ............ T081 92810515710 ...... T196 94846144 ............ T036 97042268 ............ T147
8943864970 ........ T220 90410223 ............ T203 92810515730 ...... T196 94847323 ............ T41066 978M 6M250 AA. T42035
8944161450 ........ T088 90410768 ............ T285 92810515740 ...... T196 94848472 ............ T176 978M 6M250 BA. T42036
8944233311 ........ T42001 90410771 ............ T285 92810515750 ...... T196 94849175 ............ T036 978M 6268 AA.... T294
8944294860 ........ T169 90500360 ............ T285 93202400 ............ T43002 94849597 ............ T036 99314718701 ...... T290
8944520940 ........ T162 90530599 ............ T285 94029834 ............ T075 94854403 ............ T236 99919213150 ...... T213

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Table of Contents WARNING

PARA MAS MANUALES VISÍTENOS EN

Timing System Operation

Today’s Timing Belts are Highly Sophisticated

HNBR Elastomeric Compound High-Strength Tensile Cord

Improved Tooth Jacket

Tooth Profiles Aren’t Interchangeable

Trapezoidal Curvilinear Modified Curvilinear

Positioning Marks for Easy Installation

Several engine manufacturers use a pivot arm in correlation with a hydraulic

Automatic Spring Loaded Tensioner

Also known as “frictional” tensioner. Manufacturers are increasing their usage

Installation Shaft – Assures proper positioning on the engine

Thrust Washer – A self-lubricating surface that provides the

Arm – Torque from the spring is transmitted to the pulley

Spring – Designed with a specific torque for each application,

Spring Support – This highly wear resistant, engineered polymer

Pivot Shaft – Sustains alignment between the tensioner arm and

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

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

1. Too low or high belt tension. 1. Adjust tension to recommended value.

1. Extreme high temperature 1. Overheated engine; Seized or partially seized pulley

Land Wear 1. Excessive tension 1. Adjust tension to recommended value.

1. Damage due to handling. 1. Follow proper handling instructions.

1. High tension. 1. Adjust tension to recommended value.

Free Running Interference

Timing Belt Tension Tester

Hydraulic Tensioner Pin Set

Cam Gear Sprocket Tool

Gates offers several timing belt sales aids:

Suggested Installation Installation Suggested Installation Installation

Micro-V® Belt Tension Ranges for Manual Tensioners

Suggested Installation Installation Suggested Installation Installation

1997-98 2.0L 4-Cyl. (DOHC Turbo) *

2000-03 2.5L 4-Cyl. (SOHC) * T307 105,000 635

CAUTION: Always adjust timing belt tension with engine cold.

PARA MAS MANUALES VISÍTENOS EN

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

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

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

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

REMOVAL & INSTALLATION

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Locating Camshaft Timing Marks

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

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

REMOVAL & INSTALLATION

Fig. 3: Locating Timing Belt Adjuster Bolt

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

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

NOTE: Some vehicles may be equipped with radio/cassette or

1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.