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Table of Contents

Introduction & Technical Information . . . . . . . . . . A1 Alphabetical Model Listing . . . . . . . . . . . . . . . . A15 Replacement Instructions . . . . . . . . . . . . . . . . . . . 1 Changeover Listing . . . . . . . . . . . . . . . . . . . . . 786 Manufacturers Part Numbers . . . . . . . . . . . . . . 800

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

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

PowerGripTiming Component Kits


PowerGrip Timing Component Kits give you the best and most complete repair solution for your customers. Save time and money by preventing costly comebacks and warranties. Ideal for the consumer because the job is done right the first time; saving them from returning when other components fail and accrue additional labor costs. A broken belt can cause severe and expensive engine damage. A failing or failed tensioner or idler pulley bearing often causes timing belt failure. Thats why each kit comes with the right components, plus detailed installation instructions specific to each application. With PowerGrip kits, its not necessary to multi-source components, look up several different manufacturers, or present your customer with several cartons containing different parts. Deliver in one carton with all the components required to do a thorough job.
(Kits can contain multiple belts, tensioners, idler and tensioner pulleys, depending on the application. Kits do not contain hydraulic tensioning cylinders or tensioning springs.)

PowerGrip Timing Components!


Gates is the largest producer of automotive timing belts in the world. Because we are the leader, we are the experts in the timing system. Our expertise is used globally to help OEMs design the most durable and efficient timing systems available. Now Gates brings this expertise to you with PowerGrip Timing tensioners and idlers! Although Gates recommends a PowerGrip Timing Component Kit whenever changing a timing belt, there are those who will only want to replace a single part. PowerGrip Timing Components provide the solution. The broad Gates line covers passenger car and light truck applications and includes automatic timing tensioners that, until now, were only available through an OEM dealership. So, whether its the complete job or just what's necessary, Gates PowerGrip Timing Component System products are the solution!
Note: Beware of low cost timing belts with little or no warranty. For Gates warranty information, see inside front cover. A1

Gates Timing Component Oil Seals

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

Timing System Operation


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

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

A2

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

Todays Timing Belts are Highly Sophisticated


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

Formulated for better heat resistance and durability

Designed for high-tension applications


Improved Tooth Jacket

Engineered for improved wear resistance

Tooth Profiles Arent Interchangeable


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

Positioning Marks for Easy Installation


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

A3

Timing System Component Identification


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

Automatic Spring Loaded Tensioner


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

A5

What Makes Up a PowerGrip Automatic Timing Belt Tensioner?


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

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

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

Timing Belt System Troubleshooting


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

Damaged Pulley Surface: A pitted, cracked, uneven, discolored or chipped pulley should always be replaced. Foreign material build-up on the pulley surface is also an issue and should be removed or replace the pulley.

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

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

A7

Timing Belt Troubleshooting Guide


Synchronous belts have been used on automotive camshaft drives for more than 20 years. Our belts will give OEM equivalent service if the following points are observed.

Storage
Belts should be kept in their original packaging until needed. Store in an environment which avoids: Temperature extremes Direct sunlight High humidity Contamination by oil, water, chemicals, etc.

Handling
It is important that belts are not crimped during handling since this could seriously damage the tensile members and lead to premature failure.

Installation Tips
IMPORTANT: Avoid crimping the belt when installing it on pulleys no tools should be used on the belt. Replace and properly refit timing cover to prevent drive contamination by foreign matter.

Replacement
Follow vehicle manufacturers instructions regarding belt replacement intervals. If the belt is removed, then a new belt should be installed. If engine is being repaired and belt is near OEM recommended replacement interval, its a good time to replace the belt.

A8

Timing Belt Troubleshooting Guide


Symptom Probable Cause
1. Excessive shock load. 2. Improper belt handling and storage prior to installation. 3. Debris or foreign object in drive. 4. Extreme pulley/sprocket run-out. 5. Extreme Over-tension. 1. Seized Drive Component 2. Excessive shock loads. 3. Extreme sprocket run-out. 4. Worn sprocket. 5. Misaligned drive. 6. Belt under tensioned. 1. Too low or high belt tension. 2. Belt running partly off unflanged sprocket. 3. Misaligned drive. 4. Worn sprocket. 1. Extreme high temperature 2. Extreme low temperature at start-up. 3. Cocked sprocket. 4. Excessive tension 1. Excessive tension 2. Worn Sprocket 1. Oil, fuel, coolant leak.

Concern/Corrective Action
1. Excessive RPMs; Modified engine. 2. Follow proper storage and handling procedures. 3. Remove objects; Replace pulleys. 4. Replace pulley/sprocket. 5. Adjust tension to recommended value. 1. Replace Component (Tensioner/Idler pulley, W.P., camshaft, Oil pump). 2. Excessive RPMs; Modified engine. 3. Check camshaft/crankshaft journals. 4. Replace sprocket. 5. Worn sprocket bearing, replace sprocket; Bent bracket; Improper sprocket installation. 6. Adjust tension to recommended value. 1. Adjust tension to recommended value. 2. Correct alignment. 3. Worn sprocket bearing, replace sprocket; Bent bracket; Improper sprocket installation. 4. Replace sprocket. 1. Overheated engine; Seized or partially seized pulley 2. Install engine heater 3. Replace Sprocket. 4. Adjust tension to recommended value. 1. Adjust tension to recommended value. 2. Replace Sprocket 1. Replace faulty seals and/or gaskets; Check timing cover for improper installation, replace if cracked or worn. 1. Follow proper handling instructions. 2. Replace sprocket. 3. Adjust tension to recommended value. 4. Replace sprocket. 5. Correct alignment. 6. Remove obstruction or correct alignment. 1. Adjust tension to recommended value. 2. Adjust tension to recommended value. 3. Worn sprocket bearing, replace sprocket; Bent bracket; Improper sprocket installation. 4. Replace pulley(s).

Tensile Failure

Tooth Shear

Tooth Wear

Backside Cracks

Land Wear (wear between teeth) Contamination

Edge Wear

1. Damage due to handling. 2. Flange damage. 3. Belt tension too low. 4. Rough belt pulley flange. 5. Improper tracking. 6. Belt contacting engine, timing cover or other engine component. 1. High tension. 2. Low tension. 3. Misalignment. 4. Damaged pulley flange.

Unusual Noise

A9

Free Running or Interference Engine? You and Your Customers Need to Know.
Automobile engines can be classified as either Free-Running or Interference, depending on what occurs if piston/valve synchronization is lost. As illustrated below, in the free-running engine with the crankshaft still moving, there is enough clearance between the valve and piston, even if the cam stops with a valve fully open. However, interference engines usually sustain damage if synchronization is lost. As illustrated, disrupted synchronization allows the piston and valve to collide causing damage and very expensive repairs for the vehicle owner. Damage can occur to valves, pistons, or heads, and in some cases, completely ruin the engine. Most import (with higher compression engines) and most car and light truck diesel engines are interference. To avoid costly engine repairs, follow the auto manufacturers mileage replacement recommendations or we recommend timing belt replacement at around 60,000 miles.

Free Running
No Valve/Piston Interference

Interference
Valve/Piston Interference

NOTE: For your convenience, interference engines have been footnoted with a star in the application listings of this publication and are noted in the index. This lets you easily identify them, and pass that information on to your customers. Since timing belts are inside the engine they tend to be an out-of-sight, out-of-mind item and are seldom thought of as a part of routine maintenance. Here are some questions to ask customers that will help sell belts and protect the customer from expensive repairs: 1. Did you buy the car new? If yes, theyll know if the belt has ever been replaced. 2. Did you buy the car used? If so, they wont know if the belt has been replaced. This is a flag for the customer to get the belt checked, replaced or at least be aware that he has a timing belt. 3. How many miles are on the vehicle? Generally belts should be replaced at around 60,000 miles or less. Our Timing Belt Replacement Recommendations Booklet is an excellent tool for determining replacement intervals. 4. Have you ever replaced the timing belt? If the answer is yes or no (and the customer knows the mileage) you can determine where the vehicle is in the replacement cycle. Heres a helpful hint for customers with vehicles within a few thousand miles of the recommended replacement interval. If they are having any engine repair done, have the timing belt and pulleys checked. If either/or both need replacing, do it now, along with the other repairs and save time and money.

A10

Overhead Valve Engine Identification


The engine illustrations below are all overhead valve type engines. These diagrams are provided for your reference and convenience. This page is also for customers who may not know the engine type they have, but may be able to identify it through these illustrations.

A11

Timing System Tools


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

Timing Belt Tension Tester


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

Hydraulic Tensioner Pin Set


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

A12

Timing System Tools - Continued


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

Cam Gear Sprocket Tool


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

Gates offers several timing belt sales aids:

Timing Belt Counter Card (428-1437) and Brochures (428-1438)

PowerGrip Timing Systems Product Catalog (428-1448)

Timing Belt Replacement Mileage Wall Chart (428-0408)

A13

Belt Tensioning
V- Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the Gates Krikit Tension Gauge, to determine proper tension from the Installation Chart. Tension ranges below are for drives requiring single belts. If multiple belts are needed for a drive, divide tension by number of belts to give per belt tension to be measured. Position belt and set tension to the prescribed Installation Tension. Run belt for five minutes. If belt tension drops below Suggested Tension range, retighten belt to Installation Tension. This will allow the belt to seat-in and run at Suggested Tension after it has operated under normal driving conditions.
Suggested Tension (lbs.) Ranges 45-65 60-85 85-115 105-145 135-185 155-200 160-220 Installation Tension (lbs.) Used Belts 60.0 75.0 100.0 120.0 150.0 170.0 175.0 Installation Tension (lbs.) New Belts 80.0 100.0 130.0 160.0 200.0 215.0 235.0 1" 1-1/16" 1-1/8" 1-5/16" Suggested Tension (lbs.) Ranges 175-240 190-255 215-295 225-310 245-330 285-385 Installation Tension (lbs.) Used Belts 190.0 205.0 230.0 240.0 260.0 300.0 Installation Tension (lbs.) New Belts 255.0 270.0 310.0 325.0 345.0 400.0

Belt Top Width 1/4" 5/16" 3/8" 1/2" 5/8" 11/16" 3/4"

Belt Top Width 13/16" 7/8"

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 Tension (lbs.) Ranges 45-60 60-80 75-100 90-125 105-145 120-160 Installation Tension (lbs.) Used Belts 67.5 90.0 112.5 135.0 157.5 180.0 Installation Tension (lbs.) New Belts 90.0 120.0 150.0 187.5 217.5 240.0 Suggested Tension (lbs.) Ranges 135-180 150-200 165-220 180-240 210-280 Installation Tension (lbs.) Used Belts 202.5 225.0 247.5 270.0 292.5 Installation Tension (lbs.) New Belts 270.0 300.0 333.0 360.0 420.0

Number of Ribs 3 4 5 6 7 8

Number of Ribs 9 10 11 12 14

NOTE:

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

A14

ALPHABETICAL MODEL LISTING


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

ACURA
Passenger Cars EL (Canadian) 1997-00 1.6L 4-Cyl. *# Integra 1986-89 1.6L 4-Cyl. *# 1992-93 1.7L 4-Cyl. *# 1990-94 1.8L 4-Cyl. (Exc. VTEC) *# 1995-96 1.8L 4-Cyl. (Exc. VTEC) *# 1997-01 1994 1995-96 1997-01 Legend 1986-87 1987-89 1990 1991-94 1995 MDX 2001-04 NSX 1991-96 1997-04 1997-04 NSX-T 1995-96 1997-03 1997-03 Vigor 1992-94 2.2CL 1997 1.8L 4-Cyl. (Exc. VTEC) *# 1.8L 4-Cyl. (VTEC) *# 1.8L 4-Cyl. (VTEC) *# 1.8L 4-Cyl. (VTEC) *# 2.5L V6 *# 2.7L V6 *# 2.7L V6 *# 3.2L V6 (C32A1) *# 3.2L V6 (C32A1) *# 3.5L V6 (J35A3) *# 3.0L V6 3.0L V6 3.2L V6 3.0L V6 3.0L V6 3.2L V6 2.5L 5-Cyl. *# 2.2L 4-Cyl. *# Balance Shaft Camshaft 2.3CL 1998-99 2.5TL 1995-96 1997-98 3.0CL 1997-99 3.2CL 2001-03 2.3L 4-Cyl. *# Balance Shaft Camshaft 2.5L 5-Cyl. *# 2.5L 5-Cyl. *# 3.0L V6 (J30A1) *# 3.2L V6 (J32A1/A2) *# T224 T130 T227 T184 T184 T184 T247 T247 T247 T129 T129 T129 T193 T193 T286
4

105,000 3 TCK130 TCK227 TCK184 TCK184 TCK184 TCK247 TCK247 TCK247 TCK129 TCK129 TCK129 TCK193 TCK193 TCK286 T41018 T41016 T41016 T41016 T41016 T41016 T41016 T41016 T41015 T41015 T41015 T41021 T41021 Not Available Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Available 60,000 1 90,000 90,000 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 60,000 Severe 105,000 3 60,000 1 60,000 1 90,000 90,000 90,000 Normal 60,000 Severe 105,000 3 Inspect at 90,000, replace if needed 105,000 3 105,000 3 Inspect at 90,000, replace if needed 105,000 3 105,000 3 T41020 TCK244 TCK244 T41013 T41014 Not Applicable Not Applicable Not Applicable 90,000 90,000 Normal 2 60,000 Severe 90,000 Normal 2 60,000 Severe 105,000 3 105,000 3 90,000 Normal 60,000 Severe 105,000 3 105,000 3 105,000 3

1 4 5 6 6 6 6 6 6 6 6 12 12 12 26 26 26 23 14 14 14 14 14 14 14 14 10 8 8 8 8 8 8 10 10 10 20 23

4 4

4 4

T211 T186 T244

T186 T244 T211 T211 T286 T286

TCK244 TCK244

T41013 T41014 T41020 T41020

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

TCK286 TCK286

Not Available Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A15

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year 3.2TL 1996 1997-98 1999 2000 2001-03 2004 3.5RL 1996-04 Light Trucks SLX 1996-97 1999-98 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

ACURA (Cont.)
3.2L V6 (C32A6) *# 3.2L V6 (C32A6) *# 3.2L V6 (J32A1/A2) *# 3.2L V6 (J32A1/A2) *# 3.2L V6 (J32A1/A2) *# 3.2L V6 (J32A3) *# 3.5L V6 (C35A1) *# Balance Shaft Camshaft T193 T193 T286 T286 T286 T329 T280 T279 TCK193 TCK193 TCK286** TCK286** T41021 T41021 T41090** T41090** Not Applicable Not Applicable T42038 T42038 90,000 Normal 60,000 Severe 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 26 26 26 20 23 23 23 29 29

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

T221 T303

TCK221**

T41028**

T42002

60,000 75,000

35 33

ALFA ROMEO
GTV Coupe 1982-86 164L, LS & S 1991-93 Alliance 1985-87 Concord 1978-79 Encore 1985-86 Gremlin 1977-78 Spirit 1979 2.5L V6 3.0L V6 T120 T120 50,000 50,000 37 39

AMERICAN MOTORS
1.7L 4-Cyl. * 2.0L 4-Cyl. * 1.7L 4-Cyl. * 2.0L 4-Cyl. * 2.0L 4-Cyl. * T119 T017 T119 T017 T017 TCK017 TCK017 T41079 T41079 Not Applicable Not Applicable TCK017 T41079 Not Applicable 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 609 41 41 41 41

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

T205

60,000

292

T164 T212

TCK164 TCK212

T41064 T41065

Not Applicable Not Applicable

60,000 1 60,000

298 300

AUDI
Allroad 2001-04 A4 1997-98 2.7L V6 Twin Turbo (APB) *# 1.8L 4-Cyl. Turbo (AEB) * 152 Tooth Belt 5 153 Tooth Belt T297 T291 T317 105,000 105,000 Normal 52,500 Severe 105,000 Normal 52,500 Severe 72 47 47 47 47

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. 5 - ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt). A16

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

AUDI (Cont.)
A4 (Cont.) 1999-00 1.8L 4-Cyl. Turbo (AEB & ATW) * 152 Tooth Belt 5 153 Tooth Belt 2000-01 1.8L 4-Cyl. Turbo (AWM) * 2002-04 1.8L 4-Cyl. Turbo (AWM) * 1996 2.8L V6, 12-Valve *# 1997 2.8L V6, 12-Valve *# 1998 2.8L V6, 30-Valve *# 1999 2.8L V6, 30-Valve *# 2000-01 2.8L V6, 30-Valve *# A4 Avant & Sedan 2002-04 1.8L 4-Cyl. Turbo (AMB) *# 2002-04 A4 Cabriolet 2003-04 2002-04 A4 Quattro 1997-98 3.0L V6, 30-Valve (AVK) *#

T291 T317 T306 T306 T218 T218 T297 T297 T297 T306 T330

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

47 47 47 47 59 59 80 80 82 82 82 49 49 86 86 49 49 86 86

1.8L 4-Cyl. Turbo (AMB) *# 3.0L V6, 30-Valve (AVK) *#

T306 T330

1.8L 4-Cyl. Turbo (AEB) * 152 Tooth Belt 153 Tooth Belt 1.8L 4-Cyl. Turbo (AEB & ATW) * 152 Tooth Belt 5 153 Tooth Belt

T291 T317 T291 T317 T306 T306 T218 T218 T297 T297

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

47 47 47 47 47 47 47 59 59 80 80 82 82

1999-00

2000-01 2002-04 1996 1997 1998 1999

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. 5 - ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt). A17

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

AUDI (Cont.)
A6 1995-96 1997 1998 1998 1999 2000 2002-04 2.8L V6, 12-Valve *# 2.8L V6, 12-Valve *# 2.8L V6, 12-Valve *# 2.8L V6, 30-Valve *# 2.8L V6, 30-Valve *# 2.8L V6, 30-Valve *# 3.0L V6, 30-Valve (AVK) *# T218 T218 T297 T297 T297 T297 T330 T297 T218 T218 T297 T297 T297 T297 T297 T207 T207 T297 T207 T207 T297 T218 T218 T065 T065 T127 T127 T197 T017 T065 T065 T127 T225 T297 T225 TCK017 T41079 Not Applicable 60,000 1 90,000 90,000 90,000 75,000 105,000 105,000 Normal 52,500 Severe 105,000 60,000 1 90,000 90,000 90,000 75,000 105,000 105,000 Normal 52,500 Severe 90,000 75,000 105,000 90,000 75,000 105,000 60,000 1 90,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 105,000 60,000 1 80 80 80 82 82 82 86 86 72 80 80 80 82 82 82 111 111 104 104 108 104 104 108 80 80 118 118 118 118 68 43 118 118 118 66 76 66

A6 Quattro & Quattro Turbo 2000-04 2.7L V6, Twin Turbo *# 1995-96 2.8L V6, 12-Valve *# 1997 2.8L V6, 12-Valve *# 1998 2.8L V6, 12-Valve *# 1998 2.8L V6, 30-Valve *# 1999 2.8L V6, 30-Valve *# 2000-01 2.8L V6, 30-Valve *# 2000-04 4.2L V8 *# A8 1997-98 1999 2000-03 A8 Quattro 1997-98 1999 2000 Cabriolet 1994-96 1997-98 Coupe 1981-83 1984-85 Coupe GT 1986-87 Coupe Quattro 1990-91 Fox 1973-79 Quattro 1983 1984-85 S4 1992-94 S4 Quattro 2000-02 S4 Sedan 1992-94 3.7L V8 (AEW) *# 3.7L V8 (AEW) *# 4.2L V8 *# 4.2L V8 (ABZ Engine) *# 4.2L V8 (ABZ Engine) *# 4.2L V8 (ABZ Engine) *# 2.8L V6, 12-Valve *# 2.8L V6, 12-Valve *# 2.2L 5-Cyl. # 2.2L 5-Cyl. # 113 Tooth Belt 120 Tooth Belt 2.2L 5-Cyl. # 2.3L 5-Cyl. # 1.6L 4-Cyl. # 2.2L 5-Cyl. # 2.2L 5-Cyl. # 113 Tooth Belt 120 Tooth Belt 2.2L 5-Cyl. Turbo 2.7L V6 Twin Turbo *# 2.2L 5-Cyl. Turbo #

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A18

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

AUDI (Cont.)
S6 1995 2.2L 5-Cyl. Turbo # S6 Avant Quattro 2002-03 4.2L V8 # S6 Quattro 1995 2.2L 5-Cyl. Turbo # S8 2001-03 4.2L V8 *# TT Coupe & Roadster 2000-04 1.8L 4-Cyl. Turbo *# V8 Quattro 1990-91 3.6L V8 (PT Engine) *# 1992-94 4.2L V8 (ABH Engine) *# 80 1988-90 2.0L 4-Cyl. * 1991-92 2.3L 5-Cyl. # 80 Quattro 1988 2.3L 5-Cyl. # 1989 2.3L 5-Cyl. # Up To Chas. 89J394742 From Chas. 89J394743 1990-92 2.3L 5-Cyl. # 90 1988 2.0L 4-Cyl. * 1988 2.3L 5-Cyl. # 1989 2.3L 5-Cyl. # Up To Chas. 89J396702 From Chas. 89J396703 1990-91 2.3L 5-Cyl. # 1993-95 2.8L V6, 12-Valve *# 90 Quattro 1988 2.3L 5-Cyl. # 1989 2.3L 5-Cyl. # Up To Chas. 89J394742 From Chas. 89J394743 1990-92 2.3L 5-Cyl. # 1993-95 2.8L V6, 12-Valve *# 100 1989-91 2.3L 5-Cyl. # Up To Chas. 063969 From Chas. 063970 1990-91 2.3L 5-Cyl. # 1992-94 2.8L V6, 12-Valve *# 100 Quattro 1989-91 2.3L 5-Cyl. # Up To Chas. 063969 From Chas. 063970 1990-91 2.3L 5-Cyl. # 1992-94 2.8L V6, 12-Valve *# T225 T297 T225 T297 T306 T207 T207 T017 T170 T127 T127 T170 T170 T017 T127 T127 T170 T170 T218 T127 T127 T170 T170 T218 T127 T170 T170 T218 T127 T170 T170 T218 TCK017 T41079 Not Applicable TCK017 T41079 Not Applicable 60,000 1 105,000 Normal 52,500 Severe 60,000 1 105,000 120,000 60,000 90,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 66 111 111 66 108 56 98 98 63 70 70 70 70 70 63 70 70 70 70 80 70 70 70 70 80 70 70 70 80 70 70 70 80

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A19

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

AUDI (Cont.)
200 1989 1990-91 200 Quattro 1989 2.2L 5-Cyl. # Up To Chas. 44K400000 From Chas. 44K400001 2.2L 5-Cyl. # 2.2L 5-Cyl. # Up To Chas. 44K004457 From Chas. 44K004458 2.2L 5-Cyl. # T127 T170 T170 60,000 1 60,000 1 60,000 1 118 118 118

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

T127 T170 T170 T043 T017 T065 T127 T127 T017 T065 T127 T127 T083 T082 T083 T082 T065 T127 T127 T127 T065 T127 T127 T127 TCK017 T41079 Not Applicable TCK017 T41079 Not Applicable

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

118 118 118 42 43 118 118 118 45 118 118 118 65 65 65 65 118 118 118 70 118 118 118 70

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

BMW
325 Series 1987 2.5L 6-Cyl. * 127 Tooth Belt 128 Tooth Belt T131 T106 60,000 3 60,000 3 120 120

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A20

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

BMW (Cont.)
325 Series (Cont.) 1988 2.5L 6-Cyl. * 127 Tooth Belt 128 Tooth Belt 1989-91 2.5L 6-Cyl. * 1984-87 2.7L 6-Cyl. * 127 Tooth Belt 128 Tooth Belt 1988 2.7L 6-Cyl. * 127 Tooth Belt 128 Tooth Belt 525i 1989-93 2.5L 6-Cyl. * 1994-95 2.5L 6-Cyl. * 528e 1982-88 2.7L 6-Cyl. * 127 Tooth Belt 128 Tooth Belt T131 T106 T131 T131 T106 T131 T106 T131 T131 T131 T106 TCK131 TCK131 T41083 T41083 T41083 Not Applicable Not Applicable TCK131 TCK131 T41083 T41083 Not Applicable Not Applicable 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 60,000 3 120 120 120 120 120 120 120 120 120 120 120

BUICK
Skyhawk 1982-86 1987-88 1.8L 4-Cyl. # 2.0L 4-Cyl. # T081 T081 TCK081 TCK081A Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 271 272

CADILLAC
Catera 1997-98 1999-01 CTS 2003-04 3.0L V6 (DOHC) *# 3.0L V6 (DOHC) *# 3.2L V6 * T285 T285 T285 TCK285 TCK285A Not Available Not Available Not Available Not Available 100,000 100,000 100,000 274 274 278

CHEVROLET
Passenger Cars Aveo 2004 1.6L 4-Cyl. # Chevette 1976 1.4L 4-Cyl. 1977 1.4L 4-Cyl. 1976 1.6L 4-Cyl. 1977-78 1.6L 4-Cyl. 1979-87 1.6L 4-Cyl. 1981-86 1.8L 4-Cyl. Diesel * Lumina (Exc. Van) 1991-95 3.4L V6 # 1996-97 3.4L V6 *# Metro 1998-00 1.0L 3-Cyl. 1998-01 Monte Carlo 1995 1996-97 Nova 1988 1985-88 1.3L 4-Cyl. 3.4L V6 # 3.4L V6 *# 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) T310 T037 T039 T037 T039 T061 T076 T192 T273 T194 T194 T192 T273 T112 T070 TCK192 TCK273 TCK070 Not Available Not Available T41066 Not Available Not Available Not Applicable TCK192 TCK273 TCK194A Not Available Not Available T41010 Not Available Not Available Not Applicable 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 Inspect at 60,000; replace at 100,000 100,000 60,000 60,000 60,000 1 60,000 1 266 265 265 265 265 265 270 284 284 294 296 284 284 269 269

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A21

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Spectrum 1985-87 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

CHEVROLET (Cont.)
1.5L 4-Cyl. *# Up To 4/30/87 From 5/1/87 1988 1.5L 4-Cyl. *# Sprint (Includes Canadian) 1985-88 1.0L 3-Cyl. 1989-91 1.0L 3-Cyl. T118 T162 T162 T095 T166 TCK118 TCK118 Not Available Not Available Not Applicable Not Applicable 60,000 60,000 60,000 60,000 60,000 293 293 293 294 294

T41009

Not Applicable

CHEVROLET/G.M.C.
Light Trucks LUV 1981-82 2.2L 4-Cyl. Diesel * S10 & S15 Pickups 1983-85 2.2L 4-Cyl. Diesel * Tracker 1998-02 1.6L 4-Cyl. (SOHC, VIN 6) T075 T075 T212 TCK212 T41065 Not Applicable 60,000 60,000 60,000 405 405 300

CHRYSLER
Passenger Cars Cirrus 2000 2.0L 4-Cyl. (SOHC, VIN C) *# 1995-96 1997 2000 1995-00 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.5L V6 *# T245 T265 T265 T265 T259 TCK259** T43005 T43005 T41039** Not Available Not Available T42018 100,000 Federal 105,000 Calif. 105,000 105,000 100,000 Federal 105,000 California 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 105,000 100,000 Federal 105,000 California 100,000 Federal 105,000 California 105,000 105,000 100,000 Federal 105,000 California 100,000 Federal 105,000 California 102,000 60,000 1 60,000 1 105,000 100,000 Federal 105,000 California 100,000 Federal 105,000 California 131 131 150 150 150 150 162 162 162 162 182 182 182 182 182 182 182 182 182 182 182 182 143 143 182 182 182 182 182

Concorde (Includes Canadian) 1998-99 3.2L V6 *# 2000 3.2L V6 *# 2001 1993-94 1995-97 2000-01 2002 3.2L V6 *# 3.5L V6 *# 3.5L V6 *# 3.5L V6 *# 3.5L V6 *#

T295 T295 T295 T219 T255 T295 T295 T295 T071 T071 T295 T295 T295

TCK295** TCK295** TCK295** TCK219** TCK255** TCK295** TCK295** TCK295** TCK071 TCK071 TCK295** TCK295** TCK295**

T41084** T41084** T41084** T41084** T41084** T41084** T41084** T41000 T41000 T41084** T41084** T41084**

Not Applicable Not Applicable Not Applicable Not Applicable T41002** Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A22

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

CHRYSLER (Cont.)
Intrepid (Includes Canadian - Cont.) 1993-94 3.5L V6 *# 1995-97 3.5L V6 *# 2000-02 3.5L V6 *# 2003-04 Laser 1990-94 1984-86 1986 LeBaron & 1982-88 1989-90 1986-87 1988 1989-94 1990-93 1994-95 LHS 1994 1995-97 1999 2000-01 New Yorker 1983-88 1986-87 1988 1988-89 1994 1995-96 PT Cruiser 2001 2002 2003-04 3.5L V6 *# 2.0L 4-Cyl. (DOHC, 4G6) *# Balance Shaft Camshaft 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) LeBaron GTS 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 3.5L V6 *# 3.5L V6 *# 3.5L V6 *# 3.5L V6 *# 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.5L V6 *# 3.5L V6 *# 2.4L 4-Cyl. (DOHC, VIN B) *# 2.4L 4-Cyl. (DOHC, VIN B) *# 2.4L 4-Cyl. (DOHC, VIN B) *# T219 T255 T295 T295 T168 T167 T071 T114 T071 T153 T114 T132 T153 T139 T139 T219 T255 T295 T295 T071 T114 T132 T139 T219 T255 T265 T265 T265 TCK219** TCK255** TCK295** TCK295** TCK167** TCK167** TCK071 TCK114 TCK071 TCK153 TCK114 TCK132 TCK153 TCK139 TCK139 TCK219** TCK255** TCK295** TCK295** TCK071 TCK114 TCK139 TCK219** TCK255** T41084** T41002** T41084** T41084** T41047 T41046** T41000 T41000 T41001 Not Available Not Available T41001 T41048 T41048 T41084** T41002** T41084** T41084** T41000 Not Available T41048 T41084** T41002** T43005 T43005 T43008 Not Applicable T41002 Not Applicable Not Applicable Not Applicable T42017 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T41002 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T41002 Not Available Not Available 105,000 105,000 100,000 Federal 105,000 California 102,000 60,000 2 60,000 2 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 60,000 3 Federal 100,000 California 105,000 105,000 105,000 100,000 Federal 105,000 California 60,000 1 60,000 1 60,000 1 60,000 3 105,000 105,000 120,000 90,000 102,000 Non-Turbo 105,000 Turbo 90,000 Severe 105,000 105,000 90,000 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 182 182 182 182 182 175 175 143 143 143 143 143 143 143 164 164 164 182 182 182 182 182 143 143 143 164 182 182 152 152 152 152 152 150 150 156 162 162 162 162 200 200 200 200

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

T265 T265 T265 T259

TCK259**

T43005 T43005 T41039**

Not Available Not Available T42018

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

T246

TCK246**

T41002**

T41002

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A23

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

CHRYSLER (Cont.)
Sebring Coupe (Cont.) 2001-02 2.4L 4-Cyl. (SOHC, VIN G) *# Balance Shaft Camshaft 2003-04 2.4L 4-Cyl. (SOHC, VIN G) *# Balance Shaft Camshaft 1995-00 2.5L V6 *# T168 T232 T168 T232 T259 TCK259** T41039** T42018 60,000 3 (Exc. CA , CT & MA) 100,000 3 (CA , CT & MA) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 90,000 TCK153 TCK139 TCK295** TCK295** T41001 T41048 T41084** T41084** Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 105,000 100,000 Federal 105,000 California 102,000 159 159 159 159 159 159 159 159 162 162 162 162 168 168 168 168 168 168 168 168 156 141 164 182 182 182 182

2001-02

3.0L V6 (SOHC) *#

T259

TCK259**

T41039**

T42018

2003-04

3.0L V6 (SOHC) *#

T259

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

2.4L 4-Cyl. (DOHC, VIN X) # 2.2L 4-Cyl. (DOHC, VIN R) 3.0L V6 (SOHC) # 3.5L V6 *# 3.5L V6 *# 3.5L V6 *#

T265 T153 T139 T295 T295 T295

3.5L V6, 24-Valve *# 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.4L 4-Cyl. (DOHC, VIN B) *# 2.4L 4-Cyl. (DOHC, VIN B) *#

T295 T071 T114 T132 T265 T265 TCK071 T41000 Not Applicable

N/A 60,000 1 60,000 1 60,000 1 120,000 120,000

170 143 143 143 156 156

T43005 Not Available

Not Available Not Available

DAEWOO
Lanos 1999-02 Leganza 1999-02 Nubira 1999-02 1.6L 4-Cyl. (DOHC) *# 2.2L 4-Cyl. (DOHC) *# 2.0L 4-Cyl. (DOHC) *# T310 T305 T309 60,000 Federal 102,000 Federal 3 72,000 Federal 102,000 Federal 3 72,000 Federal 102,000 Federal 3 205 205 210 210 208 208

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A24

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DAIHATSU
Passenger Cars Charade 1988-92 1.0L 3-Cyl. *# 1989-92 1.3L 4-Cyl. *# Light Trucks Rocky 1990-92 1.6L 4-Cyl. *# T178 T181 T182 T41003 T41004 T41004 60,000 60,000 60,000 212 214 214

DATSUN (SEE NISSAN) DODGE


Passenger Cars Aries 1981-88 2.2L 4-Cyl. (SOHC) 1989 2.2L 4-Cyl. (SOHC) 1986-87 2.5L 4-Cyl. (SOHC) 1988 2.5L 4-Cyl. (SOHC) 1989 2.5L 4-Cyl. (SOHC) Avenger 1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# T071 T153 T114 T132 T153 T246 TCK071 TCK153 TCK114 TCK153 TCK246** T41000 T41001 T41001 T41002** Not Applicable Not Applicable Not Applicable Not Applicable T41002 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 60,000 2 60,000 2 TCK017 TCK071 TCK073 TCK073 TCK128 TCK191 TCK191 T41079 T41000 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 143 143 143 143 143 200 200 200 200 162 162 162 162 126 124 124 128 143 122 122 173 173 173 173 126 126 126 124 124 192

1995-00

2.5L V6 *#

T259

TCK259**

T41039**

T42018

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

1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) Balance Shaft Camshaft 1.7L 4-Cyl. * 2.2L 4-Cyl. (SOHC) 1.4L 4-Cyl. * 1.4L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.6L 4-Cyl. (SOHC, RWD) w/o Balance Shaft 1.6L 4-Cyl. (SOHC, FWD) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) Balance Shaft Camshaft 1.6L 4-Cyl. (DOHC) *

T064 T062 T013 T017 T071 T073 T073 T073 T128 T191 T191 T064 T064 T093 T062 T013 T165

T41042 T41042 T41051

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A25

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DODGE (Cont.)
Colt (Cont.) 1989-90 1.8L 4-Cyl. (VIN T) 1992-94 1.8L 4-Cyl. (VINs C & D) # Colt (Canadian) 1985-86 1.5L 4-Cyl. * 1989-90 1.5L 4-Cyl. * 1991 1.5L 4-Cyl. * 1992 & 1995 1.5L 4-Cyl. * Colt Vista (Includes Canadian) 1992-94 1.8L 4-Cyl. (VINs C & D) # 1984-86 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1987-89 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1990-91 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1992 2.4L 4-Cyl. Balance Shaft Camshaft 1993 2.4L 4-Cyl. Balance Shaft Camshaft 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt Wagon (Includes Canadian) 1989-90 1.8L 4-Cyl. (VIN T) 1992 2.4L 4-Cyl. Balance Shaft Camshaft 1993 2.4L 4-Cyl. Balance Shaft Camshaft 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt 100 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) * Colt 200 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) * Daytona & Daytona Shelby (Includes Canadian) 1984-88 2.2L 4-Cyl. (SOHC) 1989-90 2.2L 4-Cyl. (SOHC) 1992-93 2.2L 4-Cyl. (DOHC, VIN A) 1986-87 2.5L 4-Cyl. (SOHC) 1988 2.5L 4-Cyl. (SOHC) 1989-93 2.5L 4-Cyl. (SOHC) 1990-93 3.0L V6 (SOHC) # T093 T201 T073 T128 T128 T191 T201 T090 T089 T159 T158 T159 T158 T159 T204 T159 T230 T168 T230 T093 T159 T204 T159 T230 T168 T230 T165 T165 T071 T153 T206 T114 T132 T153 T139 TCK071 TCK153 TCK114 TCK153 TCK139 T41000 T41001 Not Available T41001 T41048 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK158A TCK158A TCK158A TCK158A T41045 T41044 T41045 T41044 Not Applicable Not Applicable Not Applicable Not Applicable TCK128 TCK128 TCK191 T41042 T41042 T41051 Not Applicable Not Applicable Not Applicable 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 130 198 173 173 173 173 198 180 180 180 180 180 180 203 203 203 203 203 203 130 203 203 203 203 203 203 192 192 143 143 139 143 143 143 164

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A26

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DODGE (Cont.)
Dynasty (Includes Canadian) 1988 2.5L 4-Cyl. (SOHC) 1989-93 2.5L 4-Cyl. (SOHC) 1988-93 3.0L V6 (SOHC) # Expo (Canadian) 1987-88 2.2L 4-Cyl. 1989 2.2L 4-Cyl. Intrepid (Includes Canadian) 1998-99 3.2L V6 *# 2000 3.2L V6 *# 2001 1993-94 1995-97 2000-02 2003-04 Lancer 1985-88 1989 1986-87 1988 1989 Neon 1995-99 1995-97 1998-99 2000-02 2003-04 2003-04 Omni 1978-83 1981-88 1989-90 Rampage 1982-84 Shadow 1987-88 1989-94 1988 1989-94 1992-93 1994 Spirit 1991-92 1989-95 1989-93 3.2L V6 *# 3.5L V6 *# 3.5L V6 *# 3.5L V6 *# 3.5L V6 *# 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.0L 4-Cyl. (DOHC, VIN Y) *# 2.0L 4-Cyl. (SOHC, VIN C) *# 2.0L 4-Cyl. (SOHC, VIN C) *# 2.0L 4-Cyl. *# (SOHC, VINs C & F) 2.0L 4-Cyl. *# (SOHC, VINs C & F) 2.4L 4-Cyl. (DOHC, VIN S) *# 1.7L 4-Cyl. * 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 2.2L 4-Cyl. (DOHC, VIN A) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # T132 T153 T139 T071 T153 T295 T295 T295 T219 T255 T295 T295 T071 T153 T114 T132 T153 T246 T245 T245 T245 T245 T265 T017 T071 T153 T071 T071 T153 T132 T153 T139 T139 T206 T153 T139 TCK017 TCK071 TCK153 TCK071 TCK071 TCK153 TCK153 TCK139 TCK139 T41079 T41000 T41001 T41000 T41000 T41001 T41001 T41048 T41048 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK071 TCK153 TCK153 TCK246** TCK245** T41000 T41001 T41001 T41002** T41002** T43001 Not Applicable Not Applicable Not Applicable T41002 Not Applicable TCK219** TCK255** TCK295** T41084** T41002** T41084** Not Applicable Not Applicable Not Applicable TCK153 TCK139 TCK071 TCK153 TCK295 TCK295** T41001 T41048 T41000 T41001 T41084** T41084** Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 3 60,000 1 60,000 1 105,000 100,000 Federal 105,000 California 100,000 Federal 105,000 California 105,000 105,000 100,000 Federal 105,000 California 102,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 105,000 105,000 105,000 105,000 105,000 105,000 Normal 90,000 Severe 60,000 1 60,000 1 60,000 1 60,000 1 143 143 164 143 143 182 182 182 182 182 182 182 182 182 182 143 143 143 143 143 200 131 131 134 134 152 152 128 143 143 143 143 143 143 143 164 164 164 139 143 164

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

TCK153 TCK139

T41001 T41048

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A27

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Spirit (Cont.) 1994-95 Stealth 1991-93 1991-93 1994-96 1994-96 1991-93 1994-96 Stratus 1995-99 2000 1995-96 1997-99 2000 2001-02 2003-04 2001-04 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DODGE (Cont.)
3.0L V6 (SOHC) # 3.0L V6 *# (DOHC Non-Turbo) 3.0L V6 (DOHC Turbo) *# 3.0L V6 *# (DOHC Non-Turbo) 3.0L V6 (DOHC Turbo) *# 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 2.0L 4-Cyl. (SOHC, VIN C) *# 2.0L 4-Cyl. (SOHC, VIN C) *# 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (DOHC, VIN X) # 2.4L 4-Cyl. (SOHC, VIN G) # Balance Shaft Camshaft 2.5L V6 *# 3.0L V6 (SOHC) *# T139 T195 T195 T195 T195 T139 T139 T245 T245 T265 T265 T265 T265 T265 T168 T232 T259 T259 TCK259** TCK259** T41039** T41039** T42018 T42018 T43005 T43005 T43005 Not Available Not Available Not Available TCK139 TCK139 TCK245** T41048 T41048 T41002** TCK139 TCK195 TCK195 T41048 T41039 T41039 Not Applicable T42018 T42018 60,000 3 Federal 100,000 3 California 60,000 3 164 164 189 189 189 189 189 189 164 164 164 131 131 131 131 150 150 150 150 156 156 159 159 159 159 162 168 168 168 168 128 143 143 143 143 143 180 180 180 180

60,000 3 60,000 3 Federal 100,000 3 California 60,000 3 Federal 100,000 3 California Not Applicable 60,000 3 Not Applicable 60,000 3 Federal 100,000 3 California Not Applicable 100,000 Federal 105,000 California 100,000 Federal 105,000 California 105,000 105,000 100,000 Federal 105,000 California 90,000 90,000 60,000 2, 3 (Exc. CA & Select) 100,000 2, 3 (CA & Select) 60,000 3 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 2 60,000 2 60,000 2 60,000 2

1995-00 Stratus Coupe 2001-04

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

T017 T071 T071 T071 T114 T132 T159 T155 T159 T155

TCK017 TCK071 TCK071 TCK071 TCK114

T41079 T41000 T41000 T41000 Not Available

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

TCK155 TCK155

T41053 T41043

Not Applicable Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A28

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Light Trucks Caravan 1982-83 1984-87 1988 1996 1997-00 2001-02 2003-04 1986 1987 1988 1989-95 1987-93 1994-96 1997-00 Dakota 1987-88 1989-95 Mini Ram Van 1984-87 1987 1988 1987-93 Raider 1989 Ram 50 1983-86 1987-89 1983-85 1990-92 1993 1990-91 Scamp Pickup 1983 Voyager 1984-87 1996 1997-00 1987 1988 1989-95 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DODGE/PLYMOUTH
2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.4L 4-Cyl. (DOHC, VIN B) # 2.4L 4-Cyl. (DOHC, VIN B) # 2.4L 4-Cyl. (DOHC, VIN B) *# 2.4L 4-Cyl. (DOHC, VIN B) *# 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.3L 4-Cyl. Turbo Diesel *# Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 3.0L V6 (SOHC) # 2.2L 4-Cyl. 2.2L 4-Cyl. 2.4L 4-Cyl. (DOHC, VIN B) # 2.4L 4-Cyl. (DOHC, VIN B) # 2.5L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. T071 T071 T071 T265 T265 T265 T265 T114 T114 T132 T153 T139 T139 T139 T071 T153 T071 T114 T132 T139 T139 T090 T089 T159 T158 T092 T091 T159 T124 T168 T229 T139 T071 T071 T265 T265 T114 T132 T153 TCK124 TCK124 TCK158A TCK158A T41045 T41044 T41049 T41050 T41053 T41044 Not Applicable Not Applicable Not Applicable Not Applicable T41000 T41000 T41000 Not Available T43005 T43005 Not Available T41001 T41001 T41048 T41048 T41048 T41000 T41001 T41000 Not Available T41048 T41048 Not Applicable Not Applicable Not Applicable Not Available Not Available Not Available Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 1 120,000 120,000 120,000 120,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 Federal 100,000 3 California 60,000 3 60,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 60,000 3 60,000 2 60,000 2 60,000 2 60,000 2 50,000 2 50,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 3 60,000 1 60,000 1 120,000 120,000 60,000 1 60,000 1 60,000 1 143 143 143 148 148 156 156 143 143 143 143 164 164 164 164 143 143 143 143 143 164 164 180 180 180 180 185 185 187 187 187 187 164 143 143 148 148 143 143 143

TCK071

TCK114 TCK132 TCK153 TCK139 TCK139 TCK139 TCK071 TCK153 TCK071 TCK132 TCK139 TCK139

TCK139 TCK071 TCK071 TCK114 TCK132 TCK153

T41048 T41000 T41000 Not Available T43005 Not Available Not Available T41001

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A29

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

DODGE/PLYMOUTH (Cont.)
Voyager (Cont.) 1987-93 3.0L V6 (SOHC) # 1994-96 3.0L V6 (SOHC) # 1997-00 3.0L V6 (SOHC) # T139 T139 T139 TCK139 TCK139 TCK139 T41048 T41048 T41048 Not Applicable Not Applicable Not Applicable 60,000 3 60,000 3 Federal 100,000 3 California 60,0003 164 164 164 164

EAGLE
Medallion 1989 Summit 1989-90 1991-96 1989-90 1992-96 1992 1993-96 2.2L 4-Cyl. 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.6L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (VINs C & D) # 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft T140 T128 T191 T165 T201 T159 T204 T168 T230 T201 T159 T158 T168 T167 T246 T246 TCK158 TCK158 TCK167** TCK167** TCK246** TCK246** T41057 T41056 T41047 T41046** T41002** T41002** Not Applicable Not Applicable Not Applicable T42017 T41002 T41002 TCK128 TCK191 T41042 T41051 Not Applicable Not Applicable 60,000 1 60,000 60,000 60,000 60,000 60,000 2, 3 60,000 2, 3 60,000 2, 3 60,000 2, 3 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2, 3 Federal 100,0002, 3 California 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) TCK219** TCK255** TCK128 TCK191 T41084** T41002** T41042 T41051 Not Applicable Not Applicable Not Applicable Not Applicable 105,000 105,000 60,000 60,000 60,000 216 173 173 192 198 203 203 203 203 198 195 195 175 175 200 200 200 200 200 200 175 175 175 175 175 175 182 182 173 173 192

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

1995-96

2.0L 4-Cyl. (DOHC Turbo) * Balance Shaft Camshaft 2.0L 4-Cyl. (DOHC Turbo) * Balance Shaft Camshaft

T168 T167 T168 T167 T219 T255 T128 T191 T165

1997-98

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A30

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

EAGLE (Cont.)
Vista (Canadian - Cont.) 1989 1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1989-91 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2000 GTX (Canadian) 1989-93 2.0L 4-Cyl. (DOHC) * Balance Shaft Camshaft 1989-92 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft T093 T159 T158 T168 T167 T159 T155 TCK158A TCK158A TCK167 TCK167 T41045 T41044 T41047 T41046 Not Applicable Not Applicable Not Applicable T42017 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 126 180 180 175 175 180 180

FIAT
Brava 1974-78 1979-81 Spider 2000 1979-82 Strada 1979-82 X1/9 1974-78 1979-83 124 Series 1971-74 1974-78 128 Series 1973-79 131 Series 1975-78 1.8L 4-Cyl. * 2.0L 4-Cyl. * 2.0L 4-Cyl. * 1.5L 4-Cyl. * 1.3L 4-Cyl. * 1.5L 4-Cyl. * 1.6L 4-Cyl. * 1.8L 4-Cyl. * 1.3L 4-Cyl. * 1.8L 4-Cyl. * T020 T068 T068 T069 T018 T069 T020 T020 T018 T020 25,000 30,000 30,000 30,000 36,000 30,000 25,000 25,000 36,000 25,000 218 220 220 217 217 217 218 218 217 218

FORD
Passenger Cars Aspire 1994-97 1.3L 4-Cyl. Contour 1995-97 1998 1999 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) Up To 3/28/1999 From 3/29/1999 2000 Escort 1981-85 1991-96 1985-90 2.0L 4-Cyl. (DOHC, VIN 3) 1.6L 4-Cyl. (SOHC) *# 1.8L 4-Cyl. (DOHC) 1.9L 4-Cyl. (SOHC) *# T185 T258 T294 T294 T294 T294 T067 T179 T067 TCK185 TCK285 TCK294 TCK294 TCK294A TCK294A TCK067 TCK179 TCK067 T41030 T41008 T43003 T43003 T43003 T43003 T41006 T41031 T41006 Not Applicable T42032 (LH) T42033 (RH) T42035 (Upr) T42034 (Lwr) T42035 T42034 T42036 T42034 T42036 T42034 (Upr) (Lwr) (Upr) (Lwr) (Upr) (Lwr) 60,000 Federal 105,000 California 60,000 1 Inspect at 120,000; replace if needed Inspect at 120,000; replace if needed Inspect at 120,000; replace if needed Inspect at 120,000; replace if needed 60,000 60,000 60,000 221 221 234 236 236 236 236 236 236 236 236 224 227 224

Not Applicable T42005 Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A31

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

FORD (Cont.)
Escort (Cont.) 1991 1992-96 1984-87 1997-00 1.9L 4-Cyl. (SOHC) *# Up To 3/25/1991 From 3/26/1991 1.9L 4-Cyl. (SOHC) # 2.0L 4-Cyl. Diesel *# Camshaft Injection Pump 2.0L 4-Cyl. (SOHC, VIN P) T067 T194 T194 T103 T102 T283 T283 T294 T294 T067 T067 T014 T141 T185 T294 T294 T283 T283 T014 T014 T014 T014 T210 T014 T210 T014 T013 T014 T228 T134 TCK067 TCK194 TCK194 T41006 T41007 T41007 Not Applicable Not Applicable Not Applicable 60,000 60,000 60,000 100,000 2 100,000 2 Inspect at 120,000; replace if needed 120,000 Inspect at 120,000; replace if needed 120,000 60,000 60,000 60,000 1 60,000 60,000 120,000 120,000 Inspect at 120,000; replace if needed 120,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 Federal 105,000 California 60,000 224 224 224 229 229 250 250 250 240 240 240 224 224 254 221 221 242 246 250 250 250 254 254 254 254 254 254 254 254 226 254 252 252 252

TCK283 TCK283 TCK294 TCK294A TCK067 TCK067 TCK014 TCK141 TCK185 TCK294A TCK294A TCK283 TCK283 TCK014 TCK014 TCK014 TCK014 TCK014 TCK014 TCK014 TCK228 TCK134

T43004 T43004 T43003 T43003 T41006 T41006 T41005 T41030 T41030 T43003 T43003 T43004 T43004 T41005 T41005 T41005 T41005 T41005 T41005 T41005 T41091 T41029

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

2001-02 2.0L 4-Cyl. (SOHC, VIN P) Escort Coupe & ZX2 1998-2/9/99 2.0L 4-Cyl. (DOHC, VIN 3) 2/10/99-2003 2.0L 4-Cyl. (DOHC, VIN 3) EXP 1982-85 1986-88 Fairmont 1978-83 Festiva 1988-89 1990-93 Focus 2000-04 2002-04 2000 2001-04 Granada 1981-82 LTD 1983-86 Mustang 1974-79 1980-91 1992 1993 Mustang II 1974-78 Pinto 1971-74 1974-80 Probe 1993-97 1989-92 1.6L 4-Cyl. (SOHC) *# 1.9L 4-Cyl. *# 2.3L 4-Cyl. 1.3L 4-Cyl. 1.3L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN 3) * 2.0L 4-Cyl. (DOHC, VIN 5) * 2.0L 4-Cyl. (SOHC, VIN P) 2.0L 4-Cyl. (SOHC, VIN P) 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. Round Tooth Sprocket Square Tooth Sprocket 2.3L 4-Cyl. 2.3L 4-Cyl. 2.0L 4-Cyl. 2.3L 4-Cyl. 2.0L 4-Cyl. * 2.2L 4-Cyl. *

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42036 (Upr) T42034 (Lwr) T42036 (Upr) T42034 (Lwr) Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42008 T42003

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A32

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

FORD (Cont.)
Probe (Cont.) 1993-97 Taurus SHO 1989-95 1993-95 Tempo 1984-86 Thunderbird 1983-88 Light Trucks Aerostar 1987 Courier 1977-82 Escape 2001-04 Ranger 1983-88 1983-91 1992 1993-94 1995-97 1985-87 1998-00 2001 2.5L V6 *# 3.0L V6 3.2L V6 2.0L 4-Cyl. Diesel *# Camshaft Injection Pump 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN B) * 2.0L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. Round Tooth Sprocket Square Tooth Sprocket 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. Diesel * Balance Shaft Camshaft 2.5L 4-Cyl. T214 T248 T248 T103 T102 T014 T014 T014 T294 T014 T014 T210 T014 T210 T276 T092 T091 T276 T276 TCK014 TCK014 TCK014 TCK294A T41005 T41005 T41005 T41085 Not Applicable Not Applicable Not Applicable T42036 (Upr) T42034 (Lwr) Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK214** T41034** T42010 (Upr) T42009 (Lwr) 60,000 Federal 105,000 California 100,000 100,000 100,000 2 100,000 2 60,000 1 60,000 1 60,000 1 120,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 1 60,000 1 Inspect at 120,000; replace if needed 120,000 260 260 263 263 229 229 254 254 254 231 254 254 254 254 254 258 256 256 259 259 259

TCK014 TCK210 TCK014 TCK210 TCK276

T41005 T41005 T41005 T41005 T41005

TCK276 TCK276

T41005 T41005

Not Applicable Not Applicable

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

GEO
Passenger Cars Metro 1989-92 1.0L 3-Cyl. 1993 1.0L 3-Cyl. 4-Bolt Sprocket 5-Bolt Sprocket 1994-95 1.0L 3-Cyl. 1996-97 1.0L 3-Cyl. 1998-00 1.0L 3-Cyl. 1992-93 1994 1995-97 1998-01 1.3L 4-Cyl. 1.3L 4-Cyl. 1.3L 4-Cyl. 1.3L 4-Cyl. T166 T166 T241 T241 T194 T194 T095 T243 T272 T194 TCK166 TCK166 TCK241 TCK241 TCK194A TCK194A T41009 T41009 T41010 T41010 Not Applicable Not Applicable Not Applicable Not Applicable 60,000 60,000 60,000 60,000 60,000 Inspect at 60,000; replace at 100,000 60,000 60,000 60,000 Inspect at 60,000; replace at 100,000 294 294 294 294 294 294 294 296 296 296 296 296

TCK272

T41065

Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A33

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

GEO (Cont.)
Metro (Canadian) 1992-93 1.3L 4-Cyl. 1994 1.3L 4-Cyl. Prizm 1989-92 1.6L 4-Cyl. (DOHC, VIN 6) * 1993-97 1993-97 Prizm GSI 1990-92 Spectrum 1989 Storm 1990-91 1990-93 1992-93 Light Trucks Tracker 1989-95 1994-02 1.6L 4-Cyl. (DOHC, VIN 6) * 1.8L 4-Cyl. (DOHC, VIN 8) * 1.6L 4-Cyl. (DOHC, VIN 5) 1.5L 4-Cyl. *# 1.6L 4-Cyl. (DOHC) # 1.6L 4-Cyl. (SOHC) *# 1.8L 4-Cyl. (DOHC) # 1.6L 4-Cyl. (SOHC, VIN U) 1.6L 4-Cyl. (SOHC, VIN 6) T095 T243 T036 T236 T235 T176 T162 T169 T177 T205 T164 T212 TCK177 T41027 Not Available T42001 Not Applicable TCK036 TCK236 TCK235 T41066 T41072 T41072 Not Applicable Not Applicable Not Applicable 60,000 60,000 Inspect at 30,000 3, replace at 60,000 Inspect at 30,000 3, replace at 60,000 Inspect at 30,000 3, replace at 60,000 60,000 60,000 60,000 30,000 60,000 60,000 1 60,000 296 296 290 290 290 290 290 290 287 293 292 288 292 298 300

TCK164 TCK212

T41064 T41065

Not Applicable Not Applicable

HONDA
Passenger Cars Accord (Includes Canadian) 1976-78 1.6L 4-Cyl. (SOHC) * 1979-83 1.6L 4-Cyl. (SOHC) * 1979-83 1.8L 4-Cyl. * 1984-85 1.8L 4-Cyl. * 1986-89 2.0L 4-Cyl. * 1990-93 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1994 (EX) 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1994 (Exc. EX) 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1995 (EX) 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1995 (Exc. EX) 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft T041 T041 T041 T094 T160 T186 T187 T186 T244 T186 T187 T186 T244 T186 T187 TCK041 TCK160 TCK160 TCK186 TCK186 TCK244 TCK244 TCK186 TCK186 TCK244 TCK244 TCK186 TCK186 Not Available T41012 T41012 T41013 T41014 T41013 T41014 T41013 T41014 T41013 T41014 T41013 T41014 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 2 90,000 2 90,000 2 90,000 2 90,000 2 90,000 2 90,000 2 Normal 60,000 2 Severe 90,000 2 Normal 60,000 2 Severe 90,000 2 Normal 60,000 2 Severe 90,000 2 Normal 60,000 2 Severe 314 314 324 324 329 338 338 338 338 338 338 338 338 338 338 338 338 338 338

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A34

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

HONDA (Cont.)
Accord (Includes Canadian - Cont.) 1996 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft (w/o VTEC) Camshaft (w/ VTEC) 1997 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft (w/o VTEC) Camshaft (w/ VTEC) 2.3L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 2.7L V6 *# 2.7L V6 *# 3.0L V6 (J30A1) *# 3.0L V6 (J30A1) *# 3.0L V6 (J30A1) *# 1.2L 4-Cyl. * 1.3L 4-Cyl. *# Canada USA 1.3L 4-Cyl. *# 1.3L 4-Cyl. *# 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.6L 4-Cyl. (DOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# T186 T187 T244 T186 T187 T244 T186 T244 T263 T263 T286 T286 T329 T028 T028 T073 T099 T161 T041 T099 T161 T143 T143 T143 T227 T145 T145 T145 T224 T224 T224 T224 T224 T312 T028 T036 T041 TCK041 Not Available Not Applicable TCK186 TCK244 T41013 T41014 T41014 T41013 T41014 T41014 T41013 T41014 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 90,000 2 60,000 2 90,000 2 60,000 2 90,000 2 60,000 2 Normal Severe Normal Severe Normal Severe 338 338 338 338 338 338 338 338 338 342 342 347 347 347 348 348 348 302 303 303 303 303 306 306 306 306 306 306 306 312 314 314 314 314 314 314 314 318 318 318 321 303 306 306

TCK186 TCK244 TCK244

105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 90,000 Normal 60,000 Severe 105,000 3 105,000 3 105,000 3 105,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 90,000 Normal 60,000 Severe 105,000 3 60,000 1 90,000 90,000 90,000 90,000 90,000 Normal 60,000 Severe 90,000 Normal 60,000 Severe 105,000 3 110,000 3 60,000 1 60,000 1 60,000 1

1998-02 1996 1997 1998-00 2001-02 2003-04 Civic 1973-79 1980-83 1984-85 1986-87 1980-83 1984-85 1986-87 1988-89 1990-94 1995 1999-00 1988-89 1991 1992 Except Si Si 1993-94 1995 1996

TCK286

T41090

T42038

TCK161 TCK161 TCK161 TCK161 TCK143 TCK143 TCK143 TCK227 TCK145 TCK145 TCK145 TCK244 TCK244 TCK244 TCK224 TCK224

T41017 T41017 T41017 T41017 T41011 T41011 T41011 T41016 T41011 T41011 T41011 T41023 T41023 T41023 T41023 T41023

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

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A35

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

HONDA (Cont.)
Civic CRX 1984 1.3L 4-Cyl. *# 1984-85 1.5L 4-Cyl. *# 1986-87 1.5L 4-Cyl. *# 1988-89 1.6L 4-Cyl. (SOHC) *# 1990-91 1.6L 4-Cyl. (SOHC) *# Civic del Sol (Except VX) 1993-94 1.5L 4-Cyl. *# 1995 1.5L 4-Cyl. *# 1993-94 1995 1996 1997 1994 1995-96 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (DOHC) *# 1.6L 4-Cyl. (DOHC) *# T099 T099 T161 T145 T145 T143 T143 T224 T224 T224 T224 T227 T227 T227 T223 T223 T223 T223 T041 T041 T094 T094 T160 T094 T160 T144 T144 T142 T142 T142 T186 T226 T186 T226 T186 T226 TCK161 TCK161 TCK161 TCK145 TCK143 TCK143 TCK224 TCK224 TCK224 TCK224 TCK227 TCK227 TCK227 T41017 T41017 T41017 T41011 T41011 T41011 T41023 T41023 T41023 T41023 T41016 T41016 T41016 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 1 60,000 1 90,000 90,000 90,000 Normal 60,000 Severe 90,000 90,000 Normal 60,000 Severe 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 60,000 Severe 90,000 90,000 Normal 60,000 Severe 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 60,000 1 90,000 90,000 90,000 2 90,000 2 90,000 2 Normal 60,000 2 Severe 90,000 2 Normal 60,000 2 Severe 105,000 2, 3 105,000 2, 3 303 306 306 314 314 306 306 306 314 314 314 318 318 318 312 312 312 312 306 306 306 306 306 306 314 324 324 324 324 329 329 329 329 331 331 331 333 333 333 333 333 333 333 333

1997 1.6L 4-Cyl. (DOHC) *# Civic del Sol VX 1993-94 1.5L 4-Cyl. *# 1995 1.5L 4-Cyl. *# Civic VX 1992-94 1995 Prelude 1980-82 1979-82 1983 1984-85 1986-87 1985 1986-87 1988-89 1990 1988-89 1990-91 1990-91 1993-94 1995-96 1.5L 4-Cyl. *# 1.5L 4-Cyl. *# 1.6L 4-Cyl. (SOHC) * 1.8L 4-Cyl. * 1.8L 4-Cyl. *# 1.8L 4-Cyl. *# 1.8L 4-Cyl. *# 2.0L 4-Cyl. (SOHC) * 2.0L 4-Cyl. (SOHC) * 2.0L 4-Cyl. (SOHC) *# 2.0L 4-Cyl. (SOHC) *# 2.0L 4-Cyl. (DOHC) *# 2.0L 4-Cyl. (DOHC) *# 2.1L 4-Cyl. (DOHC) *# 2.2L 4-Cyl. (DOHC) *# Balance Shaft Camshaft 2.2L 4-Cyl. (DOHC) *# Balance Shaft Camshaft 1997-01 2.2L 4-Cyl. (DOHC) *# Balance Shaft Camshaft

TCK160 TCK160 TCK160 TCK160 TCK142 TCK142 TCK142 TCK186 TCK186 TCK186 TCK186 TCK186 TCK186

T41012 T41012 T41012 T41012 T41019 T41019 T41019 T41019 T41019 T41022 T41024 T41022 T41024 T41022 T41024

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A36

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

HONDA (Cont.)
Prelude (Cont.) 1992-94 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1995-96 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1992-94 1995-96 2.3L 4-Cyl. (DOHC) *# Balance Shaft Camshaft 2.3L 4-Cyl. (DOHC) *# Balance Shaft Camshaft Light Trucks CR-V 1997-01 Odyssey 1995-96 1997 1998 1999-04 Passport 1994-96 1994-97 1998-99 2000-02 Pilot 2003-04 T186 T187 T186 T187 T186 T216 T186 T216 TCK186 TCK186 TCK186 TCK186 TCK216 TCK216 TCK216 TCK216 T41013 T41014 T41013 T41014 T41013 T41014 T41013 T41014 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 90,000 2 90,000 2 90,000 2 60,000 2 90,000 2 60,000 2 Normal Severe Normal Severe 338 338 338 338 338 338 338 338 338 338 338 338

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

2.0L 4-Cyl. *# 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 2.3L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 3.5L V6 (J35A1 & J35A4) *# 2.6L 4-Cyl. * 3.2L V6 (SOHC) # 3.2L V6 (DOHC) # 3.2L V6 (DOHC) # 3.5L V6 (J35A1 & J35A4) *#

T184 T186 T187 T186 T187 T186 T244 T286 T147 T221 T303 T303 T286

TCK184 TCK186 TCK186 TCK186 TCK186 TCK244 TCK244 TCK147 TCK221

T41016 T41013 T41014 T41013 T41014 T41013 T41014 T41026 T41028

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42002

105,000 3 90,000 2 90,000 2 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 3 60,000 60,000 75,000 105,000 3 105,000
3

327 336 336 336 336 342 342 348 345 35 351 351 348

HYUNDAI
Accent 1996 1997 1995-96 1997-99 2000-02 2001-04 Elantra 1992-95 1.5L 4-Cyl. (DOHC) * 1.5L 4-Cyl. (DOHC) * 1.5L 4-Cyl. (SOHC) * 1.5L 4-Cyl. (SOHC) * 1.5L 4-Cyl. (SOHC) * 1.6L 4-Cyl. (DOHC) * 1.6L 4-Cyl. (DOHC) * Balance Shaft Camshaft T282 T282 T191 T191 T324 T282 T168 T165 T41037 T41037 T41051 T41051 T41037 T41037 T41047 T41046 T42016 T42016 Not Applicable Not Applicable Not Applicable Not Available Not Applicable T42017 60,000 60,000 3 60,000 60,000 3 60,000 3 60,000 3 60,000 60,000
2 2

TCK191 TCK191

353 353 354 354 354 356 357 357

TCK165 TCK165

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A37

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

HYUNDAI (Cont.)
Elantra (Cont.) 1993-95 1.8L 4-Cyl. (DOHC) * Balance Shaft Camshaft 1996-98 1.8L 4-Cyl. * 1999-01 2.0L 4-Cyl. (DOHC) * 2002-03 2.0L 4-Cyl. (DOHC) * 2004 2.0L 4-Cyl. (DOHC) * Excel 1986-89 1.5L 4-Cyl. (SOHC) * 1990-94 1.5L 4-Cyl. (SOHC) * Santa Fe 2001-04 2.4L 4-Cyl. (DOHC) *# Balance Shaft Camshaft 2001-04 2.7L V6 (DOHC) *# Scoupe 1991-93 1.5L 4-Cyl. (SOHC) * 1994-95 1.5L 4-Cyl. (SOHC) * Sonata 1992-98 2.0L 4-Cyl. (DOHC) * Balance Shaft Camshaft 1989-91 2.4L 4-Cyl. (SOHC) * Balance Shaft Camshaft 1999-2003 2.4L 4-Cyl. (DOHC) *# Balance Shaft Camshaft 1999-01 2.5L V6 (DOHC) *# 2002-04 2.7L V6 (DOHC) *# 1990-98 3.0L V6 *# Tiburon 1997 1.8L 4-Cyl. * 1997 2.0L 4-Cyl. * 1998-01 2.0L 4-Cyl. * 2003-04 2.0L 4-Cyl. * 2003-04 2.7L 4-Cyl. *# XG300 2001 3.0L V6 (DOHC) *# XG350 2002-03 3.5L V6 (DOHC) *# 2004 3.5L V6 (DOHC) *# T168 T167 T278 T284 T284 T284 T073 T128 T314 T313 T315 T128 T128 T168 T167 T159 T124 T314 T313 T315 T315 T139 T278 T284 T284 T284 T315 T322 T323 T323 T41040 T41040 T42014 T42014 TCK128 TCK191 TCK167 TCK167 TCK124 TCK124 TCK167** TCK167** TCK278 TCK284 T41047 T41046** T41041 T41041 Not Applicable T42017 T42015 T42015 60,000 2 60,000 2 60,000 3 60,000 3 60,000 3 60,000 3 60,000 60,000 60,000 60,000 60,000
2 2 3

357 357 361 361 361 362 354 354 371 371 383 354 354 368 368 374 374 371 371 381 383 376 361 361 361 361 383 385 385 378

TCK073 TCK128

Not Available T41042

Not Applicable Not Applicable

T42014 T41042 T41051 T41047 T41046 T41053 T41044

Not Available Not Applicable Not Applicable Not Applicable T42017 Not Applicable Not Applicable

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


2, 3 2, 3

2 2

TCK139 TCK278 TCK284

T41048 T41041 T41041 T41041

T42014 T42014 Not Applicable T42015 T42015 T42015 T42014

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

INFINITI
Passenger Cars J30 1993 3.0L V6 * 1994-97 3.0L V6 * M30 1990-92 3.0L V6 * T180 T251 T104 TCK104 T41059 Not Applicable 60,000 60,000 60,000 388 388 391

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A38

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

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 From 7/1/86 1988-90 1.5L 4-Cyl. *# 1989 1.6L 4-Cyl. (DOHC) # 1981-84 1.8L 4-Cyl. Diesel * Impulse 1990-92 1.6L 4-Cyl. Non-Turbo # 1991-92 1.6L 4-Cyl. Turbo # 1992 1.8L 4-Cyl. # 1985-89 2.0L 4-Cyl. Turbo * 1988-89 2.3L 4-Cyl. * Stylus 1991 1.6L 4-Cyl. (DOHC) # 1991 1.6L 4-Cyl. (SOHC) *# 1992-93 1.6L 4-Cyl. (SOHC) *# 1992-93 1.8L 4-Cyl. (SOHC) # Light Trucks Amigo 1998 2.2L 4-Cyl. (DOHC) *# 1999-00 2.2L 4-Cyl. (DOHC) *# 1989-93 1989-94 1998 1999-00 Axiom 2002-04 Oasis 1996 2.3L 4-Cyl. * 2.6L 4-Cyl. * 3.2L V6 (DOHC) # 3.2L V6 (DOHC) # 3.5L V6 (DOHC) *# 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 1997 1998-99 2.2L 4-Cyl. (SOHC) *# Balance Shaft Camshaft 2.3L 4-Cyl. (SOHC) *# Balance Shaft Camshaft

T118 T162 T162 T169 T076 T169 T169 T205 T121 T122 T169 T177 T177 T205 T305 T305 T122 T147 T303 T303 T303

TCK118 TCK118 TCK118

Not Available Not Available Not Available T41027 T41027 T41027 T41027

Not Applicable Not Applicable Not Applicable T42001 T42001 T42001 T42001 Not Applicable T42001 Not Applicable Not Applicable T42001

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

293 293 293 397 400 397 397 397 402 402 397 397 397 397 407 407 407 402 402 416 416 416 416 416 409 409 409 409 409 409 411 411 405 402 402

TCK122 TCK177 TCK177

T41025 T41027 Not Available Not Available T41027

TCK122 TCK147

T41025 T41026

Not Applicable Not Applicable

T186 T187 T186 T187 T186 T244 T075 T122 T147

TCK186 TCK186 TCK186 TCK186 TCK244 TCK244 TCK122 TCK147

T41013 T41014 T41013 T41014 T41013 T41014 T41025 T41026

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

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

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A39

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

ISUZU (Cont.)
Rodeo 1998 1999-00 2001-03 1991-97 1993-97 1998 1999-04 2004 Rodeo Sport 2001-03 2001-03 Trooper 1990-91 1992-95 1992-97 1998 1999-02 Trooper II 1984-87 1986-87 1988-89 VehiCROSS 1999-01 2.2L 4-Cyl. (DOHC) *# 2.2L 4-Cyl. (DOHC) *# 2.2L 4-Cyl. (DOHC) *# 2.6L 4-Cyl. * 3.2L V6 (SOHC) # 3.2L V6 (DOHC) # 3.2L V6 (DOHC) # 3.5L V6 (DOHC) # 2.2L 4-Cyl. (DOHC) *# 3.2L V6 (DOHC) *# 2.6L 4-Cyl. * 3.2L V6 (DOHC) # 3.2L V6 (SOHC) # 3.5L V6 (DOHC) # 3.5L V6 (DOHC) # 2.2L 4-Cyl. Diesel * 2.3L 4-Cyl. * 2.6L 4-Cyl. * 3.5L V6 (DOHC) # T305 T305 T305 T147 T221 T303 T303 T303 T305 T303 T147 T220 T221 T303 T303 T075 T122 T147 T303 TCK147 TCK221** T41026 T41028 T41028** Not Applicable T42002 T42002 TCK147 TCK221** T41026 T41028** Not Applicable T42002 75,000 100,000 Normal 75,000 Severe 75,000 Normal 60,000 Severe 60,000 60,000 75,000 100,000 Normal 75,000 Severe 100,000 Normal 75,000 Severe 75,000 Normal 60,000 Severe 100,000 Normal 75,000 Severe 60,000 60,000 60,000 75,000 100,000 Normal 75,000 Severe 60,000 60,000 60,000 100,000 Normal 75,000 Severe 407 407 407 407 407 402 414 416 416 416 416 416 407 407 416 416 402 414 414 416 416 416 405 402 402 416 416

TCK122 TCK147

T41025 T41026

Not Applicable Not Applicable

JEEP
Liberty 2002 2003-04 Wrangler 2003-04 2.4L 4-Cyl. (DOHC, VIN 1) *# 2.4L 4-Cyl. (DOHC, VIN 1) *# 2.4L 4-Cyl. (DOHC, VIN 1) *# T265 T265 T265 T43005 T43008 T43008 Not Available Not Available Not Available 120,000 Normal 90,000 Severe 120,000 Normal 90,000 Severe 120,000 Normal 90,000 Severe 145 145 145 145 145 145

KIA
Passenger Cars Amanti 2004 3.5L V6 (DOHC) *# Optima 2001-04 2.4L V6 (DOHC) * Balance Shaft Camshaft T323 T314 T313 T41038 T41087** Not Applicable T42017 60,000 3 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 385 428 428 428 428

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A40

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

KIA (Cont.)
Optima (Cont.) 2001 2.5L V6 (DOHC) *# 2002-04 Rio 2001-02 2003-04 Sephia 1994-95 1996-97 1995-97 1998-01 1996-97 Spectra 2000-04 Light Trucks Sedona 2002-04 Sorento 2003 2004 Sportage 1995-02 1995 2.7L V6 (DOHC) *# 1.5L 4-Cyl. (DOHC) * 1.6L 4-Cyl. (DOHC) * 1.6L 4-Cyl. (SOHC) * 1.6L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (SOHC) * 1.8L 4-Cyl. (DOHC) * T315 T315 T318 T318 T185 T179 T179 T302 T185 T302 T41032 Not Available TCK185 TCK179 TCK179 T41030 T41031 T41031 T41032 Not Applicable T42005 T42005 T42005 T41040** T41040** T42014 T42014 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 60,000 3 60,000 3 Normal 40,000 Severe 60,000 3 Normal 40,000 Severe 105,000 (CA) 3 60,000 (Exc. CA) 105,000 (CA) 3 60,000 (Exc. CA) 381 381 383 383 418 418 418 418 421 421 420 420 420 420 423 423 421 421 423 423 385 385 385 385 385 425 425 427 427

3.5L V6 (DOHC) *# 3.5L V6 (DOHC) *# 3.5L V6 (DOHC) *# 2.0L 4-Cyl. (DOHC) * 2.0L 4-Cyl. (SOHC) *

T323 T323 T323 T281 T264 TCK281

T41039** T41039**

T42018 T42018

T41029 T41029

T42004 T42003

LANCIA
Beta 1976-78 1.8L 4-Cyl. * T020 25,000 430

LAND ROVER
Freelander 2002-04 2.5L KV6 (DOHC) *# Front Rear T327 T326 72,000 3 72,000 3 431 431

LEXUS
ES 250 1990-91 ES 300 1992-93 1994-98 1999-01 2.5L V6 (2VZ-FE) # 3.0L V6 (3VZ-FE) # 3.0L V6 (1MZ-FE) # 3.0L V6 (1MZ-FE) # T157 T200 T257 T257 TCK157** TCK200** T41057** T41057** T42030 T42030 60,000 1, 3 60,000 1, 3 60,000 1, 3 90,000 442 442 442 451

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A41

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year ES 300 (Cont.) 2002-03 ES 330 2004 GS 300 1993-97 1998-04 GS 400 1998-99 2000 GS 430 2001-04 IS 300 2001-04 LS 400 1990-94 1995-97 1998-00 LS 430 2001-04 SC 300 1993-97 1998-00 SC 400 1992-94 1995-97 1998-00 SC 430 2002-04 Light Trucks GX 470 2003-04 LX 470 1998-04 RX 300 1999-01 2002-03 RX 330 2004 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

LEXUS (Cont.)
3.0L V6 (1MZ-FE) # 3.3L V6 (3MZ-FE) *# 3.0L 6-Cyl. (2JZ-GE) 3.0L 6-Cyl. (2JZ-GE) * 4.0L V8 (1UZ-FE) *# 4.0L V8 (1UZ-FE) *# 4.3L V8 (3UZ-FE) * 3.0L 6-Cyl. (2JZ-GE) * 4.0L V8 (1UZ-FE) # 4.0L V8 (1UZ-FE) # 4.0L V8 (1UZFE) *# 4.3L V8 (3UZ-FE) * 3.0L 6-Cyl. (2JZ-GE) * 3.0L 6-Cyl. (2JZ-GE) 4.0L V8 (1UZ-FE) # 4.0L V8 (1UZ-FE) # 4.0L V8 (1UZ-FE) # 4.3L V8 (3UZ-FE) * 4.7L V8 (2UZ-FE) *# 4.7L V8 (2UZ-FE) *# 3.0L V6 (1MZ-FE) *# 3.0L V6 (1MZ-FE) *# 3.3L V6 (3MZ-FE) *# T257 T257 T215 T215 T298 T298 T298 T215 T190 T190 T298 T298 T215 T215 T190 T190 T298 T298 T298 T298 T257 T257 T257 TCK257** T41075** T42030 Not Available T42031 Not Available T42031 Not Available Not Available T42031 T42031 90,000 90,000 60,000 1, 3 90,000 90,000 90,000 90,000 90,000 60,000 1, 3 90,000 Normal 60,000 Severe 90,000 90,000 60,000 1, 3 90,000 60,000 1, 3 90,000 Normal 60,000 Severe 90,000 90,000 90,000 90,000 90,000 90,000 90,000 451 472 446 448 458 458 462 448 454 454 454 458 462 446 448 454 454 454 458 467 482 477 451 451 472

MAZDA
Passenger Cars Miata & MX-5 Miata 1990-92 1.6L 4-Cyl. (DOHC) 1993 1.6L 4-Cyl. (DOHC) 1994-96 1997 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) T179 T179 T179 T179 TCK179 TCK179 TCK179 TCK179 T41031 T41031 T41031 T41031 T42005 T42005 T42005 T42005 60,000 60,000 Federal 105,000 California 60,000 Federal 105,000 California 60,000 (Exc. CA & MA) 105,000 (CA & MA) 489 489 489 492 492 492 492 492

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A42

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MAZDA (Cont.)
Miata & MX-5 Miata (Cont.) 1999-00 1.8L 4-Cyl. (DOHC) T179 TCK179 T41031 T42005 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 60,000 492 492 492 492 492 514 514 514 514 514 514 514 514 514 514 518 518 518 518 518 518 518 518 518 518 489 489 489 489 489 499 499 499 499 499 504 504 504 504 504 504 571 578 578 578

2001-04 Millenia 1995-96 1997-98 1999-00

1.8L 4-Cyl. (DOHC) 2.3L V6 2.3L V6 2.3L V6

T179 T267 T267 T267

TCK179

T41031

T42005

2001-02 1995-96 1997-98 1999-00

2.3L V6 2.5L V6 2.5L V6 2.5L V6

T267 T214 T214 T214

TCK214** TCK214** TCK214**

T41034** T41034** T41034**

2001-02 MX-3 1994-95 1992 1993 1992 1993

2.5L V6 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.8L V6 1.8L V6

T214 T179 T185 T185 T214 T214 T214 T228 T228 T228 T134 T214 T214

TCK214** TCK179 TCK185 TCK185 TCK214** TCK214** TCK214** TCK228 TCK228 TCK228 TCK134 TCK214** TCK214**

T41034** T41031 T41030 T41030 T41034** T41034** T41034** T41091 T41091 T41091 T41029 T41034** T41034**

60,000 Federal 105,000 California 60,000 3 (Exc, CA & MA) 105,000 3 (CA & MA) 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 60,000 60,000 Federal T42010 (Upr) T42009 (Lwr) 105,000 California 60,000 3 T42010 (Upr) T42009 (Lwr) (Exc. CA & MA) 105,000 3 (CA & MA) T42010 (Upr) 60,000 3 T42009 (Lwr) (Exc. CA & Select) 105,000 3 (CA & Select) 105,000 3 T42010 (Upr) T42009 (Lwr) T42005 Not Applicable Not Applicable T42010 T42009 T42010 T42009 (Upr) (Lwr) (Upr) (Lwr) 60,000 Federal 105,000 California 60,000 60,000 Federal 105,000 California 60,000 60,000 Federal 105,000 California 60,000 Federal 105,000 California

MX-3 (Canadian) 1995 1.8L V6 MX-6 1993 1994-96 1997 1988-92 1993 1994-96 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.2L 4-Cyl. * 2.5L V6 2.5L V6

T42010 (Upr) T42009 (Lwr) T42008 T42008

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A43

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year MX-6 (Cont.) 1997 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MAZDA (Cont.)
2.5L V6 T214 TCK214** T41034** T42010 (Upr) T42009 (Lwr) 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 578 578 578 578

Protege 1995-97 1998

1.5L 4-Cyl. 1.5L 4-Cyl. Up To Eng. No. 19472 From Eng. No. 19473

T266 T266 T308 T308

TCK266 TCK266 TCK266

Not Available Not Available Not Available

Not Available 60,000 (Ex. CA & MA) 486 105,000 (CA & MA) 3 486 Not Available 60,000 (Ex. CA & MA) 105,000 (CA & MA) 3 Not Available 60,000 (Ex. CA & MA) 105,000 (CA & MA) 3 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 105,000 3 T42005 60,000 T42005 60,000 Federal 105,000 California T42005 60,000 Federal 105,000 California T42005 60,000 3 (Exc. CA & MA) 105,000 3 (CA & MA) 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) Not Applicable 60,000 Not Applicable 60,000 Federal 105,000 California T42008 105,000 3 T42008 105,000 3 60,000 Federal 105,000 California 60,000 60,000 60,000 60,000 60,000 Federal 105,000 California 100,000 100,000 60,000 486 486 486 486 487 487 487 487 487 489 489 489 492 492 492 492 492 497 497 497 497 489 489 489 504 504 521 521 489 489 489 489 489 489 502 502 511

1999-00

1.6L 4-Cyl. (DOHC)

2001 1990-92 1993-94 1995-96 1997-98 1999-00

1.6L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC)

T308 T179 T179 T179 T179 T316

TCK179 TCK179 TCK179 TCK179

T41031 T41031 T41031 T41031

1990-92 1993-94

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

T185 T185 T228 T228 T183 T149 T123 T141 T185 T185

TCK185 TCK185 TCK228 TCK228

T41030 T41030 T41091 T41091

2001-03 2.0L 4-Cyl. (DOHC) * Protege5 2002-03 2.0L 4-Cyl. (DOHC) * Serenia (Canadian) 1992-95 3.0L V6 (DOHC) * 323 1988-89 1986 1987-89 1990-92 1993-94 626 1984-85 1983 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 2.0L 4-Cyl. Diesel * Camshaft Injection Pump 2.0L 4-Cyl. (SOHC) *

TCK141 TCK185 TCK185

T41030 T41030 T41030

Not Applicable Not Applicable Not Applicable

T103 T102 T088

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A44

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year 626 (Cont.) 1984-85 1986-87 1993 1994-96 1997-00 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MAZDA (Cont.)
2.0L 4-Cyl. (SOHC) * Round Tooth Sprocket Square Tooth Sprocket 2.0L 4-Cyl. (SOHC) *# 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) T113 T088 T117 T228 T228 T228 60,000 60,000 60,000 60,000 60,000 Federal 105,000 California 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 105,000 3 60,000 60,000 60,000 Federal 105,000 California 60,000 3 (Exc. CA & Select) 105,000 3 (CA & Select) 105,000 3 60,000 Federal 105,000 California 60,000 Federal 105,000 California 60,000 511 511 511 504 504 504 504 504 504 504 504 511 518 518 518 518 518 518 518 518 521 521 521 521 523

TCK117 TCK228 TCK228 TCK228

T41035 T41091 T41091 T41091

Not Applicable T42008 T42008 T42008

2001-02 1988-92 1993 1994-96 1997-00

2.0L 4-Cyl. (DOHC) 2.2L 4-Cyl. * 2.5L V6 2.5L V6 2.5L V6

T228 T134 T214 T214 T214

TCK228 TCK134 TCK214** TCK214** TCK214**

T41091 T41029 T41034** T41034** T41034**

T42008 T42003 T42010 (Upr) T42009 (Lwr) T42010 (Upr) T42009 (Lwr) T42010 (Upr) T42009 (Lwr) T42010 (Upr) T42009 (Lwr) T42007 T42006 T42013 T42012 T42011 T42001 (Upr) (Lwr) (Upr) (Lwr) (Upr) (Lwr)

2001-02 929 1990-91 1992-95 1988-91 Light Trucks B2000 1986 1987 B2200 1987-93 B2300 1994 1995-97 B2500 1998-00 MPV 1989-93 1994-96 1997-98

2.5L V6 3.0L V6 (DOHC) * 3.0L V6 (DOHC) * 3.0L V6 (SOHC) *

T214 T183 T183 T146

TCK214** TCK183A** TCK183** TCK146**

T41034** T41036** T41036** T41033**

2.0L 4-Cyl. (SOHC) * Up To Chas. 568707 From Chas. 568708 2.0L 4-Cyl. (SOHC) * 2.2L 4-Cyl. * 2.3L 4-Cyl. 2.3L 4-Cyl. 2.5L 4-Cyl. 3.0L V6 (SOHC) * 3.0L V6 (SOHC) * 3.0L V6 (SOHC) *

T113 T117 T117 T134 T210 T276 T276 T146 T146 T146

TCK117 TCK134 TCK210 TCK276 TCK276 TCK146** TCK146** TCK146**

T41035 T41029 T41005 T41005 T41005 T41033** T41033** T41033**

Not Applicable T42003 Not Applicable Not Applicable Not Applicable T42011 T42001 T42011 T42001 T42011 T42001 (Upr) (Lwr) (Upr) (Lwr) (Upr) (Lwr)

60,000 60,000 60,000 60,000 60,000 60,000 120,000 60,000 60,000 Federal 105,000 California 60,000 3 (Exc. CA & MA) 105,000 3 (CA & MA)

511 511 511 511 513 513 517 523 523 523 523 523 523

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A45

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Tribute 2001-04 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MAZDA (Cont.)
2.0L 4-Cyl. (DOHC) T294 TCK294A T43003 T42036 (Upr) T42034 (Lwr) 90,000 508

MERCURY
Passenger Cars Bobcat 1974 2.0L 4-Cyl. 1975-80 2.3L 4-Cyl. Capri 1972 1.6L 4-Cyl. 1991-94 1.6L 4-Cyl. (DOHC) 1971-74 2.0L 4-Cyl. 1976-86 2.3L 4-Cyl. Cougar 1999 2.0L 4-Cyl. (DOHC, VIN 3) Up To 3/28/1999 From 3/29/1999 2000 2001-02 1981 1984-86 LN7 1982-83 Lynx 1981-85 1985-87 1984-87 Marquis 1983-86 Mystique 1995-97 1998 1999 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 2.3L 4-Cyl. 2.3L 4-Cyl. 1.6L 4-Cyl. (SOHC) *# 1.6L 4-Cyl. (SOHC) *# 1.9L 4-Cyl. (SOHC) *# 2.0L 4-Cyl. Diesel *# Camshaft Injection Pump 2.3L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) Up To 3/28/1999 From 3/29/1999 2000 Topaz 1984-86 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. Diesel *# Camshaft Injection Pump T013 T014 T013 T179 T013 T014 T294 T294 T294 T294 T014 T014 T067 T067 T067 T103 T102 T014 T258 T294 T294 T294 T294 TCK014 TCK258 TCK294 TCK294 TCK294A TCK294A T41005 T41008 T43003 T43003 T43003 T43003 Not Applicable T42032 (LH) T42033 (RH) T42035 (Upr) T42034 (Lwr) T42035 T42034 T42036 T42034 T42036 T42034 (Upr) (Lwr) (Upr) (Lwr) (Upr) (Lwr) 60,000 1 60,000 1 60,000 1 60,000 60,000 1 60,000 1 Inspect at 120,000, replace if needed Inspect at 120,000, replace if needed Inspect at 120,000, replace if needed 120,000 60,000 1 60,000 1 60,000 60,000 60,000 100,000 2 100,000 2 60,000 1 60,000 1 Inspect at 120,000, replace if needed Inspect at 120,000, replace if needed Inspect at 120,000, replace if needed Inspect at 120,000, replace if needed 100,000 2 100,000 2 226 254 226 222 226 254 236 236 236 236 236 236 236 254 254 224 224 224 229 229 254 234 236 236 236 236 236 236 236 236 229 229

TCK014 TCK179 TCK014 TCK294 TCK294A TCK294A TCK294A TCK014 TCK014 TCK067 TCK067 TCK067

T41005 T41031 T41005 T43003 T43003 T43003 T43003 T41005 T41005 T41006 T41006 T41006

Not Applicable T42005 Not Applicable T42035 (Upr) T42034 (Lwr) T42036 (Upr) T42034 (Lwr) T42036 (Upr) T42034 (Lwr) T42036 (Upr) T42034 (Lwr) Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

T103 T102

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A46

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Tracer 1987-90 1991-96 1991 1992-96 1997-99 Zephyr 1978-83 Light Trucks Villager 1993 1994-98 1999-02 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MERCURY (Cont.)
1.6L 4-Cyl. (SOHC) *# 1.8L 4-Cyl. (DOHC) 1.9L 4-Cyl. (SOHC) *# Up To 3/25/1991 From 3/26/1991 1.9L 4-Cyl. (SOHC) # 2.0L 4-Cyl. (SOHC, VIN P) 2.3L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.3L V6 (SOHC) * T141 T179 T067 T194 T194 T283 T014 T104 T249 T249 TCK141 TCK179 TCK067 TCK194 TCK194 T41030 T41031 T41006 T41007 T41007 Not Applicable T42005 Not Applicable Not Applicable Not Applicable 60,000 60,000 60,000 60,000 60,000 Inspect at 120,000, replace if needed 60,000 1 105,000 105,000 105,000 224 227 224 224 224 250 250 254 262 262 393

TCK014 TCK104 TCK249

T41005 T41059 T41059

Not Applicable Not Applicable Not Applicable

MERKUR
XR4Ti 1985-89 2.3L 4-Cyl. T014 TCK014 T41005 Not Applicable 60,000 1 254

MITSUBISHI
Passenger Cars Cordia & Tredia 1983-84 1.8L 4-Cyl. Balance Shaft Camshaft 1985-86 1.8L 4-Cyl. Balance Shaft Camshaft 1987-88 1.8L 4-Cy Balance Shaft Camshaft 1984 2.0L 4-Cyl. Balance Shaft Camshaft 1985-86 2.0L 4-Cyl. Balance Shaft Camshaft 1987-88 2.0L 4-Cyl. Balance Shaft Camshaft Diamante 1992-93 3.0L V6 (DOHC) *# 1994-95 3.0L V6 (DOHC) *# 1992-93 1994-96 1997-02 3.0L V6 (SOHC, 12-Valve) # 3.0L V6 (SOHC, 12-Valve) # 3.5L V6 (SOHC) *#

T090 T089 T159 T089 T159 T158 T090 T089 T159 T089 T159 T158 T195 T195 T139 T139 T287 TCK195** TCK195** TCK139 TCK139 TCK287 T41039** T41039** T41048 T41048 Not Available T42018 T42018 Not Applicable Not Applicable Not Available TCK158 TCK158 T41057 T41056 Not Applicable Not Applicable

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

530 530 530 530 530 530 530 530 530 530 530 530 189 189 189 563 563 563 575 575 575 575

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A47

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
Diamante (Cont.) 2003-04 3.5L V6 (SOHC) *# T287 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) TCK158 TCK158 TCK167** TCK167** TCK246** TCK246** T41057 T41058 T41047 T41046 T41002** T41002** Not Applicable Not Applicable Not Applicable T42017 T41002 T41002 60,000 2 60,000 2 60,000 2 60,000 2 60,000 3 Federal 100,000 3 California 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2 Federal 100,000 2 California 60,000 2 Federal 100,000 2 California 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 575 575 575 575 195 195 537 537 200 200 200 200 200 200 537 537 537 537 537 537 537 537 537 537 537 537 558 558 558 558 558 558 558 558 558 558 558 558

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

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

T159 T158 T168 T167 T246 T246

1995-97

2.0L 4-Cyl. (DOHC) Turbo * Balance Shaft Camshaft

T168 T167 T168

1998-99

2.0L 4-Cyl. (DOHC) Turbo * Balance Shaft

Camshaft

T167

1996

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

T168 T230 T168

1997-99

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

Camshaft

T230

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A48

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
Eclipse (Cont.) 2000 2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft T168 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2, 3 (Exc. CA, CT & MA) 100,000 2, 3 (CA, CT & MA) 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 (Exc. CA & Select) 100,000 2, 3 (CA & Select) 60,000 2, 3 (Exc. CA & Select) 100,000 2, 3 (CA & Select) 60,000 2, 3 (Exc. CA & Select) 100,000 2, 3 (CA & Select) 60,000 2, 3 (Exc. CA & Select) 100,000 2, 3 (CA & Select) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 Federal 100,000 California 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 60,000 3 Federal 100,000 3 California 60,000 2, 3 60,000 2, 3 60,000 2, 3 60,000 2, 3 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 568 568 568 568 568 568 568 568 568 568 198 198 198 203 203 203 203

Camshaft

T232

2001

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

T168 T232 T168

2002-03

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

Camshaft

T232

2004

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

T168

Camshaft

T332

2000

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

T259

TCK259**

T41039**

T42018

2001 2002-04

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

T259 T259

TCK259** TCK259**

T41039** T41039**

T42018 T42018

Expo & Expo LRV 1992-93 1.8L 4-Cyl. (VINs C & D) # 1994 1.8L 4-Cyl. (VINs C & D) # 1992 1993-95 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft

T201 T201 T159 T204 T168 T230

TCK201 TCK201

T41052 T41052

Not Applicable Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A49

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Galant 1989-92 1993 1989-92 1993 1994 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (DOHC) * Balance Shaft Camshaft 2.0L 4-Cyl. (DOHC) * Balance Shaft Camshaft 2.4L 4-Cyl. (DOHC) * Balance Shaft Camshaft Up To May, 1994 1985-87 1994-96 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft Camshaft 1997-98 2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft T159 T155 T168 T232 T168 T167 T168 T232 T168 T256 T159 T124 T168 T230 T168 TCK256** TCK124 TCK124 TCK155 TCK155 TCK232 TCK232 TCK167** TCK167** TCK232 TCK232 T41053 T41043 T41047 T41054 T41047** T41046** T41047 T41054 T41038 T41054** T41053 T41044 T42017 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42017 Not Applicable Not Applicable 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 Federal 100,000 California 60,000 2 Federal 100,000 California 60,000 2 60,000 2 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2, 3 Federal 100,000 2, 3 California 60,000 2 , 3 (Exc. CA , CT & MA) 100,000 2 , 3 (CA , CT & MA) 60,000 2 , 3 (Exc. CA , CT & MA) 100,000 2 , 3 (CA , CT & MA) 60,000 2 , 3 (Exc. CA , CT & MA) 100,000 2 , 3 (CA , CT & MA) 60,000 2 , 3 (Exc. CA , CT & MA) 100,000 2 , 3 (CA , CT & MA) 60,000 2 , 3 Federal 100,000 California 60,000 2 , 3 Federal 100,000 California 530 530 530 530 537 537 537 537 544 544 544 544 555 555 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558

Camshaft

T230

1999-00

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

T168

Camshaft

T232

2001

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

T168 T232

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A50

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Galant (Cont.) 2002-03 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft T168 60,000 2 , 3 (Exc. CA & Select) 100,000 2 , 3 (CA & Select) 60,000 2 , 3 (Exc. CA & Select) 100,000 2 , 3 (CA & Select) 60,000 2 , 3 (Exc. CA & Select) 100,000 2 , 3 (CA & Select) 60,000 2 , 3 (Exc. CA & Select) 100,000 2 , 3 (CA & Select) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 Federal 100,000 California 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA, MA & VT) 100,000 3 (CA , MA & VT) 60,000 60,000 3 (Exc. CA , MA & VT) 100,000 3 (CA , MA & VT) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA , MA & VT) 100,000 3 (CA , MA & VT) TCK073 Not Applicable 60,000 60,000 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 558 568 568 568 568 568 568 568 568 568 568 582 582 582 582 563 542 542 542 542 547 547 547 547 532 532 532 532 525 525

Camshaft

T232

2004

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

T168

Camshaft

T332

1999-00

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

T259

TCK259**

T41039**

T42018

2001 2002-03

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

T259 T259

TCK259** TCK259**

T41039** T41039**

T42018 T42018

2004

3.8L V6 (SOHC)

Galant Sigma 1988 Lancer 2002-04

3.0L V6 (SOHC, 12-Valve) # 2.0L 4-Cyl. (SOHC) *#

T139 T201

TCK139

T41048

Not Applicable

2004

2.4L 4-Cyl. (SOHC) *

T332

Lancer Evolution Turbo 2003-04 2.0L 4-Cyl. (DOHC) *# Balance Shaft Camshaft Mirage 1985-86 1.5L 4-Cyl. * Up To 5/31/1986 From 6/1/1986

T168 T167

T073 T073

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A51

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
Mirage (Cont.) 1987-90 1991 1992-93 1994-96 1997-99 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * T128 T191 T191 T191 T289 TCK128 TCK191 TCK191 TCK191 TCK289 T41042 T41051 T41042 T41051 Not Available 60,000 60,000 60,000 60,000 Federal 100,000 3 California Not Applicable 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) Not Applicable 60,000 Not Applicable 60,000 60,000 60,000 Not Applicable 60,000 Not Applicable 60,000 Federal 100,000 3 California 60,000 3 (Exc. CA, CT & MA) 100,000 3 (CA, CT & MA) Not Applicable Not Applicable Not Applicable Not Applicable T42018 T42018 T42018 60,000 60,000 60,000 Federal 100,000 California 60,000 60,000 60,000 3 Federal 100,000 California 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Ex. CA & MA) 100,000 (CA & MA) 60,000 3 (Ex. CA, CT & MA) 100,000 (CA, CT & MA) Not Applicable Not Applicable Not Applicable Not Applicable 525 525 525 525 525 525 525 525 525 525 525 525 525 528 528 192 192 198 198 198 198 198 198 198 525 525 525 525 563 189 189 189 189 189 189 189 189 189 189 563 563 563 563

2000-02

1.5L 4-Cyl. *

T289

1985-86 1987-88 1989 1991-92 1993 1994-96 1997-02

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

T093 T093 T165 T165 T201 T201 T288

T41055 T41056 TCK201 TCK201 T41052 T41052

Precis 1987-89 1990-93 1994

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

T073 T128 T128 T139 T195 T195 T195

TCK073 TCK128 TCK128 TCK139 TCK195** TCK195** TCK195**

Not Available T41042 T41042 T41048 T41039** T41039** T41039**

Sigma 1989-90 3.0L V6 (SOHC, 12-Valve) # Tredia (See Cordia) 3000GT 1991-93 3.0L V6 (DOHC) *# 1994-95 3.0L V6 (DOHC) *# 1996-98 3.0L V6 (DOHC) *#

1999 1997-99

3.0L V6 (DOHC) *# 3.0L V6 (SOHC, 12-Valve) #

T195 T139

TCK195** TCK139

T41039** T41048

T42018 Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A52

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Light Trucks Endeavor 2004 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
3.8L V6 (SOHC) *#
4

60,000 3 (Exc. CA, MA & VT) 100,000 3 (CA, MA & VT) TCK139 TCK139 TCK259** T41048 T41048 T41039** Not Applicable Not Applicable Not Applicable 60,000 60,000 3 Federal 100,000 California 60,000 3 Federal 100,000 California 60,000 3 Federal 100,000 California 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA , MA & VT) 100,000 3 (CA , MA & VT) 60,000 2, 3 (Exc. CA , CT & MA) 100,000 2, 3 (CA , CT & MA) 60,000 2 , 3 (Exc. CA , CT & MA) 100,000 2, 3 (CA , CT & MA) 60,000 2 , 3 60,000 2 , 3 60,000 3 (Exc. CA , CT & MA) 100,000 2, 3 (CA , CT & MA) 60,000 3 (Exc. CA , CT & MA) 100,000 2, 3 (CA , CT & MA) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select)

582 582 582 582 563 563 563 568 568 572 572 575 575 575 575 575 575 575 575 586 586 586 586 558 558 558 558 558 558 558 558 558 558 568 568 568 568 568 568 568 568 575 575 575 575

Montero 1989-93 1994 1995-96 1994-96 1997-00

3.0L V6 (SOHC, 12-Valve) # 3.0L V6 (SOHC, 12-Valve) # 3.0L V6 (SOHC, 24-Valve) *# 3.5L V6 (DOHC) *# 3.5L V6 (SOHC) *#

T139 T139 T259 T253 T287

TCK287

Not Available

Not Available

2001-02

3.5L V6 (SOHC) *#

T320

2003-04

3.8L V6 (SOHC) *#

T320

Montero Sport 1997-98

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

T168

Camshaft

T230

1999 1997-02

2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft Camshaft 3.0L V6 (SOHC, 24-Valve) *#

T168 T232 T259

TCK259**

T41039**

T42018

2003

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

T259

1999-00

3.5L V6 (SOHC) *#

T287

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A53

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

MITSUBISHI (Cont.)
Montero Sport (Cont.) 2001-02 3.5L V6 (SOHC) *# T287 TCK287 Not Available Not Available 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Exc. CA & Select) 100,000 3 (CA & Select) 60,000 3 (Ex. CA & Select) 100,000 (CA & Select) 60,000 2 60,000 2 TCK158A TCK158A T41045 T41044 T41049 T41050 TCK124 TCK124 T41053 T41044 Not Applicable Not Applicable Not Applicable Not Applicable 60,000 2 60,000 2 50,000 2 50,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 Federal 100,000 California 60,000 2 60,000 2 575 575 575 575 575 575 575 575 547 547 547 547 530 530 530 530 185 185 187 187 187 187 563 563 563 555 555

2003-04

3.5L V6 (SOHC) *#

T287

Outlander 2003-04

2.4L 4-Cyl. (SOHC, VIN G) * Balance Shaft Camshaft (2003) Camshaft (2004) 2.0L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. Balance Shaft Camshaft 2.3L 4-Cyl. Turbo Diesel * Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 3.0L V6 (SOHC, 12-Valve) # 3.0L V6 (SOHC, 12-Valve) # 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft

T168 T232 T332 T090 T089 T159 T158 T092 T091 T159 T124 T168 T229 T139 T139

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

TCK139 TCK139

T41048 T41048

Not Applicable Not Applicable

T159 T124

TCK124 TCK124

T41053 T41044

Not Applicable Not Applicable

NISSAN
Passenger Cars Maxima 1985 3.0L V6 (SOHC) * 1986-91 3.0L V6 (SOHC) * 1992-94 3.0L V6 (SOHC) * Round Tooth Sprocket Square Tooth Sprocket Pulsar & Pulsar NX (Includes Canadian) 1983-84 1.5L 4-Cyl. (SOHC) * 1983-85 1.6L 4-Cyl. (SOHC) * 1986-88 1.6L 4-Cyl. (SOHC) * 1987 1.6L 4-Cyl. (DOHC) * 1988-89 1.8L 4-Cyl. (DOHC) * T104 T104 T249 T104 T077 T077 T077 T137 T137 TCK104 TCK104 TCK249 TCK104 TCK077 TCK077 TCK077 T41059 T41059 T41059 T41059 T41058 T41058 T41058 T41058 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 1 60,000 60,000 60,000 60,000 1 60,000 1 60,000 60,000 60,000 596 596 596 596 589 589 589 590 590

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A54

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

NISSAN (Cont.)
Sentra (Includes Canadian) 1982-83 1.5L 4-Cyl. (SOHC) * 1983-85 1.6L 4-Cyl. (SOHC) * 1986-88 1.6L 4-Cyl. (SOHC) * 1983-85 1.7L 4-Cyl. Diesel * Camshaft Injection Pump 1986-87 1.7L 4-Cyl. Diesel * Camshaft Injection Pump Stanza 1982-85 2.0L 4-Cyl. * 1986-89 2.0L 4-Cyl. * Stanza Wagon 1982-85 2.0L 4-Cyl. * 1986-89 2.0L 4-Cyl. * 200SX (Includes Canadian) 1984-85 1.8L 4-Cyl. Turbo 1986-87 1.8L 4-Cyl. Turbo 1984-85 2.0L 4-Cyl. * 1986-87 2.0L 4-Cyl. * 1988 2.0L 4-Cyl. * 1987-88 3.0L V6 (SOHC) * 300ZX 1984-85 3.0L V6 (SOHC) * 1986-89 3.0L V6 (SOHC) * 1990-92 3.0L V6 (DOHC) * 1993 1994-96 1994-96 310 1982 Light Trucks Frontier 1999-03 2004 Pathfinder 1986-92 1993-94 1995-96 1996-00 Pickup 1986-92 3.0L V6 (DOHC) * 3.0L V6 (DOHC) Turbo * 3.0L V6 * (DOHC) Non-Turbo 1.5L 4-Cyl. * 3.3L V6 (SOHC) * 3.3L V6 (SOHC) * 3.0L V6 (SOHC) * 3.0L V6 (SOHC) * Round Tooth Sprocket Square Tooth Sprocket 3.0L V6 (SOHC) * 3.3L V6 (SOHC) * 3.0L V6 (SOHC) * T077 T077 T077 T096 T097 T096 T097 T078 T078 T078 T078 T100 T100 T078 T078 T078 T104 T104 T104 T180 T180 T251 T251 T077 T249 T249 T104 T249 T104 T249 T249 T104 TCK077 TCK249 TCK249 TCK104 TCK249 TCK104 TCK249 TCK249 TCK104 TCK078 TCK078 TCK078 TCK078 T41088 T41088 T41088 T41088 Not Applicable Not Applicable Not Applicable Not Applicable TCK077 TCK077 TCK077 T41058 T41058 T41058 Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 60,000 1 60,000 1 60,000 60,000 60,000 1 60,000 60,000 1 60,000 60,000 1 60,000 60,000 1 60,000 60,000 60,000 589 589 589 592 592 592 592 593 593 593 593 593 593 593 593 593 596 596 596 594 594 594 594 594 594 589 393 393 596 596 596 596 393 596

TCK078A TCK078A TCK078 TCK104 TCK104 TCK104

T41089 T41089 T41088 T41059 T41059 T41059 T41085** T41085** T41085** T41085** T41058 T41059 T41059 T41059 T41059 T41059 T41059 T41059

Not Applicable Not Applicable Not Applicable Not Applicable

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A55

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Pickup (Cont.) 1993-94 1995 Quest 1993-94 1995-98 1999-02 Xterra 2000-02 2003-04 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

NISSAN (Cont.)
3.0L V6 (SOHC) * Round Tooth Sprocket Square Tooth Sprocket 3.0L V6 (SOHC) * 3.0L V6 (SOHC) * Round Tooth Sprocket Square Tooth Sprocket 3.0L V6 (SOHC) * 3.3L V6 (SOHC) * 3.3L V6 (SOHC) * 3.3L V6 (SOHC) * T249 T104 T249 T249 T104 T249 T249 T249 T249 TCK249 TCK104 TCK249 TCK249 TCK104 TCK249 TCK249 TCK249 TCK249 T41059 T41059 T41059 T41059 T41059 T41059 T41059 T41059 T41059 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 60,000 60,000 60,000 60,000 60,000 60,000 105,000 105,000 105,000 596 596 596 596 596 596 393 393 393

OLDSMOBILE
Cutlass Supreme 1991-95 3.4L V6 # 1996 3.4L V6 *# Firenza 1982-86 1.8L 4-Cyl. # 1987-88 2.0L 4-Cyl. # T192 T273 T081 T081 TCK192 TCK273 TCK081 Not Available Not Available Not Available Not Available 60,000 60,000 60,000 1 60,000 1 284 284 271 272

Not Applicable Not Applicable

OPTIMA
Optima (Canadian) 1988-92 1.6L 4-Cyl. # 1988-89 2.0L 4-Cyl. # 1990-91 2.0L 4-Cyl. # T148 T081 T163 60,000 1 60,000 1 60,000 1 599 599 599

TCK163

T43002

Not Applicable

PEUGEOT
405 1989-91 1989-91 505 1986-91 1.9L 4-Cyl. (DOHC) 1.9L 4-Cyl. (SOHC) 2.2L 4-Cyl. (Exc. Turbo) T188 T189 T140 60,000 1 60,000 1 60,000 1 600 600 602

PLYMOUTH
Passenger Cars Acclaim 1989-95 2.5L 4-Cyl. (SOHC) 1989-93 3.0L V6 (SOHC) # 1994-95 3.0L V6 (SOHC) # Arrow 1978-80 1977-80 Breeze 1996-99 2000 1997-99 1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (SOHC, VIN C) *# 2.0L 4-Cyl. (SOHC, VIN C) *# 2.4L 4-Cyl. (DOHC, VIN X) # T153 T139 T139 TCK153 TCK139 TCK139 T41001 T41048 T41048 Not Applicable Not Applicable Not Applicable 60,000 1 60,000 60,000 3 Federal 100,000 California 60,000 60,000 2 60,000 2 TCK245** T41002** Not Applicable 100,000 Federal 105,000 California 100,000 Federal 105,000 California 105,000 143 164 164 164 126 124 124 131 131 131 131 150

T064 T062 T013 T245 T245 T265 T43005 Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A56

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Breeze (Cont.) 2000 Caravelle 1983-88 1986-87 1988 Champ 1979 1980-82 1979-82 1979-80 Colt 1979-82 1983-84 1985-86 1987-90 1991-94 1978-79 1979-82 1983-89 1977-80 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

PLYMOUTH (Cont.)
2.4L 4-Cyl. (DOHC, VIN X) # 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 1.4L 4-Cyl. * 1.4L 4-Cyl. * 1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) Balance Shaft Camshaft 1.4L 4-Cyl. * 1.4L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.5L 4-Cyl. * 1.6L 4-Cyl. (RWD) w/o Balance Shaft 1.6L 4-Cyl. (FWD) w/o Balance Shaft 1.6L 4-Cyl. w/o Bal. Shaft w/o Balance Shaft 1.6L 4-Cyl. Balance Shaft Camshaft 1.6L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (VIN T) 1.8L 4-Cyl. (VINs C & D) # T265 T071 T114 T132 T073 T073 T064 T062 T013 T073 T073 T073 T128 T191 T064 T064 T093 T062 T013 T165 T093 T201 T128 T191 T201 T090 T089 T159 T158 T159 T158 T159 T204 T159 T230 TCK158A TCK158A TCK158A TCK158A T41045 T41044 T41045 T41044 Not Applicable Not Applicable Not Applicable Not Applicable TCK128 TCK191 T41042 T41051 Not Applicable Not Applicable TCK073 TCK073 TCK128 TCK191 Not Available Not Available T41042 T41051 Not Applicable Not Applicable Not Applicable Not Applicable TCK071 TCK114 TCK132 TCK073 T43005 T41000 Not Available Not Applicable Not Applicable Not Applicable Not Applicable 100,000 Federal 105,000 California 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 60,000 2 60,000 2 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 150 150 143 143 143 122 122 126 124 124 122 122 173 173 173 126 126 126 124 124 192 130 198 173 173 198 180 180 180 180 180 180 203 203 203 203

Not Available

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A57

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

PLYMOUTH (Cont.)
Colt Vista (Includes Canadian - Cont.) 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt 100 & 200 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) * Horizon 1978-83 1.7L 4-Cyl. * 1981-88 2.2L 4-Cyl. (SOHC) 1989-90 2.2L 4-Cyl. (SOHC) Laser 1990-94 1.8L 4-Cyl. Balance Shaft Camshaft 1990-94 2.0L 4-Cyl. (DOHC) * Balance Shaft Camshaft Neon 1995-99 2.0L 4-Cyl. (DOHC, VIN Y) *# 1995-97 2.0L 4-Cyl. (SOHC, VIN C) *# 1998-99 2.0L 4-Cyl. (SOHC, VIN C) *# 2000-04 2.0L 4-Cyl. *# (SOHC, VINs C & F) Prowler 1999 3.5L V6 *# 2000-02 3.5L V6 *# Reliant 1981-88 1989 1986-87 1988 1989 Sapporo 1978-80 1977-80 Scamp Pickup 1983 Sundance 1987-88 1989-94 1988 1989-94 1992-93 1994 TC3 1981-82 1981-82 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) w/o Balance Shaft 1.6L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 2.5L 4-Cyl. (SOHC) 3.0L V6 (SOHC) # 3.0L V6 (SOHC) # 1.7L 4-Cyl. * 2.2L 4-Cyl. (SOHC) T168 T230 T165 T017 T071 T153 T159 T158 T168 T167 T246 T245 T245 T245 T295 T295 T071 T153 T114 T132 T153 T064 T062 T013 T071 T071 T153 T132 T153 T139 T139 T017 T071 TCK071 TCK071 TCK153 TCK132 TCK153 TCK139 TCK139 TCK017 TCK071 T41000 T41000 T41001 T41001 T41001 T41048 T41048 T41079 T41000 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK071 TCK071 TCK114 TCK153 T41000 T41001 Not Available T41001 Not Applicable Not Applicable Not Applicable Not Applicable TCK017 TCK071 TCK153 TCK158 TCK158 TCK167** TCK167** TCK246** TCK245** TCK245** T41079 T41000 T41001 T41057 T41056 T41047 T41046** T41002** T41002** T41002** Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42017 T41002 Not Applicable Not Applicable 60,000 2 60,000 2 60,000 60,000 1 60,000 1 60,000 1 60,000 2 60,000 2 60,000 2 60,000 2 105,000 105,000 105,000 105,000 105,000 100,000 Federal 105,000 California 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 2 60,000 2 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 60,000 1 60,000 1 203 203 192 128 143 143 195 195 175 175 200 131 131 134 182 182 182 143 143 143 143 143 126 124 124 143 143 143 143 143 164 164 128 143

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A58

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

PLYMOUTH (Cont.)
Turismo 1983 1.7L 4-Cyl. * 1983-87 2.2L 4-Cyl. (SOHC) Light Trucks (See DODGE/PLYMOUTH Light Trucks) T017 T071 TCK017 TCK071 T41079 T41000 Not Applicable Not Applicable 60,000 1 60,000 1 128 143

PONTIAC
Passenger Cars Acadian (Canadian) 1976 1.4L 4-Cyl. 1977 1.4L 4-Cyl. 1976 1.6L 4-Cyl. 1977-78 1.6L 4-Cyl. 1979-87 1.6L 4-Cyl. 1981-85 1.8L 4-Cyl. Diesel * Firefly (Canadian) 1985-88 1.0L 3-Cyl. 1989-91 1.0L 3-Cyl. 1994-95 1.0L 3-Cyl. 1996-97 1.0L 3-Cyl. 1998-00 1.0L 3-Cyl. 1995-97 1.3L 4-Cyl. 1998-00 1.3L 4-Cyl. Grand Am 1987-88 2.0L 4-Cyl. # 1989 2.0L 4-Cyl. # Grand Prix 1991-95 3.4L V6 # 1996 3.4L V6 *# J2000 1982 1.8L 4-Cyl. # LeMans 1988-89 1.6L 4-Cyl. # 1990 1.6L 4-Cyl. *# With Tensioner Without Tensioner 1991-93 1.6L 4-Cyl. *# 1989 2.0L 4-Cyl. # First Design Second Design 1990 2.0L 4-Cyl. # Sunbird 1985-86 1.8L 4-Cyl. # 1987-88 2.0L 4-Cyl. # 1989-94 2.0L 4-Cyl. # Sunburst (Canadian) 1985-88 1.5L 4-Cyl. *# T1000 1981-82 1.6L 4-Cyl. 1000 1983-87 1.6L 4-Cyl. 2000 1983 1.8L 4-Cyl. # T037 T039 T037 T039 T061 T076 T095 T166 T241 T194 T194 T272 T194 T081 T163 T192 T273 T081 T148 T203 T148 T203 T081 T163 T163 T081 T081 T163 T118 T061 T061 T081 TCK081 Not Applicable Not Applicable TCK166 TCK241 TCK194A TCK194A TCK272 TCK081A TCK163 TCK192 TCK273 TCK081 TCK148 TCK148 TCK081A TCK163 TCK163 TCK081 TCK081A TCK163 TCK118 Not Available Not Available T41010 T41010 T41065 Not Available Not Available Not Applicable Not Applicable Not Applicable 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 60,000 100,000 60,000 100,000 60,000 1 60,000 1 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 1 60,000 1 60,000 1 265 265 265 265 265 270 294 294 294 294 294 296 296 272 272 285 285 271 268 268 268 268 272 272 272 271 272 272 293 265 265 271

Not Applicable Not Applicable T43002 Not Applicable Not Available Not Available Not Available Not Available

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T43002 Not Applicable T43002 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T43002 Not Applicable Not Available Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A59

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

PONTIAC (Cont.)
2000 Sunbird 1984 1.8L 4-Cyl. # Light Trucks Sunrunner (Canadian) 1989-95 1.6L 4-Cyl. (SOHC, VIN U) 1994-02 1.6L 4-Cyl. (SOHC, VIN 6) T081 T164 T212 TCK081 TCK164 TCK212 Not Applicable Not Applicable T41064 T41065 Not Applicable Not Applicable 60,000 1 60,000 1 60,000 271 298 300

PORSCHE
924 1977-82 1987-88 928 1978-82 1983-84 1985-91 1992-95 944 1983-89 2.0L 4-Cyl. * 2.5L 4-Cyl. *# Balance Shaft Camshaft 4.5L V8 *# 4.7L V8 *# 5.0L V8 *# 5.4L V8 *# T017 T293 T107 T196 T196 T196 T196 T293 T107 T293 T107 T293 T152 T293 T152 T293 T152 TCK017 T41079 Not Applicable 45,000 3 45,000 45,000 60,000 60,000 60,000 60,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 603 604 604 607 607 607 607 604 604 604 604 604 604 604 604 604 604

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

RENAULT
Alliance & Encore 1985-87 1.7L 4-Cyl. * Fuego 1984-85 2.2L 4-Cyl. Sportwagon 1984-86 2.2L 4-Cyl. T119 T140 T140 60,000 1 60,000 1 60,000 1 609 610 610

SAAB
900 1994-97 9000 1995-97 9-5 1999-03 2.5L V6 * 3.0L V6 * 3.0L V6 (DOHC) T285 T285 T285 TCK285 Not Available Not Available 60,000 60,000 90,000 612 612 613

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A60

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

SATURN
LS2 & LW2 2000 3.0L V6 (DOHC, VIN R) *# L300 & LW300 2001 3.0L V6 (DOHC, VIN R) *# 2002-04 3.0L V6 (DOHC, VIN R) *# Up To S/N 578511 From S/N 578512 Vue 2002-03 3.0L V6 (DOHC, VIN B) *# 2004 3.5L V6 (SOHC) *# T285 T285 T285 T285 T285 T329 100,000 100,000 100,000 100,000 100,000 100,000 619 619 619 616 616 622

STERLING
825 1987-88 827 1989-91 2.5L V6 *# 2.7L V6 *# T129 T129 TCK129 TCK129 T41015 T41015 Not Applicable Not Applicable 60,000 1 60,000 1 624 624

SUBARU
Passenger Cars Coupe 1985-89 1.8L 4-Cyl. Left Hand Belt Right Hand Belt Forester 1998 2.5L 4-Cyl. (DOHC) # 1999-04 2.5L 4-Cyl. (SOHC) * Impreza & Outback Sport 1993 1.8L 4-Cyl. 1994 1995-97 2002-04 1995-96 1997-98 1999-01 1998 1.8L 4-Cyl. 1.8L 4-Cyl. 2.0L 4-Cyl. (DOHC) Turbo * 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) 2.2L 4-Cyl. (SOHC) * 2.5L 4-Cyl. (DOHC) #

T299 T300 T277 T304 T172 T254 T254 T328 T254 T254 T304 T277 T304 T135 T172

TCK299 TCK299

T41061 T41062

T42022 Not Applicable

52,000 2 52,000 2 105,000 105,000

628 628 637 635 627 627 627 627 630 627 627 627 627 635 637 635 626 627

TCK172** TCK254** TCK254**

T41063** T41063** T41063**

TCK254**

T41063**

TCK277**

T41092**

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

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

T41060 TCK172** T41063**

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A61

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

SUBARU (Cont.)
Legacy & Outback (Cont.) 1994 2.2L 4-Cyl. 1995-96 2.2L 4-Cyl. 1997-98 1999 1996-97 1998-99 2.2L 4-Cyl. 2.2L 4-Cyl. (SOHC) * 2.5L 4-Cyl. (DOHC) # 2.5L 4-Cyl. (DOHC) # T254 T254 T254 T304 T277 T277 TCK277** TCK277** T41092** T41092** TCK254** TCK254** 60,000 60,000 Federal 105,000 California 60,000 Federal 105,000 California 105,000 T42023 (Upr-L) 60,000 T42023 (Lwr-L) T42024 (Lwr-R) T42023 (Upr-L) 105,000 T42023 (Lwr-L) T42024 (Lwr-R) 105,000 TCK299 TCK299 TCK299 TCK299 TCK299 TCK299 T41061 T41062 T41061 T41062 T42022 Not Applicable T42022 Not Applicable Not Applicable Not Applicable 52,000 2 52,000 2 52,000 2 52,000 2 52,000 2 52,000 2 60,000 60,000 Federal 105,000 Calif. TCK299 TCK299 T41061 T41062 T42022 Not Applicable 52,000 2 52,000 2 60,000 2 60,000 2 105,000 Not Applicable Not Applicable 627 627 627 627 627 635 637 637

2000-03 Loyale 1990-94 RX 1985-89

2.5L 4-Cyl. (SOHC) * 1.8L 4-Cyl. Left Hand Right Hand

T307 T299 T300 T299 T300 T299 T300 T209 T209

635 628 628 628 628 628 628 644 644 644 628 628 641 641 635

1.8L 4-Cyl. Left Hand Right Hand Sedan & Station Wagon 1985-89 1.8L 4-Cyl. Left Hand Right Hand SVX 1992-94 3.3L 6-Cyl. 1995-97 3.3L 6-Cyl. XT 1985-91 XT6 1988-91 Light Trucks Baja 2003-04 1.8L 4-Cyl. Left Hand Right Hand 2.7L 6-Cyl. Left Hand Right Hand 2.5L 4-Cyl. (SOHC) *

T299 T300 T151 T150 T307

SUZUKI
Passenger Cars Esteem 1995-00 1.6L 4-Cyl. (SOHC) Esteem (Canadian) 2001-02 1.6L 4-Cyl. (SOHC) Forenza 2004 2.0L 4-Cyl. T212 T212 T309 TCK212 TCK212 T41065 T41065 Not Applicable Not Applicable 60,000 60,000 Inspect at 30,000 Replace at 60,000 649 649 651 651

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A62

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Swift 1989-92 1993-94 1989-92 1993 1994 1995-97 1998-01 Light Trucks Samurai 1985 1986-92 1993 1994 1995 Sidekick 1989 1989-91 1992 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

SUZUKI (Cont.)
1.3L 4-Cyl. (DOHC) * 1.3L 4-Cyl. (DOHC) * 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) 1.3L 4-Cyl. (SOHC) Up To VIN R4100375 From VIN R4100376 1.3L 4-Cyl. (SOHC) T171 T171 T095 T095 T243 T272 T194 T095 T095 T095 T095 T243 T243 T095 T164 T164 T212 T164 T212 T212 T212 T212 60,000 1 60,000 60,000 1 60,000 60,000 60,000 60,000 60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000 645 645 647 647 647 647 647 647 647 647 647 647 647 647 649 649 649 649 649 649 649 649

TCK095 TCK095 TCK272 TCK194A

T41064 T41064 T41065

Not Applicable Not Applicable Not Applicable Not Applicable

TCK095 TCK095 TCK095

T41064 T41064

Not Applicable Not Applicable Not Applicable

1.3L 4-Cyl. (SOHC) 1.6L 4-Cyl. 1.6L 4-Cyl. Convertible Hardtop 1993-95 1.6L 4-Cyl. Convertible Hardtop 1996-98 1.6L 4-Cyl. Vitara (Includes Canadian) 1999-01 1.6L 4-Cyl. X-90 1996-98 1.6L 4-Cyl.

TCK095 TCK164 TCK164 TCK212 TCK164 TCK212 TCK212 TCK212 TCK212

T41064 T41064 T41064 T41065 T41064 T41065 T41065 T41065 T41065

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

TOYOTA
Passenger Cars Avalon 1995-97 3.0L V6 # 1998-04 3.0L V6 (1MZ-FE) *# Camry 1984-86 1.8L 4-Cyl. Diesel 1983-85 2.0L 4-Cyl. # 1986 2.0L 4-Cyl. # 1987 2.0L 4-Cyl. # GT-S Exc. GT-S 1988-91 2.0L 4-Cyl. # 1992-97 2.2L 4-Cyl. # 1998-01 2.2L 4-Cyl. 1988-91 2.5L V6 # 1992-93 3.0L V6 # 1994-97 3.0L V6 # 1998-02 3.0L V6 (1MZ-FE) *# 2003-04 3.0L V6 (1MZ-FE) *# 2004 3.3L V6 (3MZ-FE) *# T257 T257 T098 T087 T087 T125 T138 T138 T199 T199 T157 T200 T257 T257 T257 T257 TCK257** TCK257** TCK087 TCK087 TCK199 TCK199 TCK199 TCK199 TCK157** TCK200** TCK257** TCK257** T41075** T41075** T41077 T41070 T41070 T41067 T41067 T41067 T41067 T41067 T41075** T41075** T41075** T41075** T42030 T42030 T42027 T42025 T42025 T42025 T42025 T42025 T42025 T42025 T42030 T42030 T42030 T42030 60,000 Severe 90,000 60,000 60,000 1 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 90,000 60,000 Severe 60,000 Severe 60,000 Severe 90,000 90,000 90,000 683 697 667 669 669 669 669 669 678 678 683 683 683 697 697 472

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A63

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

TOYOTA (Cont.)
Camry Solara 1999-00 2.2L 4-Cyl. 2001 2.2L 4-Cyl. 1999-03 3.0L V6 (1MZ-FE) *# 2004 3.3L V6 (3MZ-FE) *# Celica, Celica GT & ST 1990-92 1.6L 4-Cyl. (DOHC) 1993 1.6L 4-Cyl. (DOHC) 1994-97 1.8L 4-Cyl. (DOHC) 1986 2.0L 4-Cyl. # 1987-89 2.0L 4-Cyl. # 1990 2.0L 4-Cyl. # 1991-93 2.0L 4-Cyl. # 1990-91 2.2L 4-Cyl. 1992-97 2.2L 4-Cyl. 1998-99 2.2L 4-Cyl. Celica GTS 1986 2.0L 4-Cyl. # 1987-88 2.0L 4-Cyl. # 1990-91 2.2L 4-Cyl. 1992-93 2.2L 4-Cyl. Celica Supra 1982-83 2.8L 6-Cyl. 1984-85 2.8L 6-Cyl. Corolla 1983-85 1.6L 4-Cyl. (SOHC) 1986-87 1.6L 4-Cyl. (SOHC) 1988 1.6L 4-Cyl. (SOHC) 1988-92 1.6L 4-Cyl. (DOHC, 4A-FE) 1993-97 1.6L 4-Cyl. (DOHC, 4A-FE) 1984-85 1.8L 4-Cyl. Diesel 1993-97 1.8L 4-Cyl. (7A-FE) Corolla FX & FX-16 1987-88 1.6L 4-Cyl. (SOHC) 1985 1.6L 4-Cyl. (DOHC, 4A-GE) 1986-88 1.6L 4-Cyl. (DOHC, 4A-GE) Corolla GTS 1985 1.6L 4-Cyl. (DOHC, 4A-GE) 1986-88 1.6L 4-Cyl. (DOHC, 4A-GE) 1989 1.6L 4-Cyl. (4A-GE/GELC) 1990-91 1.6L 4-Cyl. (4A-GE/GELC) Corolla SR5 1985 1.6L 4-Cyl. 1986-87 1.6L 4-Cyl. 1988 1.6L 4-Cyl. Corolla Sport 1985 1.6L 4-Cyl. (4A-GE) 1986-87 1.6L 4-Cyl. (4A-GE) Corolla Tercel 1980-82 1.5L 4-Cyl. Cressida 1983 2.8L 6-Cyl. 1984-85 2.8L 6-Cyl. T199 T199 T257 T257 T036 T239 T235 T087 T138 T125 T125 T138 T199 T199 T125 T125 T138 T199 T074 T101 T070 T070 T036 T036 T236 T098 T235 T070 T112 T112 T112 T112 T176 T176 T070 T070 T036 T112 T112 T070 T074 T101 TCK199 TCK199 TCK257** TCK036 TCK235 TCK087 TCK199 TCK199 TCK199 TCK199 T41067 T41067 T41075** T41066 T41072 T41070 T41067 T41067 T41067 T41067 T41067 T41070 TCK199 TCK199 TCK101 TCK070 TCK070 TCK036 TCK036 TCK236 TCK235 TCK070 TCK176 TCK176 TCK176 TCK176 TCK176 TCK070 TCK070 TCK036 TCK176 TCK176 TCK070 TCK101 T41067 T41067 T41069 T41066 T41066 T41066 T41066 T41072 T41077 T41072 T41066 T41074 T41074 T41074 T41074 T41074 T41066 T41066 T41066 T41074 T41074 T41066 T41069 T42025 T42025 T42030 Not Applicable Not Applicable T42025 T42025 T42025 T42025 T42025 T42025 T42025 T42025 T42025 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable T42027 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 90,000 90,000 90,000 90,000 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 90,000 60,000 60,000 60,000 60,000 Severe Severe Severe Severe 678 678 697 472 664 664 664 669 669 669 669 678 678 678 669 669 678 678 687 687 662 662 662 664 664 667 664 662 660 660 660 660 660 660 662 662 662 660 660 653 687 687

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A64

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

TOYOTA (Cont.)
Cressida (Cont.) 1986-88 2.8L 6-Cyl. 1989-91 3.0L 6-Cyl. (7M-GE) 1992 3.0L 6-Cyl. (7M-GE) MR2 1985 1.6L 4-Cyl. (4A-GE) 1986-88 1.6L 4-Cyl. (4A-GE) 1989 1.6L 4-Cyl. (4A-GE) 1991-95 2.0L 4-Cyl. # 1991 2.2L 4-Cyl. # 1992-95 2.2L 4-Cyl. # Paseo (Includes Canadian) 1992-97 1.5L 4-Cyl. (5E-FE) 1998 1.5L 4-Cyl. (5E-FE) 1999 1.5L 4-Cyl. (5E-FE) Supra 1986 2.8L 6-Cyl. 1986-90 3.0L 6-Cyl. (7M-GE & GTE) 1991-92 3.0L 6-Cyl. (7M-GE & GTE) 1993-97 3.0L 6-Cyl. (2JZ-GE & 2JZ-GTE) 1998 3.0L 6-Cyl. (2JZ-GE & 2JZ-GTE) Tercel 1983-86 1.5L 4-Cyl. (3A-C) 1988-94 1.5L 4-Cyl. (3E) *# 1995-97 1.5L 4-Cyl. (5E-FE) 1998 1.5L 4-Cyl. (5E-FE) Tercel (Canadian) 1999 1.5L 4-Cyl. (5E-FE) Tercel Sedan 1987 1.5L 4-Cyl. (3E) * Tercel Wagon 1987-88 1.5L 4-Cyl. (3A-C) Light Trucks Highlander 2001-03 3.0L V6 (1MZ-FE) *# 2004 3.3L V6 (3MZ-FE) *# Land Cruiser 1998-01 4.7L V8 (2UZ-FE) *# 2002-04 4.7L V8 (2UZ-FE) *# Pickup 1981 2.2L 4-Cyl. Diesel * 1982 2.2L 4-Cyl. Diesel * Up To 5/31/1982 From 6/1/1982 1983 2.2L 4-Cyl. Diesel * 1984-87 2.4L 4-Cyl. Diesel * 1988-91 3.0L V6 (3V-ZE) # 1992 3.0L V6 (3V-ZE) # Up To 8/92 From 9/92 1993-95 3.0L V6 (3V-ZE) # T101 T126 T237 T112 T112 T176 T125 T138 T199 T208 T208 T208 T101 T126 T237 T215 T215 T070 T233 T208 T208 T208 T136 T070 T257 T257 T298 T298 T079 T079 T084 T084 T084 T154 T154 T240 T240 TCK070 TCK257** T41066 T41075** T41078 T41078 T41068 T41068 T41068 T41068 TCK240** TCK240** TCK240A** TCK240A** T41073** T41073** Not Available Not Available Not Applicable T42030 T42031 T42031 T42026 T42026 T42026 T42026 T42037 T42037 T42037 T42037 TCK070 TCK233 TCK208 TCK208 TCK208 T41066 T41076 T41071 T41071 T41071 Not Applicable T42028 T42029 T42029 T42029 TCK101 T41069 Not Applicable 60,000 Severe 60,000 Severe 60,000 Severe 60,000 1 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 90,000 Severe 90,000 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 90,000 Severe 60,000 1 60,000 Severe 60,000 Severe 90,000 Severe 90,000 60,000 Severe 60,000 Severe 90,000 90,000 90,000 90,000 100,000 100,000 100,000 100,000 100,000 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 687 695 695 660 660 660 669 678 678 658 658 658 687 695 695 689 691 653 655 658 658 658 655 653 697 472 477 477 676 676 676 676 681 702 702 702 702

TCK176 TCK176 TCK176 TCK199 TCK199 TCK208 TCK208 TCK208 TCK101

T41074 T41074 T41074 T41067 T41067 T41071 T41071 T41071 T41069

Not Applicable Not Applicable Not Applicable T42025 T42025 T42029 T42029 T42029 Not Applicable

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A65

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year RAV4 1996-97 1998 1999-00 Sequoia 2001-03 Sienna 1998-03 2004 Tacoma 1995-97 1998-04 Tundra 2000-04 2000-01 2002-03 T100 1993-94 1995-97 1998 4Runner 1988-91 1992 1993-95 1996-97 1998-02 2003-04 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

TOYOTA (Cont.)
2.0L 4-Cyl. # 2.0L 4-Cyl. # 2.0L 4-Cyl. # 4.7L V8 (2UZ-FE) *# 3.0L V6 (1MZ-FE) *# 3.3L V6 (3MZ-FE) *# 3.4L V6 (5VZ-FE) *# 3.4L V6 (5VZ-FE) *# 3.4L V6 (5VZ-FE) *# 4.7L V8 (2UZ-FE) *# 4.7L V8 (2UZ-FE) *# 3.0L V6 (3V-ZE) # 3.4L V6 (5VZ-FE) *# 3.4L V6 (5VZ-FE) *# 3.0L V6 (3V-ZE) # 3.0L V6 (3V-ZE) # Up To 8/92 From 9/92 3.0L V6 (3V-ZE) # 3.4L V6 (5VZ-FE) *# 3.4L V6 (5VZ-FE) *# 4.7L V8 (2UZ-FE) *# T199 T199 T199 T298 T257 T257 T271 T271 T271 T298 T298 T240 T271 T271 T154 T154 T240 T240 T271 T271 T298 TCK257** TCK271 TCK271 TCK271 T41075** Not Available Not Available Not Available T41078** Not Available Not Available Not Available T41073** T41073** Not Available Not Available Not Available Not Available T42030 Not Available Not Available Not Available T42031 T42037 Not Available Not Available T42037 T42037 T42037 T42037 Not Available Not Available TCK199 TCK199 TCK199 T41067 T41067 T41067 T42025 T42025 T42025 60,000 Severe 90,000 Severe 90,000 90,000 90,000 90,000 60,000 Severe 90,000 90,000 90,000 90,000 60,000 Severe 60,000 Severe 90,000 60,000, Severe 60,000 Severe 60,000 Severe 60,000 Severe 60,000 Severe 90,000 90,000 674 674 674 477 697 472 705 705 705 477 477 702 705 705 702 702 702 702 705 705 482

TCK240A** TCK271 TCK271 TCK240** TCK240** TCK240A** TCK240A** TCK271 TCK271

VOLKSWAGEN
Passenger Cars Beetle (New Beetle) 1999-04 1.8L 4-Cyl. *# (APH, AWP, & AWV) 1998 1.9L 4-Cyl. Diesel (ALH) *# 1999 1.9L 4-Cyl. Diesel (ALH) *# 2000 2001 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# Up To Eng. No. 500,000 From Eng. No. 500,001 2002 2003-04 2004 1998-00 2001-03 2004 Cabrio 1995-02 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (BEW) *# 2.0L 4-Cyl. (Exc. ABA) *# 2.0L 4-Cyl. (Exc. ABA) *# 2.0L 4-Cyl. (Exc. ABA) *# 2.0L 4-Cyl. (ABA) * T306 T301 T301 or T321 T301 T301 T321 T321 T321 T321 T296 T296 T296 T262 T43007 T43007 T43007 T43007 T43007 T43007 T43007 TCK296 TCK296 TCK296 TCK262 T43010 T43010 T43010 T41079 Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Applicable 105,000 60,000 60,000 40,000 40,000 (A/T) 60,000 (M/T) 40,000 (A/T) 60,000 (M/T) 80,000 100,000 90,000 60,000 1 105,000 N/A 60,000 1 715 733 733 733 733 733 733 733 733 733 736 743 743 743 740

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A66

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Cabriolet 1985-93 Corrado 1990-92 Dasher 1974-75 1979-80 1976-80 1981 Fox 1987-93 Golf 1985-87 1985-92 2000-01 1993-97 1999 2000 2001 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLKSWAGEN (Cont.)
1.8L 4-Cyl. (SOHC) * 1.8L 4-Cyl. (SOHC) * 1.5L 4-Cyl. * 1.5L 4-Cyl. Diesel * 1.6L 4-Cyl. * 1.6L 4-Cyl. Diesel * 1.8L 4-Cyl. (SOHC) * 1.6L 4-Cyl. Diesel * 1.8L 4-Cyl. (SOHC) * 1.8L 4-Cyl. Turbo *# 1.9L 4-Cyl. Diesel * (AAZ, AHU & 1Z) 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# Eng. No. 500,000 & Before Eng. No. 500,001 & After 2002 1.9L 4-Cyl. Diesel (ALH) *# 2003-04 1.9L 4-Cyl. Diesel (ALH) *# 2004 1.9L 4-Cyl. Diesel (BEW) *# 1993-99 2.0L 4-Cyl. (ABA) * 1999-00 2.0L 4-Cyl. (Exc. ABA) *# 2001-03 2.0L 4-Cyl. (Exc. BBW) *# 2004 2.0L 4-Cyl. (Exc. BBW) *# 2004 2.0L 4-Cyl. (BBW) *# Golf (Canadian) 1988-92 1.6L 4-Cyl. Diesel * 1993-95 1.8L 4-Cyl. (SOHC) * 1995 2.0L 4-Cyl. (ABA) * Golf III 1993-95 1.9 4-Cyl. Turbo Diesel * GTI 1987-89 1.8L 4-Cyl. (DOHC) * 1985-92 1.8L 4-Cyl. (SOHC) * 2000-04 1.8L 4-Cyl. Turbo *# 1990-92 2.0L 4-Cyl. (DOHC) * 1996-99 2.0L 4-Cyl. (ABA) * 1999-00 2.0L 4-Cyl. (Exc. ABA) *# GTI (Canadian) 1993-95 2.0L 4-Cyl. (ABA) * Jetta 1980 1.6L 4-Cyl. * 1981-86 1.6L 4-Cyl. Diesel * 1989-92 1.6L 4-Cyl. Diesel * 1981-84 1.7L 4-Cyl. * T017 T017 T017 T043 T017 T043 T017 T043 T017 T306 T242 T301 or T321 T301 T301 T321 T321 T321 T321 T262 T296 T296 T296 T296 T043 T017 T262 T242 T292 T017 T306 T292 T262 T296 T262 T017 T043 T043 T017 TCK017 TCK262 TCK296 TCK262 TCK017 TCK017 T41079 T41079 T43010 T41079 T41079 T41080 T41079 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK017 TCK017 TCK017 TCK017 TCK017 TCK017 T41079 T41079 T41079 T41080 T41079 T41080 T41079 T41080 T41079 T43006 T43007 T43007 T43007 T43007 T43007 T43007 TCK262 TCK296 TCK296 TCK296 TCK296 TCK017 TCK262 T41079 T43010 T43010 T43010 T43010 T41079 T41079 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Applicable Not Available Not Available Not Available Not Available Not Applicable Not Applicable 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 120,000 60,000 60,000 40,000 40,000 (A/T) 60,000 (M/T) 40,000 (A/T) 60,000 (M/T) 80,000 100,000 90,000 60,000 1 60,000 1 60,000 1 N/A N/A 60,000 1 60,000 1 60,000 1 60,000 3 60,000 1 60,000 1 120,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 724 724 711 710 711 710 724 710 724 712 728 733 733 733 733 733 733 733 733 736 740 743 743 743 746 710 724 740 728 726 724 712 726 740 743 740 711 710 710 711

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A67

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Jetta (Cont.) 1987-89 1984-92 2000-04 1993-98 1999 2000 2001 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLKSWAGEN (Cont.)
1.8L 4-Cyl. (DOHC) * 1.8L 4-Cyl. (SOHC) * 1.8L 4-Cyl. Turbo *# 1.9L 4-Cyl. Diesel * (AAZ, AHU & 1Z) 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# 1.9L 4-Cyl. Diesel (ALH) *# Up To Eng. No. 500,000 From Eng. No. 500,001 2002 1.9L 4-Cyl. Diesel (ALH) *# 2003-04 1.9L 4-Cyl. Diesel (ALH) *# 2004 1.9L 4-Cyl. Diesel (BEW) *# 1990-92 2.0L 4-Cyl. (DOHC) * 1993-99 2.0L 4-Cyl. (ABA) * 1999-00 2.0L 4-Cyl. (Exc. ABA) *# 2001-03 2.0L 4-Cyl. (Exc. BBW) *# 2004 2.0L 4-Cyl. (Exc. BBW) *# 2004 2.0L 4-Cyl. (BBW) *# Jetta (Canadian) 1986 1.6L 4-Cyl. Diesel * 1988-92 1.6L 4-Cyl. Diesel * 1993-95 1.8L 4-Cyl. (SOHC) * Jetta III 1993-95 1.9L 4-Cyl. Turbo Diesel * Passat 1996-97 1.9L 4-Cyl. Turbo Diesel * 1998-99 1.8L 4-Cyl. (AEB) *# 152 Tooth Belt 5 153 Tooth Belt 2000 1.8L 4-Cyl. (AEB & ATW) *# 152 Tooth Belt 5 153 Tooth Belt 2000-04 1.8L 4-Cyl. (AUG & AWM) *# 1990-92 2.0L 4-Cyl. (DOHC) * 1993-96 2.0L 4-Cyl. (ABA) * 1998 2.8L V6 *# 1999 2.8L V6 *# 2000-04 2.8L V6 *# Passat (Canadian) 1992-94 1.8L 4-Cyl. (SOHC) * 1993-94 1.9L 4-Cyl. Turbo Diesel * 1995-97 1.9L 4-Cyl. Turbo Diesel * 1998 1.9L 4-Cyl. Turbo Diesel * T292 T017 T306 T242 T301 or T321 T301 T301 T321 T321 T321 T321 T292 T262 T296 T296 T296 T296 T043 T043 T017 T242 T242 T291 T317 T291 T317 T306 T292 T262 T297 T297 T297 T017 T242 T242 T242 T43006 Not Available TCK017 T41079 T43006 T43007 T43007 T43007 T43007 T43007 T43007 TCK262 TCK296 TCK296 TCK296 TCK296 T41079 T43010 T43010 T43010 T43010 T41080 TCK017 T41079 Not Applicable Not Applicable Not Available Not Available Not Available Not Available Not Available Not Available Not Available Not Applicable Not Available Not Available Not Available Not Available 60,000 1 60,000 1 120,000 60,000 60,000 40,000 40,000 (A/T) 60,000 (M/T) 40,000 (A/T) 60,000 (M/T) 80,000 100,000 90,000 60,000 1 60,000 1 60,000 1 60,000 1 N/A N/A 60,000 1 60,000 1 60,000 1 60,000 3 60,000 3 90,000 90,000 105,000 3 105,000 3 105,000 3 60,000 1 60,000 1 90,000 75,000 105,000 60,000 1 60,000 3 60,000 3 60,000 3 726 724 712 728 733 733 733 733 733 733 733 733 736 726 740 743 743 743 746 710 710 724 728 728 718 718 718 718 720 726 740 755 755 755 724 728 728 728

TCK262

T41079

Not Applicable

TCK017

T41079 T43006

Not Applicable Not Available

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. 5 - ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt). A68

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Quantum 1982-85 1982-83 1985 1984-85 1983-86 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLKSWAGEN (Cont.)
1.6L 4-Cyl. Diesel * 1.7L 4-Cyl. * 1.8L 4-Cyl. (SOHC) * 2.1L 5-Cyl. # .70 Belt Width .75 Belt Width 2.2L 5-Cyl. # .70 Belt Width .75 Belt Width 2.2L 5-Cyl. # T043 T017 T017 T127 T065 T127 T065 T127 T017 T043 T043 T017 T043 T017 T017 T017 T017 T017 T292 T017
4

TCK017 TCK017

T41080 T41079 T41079

Not Applicable Not Applicable

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


1 1

710 711 724 118 118 118 118 118 711 710 710 711 710 711 724 711 711 711 726 724 750 710 711 710 711 750 710

1 1 1

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

TCK017 TCK017 TCK017 TCK017 TCK017 TCK017 TCK017 TCK017

T41079 T41080 T41079 T41080 T41079 T41079 T41079 T41079 T41079 T41079

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

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

T043 T017 T043 T017


4

TCK017 TCK017

T41080 T41079 T41080 T41079

Not Applicable Not Applicable

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

T043

T41080

60,000 1

VOLVO
C70 1998 1999-01 2002-04 2.3L 5-Cyl. Turbo *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.3L 5-Cyl. Turbo *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.3L 5-Cyl. Turbo *# T252 T311 T252 T311 T252 70,000 70,000 105,000 3 105,000 3 105,000 766 766 766 766 775

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. 5 - ATW engines use T317 (153 tooth belt). AEB engines originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt). A69

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year C70 (Cont.) 1998 1999-01 2002-04 Coupe 1991 DL & GL 1980-83 1982 1983-85 1980-84 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLVO (Cont.)
2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.4L 5-Cyl. Turbo *# 2.3L 4-Cyl. (B230, F & FT) * 2.1L 4-Cyl. (B21) * 2.3L 4-Cyl. (B23) * 2.3L 4-Cyl. (B23) * 2.4L 6-Cyl. Diesel * Camshaft Injection Pump T252 T311 T252 T311 T331 T032 T032 T032 T032 T083 T082 T032 T032 T032 T032 T032 T252 T311 T311 T331 T331 T252 T311 T252 T252 T311 T252 T331 T252 T311 T252 T311 TCK032 TCK032 TCK032 TCK032 TCK032 T41081 T41081 T41081 T41081 T41081 Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable TCK032 TCK032 TCK032 TCK032 T41081 T41081 T41081 T41081 Not Applicable Not Applicable Not Applicable Not Applicable 70,000 70,000 105,000 3 105,000 3 105,000 50,000 40,000 40,000 40,000 75,000 2 75,000 2 40,000 40,000 40,000 40,000 40,000 105,000 3 105,000 3 105,000 3 120,000 120,000 105,000 3 105,000 3 105,000 105,000 3 105,000 3 105,000 105,000 70,000 70,000 105,000 3 105,000 3 766 766 766 766 775 770 765 765 765 780 780 765 765 765 765 765 758 758 762 777 777 766 766 775 766 766 775 775 766 766 766 766

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

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A70

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year S70 (Cont.) 1998 1999-00 S80 1999 2000-01 2002-03 1999 2000-03 S90 1997-98 V40 2000-01 2002-04 V70 1998 1999-01 2002-04 1998 1999-01 2002-04 2002-04 V90 1997-98 XC90 2003 2004 2003-04 240 1986-92 1993 242, 244 & 245 1976-79 740 Series 1986-92 1985-86 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLVO (Cont.)
2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.8L 6-Cyl. Turbo * 2.8L 6-Cyl. Turbo * 2.9L 6-Cyl. Turbo * 2.9L 6-Cyl. Non-Turbo * 2.9L 6-Cyl. Non-Turbo * 2.9L 6-Cyl. Turbo *# 1.9L 4-Cyl. Turbo *# To Eng. VIN 1219110 From Eng. VIN 1219111 1.9L 4-Cyl. Turbo *# 2.3L 5-Cyl. Turbo *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.3L 5-Cyl. Turbo *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.3L 5-Cyl. Turbo *# 2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.4L 5-Cyl. *# To Eng. VIN 1266127 From Eng. VIN 1266128 2.4L 5-Cyl. Non-Turbo *# 2.4L 5-Cyl. Turbo *# 2.9L 6-Cyl. Turbo *# 2.5L 5-Cyl. Turbo *# 2.5L 5-Cyl. Turbo *# 2.9L 6-Cyl. Turbo * 2.3L 4-Cyl. (B230, F & FT) * 2.3L 4-Cyl. (B230, F & FT) * 2.1L 4-Cyl. (B21) * 2.3L 4-Cyl. (B230, F & FT) * 2.4L 6-Cyl. Diesel * Camshaft Injection Pump T252 T311 T252 T311 T270 T319 T319 T270 T319 T270 T252 T311 T311 T252 T311 T252 T311 T252 T252 T311 T252 T311 T252 T331 T270 T331 T331 T319 T032 T234 T032 T032 T083 T082 TCK032 TCK234 TCK032 TCK032 T41081 Not Available T41081 T41081 Not Applicable Not Applicable Not Applicable Not Applicable 70,000 70,000 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 105,000 3 70,000 105,000 3 105,000 3 105,000 3 70,000 70,000 105,000 3 105,000 3 105,000 70,000 70,000 105,000 3 105,000 3 105,000 105,000 70,000 120,000 120,000 (AWD) 105,000 (FWD) 120,000 3 50,000 50,000 40,000 50,000 75,000 2 75,000 2 766 766 766 766 782 782 782 782 782 768 758 758 762 766 766 766 766 775 766 766 766 766 775 775 768 775 775 775 782 770 770 765 770 780 780

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A71

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLVO (Cont.)
740 Series (Canadian) 1986-88 2.3L 4-Cyl. (B234, DOHC) *# Balance Shaft Camshaft 1989 2.3L 4-Cyl. (B234, DOHC) *# Automatic Tensioner Balance Shaft Camshaft Manual Tensioner Balance Shaft Camshaft 1990 2.3L 4-Cyl. (B234, DOHC) *# Balance Shaft Camshaft 760 Series 1985-90 2.3L 4-Cyl. (B230, F & FT) * 1985 2.4L 6-Cyl. Diesel * Camshaft Injection Pump 760 GLE 1984 2.3L 4-Cyl. (B23) * 1983-84 2.4L 6-Cyl. Diesel * Camshaft Injection Pump 780 Series 1989-90 2.3L 4-Cyl. (B230, F & FT) * 850 1994 2.3L 5-Cyl. Turbo *# Up To Eng. No. 131034 From Eng. No. 131035 1995-97 2.3L 5-Cyl. Turbo *# 1993 2.4L 5-Cyl. Turbo *# Up To Eng. No. 131034 From Eng. No. 131035 1994-97 2.4L 5-Cyl. Turbo *# 850 (Canadian) 1996 2.3L 5-Cyl. Turbo *# 1995 2.4L 5-Cyl. Turbo *# Up To Eng. No. 131034 From Eng. No. 131035 940 Series 1991-92 2.3L 4-Cyl. (B230, F & FT) * 1993 2.3L 4-Cyl. (B230, F & FT) * 1994-95 2.3L 4-Cyl. (B230, F & FT) * 940 (Canadian) 1991 2.3L 4-Cyl. (B234, DOHC) *# Balance Shaft Camshaft 1992 2.3L 4-Cyl. (B234, DOHC) *# Balance Shaft Camshaft T174 T173 T174 T198 T174 T173 T174 T173 T032 T083 T082 T032 T083 T082 T032 T217 T252 T252 T217 T252 T252 T252 T217 T269 T032 T234 T234 TCK032 TCK234 TCK234 T41081 Not Available Not Available Not Applicable Not Applicable Not Applicable TCK032 T41081 Not Applicable TCK032 T41081 Not Applicable TCK032 T41081 Not Applicable 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 75,000 2 75,000 2 40,000 75,000 2 75,000 2 50,000 70,000 70,000 70,000 50,000 70,000 70,000 70,000 70,000 70,000 50,000 50,000 50,000 w/o EGR 100,000 w/ EGR 50,000 2 50,000 2 TCK032 TCK032 T41081 T41081 Not Applicable Not Applicable 50,000 2 50,000 2 771 771 771 771 771 771 771 771 770 780 780 765 780 780 770 768 768 768 768 768 768 768 768 768 770 770 770 770 771 771 771 771

T174 T198 T174 T198

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A72

ALPHABETICAL MODEL LISTING (Cont.)


Make Model/ Year 960 1992-93 1994 1995-97 Engine Timing Belt Part No. Timing Component Kit Part No. Timing Tensioners Timing Pulleys Recommended Replacement Interval (Miles)
Page

VOLVO (Cont.)
2.9L 6-Cyl. *# 2.9L 6-Cyl. *# 2.9L 6-Cyl. *# T217 T252 T270 30,000 3 50,000 70,000 768 768 768

YUGO
GV Series 1986-89 1987 1.1L 4-Cyl. * 1.3L 4-Cyl. * T018 T018 60,000 1 60,000 1 785 785

* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-10 for interference engine cautions. # - Uses a timing belt driven water pump. ** - Does not include camshaft tensioner hydraulic assembly. 1 - Belt manufacturers suggest the belt be replaced at 60,000 mile intervals. 2 - The vehicle manufacturer recommends replacing all belts at the same time. 3 - See timing belt repair procedure for more information on belt replacement interval. 4 - While a replacement timing belt is not available, a timing belt repair procedure has been included for your convenience. A73

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

Labor Time

Belt Part No.

2.0 Hours .. ..... T224

With Air Conditioning, add .4 hours. With Cruise Control, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

2) Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 3. 3) Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing mark are aligned with TDC marks. 4) Loosen and retighten adjusting bolt to tension timing belt. Install lower cover. Install crankshaft pulley. Tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley. CAUTION: Always adjust timing belt tension with engine cold. 5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. 6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: If the radio has a coded theft protection circuit, be sure to get the customers code before disconnecting battery. Removal 1) Disconnect battery negative cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 3. 2) Remove engine oil dipstick. Remove power steering pump, and set aside with hoses attached. Remove timing belt upper cover and A/C drive belt idler pulley bracket. 3) Use jack to support engine. Working from front of engine, remove engine mount bracket nuts. Remove crankshaft pulley. Remove lower cover and dipstick tube. 4) Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump. Loosen the timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. See Fig. 1. Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 2.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 17 (24) Alternator Adjusting Bolt ............................................................................................ 17 (24) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Pulley Center Bolt .................................................................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 ...................................................................................................................... 14 (20) Step 2 ............................................................................ ...................... Plus 90 Clockwise Engine Mount Bracket Nuts ...................................................................................... 54 (74) Power Steering Pump Bracket Bolt Power Steering Pump Lock Bolt .............................................................................. 17 (24) Timing Belt Tensioner Adjusting Bolt ........................................................................ 33 (45) INCH Lbs. (N.m) CKF Sensor Bolt ..................................................................................................... 106 Engine Lower Splash Shield .................................................................................... 89 Timing Belt Cover Bolt .............................................................................................. 89 Water Pump Bolt ..................................................................................................... 106
1

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

Lubricate bolt threads and bolt head shoulder.

ACURA
1.6L 4-Cylinder EL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

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

ACURA
1.6L 4-Cylinder EL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Timing Belt Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Bolt

ACURA
1.6L 4-Cylinder Integra
Labor Time Component Belt Kit No. Part No.

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


1

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

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic 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 counterclockwise to bring piston in cylinder No. 1 to TDC of its compression stroke. Remove all drive belts. Remove A/C compressor and power steering pump, and position out of the way without disconnecting hoses. Remove crankshaft pulley. See Fig. 1. 2) Remove engine valve cover and upper timing belt cover. Remove lower timing belt cover from engine block. Loosen timing belt tensioner to relieve tension on timing belt. 3) Slide belt off sprockets. Remove bolts, washers, camshaft sprockets, and Woodruff key (if necessary). Installation 1) Ensure No. 1 piston is still at TDC. Install Woodruff keys, camshaft sprockets, washer, and retaining bolts (if removed). Position UP mark on sprockets at top. Align grooves on sprockets. See Fig. 2. 2) Install timing belt on sprockets. Use care not to excessively bend or twist belt. 3) Rotate crankshaft counterclockwise 3 teeth on camshaft sprockets to create tension on belt. Tighten tensioner adjustment bolt. To complete installation, reverse removal procedure. Adjust the drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor/Bracket Bolts ................................................................................. 33 (45) Alternator Belt Adjustment Bolt ................................................................................. 17 (23) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Pulley Bolt ................................................................................................. 27 (37) Crankshaft Pulley Bolt ............................................................................................. 83 (112) Power Steering Pump Mounting Bolts ......................................... ................. 29-33 (38-45) Timing Belt Adjustment Bolt ...................................................................................... 33 (45) Wheel Lug Nuts ...................................................................................................... 80 (110) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................................................................ 86 (10) Valve Cover Nuts ...................................................................................................... 86 (10)

Fig. 2: Locating Camshaft Timing Marks

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

Labor Time

Component Belt Kit No. Part No.

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

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

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

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts .......................................................................................... 27 (37) Crankshaft Pulley Bolt 1992 ....................................................................................................................... 87 (118) 1993 ................................................................................................................... 1 133 (180) Power Steering Mount Bolt ....................................................................................... 17 (23) Timing Belt Tension Adjuster Bolt .............................................................................. 40 (54 INCH Lbs. (N.m) Timing Belt Cover Bolts .......................................................................................... 108 (12) Valve Cover Nuts ...................................................................................................... 84 (10)
1

Tighten to 147 ft. lbs. (200 N.m), loosen, then retighten to 133 ft. lbs. (180 N.m).
Courtesy of American Honda Motor Co., Inc.

Fig. 3: Locating Timing Belt Adjuster Bolt

ACURA
1.8L 4-Cylinder
Labor Time Component Belt Kit No. Part No.

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

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

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-94 models, manufacturer recommends the belt be replaced every 90,000 miles. For 1995-96 models, the manufacturer recommends the belt be replaced every 90,000 miles for normal service and 60,000 miles for severe service. For 1997-01 models, normal replacement interval is at 105,000 miles or 84 months. For 1997-01 models, replace belt at 60,000 miles if vehicle is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees C). NOTE: Some vehicles may be equipped with radio/cassette or radio/CD players that contain anti-theft protection circuit. When battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE and will be inoperative until proper code is entered by vehicle owner.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor/Bracket Bolts ................................................................................. 17 (23) Alternator Belt Adjustment Bolt ................................................................................. 17 (23) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Sprocket Bolts .......................................................................................... 27 (37) Crankshaft Pulley Bolt 1990-92 .................................................................................................................. 87 (118) 1993-01 .............................................................................................................. 1 133 (180) Engine Block-To Transaxle Bolt ................................................................................ 47 (64) Engine Mount Bolts ....................................................................... ..................................... 2 Power Steering Bolt .................................................................................................. 17 (23) Timing Belt Tension Adjuster Bolt ............................................................................. 40 (54) INCH Lbs. (N.m) Timing Belt Cover Bolts .......................................................................................... 106 (12) Valve Cover Nuts ...................................................................................................... 88 (10) Water Pump Bolt ..................................................................................................... 106 (12)
1

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove left front wheel. Remove left front wheelwell splash shield. Remove all drive belts. Remove power steering pump with hoses attached. Set power steering pump aside. 2) Remove valve cover and upper timing belt cover. See Fig. 1. Turn crankshaft counterclockwise to bring No. 1 piston to TDC of its compression stroke. Position UP mark on sprockets at top. See Fig. 2. Align grooves on sprockets. Remove crankshaft pulley. 3) Remove left engine mount bolts and nut. Remove engine mount. See Fig. 3. Remove lower timing belt cover. Loosen timing belt tension adjuster bolt. Push tensioner to relieve tension on timing belt. Retighten adjuster bolt. Remove timing belt. Installation Ensure No. 1 piston is at TDC. See Fig. 4. Install timing belt onto sprockets. DO NOT bend or twist belt excessively. Adjust timing belt tension. To complete installation, reverse removal procedure. On 1993-01 models, tighten crankshaft pulley bolt to 147 ft. lbs. (200 N.m), loosen, then retorque to 133 ft. lbs. (180 N.m). On all models, adjust drive belts to proper tension.

Tighten crankshaft pulley bolt to 147 ft. lbs. (200 N.m), loosen, then retorque to 133 ft. lbs. (180 N.m). See Fig. 3.

ACURA
1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Positioning Camshaft

Courtesy of American Honda Motor Co., Inc.

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

ACURA
2.2L & 2.3L 4-Cylinder
Labor Time Component Belt Kit No. Part No. 5) Push tensioner to remove tension from balance shaft belt adjuster, then retighten nut. 6) Scribe a line 2.9 (74 mm) from the end of a 6x100 mm bolt. See Fig. 5. Remove bolt from side of engine block. To align balance shaft, insert bolt through hole and into balance shaft. 7) Align groove on balance shaft pulley with pointer on oil pump housing. See Fig. 6. Install balance shaft belt. Loosen adjuster nut about one turn to tension balance shaft belt. 8) Remove 6x100 mm bolt from balance shaft. Install sealing bolt in side of engine block. Install crankshaft pulley and bolt. Rotate crankshaft about one turn counterclockwise, then tighten adjuster nut. Remove 6x1.0 mm bolt from timing belt adjuster arm. 9) Remove crankshaft pulley. Install lower cover. Install rubber seal around adjuster nut. DO NOT loosen adjuster nut. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

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

TCK244 .. ..... T186 TCK244 .. ..... T244

TCK244 .. ..... T186 TCK244 .. ..... T244

With balance shaft belt, add .2 hour.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For the 2.2CL, normal replacement interval is 90,000 miles for normal service or 60,000 miles for severe service. For the 2.3CL, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

Fig. 1: Identifying TDC Mark On Crankshaft Drive Pulley

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount. 2) Remove oil dipstick and pipe. Remove valve cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. Loosen timing belt tension adjuster bolt about 1/2 turn. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tension adjuster bolt. Remove balance shaft drive pulley. Remove balance shaft belt and timing belt from pulleys. Installation 1) Ensure No. 1 piston is at TDC of compression stroke. See Fig. 1. Align camshaft pulley with mating marks on back cover upper surface. Ensure UP mark is at 12 oclock position. See Fig. 2. 2) Install timing belt in sequence shown. See Fig. 3. Loosen and retighten the timing belt adjusting nut about one turn. Install balance shaft drive pulley and lower cover. Install crankshaft pulley and center bolt. 3) Rotate crankshaft about 5-6 times counterclockwise. Set No. 1 piston at TDC. Loosen timing belt adjusting nut about one turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten timing belt adjusting nut. Make sure crankshaft and camshaft pulleys are at TDC. 4) Remove crankshaft pulley and lower cover. Ensure crankshaft is still at TDC. Lock timing belt adjuster arm in place by installing a 6x1.0 mm bolt. See Fig. 4. Loosen timing belt adjusting nut about one turn, and make sure balance shaft belt adjuster moves freely.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Camshaft Sprocket Timing Marks

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

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning & Locking Balance Shaft

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Timing Belt Adjuster Nut

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Bracket-To-Engine Bolt ............................................................................. 33 (45) Camshaft Sprocket Bolt ............................................................................................ 27 (37) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Power Steering Pump Mount Bolt ............................................................................ 16 (22) Timing Belt Tension Adjuster Nut ............................................................................. 33 (45) Wheel Lug Nuts ...................................................................................................... 80 (110) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............. 86-104 (7.2-8.7) Valve Cover Bolt ...................................................................................................... 86 (9.8)
Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Balance Shaft Pulley

10

ACURA
2.5L 5-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

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

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For Vigor, normal replacement interval is 90,000 miles. For 1995-96 2.5TL, replacement interval is 90,000 miles for normal service and 60,000 for severe service. For 1997-98 2.5TL, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

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

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View of Timing Belt Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Locating Timing Belt Adjuster Bolt

ACURA
2.5L 5-Cylinder (Cont.)

11

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft Timing Marks


Courtesy of American Honda Motor Co., Inc.

Fig. 5: Positioning Camshaft

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Camshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

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

12

ACURA
2.5L & 2.7L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

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

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1986-89 models, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles. For 1990 models, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove negative battery cable. Turn crankshaft clockwise to bring No. 1 piston to TDC of compression stroke. Remove pulley cover from upper timing belt cover. Remove engine wiring harness clamp from right side of engine compartment. 2) Support front of engine. On right side of engine compartment, remove engine-to-body mount (on front of engine). Remove lower engine splash shield. Remove A/C, power steering, and all other drive belts. 3) Remove alternator. Leaving hoses connected, remove power steering pump and secure out of way. Remove upper timing belt pulley covers. Remove crankshaft pulley. Remove timing belt lower cover. 4) Loosen timing belt tensioner to relieve tension on timing belt. See Figs. 1 and 2. Check belt for damage, missing teeth or cracks. Installation 1) Remove spark plugs. Turn crankshaft clockwise to bring No. 1 piston to TDC of compression stroke. Advance crankshaft an additional 15 degrees from TDC position. 2) Rotate camshaft pulleys to compression stroke (TDC position) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC position. 3) Push timing belt tensioner to full release position and snug adjuster bolt. Install timing belt over crankshaft pulley, front camshaft pulley, water pump pulley, tensioner and rear camshaft pulley. See Fig. 1. 4) Note position of timing belt pulley guides on both sides of crankshaft. Install pulley guides so guides form a V groove for belt to ride in. Loosen timing belt tensioner bolt. NOTE: Always adjust timing belt tension with engine cold. 5) Set No. 1 piston to TDC on compression stroke. Rotate crankshaft clockwise 9 teeth on rear camshaft pulley. Blue mark on crankshaft pulley should match pointer on lower cover. Loosen timing belt tensioner bolt. See Fig. 1. 6) Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Adjusting Timing Belt NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolts .............................................................................................. 16 (22) A/C Compressor Bracket Bolts ................................................................................. 33 (45) Alternator Bracket Bolts ............................................................................................ 33 (45) Alternator Mount Bolts .............................................................................................. 16 (22) Camshaft Pulley Bolts ............................................................................................... 23 (31) Crankshaft Pulley Bolt ........................................................................................... 123 (170) Engine Mount Bolts ................................................................................................... 40 (54) Power Steering Pump Mount Bolt ............................................................................ 33 (45) Timing Belt Tensioner Bolt ........................................................................................ 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................................................................ 86 (10) Valve Cover Bolts .................................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

ACURA
2.5L & 2.7L V6 (Cont.)

13

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

14

ACURA
3.0L & 3.2L NSX & NSX-T
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 3.0L V6 NSX 1991-04 NSX-T 1995-03 3.2L V6 NSX 1997-04 NSX-T 1997-03

..................................................... 4.8 Hours ... ....... N/A ..................................................... 4.8 Hours ... ....... N/A

..................................................... 4.8 Hours ... ....... N/A ..................................................... 4.8 Hours ... ....... N/A
Courtesy of American Honda Motor Co., Inc.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Removing Intake Manifold Plate & Top Cover

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1991-96 models, inspect belt at 90,000 miles, and replace if necessary. For 1997-04 models, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under 20 degrees F).

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. CAUTION: DO NOT rotate crankshaft counterclockwise. Timing belt could jump a tooth on camshaft pulleys.

TIMING BELT
NOTE: Different ignition coils and ignition coil covers are used for front side and rear side. Be sure to use correct ones for side being serviced. Coils and covers for front side are marked FR. Coils and covers for rear side are marked RR. Removal 1) Mark timing belt direction of rotation BEFORE removal. Remove spare tire and spare tire holder. Disconnect negative battery cable. Disconnect positive battery cable. 2) Raise vehicle on hoist and remove right rear wheel. Remove engine oil cooler base assembly mounting bolts. Wire oil cooler base assembly out of way without disconnecting hoses. Lower vehicle. Remove engine compartment strut brace, if equipped. 3) Remove intake manifold plate and top cover. See Fig. 1. Remove ignition coil covers, fuel injector covers and wire harness covers. Disconnect electrical connectors from ignition coils. Remove ignition coils and spark plugs. 4) Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. See Fig. 2. Remove expansion tank, and set out of way without removing coolant hoses. 5) Remove air cleaner assembly and breather hose. Disconnect electrical connectors from generator. Remove belt cover, mounting bolt, adjusting bolt, and mounting nut from generator. Remove generator belt and generator. See Fig. 3 or 4. 6) Remove cylinder head covers. Remove side engine mount bolts. Push side engine mount bracket into body support bracket. Remove transmission mount. See Fig. 5. Place wood brace under front of engine and pad oil pan for protection. Using a oor jack, tilt front of engine 5. See Fig. 6. 7) Remove generator bracket stiffener, dipstick and dipstick pipe. See Fig. 7. Loosen A/C idler pulley center nut and adjusting nut. Remove A/C compressor belt.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying Camshaft & Crankshaft Positions With No. 1 Cylinder At TDC

ACURA
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.

15

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Removing Side Engine Mount Bolts & Transmission Mount Through-Bolt

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Removing Generator (1991-94)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Tilting Engine For Timing Belt Removal

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Removing Generator Bracket Stiffener


Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing Generator (1995-04) Inspection 1) Inspect timing belt for cracks or damaged teeth. Ensure timing belt is not contaminated with oil or coolant. If one edge of belt is damaged, check alignment of gears and tensioner. Replace as necessary.

2) Ensure water pump pulley turns freely (both directions on 1991-94 models; counterclockwise on 1995 and later models). Check for signs of seal leakage. Small amount of weeping from bleed holes is normal. See Figs. 10 and 11. Installation 1) To install, reverse removal procedure. Clean middle and lower timing belt covers, and timing belt drive pulley. Ensure No. 1 piston is at TDC of compression stroke. On 1991-94 models, set timing belt drive pulley (crankshaft) keyway pointing upward. See Fig. 12.

16

ACURA
3.0L & 3.2L NSX & NSX-T (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 9: Releasing Timing Belt Tension 2) On 1995-04 models, set timing belt drive pulley (crankshaft) keyway pointing upward and align mark on tooth side of pulley with pointer on oil pump. See Fig. 12. 3) On all models, set front camshaft pulleys so piston No. 1 is at TDC. Align TDC marks on front exhaust camshaft pulley and front intake camshaft pulley to pointer on back cover. See Fig. 13. Set rear camshaft pulleys so piston No. 1 is at TDC. Align TDC mark on rear intake camshaft pulley to pointer on back cover. Align rear exhaust camshaft pulley 1/2 tooth clockwise past TDC. See Fig. 14. 4) Install timing belt onto timing belt drive pulley (crankshaft), tension adjusting pulley, front exhaust camshaft pulley, front intake camshaft pulley, water pump pulley, rear intake camshaft pulley and rear exhaust camshaft pulley, in that order. See Fig. 15. Ensure timing belt drive pulley (crankshaft) and camshaft pulleys are still at TDC. See Figs. 12-14.

Courtesy of American Honda Motor Co., Inc.

Fig. 10: Inspecting Water Pump (1991-96)

ACURA
3.0L & 3.2L NSX & NSX-T (Cont.)

17

Courtesy of American Honda Motor Co., Inc.

Fig. 13: Setting Front Camshaft Pulleys For Timing Belt Installation

Courtesy of American Honda Motor Co., Inc.

Fig. 11: Inspecting Water Pump (1997-04)

Courtesy of American Honda Motor Co., Inc.

Fig. 14: Setting Rear Camshaft Pulleys For Timing Belt Installation

Courtesy of American Honda Motor Co., Inc.

Fig. 12: Setting Crankshaft For Timing Belt Installation 5) Remove slack in timing belt between timing belt drive pulley (crankshaft) and front exhaust camshaft pulley, front exhaust camshaft and front intake camshaft pulleys, front intake camshaft and water pump pulleys, water pump and rear intake camshaft pulleys, and rear intake camshaft and rear exhaust camshaft pulleys, in order, by turning each camshaft pulley SLIGHTLY.

Courtesy of American Honda Motor Co., Inc.

Fig. 15: Installing Timing Belt

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 specication. See TORQUE SPECIFICATIONS. 7) If No. 1 piston is at TDC, rotate crankshaft CLOCKWISE 9 teeth on camshaft pulley. Blue mark on crankshaft pulley should be aligned with pointer on lower cover, and TDC mark (White mark) on crankshaft pulley should be at about 5 oclock position. See Fig. 16. Loosen adjusting bolt. Retighten adjusting bolt to specication. See TORQUE SPECIFICATIONS. 8) Install timing belt lower cover, rear middle cover and front middle cover. Install crankshaft pulley with No. 1 piston at TDC of compression stroke. Hold crankshaft pulley and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 9) Verify that No. 1 piston and camshaft pulleys are still at TDC. See Fig. 17. When camshafts are at TDC, 5.0 mm pin punches can be inserted through camshaft holder hole into camshaft hole to hold camshafts at TDC. See Fig. 17. If crankshaft and camshafts are at TDC, go to step 11). If a camshaft is not positioned at TDC, go to next step.

Courtesy of American Honda Motor Co., Inc.

Fig. 16: Final Step Of Adjusting Timing Belt Tension 10) If a camshaft is not positioned at TDC, remove timing belt lower cover, rear middle cover, front middle cover and timing belt. Adjust position of crankshaft and camshaft pulleys, and reinstall timing belt. See Figs. 12-14. Align holes on camshaft holder with camshaft holes and insert 5.0 mm pin punches to hold camshafts at TDC. Remove pin punches after timing belt has been reinstalled. Go to next step. 11) Complete installation of components in reverse order of removal. Always use NEW O ring at engine oil cooler base and NEW rubber seals on intake side of ignition coil covers. Apply thin layer of liquid gasket to cylinder head cover mating surface and rubber seals to hold seals in place. After all nuts and bolts have been tightened to specication, adjust A/C compressor belt and generator belt tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 17: Checking Crankshaft & Camshaft Pulleys At TDC

ACURA
3.0L & 3.2L NSX & NSX-T (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Holder Bolts (8 mm) ................................................................................. 16 (22) Camshaft Holder Bridge Bolts .................................................................................. 16 (22) Camshaft Pulley Bolts ............................................................................................... 51 (69) Crankshaft Pulley Bolt ......................................................................................... 1 181 (245) Generator Bracket 8 mm Bolts .............................................................................................................. 16 (22) 10 mm Bolts ............................................................................................................ 33 (45) Generator Bracket Stiffener 8 mm Bolts .............................................................................................................. 16 (22) 10 mm Bolts ............................................................................................................ 33 (45) Generator Mounting Bolt & Nut ................................................................................ 33 (45) Idler Pulley Assembly Bolts ...................................................................................... 16 (22) Idler Pulley Center Nut ............................................................................................. 33 (45) Side Engine Mount Mounting Bolts ......................................................................................................... 53 (72) Through-Bolt ............................................................................................................ 69 (94) Timing Belt Adjusting Bolt ......................................................................................... 31 (42) Water Pump Mounting Bolts (8 mm) ........................................................................ 16 (22) INCH Lbs. (N.m) Camshaft Holder Bolts (6 mm) ................................................................................. 88 (10) Dipstick Pipe Bolt .................................................................................................... 106 (12) Generator Adjusting Bolt (1991-94) ........................................................................................... 71 (8) Cover Bolts ............................................................................................................ 106 (12) Ignition Coil Bolts .................................................................................................... 106 (12) Ignition Coil Cover Bolts ........................................................................................... 88 (10) Timing Belt Cover Bolts .......................................................................................... 106 (12) Water Pump Mounting Bolts (6 mm) ...................................................................... 106 (12)
1

19

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).

20

ACURA
3.0L & 3.2L V6 3.0CL & 1999 3.2TL
REMOVAL & INSTALLATION
Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application

3.0L V6 (J30A1) 3.0CL 1997-99 ............................... 4.0 Hours ... .. TCK286 .. ..... T286 3.2L V6 (J32A1/A2) 3.2TL 1999 .................................... 4.0 Hours ... .. TCK286 .. ..... T286 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

TIMING BELT
Removal 1) Disconnect negative battery cable. Turn crankshaft pulley so that No. 1 piston is at TDC on compression stroke. White mark on crankshaft pulley should align with pointer on front cover. Remove rubber plugs from front and rear upper timing belt covers. Ensure camshaft sprocket timing marks are aligned with tabs on bottom of access holes. Remove lower engine splash shield. Remove the generator and power steering pump drive belts. 2) Remove dipstick tube from front of engine. Support engine with a jack, and remove engine side mount from front of engine. Remove crankshaft pulley center bolt and pulley. 3) Remove upper and lower timing belt covers. See Fig. 1. If reusing timing belt, mark direction of belt rotation for installation reference. 4) Remove one of the battery clamp bolts from battery tray. Grind threaded end of bolt to a partial point (about 45-degree chamfer). Thread battery bolt into rear cover to hold timing belt adjuster in installed position. Hand tighten ONLY. See Fig. 2. 5) Remove side engine mount bracket from front of engine (above water pump pulley). Loosen timing belt idler pulley bolt 5-6 turns. Remove timing belt.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

ACURA
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 at-bladed screwdriver into maintenance hole. Place stopper on auto-tensioner while turning screwdriver clockwise to compress tensioner to bottom. 4) If any of the oil has spilled or leaked out of the auto-tensioner, rell it with 5W-30 motor oil. The total capacity is 6.5 ml (0.22 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 specication. 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 specication. See TORQUE SPECIFICATIONS. Adjust drive belt to correct tension.

21

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Compressing Auto-Tensioner

22

ACURA
3.0L & 3.2L V6 3.0CL & 1999 3.2TL (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Center Bolt ................................................................................ 67 (90) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Side Mount Bracket-To-Mount Through-Bolt 3.0CL ....................................................................................................................... 47 (64) 3.2TL ........................................................................................................................ 40 (54) Engine Side Mount-To-Engine Bolts ......................................................................... 33 (44) Idler Pulley Bolt ......................................................................................................... 33 (44) Power Steering Pump Lock Nut ............................................................................... 17 (24) Power Steering Pump Mount Bolt ............................................................................ 17 (24) INCH Lbs. (N.m)
Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Timing Belt

Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8) Auto-Tensioner Mount Bolts .................................................................................... 106 (12) Lower Engine Splash Shield Bolts ......................................................................... 106 (12) Timing Belt Cover Bolts .......................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

ACURA
3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL)
NOTE: For timing belt replacement information on 3.2L NSX and NSX-T, see 3.0L & 3.2L NSX & NSX-T article. For timing belt replacement information on 3.5L 3.5RL, see 3.5L V6 3.5RL article. TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

23

5) Using a battery hold-down bolt, grind threaded end to a slight bevel. Hand tighten bolt into timing belt adjuster to hold position. See Fig. 3. 6) Remove engine mount bracket on end of front cylinder head. Loosen idler pulley bolt about 5-6 turns, then remove timing belt.

3.2L V6 (J32A1/A2) 3.2CL 2001-03 ............................... 4.0 Hours ... .. TCK286 .. ..... 3.2TL 2000 .................................... 4.0 Hours ... . 1 TCK286 . ..... 2001-03 ............................... 4.0 Hours ... ...... ..... ...... ..... TL 2004 ................................. ........ N/A ........ ...... ..... ...... ..... 3.5L V6 (J35A3) MDX 2001-04 ............................... 4.0 Hours ... .. TCK286 .. .....
1

T286 T286 T286 T329

T286

Timing component kit does not include camshaft tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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).

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing Side Engine Mount Bracket

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Radio and navigation system (if equipped) contain an antitheft protection circuit. Obtain anti-theft code numbers before disconnecting battery. Note radio preset frequencies.

TIMING BELT
NOTE: To inspect belt to determine if replacement is needed, disconnect negative battery cable. Remove ignition coil cover (if necessary) and front upper timing belt cover. Inspect timing belt for cracks or signs of oil or coolant leakage onto belt. Replace belt if necessary. Removal (Except 2003-04 MDX) 1) Set No. 1 piston to TDC by turning crankshaft so White mark aligns with pointer. On MDX and 3.2CL, ensure marks on front camshaft pulley and front cover are aligned. On 3.2TL, check through rear timing belt cover opening to ensure camshaft pulley mark and rear cover mark are aligned. 2) Raise vehicle and remove front wheels. Remove splash shield. Using lever tool, move auto-tensioner to relieve tension from generator belt. Remove generator belt. 3) Loosen power steering pump adjusting nut, lock nut and mounting bolt. Remove power steering pump belt. Support engine with jack and wood block under oil pan. Remove side engine mount bracket. See Fig. 1. 4) Remove dipstick and tube. Discard O ring. Hold crankshaft pulley, and remove pulley bolt. Remove upper timing belt covers and lower timing belt cover. See Fig. 2.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components Removal (2003-04 MDX) 1) Set No. 1 piston to TDC by turning crankshaft so White mark aligns with pointer. Ensure marks on front camshaft pulley and front cover are aligned. 2) Raise vehicle and remove front wheels. Remove splash shield. Using lever tool, move auto-tensioner to relieve tension from generator belt. Remove generator belt. 3) Support engine with jack and wood block under oil pan. Remove side engine mount bracket. See Fig. 1.

24

ACURA
3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL) (Cont.)
9) On 2003-04 MDX, perform Powertrain Control Module (PCM) reset procedure and Crankshaft Position (CKP) pattern learn procedure. See RESET PROCEDURES (2003-04 MDX).

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Hold-Down Bolt To Hold Timing Belt Adjuster In Position 4) Hold crankshaft pulley, and remove pulley bolt. Remove upper timing belt covers and lower timing belt cover. See Fig. 2. 5) Using a battery hold-down bolt, grind threaded end to a slight bevel. Hand tighten bolt into timing belt adjuster to hold position. See Fig. 3. 6) Remove engine mount bracket on end of front cylinder head. Remove idler pulley bolt, and idler pulley. Remove timing belt. Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Check sprockets and pulleys for wear, cracks or damage. Replace components if necessary. Installation (New Belt All Models) 1) Clean timing belt pulleys, and the upper and lower covers. Ensure timing belt pulley is still set to TDC position. See Fig. 4. Clean camshaft pulleys. Set pulleys to TDC position by aligning TDC marks on camshaft pulleys with pointers on back covers. Remove battery hold-down bolt from back cover. 2) Remove auto-tensioner. Ensure maintenance bolt is always pointing upward. Ensure no oil leaks or spills from auto-tensioner during handling. CAUTION: Do NOT exceed 2200 lbs. of pressure when compressing auto-tensioner. 3) Align holes on rod and auto-tensioner housing. Mount auto-tensioner in press, and slowly compress until a holding pin can be placed through housing and rod. See Fig. 5. 4) Install auto-tensioner, making sure the pin stays in place. On 2003-04 MDX, apply liquid thread lock to idler pulley bolt, and loosely install idler pulley. On all models, install timing belt, working in counterclockwise direction, until belt is around all pulleys in the following order: crankshaft sprocket, idler pulley, front camshaft pulley, water pump pulley, rear camshaft pulley and tensioner adjusting pulley. See Fig. 6. 5) Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Pull out set pin of auto-tensioner. Install engine mount bracket. If timing belt guide plate was removed, install with concave side facing outward. Install upper and lower timing belt covers. 6) Clean crankshaft pulley and bolt. Lubricate pulley bolt and washer. Install crankshaft pulley, and tighten bolt to specication 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 specication (tighten shorter vertical mounting bolts rst, then horizontal mounting bolt). See TORQUE SPECIFICATIONS. Reconnect negative battery cable. Reset radio and navigation system (if equipped) anti-theft code. Reset preset radio frequencies.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Compressing Auto-Tensioner

ACURA
3.2L V6 (Except NSX & NSX-T) & 3.5L V6 (Except 3.5RL) (Cont.)
RESET PROCEDURES (2003-04 MDX)

25

Powertrain Control Module (PCM) Reset Procedure/Clearing Diagnostic Trouble Codes To clear codes using the Honda PGM Tester or the HDS, use the CLEAR COMMAND. The PCM stores data and DTCs to correct the system even when there is no electrical power (such as the No. 10 BACK UP fuse removed or battery negative cable disconnected). 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 specic 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 misre or CKP sensor. If CKP pattern data is cleared from PCM, you must do the CKP pattern relearn procedure by test drive. See CKP PATTERN LEARN PROCEDURE. NOTE: Enable criteria: Engine coolant temperature must be 176F (80C) or higher. Crankshaft Position (CKP) Pattern Learn Procedure 1) Having cleared the CKP pattern from PCM, leave Honda PGM Tester or the HDS connected to DLC and turn ignition switch off. Turn ignition switch on. Wait for 30 seconds. 2) Start vehicle and test drive on a level road. Decelerate (with throttle fully closed) from engine speed of 2500 RPM to 1000 RPM with A/T in 2 or D3 position. 3) Stop vehicle. DO NOT turn the ignition switch off. Select the ALL DATA list in DATA LIST menu using Honda PGM Tester or the HDS . 4) Check status of PULSER F/B LEARN. If it is set to NG, enable criteria was probably not met. Repeat the procedure from beginning.

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt Installation (Used Belt All Models) 1) Clean timing belt pulleys, and the upper and lower covers. Ensure timing belt pulley is still set to TDC position. See Fig. 4. Clean camshaft pulleys. Set pulleys to TDC position by aligning TDC marks on camshaft pulleys with pointers on back covers. 2) On 2003-04 MDX, apply liquid thread lock to idler pulley bolt, and loosely install idler pulley. If auto-tensioner has extended and timing belt cannot be installed, perform new belt installation procedure. See INSTALLATION (NEW BELT ALL MODELS). On all other models, if auto-tensioner has extended and timing belt cannot be installed, remove and compress auto-tensioner. Install auto-tensioner. 3) Install timing belt, working in counterclockwise direction, until belt is around all pulleys in the following order: crankshaft sprocket, idler pulley, front camshaft pulley, water pump pulley, rear camshaft pulley and tensioner adjusting pulley. See Fig. 6. 4) Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Remove battery hold-down bolt from back cover. Install engine mount bracket. If timing belt guide plate was removed, install with concave side facing outward. Install upper and lower timing belt covers. 5) Clean crankshaft pulley and bolt. Lubricate pulley bolt and washer. Install crankshaft pulley, and tighten bolt to specication while holding pulley. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley about 5-6 turns clockwise so timing belt properly sets on all pulleys. 6) Turn crankshaft pulley to align TDC mark. Check TDC mark alignment of camshaft pulleys. If camshaft pulley marks are at TDC, go to next step. If camshaft pulley marks are not at TDC, repeat installation procedure. 7) On all models except 2003-04 MDX, install dipstick and tube with NEW O ring. Install and adjust tension of power steering belt. On all models, install generator belt. Install side engine mount bracket, and tighten bolts to specication (tighten shorter vertical mounting bolts rst, then horizontal mounting bolt). See TORQUE SPECIFICATIONS. Reconnect negative battery cable. Reset radio and navigation system anti-theft code. Reset preset radio frequencies. 8) On 2003-04 MDX, perform Powertrain Control Module (PCM) reset procedure and Crankshaft Position (CKP) pattern learn procedure. See RESET PROCEDURES (2003-04 MDX).

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Center Bolt ................................................................................ 67 (90) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Mount Bracket 6 x 1.0 mm Bolt ..................................................................................................... 8.7 (12) 10 x 1.25 mm Bolt .................................................................................................. 33 (44) Engine Side Mount Bracket 10 x 1.25 mm Bolt .................................................................................................. 33 (44) 12 x 1.25 mm Bolt .................................................................................................. 40 (54) Idler Pulley Bolt ......................................................................................................... 33 (44) Power Steering Pump Lock Nut ............................................................................... 17 (24) Power Steering Pump Mount Bolt ............................................................................ 17 (24) INCH Lbs. (N.m) Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8) Auto-Tensioner Mount Bolts .................................................................................... 106 (12) Dipstick & Tube ....................................................................................................... 106 (12) Lower Engine Splash Shield Bolts ......................................................................... 106 (12) Timing Belt Cover Bolts .......................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

26

ACURA
3.2L V6 Legend & 1996-98 3.2TL
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

3.2L V6 Legend (C32A1) 1991-95 ............................... 5.6 Hours ... .. TCK193 .. ..... T193 3.2TL (C32A6) 1996-98 ............................... 4.0 Hours ... .. TCK193 .. ..... T193 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1991-94 model years, manufacturer recommends belt be replaced every 90,000 miles or 72 months. For 1995-96 model years, replacement interval is 90,000 miles for normal service and 60,000 miles for severe service. For 1997-98 model years, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Some vehicles may be equipped with radio/cassette or radio/CD players that contain anti-theft protection circuit. Obtain radio anti-theft code from vehicle owner before disconnecting negative battery cable.

TIMING BELT
Removal (1991-93) 1) Disconnect negative battery cable. Remove injector harness covers. See Fig. 1. Remove engine wiring harness from front of engine. Disconnect breather pipe. Remove vacuum pipe bracket. Remove accessory drive belts. 2) Remove timing belt upper covers. See Fig. 2. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure timing marks are aligned. Remove A/C belt tensioner pulley. Remove crankshaft pulley. Remove engine oil dipstick tube. 3) Remove timing belt lower cover. If timing belt is to be reused, mark belt with arrow indicating direction of rotation. Loosen timing belt adjusting bolt 1/2 turn. Push tensioner to release belt tension, then retighten adjusting bolt. Remove timing belt. CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed, because pistons may hit valves, causing damage. Do NOT rotate crankshaft when tension adjusting bolt is loose. Installation (1991-93) 1) Remove spark plugs. When installing timing belt, turn crankshaft clockwise 15 degrees past No. 1 cylinder TDC. After adjusting left and right camshaft pulleys to TDC, turn crankshaft pulley counterclockwise back to TDC. 2) Install timing belt in this sequence: Crankshaft pulley, tensioner pulley, left camshaft, water pump pulley, right camshaft. To ease installation, advance right camshaft pulley about a half tooth from TDC position. 3) Loosen timing belt tension adjusting bolt, and retighten it after tensioning the timing belt. Temporarily install lower timing belt cover and crankshaft pulley. Rotate crankshaft about 5-6 turns clockwise to seat timing belt. Place No. 1 piston at TDC of compression stroke. 4) Rotate crankshaft clockwise 9 teeth on camshaft pulley. Blue mark on crankshaft pulley will should line up with pointer on lower cover. See Fig. 3.
Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Intake Manifold (1991-93) 5) Loosen timing belt adjusting bolt 180 degrees. Tighten timing belt adjusting bolt to 31 ft. lbs. (42 N.m). Verify crankshaft and camshaft timing marks are still aligned. If timing marks are not aligned, repeat timing belt installation procedure. To complete installation, reverse removal procedure. Coat crankshaft pulley center bolt threads with oil before installation. Adjust accessory drive belt to proper tension. NOTE: After installing timing belt, slowly rotate engine clockwise several times to be sure valves do not contact pistons. Removal (1994-98) 1) Disconnect negative battery cable. Use jack to support engine. Remove center bracket and mount from front, lower part of engine. Remove the generator, A/C compressor, and power steering belts. 2) If equipped, remove Traction Control System (TCS) valve assembly brackets. Disconnect TCS throttle sensor and actuator connectors. See Fig. 4. Remove TCS control valve assembly, leaving breather pipe by-pass hose connected. 3) Remove engine front wiring harness cover with oil pressure switch and engine ground cable connectors. Remove idler pulley bracket, dipstick, and dipstick pipe. Remove crankshaft pulley. 4) Remove timing belt upper and lower covers. See Fig. 2. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Align timing marks. See Fig. 5. Loosen timing belt adjusting bolt 180 degrees to remove tension from belt. Retighten adjusting bolt.

ACURA
3.2L V6 Legend & 1996-98 3.2TL (Cont.)

27

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components 5) If timing belt is to be reused, mark direction of belt rotation before removing. Remove timing belt. Installation (1994-98) 1) Remove all spark plugs. Ensure No. 1 piston is at TDC of compression stroke. Position crankshaft and camshaft pulleys as shown. See Fig. 5. 2) Adjust camshaft pulley(s) until TDC mark on pulley and pointer on cover plate are aligned. If reusing timing belt, ensure arrow made in removal procedure points in direction of original rotation. 3) Install timing belt in this sequence: Crankshaft pulley, tension adjuster pulley, left camshaft pulley, water pump pulley, and right camshaft pulley. Loosen and tighten tensioner adjuster bolt to remove slack in belt. 4) Install upper and lower covers and crankshaft pulley. Tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise 5-6 revolutions to seat timing belt. 5) Adjust timing belt tension. Remove upper left camshaft cover. Remove damper from center bracket. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Rotate crankshaft 9 teeth clockwise on camshaft pulley. Align Blue mark on crankshaft pulley with pointer on lower cover. See Fig. 3. Loosen tensioner adjusting bolt 1/2 turn, then tighten bolt to 31 ft. lbs. (42 N.m). 6) Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Verify camshaft timing marks are aligned. If timing marks are not aligned, repeat timing belt installation procedure. To complete installation, reverse removal procedure. Coat crankshaft pulley center bolt threads with oil before installation. NOTE: After installing timing belt, slowly rotate engine clockwise several times to be sure valves do not contact pistons.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Timing Marks For Timing Belt Tension

28

ACURA
3.2L V6 Legend & 1996-98 3.2TL (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolts ............................................................................................... 23 (31) Center Bracket Bolts ................................................................................................. 40 (54) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Power Steering Mount Lock Nut .............................................................................. 16 (22) TCS Lower Bracket Bolts ......................................................................................... 16 (22) Timing Belt Adjusting Bolt ......................................................................................... 31 (42) INCH Lbs. (N.m) Front Engine Wiring Harness Bolts ........................................................................ 106 (12) TCS Upper Bracket Bolts ....................................................................................... 106 (12) Timing Belt Cover Bolts .......................................................................................... 106 (12)
Courtesy of American Honda Motor Co., Inc.

Fig. 4: Locating TCS Connectors & Control Valve

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (TDC)

ACURA
3.5L V6 3.5RL
TIMING BELT APPLICATION Application Labor Time Belt Part No.

29

3.5L V6 (C35A1) 3.5RL 1996-04 Balancer .............................................. .......... 1 .......... ..... T280 Camshaft ................................................ 4.6 Hours ... ..... T279
1

Balancer belt labor included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under 20 degrees F).

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Locating TCS Connectors & Control Valve of crankshaft. Ensure timing belt drive pulley is set so that No. 1 piston is at TDC. Align TDC mark on timing belt drive pulley with pointer on oil pump. See Fig. 3. NOTE: For easier installation, turn right camshaft pulley clockwise about half a tooth from TDC position. Ensure crankshaft pulley and left camshaft pulley are at TDC. 2) Set camshaft pulleys so that No. 1 piston is at TDC. Align TDC marks on camshaft pulleys to pointers on back covers. See Fig. 3. Install timing belt (in sequence) on timing belt drive (crankshaft) pulley, adjusting pulley, left camshaft pulley, water pump pulley, and right camshaft pulley. See Fig. 4. Ensure camshaft and crankshaft pulleys remain at TDC. Loosen and retighten timing belt adjusting bolt. Install lower cover and crankshaft pulley. 3) Rotate crankshaft clockwise 5-6 turns to properly position timing belt on pulleys. To set timing belt tension, set No. 1 piston at TDC of compression stroke. White mark on crankshaft pulley must be aligned with pointer on lower cover. See Fig. 5. Rotate crankshaft clockwise 10 teeth on camshaft pulley. Blue mark on crankshaft pulley should align with pointer on lower cover. Loosen timing belt adjusting bolt 180 degrees. Tighten adjusting bolt to specication. See TORQUE SPECIFICATIONS. 4) Remove crankshaft pulley and lower cover. Install timing belt guide plate and balancer belt drive pulley on crankshaft. See Fig. 2. Ensure guide plate is installed in correction direction. 5) Remove 12-mm sealing bolt from side of engine block. See Fig. 6. Align maintenance hole and balancer shaft hole. Insert a 6-mm bolt into sealing bolt hole. Ensure balancer belt pulley pointer aligns with pointer on balancer gear case. See Fig. 7. 6) Set timing belt drive pulley so that No. 1 piston is at TDC. Install balancer belt pulley. Install balancer belt. Loosen and retighten balancer belt adjusting bolt to tension balancer belt. Remove 6-mm bolt. Install sealing bolt in maintenance hole, using a new washer. 7) Install crankshaft pulley. Rotate crankshaft pulley about 5 or 6 turns clockwise to position balancer belt on pulleys. Loosen balancer belt adjusting bolt 180 degrees. Tighten balancer belt adjusting bolt to specication. See TORQUE SPECIFICATIONS. 8) Remove crankshaft pulley. Install upper and lower covers, then install crankshaft pulley. Ensure crankshaft pulley and camshaft pulley are at TDC. Remove inspection plugs in upper camshaft covers to check pulley alignment. 9) To complete installation, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Some vehicles may be equipped with radio/cassette or radio/CD players that contain anti-theft protection circuit. When battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE and will be inoperative until proper code is entered by vehicle owner.

TIMING & BALANCER BELTS


Removal 1) Turn crankshaft until No. 1 piston is at TDC of compression stroke. Remove engine cover, intake air duct, and air cleaner assembly. 2) Loosen alternator mounting bolt, lock bolt and adjusting rod, then remove alternator belt. Loosen idler pulley center nut and adjuster bolt. Remove A/C belt. Remove Traction Control System (TCS) control valve upper and lower brackets. Loosen adjusting bolt, lock nut and mounting bolt, then remove power steering pump belt. 3) Disconnect TCS throttle sensor connector, TCS throttle actuator connector and throttle position sensor connector. Remove TCS control valve assembly. See Fig. 1. Disconnect vehicle speed sensor subharness connector, then remove wire harness holder. 4) Remove crankcase breather hose and vacuum hoses from front of right upper cover. Remove Ignition Control Module (ICM) bracket from right upper cover. Remove idler pulley bracket, dipstick, and dipstick tube. Remove crankshaft pulley. See Fig. 2. 5) Remove upper and lower covers. If reusing balancer timing belt, mark direction of belt rotation for installation reference. Loosen balancer timing belt adjuster bolt 180 degrees. Push on tensioner to release belt tension, then retighten adjusting bolt. Remove balancer timing belt. 6) If camshaft timing belt is to be reused, mark direction of rotation before removing. Loosen camshaft timing belt adjuster bolt 180 degrees. Push on tensioner to release belt tension, then retighten adjusting bolt. Remove camshaft timing belt. CAUTION: DO NOT rotate crankshaft pulley or camshaft pulley with timing belt removed. Pistons may hit valves and cause damage. NOTE: Ensure water pump turns freely in clockwise direction and there are no leaks. Installation 1) Remove spark plugs. Remove balancer belt drive pulley. Noting installed position, remove timing belt guide plate from end

30

ACURA
3.5L V6 3.5RL (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

ACURA
3.5L V6 3.5RL (Cont.)

31

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Routing

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning TDC Timing Marks

Fig. 5: Aligning Timing Marks (TDC)

32

ACURA
3.5L V6 3.5RL (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Balancer Belt Tension Adjusting Bolt ........................................................................ 33 (44) Camshaft Pulley Bolt ................................................................................................. 23 (31) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Idler Pulley Bracket Bolt ........................................................................................... 16 (22) Engine Sealing Bolt (12 mm) ................................................................................... 14 (20) Traction Control System (TCS) Control Valve Lower Bracket Bolts ................................................................................................ 16 (22) Upper Bracket Bolts .................................................................... ..................................... 1 Timing Belt Tension Adjuster Bolt ............................................................................. 31 (42) Water Pump Bolt (8 x 1.25 mm) .............................................................................. 16 (22) INCH Lbs. (N.m) Engine Cover Bolts/Nuts ........................................................................................... 89 Dipstick Tube Bolt ................................................................................................... 106 Ignition Control Module (ICM) Bracket Bolts ......................................................... 106 Timing Belt Cover Bolts .......................................................................................... 106 Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106 Wire Harness Holder Bolts ..................................................................................... 106
1

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

Tighten bolts to 106 INCH lbs. (12 N.m).

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Balancer Shaft Lock Bolt

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Balancer Shaft Marks

ACURA
3.5L V6 SLX
TIMING BELT APPLICATION Application Labor Time Belt Part No.

33

3.5L V6 DOHC SLX 1998-99 ..................................................... 2.4 Hours ... ..... T303 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 75,000 miles for 1998-99 model years.
Courtesy of Isuzu Motor Co.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove serpentine drive belt. 2) Remove cooling fan and drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. 3) Remove power steering pump with hoses attached, and set aside. Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, remove crankshaft pulley. 4) Remove timing belt covers. Rotate crankshaft to align timing marks. See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be at TDC. 5) If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt. CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up.

Fig. 2: Aligning Crankshaft Timing Marks water pump pulley and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys. 4) Install timing belt around idler pulley and tensioner pulley. Temporarily install crankshaft pulley. Turn pulley clockwise slightly to give some belt slack between the crankshaft sprocket and right hand camshaft sprocket. NOTE: It will take about 220 lbs. (100 kg) to compress timing belt tensioner rod. 5) Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. 6) Install tensioner on engine with locking pin in place. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove locking pin from timing belt tensioner. Remove clips from camshaft and crankshaft sprockets. 8) Rotate crankshaft 2 turns clockwise. Ensure timing marks are still aligned. 9) Remove crankshaft pulley and install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6. 10) Install crankshaft pulley. Tighten center bolt to specication. Install cooling fan pulley. Install power steering pump. Install cooling fan. Install serpentine drive belt idler pulley and tensioner assemblies. Install radiator fan shroud. Connect battery.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation. Installation 1) Align grove on crankshaft sprocket with mark on oil pump. See Fig. 2. Install timing belt on crankshaft pulley, aligning White dotted line on belt with timing mark on crankshaft pulley. Secure belt to sprocket with spring clip. 2) Align timing mark on right hand (passengers side) camshaft sprocket with alignment mark on valve cover. See Fig. 3. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip. 3) Align timing mark on left hand (drivers side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

34

ACURA
3.5L V6 SLX (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 72 (98) Cooling Fan Pulley Bolt ............................................................................................ 16 (22) Crankshaft Pulley Bolt ........................................................................................... 123 (167) Power Steering Pump Bolt M8 Bolt .................................................................................................................... 16 (22) M10 .......................................................................................................................... 34 (46) Timing Belt Cover Bolt .............................................................................................. 14 (19) Timing Belt Idler Arm Pulley Bolt ............................................................................. 38 (52) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42) Water Pump Bolt ....................................................................................................... 18 (25)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt Cover Bushings

ACURA & HONDA


3.2L V6 1994-97
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

35

3.2L V6 SOHC Passport 1994-97 .............................. 1 2.8 Hours .. .. TCK221 .. ..... T221 SLX 1996-97 ............................... 2.8 Hours ... .. TCK221 .. ..... T221
1

Installation 1) Ensure all timing marks are aligned. Install belt over one pulley at a time starting at crankshaft sprocket working counterclockwise. Belt should go over tensioner last. Secure belt at each pulley during installation with pinch clips. See Fig. 3. CAUTION: To ensure correct timing belt installation, ensure direction of rotation arrows are pointing in proper direction. If timing belt is being reused, install belt in original direction of rotation. 2) Compress timing belt tensioner pusher and insert pin to retain pusher. Apply pressure to tensioner against belt and install tensioner pusher. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 3) Loosen tensioner pulley bolt. Apply pressure on belt by rotating tensioner. Tighten tensioner pulley bolt to specication. Remove pin from timing belt tensioner pusher. 4) Remove pinch clips from timing belt, (if used). Install crankshaft pulley, tightening center bolt nger tight. Rotate crankshaft 2 turns clockwise. Ensure timing belt tensioner pusher rod protrudes proper amount. See Fig. 4. 5) If timing belt tensioner pusher rod protrusion is not within specication, remove pusher, loosen tensioner pulley bolt and readjust. Reset timing belt tensioner pusher rod and repeat timing belt tensioning procedure. Remove crankshaft pulley and install timing belt cover. To complete installation, reverse removal procedure. Tighten nuts and bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove cooling fan assembly. Remove all accessory drive belts. 2) Remove fan pulley assembly. Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, remove crankshaft pulley. Remove oil cooler hose from timing cover. Remove timing belt cover. Align all timing marks prior to belt removal. See Figs. 1 and 2. Remove belt tensioner pusher and timing belt.

Courtesy of Isuzu Motor Co.

Fig. 3: Installing Pinch Clips On Timing Belt

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks

Courtesy of Isuzu Motor Co.

Fig. 4: Adjusting Timing Belt Tensioner Pusher


Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

36

ACURA & HONDA


3.2L V6 1994-97 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ................................................................................................. 41 (56) Camshaft Sprocket Bolt ............................................................................................ 41 (56) Crankshaft Pulley Bolt ........................................................................................... 123 (167) Fan Pulley Bolt .......................................................................................................... 16 (22) Front Plate Bolt ......................................................................................................... 14 (19) Idler Arm Retaining Bolt ............................................................................................ 33 (44) Power Steering Pump Bolt ....................................................................................... 34 (46) Timing Belt Cover Bolt .............................................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................................................................. 32 (43) Timing Belt Tensioner Pusher Bolt ........................................................................... 14 (19) Upper Intake Manifold Bolt ....................................................................................... 18 (24) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ....................................................................................... 87 (10) Cooling Fan Assembly Nut ......................................................................................... 69 (8)

Courtesy of Isuzu Motor Co.

Fig. 5: Exploded View Of Cylinder Head Components

ALFA ROMEO
2.5L V6 GTV
TIMING BELT APPLICATION Application Labor Time Belt Part No.

37

2.5L V6 GTV Coupe 1982-86 ..................................................... 3.9 Hours ... ..... T120 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Unplug connector from airow sensor and release cable from bracket. Disconnect hose from air intake duct and separate duct from throttle body. 2) Disconnect idle speed adjustment hose from air intake box. See Fig. 2. Disconnect air hose and wiring to auxiliary air solenoid valve. Remove auxiliary air solenoid valve from timing belt cover. 3) Disconnect distributor vacuum hose from throttle body. Disconnect oil vapor hose from timing belt cover. Disconnect fuel vapor canister hose from air intake box. 4) Disconnect pressure regulator hose. Remove air lter cover, air intake duct, and oil vapor separator. Remove air lter. Disconnect spark plug leads, coil lead, and remove distributor cap. Remove timing belt covers. 5) Remove all fan belts. Disconnect coolant hoses and wiring from thermostat housing. Remove coolant temperature sending unit from thermostat housing. Clean spark plug seats and remove spark plugs. 6) Remove bolt, screws, and timing belt cover. Engage 5th gear and push vehicle forward until P (TDC notch) on crankshaft pulley aligns with reference pin. See Fig. 1. 7) Ensure camshaft marks align with marks on camshaft caps. Ignition rotor must point toward notch on distributor body. Make sure piston in cylinder No. 1 is at TDC of compression stroke (both valves closed). 8) Lift arm of timing belt tensioner and insert Adjustment Pin (A.2.0363) in block to keep tensioner arm up. Loosen nuts on tensioner arm, press tensioner downward to end of travel, and then tighten top nut. Remove timing belt from pulleys. Installation 1) Check that engine is on TDC of compression stroke by installing TDC Adapter (C.6.0183) and dial indicator into spark plug seat of cylinder No. 1. Ensure P (TDC notch) on crankshaft pulley aligns with reference pin and camshafts are aligned with marks on camshaft caps. See Fig. 1. 2) Install timing belt over crankshaft pulley, left cylinder head, right cylinder head, distributor drive gear, and over belt tensioner pulleys. Loosen top nut on belt tensioner. 3) Engage 5th gear on transmission and push vehicle forward to rotate crankshaft 2 complete revolutions. Stop vehicle when P (TDC notch) on crankshaft pulley aligns with reference pin. 4) Recheck all alignment marks and ensure rotor points toward reference notch. Press belt tensioner against timing belt and tighten tensioner arm nuts. Lift tensioner arm slightly and remove adjustment pin. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 1: Replacing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tensioner Pulley Bolt ......................................................................................... 15 (20) Camshaft Hub Nut .................................................................................................. 85 (115) Crankshaft Pulley Nut ........................................................................................... 174 (235) INCH Lbs. (N.m) Front Cover Bolts .......................................................................... ..................... 72-82 (8-9) Valve Cover Bolts .............................................................................................. 82-96 (9-11)

38

ALFA ROMEO
2.5L V6 GTV (Cont.)

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 2: Disconnecting Engine Components

ALFA ROMEO
3.0L V6
TIMING BELT APPLICATION Application Labor Time Belt Part No.

39

3.0L V6 164 1991-93 ..................................................... 4.8 Hours ... ..... T120 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right front inner fenders. Disconnect throttle opening switch electrical connector. Remove throttle body cover. 2) Remove water pump, air conditioning, and power steering drive belts. Remove hydraulic belt tensioner. Disconnect crankshaft position sensor connector, and remove sensor. Disconnect constant idle speed actuator electrical connector. Disconnect oil vapor separator hoses. 3) Disconnect accelerator cable. On models equipped with automatic transmission, disconnect kickdown cable. On S models, disconnect engine throttle sensor electrical connector. On all models, disconnect fuel vapor and cruise control hoses. 4) Disconnect fuel pressure regulator and power brake unit vacuum hoses. Disconnect ground strap from air intake box. Remove air intake box attaching screws and clamps, and remove air intake box. 5) Disconnect spark plug wires for cylinders No. 1, 2 and 3. Remove intake ducts and gaskets. Remove right valve cover and gasket. Disconnect spark plug wires for cylinders No. 4, 5 and 6. Remove left side valve cover and gasket. 6) Partially drain cooling system. Disconnect coolant hose from thermostat unit. Disconnect return hose from water pump. Disconnect coolant temperature switch and sensor electrical connectors. If equipped, disconnect oil cooling tubes from heat exchanger. 7) Remove timing belt covers. Remove spark plugs Rotate crankshaft so No. 1 cylinder is at TDC of compression stroke. Flywheel and transmission housing timing marks should align. See Fig. 1. Camshaft sprocket timing marks should align with bearing cap marks. See Fig. 2. 8) Lift belt tensioner arm from timing belt. Insert Holding Tool (1.820.053.00) or equivalent into hole on arm to lock in position. Loosen hydraulic belt tensioner retaining nuts. Push tensioner downward to limit of travel, and tighten upper retaining nut. Remove timing belt. Installation 1) Position Adapter (1.825.007.000), or equivalent, and a dial indicator into No. 1 cylinder spark plug hole. See Fig. 2. Ensure camshaft and crankshaft timing marks align. 2) Install timing belt over crankshaft sprocket, left camshaft sprocket, right camshaft sprocket, and oil pump sprocket hydraulic belt tensioner pulley. See Fig. 3. Maintain tension on timing belt during installation. Loosen timing belt hydraulic tensioner upper retaining nut. 3) Turn crankshaft in normal direction of rotation 2-3 revolutions to seat timing belt. Keep timing belt under tension and push hydraulic tension pulley against timing belt. Tighten 2 tensioner retaining nuts. Slightly lift belt tensioner arm, then release tensioner arm by removing tool holding arm in position.

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 1: Identifying Flywheel Timing Marks 4) Position No. 1 cylinder at TDC compression stroke. Ensure crankshaft and camshaft timing marks are aligned. If timing marks are not aligned, timing belt must be removed and repositioned. Install spark plugs. Install timing belt covers. 5) On models with heat exchanger, connect oil cooler tubes. On all models, connect coolant hose to thermostat unit, and return hose to water pump. Plug in coolant switch and sensor electrical connectors. Install left side valve cover and gasket. 6) Connect spark plug wires for cylinders No. 4, 5 and 6. Install right side valve cover and gasket. Install intake ducts and gaskets. Connect spark plug wires for cylinders No. 1, 2 and 3. Install air intake box. Connect ground strap to air intake box. Connect fuel pressure regulator and power brake unit vacuum hoses. Connect fuel vapor and cruise control hoses. 7) On S models, connect engine throttle sensor electrical connector. Connect accelerator cable. On models with automatic transmission, connect kickdown cable. Install throttle body cover. Connect throttle body switch electrical connector. 8) Connect oil vapor separator hoses. Connect constant idle speed actuator electrical connector. Install crankshaft position sensor and electrical connector. Install hydraulic drive belt tensioner. Install power steering pump, A/C compressor, and water pump drive belts. 9) Install front right inner fenders. Install right front wheel and tire assembly, then lower vehicle. Connect negative battery cable. Adjust accessory drive belt tension.

40

ALFA ROMEO
3.0L V6 (Cont.)

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 3: Installing Timing Belt

Courtesy of Alfa Romeo Auto S.p.A.

Fig. 2: Identifying Camshaft Timing Marks

AMERICAN MOTORS
2.0L 4-Cylinder
TIMING BELT APPLICATION Application
1

41

Labor Time Component Belt Kit No. Part No.

2.0L 4-Cyl. Concord & Gremlin 1977-78 ............................... 1.5 Hours ... .. TCK017 .. ..... T017 Concord & Spirit 1979 .................................... 1.5 Hours ... .. TCK017 .. ..... T017
1

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of American Motors/Renault Corp.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles.

Fig. 1: Aligning Timing Marks

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. CAUTION: Rotate engine by turning crankshaft. Do not turn engine by camshaft. Removal 1) Disconnect negative battery cable. Rotate engine until timing mark (notch) on crankshaft is pointing to zero. Camshaft sprocket timing mark should now be adjacent to pointer on cylinder head cover. See Fig. 1. 2) Loosen front pulley retaining screws. Remove alternator and power steering drive belts. Remove cam drive belt shield. 3) Mark rotation of belt rotation before removal. Loosen tensioner retaining screw and remove camshaft drive belt. See Fig. 2. CAUTION: Use hands to install belt. DO NOT pry with tool. Installation 1) Mount belt onto crankshaft sprocket. Position belt in tensioning pulley groove and install belt to camshaft sprocket. See Fig. 2. CAUTION: Excessive tension may cause pulley to fail. 2) Turn offset adjusting nut on tensioning pulley clockwise to tighten belt tension. When belt can be twisted 90 with thumb and forenger, belt is properly tensioned. 3) Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of American Motors/Renault Corp.

Fig. 2: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Belt Tensioning Idler Screw ..................................................................... 29 (39) Camshaft Sprocket Screw ........................................................................................ 58 (78) Crankshaft Sprocket Screw .................................................................................. 181 (123) Water Pump Screw (Large) ...................................................................................... 16 (21) INCH Lbs. (N.m) Camshaft Rear Bearing Cap Screw ......................................................................... 84 (10) Water Pump Screw (Small) ...................................................................................... 84 (10)

42

AUDI
1.6L 4-Cylinder Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. 4000 Diesel 1982-83 ..................................................... 2.3 Hours ... ..... T043 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Courtesy of Audi of America, Inc.

Fig. 1: Installing Camshaft Locking Tool

REMOVAL & INSTALLATION


TIMING BELT & SPROCKET
Removal 1) Disconnect negative battery cable. Remove accessory drive belts. Remove timing belt cover and camshaft cover. Turn crankshaft to place No. 1 piston on TDC at end of compression stroke. Lobes of camshaft on No. 1 cylinder must point upward. 2) Secure camshaft in place by installing Setting Bar (2065) at rear of camshaft. Tool must be properly installed to prevent camshaft from moving. See Fig. 1. 3) Insert Pin Tool (2064) through small cutout in injection pump sprocket to lock sprocket in place. Injection pump sprocket must not be allowed to move. 4) Check that timing marks on injection pump sprocket, pump body and mounting plate are aligned. Check that TDC mark on ywheel is aligned with reference mark on bellhousing. 5) Loosen timing belt tensioner to relieve tension on timing belt. Remove crankshaft pulley. Do not allow crankshaft to turn. Remove timing belt. Installation 1) Check that TDC mark on ywheel is still aligned with reference mark. Loosen camshaft sprocket bolt 1/2 turn. Loosen sprocket from camshaft by tapping with a rubber mallet. 2) Install timing belt. Tighten camshaft sprocket bolt. Remove pin tool from injection pump sprocket. Apply tension to belt by turning timing belt tensioner to right. 3) Using Tension Gauge (210), check timing belt tension midway between camshaft and injection pump sprockets. Tension is correct if gauge reads 12-13. See Fig. 2. 4) Turn crankshaft clockwise 2 turns. Strike timing belt with a rubber mallet midway between camshaft sprocket and injection pump sprocket. Using Tension Gauge (210), recheck timing belt tension. 5) If necessary, readjust timing belt tension. Check injection pump timing. Install remaining components in reverse order of removal. Adjust drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 2: Using Timing Belt Tension Gauge

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley/Damper Standard .............................................................................................................. 108 (150) Turbo .................................................................................................................... 145 (200) Injection Pump Sprocket ........................................................................................... 33 (45) Intermediate Shaft Pulley .......................................................................................... 33 (45) Timing Belt Tensioner ................................................................................................ 33 (45)

AUDI
1.6L & 1.7L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

43

1.6L 4-Cyl. Fox 1973-79 ............................... 1.1 Hours ... .. TCK017 .. ..... T017 1.7L 4-Cyl. 4000 1980-83 ............................... 1.1 Hours ... .. TCK017 .. ..... T017 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Courtesy of Audi of America, Inc.

Fig. 2: Aligning Timing Marks (1.6L)

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal Disconnect negative battery cable. Ensure No. 1 piston is at TDC on compression stroke and that crankshaft pulley notch is aligned with sprocket mark at TDC pointer. Remove radiator grille. Remove accessory drive belts. Remove water pump pulley. Remove camshaft belt guard. Loosen mounting nut of camshaft belt tensioner arm and remove tension from belt. Slide belt forward off camshaft sprocket. Installation Install new belt and adjust tensioner arm until belt can be turned 90 with thumb and index nger at a point midway between camshaft sprocket and intermediate sprocket. Check valve timing. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Camshaft Sprocket With Upper Edge Of Gasket (1.7L)

Courtesy of Audi of America, Inc.

Fig. 4: Adjusting Timing Belt Tension (1.7L)

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components (1.7L)

44

AUDI
1.6L & 1.7L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket .................................................................................................... 58 (80) Crankshaft Drive Belt Sprocket ................................................................................ 58 (80) Crankshaft V Belt Pulley ........................................................................................ 14 (20) Drive Belt Tension Nut .............................................................................................. 33 (45) Intermediate Shaft Sprocket ..................................................................................... 58 (80)

AUDI
1.8L 4-Cylinder 1984-87
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

45

1.8L 4-Cyl. 4000S 1984-87 ............................... 1.1 Hours ... .. TCK017 .. ..... T017 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specied scheduled maintenance, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

Installation 1) Set crankshaft at point just before TDC compression for No. 1 cylinder. Place timing belt on crankshaft and intermediate shaft sprockets. Install crankshaft pulley and tighten all 4 bolts. Align mark on crankshaft pulley with mark on intermediate shaft sprocket at TDC. See Fig. 2. 2) Position camshaft so mark on back of sprocket is in line with upper edge of timing belt rear cover. See Fig. 3. Both lobes for No. 1 cylinder should point upward at 45 degrees from camshaft follower so both valves are closed. Install timing belt on camshaft sprocket. 3) Adjust timing belt tension by turning tensioner adjusting hex clockwise against belt. Make sure shaft timing marks have not moved. Tighten tensioner lock nut, and check tension of timing belt at point midway between camshaft sprocket and intermediate sprocket. See Fig. 4. 4) Belt has correct tension when it can be twisted 90 degrees with thumb and nger pressure. Rotate engine by hand through 2 revolutions in clockwise direction. Check all timing marks. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: Never use camshaft sprocket attaching bolt to turn engine, as timing belt could be stretched. 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 ywheel timing marks are correctly aligned. 3) Loosen timing belt tensioner to relieve tension on timing belt. Slide timing belt off intermediate shaft sprockets.
Courtesy of Audi of America, Inc.

Fig. 2: Aligning Intermediate Shaft & Crankshaft

Courtesy of Audi of America, Inc.

Fig. 3: Setting Camshaft Timing Marks


Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components (16-Valve Shown)

46

AUDI
1.8L 4-Cylinder 1984-87 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 8-Valve ..................................................................................................................... 58 (80) 16-Valve ................................................................................................................... 48 (65) Crankshaft Pulley Nut ............................................................................................... 14 (20) Crankshaft Sprocket Bolt ...................................................................................... 148 (200) Intermediate Shaft Sprocket Bolt 8-Valve ..................................................................................................................... 58 (80) 16-Valve ................................................................................................................... 48 (65) Timing Belt Tensioner Nut ........................................................................................ 33 (45)

Courtesy of Audi of America, Inc.

Fig. 4: Adjusting Timing Belt Tension

AUDI
1.8L 4-Cylinder Turbo AEB & ATW Engines 1997-00 A4
TIMING BELT APPLICATION Application Labor Time Belt Part No.

47

1.8L 4-Cylinder Turbo (AEB & ATW) A4 & A4 Quattro 1997-00 152 Tooth Belt ........................................ 4.7 Hours ... ..... T291 153 Tooth Belt ........................................ 4.7 Hours ... ..... T317 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 105,000 mile intervals under normal driving conditions, and 52,500 mile intervals under severe driving conditions.

REMOVAL & INSTALLATION


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

NOTE: ATW engines use T317 (153 tooth belt). AEB engines are originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt).

Fig. 1: Exploded View Of Lock Carrier Assembly (A4)

TIMING BELT
Removal 1) Remove complete front bumper assembly. Remove engine undercover. Remove air intake duct from air lter housing. Disconnect all necessary electrical connectors from front of vehicle. 2) Install Lock Carrier Support Tool (3369) through lock carrier to chassis. See Figs. 1 and 2. Remove lock carrier support bolts securing lock carrier to vehicle. Slide lock carrier forward onto support tool. This will allow servicing of front engine components. 3) Remove serpentine drive belts. Remove serpentine drive belt tensioner. Remove viscous fan clutch and pulley assembly. Viscous fan pulley is secured by one Allen-head bolt. Allen-head bolt is removed from rear of pulley, through access hole in accessory mount bracket. CAUTION: Crankshaft center bolt is torque-to-yield type. Manufacturer recommends replacing bolt if it is loosened or removed. 4) Remove upper timing belt cover. Rotate crankshaft by hand to Top Dead Center (TDC). See Fig. 3. Remove crankshaft vibration damper pulley. It is NOT necessary to remove crankshaft center bolt. Remove lower timing belt cover. 5) Mark timing belt running direction. Using Torx T45 bit, loosen timing belt tensioner. Push timing belt tensioner down, and remove timing belt. CAUTION: To prevent pistons from hitting valves, make sure crankshaft is NOT at TDC for any piston before turning camshaft. Installation 1) Align mark on camshaft sprocket with mark on cylinder head cover and/or timing belt guard. See Fig. 3. Install timing belt on crankshaft sprocket. Install lower timing belt cover. Install vibration damper pulley, and tighten bolts to specication. See TORQUE SPECIFICATIONS. 2) Ensure crankshaft vibration damper is correctly aligned to lower timing belt cover. See Fig. 3. 3) Install timing belt on the tensioner and camshaft sprocket. To tension timing belt, use spanner wrench to rotate tensioner pulley clockwise until tensioner piston No. 1 is fully extended, and piston No. 2 lifts about .040 (1 mm). See Fig. 4.

Courtesy of Audi of America, Inc.

Fig. 2: Positioning Lock Carrier Support Tool (3369) 4) Tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions in normal direction of rotation. Make sure camshaft and crankshaft timing marks are aligned. 5) Belt tension is correct if edge of tensioner lever aligns with piston upper edge (Area A), or piston No. 1 is extended 0.98-1.14 (25-29 mm) (dimension D). See Fig. 5. Check for wear in Areas B and C. 6) Install upper timing belt cover. Install serpentine drive belt tensioner and belt. To complete installation, reverse removal procedure. Ensure lock carrier Torx bolts are installed in correct position. See Fig. 6.

48

AUDI

1.8L 4-Cylinder Turbo AEB & ATW Engines 1997-00 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 6: Positioning Lock Carrier Assembly Torx Bolts


Courtesy of Audi of America, Inc.

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

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 48 (65) Crankshaft Sprocket Center Bolt 1 Step 1 ...................................................................................................................... 66 (90) Step 2 ................................................................................................... Additional 1/4 Turn Lock Carrier-To-Frame Bolts ..................................................................................... 33 (45) Lower Timing Belt Cover-To-Engine M6 .............................................................................................................................. 7 (10) M8 ............................................................................................................................ 15 (20) Serpentine Belt Tensioner Bolt ................................................................................. 18 (25) Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25) Vibration Damper Pulley Bolts 2 ................................................................................ 30 (40) Viscous Cooling Fan Pulley Bolt .............................................................................. 33 (45) INCH Lbs. (N.m) Lock Carrier-To-Fender Torx Bolts ............................................................................ 89 (10) Timing Belt Tensioner Bottom Bolt ........................................................................... 89 (10) Water Pump Bolt ....................................................................................................... 89 (10)
1 2

Courtesy of Audi of America, Inc.

Fig. 4: Tensioning Camshaft Belt

REPLACE torque-to-yield bolt if loosened or removed. Bolt strength grade is 10.9.

Courtesy of Audi of America, Inc.

Fig. 5: Identifying Tensioner Dimensions

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4
TIMING BELT APPLICATION Application Labor Time Belt Part No.

49

1.8L 4-Cylinder Turbo (AMB) A4 Avant & Sedan 2002-04 ..................................................... 4.4 Hours ... ..... T306 A4 Cabriolet 2003-04 ..................................................... 4.4 Hours ... ..... T306 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

NOTE: Take special note of the installed position of the upper part of the timing belt cover, particularly where it meets the center part of the timing belt cover. CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft. To turn engine over, use center bolt on the crankshaft. 14) Remove upper part of timing belt cover. Bring engine to TDC cylinder 1. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Remove vibration damper. Remove center and lower part of timing belt cover. CAUTION: Timing belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force. 15) When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with Locking Plate (T10008). See Fig. 15. CAUTION: The stop tab of the eccentric bolt must not be bent.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 105,000 mile intervals under normal driving conditions, 52,500 mile intervals under severe driving conditions.

REMOVAL & INSTALLATION


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

NOTE: Mark direction of rotation of timing belt with chalk or felt tip pen. 16) To release tension from timing belt, loosen nut on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool (3387). See Fig. 16. Remove timing belt.

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 lter on lock carrier. Remove left cover in engine compartment. Pull off hood seal from lock carrier and fender edges. 4) Loosen left and right wheelhousing liners in front area. See Fig. 3. Pull back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip bumper rear edge from catch (B). See Fig. 4. Repeat procedure on opposite side of the vehicle. 5) Release catches (1-4) using a screwdriver and remove air inlet grille on left and right on bottom part of bumper. See Fig. 5. Remove left and right retaining bolts until bumper is fully released. See Fig. 6. 6) If installed, disconnect hose (1) to headlight cleaning system. Disconnect harness connectors (2) and remove bumper. See Fig. 7. 7) Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward). 8) On right side, remove bolt (5) and install support tool (3369) in its place. See Figs. 8 and 9. 9) On left side, install support tool (3369) in threaded hole in chassis. See Fig. 10. 10) Remove on both sides, all bolts (2). See Fig. 8. 11) Remove on both sides, all bolts (3 and 4). See Fig. 8. Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole. 12) Secure lock carrier in this position, by placing fender bolts in holes. See Fig. 11. To install, reverse placing in service position procedure. NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior to removal. Running a used belt in the opposite direction could destroy it. 13) Remove engine cover by lifting up. Swivel tensioning element in direction of arrow to slacken off ribbed belt. See Fig. 12. Lock tensioner using a mandrel (T10060) and remove ribbed belt. See Fig. 13. Remove ribbed belt tensioner.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Under-Car Noise Insulation (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts (Sedan & Avant)

50

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 6: Identifying Bumper Fasteners (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 3: Locating Wheelhousing Fasteners (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Washer Hoses & Harness Connectors (Sedan & Avant)

Courtesy of Audi of America, Inc.

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

Courtesy of Audi of America, Inc.

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

Courtesy of Audi of America, Inc.

Fig. 5: Removing Grilles (Sedan & Avant)

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

51

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Support Tool (Part No. 3369)


Courtesy of Audi of America, Inc.

Fig. 13: Locking Ribbed Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis (Sedan & Avant)

Courtesy of Audi of America, Inc.

Fig. 14: Identifying Top Dead Center (TDC) Position

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position

Courtesy of Audi of America, Inc.

Fig. 15: Compressing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 12: Removing/Installing Ribbed Belt

52

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)
CAUTION: The stop tab of the eccentric bolt must not be bent. NOTE: Mark direction of rotation of timing belt with chalk or felt tip pen. 10) To release tension from timing belt, loosen nut on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool (3387). See Fig. 16. Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 16: Releasing Timing Belt Tension Removal (Cabriolet) 1) Loosen bolts or quick release fasteners (1 and 2). See Fig. 17. The rear noise insulation quick-release fasteners (3) should remain installed. The quick-release fasteners remain in the bumper cover (1). 2) Loosen the wheel housing liners on left and right at front. Pull the wheel housing liner back. Remove the bolt (2) and nuts (1). See Fig. 18. Unclip bumper extension from catch (B). 3) Remove bolts and tilt front grille slightly forward and pull it out in an upward direction from bumper cover. Remove bolts (1-8) and pull side extensions out of guide piece. See Fig. 19. Pull bumper cover forward slightly. 4) If equipped, disconnect hose for headlight washer unit. Disconnect connector(s) and remove bumper cover from vehicle. 5) Remove left and right engine compartment covers. Remove air duct between lock carrier and air cleaner (air duct is bolted to lock carrier). Install Lock Carrier Support Tool (3369) into thread on left and right side near impact absorbers. See Figs. 9 and 20. 6) Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender ange. See Fig. 11. NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior to removal. Running a used belt in the opposite direction could destroy it. 7) Remove engine cover by lifting up. Swivel tensioning element in direction of arrow to slacken off ribbed belt. See Fig. 12. Lock tensioner using a mandrel (T10060) and remove ribbed belt. See Fig. 13. Remove ribbed belt tensioner. NOTE: Take special note of the installed position of the upper part of the timing belt cover, particularly where it meets the center part of the timing belt cover. CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft. To turn engine over, use center bolt on the crankshaft. 8) Remove upper part of timing belt cover. Bring engine to TDC cylinder 1. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Remove vibration damper. Remove center and lower part of timing belt cover. CAUTION: Timing belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force. 9) When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with Locking Plate (T10008). See Fig. 15.

Courtesy of Audi of America, Inc.

Fig. 17: Identifying Bumper Cover Fasteners (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 18: Identifying Bumper Cover Fasteners At Wheel Opening (Cabriolet) CAUTION: To prevent pistons from hitting valves, make sure crankshaft is NOT at TDC for any piston before turning camshaft. Installation (Sedan & Avant) 1) Place timing belt on crankshaft sprocket (if reusing belt, observe direction of rotation). Install lower part of timing belt cover. Install vibration dampener. The hole in the vibration damper must be located over the raised part on the crankshaft timing belt sprocket. Tighten vibration damper/pulley to specication. See TORQUE SPECIFICATIONS. 2) If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks. See Fig. 14. Install timing belt in this order: water pump, tensioning pulley, camshaft sprocket.

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

53

vehicle. Torque left and right retaining bolts to specication. 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 specication. See TORQUE SPECIFICATIONS. 2) If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks. See Fig. 14. Install timing belt in this order: water pump, tensioning pulley, camshaft sprocket. NOTE: If the timing belt tensioner has not been restrained and is at its travel limit, it must be pushed back in the installed position together with the pulley. This procedure can take up to 5 minutes. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate (T10008). See Fig. 15. 3) Turn eccentric bolt counter-clockwise in direction of arrow using special tool (3387). See Fig. 21. Hold eccentric bolt in this position and remove locking plate. Turn eccentric bolt clockwise to right in direction of arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed between tensioning lever and tensioner housing. See Fig. 22. Hold eccentric bolt in this position and tighten pulley nut to specication. See TORQUE SPECIFICATIONS. 4) Turn crankshaft two complete turns by hand in direction of engine rotation until crankshaft is at TDC again. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check dimension between tensioning lever and tensioner housing with a gauge. Dimension should be 6-10 mm. If dimension is not obtained, tension timing belt again. Go to step 3). 5) Install center and upper timing belt cover and ribbed belt tensioner. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. When installing ribbed belt, make sure that direction of rotation is correct and that belt is installed correctly to pulleys. On vehicles with A/C, install ribbed belt to A/C compressor last. 6) To install lock carrier, reverse removal procedures outlined in REMOVAL (CABRIOLET). Torque all fasteners to specication. See TORQUE SPECIFICATIONS. NOTE: Prior to installation of the bumper cover check for presence of threaded pins (2) at the bumper extensions as well as grommets (3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m). 7) To install bumper cover, reverse removal procedures outlined in REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and connect the hose of headlight washer unit as necessary. Reconnect connectors as necessary. Ensure that the threaded pins in the bumper side extensions engage in the holes at the fender. 8) Clip in side extensions and fasten using the bolts (8). See Fig. 19. Loosely screw in bolt (3). Tighten bolts (2 and 4) to 48 INCH lbs. (6 N.m), and bolts (5, 6 and 7) to 24 INCH lbs. (3 N.m). Close hood and check overlap or gap dimension of bumper cover with respect to the hood. If OK, tighten all the bolts. If not, open hood and loosen bolts (2 or/and 4) to correct upper bumper as required. Tighten bolt (3) to 48 INCH lbs. (6 N.m). 9) Verify fender gaps as follow: A = 2 mm +/ 0.5 mm, B = 0 mm +/ 0.5 mm and C = 0 mm +/ 0.5 mm. See Fig. 24. Gap dimensions can be checked using Audi special tool (3371). Adjust gaps as necessary. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Remainder of installation is the reverse of removal.

Courtesy of Audi of America, Inc.

Fig. 19: Removing Bumper Cover (Cabriolet) NOTE: If the timing belt tensioner has not been restrained and is at its travel limit, it must be pushed back in the installed position together with the pulley. This procedure can take up to 5 minutes. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate (T10008). See Fig. 15. 3) Turn eccentric bolt counter-clockwise in direction of arrow using special tool (3387). See Fig. 21. Hold eccentric bolt in this position and remove locking plate. Turn eccentric bolt clockwise to right in direction of arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed between tensioning lever and tensioner housing. See Fig. 22. Hold eccentric bolt in this position and tighten pulley nut to specication. See TORQUE SPECIFICATIONS. 4) Turn crankshaft two complete turns by hand in direction of engine rotation until crankshaft is at TDC again. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. See Fig. 14. Check dimension between tensioning lever and tensioner housing with a gauge. Dimension should be 6-10 mm. If dimension is not obtained, tension timing belt again. Go to step 3). 5) Install center and upper timing belt cover and ribbed belt tensioner. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. When installing ribbed belt, make sure that direction of rotation is correct and that belt is installed correctly to pulleys. On vehicles with A/C, install ribbed belt to A/C compressor last. 6) To install lock carrier, reverse removal procedures outlined in REMOVAL (SEDAN & AVANT). Torque all fasteners to specication. See TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See Fig. 23. NOTE: Before installing bumper, check for the presence of threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders. Always replace bumper retaining bolts. 7) Slide bumper onto impact absorber and re-connect hose (1) of headlight cleaning system and electrical harness connectors (2). See Fig. 7. Move bumper into installation position. Make sure threaded pins in bumper side edges engage into holes at the fenders. Install bumper retaining bolts until bumper can stay in place without any assistance. 8) Do not tighten completely allowing for any necessary adjustments. Pull back wheelhousing liner (A). See Fig. 3. Engage bumper rear edge into catch (B). Torque nuts. Repeat procedure on opposite side of the

54

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 20: Exploded View Of Lock Carrier Components (Cabriolet)

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 23: Identifying Torque Support Bolts (Sedan & Avant)

Fig. 21: Releasing Locking Plate From Tensioner

Courtesy of Audi of America, Inc.

Fig. 24: Bumper Cover Gaps (Cabriolet)


Courtesy of Audi of America, Inc.

Fig. 22: Adjusting Timing Belt Tensioner

AUDI
1.8L 4-Cylinder Turbo AMB Engine 2002-04 A4 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) Camshaft Gear Bolt .................................................................................................. 48 (65) Crankshaft Gear Bolt .............................................................................................. 1 66 (90) Impact Absorber-To-Bumper Bolts ............................................................................ 17 (23) Impact Absorber-To-Frame Bolts .............................................................................. 33 (45) Ribbed Belt Tensioner-To-Bracket Bolts ................................................................... 17 (23) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) Timing Belt Tensioner-To-Bracket Bolts Smaller Bolt ............................................................................................................. 11 (15) Larger Bolt ............................................................................................................... 18 (25) Torque Reaction Support Bolts ................................................................................. 21 (28) Wheel Bolt ............................................................................................................... 89 (120) INCH Lbs. (N.m) Timing Belt Guard Bolts 2 ......................................................................................... 89 (10) Vibration Damper Bolts 3 ......................................................................................... 1 89 (10)
1 2 3

55

After achieving torque, tighten an additional quarter turn (90). Install with locking uid D 000 600 A2. Replace bolts.

56

AUDI
1.8L 4-Cylinder Turbo AMU, ATC, AWP & BEA Engines TT

TIMING BELT APPLICATION Application Labor Time Belt Part No. CAUTION: To prevent engine damage, DO NOT turn camshaft while the crankshaft is at TDC. 11) SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that a locking pin or drill bit can be inserted through the tensioner body, locking the tensioner in place. Pull out timing belt through space between engine support and cylinder block.

1.8L 4-Cylinder Turbo (AMU, ATC & AWP) TT Coupe & Roadster 2000-04 ..................................................... 3.4 Hours ... ..... T306 NOTE: Engine code is located on machined pad on bellhousing ange, where engine connects to transaxle. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) On ATC and AWP engines, disconnect charge air cooler duct at bottom of right-hand crossmember. See Fig. 1. To identify engine, check engine code located on a pad on engine block near bellhousing of transmission. See Fig. 2. On all models, remove center and right-hand noise insulation panels from under vehicle. See Fig. 3. 2) Rotate serpentine drive belt tensioner clockwise (as viewed from front of engine) to relieve belt tension. Remove serpentine drive belt and tensioner. See Fig. 4. 3) Remove cooling system expansion tank and power steering reservoir bolts, leaving hoses attached, secure expansion tank and reservoir out of way. 4) Remove vacuum hose connecting fuel evaporative canister to throttle body. Unplug electrical connectors on coolant expansion tank and fuel evaporative canister. Remove upper timing belt cover. 5) Remove weight of engine from engine mounts by installing Support Bracket (10-222) or equivalent. Engine may be supported from below using oor jack. Use care not to damage components. 6) Turn crankshaft sprocket center bolt in normal direction of rotation to align the crankshaft vibration damper at TDC of No. 1 cylinder. Ensure camshaft sprocket timing mark is aligned with mark on rear timing belt cover. See Fig. 6. Slightly lift engine. NOTE: Crankshaft sprocket center bolt is a torque-to-yield type. If removed, manufacturer recommends replacing the bolt. 7) Remove 4 bolts around center bolt on vibration damper. Remove vibration damper. It is NOT necessary to remove crankshaft center bolt. DO NOT move crankshaft during removal of vibration dampener. NOTE: Engine console and right-hand engine support bolts are torque-to-yield type. Manufacturer recommends replacing the bolts if they are removed. 8) Remove center and bottom timing belt covers. Remove bolts from engine console and right-hand engine support arm. See Fig. 7. Remove engine console and right-hand engine support arm. 9) Remove bolts for engine support, but do not remove engine support. See Fig. 8. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. 10) Screw a M5 x 55 stud into the timing belt tensioner bracket. See Fig. 9. Install hex nut and washer onto stud.

Courtesy of Audi of America, Inc.

Fig. 1: Identifying Air Duct (ATC & AWP Engines)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Engine Code Installation 1) Install timing belt onto crankshaft sprocket. Install lower timing belt cover. Install vibration damper pulley, making sure notch in center hole of vibration damper is aligned with projection on crankshaft sprocket. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 2) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 6. Install timing belt on water pump, tensioner pulley and camshaft sprocket. 3) Remove locking pin or drill bit from timing belt tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions in normal direction of rotation. Align camshaft and crankshaft timing marks. 4) Install engine right-hand engine support arm and console using NEW bolts. Adjust engine console and right-hand engine support arm so clearance is about 0.50 (13 mm). See Fig. 7. 5) Remove Engine Support Bracket (10-222) or oor jack from under vehicle. Install center and upper timing belt covers. Install serpentine belt tensioner and serpentine belt.

AUDI
1.8L 4-Cylinder Turbo AMU, ATC, AWP & BEA Engines TT (Cont.)
6) Install coolant expansion tank and power steering reservoir. Install vacuum line between fuel evaporative canister and throttle body. To install remaining components, reverse removal procedure.

57

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Components

Fig. 3: Identifying Noise Insulation Panels

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Timing Marks


Courtesy of Audi of America, Inc.

Fig. 4: Identifying Serpentine Belt & Tensioner

58

AUDI
1.8L 4-Cylinder Turbo AMU, ATC, AWP & BEA Engines TT (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 48 (65) Crankshaft Sprocket Center Bolt 1 Step 1 ...................................................................................................................... 66 (90) Step 2 ................................................................................................... Additional 1/4 Turn Engine Console-To-Body 1 Step 1 ...................................................................................................................... 30 (40) Step 2 ................................................................................................... Additional 1/4 Turn Engine Support Arm-To-Engine Bracket 1 Step 1 ...................................................................................................................... 44 (60) Step 2 ................................................................................................... Additional 1/4 Turn Serpentine Belt Tensioner Bolt ................................................................................. 18 (25) Timing Belt Tensioner Bottom Bolt .............................................................................................................. 11 (15) Top Bolt ................................................................................................................... 15 (20) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) Vibration Damper-To-Crankshaft Sprocket ............................................................... 18 (25) Water Pump Bolt ....................................................................................................... 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 7: Locating Right-Hand Engine Support Arm

Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Right-Hand Engine Support

Courtesy of Audi of America, Inc.

Fig. 9: Compressing Timing Belt Tensioner

AUDI
1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4
TIMING BELT APPLICATION Application Labor Time Belt Part No.

59

1.8L 4-Cylinder Turbo (AWM Engine) A4 & A4 Quattro 2000 ........................................................... 4.7 Hours ... ..... T306 2001-04 ..................................................... 4.4 Hours ... ..... T306 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of Audi of America, Inc.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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.

Fig. 1: Identifying Lower Engine Shield (Noise Insulator) Mounting Points

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Raise and support vehicle. Remove front tires. Remove lower front engine shield (noise insulator). See Fig. 1. With vehicle raised, remove Torx screws at wheelhousing liner. 2) Remove air inlet grilles by using screwdriver to disengage clips. See Fig. 2. Remove inner end of grille rst. Remove bolt/washer assembly (1). See Fig. 3. 3) Unclip bumper from bracket (9) and pull forward. Disconnect any wiring harness attached to the front bumper and remove front bumper cover. 4) Remove lower air duct hose-to-charge air cooler. See Fig. 4. Remove air duct between lock carrier and air lter housing. Disconnect harness retaining clips from left side of radiator shroud. 5) Remove bolt and install Lock Carrier Support Tool (3369) through lock carrier to chassis. See Figs. 5, 6 and 7. Install Lock Carrier Support Tool into bore on opposite side of vehicle. See Fig. 5. Remove lock carrier support bolts securing lock carrier to vehicle. Slide lock carrier forward onto support tool. Secure lock carrier to vehicle using holes in lock carrier and fender. See Fig. 8. This will allow servicing of front engine components. 6) Remove engine cover and loosen bolts securing ribbed belt tensioning roller for A/C compressor. Remove A/C compressor belt. Rotate tensioner in direction of arrow to loosen ribbed belt. See Fig. 9. Remove ribbed belt from generator and release tensioner. NOTE: When lock carrier is in the service position, ribbed belt tensioner can be secured to prevent from turning by inserting a suitable pin or Allen key into holes. See Fig. 10. 7) Secure pulley for viscous fan with pin punch (1) and remove using Allen key (2). See Fig. 11. Remove viscous fan from mounting. NOTE: If serpentine belt is to be reused, mark direction of timing belt rotation with chalk or felt pen before removing the belt. If belt rotates in the wrong direction when it is retted, belt breakage may result. 8) Remove upper timing belt guard. Set crankshaft to markings for TDC of No. 1 cylinder by turning central bolt on crankshaft sprocket in direction of rotation. See Fig. 12. 9) Unbolt and remove vibration damper. Remove lower and center sections of timing belt guard. Attach Socket Head Fastener (T10092 or any M5 x 55 stud) into tensioner for timing belt. See Fig. 13. Only tension pressure piston of tensioner until pressure piston can be secured with pin (T40011). Remove timing belt.

Courtesy of Audi of America, Inc.

Fig. 2: Removing Inner End Of Air Inlet Grill (A4) CAUTION: To prevent pistons from hitting valves, make sure crankshaft is NOT at TDC for any piston before turning camshaft. Installation 1) Align marking on camshaft sprocket with marking at cylinder head cover. See Fig. 12. Place timing belt on crankshaft sprocket (if reusing old belt, observe direction of rotation noted during removal). Install lower timing belt guard. Secure vibration damper/belt pulley with one bolt (note installation arrangement). Set crankshaft to TDC for cylinder No. 1. Install timing belt onto coolant pump, then tensioning roller, and nally camshaft sprocket. 2) Remove socket head fastener (T10092) and pull out pin (T40011) from tensioner. See Fig. 10. 3) Turn crankshaft two full turns in direction of rotation (by turning central bolt on crankshaft sprocket by hand) and check that camshaft and crankshaft marks align with their reference points. Install remaining vibration damper bolts and torque to specication. See TORQUE SPECIFICATIONS. 4) Install timing belt guard (center and top sections). Install viscous fan. Install tensioner for ribbed belt. Attach ribbed belt to pulleys from crankshaft and vane pump and, if necessary, pull up with auxiliary tool. Swivel tensioner for ribbed belt in direction of arrow. See Fig. 9. Install ribbed belt over generator pulley last. Release tensioner and check that ribbed belt is properly seated. 5) Fit ribbed belt for A/C compressor. Attach torque wrench at 7 oclock position to hex on tensioner and pretension to 22 ft. lbs. (30 N.m). While applying tension, tighten tensioner bolts to 17 ft. lbs. (23 N.m). 6) For installation of lock carrier, reverse removal procedures outlined in REMOVAL. After installing lock carrier, ensure harness next to radiator is routed correctly. Attach limit stop for torque reaction support to rest on rubber buffer for reaction support under its own weight. See Fig. 14. Torque bolts to specication. See TORQUE SPECIFICATIONS. 7) For installation of bumper, reverse removal procedures outlined in REMOVAL. Bumper height is adjusted by shifting the threaded sleeve in the impact absorber. See Fig. 15. Tighten combination bolt to 17 ft. lbs. (23 N.m) when installing bumper. Bolt (4) is for securing impact absorber to lock carrier for service position. Torque to 3 ft. lbs. (4 N.m).

60

AUDI
1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 3: Identifying Front Bumper Components (A4)

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Air Charge Cooler Hose (A4)

Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Lock Carrier Assembly (A4)

AUDI
1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

61

Courtesy of Volkswagen United States, Inc.

Fig. 6: Identifying Support Tool (3369)


Courtesy of Audi of America, Inc.

Fig. 9: Removing/Installing Alternator Belt (A4)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 7: Positioning Lock Carrier Support Tool (3369)

Fig. 10: Securing Tensioner

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 11: Removing Viscous Fan

Fig. 8: Positioning Lock Carrier Assembly Torx Bolts

62

AUDI
1.8L 4-Cylinder Turbo AWM Engine 2000-04 A4 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 12: Identifying Top Dead Center (TDC) position

Courtesy of Audi of America, Inc.

Fig. 15: Adjusting Front Bumper Height (A4)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) Camshaft Gear Bolt .................................................................................................. 48 (65) Crankshaft Gear Bolt .............................................................................................. 1 66 (90) Impact Absorber-To-Bumper Bolts ............................................................................ 17 (23) Impact Absorber-To-Frame Bolts .............................................................................. 33 (45) Ribbed Belt Tensioner-To-Bracket Bolts ................................................................... 17 (23) Timing Belt Guard Bolts 2 ........................................................................................... 7 (10) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) Timing Belt Tensioner-To-Bracket Bolts Smaller Bolt ............................................................................................................. 11 (15) Larger Bolt ............................................................................................................... 18 (25) Torque Reaction Support Bolts ................................................................................. 21 (28) Vibration Damper Bolts 3 ........................................................................................... 1 7 (10)
1 2 3

Fig. 13: Compressing Timing Belt Tensioner

After achieving torque, tighten an additional quarter turn (90). Install with locking uid D 000 600 A2. Replace bolts.

Courtesy of Audi of America, Inc.

Fig. 14: Adjusting Stop For Torque Reaction Support

AUDI
2.0L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

63

2.0L 4-Cyl. 80 1988-90 ............................... 1.8 Hours ... .. TCK017 .. ..... T017 90 1988 .................................... 1.8 Hours ... .. TCK017 .. ..... T017 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Installation 1) Align ywheel/explate 0 mark with pointer. Remove distributor cap, and check position of ignition rotor. Rotate intermediate shaft and position rotor at No. 1 cylinder mark on housing. See Fig. 2. Install timing belt on crankshaft and intermediate shaft gears. 2) With intermediate shaft/ignition rotor positioned, rotate crankshaft and align mark on crankshaft pulley with mark on intermediate shaft sprocket. Position camshaft sprocket mark even with base of valve cover. See Fig. 3 or 4. Install timing belt on camshaft sprocket. 3) Rotate tensioner clockwise to tighten belt and install lock nut. Proper tension is achieved when belt can be twisted 90 degrees. See Fig. 5. Rotate crankshaft 2 revolutions and check timing mark alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

Courtesy of Audi of America, Inc.

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal 1) Disconnect negative battery cable. Use exploded view to locate components. See Fig. 1. Match mark all components for reassembly reference. Place crankshaft at TDC with No. 1 cylinder on compression stroke. Remove alternator belt. Remove A/C and power steering belts (if equipped). 2) Remove upper timing belt cover. Remove water pump and crankshaft pulleys. Remove lower timing belt cover. Remove timing belt.

Fig. 2: Aligning Ignition Rotor

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks (8-Valve)


Courtesy of Audi of America, Inc.

Fig. 1: Exploded View of Timing Belt & Components

64

AUDI
2.0L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 58 (80) Crankshaft Pulley Nut ................................................................................................. 5 (20) Crankshaft Sprocket Bolt ...................................................................................... 133 (180) Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45) Water Pump Pulley ................................................................................................... 15 (20) INCH Lbs. (N.m) Timing Belt Cover Bolts .............................................................................................. 53 (6)

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Timing Marks (16-Valve)

Courtesy of Audi of America, Inc.

Fig. 5: Checking Proper Timing Belt Tension

AUDI
2.0L 5-Cylinder Diesel & Turbo Diesel
TIMING BELT APPLICATION Application 2.0L 5-Cyl. Diesel 5000 1979-83 Camshaft ................................................ Inject. Pump ........................................... 2.0L 5-Cyl. Turbo Diesel 5000 1979-83 Camshaft ................................................ Inject. Pump ........................................... Labor Time Belt Part No.

65

2.6 Hours ... ..... T083 1.1 Hours ... ..... T082

2.6 Hours ... ..... T083 1.1 Hours ... ..... T082

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components 6) Install injection pump sprocket, drive belt and inner pulley half. See Fig. 2. Tighten injection pump drive sprocket retaining bolt until it is just possible to turn sprocket on camshaft by hand. 7) Adjust fuel injection pump drive belt tension by loosening mounting bolts and repositioning mounting plate and support on engine. Using Tension Tester (VW 210), check belt tension midway between fuel injection pump and drive sprockets. 8) Tighten fuel injection pump drive sprocket bolt and remove Pin Tool (2064) from injection pump sprocket. Install remaining components in reverse order of removal. Ensure valve timing and injection pump timing are correct. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT & INJECTION PUMP BELT


Removal 1) Disconnect negative battery cable. Remove accessory drive belts. Remove outer half of vacuum pump pulley. Remove power steering pump with hoses connected, and position aside. Remove attaching bolts, and remove upper and lower timing belt covers. See Fig. 1. Remove injection pump covers. Note position and number of spacer washers on pulley. 2) Remove cam cover. Rotate crankshaft to position No. 1 cylinder at TDC. Timing marks on ywheel and clutch housing must be aligned. Also, timing marks on fuel injection pump sprocket and pump mounting plate must be aligned. 3) Lock injection pump sprocket with Pin Tool (2064). Hold inner half of vacuum pump pulley and injection pump drive sprocket with tool (3036). Remove sprocket center retaining bolt. Remove inner pulley half, pump sprocket and injection pump drive belt. 4) Secure crankshaft from moving with Support Tool (2084). Loosen crankshaft damper/pulley center bolt. Install Camshaft Holding Tool (2065A) at rear of camshaft. 5) With camshaft locked in place, loosen water pump bolts to relieve tension on timing belt. Remove crankshaft pulley with timing belt sprocket and timing belt. Installation 1) Ensure crankshaft and injection pump timing marks are aligned. Install crankshaft damper/pulley with sprocket and timing belt. Using Support Tool (2084) to hold crankshaft, install and tighten center bolt. 2) With camshaft still locked in place, loosen camshaft sprocket bolt one full turn. Using a brass drift inserted through hole in rear timing belt cover, tap camshaft sprocket loose from camshaft taper. 3) Attach timing belt to camshaft sprocket. To adjust timing belt tension, turn water pump until pump sprocket provides tension against timing belt. 4) Using tension tester (VW210), check timing belt tension midway between camshaft and water pump sprockets. Tension is correct when tester reads 12-13. 5) Check that crankshaft and injection pump timing marks are still aligned. Tighten camshaft sprocket bolt and remove camshaft holding tool.

Courtesy of Audi of America, Inc.

Fig. 2: Replacing Injection Pump Drive Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Front ......................................................................................................................... 33 (45) Rear ....................................................................................................................... 72 (100) Crankshaft Damper/Pulley (Locktite) .................................................................... 258 (350) Water Pump Bolts ..................................................................................................... 14 (20)

66

AUDI
2.2L 5-Cylinder Turbo, 1992-95
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.2L 5-Cyl. Turbo S4 1992-94 ..................................................... 1.8 Hours ... ..... T225 S6 & S6 Quattro 1995 ........................................................... 3.4 Hours ... ..... T225 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove underpanel. Remove front bumper. Remove upper radiator support with attached parts. Remove bracket for trim panel from right side of vehicle. Remove radiator bolts, radiator air guide and upper air duct from radiator. 2) Attach special Radiator Support Tool (3251) to right bumper mount bracket, and swing radiator forward. Remove viscous fan, and unclip wiring from fan frame. Relieve tension from accessory drive belt by swinging tensioner in direction shown. See Fig. 1. Insert Pin (3204) into holes. Remove belt. Remove tensioner. Remove upper timing belt guard. NOTE: Turn engine by hand using hex ange on hydraulic pump. Loosen tensioner bolts. 3) Turn crankshaft to TDC of No. 1 cylinder. See Fig. 2. Camshaft sprocket mark must align with mark on cylinder cover. See Fig. 3. Remove vibration damper. Remove lower timing belt cover. Remove timing belt with vibration damper. Installation 1) Ensure crankshaft and camshaft are at TDC of cylinder No. 1. TDC marking must be positioned below edge in inspection hole. See Fig. 2. Markings on camshaft sprocket and cylinder head cover must align. See Fig. 3. Place new belt on crankshaft pulley. Install vibration damper and at same time, t 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 forenger between camshaft sprocket and water pump. Tighten tensioner. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
Courtesy of Audi of America, Inc.

Fig. 1: Relieving Tension On Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 2: Locating No. 1 Cylinder TDC Inspection Hole

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Camshaft Sprocket Timing Marks

AUDI
2.2L 5-Cylinder Turbo, 1992-95 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

67

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20) Timing Belt Tensioner ................................................................................................ 15 (20) Vibration Damper Bolt ........................................................................................... 258 (350) Water Pump Bolt ....................................................................................................... 15 (20) INCH Lbs. (N.m) Radiator Mounting Bolts ............................................................................................ 89 (10) Timing Belt Cover ..................................................................................................... 89 (10) Valve Cover Nuts/Bolts ............................................................................................. 89 (10)

Courtesy of Audi of America, Inc.

Fig. 4: Installing Timing Belt

68

AUDI
2.3L 5-Cylinder Coupe Quattro
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.3L 5-Cyl. Coupe Quattro 1990-91 ..................................................... 1.8 Hours ... ..... T197 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT & COVER
Removal 1) Disconnect negative battery cable. Remove upper radiator cover. Remove drive belts. Remove power steering pump with pressure hoses connected. Set pump aside. Remove valve cover and outer timing belt covers. See Fig. 1. 2) Using crankshaft bolt, turn crankshaft clockwise to TDC of No. 1 cylinder compression stroke. Align timing mark on back of camshaft sprocket with upper edge of gasket. See Fig. 2. 3) Loosen water pump adjusting bolts to relieve tension on timing belt. Remove timing belt. Remove water pump to check O ring. DO NOT allow crankshaft or camshaft to move.

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components Installation 1) Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. See Fig. 3. 2) Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using nger pressure at point midway between camshaft sprocket and water pump sprocket. See Fig. 4. 3) Recheck valve timing. Complete installation in reverse order of removal. Adjust drive belts to proper tension. Fig. 2: Aligning Timing Marks

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Ignition Rotor

AUDI
2.3L 5-Cylinder Coupe Quattro (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

69

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20) Vibration Damper Bolt ........................................................................................... 258 (350) Water Pump Bolt ....................................................................................................... 15 (20) INCH Lbs. (N.m) Valve Cover Nut ........................................................................................................ 84 (10)

Courtesy of Audi of America, Inc.

Fig. 4: Checking Proper Timing Belt Tension

70

AUDI
2.3L 5-Cylinder Except Coupe Quattro
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.3L 5-Cyl. 80 1991-92 ..................................................... 80/90 Quattro 1988 ........................................................... 1989 Thru Chassis No. 89 J 394 742 ............ From Chassis No. 89 J 394 743 ........... 1990-92 ..................................................... 90 1988 ........................................................... 1989 Thru Chassis No. 89 J 396 702 ............ From Chassis No. 89 J 396 703 ........... 1990-91 ..................................................... 100/100 Quattro 1989-91 Thru Chassis No. 063 969 .................... From Chassis No. 063 970 ................... 1990-91 ..................................................... 5000S 1987-88 ..................................................... 5000S Quattro 1988 ...........................................................

1.8 Hours ... ..... T170 1.8 Hours ... ..... T127 1.8 Hours ... ..... T127 1.8 Hours ... ..... T170 1.8 Hours ... ..... T170 1.8 Hours ... ..... T127 1.8 Hours ... ..... T127 1.8 Hours ... ..... T170 1.8 Hours ... ..... T170

1.8 Hours ... ..... T127 1.8 Hours ... ..... T170 1.8 Hours ... ..... T170 2.2 Hours ... ..... T127 2.2 Hours ... ..... T127
Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal (1987-90) 1) Disconnect negative battery cable. Remove upper radiator cover. Remove drive belts. Remove power steering pump with pressure hoses connected. Set pump aside. Remove valve cover and outer timing belt covers. See Fig. 1. 2) Using crankshaft bolt, turn crankshaft clockwise to TDC of No. 1 cylinder compression stroke. Align timing mark on back of camshaft sprocket with upper edge of gasket. See Fig. 2. 3) Loosen water pump adjusting bolts to relieve tension on timing belt. Remove timing belt. Remove water pump to check O ring. DO NOT allow crankshaft or camshaft to move. Installation (1987-90) 1) Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. 2) Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using nger pressure at point midway between camshaft sprocket and water pump sprocket. Recheck valve timing. Complete installation in reverse order of removal. Adjust drive belts to proper tension. Removal (1991-92) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove upper front and lower front timing belt covers. Rotate crankshaft until timing marks are aligned. See Fig. 3. Mark an arrow on timing belt (if reusing) to indicate direction of rotation. 2) Slightly loosen 3 water pump bolts. Pivot water pump toward center of engine to relieve timing belt tension. Insert Holder (2084) into vibration damper to prevent crankshaft from turning. Using Extension (2079) and breaker bar, remove vibration damper bolt. Remove vibration damper/crankshaft sprocket. Remove timing belt.
Courtesy of Volkswagen United States, Inc.

Fig. 2: Aligning Camshaft Sprocket Installation (1991-92) 1) Ensure timing marks are aligned. See Fig. 3. With crankshaft sprocket attached to vibration damper, loop timing belt around crankshaft sprocket. Install vibration damper/crankshaft sprocket with belt onto crankshaft end, ensuring belt is not jammed between crankshaft sprocket and front cover. 2) Slightly loosen 3 water pump bolts. Pivot water pump toward center of engine to allow belt to be looped around camshaft sprocket and idler pulley. Take up all slack in belt between camshaft and water pump, and between water pump and crankshaft. 3) Pivot water pump away from engine until belt is tight. To check belt tension, grasp belt with thumb and forenger between camshaft and water pump sprocket. Belt tension is correct if belt can be twisted 90 degrees. Tighten water pump bolts to specication. Complete installation in reverse order of removal. Adjust drive belts to proper tension.

AUDI
2.3L 5-Cylinder Except Coupe Quattro (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

71

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20) Vibration Damper Bolt ........................................................................................... 258 (350) Water Pump Bolt ....................................................................................................... 15 (20) INCH Lbs. (N.m) Valve Cover Nut ........................................................................................................ 89 (10) Timing Belt Cover ..................................................................................................... 89 (10)

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks

72

AUDI
2.7L V6 DOHC APB Engine A6 Quattro & Allroad
Labor Time Belt Part No. larger holes in the securing plates on the camshaft sprockets must face one another on the inside. If this is not the case, rotate crankshaft one revolution more. WARNING: DO NOT turn engine while feeling for TDC mark. Injury could result. 9) Remove sealing plug from left side of cylinder block. See Fig. 11. The TDC mark in crankshaft must be visible (or be able to be felt) in line with sealing plug hole. Screw Crankshaft Holding Tool (Audi 3242) into sealing plug and tighten. NOTE: Center bolt does NOT have to be loosened to remove the vibration damper. 10) Remove 8 socket-head bolts and remove vibration damper. See Fig. 12. 11) Remove idler wheel for accessory drive belt. Remove timing belt guard behind vibration damper. See Fig. 13. 12) Using a hex key, turn timing belt tensioner clockwise 8 mm in direction of arrow. See Fig. 14. The toothed belt tensioning element is oil-damped and can be compressed slowly by applying constant pressure. Turn until tensioning lever compresses the oil-damped tensioner element enough to enable Pin (T40011) to be tted through the holes in the tensioner body and the plunger. This will secure plunger in position. Remove timing belt.

TIMING BELT APPLICATION Application

2.7L V6, Twin Turbo (APB Engine) A6 Quattro 2000-04 ..................................................... 5.2 Hours ... ..... T297 Allroad 2001-04 ..................................................... 5.2 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends belt and belt tensioner be replaced at 105,000 miles.

REMOVAL & INSTALLATION


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

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 anged nuts on both sides. Remove screw/washer assembly from wheelhouse liner. Remove socket-head bolts and remove bumper cover (together with impact absorber) toward front. See Fig. 2. 3) To move lock carrier into service position, perform following steps: Remove intake air duct between lock carrier and air cleaner housing at lock carrier. Remove bolts from lock carrier. On right side, remove bolt and install Support Tool (3369) into right bore. See Fig. 3. On left side, install Support Tool (3369) into threaded hole. Remove bolts on left and right. See Figs. 3 and 4. Remove bolts and pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender ange. Secure lock carrier using bolts. See Fig. 5. NOTE: Viscous fan has left-hand threads. 4) Remove viscous fan using spanner wrench and Pin Wrench (3212) to hold fan. See Fig. 6. CAUTION: Mark the direction of the accessory drive belt rotation with chalk or felt pen before removing. A used belt can break if it rotates in the opposite direction when reinstalled. 5) Using a 17-mm wrench turn belt tensioner to the right until two holes are aligned. Hold tensioner in position with Mandrel (3204). Remove accessory drive belt. See Fig. 7. 6) Unscrew bolts and remove center engine cover panel. Remove pressure hoses between charge air coolers and pressure pipes on left and right sides. See Fig. 8. Remove turbocharger pressure pipes. NOTE: Take note of position of the retaining strips. 7) Remove accessory drive belt tensioner (1). Remove left and right timing belt guards (2) and center guard (3). See Fig. 9. 8) Rotate crankshaft by hand to TDC. Ensure notch A is aligned with notch B. See Fig. 10. Check position of camshafts. Ensure that the

Courtesy of Audi of America, Inc.

Fig. 1: Removing Noise Insulation Installation 1) Insert Camshaft Locator Bar (3391) into securing plates of the two camshafts. See Fig. 15. Loosen both camshaft bolts and unscrew approximately 5 turns. NOTE: Camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be rotated, but do not move axially (up and down). 2) Remove Camshaft Locator Bar (3391). Loosen, but do not remove, both camshaft sprockets with Gear Puller (T40001). See Fig. 16. 3) Reinstall both camshaft sprockets with securing plates and tighten hand tight. 4) Position timing belt over camshaft sprockets. See Fig. 17. Install Camshaft Locator Bar (3391) on camshafts. Using hex key, turn timing belt tensioner clockwise 8 mm until pin can be removed from tensioner. See Fig. 14. 5) Pre-tension timing belt by turning tensioner pulley center bolt clockwise with a torque of 11 ft. lbs. (15 N.m). Tighten bolts on camshaft sprockets to specication. See TORQUE SPECIFICATIONS. 6) Remove camshaft locator bar. Remove crankshaft holding tool. Install plug in engine block. Install timing belt guards. 7) Remaining installation is reverse of removal procedure. For accessory drive belt routing, see Fig. 18. Ensure lock carrier-to-fender Torx bolts are installed correctly. See Fig. 5.

AUDI
2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

73

Courtesy of Audi of America, Inc.

Fig. 4: Positioning Lock Carrier Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 2: Removing Front Bumper

Courtesy of Audi of America, Inc.

Fig. 5: Securing Lock Carrier

Courtesy of Audi of America, Inc.

Fig. 3: Moving Lock Carrier To Service Position

Courtesy of Audi of America, Inc.

Fig. 6: Removing Viscous Fan

74

AUDI
2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 7: Loosening Accessory Drive Belt

Fig. 10: Aligning Crankshaft Timing Marks

Courtesy of Audi of America, Inc.

Fig. 8: Removing Pressure Hoses

Courtesy of Audi of America, Inc.

Fig. 11: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 9: Removing Accessory Drive Belt Tensioner & Timing Belt Covers Fig. 12: Removing Vibration Damper

Courtesy of Audi of America, Inc.

AUDI
2.7L V6 DOHC APB Engine A6 Quattro & Allroad (Cont.)

75

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 13: Removing Timing Belt Guard

Fig. 16: Removing Camshaft Sprockets With Gear Puller

Courtesy of Audi of America, Inc.

Fig. 17: Installing Timing Belt On Sprockets

Courtesy of Audi of America, Inc.

Fig. 14: Compressing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 18: Accessory Drive Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper Combination Bolts ....................................................................................... 17 (23) Camshaft Pulley-To-Sprocket Bolt ............................................................................ 40 (55) Crankshaft Damper Center Bolt 1 Step 1 .................................................................................................................. 147 (200) Step 2 .......................................................................................... ...... Plus 180 (1/2 Turn) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 15 (20) Idler Wheel Bolt ......................................................................................................... 33 (45) Impact Absorber Hex Bolts ....................................................................................... 33 (45) Lock Carrier-To-Body Hex Bolt ................................................................................. 37 (50) Viscous Fan ............................................................................................................... 52 (70) INCH Lbs. (N.m) Lock Carrier-To-Fender Torx Bolt ............................................................................. 89 (10) Timing Belt Tensioner Bolt ........................................................................................ 89 (10) Water Pump Bolt ....................................................................................................... 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 15: Installing Camshaft Locking Bar

ALWAYS replace bolt if loosened or removed.

76

AUDI
2.7L V6 DOHC APB Engine S4 Quattro
Labor Time Belt Part No. larger holes in the securing plates on the camshaft sprockets face one another on the inside. See Fig. 14. If this is not the case, rotate crankshaft one revolution more. WARNING: DO NOT turn engine while feeling for TDC mark. Injury could result. 11) Remove sealing plug from left side of cylinder block. The TDC mark in crankshaft must be visible (or be able to be felt) in line with sealing plug hole. NOTE: The center bolt does not have to be loosened to remove the vibration damper. 12) Screw Crankshaft Holding Tool (Audi 3242) into sealing plug and tighten. See Fig. 10. Remove crankshaft vibration damper. See Fig. 11. 13) Remove idler wheel for accessory drive belt and timing belt guard behind vibration damper. See Fig. 12. 14) Using a 8 mm hex key, turn timing belt tensioner clockwise in direction of arrow. See Fig. 13. Turn until tensioning lever compresses the oil-damped tensioner element enough to enable Pin (T40011) to be tted through holes in tensioner housing and plunger. This will secure tensioner plunger in place. Remove timing belt.

TIMING BELT APPLICATION Application

2.7L V6 Twin Turbo (APB Engine) S4 Quattro 2000-02 ..................................................... 5.5 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 2000 model vehicles, manufacturer recommends belt be replaced at 105,000 miles.

REMOVAL & INSTALLATION


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

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 rst. See Fig. 3. Remove combination bolts. Unclip bumper from bracket, and remove toward front. 3) On VIN 8DXA200001 and forward, remove bumper by removing bolt with washer, impact absorber and hex bolts. Remove Torx screws at wheel housing liner and air inlet grill at bumper by disengaging tabs at top and bottom using a screwdriver. Remove inner end of air inlet grill rst. 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. 7) Loosen accessory drive belt by using a 17-mm wrench to turn belt tensioner to the right until two holes are aligned. Hold tensioner in position with Mandrel (3204). Remove accessory drive belt. See Fig. 6. 8) Unscrew bolts and remove center engine cover panel. Remove pressure hoses between charge air coolers and pressure pipes on left and right sides. See Fig. 7. Remove pressure pipes, noting installed position of retaining strips. 9) Remove timing belt tensioner 1. Remove left and right timing belt guards 2 and center guard 3. See Fig. 8. 10) Rotate crankshaft by hand to TDC. Ensure notch A is aligned with notch B. See Fig. 9. Check position of camshafts. Ensure that the

Courtesy of Audi of America, Inc.

Fig. 1: Removing Noise Insulation

Courtesy of Audi of America, Inc.

Fig. 2: Removing Front Bumper (Up to VIN 8DXA200000 Shown; Later Models Are Similar) NOTE: Camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be turned, but do not move axially (up and down). Installation 1) Insert Camshaft Locator Bar (3391) into securing plates of the two camshafts. See Fig. 14. Loosen both camshaft bolts and unscrew approximately 5 turns. Remove Camshaft Locator Bar (3391). Loosen, but do not remove, both camshaft sprockets with Gear

AUDI
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 specication. 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 specication. See TORQUE SPECIFICATIONS.

77

Courtesy of Audi of America, Inc.

Fig. 5: Removing Viscous Fan

Courtesy of Audi of America, Inc.

Fig. 3: Removing Inner End Of Air Inlet Grill

Courtesy of Audi of America, Inc.

Fig. 6: Loosening Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 7: Removing Pressure Hoses


Courtesy of Audi of America, Inc.

Fig. 4: Moving Lock Carrier To Service Position

78

AUDI
2.7L V6 DOHC APB Engine S4 Quattro (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 8: Removing Accessory Drive Belt Tensioner

Fig. 11: Removing Vibration Damper

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 9: Aligning Crankshaft Timing Marks

Fig. 12: Removing Timing Belt Guard

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 10: Using Crankshaft Holding Tool

Fig. 13: Compressing Timing Belt Tensioner

AUDI
2.7L V6 DOHC APB Engine S4 Quattro (Cont.)

79

Courtesy of Audi of America, Inc.

Fig. 17: Routing Accessory Drive Belt

Courtesy of Audi of America, Inc.

Fig. 14: Installing Camshaft Locking Bar

Courtesy of Audi of America, Inc.

Fig. 18: Positioning Lock Carrier Torx Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper Combination Bolts ....................................................................................... 17 (23) Camshaft Sprocket Bolt ............................................................................................ 40 (55) Crankshaft Damper Center Bolt ......................................................................... 1 147 (200) Crankshaft Pulley Bolt ............................................................................................... 15 (20) Idler Wheel Bolt ......................................................................................................... 33 (45) Impact Absorber Hex Bolts ....................................................................................... 33 (45) Lock Carrier-To-Body Support (Hex) Bolts ............................................................... 33 (45) INCH Lbs. (N.m) Bracket Combination Bolts ....................................................................................... 14 (1.5) Lock Carrier-To-Fender Torx Bolts ............................................................................ 89 (10) Timing Belt Tensioner Bolt ........................................................................................ 89 (10)
1

Courtesy of Audi of America, Inc.

Fig. 15: Removing Camshaft Sprockets With Gear Puller

Plus 190 degrees. Always use new bolt.

Courtesy of Audi of America, Inc.

Fig. 16: Installing Timing Belt On Sprockets

80

AUDI
2.8L V6 12-Valve
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.8L V6 A4 1996-97 ..................................................... A4 Quattro 1996-97 ..................................................... A6 1995-97 ..................................................... 1998 ........................................................... A6 Quattro 1995-97 ..................................................... 1998 ........................................................... Cabriolet 1994-98 ..................................................... 90 & 90 Quattro 1993-95 ..................................................... 100 & 100 Quattro 1992-94 .....................................................

4.9 Hours ... ..... T218 4.9 Hours ... ..... T218 3.4 Hours ... ..... T218 4.9 Hours ... ..... T297 3.4 Hours ... ..... T218 4.9 Hours ... ..... T297 2.5 Hours ... ..... T218 2.5 Hours ... ..... T218 2.5 Hours ... ..... T218
Courtesy of Audi of America, Inc.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Crankshaft Timing Marks

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1997-98 model vehicles, manufacturer recommends belt be replaced at 90,00 miles. For 1996 and earlier model years, the manufacturer does not recommend a specic scheduled maintenance interval. However, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation. Removal 1) Disconnect negative battery cable. Remove accessory drive belt guard. Hold accessory drive belt in place with Mandrel (3204). Using a 15-mm wrench at accessory drive belt tensioner, slacken and remove accessory drive belt. 2) Rotate crankshaft by hand until cylinder No. 3 is at TDC. Ensure notch A is aligned with notch B. See Fig. 1. Note locating plate on front end of each camshaft sprocket. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. 3) Remove Crankshaft Position (CKP) sensor from left side of cylinder block, behind oil lter and above oil pan. Insert nger in CKP sensor hole. TDC hole in crankshaft should be felt. Install Crankshaft Holding Tool (Audi 3242) in CKP sensor hole. See Fig. 2. Lightly tighten crankshaft holder. 4) Remove crankshaft vibration damper. Remove lower timing belt guard. Install Camshaft Holding Tool (Audi 3243). See Fig. 3. Loosen camshaft sprocket bolts about 3 turns. DO NOT remove bolts. Remove camshaft holder. Using puller, loosen camshaft sprockets. Loosen and remove timing belt. See Fig. 4. NOTE: Camshaft sprockets must be loose enough to rotate on camshaft, but not loose enough to tilt.

Courtesy of Audi of America, Inc.

Fig. 2: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 3: Using Camshaft Holding Tool

AUDI
2.8L V6 12-Valve (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

81

Application Ft. Lbs. (N.m) Camshaft Bearing Cap Nut ....................................................................................... 11 (15) Camshaft Sprocket Bolt ............................................................................................ 52 (71) Crankshaft Damper Bolt ........................................................................................ 295 (400) Timing Belt Tensioner Bolt ........................................................................................ 33 (45) INCH Lbs. (N.m) Crankshaft Position (CKP) Sensor ........................................................................... 96 (10) Valve Cover Bolt ........................................................................... ................... 53-89 (6-10)

Courtesy of Audi of America, Inc.

Fig. 4: Exploded View Of Timing Belt & Components CAUTION: Camshaft sprockets are not keyed nor do they have alignment marks. Alignment of camshafts for proper valve timing is accomplished through the camshaft locking plates located on end of camshaft, between camshaft sprocket and retaining bolts. The larger hole on both of the camshaft locking plates should point toward the center of the engine when number one cylinder is at TDC (compression stroke). To properly align the camshafts, the camshaft holder (3243) must be used. Installation 1) Position timing belt over camshaft sprockets. See Fig. 4. Install camshaft holder. Position timing belt over all sprockets, then position over tensioner. Lightly tighten tensioner bolt (ensure tensioner can be rotated by hand). 2) Tighten belt by rotating tensioner on bolt. Tighten belt until it can be twisted 90 degrees by hand at midway point between right camshaft sprocket and water pump pulley. Tighten tensioner bolt to specication. See TORQUE SPECIFICATIONS. 3) Tighten camshaft sprocket bolts to specication. Remove camshaft holding tool. Remove crankshaft holding tool. Install Crankshaft Position (CKP) sensor. To install accessory drive belt, install mandrel. Position accessory drive belt over drive sprockets and idler roller, then over tensioner roller. Remove mandrel. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Connect negative battery cable.

82

AUDI
2.8L V6 30-Valve
10) Remove lower timing belt guard (if equipped). Remove timing belt. Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.8L V6, 30-Valve (AHA & ATQ Engines) A4 & A4 Quattro 1998-01 ..................................................... 5.2 Hours ... ..... T297 A6 & A6 Quattro, Non-Turbo 1998-01 ..................................................... 4.9 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 90,000 mile intervals for 1998 models, 75,000 mile intervals for 1999 models, and 105,000 miles on 2000-01 models.

REMOVAL & INSTALLATION


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

NOTE: Obtain radio anti-theft code before disconnecting battery.

Fig. 1: Exploded View Of Bumper Assembly (A4)

TIMING BELT
CAUTION: If reusing old timing belt, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation. Removal 1) Disconnect negative battery cable. Remove engine top cover. Working under vehicle, remove noise insulation panel from under front of vehicle. 2) Remove front bumper. See Fig. 1 or 2. Remove air intake duct from air cleaner housing. On right side of lock carrier, remove bolt and install Lock Carrier Support Tool (3369). See Figs. 3, 4 and 5. Remove lock carrier-to-body bolts. Carefully slide lock carrier forward on support tool. 3) Hold cooling fan pulley with spanner wrench. Unscrew and remove viscous cooling fan clutch from pulley. Viscous cooling fan is LEFTHAND threaded. 4) Use a 17-mm box wrench to turn serpentine belt tensioner counterclockwise to relieve belt tension and remove serpentine belt. If reusing belt, mark belt rotation direction with arrow for reassembly reference. 5) Unclip left and right timing belt guards and remove. Turn crankshaft in normal direction of rotation until TDC marks on crankshaft pulley and timing belt cover are aligned. See Figs. 6 and 7. 6) Note securing plate on front end of each camshaft sprocket. Large holes of securing plates on camshaft sprockets must face toward inside and align. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. See Fig. 8. Ensure crankshaft timing marks are still aligned. NOTE: DO NOT turn crankshaft while checking for TDC mark. Personal injury may result. 7) Remove sealing plug from left side of engine block. TDC mark on crankshaft must be visible or be felt through sealing plug hole. Install Crankshaft Holding Tool (Audi 3242) into sealing plug hole. See Fig. 9. 8) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley clockwise to compress timing belt tensioner. See Fig. 10. Compress timing belt tensioner just enough so that a 2-mm pin can be inserted through the holes in top of tensioner body and push rod. This will hold the tensioner in the compressed position. 9) Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley.

Courtesy of Audi of America, Inc.

Fig. 2: Exploded View Of Bumper Assembly (A6) NOTE: Camshaft sprockets must be loose enough to rotate on camshaft, but not loose enough to tilt. Installation 1) Install Camshaft Locator Bar (3391) into locking plates of camshafts. See Fig. 12. Loosen camshaft sprocket bolts about 5 turns. Remove locator bar. Leaving camshaft sprocket bolts in place, use gear puller to loosen camshaft sprockets on camshaft taper. 2) Ensure all timing marks are still aligned. Install timing belt on engine. Ensure belt routing is correct and there is no slack in belt. See Fig. 13. Install Camshaft Locator Bar (3391) into locking plates of camshafts. 3) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner so that 2-mm pin can be removed from tensioner. 4) Using 8-mm hex socket, place torque wrench on timing belt tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in direction of tension (clockwise). This will preload belt tension.

AUDI
2.8L V6 30-Valve (Cont.)
5) Tighten camshaft sprocket bolts to specication. 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.

83

Courtesy of Audi of America, Inc.

Fig. 5: Positioning Lock Carrier Support Tool (3369)

Courtesy of Audi of America, Inc.

Fig. 3: Exploded View Of Lock Carrier Assembly (A4)

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Crankshaft Timing Marks (1 Of 2)

Courtesy of Audi of America, Inc.

Fig. 4: Exploded View Of Lock Carrier Assembly (A6)


Courtesy of Audi of America, Inc.

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

84

AUDI
2.8L V6 30-Valve (Cont.)

Courtesy of Volkswagen United States, Inc. Courtesy of Audi of America, Inc.

Fig. 11: Marking Timing Chain & Sprockets

Fig. 8: Locating Camshaft Sprocket Holes

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 12: Installing Camshaft Locator Bar

Fig. 9: Using Crankshaft Holding Tool

Courtesy of Audi of America, Inc.

Fig. 13: Identifying Timing Belt Routing

Courtesy of Audi of America, Inc.

Fig. 10: Compressing Timing Belt Tensioner

AUDI
2.8L V6 30-Valve (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

85

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 40 (55) Crankshaft Pulley-To-Crankshaft Hex Bolt ............................................................... 15 (20) Crankshaft Pulley Center Bolt ............................................................... 1 148 (200) + 180 Lock Carrier-To-Body Bolts ....................................................................................... 37 (50) Timing Belt Idler Pulley Bolt ..................................................................................... 33 (45) Timing Belt Tensioner Center Bolt ............................................................................ 15 (20) INCH Lbs. (N.m) Lock Carrier-To-Body Torx Bolts ............................................................................... 89 (10) Timing Belt Tensioner Bolt/Nut ................................................................................. 89 (10) Water Pump Bolt ....................................................................................................... 89 (10)
1

If removed, manufacturer recommends using NEW bolt.

Courtesy of Audi of America, Inc.

Fig. 14: Positioning Lock Carrier Torx Bolts

86

AUDI
3.0L V6 AVK Engine A4 & A6
Labor Time Belt Part No. CAUTION: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt. 13) Remove front engine cover. See Fig. 12. Using Ribbed Belt Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of power steering pump. 14) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear of power steering vane pump (arrows) using 3212 spanner wrench as retainer. See Fig. 15. NOTE: Thrust washer is only installed on timing belt gear with part number 06C 105 063. Thrust washer is NOT installed for timing belt gear with part number 06C 105 063 B. 15) Remove 8 bolts attaching harmonic balancer to crankshaft and remove balancer. Remove thrust washer if equipped. 16) Without disconnecting coolant hoses, remove bolts (1, 2) attaching front coolant pipe (3) and remove timing belt guards (4, 5, 6). See Fig. 16. 17) Remove rear engine cover at rear of intake manifold. Remove screw attaching expansion tank to vehicle. Disconnect Engine Coolant Level (ECL) warning switch harness connector at bottom of expansion tank. Without disconnecting coolant hoses, tie expansion tank off to side. 18) Disconnect Mass Air Flow (MAF) sensor harness connector (1). See Fig. 17. Remove air guide hose (2) together with MAF sensor. Remove air lter housing (arrows). 19) Remove bolts (1) and (3). See Fig. 18. Disconnect hose (4) from line of secondary air injection. Pull out guide tube for oil dipstick (2) from the oil pan (upper part) toward top and swing it forward for removal. 20) Remove ignition coils from right valve cover. Remove hose of crankshaft housing ventilation located at rear of valve cover. Remove bolts for right valve cover in the sequence 12-1 and remove valve cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20. CAUTION: Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft. 21) Turn engine at crankshaft central bolt. Turn engine until the cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster Gauge (T40030) at camshafts of right cylinder head. See Fig. 22. 22) Slightly turn crankshaft back and forth so that the claw of camshaft adjuster gauge can properly grab the camshafts. Spread and tighten camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until seated without axial play. Repeat procedure for left cylinder head. 23) If installed, disconnect after-run coolant pump harness connector. Remove sealing plug of TDC mark at cylinder block. Install Locking Pin (T40026) into the hole of the removed sealing plug and tighten. See Fig. 23. Slightly turn crankshaft back and forth to allow locking pin to bottom in crankshaft properly. NOTE: During next step, catch escaping oil using a rag. 24) Pry off securing rings (1) for caps (2) at all camshaft gears. See Fig. 24. Loosen but do not remove bolts for camshaft gears. CAUTION: If reusing timing belt, mark rotational direction of belt. Reversing the direction can ruin timing belt. 25) Using an 8 mm hex socket wrench, turn timing belt tensioner in direction of arrow until tensioning lever pushes the tensioner together far enough so pin (T40011) can be inserted into the bore of the piston and housing of tensioner. See Fig. 25. The timing belt tensioner is oildampened. Compress it by slowly applying constant pressure. Loosen bolt of eccentric pulley on opposite side of tensioner and remove timing belt. Removal (Cabriolet) 1) Loosen bolts or quick release fasteners (1 and 2). See Fig. 26. The rear noise insulation quick-release fasteners (3) remain installed. The quick-release fasteners remain in bumper cover (1).

TIMING BELT APPLICATION Application

3.0L V6 (AVK Engine) A4 Avant & Sedan 2002-04 ..................................................... 5.4 Hours ... ..... T330 A4 Cabriolet 2003-04 ..................................................... 5.4 Hours ... ..... T330 A6 2002-04 ..................................................... 5.8 Hours ... ..... T330 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends belt be replaced at 105,000 miles under normal driving conditions, 52,500 miles under severe driving conditions.

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion. NOTE: To ease repair work, remove front noise insulation completely. Removal (A4) 1) Raise vehicle, remove front tires. Remove bolts and quick release screws (1 and 2). See Fig. 1. Rear noise insulation (3) remains installed. 2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking/auxiliary heater at noise insulation. See Fig. 2. 3) Remove right cover in engine compartment. Unbolt air guide between lock carrier and air lter on lock carrier. Remove left cover in engine compartment. Pull off hood seal from lock carrier and fender edges. 4) Loosen left and right wheelhousing liners in front area. See Fig. 3. Pull back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip bumper rear edge from catch (arrow B). See Fig. 4. Repeat procedure on opposite side of the vehicle. 5) Release catches (1-4) using a screwdriver and remove air inlet grille on left and right on bottom part of bumper. See Fig. 5. Remove left and right retaining bolts until bumper is fully released. See Fig. 6. 6) If installed, disconnect hose (1) to headlight cleaning system. Disconnect harness connectors (2) and remove bumper. See Fig. 7. 7) Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward). 8) On right side, remove bolt (5) and install support tool (3369) in its place. See Figs. 8 and 9. 9) On left side, install support tool (3369) in threaded hole in chassis. See Fig. 10 . 10) Remove on both sides, all bolts (2). See Fig. 8. 11) Remove on both sides, all bolts (3 and 4). See Fig. 8. Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole. 12) Secure lock carrier in this position, by placing fender bolts in holes. See Fig. 11. To install, reverse placing in service position procedure.

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)
2) Loosen the wheel housing liners on left and right at front. Pull the wheel housing liner back. Remove the bolt (2) and nuts (1). See Fig. 27. Unclip bumper extension from catch (B). 3) Remove bolts and tilt front grille slightly forward and pull it out in an upward direction from bumper cover. Remove bolts (1-8) and pull side extensions out of guide piece. See Fig. 28. Pull bumper cover forward slightly. 4) If equipped, disconnect hose for headlight washer unit. Disconnect connector(s) and remove bumper cover from vehicle. 5) Remove left and right engine compartment covers. Remove air duct between lock carrier and air cleaner (air duct is bolted to lock carrier). Install Lock Carrier Support Tool (3369) into thread on left and right side near impact absorbers. See Figs. 9 and 29. 6) Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender ange. See Fig. 11. CAUTION: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt. 7) Remove front engine cover. See Fig. 12. Using Ribbed Belt Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of power steering pump. 8) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear of power steering vane pump (arrows) using 3212 spanner wrench as retainer. See Fig. 15. Remove 8 bolts attaching harmonic balancer to crankshaft and remove balancer. Remove thrust washer if equipped. NOTE: Thrust washer is only installed on timing belt gear with part number 06C 105 063. Thrust washer is NOT installed for timing belt gear with part number 06C 105 063 B. 9) Without disconnecting coolant hoses, remove bolts (1, 2) attaching front coolant pipe (3) and remove timing belt guards (4, 5, 6). See Fig. 16. 10) Remove rear engine cover at rear of intake manifold. Remove screw attaching expansion tank to vehicle. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch at bottom of expansion tank. Without disconnecting coolant hoses, tie expansion tank off to side. 11) Disconnect electrical harness connector (1) at Mass Air Flow (MAF) sensor. See Fig. 17. Remove air guide hose (2) together with Mass Air Flow (MAF) sensor. Remove air lter housing (arrows). 12) Remove bolts (1) and (3). See Fig. 18. Disconnect hose (4) from line of secondary air injection. Pull out guide tube for oil dipstick (2) from the oil pan (upper part) toward top and swing it forward for removal. 13) Remove ignition coils from right valve cover. Remove hose of crankshaft housing ventilation located at rear of valve cover. Remove bolts for right valve cover in the sequence 12 to 1 and remove valve cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20. CAUTION: Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft. 14) Turn engine at crankshaft central bolt. Turn engine until the cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster Gauge (T40030) at camshafts of right cylinder head. See Fig. 22. 15) Slightly turn crankshaft back and forth so that the claw of camshaft adjuster gauge can properly grab the camshafts. Spread and tighten camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until seated without axial play. Repeat procedure for left cylinder head. 16) If installed, disconnect electrical harness connector at after-run coolant pump. Remove sealing plug of TDC mark at cylinder block. Install Locking Pin (T40026) into the hole of the removed sealing plug and tighten. See Fig. 23. Slightly turn crankshaft back and forth to allow locking pin to bottom in crankshaft properly. NOTE: During next step, catch escaping oil using a rag.

87

17) Pry off securing rings (1) for caps (2) at all camshaft gears. See Fig. 24. Loosen but do not remove bolts for camshaft gears. CAUTION: If reusing timing belt, mark rotational direction of belt. Reversing the direction can ruin timing belt. 18) Using an 8 mm hex socket wrench, turn timing belt tensioner in direction of arrow until tensioning lever pushes the tensioner together far enough so pin (T40011) can be inserted into the bore of the piston and housing of tensioner. See Fig. 25. The timing belt tensioner is oildampened. Compress it by slowly applying constant pressure. Loosen bolt of eccentric pulley on opposite side of tensioner and remove timing belt. NOTE: It is not necessary to completely remove noise insulation from beneath the engine. Only remove the quick release fasteners that attach to the front bumper assembly. Removal (A6) 1) Raise and support vehicle. Remove front tires. Remove lower front engine shield (noise insulator). See Fig. 30. Loosen front half of wheel housing splash shield (liner). See Fig. 31. Remove ange nut (10) on both sides. See Fig. 32. 2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking/auxiliary heater at noise insulation. See Fig. 2. 3) Remove right cover in engine compartment. Unbolt air guide between lock carrier and air lter on lock carrier. Remove left cover in engine compartment. Pull off hood seal from lock carrier and fender edges. 4) Release catches (1-4) using a screwdriver and remove air inlet grille on left and right on bottom part of bumper. See Fig. 5. Remove left and right retaining bolts until bumper is fully released. See Fig. 6. 5) Remove screw with washer assembly (6) from wheel housing liner (5). See Fig. 32. Disconnect any wiring harness that attach to the front bumper. Remove socket-head bolts (7) and remove bumper cover together with impact absorber towards front. See Fig. 32. 6) Inspect headlight and turn signal harness connectors and wiring harness (which may hang up when lock carrier is moved forward). 7) On right side, remove bolt (5) and install support tool (3369) in its place. See Figs. 8 and 9. 8) On left side, install support tool (3369) in threaded hole in chassis. See Fig. 10. 9) Remove on both sides, all (2, 3 and 4) bolts. See Fig. 8. Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole. 10) Secure lock carrier in this position, by placing fender bolts in holes. See Fig. 11. To install, reverse placing in service position procedure. CAUTION: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt. 11) Remove front engine cover. See Fig. 12. Using Ribbed Belt Installation Tool (3299) with claw for tensioner (3299/1), swing tensioner in direction of arrow. See Fig. 13. Remove ribbed belt from pulley of power steering pump. NOTE: Thrust washer is only installed on timing belt gear with part number 06C 105 063. Thrust washer is NOT installed for timing belt gear with part number 06C 105 063 B. 12) Remove ribbed belt tensioner. See Fig. 14. Remove ribbed belt gear of power steering vane pump using 3212 spanner wrench as retainer. See Fig. 15. Remove 8 bolts attaching harmonic balancer to crankshaft. Remove thrust washer. 13) Without disconnecting coolant hoses, remove bolts (1 and 2) attaching front coolant pipe (3) and remove timing belt guards (4, 5, and 6). See Fig. 16. 14) Remove rear engine cover at rear of intake manifold. Remove screw attaching expansion tank to vehicle. Disconnect Engine Coolant Level (ECL) warning switch harness connector at bottom of expansion tank. Without disconnecting coolant hoses, tie expansion tank off to side.

88

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)
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 specication. See TORQUE SPECIFICATIONS. 6) To install lock carrier, reverse removal procedures outlined in REMOVAL (A4). Torque all fasteners to specication. See TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See Fig. 40. NOTE: Before installing bumper, check for the presence of threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders. Always replace bumper retaining bolts. 7) Slide bumper onto impact absorber and re-connect hose (1) of headlight cleaning system and electrical harness connectors (2). See Fig. 7. Move bumper into installation position. Make sure threaded pins in bumper side edges engage into holes at the fenders. Install bumper retaining bolts until bumper can stay in place without any assistance. 8) Do not tighten completely allowing for any necessary adjustments. Pull back wheelhousing liner (arrow A). See Fig. 3. Engage bumper rear edge into catch (arrow B). Torque nuts. Repeat procedure on opposite side of the vehicle. Torque left and right retaining bolts to specication. See TORQUE SPECIFICATIONS. Install left and right air inlet grille on bumper. Remainder of installation is the reverse of removal. CAUTION: Before installation, ensure camshafts are aligned, crankshaft is locked in place and camshaft gear bolts are loose as described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Installation (Cabriolet) 1) Ensure bolts (1-4) attaching camshaft gears are in far enough to allow camshaft gears to spin freely without wobbling. See Fig. 36. Install timing belt. For exact valve timing adjustment, the timing belt must make exact contact with front edge of all timing belt gears. 2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise direction until the handle of the pin wrench is exactly above the center axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45 N.m) in direction of arrow to pre-tension timing belt. See Fig. 38. 3) Using 8 mm socket head wrench, turn timing belt tensioning roller in opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25. Place torque wrench horizontally on socket-head of tensioning lever. Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt. See Fig. 38. 4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs. (10 N.m) up to stop. See Fig. 39. Turn rotor of camshaft adjuster at right cylinder bank clockwise to 7.5 ft. lbs. (10 N.m) up to stop. Torque bolts for all four camshaft gears to 74 ft. lbs. (100 N.m). 5) Insert caps with new O rings at camshaft gears and secure with ring. Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove Alignment Bolt (T10026) and install sealing plug of TDC marking with new O ring into cylinder block. See Fig. 23. Install valve covers and tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to specication. See TORQUE SPECIFICATIONS. 6) To install lock carrier, reverse removal procedures outlined in REMOVAL (CABRIOLET). Torque all fasteners to specication. See TORQUE SPECIFICATIONS.

15) Disconnect Evaporative Emission (EVAP) Canister Purge Regulator Valve (1) at air lter housing. Disconnect Mass Air Flow (MAF) sensor harness connector (2). See Fig. 35. Remove air guide hose (3) together with MAF sensor. Remove air lter housing (arrows). 16) Remove bolts (1 and 3). See Fig. 18. Disconnect hose (4) from line of secondary air injection. Pull out dipstick tube (2) from the oil pan (upper part) toward top and swing it forward for removal. 17) Remove ignition coils from right valve cover. Remove hose of crankshaft housing ventilation located at rear of valve cover. Remove bolts for right valve cover in the sequence 12 to 1 and remove valve cover. See Fig. 19. Repeat procedure for left valve cover. See Fig. 20. CAUTION: Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft. 18) Turn engine at crankshaft central bolt. Turn engine until the cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly. See Fig. 21. Insert Camshaft Adjuster Gauge (T40030) at camshafts of right cylinder head. See Fig. 22. 19) Slightly turn crankshaft back and forth so that the claw of camshaft adjuster gauge can properly grab the camshafts. Spread and tighten camshaft adjuster gauge with threaded shaft to 7 ft. lbs. (10 N.m) until it is seated without axial play. 20) Repeat procedure for left cylinder head. If installed, disconnect electrical harness connector at after-run coolant pump. Remove sealing plug of TDC mark at cylinder block. Install Locking Pin (T40026) into the hole of the removed sealing plug and tighten. See Fig. 23. Slightly turn crankshaft back and forth to allow locking pin to bottom in crankshaft properly. NOTE: During next step, catch escaping oil using a rag. 21) Pry off securing rings (1) for caps (2) at all camshaft gears. See Fig. 24. Loosen but do not remove bolts for camshaft gears. CAUTION: Mark rotational direction of timing belt. Reversing the direction in which it runs can ruin it. 22) Using an 8 mm hex socket wrench, turn timing belt tensioner in direction of arrow until tensioning lever pushes the tensioner together far enough so pin (T40011) can be inserted into the bore of the pistons and housing. See Fig. 25. The timing belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Loosen bolt of eccentric pulley on opposite side of tensioner and remove timing belt. CAUTION: Before installation, ensure camshafts are aligned, crankshaft is locked in place and camshaft gear bolts are loose as described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Installation (A4) 1) Ensure bolts (1-4) attaching camshaft gears are in far enough to allow camshaft gears to spin freely without wobbling. See Fig. 36. Install timing belt. For exact valve timing adjustment, the timing belt must make exact contact with front edge of all timing belt gears. 2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise direction until the handle of the pin wrench is exactly above the center axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45 N.m) in direction of arrow to pre-tension timing belt. See Fig. 38. 3) Using 8 mm socket head wrench, turn timing belt tensioning roller in opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25. Place torque wrench horizontally on socket-head of tensioning lever. Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt. See Fig. 38. 4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs. (10 N.m) up to stop. See Fig. 39. Turn rotor of camshaft adjuster at right cylinder bank clockwise to 7.5 ft. lbs. (10 N.m) up to stop. Torque bolts for all four camshaft gears to 74 ft. lbs. (100 N.m).

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)
NOTE: Prior to installation of the bumper cover check for presence of threaded pins (2) at the bumper extensions as well as grommets (3) in the fenders. Tighten cap nut to 48 INCH lbs. (6 N.m). 7) To install bumper cover, reverse removal procedures outlined in REMOVAL (CABRIOLET). Slide bumper cover onto lock carrier and connect the hose of headlight washer unit as necessary. Reconnect connectors as necessary. Ensure that the threaded pins in the bumper side extensions engage in the holes at the fender. 8) Clip in side extensions and fasten using the bolts (8). See Fig. 28. Loosely screw in bolt (3). Tighten bolts (2 and 4) to 48 INCH lbs. (6 N.m), and bolts (5, 6 and 7) to 24 INCH lbs. (3 N.m). Close hood and check overlap or gap dimension of bumper cover with respect to the hood. If OK, tighten all the bolts. If not, open hood and loosen bolts (2 or/and 4) to correct upper bumper as required. Tighten bolt (3) to 48 INCH lbs. (6 N.m). 9) Verify fender gaps as follow: A = 2 mm 0.5 mm, B = 0 mm 0.5 mm and C = 0 mm 0.5 mm. See Fig. 41. Gap dimensions can be checked using Audi special tool (3371). Adjust gaps as necessary. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Remainder of installation is the reverse of removal. CAUTION: Before installation, ensure camshafts are aligned, crankshaft is locked in place and camshaft gear bolts are loose as described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Installation (A6) 1) Ensure bolts (1-4) attaching camshaft gears are in far enough to allow camshaft gears to spin freely without wobbling. See Fig. 36. Install timing belt. For exact valve timing adjustment, the timing belt must make exact contact with front edge of all timing belt gears. 2) Using Pin Wrench (3387), turn eccentric pulley (1) in clockwise direction until the handle of the pin wrench is exactly above the center axle of coolant pump gear (2). See Fig. 37. Hold pin wrench in this position and tighten bolt (3) to 33 ft. lbs. (45 N.m). Place torque wrench horizontally on socket-head of tensioning lever. Turn with 33 ft. lbs. (45 N.m) in direction of arrow to pre-tension timing belt. See Fig. 38. 3) Using 8 mm socket head wrench, turn timing belt tensioning roller in opposite direction of arrow until pin (T40011) can pulled out. See Fig. 25. Place torque wrench horizontally on socket-head of tensioning lever. Turn with 18 ft. lbs. (25 N.m) in direction of arrow to tension timing belt. See Fig. 38. 4) Insert Socket (T40028) at camshaft adjuster of exhaust camshaft on left cylinder bank. Turn rotor of camshaft adjuster clockwise to 7.5 ft. lbs. (10 N.m) up to stop. See Fig. 39. Repeat for right cylinder bank. Torque bolts for all four camshaft gears to 74 ft. lbs. (100 N.m). 5) Insert caps with new O rings at camshaft gears and secure with ring. Remove Camshaft Adjuster Gauge (T40030). See Fig. 22. Remove Alignment Bolt (T10026) and install sealing plug of TDC marking with new O ring into cylinder block. See Fig. 23. Install valve covers and tighten in sequence. See Figs. 19 and 20. Install timing belt guards. See Fig. 16. Install harmonic balancer and ribbed belt. Torque all fasteners to specication. See TORQUE SPECIFICATIONS. 6) To install lock carrier, reverse removal procedures outlined in REMOVAL (A6). Torque all fasteners to specication. See TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See Fig. 40. 7) Before installing the bumper, ensure the expanding clips are pressed into the fender. See Fig. 42. When installing the tabs, the bumper cover must latch into clip (4). See Fig. 32. 8) Latch bumper cover (1) into guide (2). See Fig. 32. Torque ange nuts (10) to 53 INCH lbs. (6 N.m).

89

NOTE: The impact absorber is installed vertical to the cross member and has height compensating elements. See Fig. 33. 9) Torque left and right retaining bolts to specication. See TORQUE SPECIFICATIONS. Install left and right air inlet grille on bumper. Remainder of installation is the reverse of removal.

Courtesy of Audi of America, Inc.

Fig. 1: Removing Under-Car Noise Insulation (A4)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Auxiliary Heater Exhaust Pipe Bolts (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 3: Locating Wheelhousing Fasteners (A4)

90

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Front Bumper-To-Fender Fasteners (A4)

Courtesy of Audi of America, Inc.

Fig. 8: Identifying Lock Carrier Components (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 5: Removing Grilles (A4 & A6)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Support Tool (Part No. 3369)

Courtesy of Audi of America, Inc.

Fig. 6: Identifying Bumper Fasteners (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Washer Hoses & Harness Connectors (A4)

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

91

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position


Courtesy of Audi of America, Inc.

Fig. 14: Identied Ribbed Belt Tensioner Bolts

Courtesy of Audi of America, Inc.

Fig. 12: Identifying Front Engine Cover

Courtesy of Audi of America, Inc.

Fig. 15: Removing/Installing Power Steering Vane Pump Pulley

Courtesy of Audi of America, Inc.

Fig. 13: Removing/Installing Ribbed Belt

Courtesy of Audi of America, Inc.

Fig. 16: Identifying Timing Belt Guards

92

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 17: Air Filter Housing Components

Fig. 20: Left Valve Cover Bolt Sequence

Courtesy of Audi of America, Inc.

Fig. 21: Lining Up Cylinder #3 Camshaft Lobes (Right Cylinder Bank)

Courtesy of Audi of America, Inc.

Fig. 18: Identifying Secondary Air Injection Component

Courtesy of Audi of America, Inc.

Fig. 22: Installing Cam Adjuster Gauge On Cam Lobes (Right Bank Shown; Left Bank Similar)

Courtesy of Audi of America, Inc.

Fig. 19: Right Valve Cover Bolt Sequence

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

93

Courtesy of Audi of America, Inc.

Fig. 23: Installing Locking Pin Into Cylinder Block

Courtesy of Audi of America, Inc.

Fig. 26: Identifying Bumper Cover Fasteners (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 24: Removing Securing Rings

Courtesy of Audi of America, Inc.

Fig. 27: Identifying Bumper Cover Fasteners At Wheel Opening (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 25: Compressing & Securing Timing Belt Tensioner

Courtesy of Audi of America, Inc.

Fig. 28: Removing Bumper Cover (Cabriolet)

94

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 29: Exploded View Of Lock Carrier Components (Cabriolet)

Courtesy of Audi of America, Inc.

Fig. 30: Identifying Lower Engine Shield (Noise Insulator) Mounting Points (A6)

Courtesy of Audi of America, Inc.

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

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

95

Courtesy of Audi of America, Inc.

Fig. 32: Identifying Front Bumper Components (A6)

Courtesy of Audi of America, Inc.

Fig. 34: Identifying Bumper Guide Components (A6)

Courtesy of Audi of America, Inc.

Fig. 33: Identifying Bumper Attaching Point To Impact Absorber (A6)

96

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 35: Identifying EVAP & MAF Connectors (A6)

Fig. 38: Adjusting Timing Belt Tension (A4 & A6)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 36: Timing Belt Routing (A4 & A6)

Fig. 39: Preloading Camshaft Adjuster (Left Shown; Right Is Similar A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 40: Identifying Torque Support Bolts (A4 & A6)


Courtesy of Audi of America, Inc.

Fig. 37: Adjusting Eccentric Pulley (A4 & A6)

Courtesy of Audi of America, Inc.

Fig. 41: Bumper Cover Gaps (Cabriolet)

AUDI
3.0L V6 AVK Engine A4 & A6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

97

Application Ft. Lbs. (N.m) Belt Pulley Power Steering Vane Pump Bolts ......................................................... 17 (23) Bumper-To-Long Member Bolts ................................................................................ 37 (50) Camshaft Gear-To-Camshaft Bolts ......................................................................... 74 (100) Eccentric Pulley-To-Front Sealing Flange Bolt ......................................................... 33 (45) Harmonic Balancer Bolts .......................................................................................... 17 (23) Impact Absorber Bolts ............................................................................................... 37 (50) Ribbed Belt Tensioner-To-Cylinder Block M8 Bolts .................................................................................................................. 17 (23) M10 Bolts ................................................................................................................ 30 (40) Sealing Plug In Cylinder Block ................................................................................. 18 (25) Torque Support Lock-To-Lock Carrier Bolts ............................................................. 21 (28) Wheel Bolt ............................................................................................................... 89 (120) INCH Lbs. (N.m) Bumper-To-Fender Bolts ........................................................................................... Front Coolant Pipe Bolts ........................................................................................... Timing Belt Guard Bolts 1 ......................................................................................... Valve Cover Bolts ......................................................................................................
1

89 89 89 89

(10) (10) (10) (10)

Use NEW bolts.

Courtesy of Audi of America, Inc.

Fig. 42: Identifying Bumper Cover Attaching Points For Removal & Installation (A6)

98

AUDI
3.6L & 4.2L V8 1990-94
Labor Time Belt Part No. 11) Noting positions for reassembly, disconnect ignition secondary wires at ignition coils. Remove both ignition distributor caps. 12) Rotate crankshaft to TDC of compression stroke. Ensure TDC mark on crankshaft pulley aligns with mark on timing belt cover. See Fig. 10. 13) Ensure distributor rotor points to mark on distributor housing. If not, turn crankshaft one more revolution. See Fig. 11. Remove both distributors. 14) For 3.6L engine, loosen stop plate at timing belt tensioner. See Fig. 12. On 3.6L and 4.2L engines, loosen center bolt on tensioner pulley with eccentric center (right side of engine block). See Fig. 13. Remove timing belt damper top bolt. Remove timing belt tensioner pulley with eccentric center. 15) Fit Locating Flange (3199) at end of each camshaft. Locating pin on distributor ange should t in slot in locating ange. See Fig. 14. Secure locating ange with distributor mounting bolts. 16) Using spanner wrench, hold camshaft sprocket. Loosen camshaft sprocket bolts about 2 turns. DO NOT use Locating Flange (3199) to hold camshaft while loosening sprocket bolt. 17) Using a plastic hammer, LIGHTLY tap edge of camshaft sprockets until camshaft sprockets are loose. Remove camshaft sprocket Woodruff keys. 18) Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket. Remove crankshaft center bolt and remove crankshaft pulley. It is not necessary to remove sprocket from crankshaft. Remove timing belt.

TIMING BELT APPLICATION Application

3.6L V8 (PT Engine) V8 Quattro 1990-91 ..................................................... 4.3 Hours ... ..... T207 4.2L V8 (ABH Engine) V8 Quattro 1992-94 ..................................................... 4.3 Hours ... ..... T207 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends belt be replaced at 60,000 miles on 3.6L engines, and 90,000 miles on 4.2L engines. Replacement interval revision is from Audi technical service bulletin 93-02, September 1, 1993.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: If serpentine or timing belt is being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation. Removal 1) Disconnect negative battery cable. Battery is under rear seat. Remove noise insulation panel from under front of vehicle. Remove coolant expansion tank cap. Drain coolant from radiator. Remove alternator cooling air duct. See Fig. 1. Loosen clip and disconnect coolant temperature sensor harness connector. 2) Disconnect outer half of air duct at alternator. Remove screws securing wiring harness at alternator. Using 13-mm box wrench, turn serpentine belt tensioner clockwise to relieve tension. See Figs. 2 and 3. Remove alternator and set aside. 3) Working from under vehicle, remove lower timing belt cover. In engine compartment, remove bolt securing intake air ducts. Remove left and right side intake air ducts. Remove upper part of air cleaner housing and air lter. 4) Remove bolts securing lower part of air cleaner housing. Lift out lower part of air cleaner housing. Remove upper radiator hose. Remove electric cooling fan bolts. See Fig. 4. Remove electric cooling fan. Remove serpentine belt. 5) Remove lower radiator hose from thermostat housing. Move lower radiator hose to right at rear. Remove viscous fan shroud. Remove bolts securing viscous fan to pulley and remove fan. 6) Disconnect fan shrouds for viscous fan and electric fan. 7) Hold viscous cooling fan mount with a spanner wrench. Loosen viscous cooling fan by turning clockwise. Viscous cooling fan is LEFTHAND threaded. See Fig. 5. Lift out fan and shroud. 8) Remove front engine support mount. Note number and position of shims for reassembly. Remove lower radiator hose. Loosen center bolt of crankshaft pulley one turn while using Crankshaft Pulley Holder (3197). See Fig. 6. 9) Remove anged nuts and left side timing belt cover. See Fig. 7. Remove lower radiator hose support from front of engine. 10) Turn serpentine belt tensioner clockwise and insert Setting Tool (3204) below mounting bolt. See Figs. 8 and 9. Remove 2 lower mounting bolts from right side timing belt cover. Do not loosen upper mounting bolt yet. Remove Setting Tool (3204). Remove top mounting bolt from right side timing belt cover. Remove right side timing belt cover.

Courtesy of Audi of America, Inc.

Fig. 1: Locating Coolant Temperature Sensor Inspection Inspect tensioner and idler pulley for ease of rotation and rough bearings. Replace as necessary. Installation 1) Ensure crankshaft is still at TDC position. Place timing belt over crankshaft sprocket. Install crankshaft pulley on crankshaft. Install 4 bolts that hold crankshaft pulley to sprocket. Hand tighten temporarily. 2) Apply locking sealant (AMV 188 0012), or equivalent, to crankshaft center bolt threads. Install crankshaft pulley center bolt and hand tighten temporarily. 3) Loosen camshaft sprocket center bolts by about 1 turn. Camshaft sprocket should still be loose on camshaft. Install Vibration Damper Locking Tool (3211). If there is no hole to accept Vibration Damper Locking Tool, ensure TDC mark on vibration damper is aligned with pointer before and after tightening camshaft sprockets. 4) Position timing belt in position over idler pulleys, water pump pulley and camshaft sprockets. Install tensioner pulley with eccentric center. Leave center nut loose so that eccentric can be turned. Fully tighten 4 crankshaft pulley bolts to specication. See TORQUE SPECIFICATIONS. 5) On 3.6L engine, insert Adjusting Tool (3204) into tensioner lever so that tool engages recess on back of stop plate. See Fig. 15. Firmly press tensioner lever once by hand clockwise. See Fig. 16. 6) On 3.6L and 4.2L engines, set basic timing belt tension by turning tensioner pulley with eccentric center in clockwise direction. Use span-

AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
ner wrench to turn eccentric. Turn eccentric until damper length is at specied dimension. See Fig. 17. Tighten tensioner pulley center nut to specication. See TORQUE SPECIFICATIONS. 7) Holding camshaft sprockets in place, tighten camshaft sprocket center bolts to specication. Remove camshaft Locating Flanges (3199). Turn crankshaft at least 2 turns. Tighten crankshaft pulley center bolt to specication. 8) Ensure timing belt damper length is still correct. Readjust, if necessary. On 3.6L engine, tighten stop plate mounting bolt to specication. See TORQUE SPECIFICATIONS. Remove Adjusting Tool (3204). 9) On 3.6L and 4.2L engines, to complete installation, reverse removal procedure. When relling cooling system, manufacturer recommends using Audi anti-freeze (Part No. G 001 1V8A). Use 50/50 mix of coolant and water. 10) To bleed air from cooling system, turn on ignition with engine off. Set A/C controls to high. Open radiator expansion tank. Fill with coolant while squeezing upper hoses to allow trapped air to escape. Install expansion tank cap. 11) Start and run engine between 2000-3000 RPM until warm. With A/C still on high, raise engine RPM to 4000-5000 RPM several times. Coolant temperature gauge must read just under 212F (100C). Turn off ignition. After about 5-10 minutes, carefully open expansion tank cap. Top off coolant level to MAX mark. Restart engine and repeat topping off procedure. Adjust drive belts to proper tension.

99

Courtesy of Audi of America, Inc.

Fig. 2: Exploded View Of Serpentine Belt Assembly

100

AUDI
3.6L & 4.2L V8 1990-94 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 5: Removing Viscous Cooling Fan (Left-Hand Thread)


Courtesy of Audi of America, Inc.

Fig. 3: Removing Serpentine Belt

Courtesy of Audi of America, Inc.

Fig. 6: Loosening Crankshaft Pulley Center Bolt

Courtesy of Audi of America, Inc.

Fig. 4: Removing Electric Cooling Fan

Courtesy of Audi of America, Inc.

Fig. 7: Removing Left Side Timing Belt Cover

AUDI
3.6L & 4.2L V8 1990-94 (Cont.)

101

Courtesy of Audi of America, Inc.

Fig. 8: Exploded View Of Timing Belt Assembly

Courtesy of Audi of America, Inc.

Fig. 10: Aligning Crankshaft Pulley Timing Marks


Courtesy of Audi of America, Inc.

Fig. 9: Positioning Serpentine Belt Tension

102

AUDI
3.6L & 4.2L V8 1990-94 (Cont.)

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 11: Aligning Distributor Rotor To Housing

Fig. 14: Positioning Camshafts With Locating Flange (3199)

Courtesy of Audi of America, Inc.

Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate (3.6L Engine)
Courtesy of Audi of America, Inc.

Fig. 12: Identifying Timing Belt Routing

Courtesy of Audi of America, Inc.

Courtesy of Audi of America, Inc.

Fig. 13: Timing Belt Tensioner With Eccentric Center

Fig. 16: Rotating Tensioner Lever In Direction Of Arrow

AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

103

Application Ft. Lbs. (N.m) Alternator Bottom Mount Bolt ................................................................................... 18 (25) Alternator Top Mounting Bolt .................................................................................... 33 (45) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Center Bolt ............................................................................ 1 332 (450) Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 18 (25) Engine Front Support Mount Bolt ............................................................................. 30 (40) Serpentine Belt Idler Pulley Bolt .............................................................................. 18 (25) Timing Belt Adjustment Damper Bolts ...................................................................... 18 (25) Timing Belt Damper Mount Bolt ............................................................................... 18 (25) Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25) Timing Belt Tensioner Nut ........................................................................................ 18 (25) INCH Lbs. (N.m) Fan Shroud Bolts ...................................................................................................... Stop Plate Mounting Bolt (3.6L) ............................................................................... Timing Belt Cover Flanged Nut ................................................................................ Water Pump Bolts .....................................................................................................
1

Courtesy of Audi of America, Inc.

Fig. 17: Setting Timing Belt Damper Length

89 89 89 89

(10) (10) (10) (10)

Install with thread locking sealant AMV 18800102.

104

AUDI
3.7L & 4.2L V8 1997-99
TIMING BELT
Labor Time Belt Part No. CAUTION: If serpentine or timing belt are being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation. Removal 1) Disconnect negative battery cable. Remove noise insulation panel from under front of vehicle. Remove air intake grille from front of bumper. Drain coolant from radiator. 2) Using box wrench, turn serpentine belt tensioner clockwise to relieve tension. Remove serpentine belt. See Fig. 1. Remove engine top trim cover. Remove coolant hose retaining clamp on right side upper timing belt cover. 3) Remove air intake duct between air cleaner and throttle body. Disconnect fan shrouds for viscous fan and electric fan. 4) Hold viscous cooling fan pulley with a spanner wrench. Remove viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded. See Fig. 2. 5) Remove right front engine mount. See Fig. 3. Remove coolant hoses at front of engine. Rotate crankshaft to TDC of compression stroke. Ensure TDC mark on crankshaft pulley aligns with mark on timing belt cover. See Fig. 4.

TIMING BELT APPLICATION Application

3.7L V8 (AEW Engine) A8 1997-99 ..................................................... 4.9 Hours ... ..... T207 4.2L V8 (ABZ Engine) A8 Quattro 1997-99 ..................................................... 4.9 Hours ... ..... T207 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1997 and 1998 model vehicles, manufacturer recommends belt be replaced at 90,000 miles. For 1999 model year, the manufacturer recommends the belt be replaced at 75,000 miles.

REMOVAL & INSTALLATION


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

Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Serpentine Belt Assembly

AUDI
3.7L & 4.2L V8 1997-99 (Cont.)
CAUTION: Manufacturer recommends that crankshaft pulley center bolt be REPLACED whenever the bolt is loosened or removed. 6) Holding crankshaft pulley with Crankshaft Pulley Holder (3197), loosen center bolt about 1 turn. See Fig. 5. Remove camshaft position sensor at housing at rear of left cylinder head. See Fig. 6. If camshaft sensor is NOT positioned behind sensor plate window, rotate crankshaft 1 full revolution. Remove camshaft ange at rear of right side cylinder head. 7) Disconnect harness connector from switch for intake manifold change-over valve. Remove timing belt guard. Unclip cap at guide pulley for serpentine belt at right side timing belt guard. Remove top of air cleaner housing. Remove right side timing belt guard mounting bolts. Carefully lift right side timing belt guard up and out. 8) Holding camshaft sprocket with Sprocket Holder (3036), loosen camshaft sprocket bolts. See Fig. 7. Remove camshaft position sensor plate and housing. See Fig. 6. Install Camshaft Locking Device (3341) at rear of each cylinder head. If necessary, rotate camshaft to allow locking device to engage. See Fig. 8. Camshafts can be rotated by removing the valve cover and using the hex machined into the front end of the camshaft. CAUTION: The Camshaft Locking Devices (3341) are NOT to be used to hold camshafts in place when loosening or tightening the camshaft sprocket bolts. 9) Using spanner wrench, hold timing belt tensioner pulley. Loosen tensioner pulley center nut. See Figs. 9 and 10. Turn tensioner pulley to relieve timing belt tension. 10) Remove timing belt from camshaft sprockets. LIGHTLY strike edge of camshaft sprockets with plastic hammer to loosen sprocket from tapered ends of camshafts. 11) Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket. Remove crankshaft center bolt and remove crankshaft pulley. It is not necessary to remove sprocket from crankshaft. Remove timing belt.

105

Courtesy of Audi of America, Inc.

Fig. 3: Removing Right Front Engine Mount

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Crankshaft Pulley TDC Marks

Courtesy of Audi of America, Inc.

Fig. 5: Loosening Crankshaft Pulley Center Bolt 3) Loosen camshaft sprocket center bolts by about 1 turn. Camshaft sprocket should still be loose on camshaft tapers. Position timing belt in position over idler pulleys, water pump pulley and camshaft sprockets. See Fig. 9. 4) Push timing belt over tensioner pulley. Tighten tensioner pulley center nut hand tight. Eccentric insert should still be able to turn. 5) Tighten 4 crankshaft pulley-to-crankshaft sprocket mounting nuts. See TORQUE SPECIFICATIONS. 6) To set basic timing belt tension, turn tensioner pulley eccentric insert clockwise. Use a spanner wrench inserted into the 2 holes in the eccentric insert. Adjust position of timing belt tensioner until damper length is within specied range. See Fig. 11. 7) Tighten timing belt tensioner center nut to specication. See TORQUE SPECIFICATIONS. Holding camshaft sprockets in place, tighten camshaft sprocket center bolts to specication.

Courtesy of Audi of America, Inc.

Fig. 2: Removing Viscous Cooling Fan (Left-Hand Thread) Installation 1) Ensure crankshaft is still at TDC position. Place timing belt over crankshaft sprocket. Install crankshaft pulley on crankshaft. Install 4 bolts that hold crankshaft pulley to sprocket. Hand tighten temporarily. CAUTION: Manufacturer recommends that crankshaft pulley center bolt be REPLACED whenever the bolt is loosened or removed. 2) Lightly oil threads and contact surfaces of NEW center bolt. Using locking compound AMV 00102, or equivalent, install crankshaft pulley center bolt and hand-tighten temporarily.

106

AUDI
3.7L & 4.2L V8 1997-99 (Cont.)

Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.

Fig. 8: Installing Camshaft Locking Device (3341) 12) Disconnect 2-pin electrical connector from coolant pump unit. Coolant pump unit is located in left rear corner of engine compartment, near power brake booster. 13) Set A/C controls to LO position. Start engine and run at about 2000 RPM for about 3 minutes. Check coolant level in radiator expansion tank. Rell 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. Rell radiator expansion tank.

Fig. 6: Locating Camshaft Position Sensor & Housing

Courtesy of Audi of America, Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Position Sensor Housing Bolt .................................................................. 15 (20) Camshaft Sprocket Bolt ............................................................................................ 41 (55) Crankshaft Pulley Center Bolt ............................................................................ 1 332 (450) Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 18 (25) Serpentine Belt Idler Pulley Bolt .............................................................................. 18 (25) Timing Belt Adjustment Damper Bolts ...................................................................... 18 (25) Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25) Timing Belt Tensioner Nut ........................................................................................ 18 (25) INCH Lbs. (N.m) Timing Belt Cover Flanged Nut ................................................................................ 89 (10) Water Pump Bolts ..................................................................................................... 89 (10)
1

Fig. 7: Loosening Camshaft Sprocket Bolts 8) Remove Camshaft Locking Device (3341) from rear of each camshaft. Install housing behind camshaft position sensor and tighten bolts to specication. Camshaft position sensor plate MUST engage in camshaft with catch. 9) Turn crankshaft at least 2 revolutions in normal direction of rotation. Tighten crankshaft center bolt to specication. Check timing belt damper length. Readjust timing belt tension, if necessary. 10) To complete installation, reverse removal procedure. When relling cooling system, use Audi coolant additive G12-A8D TL 774D (Red color). Use 50/50 mix of coolant and water. 11) Before lling cooling system, open vent screws at heater core feed and return lines (rear of engine). Remove cap from radiator expansion tank. Add coolant until it ows from vent valves. Close vent valves. Install cap on radiator expansion tank.

Use NEW bolt if loosened or removed. Oil threads. Install with thread locking compound AMV 00102, or equivalent.

AUDI
3.7L & 4.2L V8 1997-99 (Cont.)

107

Courtesy of Audi of America, Inc.

Fig. 9: Exploded View Of Timing Belt & Components

Courtesy of Audi of America, Inc.

Fig. 10: Locating Timing Belt Tensioner Pulley


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Fig. 11: Adjusting Timing Belt Damper Length

108

AUDI
4.2L V8 AKB, AUX & AYS Engines A8 & S8
Labor Time Belt Part No. sprocket. Remove timing belt along with camshaft sprocket for cylinders No. 1 through No. 4 (passenger side cylinder head).

TIMING BELT APPLICATION Application

4.2L V8 (AKB, AUX & AYS Engines) A8 2000-03 ..................................................... 4.9 Hours ... ..... T297 S8 2001-03 ..................................................... 4.9 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation. Removal 1) Raise and support vehicle. Remove noise insulation panel from under front of vehicle. 2) Remove trim cover at front of engine compartment. Remove air intake duct for air cleaner. Remove engine top trim cover and cylinder head trim covers. 3) Remove outer ring for viscous fan. Hold viscous cooling fan pulley with pin wrench (3212). See Fig. 1. Remove viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded. 4) Using box wrench, turn serpentine belt tensioner clockwise with 19 mm ring wrench until the two holes are aligned. Hold tensioner in position with pin (3204). See Fig. 2. Remove serpentine belt. 5) Disengage spring clips at timing belt covers. Remove timing belt covers. 6) Rotate crankshaft by hand to TDC of compression stroke. Ensure TDC mark on vibration dampener aligns with mark on engine. See Fig. 3. 7) Check position of camshafts. Larger hole in camshaft sprocket securing plates must face inboard and align with each other. See Fig. 4. 8) Remove sealing plug from lower left side of engine block. TDC drilling in crankshaft MUST be behind sealing plug hole. Screw Crankshaft Clamping Bolt (3242) into hole. See Fig. 5. CAUTION: Manufacturer recommends REPLACING vibration dampener center bolt if it has been loosened or removed. 9) Remove serpentine belt tensioner from front of engine block. Remove vibration dampener retaining bolts. It is NOT necessary to remove center bolt. Remove vibration dampener. 10) Remove bracket for viscous cooling fan. See Fig. 6. 11) Using 8-mm hex wrench, SLOWLY compress hydraulic timing belt tensioner by turning tensioning lever counterclockwise. See Fig. 7. Insert Spring Pin (T40011) through top of timing belt tensioner and through hole in top of tensioner piston. 12) Install Camshaft Bar (T40005) onto securing plates of both camshafts. See Fig. 8. 13) Loosen both camshaft sprocket securing bolts about 5 turns. Remove Camshaft Bar (T40005). Using 2-jaw gear puller, loosen camshaft sprockets so that they are free to rotate, but not tilt, on the end of the camshaft. 14) Loosen center bolt of timing belt tensioner pulley with eccentric center. Tensioner pulley is located above and to the right of crankshaft

Courtesy of Audi of America, Inc.

Fig. 1: Removing Viscous Cooling Fan (Left-Hand Threads)

Courtesy of Audi of America, Inc.

Fig. 2: Removing & Installing Serpentine Belt

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Crankshaft Pulley TDC Marks

AUDI
4.2L V8 AKB, AUX & AYS Engines A8 & S8 (Cont.)

109

Courtesy of Audi of America, Inc.

Fig. 4: Aligning Camshaft Sprocket Securing Plate Holes

Courtesy of Audi of America, Inc.

Fig. 7: Relieving Timing Belt Tension

Courtesy of Audi of America, Inc.

Fig. 5: Locating Crankshaft Clamping Bolt (3242)

Courtesy of Audi of America, Inc.

Fig. 8: Installing Camshaft Bar (T40005) 3) Attach Camshaft Bar (T40005) to camshafts. Insert a 5-mm drill bit between the tensioning lever and the tip of the hydraulic tensioner piston. 4) Set initial timing belt tension using Tensioning Key (T40009), Socket Attachment (5122) and Torque Wrench (1410). See Fig. 9. Set tension to 35 INCH lbs. (4 N.m). While holding tensioner at this point, tighten center nut to 16 ft. lbs. (22 N.m). Remove 5-mm drill bit. 5) Using 8-mm hex wrench, rotate timing belt tensioning lever counterclockwise until Spring Pin (T40011) can be removed from hydraulic tensioner. 6) Rotate timing belt tensioner lever CLOCKWISE until a 7-mm drill bit can be inserted between the tip of the tensioning lever and the top of the hydraulic tensioner body. Tighten camshaft sprocket bolts to specication. See TORQUE SPECIFICATIONS. Keep Camshaft Bar (T40005) in place to prevent camshafts from moving. 7) Remove Camshaft Bar (T40005) after camshaft sprocket bolts are tightened. Remove 7-mm drill bit. Remove Crankshaft Clamping Bolt (3242) from side of engine block. Install sealing plug in hole. Turn crankshaft 2 revolutions in normal direction of rotation. 8) Measure distance between tensioning lever and top of hydraulic tensioner body. Dimension should be .197 (5 mm). See Fig. 10. If dimension is not correct, readjust timing belt tension until dimension is .197 (5 mm).

Courtesy of Audi of America, Inc.

Fig. 6: Locating Viscous Cooling Fan Mounting Bracket Installation 1) Ensure crankshaft is still at TDC position. Place timing belt over crankshaft sprocket, tensioner pulleys, camshaft sprocket for cylinders No. 5 through No. 8, water pump pulley and dampener pulley. Then take camshaft sprocket for cylinder bank 1-4, install toothed belt and bolt sprocket onto camshaft. 2) Lightly secure both camshaft sprockets with securing plates by tightening hand-tight. Camshaft sprockets must be tight enough on camshaft tapers to be turned, but should not tilt back and forth.

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 specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. When installing serpentine belt, rotate tensioner clockwise and remove pin.
Courtesy of Audi of America, Inc.

Fig. 11: Measuring Timing Belt-To-Guard Clearance (Right-Side Cylinder Head)

Courtesy of Audi of America, Inc.

Fig. 9: Setting Initial Timing Belt Tension

Courtesy of Audi of America, Inc.

Fig. 12: Measuring Timing Belt-To-Guard Clearance (Left-Side Cylinder Head)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 41 (55) Vibration Dampener Center Bolt Step 1 ................................................................................................................ 1 148 (200) Step 2 .................................................................................................................. Plus 180 Vibration Dampener-To-Sprocket Bolts ..................................................................... 15 (20) Timing Belt Tensioner Center Nut ............................................................................ 16 (22) Viscous Cooling Fan-To-Pulley ................................................................................. 52 (70) Water Pump Bolts ..................................................................................................... 10 (14)
Courtesy of Audi of America, Inc.

INCH Lbs. (N.m) Timing Belt Hydraulic Tensioner Bolts ...................................................................... 89 (10) Timing Belt Rear Cover Bolts ................................................................................... 89 (10) Viscous Cooling Fan Bracket Mount Bolts .............................................................. 89 (10)
1

Fig. 10: Measuring Tensioning Lever-To-Piston Clearance

Use NEW bolt if loosened or removed.

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6
TIMING BELT APPLICATION Application Labor Time Belt Part No.

111

4.2L V8 (ART, AWN & BBD Engines) A6 Quattro 2000-04 ..................................................... 6.4 Hours ... ..... T297 S6 Avant Quattro 2002-03 ..................................................... 6.4 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends belt be replaced at 105,000 miles under normal driving conditions, and 52,500 miles under severe driving conditions.

REMOVAL & INSTALLATION


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

12) Using a 19-mm wrench, rotate drive belt tensioner clockwise to loosen belt tensioner. Secure belt tensioner using Drift (3204). Remove drive belt. Ensure belt has no splits, cracks or other damage. Replace drive belt if necessary. See Fig. 13. 13) Remove upper cylinder head covers. Disengage clips and remove timing belt cover. Remove noise insulation panel. Rotate crankshaft by to Top Dead Center (TDC). See Fig. 14. 14) Check position of camshafts. Larger holes of camshaft securing plates (located on front of camshaft sprockets) must be on inside and must align. See Fig. 15. If camshafts are in correct position, go to next step. If camshafts are not in correct position, rotate crankshaft one turn further. 15) Remove sealing plug from alignment access hole in left side of engine block. Ensure that hole in crankshaft is visible through alignment access hole. Install Crankshaft Holder (3242) into alignment access hole to prevent crankshaft from rotating. See Fig. 16. 16) Remove accessory drive belt tensioner. Loosen 8 Allen-headed bolts and remove crankshaft vibration damper (center bolt does not have to be removed). Remove engine torque support. See Fig. 17. NOTE: Timing belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. 17) Using an 8-mm wrench, turn timing belt tensioning roller clockwise until tensioning lever compresses tensioner so a pin (2 mm in diameter) can be inserted into plunger. See Fig. 18. Insert pin and release tension. 18) Install Camshaft Locator Bar (3391) into camshaft locking plates. Loosen camshaft bolts and back bolts out 5 turns. Remove camshaft locator bar. Using Camshaft Sprocket Puller (T40001), remove camshaft sprocket. See Fig. 19. Loosen timing belt tensioning roller. Remove timing belt and left camshaft sprocket together.

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools to allow servicing of front engine components. Lock carrier can be removed at technicians discretion. 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 ange nut on both sides. See Figs. 3 and 4. 2) For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking/auxiliary heater at noise insulation. See Fig. 5. 3) Remove right cover in engine compartment. Unbolt air guide between lock carrier and air lter on lock carrier. Remove left cover in engine compartment. Pull off hood seal from lock carrier and fender edges. 4) Release catches (1-4) using a screwdriver, and remove air inlet grille on left and right sides of bottom part of bumper. See Fig. 6. Remove left and right retaining bolts until bumper is fully released. See Fig. 7. 5) Remove screw with washer assembly (6) from wheelhousing liner (5). See Fig. 3. Disconnect any wiring harness that attaches to the front bumper. Remove socket-head bolts (7), and remove bumper cover together with impact absorber towards front. See Fig. 3. 6) Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward). 7) On passengers side, remove bolt (5) and install Support Tool (3369) in its place. See Figs. 8 and 9. 8) On drivers side, install Support Tool (3369) in threaded hole in chassis. See Fig. 10. 9) Remove bolts (2, 3 and 4) from both sides. See Fig. 8. Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward-threaded fender bolt hole. 10) Secure lock carrier in this position by placing fender bolts in holes. See Fig. 11. NOTE: Fan clutch is tted with left-handed threads. Turn clockwise to loosen. 11) Remove air intake hose to air cleaner. Remove engine cover. See Fig. 12. Using Spanner Wrench (3212) to hold fan clutch pulley, use Open-End Spanner (3312) or equivalent to loosen fan clutch. Remove radiator fan and fan shroud from vehicle.

Courtesy of Audi of America, Inc.

Fig. 1: Identifying Lower Engine Shield (Noise Insulator) Mounting Points CAUTION: Before installation, ensure camshafts are aligned, crankshaft is locked in place and camshaft gear bolts are loose as described in removal procedures. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Installation 1) Install timing belt rst to crankshaft, then to tensioner, water pump, timing belt tensioning roller and right camshaft sprocket. See Fig. 20. Install left camshaft sprocket to camshaft with timing belt, and hand tighten camshaft sprocket bolts. Camshaft sprockets must be able to move on tapered camshaft. 2) Install Camshaft Holding Bar. See Fig. 21. Insert a 5-mm drill bit between timing belt tensioner and tensioner piston. See Fig. 22. Using Spanner (T40009) and torque wrench, apply 35 INCH lbs. (4 N.m) to timing belt tensioning roller. See Fig. 23. Remove drill bit. 3) Using an 8-mm Allen wrench, turn timing belt tensioner clockwise until tensioning lever compresses and remove pin. See Fig. 18. Continue turning timing belt tensioner clockwise until a 7-mm drill bit can be inserted between timing belt tensioner and tensioner piston. Tighten camshaft sprockets to 41 ft. lbs. (55 N.m).

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 specied, go to next step. If dimension is not as specied, 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 specied, go to next step. If dimension is as specied, 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 specication. See TORQUE SPECIFICATIONS. 7) To install lock carrier, reverse removal procedures outlined in REMOVAL. Torque all fasteners to specication. See TORQUE SPECIFICATIONS. Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). See Fig. 26. 8) Before installing the bumper, ensure the expanding clips are pressed into the fender. See Fig. 27. When installing the tabs, the bumper cover must latch into clip (4). See Figs. 3 and 4. 9) Latch bumper cover (1) into guide (2). See Fig. 3. Torque ange nuts (10) to 53 INCH lbs. (6 N.m). NOTE: The impact absorber is installed vertical to the cross member and has height compensating elements. See Fig. 28. 10) Torque left and right retaining bolts to specication. See TORQUE SPECIFICATIONS. Install left and right air inlet grille on bumper. To complete installation, reverse removal procedures.

Courtesy of Audi of America, Inc.

Fig. 3: Identifying Front Bumper Components (1 Of 2)

Courtesy of Audi of America, Inc.

Fig. 2: Identifying Wheelhousing Liner Components

Courtesy of Audi of America, Inc.

Fig. 4: Identifying Front Bumper Components (2 Of 2)

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

113

Courtesy of Audi of America, Inc. Courtesy of Volkswagen United States, Inc.

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

Courtesy of Audi of America, Inc.

Fig. 6: Removing Grilles


Courtesy of Audi of America, Inc.

Fig. 10: Installing Support Tool (3369) Into Chassis

Courtesy of Audi of America, Inc.

Fig. 7: Identifying Bumper Fasteners

Courtesy of Audi of America, Inc.

Fig. 11: Securing Lock Carrier In Service Position

Courtesy of Audi of America, Inc.

Fig. 12: Removing Engine Cover


Courtesy of Audi of America, Inc.

Fig. 8: Identifying Lock Carrier Components

114

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 13: Drive Belt Routing

Courtesy of Audi of America, Inc.

Fig. 16: Installing Crankshaft Holder

Courtesy of Audi of America, Inc.

Fig. 14: Aligning Timing Marks

Courtesy of Audi of America, Inc.

Fig. 17: Removing Engine Torque Support

Courtesy of Volkswagen United States, Inc.

Fig. 15: Aligning Camshaft Securing Plates

Courtesy of Volkswagen United States, Inc.

Fig. 18: Compressing Timing Belt Tensioner

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

115

Courtesy of Volkswagen United States, Inc.

Fig. 19: Installing Sprocket Puller


Courtesy of Audi of America, Inc.

Fig. 23: Tensioning Timing Belt Tensioning Roller

Courtesy of Volkswagen United States, Inc.

Fig. 20: Installing Timing Belt

Courtesy of Audi of America, Inc. Courtesy of Volkswagen United States, Inc.

Fig. 24: Checking Timing Belt Tensioner Adjustment

Fig. 21: Installing Camshaft Holding Bar

Courtesy of Audi of America, Inc.

Fig. 22: Setting Up Timing Belt Tensioner

116

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

Courtesy of Audi of America, Inc.

Fig. 27: Identifying Bumper Cover Attaching Points For Removal & Installation
Courtesy of Audi of America, Inc.

Fig. 25: Checking Timing Belt Guard Adjustment

Courtesy of Audi of America, Inc.

Fig. 26: Identifying Torque Support Bolts

AUDI
4.2L V8 ART, AWN & BBD Engines A6 & S6 (Cont.)

117

Courtesy of Audi of America, Inc.

Fig. 28: Identifying Bumper Attaching Point To Impact Absorber

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper-To-Long Member Bolts ................................................................................ 37 (50) Camshaft Gear-To-Camshaft Bolts ........................................................................... 41 (55) Eccentric Pulley-To-Front Sealing Flange Bolt ......................................................... 16 (22) Timing Belt Tensioning Pulley ................................................................................... 15 (20) Timing Belt Idler Pulley ............................................................................................. 33 (45) Vibration Dampener Bolts ......................................................................................... 15 (20) Impact Absorber Bolts ............................................................................................... 37 (50) Ribbed Belt Tensioner-To-Cylinder Block M8 Bolts .................................................................................................................. 17 (23) M10 Bolts ................................................................................................................ 30 (40) Sealing Plug In Cylinder Block ................................................................................. 18 (25) Torque Support Lock-To-Lock Carrier Bolts ............................................................. 21 (28) Viscous Fan Using Torque Wrench & Open End Wrench .......................................................... 27 (37) Using Torque Wrench Without Open End Wrench ................................................ 52 (70) INCH Lbs. (N.m) Bumper-To-Fender Bolts ........................................................................................... Timing Belt Guard Bolts 1 ......................................................................................... Timing Belt Tensioner ................................................................................................ Valve Cover Bolts ......................................................................................................
1

89 89 89 89

(10) (10) (10) (10)

Use NEW bolts.

118

AUDI & VOLKSWAGEN


2.1L & 2.2L 5-Cylinder, 1978-91
REMOVAL & INSTALLATION
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove upper radiator cover. Remove drive belts. Remove power steering pump with pressure hoses connected. Set pump aside. Remove valve cover and outer timing belt covers. See Fig. 1. 2) Using crankshaft bolt, turn crankshaft clockwise to TDC of No. 1 cylinder compression stroke. Align timing mark on back of camshaft sprocket with upper edge of gasket. See Fig. 2. 3) Loosen water pump adjusting bolts to relieve tension on timing belt. Remove timing belt. Remove water pump to check O ring. DO NOT allow crankshaft or camshaft to move.

2.1L 5-Cyl. Quantum 1984-85 .70 Belt T.W. ......................................... 1 2.3 Hours .. ..... .75 Belt T.W. ......................................... 1 2.3 Hours .. ..... 2.2L 5-Cyl. Coupe 1981-83 ..................................................... 1.8 Hours ... ..... 1984-85 113 Tooth Belt ........................................ 1.8 Hours ... ..... 120 Tooth Belt ........................................ 1.8 Hours ... ..... 1986-87 ..................................................... 1.8 Hours ... ..... Quantum 1983-85 .70 Belt T.W. ......................................... 1 2.3 Hours .. ..... .75 Belt T.W. ......................................... 1 2.3 Hours .. ..... 1986 .70 Belt T.W. .......................................... 2.3 Hours ... ..... .75 Belt T.W. .......................................... 2.3 Hours ... ..... 1987-88 ..................................................... 2.3 Hours ... ..... Quattro 1983 ........................................................... 1.8 Hours ... ..... 1984-85 113 Tooth Belt ........................................ 1.8 Hours ... ..... 120 Tooth Belt ........................................ 1.8 Hours ... ..... 200 1989 Thru Chassis No. 44 K 400 000 ........... 2.5 Hours ... ..... From Chassis No. 44 K 400 001 .......... 2.5 Hours ... ..... 1990-91 ..................................................... 2.5 Hours ... ..... 200 Quattro 1989 Thru Chassis No. 44 K 004 457 ........... 2.5 Hours ... ..... From Chassis No. 44 K 004 458 .......... 2.5 Hours ... ..... 1990-91 ..................................................... 2.5 Hours ... ..... 4000 1980-81 ..................................................... 1.8 Hours ... ..... 4000CS 1986-87 ..................................................... 1.8 Hours ... ..... 4000CS Quattro 1987 ........................................................... 1.8 Hours ... ..... 4000S Quattro 1984-85 113 Tooth Belt ........................................ 1.8 Hours ... ..... 120 Tooth Belt ........................................ 1.8 Hours ... ..... 1986 ........................................................... 1.8 Hours ... ..... 5000 1978-83 ..................................................... 1.1 Hours ... ..... 5000CS Quattro 1987-88 ..................................................... 2.2 Hours ... ..... 5000S 1984-85 113 Tooth Belt ........................................ 2.2 Hours ... ..... 120 Tooth Belt ........................................ 2.2 Hours ... ..... 1986-87 ..................................................... 2.2 Hours ... .....
1

T127 T065

T065 T065 T127 T127

T127 T065 T127 T065 T127 T065 T065 T127

T127 T170 T170

T127 T170 T170


Courtesy of Audi of America, Inc.

T065 T127 T127

Fig. 1: Exploded View Of Timing Belt & Components

T065 T127 T127 T065 T127

T065 T127 T127


Courtesy of Volkswagen United States, Inc.

With Air Conditioning, Without Factory Air Conditioning, With Radiator removal, labor time is 3.9 hours.

Fig. 2: Aligning Camshaft Sprocket Installation 1) Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. See Fig. 3. 2) Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using nger pressure at point midway between camshaft sprocket and water pump sprocket. Recheck valve timing. Reverse installation order of removal. Adjust drive belts.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

AUDI & VOLKSWAGEN


2.1L & 2.2L 5-Cylinder, 1978-91 (Cont.)
NOTE: Turn engine by hand using hex ange on hydraulic pump. Loosen tensioner bolts.

119

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20) Timing Belt Tensioner ................................................................................................ 15 (20) Vibration Damper Bolt ........................................................................................... 258 (350) Water Pump Bolt ....................................................................................................... 15 (20) INCH Lbs. (N.m) Radiator Mounting Bolts ............................................................................................ 89 (10) Timing Belt Cover ..................................................................................................... 89 (10) Valve Cover Nuts/Bolts ............................................................................................. 89 (10)

Courtesy of Audi of America, Inc.

Fig. 3: Aligning Timing Marks

120

BMW
2.5L & 2.7L 6-Cylinder
Labor Time Component Belt Kit No. Part No. 2) Using a puller, remove vibration damper hub from crankshaft. Remove distributor cap and rotor. Remove cover from distributor housing. Ensure cylinder No. 1 is set to TDC on compression stroke. See Fig. 1. Remove alternator tension bracket and move aside. 3) Remove front cover. Loosen timing belt tensioner mounting bolts, and press in on tension roller. Tighten upper mounting bolt to hold tensioner in place. Remove timing belt. See Fig. 2.

TIMING BELT APPLICATION Application 2.5L 6-Cyl. 325 Series 1987-88 127 Tooth Belt ................. 128 Tooth Belt ................. 1989-91 ............................... 525i 1989-95 ............................... 2.7L 6-Cyl. 325 Series 1984-88 127 Tooth Belt ................. 128 Tooth Belt ................. 528e 1982-88 127 Tooth Belt ................. 128 Tooth Belt .................

3.2 Hours ... ...... ..... ...... ..... T131 3.2 Hours ... ...... ..... ...... ..... T106 3.2 Hours ... .. TCK131 .. ..... T131 3.2 Hours ... ...... ..... ...... ..... T131

2.7 Hours ... ...... ..... ...... ..... T131 2.7 Hours ... ...... ..... ...... ..... T106

2.7 Hours ... ...... ..... ...... ..... T131 2.7 Hours ... ...... ..... ...... ..... T106

NOTE: Use 127 tooth belt with retrot tensioner pulley. Use 128 tooth belt with OEM tensioner pulley. DO NOT use 128 tooth belt on new style adjusting pulley. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles or whenever tensioner roller has been released.

Courtesy of BMW of North America, Inc.

Fig. 1: Aligning Timing Sprockets Installation 1) Ensure arrow on camshaft sprocket is still aligned with timing mark on cylinder head. Ensure timing mark on crankshaft sprocket is aligned with notch in cover (about one oclock position). See Fig. 1. 2) Install timing belt on sprockets. Loosen tensioner adjusting bolt to allow spring tension on timing belt. Turn crankshaft in direction of normal rotation until timing belt tightens. Tighten tensioner bolt. 3) Clean gasket mating surfaces. Coat oil pan-to-cover gasket with gasket sealer. Install Centering Tool (11 2 211) on crankshaft and on intermediate shaft to align front cover. 4) Using new gasket, install and tighten timing belt cover. When installing crankshaft sprocket, lettering must face forward. Install remaining components in reverse order of removal procedure. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower splash shield. Remove all drive belts. Remove cooling fan and water pump pulley. Drain cooling system. Disconnect both hoses and transmission cooling line. Disconnect electrical connector from radiator switches. Remove radiator. Hold crankshaft in place and remove center bolt from vibration damper hub.

BMW
2.5L & 2.7L 6-Cylinder (Cont.)

121

Courtesy of BMW of North America, Inc.

Fig. 2: Exploded View Of Camshaft Drive Assembly

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ................. 47-50 (65-70) Intermediate Shaft Sprocket ......................................................... ................. 40-47 (55-64) Vibration Damper Hub ............................................................................ 283-311 (390-430)

122

CHRYSLER
1.4L 4-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.4L 4-Cyl. Colt 1979 .................................... 1980-84 ............................... Champ 1979 .................................... 1980-82 ...............................
1

1.1 Hours ... ...... ..... ...... ..... T073 1.1 Hours ... .. TCK073 .. ..... T073 1.1 Hours ... ...... ..... ...... ..... T073 1.1 Hours ... .. TCK073 .. ..... T073

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Fig. 1: Removing & Installing Timing Belt 4) Check belt tension by pushing tension side of timing belt in horizontally using about 11 lbs. (5 kg) force. Timing belt tooth end should be approximately 1/4 of tensioner mounting bolt head width (across ats) away from bolt head center. See Fig. 3. Adjust drive belts to proper tension.

TIMING BELT
Removal 1) Disconnect negative battery cable. On front wheel drive models, remove air cleaner assembly, then disconnect accelerator cable and oxygen sensor lead. On all models, mark position of spark plug wires for installation, then remove wires from spark plugs. On front wheel drive models, support engine using a suitable engine support bar. 2) Remove left engine mount bracket. Remove fan, spacer, water pump pulley and drive belt. Remove rocker arm cover and timing belt cover. Move timing belt tensioner upward toward water pump and secure. Remove timing belt from camshaft sprocket. Mark belt with an arrow indicating direction of rotation for installation reference, and remove timing belt. See Fig. 1. Installation 1) Align camshaft and crankshaft sprockets. Mount belt tensioner, spring, spacer and temporarily tighten bolt. Position spring against tensioner rst, 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 rst and slotted adjustment hole bolt last. 3) Slowly turn crankshaft one revolution clockwise and realign crankshaft sprocket timing mark at TDC. Do not push or shake belt while turning or turn crankshaft in counterclockwise direction. Loosen tensioner spring bolt rst then slotted adjustment hole bolt. Tighten tensioner bolts by tightening slotted adjustment hole bolt rst and tensioner spring bolt last.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt Tensioner

CHRYSLER
1.4L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

123

Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ................. 47-54 (64-73) Crankshaft Sprocket Bolt .............................................................. ................. 37-43 (50-58) Timing Chain Tensioner ................................................................ ................. 15-18 (20-24) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................................................................... 90-102 (10-11) Oil Pump Cover ............................................................................. ................. 72-108 (8-10)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Checking Timing Belt Tension

124

CHRYSLER
1.6L 4-Cylinder With Balance Shaft
Labor Time Belt Part No.
2 3

TIMING BELT APPLICATION Application 1.6L 4-Cyl. SOHC Arrow & Sapporo 1977-80 .................................................... 1977-80 .................................................... Challenger 1978-79 .................................................... 1978-79 .................................................... Champ 1979-80 .................................................... 1979-80 .................................................... Colt 1977-80 .................................................... 1977-80 ....................................................
1

1 1

1.8 Hours .. ... 1.9 Hours .. ... 1.8 Hours .. ... 1.9 Hours .. ... 1.8 Hours .. ... 1.9 Hours .. ... 1.8 Hours .. ... 1.9 Hours .. ...

T013 T062 T013 T062 T013 T062 T013 T062

1 1

2 3

1 1

2 3

1 1

2 3

2 3

Counterbalance shaft belt included in labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. Camshaft timing belt. Counterbalance shaft belt.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Counterbalance & Timing Belt Routing

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley, upper and lower timing belt front covers. Loosen timing belt tensioner mounting nut and bolt. Move tensioner away from timing belt and temporarily tighten nut. Remove timing belt. See Fig. 1. 2) Remove plug at bottom of left side of cylinder block. See Fig. 2. Insert a screwdriver to keep left counterbalance (silent) shaft in position. Screwdriver MUST insert at least 2.36 (59.9 mm). If not, turn oil pump sprocket (which drives left counterbalance shaft) one full turn until timing mark is aligned again. Keep screwdriver in place until timing belt is installed. 3) Remove outer crankshaft sprocket and ange. Loosen center bolt on counterbalance belt tensioner pulley. Remove counterbalance shaft belt. Installation 1) Align counterbalance shaft and crankshaft sprocket timing marks. See Fig. 3. Install counterbalance shaft belt so that there is no slack on tension side of belt. 2) Position counterbalance shaft tensioner so that the eccentric in the center of the pulley is located to the left and above the bolt. See Fig. 4. Ensure pulley ange faces toward front of engine. While keeping tension on counterbalance shaft belt, tighten tensioner pulley bolt. DO NOT allow tensioner pulley to rotate while tightening center bolt. 3) If camshaft timing belt tensioner was removed, install tensioner. Ensure tension spring is seated in correct position on water pump body. See Fig. 5. Secure tensioner away from timing belt. 4) Install outer crankshaft sprocket. Install camshaft timing belt rst on crankshaft sprocket, then around the oil pump sprocket and camshaft sprocket. Keep slack out of belt during installation. Ensure crankshaft, camshaft and oil sprocket timing marks are still aligned. 5) Remove screwdriver inserted in left side of engine block. Install plug. Temporarily install crankshaft pulley to prevent timing belt movement when crankshaft is turned. Loosen camshaft timing belt tensioner nut and bolt. 6) Lightly push camshaft belt tensioner toward timing belt. Ensure timing belt fully meshes with all teeth on sprockets. Tighten camshaft timing belt tensioner mounting nut rst, then bolt. If bolt is tightened rst, the tensioner may also turn more than necessary.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Holding Counterbalance (Silent) Shaft In Stationary Position 7) Ensure all camshaft timing marks are still aligned. Turn crankshaft one revolution in normal direction of rotation (clockwise). Do NOT turn crankshaft counterclockwise. CAUTION: Do NOT push or twist camshaft timing belt during nal tension adjustment. 8) Loosen tensioner mounting bolt and nut. This will take any slack out of timing belt. Final tighten tensioner mounting nut to specied torque. See TORQUE SPECIFICATIONS. Tighten tensioner mounting bolt. 9) To check timing belt tension, grasp camshaft timing belt between thumb and forenger. Clearance between back of timing belt and edge of rear timing case seal line should be .47 (12 mm). See Fig. 6. Readjust camshaft timing belt tension, if necessary. 10) Remove crankshaft pulley. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft sprocket center bolt and pulley bolts to specication. See TORQUE SPECIFICATIONS. Install accessory drive belts. Adjust drive belts to proper tension.

CHRYSLER
1.6L 4-Cylinder With Balance Shaft (Cont.)

125

Courtesy of DaimlerChrysler Corp.

Fig. 6: Checking Camshaft Timing Belt Tension


Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 44-57 (60-78) Crankshaft Sprocket Center Bolt .................................................. ................. 44-50 (60-68) Oil Pump Sprocket Bolt ................................................................ ................. 25-28 (34-39) Timing Belt Tensioner Mounting Bolt ............................................ ................. 16-21 (22-29) Timing Belt Tensioner Mounting Nut ............................................ ................. 16-21 (22-29) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................................................................... 90-102 (10-11)

Fig. 3: Aligning Counterbalance Shaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 4: Positioning Counterbalance Pulley

Courtesy of DaimlerChrysler Corp.

Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring

126

CHRYSLER
1.6L 4-Cylinder Without Balance Shaft
Labor Time Belt Part No. 3) Ensure all timing marks are still aligned. Temporarily install crankshaft pulley. 4) Loosen tensioner mounting bolt so that spring-loaded tensioner applies pressure to the timing belt. Lightly push tensioner up by hand to ensure timing belt completely meshes with drive sprockets. Tighten tensioner mounting nut, then tighten mounting bolt. See Fig. 3. 5) Turn crankshaft one turn in normal direction of rotation. Do NOT turn in opposite direction. Loosen the timing belt tensioner mounting bolt and nut. This will take out any slack in belt. Tighten mounting nut to specied torque. See TORQUE SPECIFICATIONS. Tighten timing belt tensioner bolt. 6) To check timing belt tension, grasp belt between thumb and forenger near timing belt tensioner. See Fig. 4. Tension is correct when distance between back of belt and edge of rear timing case cover is .47 (12 mm) with nger pressure. Readjust tension, if necessary. 7) Remove crankshaft pulley. Install timing belt covers. Install crankshaft pulley and tighten bolts to specication. On front wheel drive vehicles, install engine mount. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. SOHC, Without Balance Shaft Arrow & Sapporo 1978-80 .................................................... 1 1.6 Hours .. ..... Challenger & Colt (RWD) 1978-79 .................................................... 1 1.6 Hours .. ..... Champ 1979-82 ..................................................... 2.8 Hours ... ..... Colt (FWD) 1979-82 .................................................... 1 2.8 Hours .. ..... 1983-89 .................................................... 1 2.8 Hours .. ..... Vista (Canadian) 1989 .......................................................... 1 2.8 Hours .. .....
1

T064 T064 T064 T064 T093 T093

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. On front wheel drive only, support engine under oil pan with a oor jack. Remove engine mount on timing belt end of engine. 2) On all models, remove accessory drive belts. Remove crankshaft pulley, upper and lower timing belt front covers. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 1. 3) Loosen belt tensioner mounting nut and bolt. Move tensioner away from belt and temporarily tighten nut. Remove timing belt. See Fig. 1.
Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension


Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Timing Belt Routing & Alignment Installation 1) Ensure that all timing marks are still in alignment. See Fig. 1. If tensioner was removed, ensure spring is positioned correctly under water pump body. See Fig. 2. Secure tensioner out of way so that timing belt can be installed. 2) Install timing belt on crankshaft sprocket, on oil pump sprocket and camshaft sprocket, in that order. Keep slack out of belt during installation.

CHRYSLER
1.6L 4-Cylinder Without Balance Shaft (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

127

Application Ft. Lbs. (N.m) Timing Belt Tensioner Nut/Bolt ..................................................... ................. 16-21 (22-29) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................................................................... 90-102 (10-11)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Checking Timing Belt Tension

128

CHRYSLER
1.7L 4-Cylinder
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.7L 4-Cyl. Charger 1983 ................................... Horizon 1978-83 .............................. Omni 1978-83 .............................. TC3 1981 ................................... 1982 ................................... Turismo 1983 ................................... 024 1981-82 ..............................
1

3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017 3.1 Hours .. .. TCK017 .. ..... T017

1 2

With Air Conditioning, add .2 hours. With Air Pump, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .2 hours. With Air Pump, add .1 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal 1) Disconnect negative battery cable. If equipped, remove A/C compressor and power steering pump from mounting brackets and position aside, leaving refrigerant lines and/or hoses connected. Remove alternator from mounting bracket, and position aside. 2) Raise vehicle and remove inner fender splash shield. On 1981-83 models, remove water pump. On all models, remove AIR pump belts (if equipped). Remove idler pulley assembly. Remove crankshaft pulley and power steering belt. Remove lower plastic timing belt cover. See Fig. 1. 3) Lower vehicle and place jack under engine. Remove right motor mount through-bolt, and raise engine slightly. Loosen timing belt tensioner and remove timing belt. Installation 1) Align timing marks on crankshaft and intermediate sprockets. See Fig. 2. Turn camshaft sprocket until timing mark on sprocket is lined up with camshaft cover sealing surface. See Fig. 3. 2) Install timing belt and Belt Tensioner Tool (L-4502 or equivalent) horizontally on large hex of belt tensioner pulley, and loosen tensioner lock nut. See Fig. 4. If necessary, reset belt tensioner tool to have axis within 15 of horizontal. NOTE: Do not turn engine by turning camshaft pulley. This will cause belt to skip teeth. 3) Turn engine clockwise from TDC 2 complete crankshaft revolutions to TDC. Tighten tensioner lock nut while holding belt tensioner wrench in position. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Locating Crankshaft & Intermediate Sprocket Timing Marks

CHRYSLER
1.7L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

129

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 58 (80) Crankshaft Sprocket Bolt .......................................................................................... 58 (80) Intermediate Shaft Retainer Bolt .............................................................................. 18 (29) Intermediate Shaft Sprocket Bolt .............................................................................. 58 (80) Timing Belt Cover Screw ............................................................................................ 8 (11) Water Pump Bolts ..................................................................................................... 30 (41)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Locating Camshaft Timing Mark

Courtesy of DaimlerChrysler Corp.

Fig. 4: Tensioning Timing Belt

130

CHRYSLER
1.8L 4-Cylinder VIN T
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Colt & Colt Wagon 1989-90 ....................................................
1

2.4 Hours .. ..... T093

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of DaimlerChrysler Corp.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove protective cover below engine. Support engine and remove engine mount from timing belt end of engine. Remove spark plug wires and rocker cover. Remove drive belts and water pump pulley. Remove A/C belt tensioner (if equipped). 2) Remove crankshaft pulley assembly. Remove upper front and lower timing belt covers. Note bolt lengths and locations. Rotate engine clockwise (as viewed from timing belt end of engine) to align timing mark on camshaft sprocket with mark on upper rear cover. See Fig. 1. 3) If reusing belt, mark timing belt position on camshaft sprocket and indicate direction of belt rotation. Loosen timing belt tensioner bolt and nut. Move timing belt tensioner toward water pump to release tension, and tighten nut temporarily to maintain tensioner position. See Fig. 2. Remove timing belt.

Fig. 2: Positioning Timing Belt Tensioner shaft sprocket, in counterclockwise direction, to apply tension on tension side of belt. Ensure all timing marks are aligned. 3) Loosen belt tensioner bolt, then loosen nut to place tension on timing belt. Rotate camshaft sprocket clockwise until timing mark is offset by 2 teeth to apply tension on belt. Ensure all timing marks are aligned. Tighten tensioner nut, then tighten bolt. 4) Check belt tension by applying slight thumb pressure to timing belt in direction of timing belt lower rear cover. See Fig. 3. Ensure distance between back of timing belt (smooth side) and timing belt lower rear cover is approximately .23 (6 mm). To complete installation, reverse removal procedure. Adjust accessory drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Damper Pulley Bolt ......................................................................................... 11-13 (15-18) Engine Support Bracket Bolt ........................................................ ................. 22-30 (30-41) Front Cover Bolt .............................................................................................. 11-13 (15-18) Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27) Water Pump Bolt 8 X 70 mm .................................................................................. ................. 15-19 (20-26) All Others ................................................................................................................. 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Timing Mark Alignment & Belt Arrangement Inspection Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner for signs of grease leakage or roughness in tensioner rotation. Replace components if damaged. Installation 1) Rotate tensioner toward water pump and temporarily tighten retaining nut. See Fig. 2. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 1. 2) Apply pressure on tension side of belt, and install timing belt on oil pump sprocket and then on crankshaft sprocket. Apply force on cam-

CHRYSLER
2.0L 4-Cylinder VIN C 1995-00
TIMING BELT APPLICATION Application 2.0L 4-Cyl. SOHC Breeze 1996-00 ..................................................... Cirrus 2000 ........................................................... Neon 1995-99 ..................................................... Stratus 1995-00 ..................................................... Labor Time Belt Part No.

131

2.6 Hours ... ..... T245 2.6 Hours ... ..... T245 2.4 Hours ... ..... T245 2.6 Hours ... ..... T245

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Hydraulic Tensioner) 1) Remove No. 1 spark plug. Using dial indicator, set number one cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover. See Fig. 1. Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 2. 2) Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 3. Remove crankshaft damper bolt. Use gear puller to remove crankshaft damper. 3) Lower vehicle and place a jack under engine to support weight. Remove right engine mount. On Breeze and Stratus, remove generator (with wiring attached) and bracket, and secure out of way. On Neon, remove power steering pump with hoses attached, and secure out of way. On all models, remove right engine mount bracket from engine. See Fig. 4. 4) Remove front timing belt cover. See Fig. 1. Rotate crankshaft so that timing marks are aligned. See Fig. 2. Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Remove timing belt and tensioner. DO NOT loosen, tighten, or remove tensioner pulley pivot bolt.
Courtesy of DaimlerChrysler Corp.

CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. NOTE: When tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Index tensioner in vise the same way it is installed on engine to ensure proper pin orientation when tensioner is installed on engine. CAUTION: The following revised information regarding the tensioner pulley pivot bolt is from Chrysler technical service bulletin 09-06-96; March 29, 1996. Timing Belt Tensioner Bracket Precaution On models with hydraulic timing belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed.

Fig. 2: Aligning Timing Marks & Adjusting Belt Tension (Hydraulic Timing Belt Tensioner) Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Hydraulic Tensioner) 1) Place tensioner in soft-jawed vise and slowly compress plunger. See Fig. 5. When plunger is compressed into tensioner body, install a 5/16 (1.9 mm) hex wrench or locking pin through body and plunger to hold plunger in place until tensioner is installed. 2) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing, then back off to 3 notches before TDC.

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 manufacturers instructions to access the cam/crank relearn procedure. Perform cam/ crank relearn procedure.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Exploded View Of Splash Shield Components

Courtesy of DaimlerChrysler Corp.

Fig. 5: Compressing Hydraulic Timing Belt Tensioner

Courtesy of DaimlerChrysler Corp.

Courtesy of DaimlerChrysler Corp.

Fig. 4: Locating Right Engine Mount Bracket (Typical) 3) Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 2. Move crankshaft to 1/2 notch mark before TDC for belt installation. See Fig. 6. Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket. 4) Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block, but do not nal tighten bolts. Using a torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N. m) of torque in clockwise direction. With torque applied to tensioner pulley, move the tensioner up against the tensioner pulley bracket. Final tighten tensioner bolts. See Fig. 1. 5) Pull tensioner plunger locking pin. Pretension is correct when pin can be removed and installed. Rotate crankshaft 2 revolutions. Check alignment of the timing marks. Install front timing belt cover. Install engine mount bracket. Install generator and bracket (Breeze and Stratus) or power steering pump (Neon). 6) Install right engine mount. Remove jack from under engine. Install crankshaft damper, and tighten bolt to specication. See TORQUE SPECIFICATIONS.

Fig. 6: Aligning Crankshaft Sprocket Timing Marks NOTE: Chrysler recommends replacing worn mechanical tensioners with updated hydraulic tensioner kits. Information is from Chrysler technical service bulletin 09-06-00; March 10, 2000. Removal (Mechanical Tensioner) 1) Remove No. 1 spark plug. Using dial indicator, set number one cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover. See Fig. 1. Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 7. 2) Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 3. Remove crankshaft damper bolt. Use gear puller to remove crankshaft damper. 3) On Breeze and Stratus, lower vehicle and place a jack under engine to support weight. Remove right engine mount from engine and body. Remove generator (with wiring attached) and bracket, and secure out of way. Remove engine mount bracket from engine. For 2000 Breeze and Stratus, remove accessory drive belt idler pulley from generator bracket. Remove generator bracket-to-engine bolts. Move bracket away from engine for clearance to remove timing belt cover.

CHRYSLER
2.0L 4-Cylinder VIN C 1995-00 (Cont.)
4) On Neon, lower vehicle and place jack under engine to support weight. Remove power steering pump with hoses attached, and secure out of way. Remove right engine mount-to-engine mount bracket through-bolt. Remove engine mount bracket from engine. 5) On all models, remove timing belt cover. Rotate the crankshaft so that timing marks are aligned. See Fig. 7. 6) Install an 8-mm Allen wrench into timing belt tensioner. See Fig. 7. Insert long end of a 3-mm Allen wrench into pin hole in the front of tensioner. Slowly rotate tensioner counterclockwise with 8-mm Allen wrench while pushing lightly on the 3-mm Allen wrench, until it slides into the locking hole. 7) If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. CAUTION: Mechanical timing belt tensioner is serviced as an assembly. To prevent premature timing belt failure and engine damage, do NOT separate tensioner pulley from tensioner bracket. Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Mechanical Tensioner) 1) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing, then back off to 3 notches before TDC. 2) Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 7. Move crankshaft to 1/2 mark before TDC for belt installation. See Fig. 6. Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket. See Fig. 7. Move crankshaft sprocket to TDC to take up belt slack. 3) Remove Allen wrench from timing belt tensioner pulley. Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. If timing marks do not align, remove timing belt and realign timing marks. 4) Install front timing belt cover. Install engine mount bracket to engine. Continue installation in reverse of removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust accessory drive belts to proper tension. 5) On 1998-99 Neon, connect scan tool to Data Link Connector (DLC) under lower left edge of dash. Follow scan tool manufacturers instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure.

133

Courtesy of DaimlerChrysler Corp.

Fig. 7: Aligning Timing Marks & Adjusting Belt Tension (Mechanical Timing Belt Tensioner)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 85 (115) Crankshaft Damper Bolt ........................................................................................ 105 (142) Engine Mount Bolt ..................................................................................................... 45 (61) Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61) Generator Mounting Bolts ......................................................................................... 45 (61) Power Steering Pump Mounting Bolts ..................................................................... 40 (54) Timing Belt Tensioner Bolt (Hydraulic Tensioner) .................................................... 23 (31) Timing Belt Tensioner Bracket Bolt (Mechanical Tensioner) ................................... 23 (31) INCH Lbs. (N.m) Timing Belt Cover Bolts (M6) ................................................................................. 106 (12) Water Pump Mounting Bolts ................................................................................... 106 (12)

134

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. SOHC Neon 2000-04 ..................................................... 2.6 Hours ... ..... T245 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the timing belt be replaced at 105,000 mile intervals or at 84 months.

ADJUSTMENTS
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, oor 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 oor jack on the forward edge of transmission bellhousing. See Fig. 1. 2) With engine supported, remove upper and lower torque struts attachment bolt(s) at shock tower bracket and suspension crossmember. See Fig. 2. Verify that torque struts are free to move within shock tower bracket and crossmember. Reinstall torque strut bolt(s), but DO NOT tighten. 3) Carefully apply upward force, allowing upper engine to rotate rearward until distance between center of rearmost attaching stud on engine mount bracket (point A) and center of hole for washer hose clip on shock tower bracket (point B) is 4.7 (119 mm). See Fig. 3. 4) With engine held at proper position, tighten both upper and lower torque strut bolts to specication. See TORQUE SPECIFICATIONS. Remove oor jack.
Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Upper & Lower Engine Torque Struts

Courtesy of DaimlerChrysler Corp.

Fig. 3: Measuring Engine Position (Top View)

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: For identication 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 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

Courtesy of DaimlerChrysler Corp.

Fig. 1: Positioning Floor Jack

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)
steering pump with hoses attached, and secure out of way. Remove two remaining upper engine mount bracket bolts and remove engine mount bracket. See Fig. 9. Remove front timing belt cover bolts and remove front timing belt cover. See Fig. 4. 4) Rotate crankshaft so that timing marks are aligned. See Fig. 10. Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Remove timing belt and tensioner. DO NOT loosen, tighten, or remove tensioner pulley pivot bolt. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt.

135

Courtesy of DaimlerChrysler Corp.

Fig. 6: Removing Right Front Splash Shield


Courtesy of DaimlerChrysler Corp.

Fig. 4: Exploded View Of Timing Belt & Components (With Hydraulic Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 5: Identifying Camshaft Sprocket & Rear Cover Timing Marks

CAUTION: The following revised information regarding the tensioner pulley pivot bolt is from Chrysler technical service bulletin 09-06-96; March 29, 1996. Timing Belt Tensioner Bracket Precaution On models with hydraulic timing belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Pivot bolt is located on timing belt tensioner assembly. See Fig. 10. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed. Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged.

Courtesy of DaimlerChrysler Corp.

Fig. 8: Removing Right Engine Mount Bolt

136

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)
NOTE: When hydraulic tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Installation (With Hydraulic Tensioner) 1) Place tensioner in soft-jawed vise and slowly compress plunger. See Fig. 11. When plunger is compressed into tensioner body, install a 5/64 (1.9 mm) hex wrench or locking pin through body and plunger to hold plunger in place until tensioner is installed. 2) Set crankshaft sprocket to TDC by aligning sprocket TDC mark with TDC reference mark arrow on oil pump housing, then back off to 3 notches before TDC. See Fig. 12. 3) Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 10. Move crankshaft to 1/2 notch mark before TDC for belt installation. See Fig. 12. Install timing belt starting at crankshaft sprocket, then around water pump sprocket, and then camshaft sprocket, and nally around timing belt tensioner pulley. 4) Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block, but do not nal 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 specication. See TORQUE SPECIFICATIONS. 5) Pull tensioner plunger locking pin. Pre-tension is correct when pin can be removed and installed. Rotate crankshaft 2 revolutions. Check alignment of the timing marks. See Fig. 10. Check belt tension by installing pin into tensioner housing. If pin cannot be reinstalled, repeat tensioning procedure. 6) Install front timing belt cover. Install engine mount bracket and power steering pump. Install right engine mount, and remove jack from under engine. Install and adjust upper and lower engine torque struts. See ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS. Install crankshaft damper, and tighten bolt to specication. See TORQUE SPECIFICATIONS. 7) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle. Install accessory drive belts. Adjust drive belts to proper tension. 8) Connect scan tool to Data Link Connector (DLC), located under lower left edge of instrument panel. Turn ignition on. Perform cam/crank relearn procedure by accessing ENGINE diagnostics. Select MISCELLANEOUS, then select RELEARN CAM CRANK and follow directions on scan tool screen.

Courtesy of DaimlerChrysler Corp.

Fig. 9: Locating Engine Mount Bracket Upper & Lower Bolts

Courtesy of DaimlerChrysler Corp.

Fig. 10: Aligning Timing Marks & Adjusting Belt Tension (Hydraulic Timing Belt Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 11: Compressing Hydraulic Timing Belt Tensioner NOTE: For identication of timing belt with mechanical tensioner related components, refer to illustration. See Fig. 14.

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)

137

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 ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (With Mechanical Tensioner) 1) Set crankshaft sprocket to TDC by aligning sprocket TDC mark with TDC reference mark arrow on oil pump housing, then back off to 3 notches before TDC. See Fig. 12. 2) Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 15. Move crankshaft to 1/2 notch mark before TDC for belt installation. See Fig. 12. Install timing belt starting at crankshaft sprocket, then around water pump sprocket, and then camshaft sprocket, and nally around timing belt tensioner pulley. 3) Move crankshaft sprocket to TDC to take up belt slack. Install a 6-mm Allen wrench into hexagon opening of top plate tensioner pulley. Rotate tensioner counterclockwise with 6-mm Allen wrench. See Fig. 13. The tensioner pulley will move against timing belt and tensioner setting notch will eventually start to move clockwise. Watching movement of notch, continue rotating tensioner counterclockwise until the setting notch is aligned with spring tang. See Fig. 13. Hold tensioner setting notch aligned with spring tang, and tighten tensioner bolts to specication. See TORQUE SPECIFICATIONS. 4) Remove Allen wrench from timing belt tensioner pulley. Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. See Fig. 15. Also check if spring tang is within tolerance window. See Fig. 16. If timing marks align and spring tang is within specication, go to next step. If timing marks do not align or if spring tang is not within specication, repeat step 3). 5) Install front timing belt cover. Install engine mount bracket and power steering pump. Install right engine mount and remove jack from under engine. Install and adjust upper and lower engine torque struts. See ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS. Install crankshaft damper, and tighten bolt to specication. See TORQUE SPECIFICATIONS. 6) Raise vehicle on hoist. Install right inner splash shield. Lower vehicle. Install accessory drive belts. Adjust drive belts to proper tension. 7) Connect scan tool to Data Link Connector (DLC), located under lower left edge of instrument panel. Turn ignition on. Perform cam/crank relearn procedure by accessing ENGINE diagnostics. Select MISCELLANEOUS, then select RELEARN CAM CRANK and follow directions on scan tool screen.

Courtesy of DaimlerChrysler Corp.

Fig. 12: Adjusting Crankshaft Sprocket For Timing Belt NOTE: Chrysler recommends replacing worn mechanical tensioners with updated hydraulic tensioner kits. Information is from Chrysler technical service bulletin 09-06-00; March 10, 2000. Removal (With Mechanical Tensioner) 1) Remove No. 1 spark plug. Using dial indicator, set No. 1 cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover and ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 5. 2) Disconnect negative cable from battery, and ground strap from engine mount bracket. Remove upper torque strut from front of engine. See Fig. 2. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 6. Remove crankshaft damper bolt, and use gear puller to remove crankshaft damper. See Fig. 7. Remove lower engine torque strut. See Fig. 2. 3) Lower vehicle and place a jack under engine. Raise jack enough to support engine weight. Remove right engine mount-to-engine mount bracket bolt. See Fig. 8. Lower engine enough with jack to remove lower engine mount bracket bolt. See Fig. 9. Raise engine with jack to allow engine-to-body clearance for engine bracket removal. Remove power steering pump with hoses attached, and secure out of way. Remove two remaining upper engine mount bracket bolts and remove engine mount bracket. See Fig. 9. Remove front timing belt cover bolts and remove front timing belt cover. See Fig. 14. 4) Install a 6-mm Allen wrench into hexagon opening of top plate tensioner pulley. Slowly rotate tensioner clockwise with 6-mm Allen wrench until there is enough slack in timing belt to allow removal. If reusing old timing belt, mark belt with arrow to indicate direction of rotation. See Fig. 13. Remove timing belt. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt.

Courtesy of DaimlerChrysler Corp.

Fig. 13: Identifying Mechanical Tensioner & Adjusting Timing Belt

138

CHRYSLER
2.0L 4-Cylinder VINs C & F 2000-04 (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 14: Exploded View Of Timing Belt & Components (With Mechanical Tensioner)

Courtesy of DaimlerChrysler Corp.

Fig. 16: Timing Belt Tension Verication

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 85 (115) Crankshaft Damper Bolt ........................................................................................ 100 (136) Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61) Engine Mount Through-Bolt .................................................................................... 87 (118) Engine Torque Strut Bolts ....................................................................................... 87 (118) Power Steering Pump Mounting Bolts ..................................................................... 40 (54) Timing Belt Tensioner Bolt (Hydraulic Tensioner) .................................................... 23 (31) Timing Belt Tensioner Bracket Bolt (Mechanical Tensioner) ................................... 23 (31) Timing Belt Tensioner Lock Nut (Mechanical Tensioner) ........................................ 22 (30) INCH Lbs. (N.m) Timing Belt Cover Bolts (M6) ................................................................................. 106 (12) Water Pump Mounting Bolts ................................................................................... 106 (12)

Fig. 15: Aligning Camshaft & Crankshaft Timing Marks

CHRYSLER
2.2L 4-Cylinder DOHC, VIN A
TIMING BELT APPLICATION Application 2.2L 4-Cyl. DOHC, Turbo III Daytona (Includes Canadian) 1992-93 .................................................... Spirit 1991-92 ....................................................
1

139

Labor Time

Belt Part No.

tensioner clockwise to obtain a tension of 110 lbs. (445 N.) for a new belt, or 70 lbs. (311 N.) for a used belt. Tighten timing belt tensioner center bolt to specication. See TORQUE SPECIFICATIONS. CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate crankshaft using camshaft or intermediate shaft bolt. 5) Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. 6) Recheck timing belt tension. Readjust, if necessary. Tighten rocker arm shafts to specication in specied sequence. See Fig. 1. See TORQUE SPECIFICATIONS. 7) Install valve covers, spark plugs and ignition wire covers. Install fresh air duct. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

2.6 Hours .. ..... T206 2.6 Hours .. ..... T206

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove PCV hose. Remove upper timing belt cover. Remove accessory drive belts. Rotate crankshaft so that cylinder No. 1 is at TDC of compression stroke. 2) Raise vehicle on hoist, and remove right wheel and inner splash shield. Remove water pump pulley. Remove crankshaft pulley bolts and remove pulley. It is NOT necessary to remove center bolt from the crankshaft. 3) Remove lower accessory drive belt idler pulley and tensioner pulley. Remove lower timing belt cover. Remove accessory drive belt idler pulley bracket. 4) Lower vehicle. Place oor jack under vehicle to support weight of engine and transaxle assembly. Remove right engine mount (timing belt end of engine). Note position and number of shims for reassembly reference. 5) Remove air cleaner fresh air duct. Remove ignition secondary wire cover from top of engine. Remove valve covers. 6) Loosen center bolt of timing belt tensioner pulley to relieve timing belt tension. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Check camshaft, crankshaft and intermediate shaft seals for leaks. Replace damaged components. Installation 1) Loosen rocker arm assembly bolts about 3 turns. See Fig. 1. Align and pin both camshafts with 3/32 drill bits or pins. See Fig. 2. Accessory drive shaft does not have to be timed. Remove spark plugs. 2) Install a dial indicator in No. 1 spark plug hole. Rotate crankshaft until No. 1 piston is at TDC. Mark engine block for TDC reference. 3) Install timing belt and idler pulley in correct sequence. See Fig. 2. Remove dial indicator from cylinder head. Remove drill bits or pins from camshaft sprockets. 4) Install a belt tension gauge on the timing belt. Install tension on the belt run between the 2 camshafts. Tension gauge must contact timing belt between the teeth to get an accurate reading. Rotate timing belt

Courtesy of DaimlerChrysler Corp.

Fig. 1: Identifying Rocker Arm Loosening & Tightening Sequence

140

CHRYSLER
2.2L 4-Cylinder DOHC, VIN A (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 65 (89) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 27 (31) Crankshaft Sprocket Center Bolt .................................................. .......................... 85 (115) Intermediate Shaft Bolt ............................................................................................. 65 (88) Right Engine Mount To-Engine Bracket Through-Bolt ......................................................................... 100 (136) To-Frame Rail Bolts ................................................................................................ 50 (68) Timing Belt Tensioner Bolt ........................................................................................ 45 (61) Water Pump Pulley Bolt ............................................................................................ 21 (28) Wheel Lug Nut ........................................................................................................ 95 (129) INCH Lbs. (N.m) Rocker Arm Shaft Bolts Step 1 .................................................................................................................... 106 (12) Step 2 .................................................................................................................... 210 (24)

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt

CHRYSLER
2.2L 4-Cylinder DOHC, VIN R
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

141

9) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

2.2L 4-Cyl. DOHC, Turbo TC (Maserati) 1990 .................................... 2.9 Hours ... .. TCK153 .. ..... T153 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Rotate crankshaft so that cylinder No. 1 is at TDC of compression stroke. Raise vehicle on hoist, and remove right inner splash shield. Remove accessory drive belts. 2) Remove water pump pulley. Remove crankshaft pulley bolts and remove pulley. It is NOT necessary to remove center bolt from the crankshaft. Lower vehicle. Remove upper and lower timing belt covers. 3) Place oor jack under vehicle to support weight of engine and transaxle assembly. Remove right engine mount (timing belt end of engine). Remove valve cover. 4) Loosen center bolt of timing belt tensioner pulley. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Check camshaft, crankshaft and intermediate shaft seals for leaks. Replace damaged components. Installation 1) Turn crankshaft and intermediate shaft until the alignment marks on the sprockets are aligned. See Figs. 1 and 4. The distributor rotor must be facing the No. 1 cylinder in the distributor cap. 2) Position pin punches in intake and exhaust camshaft alignment holes. See Fig. 2. Position both camshafts so that the 2 alignment holes in the exhaust and intake camshaft sprockets are below and adjacent to the centerline of the 2 sprockets. See Fig. 1. The 2 keyways not used must be positioned at the top, outside of the vertical centerline of the camshafts. 3) Turn crankshaft until the alignment mark on the sprocket is in line with the crankshaft and intermediate shaft centerline. 4) Turn the intermediate shaft until the marking on the sprocket (if there is one) is in line with the marking on the crankshaft sprocket. If there is no marking on the intermediate shaft sprocket, set timing hole on vertical line through center of the axis, upper side, 2 degrees clockwise. 5) Position timing belt on the crankshaft sprocket rst. Then, install timing belt on intermediate shaft sprocket by turning it slightly, if necessary. Repeat this procedure for the camshaft sprockets. 6) Remove the spark plugs. Remove the pin punches. Rotate crankshaft to TDC. Place Tension Tool (C-4703) on large hex nut in center of timing belt tensioner pulley. See Fig. 3. 7) Loosen tensioner pulley lock nut. Adjust tensioner tool index, if necessary, to position the axis within 15 degrees of horizontal. See Fig. 3. CAUTION: Do NOT rotate crankshaft counterclockwise or attempt to rotate the engine using the camshaft or intermediate shaft mounting bolt. 8) Rotate crankshaft clockwise from TDC 2 full revolutions back to TDC. Tighten the lock nut on the timing belt tensioner.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Camshaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Pin Punches In Camshafts

Courtesy of DaimlerChrysler Corp.

Fig. 3: Adjusting Timing Belt Tension

142

CHRYSLER
2.2L 4-Cylinder DOHC, VIN R (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Camshaft, Crankshaft & Intermediate Shafts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 60 (80) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 21 (28) Crankshaft Sprocket Center Bolt .............................................................................. 50 (68) Generator Drive Belt Idle Pulley Bolt ....................................................................... 40 (54) Intermediate Shaft Bolt ............................................................................................. 65 (88) Right Engine Mount To-Engine Bracket Through-Bolt ........................................................................... 75 (102) To-Frame Rail Bolts ................................................................................................ 21 (28) Timing Belt Tensioner Bolt ........................................................................................ 45 (61) INCH Lbs. (N.m) Water Pump Pulley Bolt .......................................................................................... 106 (12)

CHRYSLER
2.2L & 2.5L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No. TIMING BELT APPLICATION (Cont.) Application Labor Time

143

Component Belt Kit No. Part No.

2.2L 4-Cyl. SOHC Aries & Reliant 1981-88 ............................ ... 1 2.2 Hrs. 1989 ................................. ... 1 2.2 Hrs. Caravan, Town & Country & Voyager 1982-88 ............................ ... 1 2.2 Hrs. Caravelle, New Yorker & 600 1983-88 ............................ ... 1 2.2 Hrs. Charger & Turismo 1983-87 ............................ ... 1 2.2 Hrs. Dakota 1987-88 ............................ ... 2 1.1 Hrs. Daytona 1984-88 ............................ ... 1 2.2 Hrs. 1989-93 ............................ ... 1 2.2 Hrs. E Class 1983-84 ............................ ... 1 2.2 Hrs. Executive Limo (Canadian) 1986 ................................. ... 1 2.2 Hrs. Expo (Canadian) 1987-88 ............................ ... 1 2.2 Hrs. 1989 ................................. ... 1 2.2 Hrs. Horizon & Omni 1981-88 ............................ ... 1 2.2 Hrs. 1989-90 ............................ ... 1 2.2 Hrs. Lancer 1985-88 ............................ ... 1 2.2 Hrs. 1989 ................................. ... 1 2.2 Hrs. Laser 1984-86 ............................ ... 1 2.2 Hrs. LeBaron & LeBaron GTS 1982-88 ............................ ... 1 2.2 Hrs. 1989-90 ............................ ... 1 2.2 Hrs. Mini Ram Van 1984-87 ............................ ... 1 2.2 Hrs. New Yorker 1983-88 ............................ ... 1 2.2 Hrs. Rampage 1982-84 ............................ ... 1 2.2 Hrs. Scamp Pickup 1983 ................................. ... 1 2.2 Hrs. Shadow & Sundance 1987-88 ............................ ... 1 2.2 Hrs. 1989-94 ............................ ... 1 2.2 Hrs. TC3 1981-82 ............................ ... 1 2.2 Hrs. Turismo 1983-87 ............................ ... 1 2.2 Hrs. 024 1981-82 ............................ ... 1 2.2 Hrs. 400 1982-83 ............................ ... 1 2.2 Hrs. 600 1983-88 ............................ ... 1 2.2 Hrs. 2.5L 4-Cyl. SOHC Acclaim 1989-95 ............................ ... 1 2.2 Hrs. Aries, Lancer & Reliant 1986-87 ............................ ... 1 2.2 Hrs. 1988 ................................. ... 1 2.2 Hrs. 1989 ................................. ... 1 2.2 Hrs. Caravan, Town & Country & Voyager 1986 ................................. ... 1 2.2 Hrs. 1987 ................................. ... 1 2.2 Hrs. 1988 ................................. ... 1 2.2 Hrs. 1989-95 ............................ ... 1 2.2 Hrs. Caravelle & 600 1986-87 ............................ ... 1 2.2 Hrs. 1988 ................................. ... 1 2.2 Hrs.

... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153
1

Dakota 1989-95 ............................ ... Daytona 1986-87 ............................ ... 1988 ................................. ... 1989-93 ............................ ... Dynasty 1988 ................................. ... 1989-93 ............................ ... Lancer 1986-87 ............................ ... 1988 ................................. ... 1989 ................................. ... Laser 1986 ................................. ... LeBaron & LeBaron GTS 1986-87 ............................ ... 1988 ................................. ... 1989-94 ............................ ... Mini Ram Van 1987 ................................. ... 1988 ................................. ... New Yorker 1986-87 ............................ ... 1988 ................................. ... Shadow 1988 ................................. ... 1989-94 ............................ ... Spirit 1989-95 ............................ ... Sundance 1988 ................................. ... 1989-94 ............................ ...

1.1 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... .. TCK114 ........ T114 2.2 Hrs. ... ...... ..... ...... ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... ...... ..... ...... ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... ...... ..... ............ T114 2.2 Hrs. ... ...... ..... ...... ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... .. TCK114 ........ T114 2.2 Hrs. ... .. TCK114 ........ T114 2.2 Hrs. ... .. TCK132 .. ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... ...... ..... ............ T114 2.2 Hrs. ... .. TCK132 .. ..... T132 2.2 Hrs. ... .. TCK114 ........ T114 2.2 Hrs. ... ...... ..... ...... ..... T132 2.2 Hrs. ... ...... ..... ...... ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... .. TCK153 .. ..... T153 2.2 Hrs. ... .. TCK132 .. ..... T132 2.2 Hrs. ... .. TCK153 .. ..... T153

1 1 1

1 1

1 1 1

1 1 1

1 1

1 1

1 1

1 1

... .. TCK071 .. ..... T071


2

... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK153 .. ..... T153 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071 ... .. TCK071 .. ..... T071

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .5 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory drive belts. If necessary, remove alternator, mounting brackets, and A/C compressor (if equipped). DO NOT disconnect refrigerant lines. Remove A/C belt idler pulley. 2) Raise and support vehicle. Remove right inner splash shield. Remove water pump and crankshaft pulleys. Remove upper and lower timing belt covers. See Fig. 1. Support engine using a jack. NOTE: If timing belt is to be reused, mark direction of rotation for reassembly reference. 3) Remove right engine mount bolt, and raise engine slightly. Loosen the timing belt tensioner, and remove timing belt. See Fig. 2. Installation 1) Remove spark plugs. Place cylinder No. 1 on TDC. Align timing marks on crankshaft and intermediate shaft sprockets. See

... .. TCK153 .. ..... T153 ... .. TCK114 ........ T114 ... ...... ..... ...... ..... T132 ... .. TCK153 .. ..... T153 ... ...... ..... ............ ... .. TCK114 ........ ... .. TCK132 .. ..... ... .. TCK153 .. ..... T114 T114 T132 T153

... .. TCK114 ........ T114 ... .. TCK132 .. ..... T132

144

CHRYSLER
2.2L & 2.5L 4-Cylinder (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Crankshaft, Intermediate Shaft & Camshaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Timing Belt Covers

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bracket-To-Block Bolt ................................................................................................ 70 (95) Damper Weight .............................................................................. ................. 21-23 (28-30) Intermediate Shaft Sprocket Bolt .............................................................................. 65 (88) Timing Belt Tensioner Bolt ........................................................................................ 40 (54) INCH Lbs. (N.m) Balance Shaft Chain Guide Nut ............................................................................. 106 (12) Balance Shaft Chain Pivot & Tensioner Bolt ......................................................... 106 (12) Balance Shaft Cover Bolt ....................................................................................... 106 (12) Intermediate Shaft Retainer Bolt ............................................................................ 106 (12) Timing Belt Cover Bolt ................................................................................................ 44 (5) Valve Cover Bolt ..................................................................................................... 106 (12) Water Pump Pulley Bolt .......................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 2: Adjusting Timing Belt Tension Fig. 3. Rotate camshaft sprocket until 2 marked arrows on sprocket hub align with camshaft bearing cap-to-cylinder head parting line. Small hole in camshaft sprocket must be at 12 oclock relative to cylinder head line. See Fig. 4. 2) Install timing belt. Ensure timing belt is installed in original direction of rotation. Install Timing Belt Tensioner (C-4703) horizontally on large hex of belt tensioner pulley. Loosen tensioner lock nut (if necessary) to reset belt tensioner to within a 15-degree axis of horizontal position of tool. See Fig. 2. Tighten lock nut. CAUTION: DO NOT rotate crankshaft counterclockwise. DO NOT rotate engine using camshaft or intermediate shaft sprocket bolts. 3) Rotate crankshaft clockwise 2 complete revolutions to TDC. Tighten tensioner retaining bolt to specication while holding belt tensioner wrench in position. See TORQUE SPECIFICATIONS. Check all timing marks for proper alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

CHRYSLER
2.4L 4-Cylinder DOHC, VIN 1
TIMING BELT APPLICATION Application Labor Time Belt Part No.

145

2.4L 4-Cyl. DOHC, VIN 1 Liberty 2002-04 ..................................................... 1.1 Hours ... ..... T265 Wrangler 2003-04 ..................................................... 1.0 Hours ... ..... T265 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the timing belt be replaced every 120,000 miles for normal service, or every 90,000 miles for severe service.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Crankshaft Vibration Damper

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove air cleaner upper cover, housing, and clean air tube. Raise vehicle on hoist and remove accessory drive belts. Remove bolt and crankshaft vibration damper. See Fig. 1. Remove A/C-generator belt tensioner pulley assembly. See Fig. 2. 2) Remove lower timing belt cover bolts and remove cover. See Fig. 2. Lower vehicle. Remove upper timing belt cover bolts and remove cover. See Fig. 2. CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. 3) Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 3. NOTE: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. See Fig. 3. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 4) Install a 6-mm Allen wrench into timing belt tensioner. Insert long end of a 3-mm Allen wrench into pin hole in the front of tensioner. Slowly rotate tensioner counterclockwise with 6-mm Allen wrench while pushing lightly on the 3-mm Allen wrench until it slides into the locking hole. See Fig. 4. Remove timing belt. If necessary, remove crankshaft sprocket from crankshaft using Special Tool (6793) and Insert (C-4685-C2). Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. CAUTION: Ensure that arrows on both camshaft sprockets are facing up. See Fig. 5. CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool (6792) is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage. Installation 1) If necessary, install crankshaft sprocket to crankshaft using Special Tool (6792). Set crankshaft sprocket to TDC by aligning
Courtesy of DaimlerChrysler Corp.

Fig. 2: Identifying Upper & Lower Timing Belt Covers & Drive Belt Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks sprocket with arrow on oil pump housing. See Fig. 6. Also set camshaft timing marks so that exhaust camshaft sprocket is a 1/2 notch below intake camshaft sprocket. See Figs. 5 and 6.

146

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

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Camshaft Sprockets For Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 4: Locking Timing Belt Tensioner 2) Install timing belt. Starting at the crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets and then around tensioner. See Fig. 6. Move exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. See Fig. 6. Insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley, and rotate top plate counterclockwise. See Fig. 7. 3) Tensioner pulley will move against belt and tensioner setting notch will eventually start to move clockwise. Watching movement of setting notch, continue rotating top plate counterclockwise until setting notch is aligned with spring tang. See Fig. 7. Using Allen wrench to prevent top plate from moving, tighten tensioner lock nut to specication. See TORQUE SPECIFICATIONS. Setting notch and spring tang should remain aligned after lock nut is torqued. Remove Allen wrench and torque wrench from timing belt tensioner pulley. NOTE: Repositioning the crankshaft to the TDC position must be done only during the clockwise rotation movement. If TDC is missed, rotate crankshaft an additional 2 revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise. 4) Rotate crankshaft clockwise 2 revolutions, until crankshaft is repositioned to TDC. Check alignment of camshaft and crankshaft timing marks. See Fig. 3. If timing marks do not align, remove timing belt and realign timing marks. 5) Check if spring tang is within tolerance window. See Fig. 8. If spring tang is within tolerance window, installation process is complete and nothing further is required. If spring tang is not within tolerance window, repeat installation procedure from beginning. 6) Install upper and lower timing belt covers. Install A/C-generator belt tensioner pulley. See Fig. 2. Install crankshaft vibration damper. Install accessory drive belts. Install air cleaner upper cover, housing, and clean air tube. Connect negative battery cable.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Timing Belt

Courtesy of DaimlerChrysler Corp.

Fig. 7: Adjusting Timing Belt Tension

CHRYSLER
2.4L 4-Cylinder DOHC, VIN 1 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

147

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 74 (101) Crankshaft Vibration Damper Bolt ........................................................................ 105 (142) Drive Belt Tensioner Bracket Bolts ........................................................................... 30 (41) Drive Belt Tensioner Pulley Bolt ............................................................................... 45 (61) Timing Belt Idler Pulley Bolt ..................................................................................... 45 (61) Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61) Timing Belt Tensioner Lock Nut ............................................................................... 22 (30) INCH Lbs. (N.m) Timing Belt Cover Bolts .......................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Verifying Timing Belt Tension

148

CHRYSLER
2.4L 4-Cylinder DOHC, VIN B
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.4L 4-Cyl. DOHC, VIN B Caravan & Voyager 1996-00 ....................................................
1

2.0 Hours .. ..... T265

With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Raise vehicle on hoist and remove right front wheel. Remove right inner splash panel. Remove accessory drive belts. Remove crankshaft vibration damper. 2) Remove generator drive belt idler pulley. Remove lower timing belt cover. Lower vehicle, and remove upper timing belt cover. 3) Place oor jack under vehicle to support weight of engine and transaxle assembly. Remove purge duty solenoid and wiring harness from right engine mount bracket (timing belt end of engine). 4) Remove 2 right engine mount vertical bolts from frame rail. Remove the one horizontal fastener. DO NOT remove large nut from center bolt of insulator rubber. Remove horizontal and vertical fasteners from engine side of mount. Remove right engine mount assembly. Rotate crankshaft to align timing marks on camshafts and oil pump housing. See Fig. 1. CAUTION: Crankshaft sprocket mark must be located on trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth with oil pump housing mark will cause camshaft marks to be misaligned. 5) On 1996 models equipped with hydraulic tensioner, remove hydraulic tensioner bolts and remove tensioner. Place hydraulic tensioner in vise, and SLOWLY compress tensioner plunger. Align holes in tensioner body and plunger, and insert a pin through body and plunger to lock plunger in place. Skip next step. 6) On models with a mechanical timing belt tensioner, insert a 6-mm Allen wrench into tensioner. Insert long end of 3-mm Allen wrench into pin hole on front of tensioner. While rotating the tensioner counterclockwise, push in lightly on the 3-mm Allen wrench until it can be pushed into locking hole. See Fig. 2. 7) On all models, if reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components. NOTE: If timing belt tensioner needs to be replaced, camshaft sprockets and rear timing belt cover will need to be removed. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Set camshafts timing marks together by aligning notches on sprockets. Turn exhaust camshaft sprocket clockwise about 1/2 notch below intake camshaft sprocket. See Fig. 3. 2) Install timing belt starting at crankshaft, around water pump sprocket, idler pulley, camshafts sprockets and then around tensioner pulley. 3) Move exhaust camshaft counterclockwise to take out belt slack and align timing marks. See Fig. 1. 4) On 1996 models with hydraulic timing belt tensioner, install tensioner on engine block, but do NOT nal tighten bolts. See Fig. 4. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 2: Adjusting Timing Belt Tension (Mechanical) Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner against tensioner pulley bracket and nal tighten tensioner bolts. See TORQUE SPECIFICATIONS. Remove holding pin from tensioner. Timing belt tension is correct when pin can be removed and installed freely. Skip next step. 5) On models with mechanical timing belt tensioners, pull locking Allen wrench from timing belt tensioner. 6) On all models, rotate crankshaft 2 revolutions and check alignment of timing marks. If timing marks are not correct, reposition timing belt. 7) Install right engine mount support and support bracket. Install upper and lower timing belt covers. Install generator idler pulley. Install crankshaft vibration damper. 8) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

CHRYSLER
2.4L 4-Cylinder DOHC, VIN B (Cont.)

149

Courtesy of DaimlerChrysler Corp.

Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension (Hydraulic)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 75 (101) Crankshaft Vibration Damper ................................................................................ 105 (142) Engine Mount Bracket-To-Engine Bolts .................................................................... 45 (61) Generator Drive Belt Idle Pulley Bolt ....................................................................... 40 (54) Lower Timing Belt Tensioner Bracket Bolt ............................................................... 45 (61) Right Engine Mount Frame Rail Fasteners ............................................................................................. 50 (68) Horizontal Engine Fastener ........................................................ ........................ 111 (150) Vertical Engine Fastener ....................................................................................... 75 (102) Timing Belt Tensioner (Hydraulic) Mounting Bolt .......................................................................................................... 24 (28) Timing Belt Tensioner (Mechanical) Center Bolt .............................................................................................................. 24 (28) Timing Belt Tensioner Assembly Bolt ..................................................................... 45 (61) Wheel Lug Nut ...................................................................................................... 100 (135) INCH Lbs. (N.m) Timing Belt Cover Bolts M6 (Outer-To-Inner) ................................................................................................ 40 (4.5) M6 (Inner-To-Head) ............................................................................................... 105 (12) Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt Tensioner Assembly

150

CHRYSLER
2.4L 4-Cylinder DOHC, VIN X
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.4L 4-Cyl. DOHC, VIN X Breeze 1996-00 .................................................... Cirrus 1995-00 .................................................... Sebring Convertible 1996-99 .................................................... Stratus 1995-00 ....................................................
1

3.6 Hours .. ..... T265 3.6 Hours .. ..... T265 3.6 Hours .. ..... T265 3.6 Hours .. ..... T265

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Raise vehicle on hoist and remove right front wheel. Remove right inner splash panel. Remove accessory drive belts. Remove crankshaft vibration damper. 2) Remove generator drive belt idler pulley. Remove lower timing belt cover. 3) Remove right engine support assembly vertical bolts from bottom of frame rail (timing belt end of engine). 4) Lower vehicle. Remove upper timing belt cover. Place oor 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 edge of sprocket tooth. Failure to align trailing edge of sprocket tooth with oil pump housing mark will cause camshaft marks to be misaligned. 7) On models equipped with hydraulic tensioner, remove hydraulic tensioner bolts and remove tensioner. Place hydraulic tensioner in vise, and SLOWLY compress tensioner plunger. Align the holes in the tensioner body and plunger, and insert a pin through the body and plunger to lock the plunger in place. Skip next step. 8) On models with a mechanical timing belt tensioner, insert a 6-mm Allen wrench into tensioner. Insert long end of 3-mm Allen wrench into pin hole on front of tensioner. While rotating the tensioner counterclockwise, push in lightly on the 3-mm Allen wrench until it can be pushed into locking hole. See Fig. 2. 9) On all models, if reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 2: Adjusting Timing Belt Tension (Mechanical) Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Set camshafts timing marks together by aligning notches on sprockets. Turn exhaust camshaft sprocket clockwise about 1/2 notch below intake camshaft sprocket. See Fig. 3. 2) Install timing belt starting at crankshaft, around water pump sprocket, idler pulley, camshafts sprockets and then around tensioner pulley. 3) On models with hydraulic timing belt tensioner, install tensioner on engine block, but do NOT nal tighten bolts. See Fig. 4. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner against tensioner pulley bracket and nal tighten tensioner bolts. See TORQUE SPECIFICATIONS. Remove holding pin from tensioner. Timing belt tension is correct when pin can be removed and installed freely. Skip next step.

CHRYSLER
2.4L 4-Cylinder DOHC, VIN X (Cont.)
4) On models with mechanical timing belt tensioners, pull locking Allen wrench from timing belt tensioner. 5) On all models, rotate crankshaft 2 revolutions and check alignment of timing marks. If timing marks are not correct, reposition timing belt. 6) Install right engine mount and support bracket. Install upper and lower timing belt covers. Install generator idler pulley. Install crankshaft vibration damper. 7) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

151

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension (Hydraulic)


Courtesy of DaimlerChrysler Corp.

Fig. 3: Moving Exhaust Camshaft to 1/2 Notch Position

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 75 (101) Crankshaft Vibration Damper ................................................................................ 105 (142) Generator Drive Belt Idler Pulley Bolt ...................................................................... 40 (54) Right Engine Mount Frame Rail Vertical Fasteners ................................................................................ 45 (61) To-Engine Support Bracket ..................................................................................... 45 (61) Timing Belt Tensioner (Hydraulic) Mounting Bolt .......................................................................................................... 21 (28) Timing Belt Tensioner (Mechanical) Bracket Mounting Bolt ............................................................................................. 45 (61) Wheel Lug Nut ...................................................................................................... 100 (135) INCH Lbs. (N.m) Timing Belt Cover Bolts M6 (Outer-To-Inner) ................................................................................................ 40 (4.5) M6 (Inner-To-Head) ............................................................................................... 105 (12) Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt Tensioner Assembly

152

CHRYSLER
2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.4L 4-Cyl. DOHC, VINs B & S Neon 2003-04 ..................................................... 2.3 Hours ... ..... T265 PT Cruiser 2001-04 ..................................................... 3.6 Hours ... ..... T265 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 2001 PT Cruiser, normal replacement interval is at 120,000 miles or 96 months. For 2002 PT Cruiser, normal replacement interval is at 90,000 miles. For 2003-04 PT Cruiser, normal replacement interval is at 102,000 miles or 102 months (non-turbo) or 105,000 miles or 84 months (turbo), with a severe service replacement recommendation of 90,000 miles. For Neon, normal replacement interval is at 105,000 miles or 84 months, with a severe service replacement recommendation of 90,000 miles.
Courtesy of DaimlerChrysler Corp.

Fig. 1: Positioning Floor Jack

ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
NOTE: Whenever a torque strut bolt(s) is loosened, this procedure must be performed. Upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading. NOTE: To prevent minimal upward lifting of engine, oor 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 oor jack on the forward edge of transmission bellhousing. See Fig. 1. 2) With engine supported, remove upper and lower torque struts attachment bolt(s) at shock tower bracket and suspension crossmember. See Fig. 3. Verify that torque struts are free to move within shock tower bracket and crossmember. Reinstall torque strut bolt(s), but DO NOT tighten. 3) Carefully apply upward force, allowing upper engine to rotate rearward until distance between center of rearmost attaching stud on engine mount bracket (point A) and center of hole for washer hose clip on shock tower bracket (point B) is 4.7 (119 mm). See Fig. 4. 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 specication. See TORQUE SPECIFICATIONS. Install pencil strut, and tighten nuts to specication. Remove oor jack.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Pencil Strut

REMOVAL & INSTALLATION


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

Fig. 3: Removing Upper & Lower Engine Torque Struts 2) On all models, remove upper timing belt cover bolts and remove cover. See Fig. 6. Raise vehicle on hoist and remove right front wheel. Remove splash shield. See Fig. 7. Remove accessory drive belts. Remove crankshaft damper. See Fig. 8. Remove pencil strut. See Fig. 2. Remove lower engine torque strut. See Fig. 5.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove upper engine torque strut attaching bolts and remove engine torque strut. See Fig. 5. Remove engine torque strut bracket from strut tower. On PT Cruiser (Turbo), discharge and evacuate A/C system. Disconnect A/C lines at junction block near upper timing belt cover.

CHRYSLER

153

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Measuring Engine Position (Top View) 3) Disconnect exhaust system front pipe from manifold. Disconnect A/C pressure switch at rear of compressor housing. Lower vehicle and support engine with a jack. If not done previously, discharge and evacuate A/C system. Disconnect A/C lines at junction block. Remove screw attaching ground strap to strut bracket. Remove torque strut bracket from strut tower. Remove upper radiator closure panel. Without disconnecting lines from power steering pump, remove pump and bracket and set pump aside. 4) With engine properly supported, remove right engine mount throughbolt. See Fig. 5. Raise engine with jack until engine support bracket bolts are accessible, and remove engine support bracket. See Fig. 9. Remove lower timing belt cover bolts and remove cover. See Fig. 6. CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. 5) Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 10. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 6) Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 11. Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect rotating tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components as necessary. CAUTION: Ensure that arrows on both camshaft sprockets are facing up. Installation 1) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing. Also set camshaft timing marks so that exhaust camshaft sprocket is a 1/2 notch below intake camshaft sprocket. See Fig. 12
.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Locating Engine Mounting Components

Courtesy of DaimlerChrysler Corp.

Fig. 6: Removing Front Timing Belt Covers 2) Install timing belt. Starting at the crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets, and then around tensioner. See Fig. 10. Move exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. Insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley, and rotate top plate counterclockwise. See Fig. 11. 3) Tensioner pulley will move against belt and tensioner setting notch will eventually start to move clockwise. Watching movement of setting notch, continue rotating top plate counterclockwise until setting notch is aligned with spring tang. See Fig. 11. Using Allen wrench to prevent top plate from moving, tighten tensioner lock bolt to specication. See TORQUE SPECIFICATIONS. Setting notch and spring tang should remain aligned after lock bolt is torqued. Remove Allen wrench and torque wrench.

154

CHRYSLER

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Removing Right Front Splash Shield

Courtesy of DaimlerChrysler Corp.

Fig. 10: Identifying Camshaft & Crankshaft TDC & Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 8: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 11: Adjusting Timing Belt Tension NOTE: Repositioning the crankshaft to the TDC position must be done only during the clockwise rotation movement. If TDC is missed, rotate a further 2 revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise. 4) Rotate crankshaft clockwise two complete revolutions manually for seating of belt until crankshaft is repositioned at TDC position. Verify that camshaft and crankshaft timing marks are in proper position. See Fig. 10. 5) Check if spring tang is within tolerance window. See Fig. 13. If spring tang is within tolerance window, installation process is complete and nothing further is required. If spring tang is not within tolerance window, repeat installation procedure from beginning.

Courtesy of DaimlerChrysler Corp.

Fig. 9: Removing Engine Support Bracket

CHRYSLER
6) Install upper and lower timing belt covers, and tighten bolts to specication. See TORQUE SPECIFICATIONS. Install engine support bracket. Ensure power steering pump is properly located in mounting location on bracket and tighten mount bracket bolts to specication. See TORQUE SPECIFICATIONS. 7) Lower engine into mounting position and install right engine mount through-bolt. See Fig. 5. Install power steering pump and bracket. Install upper radiator closure panel. Install engine torque strut bracket to strut tower. Connect ground strap to bracket. Tighten all bolts to specication. See TORQUE SPECIFICATIONS. Install upper torque strut attaching bolts. See Fig. 5. 8) Connect A/C lines, evacuate and recharge system. Raise vehicle and connect exhaust system to manifold. Connect A/C pressure switch connector. Install crankshaft damper and accessory drive belts. Install lower torque strut. Perform torque strut adjustment. See ENGINE TORQUE STRUT ADJUSTMENT under ADJUSTMENTS. Install pencil strut. See Fig. 2. Install splash shield and install right front wheel. Tighten all bolts to specication. See TORQUE SPECIFICATIONS. Connect negative cable to battery.

155

2.4L 4-Cylinder DOHC, VINs B & S Neon & PT Cruiser (Cont.)


TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 85 (115) Crankshaft Vibration Damper ................................................................................ 100 (136) Engine Mount Through-Bolt (Right) .............................................. .......................... 87 (118) Engine Support Bracket Bolts ................................................................................... 45 (61) Engine Torque Strut Bolts ....................................................................................... 85 (115) Pencil Strut Nut ......................................................................................................... 43 (58) Power Steering Mounting Bracket ............................................................................ 40 (54) Timing Belt Idler Pulley ............................................................................................. 45 (61) Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61) Wheel Mounting Nuts ............................................................................................ 100 (136) INCH Lbs. (N.m) Timing Belt Cover Bolts .............................................................................................. 50 (6) Timing Belt Tensioner Lock Bolt ............................................................................. 220 (25)

Courtesy of DaimlerChrysler Corp.

Fig. 12: Identifying Camshaft Sprocket Alignment For Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 13: Verifying Timing Belt Tension

156

CHRYSLER
2.4L 4-Cylinder DOHC, VINs B & X Except Neon & PT Cruiser

TIMING BELT APPLICATION Application 2.4L 4-Cyl. DOHC, VINs B & X Caravan 2001-04 .................................................... Sebring Convertible & Sedan 2001-04 .................................................... Stratus Sedan 2001-04 .................................................... Voyager 2001-03 ....................................................
1

Labor Time

Belt Part No.

CAUTION: If timing belt was damaged due to incorrect tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly.

2.0 Hours .. ..... T265 3.6 Hours .. ..... T265 3.6 Hours .. ..... T265 2.0 Hours .. ..... T265

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the timing belt be replaced every 90,000 miles for Sebring and Stratus models, and every 120,000 miles for Caravan and Voyager (this maintenance is recommended by manufacturer, but is not required to maintain emission warranty).

REMOVAL & INSTALLATION


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

Fig. 1: Removing Timing Cover & Engine Support Bracket (Caravan & Voyager)

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove upper timing belt cover bolts and remove cover. See Fig. 1 or 2. Raise vehicle on hoist and remove right front wheel. Remove splash shield. Remove accessory drive belts. Remove crankshaft damper. See Fig. 3. 2) Remove A/C-generator belt tensioner and pulley assembly. See Fig. 4. Remove generator and bracket. Remove lower timing belt cover bolts and remove cover. See Fig. 1 or 2. On Sebring and Stratus, remove coolant recovery bottle. 3) With engine properly supported, remove right engine mount. Raise engine with jack until engine support bracket bolts are accessible. Remove engine support bracket bolts and then engine bracket. See Fig. 1 or 2. CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. 4) Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 5. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. See Fig. 5. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 5) Loosen timing belt tensioner lock bolt and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 6. Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.
Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing Timing Belt Cover & Engine Support Bracket (Sebring & Stratus) Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components as necessary.

CHRYSLER
2.4L 4-Cylinder DOHC, VINs B & X Except Neon & PT Cruiser (Cont.)

157

Courtesy of DaimlerChrysler Corp.

Fig. 3: Removing Crankshaft Damper

Courtesy of DaimlerChrysler Corp.

Fig. 6: Adjusting Timing Belt Tension CAUTION: Ensure that arrows on both camshaft sprockets are facing up. Installation 1) Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing. Also set camshaft timing marks so that exhaust camshaft sprocket is a 1/2 notch below intake camshaft sprocket. See Fig. 7. 2) Install timing belt. Starting at the crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets, and then around tensioner. See Fig. 8. Move exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. Insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley, and rotate top plate counterclockwise. See Fig. 6. 3) Tensioner pulley will move against belt and tensioner setting notch will eventually start to move clockwise. Watching movement of setting notch, continue rotating top plate counterclockwise until setting notch is aligned with spring tang. See Fig. 6. Using Allen wrench to prevent top plate from moving, tighten tensioner lock bolt to specication. See TORQUE SPECIFICATIONS. Setting notch and spring tang should remain aligned after lock bolt is torqued. Remove Allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the clockwise rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise. 4) Rotate crankshaft clockwise two complete revolutions manually for seating of belt until crankshaft is repositioned at TDC position. Verify that camshaft and crankshaft timing marks are in proper position. See Fig. 5. 5) Check if spring tang is within tolerance window. See Fig. 9. If spring tang is within tolerance window, installation process is complete and nothing further is required. If spring tang is not within tolerance window, repeat installation procedure from beginning. 6) Install engine support bracket. Install upper and lower timing belt covers. See Fig. 1 or 2. Install generator and bracket. Install A/C-generator belt tensioner. See Fig. 4. Install crankshaft damper. Install right engine mount. On Sebring and Stratus, install coolant recovery bottle. On all models, install accessory drive belts. Install splash shield and right front wheel. Connect negative battery cable.

Courtesy of DaimlerChrysler Corp.

Fig. 4: Removing Drive Belt Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 5: Identifying Crankshaft & Camshaft Timing Marks

158

CHRYSLER
2.4L 4-Cylinder DOHC, VINs B & X Except Neon & PT Cruiser (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 7: Identifying Camshaft Sprocket Alignment For Timing Belt Installation

Courtesy of DaimlerChrysler Corp.

Fig. 9: Timing Belt Tension Verication

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 85 (115) Crankshaft Damper Bolt ........................................................................................ 100 (136) Drive Belt Tensioner Bolt .......................................................................................... 40 (54) Engine Mount Bracket Bolts ..................................................................................... 45 (61) Right Engine Mount Bolt ........................................................................................... 45 (61) Timing Belt Idler Pulley Bolt ..................................................................................... 45 (61) Timing Belt Tensioner Assembly Bolts ..................................................................... 45 (61) INCH Lbs. (N.m) Timing Belt Cover Bolts .............................................................................................. 50 (6) Timing Belt Tensioner Bolt ...................................................................................... 220 (25)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Identifying Camshaft & Crankshaft TDC & Timing Marks

CHRYSLER
2.4L 4-Cylinder SOHC, VIN G
TIMING BELT APPLICATION Application Labor Time Belt Part No.

159

2.4L 4-Cyl. SOHC Sebring Coupe & Stratus Coupe 2001-04 Balance Shaft ...................................... .......... 1 .......... ..... T168 Camshaft ............................................... 1 2.4 Hours .. ..... T232
1

Balance shaft belt labor time included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 2001-02 vehicles, manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Connecticut. In California, Massachusetts and Connecticut, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2003-2004 vehicles, manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts, Maine and Vermont. In California, Massachusetts, Maine and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Support weight of engine with oor jack. Move coolant reservoir bottle out of way, and remove upper engine mount located near timing belt cover. 2) Remove all accessory drive belts. Remove water pump pulley. See Fig. 1. 3) Remove crankshaft pulley. Noting bolt lengths and locations, remove upper and lower timing belt cover with gasket. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing. 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 xing bolt. CAUTION: If timing belt is to be re-used, use chalk to mark (on at side) an arrow indicating the clockwise direction. 5) Move tension pulley to water pump side, and then remove timing belt. 6) Use crankshaft pulley mounting bolt to hold Special Tool (MB991367). Loosen crankshaft sprocket mounting bolt, and remove sprocket. See Fig. 2. 7) If reusing old balance shaft belt, mark belt with arrow to indicate rotation direction. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft belt. Inspection 1) Inspect back of belt for being hard, non-elastic and having a glossy surface. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking and rubber from canvas also indicates that belt warrants replacement. Cracks are most evident at base of tooth.
Courtesy of DaimlerChrysler Corp. Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Crankshaft Sprocket & Sensing Blade 2) Check timing belt and balance shaft belt tensioner pulleys for worn bearings. Replace as necessary. 3) Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto tensioner. See Fig. 3.

Fig. 3: Inspecting Timing Belt Auto Tensioner Installation 1) Align crankshaft rear sprocket (sprocket B) and balance shaft sprocket timing marks. See Fig. 5. Install balance shaft belt. If reusing old belt, install in original direction of rotation. Ensure that there is no slack in the belt.

160

CHRYSLER
2.4L 4-Cylinder SOHC, VIN G (Cont.)

2) To prevent the crankshaft bolt from loosening, degrease or clean seating surfaces of crankshaft, crankshaft sprocket B, crankshaft sensing blade and crankshaft. See Fig. 2. Install crankshaft front sprocket. Apply engine oil to threads and seat of crankshaft sprocket bolt. Install and tighten bolt to specication while holding crankshaft stationary. See TORQUE SPECIFICATIONS. 3) Move the balance shaft tensioner pulley so that the center of the tensioner pulley is above and to the left of the centerline of the tensioner center bolt. See Fig. 6. The tensioner pulley ange 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 nger in direction of arrow, apply pressure on timing belt so tension side of belt is taut. Now tighten bolt to x the tensioner. See TORQUE SPECIFICATIONS. To ensure tension is correct, depress belt with a nger. Adjust belt tension is not within specication, 0.2-0.3 (5-7 mm). See Fig. 6. 5) Apply 22-44 lbs. force to pushrod of auto-tensioner by pressing it against a metal object (such as the engine block) and measure the movement of the pushrod. See Fig. 3. If outside standard value, replace auto-tensioner. 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 xing bolt make sure that tension pulley does not turn with bolt. 10) Loosen tension pulley xing bolt, and then use Special Tool (MD998767) and a torque wrench to tighten xing bolt to specications. Tighten bolt to 32-40 ft. lbs. (42-54 N.m). Timing belt tension torque should be 31 INCH lbs. (3.5 N.m). See Fig. 7. 11) Remove set pin that has been inserted into the auto-tensioner. 12) Turn crankshaft 2 revolutions clockwise so that the timing marks are aligned. After leaving it for 15 minutes, measure amount of protrusion of auto-tensioner. Standard value 0.15-0.18 (3.8-4.5 mm). 13) If amount of protrusion is outside the standard value, repeat steps 9)-12). 14) Check again to be sure that timing marks of each sprocket are aligned. 15) Install timing belt covers. To complete installation, reverse removal procedures.
Courtesy of DaimlerChrysler Corp.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Front Timing Belt Marks

Fig. 5: Aligning Balance Shaft Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 6: Adjusting Balance Shaft Timing Belt Tensioner

CHRYSLER
2.4L 4-Cylinder SOHC, VIN G (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

161

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Adjusting Timing Belt Tension

Application Ft. Lbs. (N.m) Auto Tensioner Bolt ....................................................................... ................. 14-20 (20-26) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98) Crankshaft Drive Belt Pulley Bolt ................................................. ................. 14-22 (20-29) Crankshaft Sprocket Center Bolt .................................................. ........... 1 80-94 (109-127) Drive Belt Tensioner Pulley Bracket Bolt ..................................... ................. 14-18 (20-25) Engine Upper Mount Mount-To-Body Through-Bolt ...................................................... ............... 2 51-69 (69-93) Mount-To-Engine Bracket Nut/Bolt .............................................. ................. 56-72 (74-98) Tensioner Pulley Center Bolt Balance Shaft Belt Pulley ........................................................... ................. 12-16 (16-22) Camshaft Belt Pulley ................................................................... ................. 32-40 (42-54) INCH Lbs. (N.m) Timing Belt Cover Bolt Lower Cover Bolts ...................................................................................... 80-97 (9.04-11) Upper Cover Bolts ....................................................................... ............. 104-130 (13-15) Water Pump Pulley Bolt ................................................................ ................ 69-81 (8-9.15)
1 2

Apply engine oil to bolt threads. Final tighten bolt with weight of engine on mount.

Courtesy of DaimlerChrysler Corp.

Fig. 8: Holding Balance Shaft In Stationary Position

162

CHRYSLER
2.5L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 2.5L V6 Avenger & Sebring Coupe 1995-00 .............................. Cirrus & Stratus 1995-00 .............................. Sebring Convertible 1996-00 ..............................
1

4.8 Hours .. .. TCK259 .. ..... T259 4.8 Hours .. .. TCK259 .. ..... T259 4.8 Hours .. .. TCK259 .. ..... T259

With Air Conditioning add .2 hours. With Power Steering, add .2 hours.
Courtesy of DaimlerChrysler Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Setting Crankshaft Sprocket

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals, except in California, Connecticut, and Massachusetts. In these states, inspect belt at 60,000 miles and replace if necessary. If not replaced at 60,000 miles, replace at 100,000 miles.

REMOVAL & INSTALLATION


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

Fig. 2: Aligning Camshaft Sprockets

TIMING BELT
Removal (Avenger & Sebring Coupe) 1) Disconnect negative battery cable. Remove coolant reservoir bottle. On models with cruise control, remove cruise control actuator and set aside. 2) On all models, raise and support vehicle. Remove right front wheel. Remove side panel from right wheelwell. 3) Remove accessory drive belts. Remove generator and bracket from engine block, and set aside. Remove crankshaft vibration damper. 4) Lower vehicle. Place oor jack under vehicle to support weight of engine and transaxle assembly. Remove engine mount-to-frame through-bolt. Remove engine mount-to-engine bracket nuts and bolt. Remove engine mount. 5) Remove 3 bolts attaching engine support bracket to engine block. Top reamer bolt may be heat seized on engine support bracket. Spray lubricant on bolt while removing. NOTE: Reamer bolt head will have a R marking for identication. 6) Remove power steering pump (hoses attached) and bracket from engine block, and set aside. Remove timing belt covers. 7) Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 1 and 2. 8) If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt tensioner pulley bolt. Remove timing belt. Remove automatic tensioner. CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. NOTE: When automatic tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Removal (Cirrus, Sebring Convertible & Stratus) 1) Disconnect negative battery cable from jumper terminal. Raise and support vehicle. Remove right front wheel. Remove accessory drive belt splash shield from right wheelwell.

2) Remove accessory drive belts. Remove right engine support assembly vertical bolts from bottom side of frame rail (timing belt end of engine). 3) Lower vehicle. Place oor jack under vehicle to support weight of engine and transaxle assembly. Remove 3 bolts attaching engine support assembly to engine block bracket. 4) Move the A/C drier aside with hoses attached. Remove coolant reservoir tank. Remove right engine support assembly. Remove 3 bolts attaching engine support bracket to engine block, and remove bracket. 5) Remove crankshaft vibration damper. Remove power steering pump (hoses attached) and bracket from engine block. Remove timing belt covers. 6) Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 1 and 2. 7) If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt automatic tensioner bolts. Remove timing belt. Remove automatic tensioner. CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. NOTE: When automatic tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Installation (All Models) 1) Place automatic tensioner into vise, and SLOWLY compress plunger. When plunger is compressed into tensioner body, install locking pin through body and plunger holes to retain plunger until tensioner is installed. See Fig. 3. 2) Index tensioner in vise the same direction as installed. This will ensure proper pin orientation when tensioner is installed in engine. See Fig. 3. 3) Set crankshaft mark with timing mark on oil pump housing, then back off 3 notches before TDC. See Fig. 1. Set camshaft sprockets by aligning timing marks on sprockets with marks on rear timing belt cover. See Fig. 2.

CHRYSLER
2.5L V6 (Cont.)
NOTE: If reusing old timing belt, install in original direction of rotation. 4) Install timing belt on right (next to rewall) camshaft sprocket rst. Install a spring clip to keep belt in position. Keeping belt taught, install belt under water pump pulley and then around front camshaft sprocket. Install spring clip on front sprocket and belt. 5) Rotate crankshaft clockwise to TDC. Continue routing belt around idler pulley, crankshaft sprocket, and tensioner pulley. Apply rotating force to crankshaft sprocket in clockwise direction to tension belt. Ensure all timing marks are still aligned. 6) Loosen tensioner pulley center bolt. Position tensioner pulley with pin holes facing down. Install Adapter (MD998767) or equivalent, and torque wrench, to tensioner pulley. See Fig. 4. Apply 39 INCH lbs. (4.4 N.m) in a counterclockwise direction to tensioner. Tighten tensioner bolt to specication, without letting tensioner pulley rotate. 7) With torque being applied to tensioner pulley, install automatic tensioner (with locking pin in place) to tensioner pulley bracket. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Pull tensioner plunger locking pin. 8) Rotate crankshaft 2 revolutions clockwise, and check alignment of timing marks. Install tensioner locking pin into automatic tensioner. Pin should slide in and out with no resistance. Even if locking pin cannot be easily inserted, belt tension is okay if automatic tensioner plunger projection is within .149-.177 (3.8-4.5 mm). Projection is measured between top edge of automatic tensioner housing and arm of tensioner pulley bracket. Retension timing belt, if necessary. 9) Install timing belt covers. Install crankshaft vibration damper. Tighten crankshaft damper bolt to specication. See TORQUE SPECIFICATIONS. NOTE: Reamer bolt head will have a R marking for identication. 10) Install engine mount bracket. On Avenger and Sebring Coupe, when installing engine support bracket to engine block, tighten top reamer bolt slowly while spraying it with lubricant. Attach engine mount so arrow on side plate points toward engine. 11) On all models, reverse removal procedure to complete installation. Adjust drive belts to proper tension.

163

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Vibration Damper Bolt ........................................................................ 134 (182) Engine Mount Bracket-To-Engine Block Cirrus, Sebring Convertible & Stratus .................................................................... 33 (45) Engine Mount-To-Engine Support Bracket Bolt/Nut Avenger & Sebring Coupe ...................................................................................... 64 (86) Engine Mount-To-Frame Through-Bolt Avenger & Sebring Coupe .......................................................................... 72-87 (98-118) Engine Support Assembly-To-Engine Mount Bracket Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74) Cirrus, Sebring Convertible & Stratus .................................................................... 45 (61) Engine Support Assembly-To-Frame Rail Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74) Cirrus, Sebring Convertible & Stratus .................................................................... 45 (61) Engine Support Bracket-To-Engine Block Bolt Avenger & Sebring Coupe .......................................................... ................. 47-54 (64-74) Generator Mount Bracket-To-Engine Block Avenger & Sebring Coupe ...................................................................................... 30 (41) Power Steering Pump Bracket-To-Engine Bolts Avenger & Sebring Coupe ...................................................................................... 16 (22) Cirrus, Sebring Convertible & Stratus .................................................................... 40 (54) Timing Belt Idler Pulley Bolt ..................................................................................... 32 (44) Timing Belt Tensioner Pivot Arm Bolt ....................................................................... 33 (45) Timing Belt Tensioner Pulley Bolt ............................................................................. 35 (48) Timing Belt Tensioner-To-Engine Bolt ...................................................................... 17 (23) Water Pump Bolt ....................................................................................................... 18 (24) Wheel Lug Nut Avenger & Sebring Coupe .......................................................... ............... 65-80 (88-108) Cirrus, Sebring Convertible & Stratus ................................................................ 100 (135) INCH Lbs. (N.m) Timing Belt Cover Bolts ................................................................ ............... 89-106 (10-12)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Compressing Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 4: Tensioning Timing Belt

164

CHRYSLER
3.0L V6 SOHC 1987-00
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

3.0L V6 Acclaim & Spirit 1989-95 ............................... 3.5 Hours ... .. Caravan, Mini Ram Van & Voyager 1987-00 .............................. 1 4.0 Hours .. .. Daytona (Includes Canadian) 1990-93 ............................... 3.5 Hours ... .. Dynasty (Includes Canadian) 1988-93 ............................... 3.5 Hours ... .. LeBaron 1990-95 .............................. 1 3.5 Hours .. .. New Yorker 1988-89 ............................... 3.5 Hours ... .. Raider 1989 ................................... 2 3.5 Hours .. .. Ram 50 1990-91 ............................... 3.5 Hours ... .. Shadow & Sundance 1992-94 ............................... 3.5 Hours ... .. Stealth 1991-96 ............................... 2.0 Hours ... .. TC Maserati 1990-91 ............................... 3.5 Hours ... ..
1

TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139 TCK139 .. ..... T139
Courtesy of DaimlerChrysler Corp.

Fig. 1: Locating Timing Belt & Sprockets 2) Raise and support vehicle. Remove right inner fender shield. Remove crankshaft pulleys and vibration damper. Lower vehicle. Support engine with oor jack. Separate right (timing belt side) engine mount from engine mount bracket located in front of timing belt cover. 3) Slightly raise engine. Remove engine mount bracket. Remove timing belt covers, noting bolt length for installation reference. Rotate engine and align timing marks on camshaft sprockets and crankshaft sprocket. See Fig. 1. If reusing timing belt, mark direction of timing belt rotation for installation reference. 4) Loosen timing belt tensioner bolt. Move timing belt tensioner away from timing belt. Remove timing belt. Note direction of ange installation on front of crankshaft, in front of crankshaft sprocket. Remove ange and crankshaft sprocket from crankshaft (if necessary). 5) If removing camshaft sprocket, hold camshaft by engaging Camshaft Sprocket Holder (MB990775) in the holes on front of camshaft sprocket. Remove camshaft sprocket bolt and washer. Remove camshaft sprocket. Caravan & Voyager 1) Raise vehicle. Remove accessory drive belt splash shield. Remove accessory drive belts. Remove crankshaft pulleys and vibration damper. 2) Lower vehicle. Support engine weight with oor jack. Remove purge duty solenoid and wiring harness from right engine mount bracket. 3) Remove 2 right engine mount insulator vertical bolts Remove the one horizontal fastener. DO NOT remove large nut from center bolt of insulator rubber. Remove horizontal and vertical fasteners from engine side of mount. Remove engine mount. 4) Remove engine support bracket from front of engine. Remove timing belt covers, noting bolt length for installation reference. Note direction of ange installation on front of crankshaft, in front of crankshaft sprocket. Remove ange. 5) Rotate crankshaft, and align timing marks on camshaft sprockets and crankshaft sprocket. See Fig. 1. If reusing timing belt, mark direction of timing belt rotation for installation reference. 6) Loosen timing belt tensioner bolt. Move timing belt tensioner away from timing belt, and temporarily tighten bolt. Remove timing belt. Raider & Ram 50 1) Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose. Remove upper radiator shroud. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove power steering pump with pressure and return hoses connected, and set aside. 2) Remove power steering pump brackets. Remove A/C tensioner pulley and mounting bracket. Remove A/C compressor (with hoses connected) and mounting bracket. Remove cooling fan bracket assembly. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 2.

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .7 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Up to 1993 model year, the manufacturer recommends the timing belt be replaced at 60,000. For 1994-96 model years, the manufacturer recommends the timing belt be replaced at 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles. Replace the timing belt at 100,000 miles, unless previously changed. For 1997-00 model years, the manufacturer recommends the belt be inspected at 60,000, and replaced if necessary. Inspect belt at 90,000 miles, and replace if necessary. This maintenance is NOT required if belt was replaced at 60,000. Inspect belt at 120,000 miles, and replace if necessary. This maintenance is NOT required if belt was replaced at 90,000 miles.

REMOVAL & INSTALLATION


TIMING BELT REMOVAL
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker, Shadow, Spirit & Sundance (1987-89) 1) Disconnect negative battery cable. Support engine and transmission with oor jack. Remove front engine mount bracket. Remove upper (front outer) timing belt cover. Align timing marks on front and rear camshaft sprockets and timing mark on crankshaft sprocket. See Fig. 1. 2) Remove crankshaft pulleys and vibration damper. Loosen timing belt tensioner bolt and remove timing belt. Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance & TC (1990-96) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove A/C compressor and power steering pump with hoses attached, and secure aside (if equipped). Remove A/C compressor mounting bracket and drive belt tensioner. Remove power steering/ alternator belt tensioner.

CHRYSLER
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 ange. 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.

165

Courtesy of DaimlerChrysler Corp.

Fig. 3: Identifying Engine Support Bracket (Stealth)

TIMING BELT INSTALLATION


Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker, Shadow, Spirit & Sundance (1987-89) 1) Install belt tensioner and tensioner spring. Install tensioner spring between water pump retaining pin and tensioner bracket with hook of spring facing outward. Turn tensioner full counterclockwise in adjustment slot, and tighten temporarily to hold tensioner in position. 2) Install timing belt on crankshaft sprocket rst 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 nally 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 ange. Loosen tensioner from temporary position, and allow it to apply tension to timing belt. Turn crankshaft 2 full turns in a clockwise direction ONLY. NOTE: Turn crankshaft smoothly and ONLY in a clockwise direction.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt & Components (Raider & Ram 50) Stealth 1) Remove lower splash shields. Remove cruise control actuator (if equipped). Remove all drive belts. Unplug electrical connector at power steering pump. Remove A/C tensioner pulley and mounting bracket. 2) Remove power steering pump, leaving hoses connected, and wire aside. Support engine. Remove front engine mount through-bolt and front engine mount. NOTE: Apply spray lubricant on reamer bolt during removal, as bolt is sometimes seized in engine support bracket. 3) Remove engine support bracket bolts in proper sequence. See Fig. 3. Remove engine support bracket. Remove timing cover cap, timing belt cover, and gaskets. Using Holder (MB990767) and Adapter Bolts (MD998719), remove crankshaft pulley. 4) Remove lower timing belt cover, gaskets, and ange. Rotate crankshaft to align all timing marks. See Fig. 1. Loosen belt tensioner bolt. Rotate belt tensioner counterclockwise to relieve belt tension. 5) If reusing timing belt, place arrow on belt to indicate belt running direction. Remove timing belt and belt tensioner.

4) Again line up all timing marks and tighten tensioner against belt. Tighten tensioner locking bolt to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. CAUTION: When reusing timing belt, ensure timing belt is installed in original direction of rotation. Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance & TC (1990-96) 1) Rotate timing belt tensioner counterclockwise and temporarily tighten bolt. Ensure all timing marks are aligned. See Fig. 1. Install timing belt on crankshaft sprocket while holding timing belt tight on tension side. If reusing timing belt, ensure timing belt is installed in original direction of rotation. 2) Install timing belt on front (radiator side) camshaft sprocket, water pump pulley, rear camshaft sprocket and then on timing belt tensioner. Ensure timing belt is installed in this order. 3) Apply rotating force on front (radiator side) camshaft sprocket in opposite direction to apply pressure on tension side of timing belt. Ensure all timing marks align. See Fig. 1. 4) Install ange on front of crankshaft sprocket (if removed) with at side against timing belt and offset side toward front of crankshaft. Loosen timing belt tensioner bolt, allowing spring tension to be applied on timing belt tensioner and timing belt. 5) Rotate crankshaft clockwise 2 full revolutions. DO NOT rotate crankshaft counterclockwise. Realign all timing marks. Tighten timing belt tensioner bolt to specication. See TORQUE SPECIFICATIONS. 6) To install remaining components, reverse removal procedure. Ensure timing belt cover bolts are installed in original location. See Fig. 4. Tighten bolts to specication. Adjust drive belts to proper tension. Caravan & Voyager 1) If timing belt tensioner spring was removed, install spring on tensioner arm with end of hook facing out (away from engine).

TIMING BELT INSPECTION


Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner for smooth rotation. Replace if defective.

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 specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Identifying Timing Belt Cover Bolt Lengths (Raider & Ram 50)
Courtesy of DaimlerChrysler Corp.

Fig. 4: Identifying Timing Belt Cover Bolt Lengths (Except Raider, Ram 50 & Stealth) 2) Ensure all timing marks are aligned. See Fig. 1. Install timing belt on crankshaft sprocket while holding timing belt tight on tension side. See Fig. 1. If reusing timing belt, ensure timing belt is installed in original direction of rotation. 3) Install timing belt on front (radiator side) camshaft sprocket, water pump pulley, rear camshaft sprocket and then on timing belt tensioner. Ensure timing belt is installed in this order and there is no slack in belt. 4) Install ange on front of crankshaft sprocket with at side against timing belt and offset side toward front of crankshaft. Loosen timing belt tensioner bolt, allowing spring tension to be applied on timing belt tensioner and timing belt. 5) Slowly rotate crankshaft clockwise 2 full revolutions. DO NOT rotate crankshaft counterclockwise. Realign all timing marks. Tighten timing belt tensioner bolt to specication. See TORQUE SPECIFICATIONS. 6) Install timing belt covers. Ensure bolts are installed in original locations. See Fig. 4. Install engine support bracket. Install right side engine mount. Install crankshaft vibration damper. 7) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. NOTE: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt. Raider & Ram 50 1) Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. 2) Rotate belt tensioner counterclockwise as far as possible, and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1. 3) Install timing belt on crankshaft sprocket and then left camshaft sprocket with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft sprocket and tensioner. Remove any slack from belt by rotating left and then right camshaft sprockets counterclockwise. Ensure all timing marks are aligned. Install ange on crankshaft. Loosen belt tensioner bolts slightly and allow tensioner to apply belt tension. 4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner.

Stealth 1) Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner, with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible. Temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1. 2) Install timing belt onto crankshaft sprocket, rear cylinder bank camshaft sprocket, water pump pulley, front cylinder bank camshaft sprocket, and timing belt tensioner. Ensure belt is installed in original direction of rotation, and all timing marks are aligned. Install ange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. 3) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner. NOTE: Engine support bracket reamer bolt must be tightened slowly. Apply lubricant onto bolt during installation. 4) Belt tension should be 44-66 lbs. (20-30 kg). To install remaining components, reverse removal procedure. Install bolts into proper holes. Install covers and engine support bracket. See Figs. 3 and 6. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Identifying Timing Belt Cover Bolt Lengths (Stealth)

CHRYSLER
3.0L V6 SOHC 1987-00 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 & STEALTH) Application Ft. Lbs. (N.m) A/C Compressor Drive Belt Idler Pulley Bolt ........................................................... 40 (54) Camshaft Sprocket Bolt ............................................................................................ 70 (95) Crankshaft Vibration Damper Bolt ........................................................................ 100 (135) Engine Bracket-To-Engine Bolt ................................................................................. 35 (47) Engine Mount-To-Frame Bolt .................................................................................... 50 (68) Engine Mount Vertical Bolt ..................................................................................... 75 (102) Timing Belt Cover Bolt .............................................................................................. 10 (14) Timing Belt Tensioner Pulley Bolt ................................................. ................. 18-21 (25-28) Water Pump Bolts ..................................................................................................... 20 (27) TORQUE SPECIFICATIONS (RAIDER & RAM 50) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt Pickup .......................................................................................... ......... 130-137 (176-186) Raider .................................................................................................... 108-116 (146-157) Left Engine Support Bracket Bolt ................................................. ................. 15-21 (20-30) Rear Engine Support Bracket Bolt ............................................... ................. 13-18 (18-25) Right Engine Support Bracket Bolt 10 X 22 mm ................................................................................ ................. 25-36 (34-49) 10 X 40 mm ................................................................................ ................. 25-36 (34-49) 12 X 22 mm & 12 X 32 mm ...................................................... ................. 47-61 (64-83) Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29) Water Pump Bolt ........................................................................... ................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12) TORQUE SPECIFICATIONS (STEALTH)

167

Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .......................................................................................... 17 (23) Camshaft Sprocket Bolt ............................................................................................ 66 (90) Crankshaft Pulley Bolt 1991 ....................................................................................................... 108-116 (146-157) 1992-94 ................................................................................................................ 136 (185) Engine Support Bracket Bolt 10 X 40 mm ................................................................................ ................. 47-54 (64-73) 10 X 40 mm .............................................................................................. 76-83 (103-113) Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42) Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49) Water Pump Bolt ....................................................................................................... 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)

168

CHRYSLER
3.0L V6 SOHC, 2001-04
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

3.0L V6 SOHC Sebring Coupe & Stratus Coupe 2001-04 ..................................................... 2.6 Hours ... ..... T259 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 2001-02 vehicles, manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Connecticut. In California, Massachusetts and Connecticut, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2003-04 vehicles, manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts, Maine and Vermont. In California, Massachusetts, Maine and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove generator and A/C compressor drive belt. Remove dipstick tube from front of engine. Remove generator with wires attached, and secure out of way. Remove power steering pump drive belt and tensioner pulley. 2) Support weight of engine with jack. Remove engine mount from timing belt end of engine. Remove engine mount bracket from engine block. 3) Using End Yoke Holder (MB990767) and Crankshaft Pulley Holder Pin (MD998715), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley. 4) Remove upper and lower timing belt covers. See Fig. 1. Remove engine support bracket from front of engine.
Courtesy of Mitsubishi Motor Sales of America.

CAUTION: Do not turn crankshaft counterclockwise. Fig. 2: Aligning Timing Marks 5) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Turn crankshaft clockwise to align camshaft and crankshaft timing marks and to set No. 1 cylinder at TDC. See Fig. 2. Loosen center bolt of timing belt tensioner pulley, and remove timing belt. Remove timing belt auto tensioner from engine block. Inspection 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. 2) Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. See Fig. 3. Apply 22-44 lbs. (98-196 N) of force to end of push rod. If auto tensioner push rod moves more than 0.039 (1 mm), replace the auto tensioner. Check push rod for cracks. Installation 1) Place auto tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto tensioner body, place at washer around plug so it will not contact the vise jaw.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Inspecting Timing Belt Auto Tensioner

CHRYSLER
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 ngers when installing timing belt. 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt by turning right bank camshaft sprocket counterclockwise. Check all timing marks again. 4) Using Tensioner Wrench (MD998767), push tensioner pulley into timing belt. Temporarily tighten center bolt. 5) Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Then turn crankshaft clockwise until timing marks are aligned. 6) Loosen tensioner pulley center bolt. Position tensioner pin holes at top of tensioner. Install Tensioner Wrench (MD998767) on tensioner pulley. See Fig. 4. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (clockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner stationary. See TORQUE SPECIFICATIONS. 7) Remove locking pin from auto tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 8) Wait for at least 5 minutes, then check auto tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto tensioner and arm of tensioner pulley bracket. Clearance should be 0.15-0.20 (3.8-5.0 mm). See Fig. 5. If protrusion is not correct, repeat tensioning procedure. 9) Install engine support bracket on engine block. Tighten top bolt rst, then working in a counterclockwise direction, tighten the remaining bolts. See Fig. 6. Install timing belt covers. Install crankshaft pulley. Apply engine oil to crankshaft pulley bolt, then tighten bolt to specication. See TORQUE SPECIFICATIONS. 10) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

169

Courtesy of DaimlerChrysler Corp.

Fig. 5: Measuring Auto Tensioner Push Rod Protrusion

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Engine Support Bracket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner-To-Engine Block Bolt ........................................... ................. 15-19 (20-26) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98) Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186) Dipstick Tube Bolt ......................................................................... ................. 31-40 (42-54) Engine Mount To-Engine Support Bracket Bolt 10-mm ........................................................................................ ................. 55-72 (74-98) 12-mm ........................................................................................ ................. 51-69 (69-93) To-Body Through-Bolt .................................................................. ............... 2 55-72 (74-98) Engine Support Bracket-To-Engine Bolt ....................................... ................. 29-36 (39-49) Generator Pivot Bolt ...................................................................... ................. 29-44 (39-59) Generator Top Bolt ........................................................................ ................. 13-18 (17-25) Power Steering Pump Belt Tensioner Bolt ................................... ................. 25-40 (34-54) Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 25-40 (34-54) Timing Belt Tensioner Center Bolt ................................................ ................. 31-40 (42-54) INCH Lbs. (N.m) Timing Belt Lower Cover Bolt ....................................................... ............... 89-106 Timing Belt Rear Cover Bolt ....................................................................... 115-133 Timing Belt Upper Cover Bolt 6-mm ............................................................................................ ............... 89-106 8-mm .......................................................................................................... 115-133
1 2

(10-12) (13-15) (10-12) (13-15)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Adjusting Timing Belt Tension

Apply engine oil to bolt threads before installation. Final tighten bolt with full weight of engine on mount.

170

CHRYSLER
3.5L V6 24 Valve
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

3.5L V6 Pacica 2004 ........................................................... 2.7 Hours ... ..... T295 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Information is not available from manufacturer.

REMOVAL & INSTALLATION


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

Fig. 1: Removing Crankshaft Damper

TIMING BELT
CAUTION: The 3.5L is NOT a freewheeling engine. Therefore, loosen the valve train rocker assemblies before servicing the timing device. Removal 1) Relieve fuel system pressure and disconnect negative battery cable. 2) Remove both cylinder head covers and loosen the rocker arm assemblies. 3) Raise vehicle on hoist. 4) Remove accessory drive belt and tensioner. 5) Remove bolts for power steering pump and move pump aside. 6) Remove right front wheel and accessory drive belt splash shield. 7) Remove crankshaft damper bolt. Using Puller (1023) and Insert (9020-R), remove crankshaft damper. See Fig. 1. 8) Remove the lower front timing belt cover fasteners. 9) Lower vehicle. 10) Support engine with a oor jack. 11) Remove the air cleaner housing. 12) Remove the front engine mount. 13) Disconnect the fuel supply line at the fuel rail. See Fig. 2. 14) Remove the upper timing belt cover bolts and remove front timing belt cover. 15) If timing belt is to be reused, mark belt running direction. 16) Rotate engine clockwise until crankshaft mark aligns with the TDC mark on the oil pump housing and the camshaft sprocket marks are aligned with the marks on the rear cover. See Fig. 3. 17) Remove the timing belt tensioner and remove timing belt. Inspection 1) Inspect both sides of the timing belt. Replace belt if any of the following conditions exist. See Fig. 4: Hardening of back rubber or back side is glossy without resilience and leaves no indent when pressed with ngernail. Cracks on rubber back. Crack on peeling of canvas. Cracks on rib root. Cracks on belt sides. Missing teeth. Abnormal wear on belt sides. The sides are normal if they are sharp as if cut by a knife. Vehicle mileage or time at component maintenance requirement. See MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE. 2) Inspect tensioner for uid leakage around the plunger seal. Replace tensioner if leaking. 3) Inspect the pivot and for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace arm and pulley assembly.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Removing & Installing Front Timing Belt Cover CAUTION: If camshafts have moved from the timing marks, always rotate camshaft toward the direction nearest the timing marks. DO NOT turn camshafts a full revolution or damage to valves and/or pistons could result. CAUTION: Index tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine. Installation 1) Place tensioner into a vise and slowly compress the plunger. See Fig. 5. Total bleed down of tensioner should take about 5 minutes. 2) When plunger is compressed into the tensioner body, install a pin through the body and plunger to retain plunger in place until tensioner is installed. 3) Align the crankshaft sprocket with the TDC mark on oil pump cover. See Fig. 3.

CHRYSLER
3.5L V6 24 Valve (Cont.)

171

Courtesy of DaimlerChrysler Corp. Courtesy of DaimlerChrysler Corp.

Fig. 4: Inspecting Timing Belt 16) Install crankshaft damper bolt. See TORQUE SPECIFICATIONS. 17) Install accessory drive belt tensioner. See TORQUE SPECIFICATIONS. 18) Install accessory drive belt. 19) Install the accessory drive belt splash shield and right front wheel. 20) Lower vehicle. 21) Tighten the rocker arm assemblies and install cylinder head covers. See TORQUE SPECIFICATIONS. 22) Connect negative battery cable.

Fig. 3: Aligning Timing Marks 4) Align the camshaft sprockets timing reference mark with the mark on the rear cover. See Fig. 3. 5) Install the timing belt starting at the crankshaft sprocket going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. 6) Holding the tensioner pulley against the belt, install the tensioner into the housing and tighten bolts. See TORQUE SPECIFICATIONS. Each camshaft mark should remain aligned at the rear cover marks. NOTE: If the camshaft gears have been removed, it is only necessary to have camshaft gear retaining bolts installed to a snug torque at this time. See TORQUE SPECIFICATIONS. 7) When tensioner is in place, pull retaining pin to allow the tensioner to extend to the pulley bracket. 8) Rotate camshaft sprocket 2 revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. See Fig. 3. If marks do not line up, repeat procedure. NOTE: If camshaft gears have been removed and timing is correct, counter hold and tighten the camshaft gears to nal torque specication. See TORQUE SPECIFICATIONS. 9) Install front timing cover. 10) Install the upper engine mount. See TORQUE SPECIFICATIONS. 11) Connect fuel supply line at fuel rail. See Fig. 2. 12) Install air cleaner housing. 13) Remove oor jack and raise vehicle. 14) Install crankshaft damper using 5.9 Bolt With Nut (C-4685-C1) and Thrust Bearing (6792), and Installer (6792-1). See Fig. 6. 15) Install power steering pump fasteners. See TORQUE SPECIFICATIONS.

Courtesy of DaimlerChrysler Corp.

Fig. 5: Installing Timing Belt Tensioner

172

CHRYSLER
3.5L V6 24 Valve (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Bolt ........................................................................ 21 (28) Camshaft Sprocket Bolt Right Side Step 1 .................................................................................................................. 75 (102) Step 2 .......................................................................................................... Plus 1/4 Turn Left Side Step 1 .................................................................................................................. 85 (115) Step 2 .......................................................................................................... Plus 1/4 Turn Crankshaft Damper Bolt ................................................................................ 70-85 (90-115) Power Steering Pump Belt Tensioner Bolt ............................................................... 17 (23) Timing Belt Cover Bolts M6 Bolts ...................................................................................... ..................................... 1 M8 Bolts .................................................................................................................. 21 (28) M10 Bolts ................................................................................................................ 40 (54) Timing Belt Tensioner Bolts ...................................................................................... 21 (28) Timing Belt Tensioner Pulley Assembly Bolt ............................................................ 45 (61) Upper Engine Mount Upper Engine Mount-To-Frame Rail Bolts ............................................................. 50 (68) Upper Engine Mount-To-Timing Belt Cover ........................................................... 40 (54) INCH Lbs. (N.m) Cylinder Head Cover Bolts ..................................................................................... 105 (12)
1

Tighten to 105 INCH Lbs. (12 N.m).

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Crankshaft Damper

CHRYSLER & EAGLE


1.5L 4-Cylinder SOHC
TIMING BELT APPLICATION Application 1.5L 4-Cyl. Colt 1985-86 ............................... 1987-88 ............................... 1989-90 ............................... 1991-94 ............................... Colt (Canadian) 1985-86 ............................... 1989-91 ............................... 1992 & 1995 ....................... Summit 1989-90 ............................... 1991-96 ............................... Vista (Canadian) 1989-91 ............................... 1992 ....................................
1

173

Labor Time

Component Belt Kit No. Part No.

2.8 2.8 2.4 2.4

Hours Hours Hours Hours

... .. TCK073 .. ..... ... ...... ..... ...... ..... ... .. TCK128 .. ..... ... .. TCK191 .. .....

T073 T128 T128 T191

2.8 Hours ... .. TCK073 .. ..... T073 2.8 Hours ... .. TCK128 .. ..... T128 2.4 Hours ... .. TCK191 .. ..... T191 2.4 Hours ... .. TCK128 .. ..... T128 2.4 Hours ... .. TCK191 .. ..... T191 2.8 Hours ... .. TCK128 .. ..... T128 2.4 Hours ... .. TCK191 .. ..... T191

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.
Courtesy of DaimlerChrysler Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Timing Marks tensioner mounting bolts. See Fig. 3. Ensure timing belt is not out of position and has not jumped a sprocket tooth. Tighten tensioner bolts. CAUTION: If pivot bolt is tightened before side bolt, belt tensioner may rotate, causing belt to be over tightened. 2) Rotate crankshaft one full revolution clockwise, until crankshaft sprocket timing mark aligns with TDC position. Recheck belt tension. To check belt tension, hold belt tensioner and timing belt together. Apply slight thumb pressure at center point of belt tensioner. See Fig. 4. A tension gauge can also be used to check belt tension. 3) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly, then disconnect accelerator cable and oxygen lead sensor. Mark position of spark plug wires for installation, then remove wires from spark plugs. Support engine using a suitable engine support bar. Remove left engine mount bracket. Remove all accessory drive belts and pulleys. CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 2) Remove timing belt covers and gaskets, noting bolt lengths and locations as they are removed. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure all timing marks are aligned. See Fig. 1. 3) Loosen timing belt tensioner bolts. Move tensioner inward toward water pump. Temporarily tighten bolt in slot side of tensioner. Remove timing belt from camshaft sprocket. Remove crankshaft pulley and timing belt. Inspection Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective. Installation 1) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. If tensioner was removed, ensure spring is installed correctly. See Fig. 2. Install timing belt onto crankshaft and camshaft sprockets. Ensure tension side is tight and all timing marks are aligned when camshaft sprocket is rotated. Install crankshaft pulley. Loosen

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Installing Timing Belt Tensioner

174

CHRYSLER & EAGLE


1.5L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1985-91 ........................................................................................ ................. 47-54 (65-75) 1992-96 ........................................................................................ ............... 52-74 (70-100) Crankshaft Sprocket Bolt 1985 ............................................................................................. ................. 37-43 (50-58) 1986-96 ........................................................................................ ............... 52-74 (70-100) Front Cover Bolt 1985-88 ........................................................................................ ................... 9-10 (12-14) Rocker Arm Adjuster Lock Nut 1989-96 ........................................................................................ ................. 10-13 (14-18) Timing Belt Tensioner Bolt 1985-96 ........................................................................................ ................. 14-20 (19-27)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

INCH Lbs. (N.m) Crankshaft Pulley Bolt 1985-90 ........................................................................................................ 90-102 (10-11) 1987-88 ........................................................................................ ............. 108-120 (12-14) 1991-96 ........................................................................................................ 90-102 (10-11) Front Cover Bolt 1989-96 ........................................................................................ ................. 84-132 (9-15) Fuel Rail Bolt 1992-96 ........................................................................................ ................. 84-108 (9-12) Rocker Cover Bolt 1989-96 ........................................................................................ ............... 13-17 (1.5-1.9) Timing Belt Cover Bolt 1989-96 ........................................................................................ ................. 84-108 (9-12) Water Pump Pulley Bolt 1986-88 ........................................................................................ ............. 108-120 (12-14) 1989-96 ........................................................................................ ..................... 72-84 (8-9)

Fig. 4: Checking Timing Belt Tension

CHRYSLER & EAGLE


2.0L 4-Cylinder DOHC, Except VIN Y
TIMING BELT APPLICATION Application 2.0L 4-Cyl. DOHC (4G6) Laser 1990-94 ............................ 1990-94 ............................ Talon (Non-Turbo & Turbo) 1990-94 ............................ 1990-94 ............................ Talon (Turbo) 1995-98 ............................ 1995-98 ............................ 2000 GTX (Canadian) 1989-93 ............................ 1989-93 ............................
1 2

175

Labor Time

Component Belt Kit No. Part No.


3 4

1, 2 1, 2

3.6 Hours . .. TCK167 .. ... 3.6 Hours . ...... ..... ...... ... 3.6 Hours . .. TCK167 .. ... 3.6 Hours . ...... ..... ...... ... 4.5 Hours . .. TCK167 .. ... 4.5 Hours . ...... ..... ...... ... 3.6 Hours . .. TCK167 .. ... 3.6 Hours . ...... ..... ...... ...

T167 T168 T167 T168 T167 T168 T167 T168

1, 2 1, 2

3 4

1, 2 1, 2

3 4

1, 2 1, 2

3 4

3 4

Balance shaft labor time included in camshaft labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. Timing belt. Balance shaft belt.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-94 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1995-97 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles. For 1998 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut and Massachusetts, timing belt replacement is recommended but not required at 60,000 miles. In these states, replace timing belt at 100,000 miles.

tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1. 5) Remove plug from left side of cylinder block. Install a .31 (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4. Screwdriver must go in at least 2.36 (60 mm) or more. If screwdriver will only go in about .79-.98 (20-25 mm), turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures that balance shaft driven by oil pump sprocket remains in correct position. 6) To remove timing belt B (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7) Remove crankshaft sensing blade (if equipped). See Fig. 5. Loosen timing belt B tensioner bolt. If reusing timing belt B, mark direction of belt rotation for reassembly reference. Remove timing belt B. Inspection 1) Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists. 2) Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 6. Length should be .47 (12 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than .039 (1 mm), replace the auto tensioner. Installation 1) Retract rod into auto tensioner housing by placing auto tensioner assembly in a soft-jawed vise. Close vise SLOWLY to push rod back into auto tensioner housing. When pin hole in cylinder aligns with pin hole in rod, insert set pin. Replace tensioner assembly if rod can be retracted easily into housing. Install auto tensioner on engine with set pin in place. 2) Align balance shaft and crankshaft timing marks with rear cover. See Fig. 7 or 8. Install timing belt B on sprockets. If using old belt, install belt in original direction of rotation. Ensure there is no slack in tension side of belt. CAUTION: Ensure tensioner pulley shaft does not rotate when bolt is tightened, or excessive pressure will be applied to timing belt. 3) Install timing belt B tensioner so center of tensioner pulley is to the left and above of retaining bolt center. See Fig. 9. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner retaining bolt without letting tensioner pulley rotate out of position. Check belt deection at designated area. Belt deection should be .20-.28 (5.0-7.0 mm). Readjust timing belt if belt deection is not within specication. CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions, or timing belt may be damaged. 4) Install crankshaft sensing blade (if equipped) in front of crankshaft sprocket B, with offset in proper direction. See Fig. 10. Install crankshaft sprocket A. Apply light coat of engine oil to crankshaft sprocket bolt threads, and tighten bolt to specication. See TORQUE SPECIFICATIONS. Install idler pulley (if removed). 5) Ensure camshaft, crankshaft and oil pump timing marks are still aligned. See Fig. 2 or 3. DO NOT remove screwdriver from side of engine block until timing belt is installed. NOTE: Intake and exhaust camshafts use same camshaft sprocket. Camshaft sprockets are provided with 2 timing marks. For exhaust camshaft sprocket, use timing mark on right with dowel pin facing up. On intake camshaft sprocket, use timing mark on the left with dowel pin hole on top. 6) Rotate camshaft sprocket so dowel pins are upward and away from cylinder head and timing marks are aligned with cylinder head surface. Timing marks should face each other. See Fig. 2 or 3. 7) Install timing belt on intake camshaft sprocket. Install spring clip to retain timing belt on sprocket. See Fig. 11. Place a wrench on each camshaft sprocket retaining bolt. Rotate camshafts so timing marks align with each other.

REMOVAL & INSTALLATION


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

TIMING BELT & BALANCE SHAFT BELT


Removal 1) Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2) Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner bracket. See Fig. 1. Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation. 3) Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. NOTE: Camshaft sprocket dowel pins will be in 12 oclock position when timing marks are correctly aligned. 4) Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or 3. Loosen tensioner pulley center bolt. Move

176

CHRYSLER & EAGLE


2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belts & Components 8) Install timing belt over exhaust camshaft. Install spring clip to retain timing belt. Install timing belt over idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove spring clips from camshaft sprockets. Timing Belt Tension Adjustment (1990-92) 1) Position timing belt tensioner pulley so that the 2 pin holes in the center eccentric are facing to the left (as viewed from timing belt end of engine) of the center bolt. Hand tighten center bolt. 2) Remove screwdriver from balance shaft hole in side of engine block. Install plug. 3) Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft 1/4 clockwise until timing marks are aligned again. No. 1 cylinder should be at TDC of compression stroke. 4) Attach Adapter (MD998767) to tensioner pulley eccentric. Attach torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in a clockwise direction. See Fig. 12. With torque applied to eccentric, tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). 5) Insert Set Screw (MD998738) through inner timing belt cover until it contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin can be removed. Remove set screw from engine. 6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes without turning crankshaft. Measure distance between top of auto tensioner body and tensioner arm. The distance should be .15-.18 (3.8-4.5 mm). See Fig. 14, Dimension A. If distance is not correct, timing belt tension will have to be readjusted. If distance is correct, go to FINAL ASSEMBLY. Timing Belt Tension Adjustment (1993-98) 1) Lift tensioner pulley upward to apply tension on timing belt. The 2 pin holes in the center of the tensioner must face down. See Fig. 13. Screw the Set Screw (MD998738) into engine support bracket until it makes contact with tensioner arm. At that point, screw the set screw in a few more threads and remove the set pin from the auto tensioner. Remove the set screw. Tighten timing belt tensioner pulley center bolt to 35 ft. lbs. (48 N.m). 2) Remove screwdriver from side of engine block and install plug. To tension timing belt, rotate crankshaft about 1/4 turn counterclockwise, then 1/4 turn clockwise until all timing marks align. 3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or equivalent to tensioner eccentric. Install torque wrench on adapter. See Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley. 4) Hold tensioner pulley at specied torque, and tighten tensioner center bolt to specication. Do not let tensioner pulley turn with bolt. See TORQUE SPECIFICATIONS. 5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are aligned. Allow engine to stand for 15 minutes without turning crankshaft. Distance between top of auto tensioner housing and tensioner arm should be .15-.18 (3.8-4.5 mm). See Fig. 14, Dimension A. If distance is incorrect, repeat tensioning procedure until distance is correct. Once distance is correct, go to FINAL ASSEMBLY. Final Assembly To install remaining components, reverse removal procedure. Ensure proper length bolts are installed in timing belt covers. See Fig. 16. See TIMING COVER BOLT LENGTH & TORQUE table. Adjust drive belts to proper tension. TIMING COVER BOLT LENGTH & TORQUE Application INCH Lbs. (N.m) A 6 x 16 mm Flange Bolt ........................... ............................................... 89-106 (10-12) B 6 x 18 mm Flange Bolt ........................... ............................................... 89-106 (10-12) C 6 x 25 mm Loose Washer Bolt .............. .......................................................... 58 (6.5) D 6 x 25 mm Flange Bolt ........................... ............................................... 89-106 (10-12) E 6 x 45 mm Flange Bolt ........................... ............................................... 89-106 (10-12)

CHRYSLER & EAGLE


2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

177

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Belt A Timing Marks (1990-93)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Holding Balance (Silent) Shaft Stationary

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Timing Belt A Timing Marks (1994-98)

178

CHRYSLER & EAGLE


2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 9: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 5: Locating Timing Belt B (Balance Shaft Belt) Components

Courtesy of DaimlerChrysler Corp.

Fig. 10: Installing Crankshaft Sprocket & Crankshaft Sensing Blade

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Inspecting Timing Belt Auto Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 11: Installing Timing Belt On Intake Sprockets

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Aligning Timing Belt B (1990-92)

Courtesy of DaimlerChrysler Corp.

Fig. 8: Aligning Timing Belt B (1993-98)

CHRYSLER & EAGLE


2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

179

Courtesy of DaimlerChrysler Corp.

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


Courtesy of Mitsubishi Motor Sales of America.

Fig. 16: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Bolt ................................................................................................... 17 (24) Balance Shaft Sprocket Bolt ..................................................................................... 33 (46) Camshaft Sprocket Bolt ............................................................................................ 65 (90) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (108-127) Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26) Engine Mount-To-Body Through-Bolt 1990-92 ........................................................................................ ................. 43-58 (60-80) 1993-98 ........................................................................................................ 72-87 (98-118) Engine Mount-To-Engine Bolt/Nut 1990-92 ........................................................................................ ................. 36-47 (50-65) 1993-98 .................................................................................................................... 49 (67) Idler Pulley Bolt ......................................................................................................... 27 (38) Timing Belt B (Balance Shaft) Tensioner Bolt ............................................. 11-16 (15-20) Timing Belt Tensioner Pulley Center Bolt ................................................................ 35 (48) Water Pump Bolt ....................................................................................................... 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt .............................................................................................. 80 (9)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Installing Set Screw On Tensioner Pulley

Courtesy of Mitsubishi Motor Sales of America.

Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion

Courtesy of DaimlerChrysler Corp.

Fig. 15: Adjusting Timing Belt Tension (1993-98)

180

CHRYSLER & EAGLE


2.0L 4-Cylinder SOHC
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. SOHC Colt Vista 1984-86 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... ..... 1987-91 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.8 Hours ... TCK158A . ..... Ram 50 1983-86 Balance Shaft .................. 2.8 Hours ... ...... ..... ...... ..... Camshaft ......................... 3 2.3 Hours .. ...... ..... ...... ..... 1987-89 Balance Shaft .................. 2.8 Hours ... ...... ..... ...... ..... Camshaft ......................... 3 2.3 Hours ... TCK158A . ..... Vista (Canada) 1989-91 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.8 Hours ... TCK158A . ..... 2000GTX (Canada) 1989-92 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.8 Hours .. ...... ..... ...... .....
1 2

T090 T089 T159 T158

T090 T089 T159 T158

T159 T158

T159 T155 Fig. 1: Aligning Timing Marks

Courtesy of DaimlerChrysler Corp.

Balance Shaft labor time included in camshaft labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .7 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. On vehicles equipped with A/C, remove upper radiator shroud and cooling fan/clutch assembly. On 1989-91 models, support engine and remove upper engine mount located near timing belt cover. 2) On all models, position No. 1 cylinder at TDC of compression stroke. Loosen pulley bolts. Remove drive belts. Remove crankshaft, water pump and power steering pulleys. Remove upper and lower front timing belt covers. 3) On 1989-91 models, remove tensioner pulley bracket. 4) On all models, relieve camshaft timing belt tensioner pressure and secure tensioner toward water pump. If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove camshaft timing belt. 5) Rotate crankshaft in direction of rotation and align timing marks. See Fig. 1. Remove crankshaft sprocket attaching bolt. Loosen main tensioner pivot and disengage spring from boss on water pump. Remove tensioner assembly. Remove balance shaft belt (belt A). 6) Remove camshaft sprocket, then crankshaft sprocket and ange. Remove plug from lower left side of cylinder block, then insert screwdriver into hole to hold balance shaft in position while removing oil pump sprocket nut. See Fig. 2. 7) Loosen right side balance shaft sprocket bolt, then remove balance shaft belt tensioner. Remove balance shaft timing belt (belt B).

Courtesy of DaimlerChrysler Corp.

Fig. 2: Locking Balance Shaft In Place Inspection Inspect back of belt for hardness, non-elasticity and glossy surface. If no mark is produced when ngernail is forced into it, replace belt. Check for rounded sides on belt, aking, peeling, cracking and separating rubber. Cracks are most evident at base of tooth. Installation 1) Install timing belt B, ensuring tension side has no slack. Align crankshaft and balance shaft sprocket timing marks with marks on timing case. See Fig. 3. Install tensioner B so only light pressure is on belt. Ensure ange on tensioner is mounted away from engine and nger-tighten bolt. Ensure that the pulley is to left of installation bolt and pulley ange faces front of engine. See Fig. 4. 2) Lift tensioner with nger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. 3) Check belt tension by pressing center of tension side inward, using index nger and measuring belt deection. Deection should be .195-.265 (5.0-7.0 mm). Readjust if not within specication. 4) Ensure camshaft timing belt sprockets align with timing marks. Ensure tensioner is fully toward water pump and install camshaft timing belt (belt A) in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure tension side of belt has no slack. Loosen tensioner mounting bolt and nut, and allow tensioner spring to tension belt.

CHRYSLER & EAGLE


2.0L 4-Cylinder SOHC (Cont.)
5) Tighten slot side bolt, and then tighten nut. Ensure all timing marks are in correct alignment. Turn crankshaft clockwise one revolution. Loosen mounting nut and bolt to allow tensioner to readjust. Tighten slot side bolt, then tighten nut. Reverse removal procedure to complete reassembly. Adjust drive belts to proper tension.

181

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt 1983-85 .......................................................................................................... 11-15 (15-20) 1986-91 ........................................................................................ ................. 15-21 (20-29) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Front Cover Bolts 1983-88 ........................................................................................ ................. 15-19 (20-26) 1989 M8 X 30 Bolt ..................................................................... ................. 20-26 (27-35) Except 1989 M8 X 30 Bolt ......................................................... ................. 14-20 (19-27) Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41) Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27) Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54) Timing Belt Cover Bolt Except Left Lower Rear .............................................................. ..................................... 1 Left Lower Rear .......................................................................... ................. 22-30 (30-41) Timing Belt Tensioner Nut 1983-85 ........................................................................................ ................. 16-21 (22-28) 1986-91 ........................................................................................ ................. 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm .......................................................................................... 9-11 (12-15) 8 X 65 mm .................................................................................. ................. 15-19 (20-26)
1

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Balance Shaft Sprocket

Tighten bolts to 84-108 INCH lbs. (9-12 N.m).

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Balance Shaft Tensioning Pulley

182

CHRYSLER & EAGLE


3.2L & 3.5L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 105,000 miles up to the 1999 model year. For 2000-02 model years, the manufacturer recommends the timing belt be replaced at 100,000 miles for Federal vehicles, and 105,000 miles for California vehicles. For 2003-04 model years, the manufacturer recommends the timing belt be replaced at 102,000 miles.

3.2L V6 Concorde & Intrepid (Includes Canadian) 1998-01 .............................. 1 2.8 Hours .. .. TCK295 .. ..... 3.5L V6 Concorde & Intrepid (Includes Canadian) 1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. ..... 1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. ..... 2000-02 .............................. 1 2.7 Hours .. .. TCK295 .. ..... 2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... ..... LHS & 300M 1994 ................................... 1 2.7 Hours .. .. TCK219 .. ..... 1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. ..... 1999-02 .............................. 1 2.7 Hours .. .. TCK295 .. ..... 2003-04 .............................. 1 2.7 Hours .. ...... ..... ...... ..... New Yorker 1994 ................................... 1 2.7 Hours .. .. TCK219 .. ..... 1995-96 .............................. 1 2.7 Hours .. .. TCK255 .. ..... Prowler 1999-02 ............................... 2.8 Hours ... ...... ..... ...... ..... Vision 1993-94 .............................. 1 2.7 Hours .. .. TCK219 .. ..... 1995-97 .............................. 1 2.7 Hours .. .. TCK255 .. .....
1

T295

T219 T255 T295 T295 T219 T255 T295 T295 T219 T255 T295 T219 T255

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. CAUTION: The following procedure can only be used if camshaft sprockets have NOT been loosened or removed. If camshaft sprockets have been removed, special tools and timing procedure are required. Removal 1) Disconnect negative battery cable from jumper terminal. Remove upper radiator crossmember (may also be referred to as the engine compartment support). Remove electric cooling fan module with fans.

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components (2000 & Up)

CHRYSLER & EAGLE


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.

183

Courtesy of DaimlerChrysler Corp.

Fig. 3: Installing Timing Belt CAUTION: If camshafts have moved from the timing marks, always rotate camshafts toward the direction nearest to the timing marks. DO NOT turn the camshafts a full revolution or damage to valves and/or pistons could result. Installation 1) When tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Place timing belt tensioner in vise with holes in plunger and housing aligned. 2) SLOWLY compress plunger. See Fig. 4. Total bleed down of plunger should take about 5 minutes. When pin holes are aligned, install locking pin through tensioner and plunger. 3) Ensure camshaft and crankshaft sprocket timing marks are still aligned. If camshaft timing marks are not aligned, always rotate camshafts toward nearest timing marks. DO NOT turn camshafts a full revolution. This could cause valves to contact pistons. 4) Install timing belt starting at crankshaft sprocket, going in a counterclockwise direction. After belt is installed on right camshaft sprocket, keep tension on belt until it is past tensioner pulley. 5) Holding tensioner pulley against belt, install tensioner into housing and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure camshaft timing marks are aligned. When tensioner is in place, pull locking pin to allow tensioner to extend to pulley bracket. 6) Rotate crankshaft sprocket 2 revolutions, and check timing marks on camshafts and crankshaft. Marks should line up within their respective locations. If marks do not line up, repeat procedure. See Figs. 2 and 3. 7) Install timing belt covers and crankshaft damper. See Fig. 1. Install accessory drive belts. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. 8) Start engine and allow to idle for about one minute. If noise is present in timing belt tensioner, air has possibly entered tensioner. To remove air, run engine at 1600-2000 RPM for 10 minutes to purge air.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks CAUTION: This procedure can only be used when the camshaft sprockets have NOT been loosened or removed from the camshafts.

184

CHRYSLER & EAGLE


3.2L & 3.5L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt 1993-97 .................................................................................................................. 85 (115) 1999-04 .................................................................................................................... 70 (95) Timing Belt Cover Bolts M6 ................................................................................................ ..................................... 1 M8 ............................................................................................................................ 21 (28) M10 .......................................................................................................................... 40 (54) Timing Belt Tensioner ................................................................................................ 21 (28) Timing Belt Tensioner Pulley Assembly ................................................................... 45 (61) INCH Lbs. (N.m) Water Pump Bolts ................................................................................................... 106 (12)
1

Tighten bolts to 106 INCH lbs. (12 N.m).

Courtesy of DaimlerChrysler Corp.

Fig. 4: Compressing Tensioner

CHRYSLER & MITSUBISHI


2.3L 4-Cylinder Diesel
TIMING BELT APPLICATION Application 2.3L 4-Cyl. Turbo Diesel Pickup 1983-85 Balance Shaft ........................................ Camshaft ............................................... Ram 50 1983-85 Balance Shaft ........................................ Camshaft ...............................................
1

185

Labor Time

Belt Part No.

1 1

1.8 Hours .. ..... T092 1.8 Hours .. ..... T091

1 1

1.8 Hours .. ..... T092 1.8 Hours .. ..... T091

With Air Conditioning, add .7 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Fig. 2: Removing Silent Shaft Sprockets 2) Install ange to injection pump sprocket, noting ange holes are offset to aid in correct installation. Lightly oil left silent shaft spacer and insert spacer with chamfered end toward seal. 3) Install both silent shaft sprockets. Tighten nut and bolt to specication. Keep silent shafts from turning by using method described in removal procedure. 4) Position and secure tensioner B fully toward water pump. Align timing marks on crankshaft sprocket and silent shaft sprockets. See Fig. 4. Install timing belt B, noting reference mark if retting old belt. 5) Install timing belt B, ensuring tension side has no slack. Check alignment of timing marks. Loosen tensioner B mounting nut and bolt, and allow tensioner spring pressure to adjust belt. 6) Tighten nut rst, then tighten bolt. DO NOT tighten bolt rst. Using index nger, press belt at center of tension side inward and measure belt deection. Deection 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 rst. Then tighten lower (fulcrum-side) bolt. Tightening bolts out of specied sequence will over-tighten belt. After tightening tensioner mounting bolts, check sprocket alignment. 11) Turn crankshaft clockwise until second tooth past timing mark on camshaft sprocket is in alignment with triangle timing mark. Turn crankshaft counterclockwise and realign timing marks. 12) Using forenger, press belt on tension side of belt between camshaft sprocket and injection pump sprocket. Measure belt deection. Deection should be .16-.20 (4-5 mm). Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

TIMING BELT & SPROCKETS


Removal 1) Disconnect negative battery cable. Remove drive belts, fan, pulleys, and timing belt covers. Position cylinder No. 1 at TDC of compression stroke and ensure timing marks are in alignment. See Fig. 1. 2) Mark belts indicating direction of rotation. Loosen nuts and bolts securing belt tensioners. Pivot tensioners toward water pump and secure. Remove timing belts and all necessary sprockets. 3) Remove silent shaft sprockets by removing plug from right side of block and cover from left side of block. Insert screwdriver and socket extension into holes to hold silent shafts in place. See Fig. 2.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Timing Marks Installation 1) Install crankshaft sprocket and ange ensuring ange on crankshaft sprocket B is installed correctly. See Fig. 3. Mount injection pump sprocket, if removed, and tighten nut to specications.

186

CHRYSLER & MITSUBISHI


2.3L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tensioner Bolts ...................................................................... ................. 16-21 (22-29) Camshaft Sprocket Bolts .............................................................. ................. 47-54 (64-73) Crankshaft Pulley Bolt ................................................................... ................. 33-34 (45-47) Crankshaft Sprocket Bolt .............................................................. ......... 123-137 (167-186) Front Case Bolts 1983-84 ........................................................................................ ................. 15-19 (20-26) 1985 ............................................................................................. ..................................... 1 Silent Shaft Sprocket Bolt ............................................................. ................. 25-28 (34-39) INCH Lbs. (N.m) Valve Cover Bolts .......................................................................... ..................... 44-53 (5-6)
Courtesy of DaimlerChrysler Corp.
1

Tighten to 108-120 INCH lbs. (12-14 N.m).

Fig. 3: Installing Crankshaft Sprocket

Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Belt B Marks

CHRYSLER & MITSUBISHI


2.4L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

187

2.4L 4-Cyl. SOHC Pickup 1990-92 Balance Shaft ............... .......... Camshaft ......................... 2 2.3 1993-96 Balance Shaft ............... .......... Camshaft ......................... 2 2.3 Ram 50 1990-91 Balance Shaft ............... .......... Camshaft ......................... 3 2.3 1992 Balance Shaft ............... .......... Camshaft ......................... 3 2.3 1993 Balance Shaft ............... .......... Camshaft ......................... 3 2.3
1 2

1 .......... ...... ..... ...... ..... T159 Hours .. .. TCK124 .. ..... T124 1 .......... ...... ..... ...... ..... T168 Hours .. ...... ..... ...... ..... T229

1 .......... ...... ..... ...... ..... T159 Hours .. .. TCK124 .. ..... T124 1 .......... ...... ..... ...... ..... T159 Hours .. .. TCK124 .. ..... T124 1 .......... ...... ..... ...... ..... T168 Hours .. ...... ..... ...... ..... T229

Courtesy of DaimlerChrysler Corp.

Balance shaft labor time included in camshaft labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .7 hours. With Power Steering, add .2 hours.

Fig. 1: Aligning Front Timing Belt

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of DaimlerChrysler Corp.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove radiator shroud, cooling fan and pulley. Remove all drive belts and crankshaft pulley. Remove upper timing belt covers and gaskets. Note bolt length and location. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing. 2) Remove crankshaft sprocket bolt and washer. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with mark on cylinder head. See Fig. 1. 3) Loosen timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt (belt A) and tensioner. DO NOT rotate crankshaft after timing belt has been removed. 4) Remove camshaft sprocket (if necessary). Remove oil pump sprocket access plug from cylinder block. See Fig. 2. Insert a .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. 5) Remove oil pump sprocket nut, and remove sprocket. Remove front crankshaft sprocket and ange. Note direction and order of installation for reassembly reference. 6) Remove rear timing belt tensioner assembly. Remove rear timing belt (belt B). Inspection Check belt teeth for cracks, damage and contamination. Inspect sprockets for damage. Check belt tensioner for leakage and roughness in rotation. Replace components if damaged.

Fig. 2: Holding Silent Shaft In Stationary Position Installation 1) Install rear crankshaft sprocket and ange. Install right silent shaft sprocket and spacer. Spacer should be installed with chamfered end into oil seal. Align timing marks. See Fig. 3. Install rear timing belt (belt B) on sprockets. 2) Install rear tensioner. Hold tensioner tightly against belt while tightening bolts. Ensure deection is .20-.28 (5.0-7.1 mm). See Fig. 4. Install camshaft sprocket. Tighten camshaft sprocket bolt to specication. See TORQUE SPECIFICATIONS. 3) Install front timing belt tensioner, tension spring and spacer. Ensure spring is properly engaged against water pump case. Rotate tensioner toward water pump, and temporarily tighten bolts. Ensure timing marks are aligned. See Fig. 1. Install front timing belt (belt A) on crankshaft. 4) Apply pressure on tension side of timing belt while installing belt (in order) on crankshaft, oil pump and camshaft sprockets. Loosen tensioner to apply spring pressure to timing belt. 5) To apply tension to belt, rotate crankshaft clockwise until camshaft sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten tensioner spacer nut. 6) To check belt tension, apply slight thumb pressure and measure deection between camshaft and oil pump sprocket. Belt deection should be .55 (14.0 mm). See Fig. 5. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

188

CHRYSLER & MITSUBISHI


2.4L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Damper Pulley Bolt ......................................................................................... 11-13 (15-18) Engine Support Bracket Bolt ........................................................ ................. 36-47 (49-64) Silent Shaft Sprocket Bolt ............................................................. ................. 25-29 (34-39) Timing Belt A Tensioner Bolt ...................................................... ................. 16-22 (22-30) Timing Belt B Tensioner Bolt ........................................................................ 11-16 (15-22) Water Pump Bolt Except 8 X 65 mm .................................................................................................. 10 (14) 8 X 65 mm .................................................................................. ................. 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Rear Timing Belt

Courtesy of DaimlerChrysler Corp.

Fig. 4: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 5: Checking Timing Belt A Tension

CHRYSLER & MITSUBISHI


3.0L V6 DOHC
TIMING BELT APPLICATION Application
1

189

Labor Time Component Belt Kit No. Part No.

sensor and crankshaft position sensor. Remove crankshaft pulley. On vehicles with ABS, remove overow tank and bracket. Remove generator/air conditioning idler pulley. NOTE: Remove remaining engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 1. 2) Remove timing belt covers. Turn crankshaft clockwise to align all timing marks. Loosen center bolt on tensioner pulley to relieve belt tension. Remove timing belt. Mark rotation direction if belt is to be reused.

3.0L V6 DOHC Diamante 1992-95 ............................... Stealth 1991-96 Non-Turbo ........................ Turbo ................................ 3000GT 1991-99 Non-Turbo ........................ Turbo ................................
1

4.7 Hours ... .. TCK195 .. ..... T195

3.4 Hours ... .. TCK195 .. ..... T195 3.6 Hours ... ...... ..... ...... ..... T195

3.9 Hours ... .. TCK195 .. ..... T195 4.3 Hours ... ...... ..... ...... ..... T195

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


CHRYSLER
Up to 1993 model year, the manufacturer recommends the belt be replaced every 60,000 miles. For 1994-96 model years, the manufacturer recommends replacing the timing belt at 60,000 miles, except in California. In California, belt replacement is recommended, but not required at 60,000 miles. Replace belt at 100,000 miles, unless previously changed.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Removing Engine Support Bracket Bolts Removal (Stealth & 3000GT) 1) Disconnect negative battery cable. Remove lower splash shields. Remove cruise control actuator (if equipped). Remove drive belts. Remove alternator. Remove drive belt tensioner. 2) Using Holder (MB990767) and Adapter Bolts (MD998754) or equivalent, remove crankshaft pulley. See Fig. 2. Disconnect brake uid level sensor. Remove upper timing belt covers. Support engine. Remove front engine mount through-bolt and front engine mount. NOTE: Engine support bracket reamer bolt may be seized. Apply penetrating lubricant to bolt during removal. 3) Remove drive belt idler pulley. Remove engine support bracket bolts in sequence. See Fig. 1. Remove engine support bracket. Remove timing belt upper and lower covers, noting length and location of cover bolts. 4) Rotate crankshaft to align all timing marks. See Fig. 3. Loosen tensioner center bolt. Remove timing belt. Installation (All Models) 1) Place automatic tensioner assembly in a soft-jawed vise. Slowly close vise to press rod back into tensioner until both rod and housing holes are aligned. Install a .055 (1.40 mm) diameter wire through both holes. 2) Remove tensioner from vise, and install assembly with wire in place. Install crankshaft sprocket (if removed). Align timing marks on crankshaft and camshaft sprockets. See Fig. 3. CAUTION: Turning camshaft sprockets while No. 1 cylinder is at TDC may damage valve and piston. Use care when aligning timing marks. 3) To lower No. 1 piston from TDC and prevent valve and piston contact, turn crankshaft back 3 sprocket teeth (measured at timing mark). Starting with front bank of cylinders, verify intake and exhaust camshaft timing marks are not within shaded area of gure. See Fig. 4. WARNING: Use care when aligning timing marks. When camshaft sprocket timing marks are in indicated area, camshaft is under valve spring pressure and may rotate suddenly, pinching hand between sprockets. 4) If camshaft sprocket timing mark is within indicated area, carefully rotate camshaft sprocket until timing mark is located in nearest safe area. See Fig. 4.

MITSUBISHI
For 1991-93 model years, the manufacturer recommends the belt be replaced every 60,000 miles. For 1994-95 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. Replace timing belt at 100,000 miles, unless previously changed. For 1996-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California and Massachusetts. In California and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. Replace timing belt at 100,000 miles, unless previously changed. For 1998 model year, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Diamante) 1) Disconnect negative battery cable. Remove left front and left side splash shields. Using engine hoist, lift engine to remove weight from engine mounts. Remove alternator and drive belt tensioner assembly. Remove engine support bracket. Disconnect power steering connections. On 1993-95 models, remove camshaft position

190

CHRYSLER & MITSUBISHI


3.0L V6 DOHC (Cont.)
7) Rotate timing belt tensioner pulley until pin holes are located above center bolt. See Fig. 7. Push tensioner pulley against belt, and tighten center bolt. Ensure all timing marks are aligned, and remove clips. 8) Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft clockwise until timing marks are realigned. Loosen tensioner center bolt. Using Tensioner Pulley Socket (MD998767) or equivalent, apply approximately 90 INCH lbs. (10 N.m) torque to tensioner pulley to prevent it from turning. See Fig. 7. Retighten center bolt to specication. 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 specication, repeat previous ve 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 specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View of Timing Belt Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks to Prevent Valve & Piston Damage

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks (Initial Alignment) 5) Rotate either camshaft sprocket clockwise to align timing marks as shown in illustration. See Fig. 5. If camshaft sprocket is rotated past timing mark, rotate it counterclockwise to realign it. Repeat procedure for other front bank camshaft sprocket. NOTE: If necessary, crankshaft sprocket may be turned one tooth counterclockwise to aid belt installation. 6) Repeat previous three steps and this step for rear cylinder bank camshafts. Align crankshaft timing mark. Install timing belt onto sprockets in sequence. See Fig. 6. Use spring-type paper clips to secure belt on sprockets. Use wrenches on camshaft sprocket bolts to prevent camshafts from turning during belt installation.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Aligning Timing Marks (Final Alignment)

CHRYSLER & MITSUBISHI


3.0L V6 DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

191

Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .......................................................................................... 17 (23) Camshaft Sprocket Bolt ............................................................................................ 66 (90) Crankshaft Pulley Bolt ........................................................................................... 136 (185) Engine Support Bracket Bolt 10 X 40 mm ................................................................................ ................. 47-54 (64-73) Except 10 X 40 mm .................................................................................. 76-83 (103-113) Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42) Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49) Water Pump Bolt ....................................................................................................... 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Timing Belt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Adjusting Timing Belt Tensioner

192

CHRYSLER, EAGLE & MITSUBISHI


1.6L 4-Cylinder DOHC
Labor Time Belt Part No. 2) Inspect auto tensioner for leaks. Replace, if necessary. Inspect tensioner pulley and idler pulley for smooth rotation. Replace if bearings are worn. CAUTION: Install ange and crankshaft sprocket in correct direction to prevent damage to timing belt. Installation 1) Rotate timing belt tensioner pulley so that the 2 pin holes are to the left of the center bolt. See Fig. 4. Tighten center bolt nger tight. Leave Allen wrench or pin installed in auto tensioner. 2) Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 2. Outer marks on sprockets should be aligned with cylinder head surface. When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. When installing timing belt, ensure this rotation is compensated for. 3) Rotate crankshaft and align timing marks on crankshaft and oil pump sprockets. If installing old timing belt, ensure it is installed in original direction of rotation. 4) Install timing belt around intake camshaft sprocket. Install spring-type paper clip on timing belt and camshaft sprocket to hold belt on sprocket. Clip should be installed below cylinder head surface, on outer side of camshaft sprocket. 5) Install box wrench on both camshaft sprocket bolts. Install timing belt around exhaust camshaft sprocket while holding camshaft sprocket bolt to align timing mark on camshaft sprocket with timing mark. 6) Install another spring-type paper clip on timing belt and exhaust camshaft sprocket to hold belt on sprocket. Install clip below cylinder head surface, on outer side of camshaft sprocket. 7) Install timing belt in the following order: around idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove both spring-type paper clips. Rotate tensioner pulley inward toward timing belt until belt is NOT sagging. Temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are aligned. CAUTION: Ensure all timing belt teeth are engaged with teeth on camshaft, oil pump and crankshaft sprockets. 8) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, then rotate clockwise until No. 1 cylinder is at TDC. Ensure timing marks are aligned. Loosen center bolt on tensioner pulley. 9) Note pin holes in tensioner pulley. Use socket wrench to rotate tensioner pulley. Using INCH lb. torque wrench and Socket Wrench (MD998752), apply a clockwise torque of 24 INCH lbs. (2.7 N.m) on tensioner pulley. See Fig. 5. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 32-41 ft. lbs. (43-55 N.m). 10) SLOWLY rotate set screw until Allen wrench or pin can be removed from auto tensioner. Remove set screw. 11) Rotate crankshaft clockwise 6 complete revolutions and leave in this position for approximately 15 minutes. After 15 minutes, measure distance between bottom edge of tensioner arm and top of auto tensioner body. Distance should be .15-.18 (3.8-4.5 mm). See Dimension A in illustration. See Fig. 6. 12) If distance is not correct, loosen timing belt tensioner pulley center bolt. Use Set Screw to compress auto tensioner again. Readjust timing belt tension using Socket Wrench (MD998752) and INCH lb. torque wrench until correct distance of .15-.18 (3.8-4.5 mm) is obtained. 13) Remove set screw. Install rubber plug in rear timing belt cover. Install upper and lower timing belt covers. Ensure timing belt cover bolts are installed in correct location. See Fig. 7. 14) Install crankshaft pulley. Install A/C compressor belt (if equipped). Install accessory drive belt tensioner bracket. Install water pump pulley. Install generator and power steering pump drive belts. Adjust drive belts to correct tension. 15) Install engine mount bracket on timing belt end of engine. Remove engine support xture. Install lower splash shield.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC Colt & Summit 1989-90 .................................................... Colt 100, Colt 200 & Vista (Canada) 1989-90 .................................................... Mirage 1989 & 1991-92 .......................................
1

3.6 Hours .. ..... T165 3.6 Hours .. ..... T165 3.4 Hours .. ..... T165

With Air Conditioning, add .2 hours. With Power Steering, add .3 hours. With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Replacement procedures include revised information from Chrysler technical service bulletin 09-01-94; January 28, 1994.

TIMING BELT
Removal 1) Raise and support vehicle. Remove lower left engine compartment splash shield. Support weight of engine from above with Support Fixture (C-4852 or 7137) or equivalent. On timing belt end of engine, remove engine mount bracket connecting engine to body. 2) Loosen, but do not remove, water pump pulley bolts. Remove generator and power steering pump drive belts. Remove water pump pulley. NOTE: It is necessary to lower engine slightly to remove the crankshaft pulley. 3) Remove accessory drive belt tensioner pulley bracket. See Fig. 1. Remove A/C compressor drive belt (if equipped). Remove water pump pulley. Remove crankshaft pulley-to-crankshaft sprocket bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft pulley center bolt. 4) Remove upper and lower timing belt covers. CAUTION: Crankshaft may need to be rotated up to 6 revolutions before all sprockets are properly aligned. 5) Rotate engine clockwise (as viewed from timing belt end of engine) to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 2. If reusing belt, mark belt with original rotation direction. 6) Remove rubber plug from inner timing belt cover. Install Set Screw (MD998738) into engine support bracket until it contacts auto tensioner arm. See Fig. 3. Remove auto tensioner. Loosen timing belt tensioner pulley center retaining bolt. 7) Compress auto tensioner push rod by SLOWLY rotating Set Screw (MD998738) until hole in auto tensioner aligns with hole in auto tensioner body. Push rod may need to be rotated to align holes. Insert a 1/16 Allen wrench or pin into aligned holes to hold push rod in compressed position. Remove timing belt. Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged.

CHRYSLER, EAGLE & MITSUBISHI


1.6L 4-Cylinder DOHC (Cont.)

193

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Timing Marks

194

CHRYSLER, EAGLE & MITSUBISHI


1.6L 4-Cylinder DOHC (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 3: Retracting Auto Tensioner Rod

Courtesy of DaimlerChrysler Corp.

Fig. 7: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS Fig. 4: Positioning Timing Belt Tensioner Pulley Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Pulley Bracket Bolt ................... ................. 17-20 (23-27) Auto Tensioner Bolt ....................................................................... ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30) Crankshaft Sprocket Center Bolt .................................................. ............. 80-94 (109-127) Engine Mount Bracket To-Body Through-Bolt .................................................................. ................. 43-58 (60-80) To-Engine Bracket Bolt/Nut ......................................................... ................. 36-47 (50-65) Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41) Tensioner Pulley Center Bolt ........................................................ ................. 32-41 (43-55) Timing Belt Cover Left Lower Rear Cover Bolt ........................................................ ................. 22-30 (30-41) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 84-106 (10-12) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of DaimlerChrysler Corp.

Fig. 5: Adjusting Timing Belt Tension

Courtesy of DaimlerChrysler Corp.

Fig. 6: Measuring Timing Belt Auto Tensioner Protrusion

CHRYSLER, EAGLE & MITSUBISHI


1.8L 4-Cylinder VINs B & T
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

195

Inspection Inspect timing belts for damaged teeth or cracks. Ensure belts are not contaminated by oil. Check tensioners for freedom of rotation. Replace components if damaged. CAUTION: Ensure right silent shaft spacer is installed with chamfered side toward oil seal, or damage to oil seal will result.

1.8L 4-Cyl. Eclipse & Laser 1990-94 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.4 Hours .. .. TCK158 .. ..... Talon 1993-94 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ......................... 2 2.4 Hours .. .. TCK158 .. .....
1 2

T159 T158

T159 T158

Installation 1) Coat outer diameter of right silent shaft spacer with engine oil. Install spacer with chamfered side toward oil seal. Install right silent shaft sprocket. Align crankshaft sprocket B and right silent shaft timing marks. See Fig. 4. Install timing belt B on sprockets. Ensure belt is installed in original direction of rotation and no slack exists in belt. CAUTION: When tightening bolt, ensure tensioner does not rotate, or excessive pressure will be applied to timing belt. 2) Install timing belt tensioner B so center of pulley is located left of tensioner bolt. See Fig. 5. Ensure ange on tensioner pulley is toward front of engine. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner bolt. 3) Check belt deection at designated area. See Fig. 5. Belt deection should be .20-.28 (5.0-7.1 mm). Readjust timing belt if belt deection is not within specication. 4) Install ange in front of crankshaft sprocket B, with offset toward crankshaft. See Fig. 1. Install crankshaft sprocket A. See Fig. 6. Install camshaft and oil pump sprockets. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 5) Install tensioner spring, tensioner spacer and timing belt A tensioner. Ensure upper end of tensioner spring contacts water pump. Rotate tensioner toward water pump, and temporarily tighten nut. 6) Ensure all timing marks are aligned. See Fig. 2. When aligning oil pump sprocket timing marks, remove plug from cylinder block. See Fig. 3. Insert a .31 (8.0 mm) diameter Phillips screwdriver into plug hole. 7) If screwdriver can only be inserted .79-.98 (20.0-24.9 mm), rotate oil pump sprocket one revolution, and realign timing mark. Insert screwdriver, and ensure it can be inserted at least 2.36 (59.9 mm). DO NOT remove screwdriver until timing belt is installed. 8) Install timing belt A on sprockets. Ensure no slack exists on tension side of belt. See Fig. 2. Install timing belt on crankshaft sprocket A, oil pump sprocket, and then on camshaft sprocket. If reused, ensure belt is installed in original direction of rotation. 9) Loosen tensioner nut to allow spring tension to be applied to timing belt. Ensure all timing marks are aligned. Remove screwdriver and install plug. To apply tension on timing belt, rotate crankshaft clockwise so camshaft sprocket moves 2 teeth past timing mark on rear timing belt cover. See Fig. 7. DO NOT rotate crankshaft counterclockwise. CAUTION: DO NOT tighten tensioner spacer nut before tightening tensioner bolt, or timing belt tensioner will rotate and apply excessive pressure on timing belt. 10) Rotate tensioner inward toward timing belt. Ensure timing belt fully engages camshaft sprocket. Tighten timing belt tensioner bolt. Tighten tensioner spacer nut. At midway location between camshaft sprocket and oil pump sprocket, push timing belt A outward toward lower timing belt cover. Note clearance between timing belt and cover. See Fig. 8. Clearance should be .47 (12.0 mm). Timing belt may need to be readjusted. 11) To complete installation, reverse removal procedure. Ensure proper length bolts are installed in designated areas in timing belt covers. See Fig. 9. Adjust drive belts to proper tension.

Balance shaft labor time included in camshaft labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). Removal 1) Disconnect negative battery cable. Disconnect power steering hose clamp. Remove engine undercover. Place wooden block between jack and oil pan. Raise engine slightly. 2) Remove engine mount assembly near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1. Remove power steering, water pump and damper pulleys. Remove adapter and crankshaft pulley. NOTE: Ensure timing marks are aligned. Mark direction of rotation of all timing belts. 3) Remove upper and lower timing belt covers and gaskets. Remove access cover. Remove crankshaft sprocket A bolt and washer. Rotate crankshaft clockwise (as viewed from timing belt side of engine), and align timing mark on camshaft sprocket with timing mark on rear upper timing belt cover. See Fig. 2. 4) Loosen timing belt tensioner bolt for timing belt A. Move tensioner toward water pump, and tighten tensioner bolt. Remove timing belt. 5) Remove timing belt tensioner, tensioner spacer and tensioner spring. See Fig. 1. Remove camshaft sprocket. Remove plug from side of cylinder block, and install a .31 (8.0 mm) diameter Phillips screwdriver to hold left silent shaft. See Fig. 3. 6) Remove oil pump sprocket nut, and remove sprocket. Remove crankshaft sprocket A and ange. Remove timing belt tensioner B. If timing belt B is to be reused, mark direction of timing belt rotation for reassembly reference. Remove timing belt B.

196

CHRYSLER, EAGLE & MITSUBISHI


1.8L 4-Cylinder VINs B & T (Cont.)

Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belts & Components

Courtesy of DaimlerChrysler Corp.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Timing Belt A Timing Marks

Fig. 3: Holding Silent Shaft In Stationary Position

CHRYSLER, EAGLE & MITSUBISHI


1.8L 4-Cylinder VINs B & T (Cont.)

197

Courtesy of DaimlerChrysler Corp.

Fig. 8: Checking Timing Belt A Tension


Courtesy of DaimlerChrysler Corp.

Fig. 4: Aligning Timing Belt B Timing Marks

Courtesy of DaimlerChrysler Corp.

Fig. 9: Identifying Timing Belt Cover Bolt Locations

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Damper Pulley Bolt ......................................................................................... 11-13 (15-18) Flywheel/Drive Plate Bolt .............................................................. ........... 94-101 (127-137) Front Cover Bolt .............................................................................................. 11-13 (15-18) Timing Belt A Tensioner Bolt ...................................................... ................. 16-22 (22-30) Timing Belt B Tensioner Bolt ........................................................................ 11-16 (15-22) Water Pump Bolt Except 8 X 65 mm .................................................................................................. 10 (14) 8 X 65 mm .................................................................................. ................. 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Fig. 5: Installing Timing Belt B Tensioner

Courtesy of DaimlerChrysler Corp.

Fig. 6: Installing Crankshaft Sprockets

Courtesy of DaimlerChrysler Corp.

Fig. 7: Applying Tension To Timing Belt A

198

CHRYSLER, EAGLE & MITSUBISHI


1.8L 4-Cylinder VINs C & D
Labor Time Component Belt Kit No. Part No. 3) If timing belt is to be reused, mark direction of rotation before removing. Loosen timing belt tensioner bolt. Using a screwdriver, move tensioner away from timing belt. Tighten bolt to secure tensioner. Remove timing belt.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Colt 1992-94 .............................. Colt Vista 1992-94 .............................. Expo 1992-94 .............................. Mirage 1993-96 .............................. 1997-02 .............................. Summit 1992-96 .............................. Summit Wagon 1992-96 ..............................
1

2.4 Hours .. ...... ..... ...... ..... T201 2.4 Hours .. ...... ..... ...... ..... T201 2.4 Hours .. .. TCK201 .. ..... T201 2.4 Hours .. .. TCK201 .. ..... T201 2.4 Hours .. ...... ..... ...... ..... T288 2.4 Hours .. ...... ..... ...... ..... T201 2.4 Hours .. ...... ..... ...... ..... T201

1 1

With Air Conditioning, add .2 hours. With Power Steering, add .3 hours. With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of DaimlerChrysler Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


CHRYSLER & EAGLE
The manufacturer recommends the belt be replaced every 60,000 miles.

MITSUBISHI
For 1992-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-02 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of DaimlerChrysler Corp.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove under cover. On Expo, remove condenser tank. On all models, remove A/C and power steering hose mounting bracket from upper engine mount at timing belt cover. Remove all accessory drive belts. Using End Yoke Holder (MB990767) and Crankshaft Pulley Holder (MD998718) or equivalent, remove crankshaft pulley bolt and pulley. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). 2) Remove upper and lower timing belt covers. See Fig. 1. Remove ange. If necessary, remove power steering pump bracket stay and engine support bracket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke, and timing mark on camshaft sprocket and crankshaft sprocket align with timing mark on engine. See Fig. 2 or 3.

Fig. 2: Aligning Timing Marks (1992-96) Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check belt tensioner for grease leakage or roughness in tensioner rotation. See Fig. 1. Replace components if damaged. Installation 1) Install timing belt tensioner, leaving bolt loose. Using a screwdriver, push tensioner toward engine mount. Tighten timing belt tensioner bolt. 2) Align camshaft sprocket and crankshaft sprocket timing marks with timing marks on engine. Keeping tension applied between camshaft, water pump and crankshaft sprockets, install timing belt in the following sequence: crankshaft sprocket, water pump sprocket, camshaft sprocket, then tensioner pulley. 3) Rotate camshaft in reverse direction and ensure that there is no slack in timing belt. Ensure timing marks are still aligned. Loosen timing belt tensioner to apply spring pressure to timing belt.

CHRYSLER, EAGLE & MITSUBISHI


1.8L 4-Cylinder VINs C & D (Cont.)

199

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Identifying Timing Belt Cover Bolt Locations

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT MIRAGE) Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ..................................................................................... 11-13 (15-18) Crankshaft Center Pulley Bolt ...................................................... ............. 80-94 (109-127) Damper Pulley Bolt ......................................................................................... 11-13 (15-18) Front Cover Bolt .............................................................................................. 11-13 (15-18) Timing Belt A Tensioner Bolt ...................................................... ................. 16-22 (22-30) Timing Belt B Tensioner Bolt ........................................................................ 11-16 (15-24) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Valve Cover Bolt ........................................................................... ..................... 48-60 (5-7) TORQUE SPECIFICATIONS (MIRAGE) Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ........................................................................... 18 (25) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Pulley Bolt ................................................................... ......... 131-139 (177-188) Engine Support Bracket Bolt .................................................................................... 36 (49) Power Steering Pump Bracket Stay Bolt ................................................................. 33 (44) Timing Belt Tensioner Bolt ........................................................................................ 18 (24) Water Pump Bolt ....................................................................................................... 18 (24) INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks (1997-02) 4) Rotate crankshaft 2 complete revolutions clockwise (as viewed from timing belt end of engine) and ensure timing marks are still aligned. Ensure timing belt teeth are properly seated in sprockets. Tighten timing belt tensioner bolt. 5) Install ange. See Fig. 4. To complete installation, reverse removal procedure. Ensure proper length bolts are installed in designated areas in timing belt covers. See Fig. 5. Adjust drive belts to proper tension.

Timing Belt Cover Bolt .............................................................................................. 97 (11)

Fig. 4: Installing Flange

200

CHRYSLER, EAGLE & MITSUBISHI


2.0L 4-Cylinder DOHC, VIN Y
Labor Time Component Belt Kit No. Part No. 2) Remove power steering pump (hoses attached) and mounting bracket from engine. Move out of way. 3) Lower vehicle. Place jack under engine for support. Remove right side engine mount. Remove engine mount bracket from front of engine. Remove timing belt cover. Rotate engine clockwise to align the camshaft and crankshaft timing marks. See Fig. 1. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. 4) Install 8-mm Allen wrench into timing belt tensioner. See Fig. 1. Insert long end of a 3-mm Allen wrench into pin hole in the front of tensioner. Slowly rotate tensioner counterclockwise with 8-mm Allen wrench while pushing lightly on the 3-mm Allen wrench, until it slides into the locking hole. If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt. CAUTION: Mechanical timing belt tensioner is serviced as an assembly. To prevent premature timing belt failure and engine damage, do not separate tensioner pulley from tensioner bracket.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC, VIN Y Avenger, Neon & Sebring Coupe 1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246 Eclipse (Non-Turbo) 1995-99 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246 Talon (Non-Turbo) 1995-98 .............................. 1 3.6 Hours .. .. TCK246 .. ..... T246
1

With Air Conditioning. add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


CHRYSLER
On Neon, the manufacturer recommends replacing the timing belt at 105,000 miles. On Avenger and Sebring Coupe, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles.

EAGLE
For 1995-96 model years, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-98 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

MITSUBISHI
For 1995-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1998-99 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Timing Marks & Adjusting Belt Tension (Mechanical Timing Belt Tensioner) Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Mechanical Timing Belt Tensioner) 1) Ensure camshaft and crankshaft timing marks are aligned. Rotate crankshaft pulley sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2. 2) Install timing belt starting from crankshaft pulley sprocket, go around water pump sprocket, idler pulley, camshaft sprockets, and then around tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack. 3) Remove Allen wrench from timing belt tensioner pulley. Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. If timing marks do not align, remove timing belt and realign timing marks. 4) Continue installation in reverse of removal procedure. Adjust drive belts to proper tension. 5) On Neon only, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Mechanical Timing Belt Tensioner) 1) On Avenger and Sebring, remove coolant reservoir and place out of way. On all models, raise and support vehicle. Remove right inner splash shield. Remove center bolt from crankshaft pulley. Use gear puller to remove crankshaft pulley.

CHRYSLER, EAGLE & MITSUBISHI


2.0L 4-Cylinder DOHC, VIN Y (Cont.)

201

NOTE: The following revised information regarding the tensioner pulley pivot bolt is from Chrysler technical service bulletin 09-06-96; March 29, 1996. Also Mitsubishi technical service bulletin 96-11-004; May 1996. Timing Belt Tensioner Bracket Precaution On models with hydraulic timing belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed. Inspection Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Hydraulic Timing Belt Tensioner) 1) Ensure camshaft and crankshaft timing marks are aligned. Rotate crankshaft pulley sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 2. 2) Install timing belt starting from crankshaft pulley sprocket, go around water pump sprocket, idler pulley, camshaft sprockets, and then around tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack. Install timing belt tensioner, but do not nal tighten fasteners yet. 3) With 21 ft. lbs. (28 N.m) of torque applied to tensioner pulley, move tensioner against pulley bracket and tighten bolts to specication. See TORQUE SPECIFICATIONS. See Fig. 4. 4) Remove tensioner plunger locking pin. Pretension is correct when locking pin can be removed and installed again. 5) Rotate crankshaft clockwise 2 revolutions and check timing belt alignment marks. Reset belt if marks are not aligned. Install timing belt covers. 6) Continue installation in reverse of removal procedure. Adjust drive belts to proper tension. 7) On Neon only, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Crankshaft Timing Mark (Hydraulic Timing Belt Tensioner Shown; Mechanical Tensioner Is Similar) Removal (Hydraulic Timing Belt Tensioner) 1) Raise and support vehicle. Remove right inner splash shield. Remove center bolt from crankshaft pulley. Use gear puller to remove crankshaft pulley. 2) Remove power steering pump (hoses attached) and mounting bracket from engine. Move out of way. 3) Lower vehicle. Place jack under engine for support. Remove right side engine mount. Remove engine mount bracket from front of engine. Remove timing belt cover. Rotate engine clockwise to align the camshaft and crankshaft timing marks. See Fig. 3. CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. 4) Loosen timing belt tensioner to remove timing belt. If reusing old belt, mark belt with arrow to indicated direction of rotation. Remove timing belt. 5) Remove tensioner from engine. It will be necessary to compress the center plunger and lock it in place. 6) Place tensioner in a soft-jawed vise. Align the hole in the end of the tensioner center plunger with the hole in the end of the tensioner body. Slowly compress the tensioner, and when holes are aligned, insert a locking pin in the tensioner.

Courtesy of DaimlerChrysler Corp. Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Adjusting Timing Belt Tension (Hydraulic Timing Belt Tensioner)

Fig. 3: Aligning Timing Marks (Hydraulic Timing Belt Tensioner)

202

CHRYSLER, EAGLE & MITSUBISHI


2.0L 4-Cylinder DOHC, VIN Y (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 75 (101) Crankshaft Pulley Bolt ........................................................................................... 105 (142) Engine Mount Bracket-To-Engine Nut/Bolt ............................................................... 30 (41) Engine Mount-To-Body Bracket Through-Bolt .............................................. 72-87 (98-118) Engine Mount-To-Engine Mount Bracket Nut/Bolt ................................................... 64 (86) Engine Mount-To-Frame Rail Bolt (Neon) ................................................................ 40 (54) Power Steering Pump Bolts ...................................................................................... 29 (39) Timing Belt Tensioner Bolt Hydraulic Belt Tensioner ......................................................................................... 30 (41) Mechanical Belt Tensioner ...................................................................................... 21 (28) Timing Belt Tensioner Pulley Bolt Hydraulic Belt Tensioner ......................................................................................... 50 (68) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................................................................ 106 (12) Water Pump Bolt ..................................................................................................... 106 (12)

CHRYSLER, EAGLE & MITSUBISHI


2.4L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Belt Part No.

203

2.4L 4-Cyl. Colt, Colt Vista & Colt Wagon (Canada) 1992 Balance Shaft ...................................... .......... Camshaft ............................................... 2 2.4 1993 Balance Shaft ...................................... .......... Camshaft ............................................... 2 2.4 1994 Balance Shaft ...................................... .......... Camshaft ............................................... 2 2.4 Expo 1992 Balance Shaft ...................................... .......... Camshaft ............................................... 3 2.4 1993-95 Balance Shaft ...................................... .......... Camshaft ............................................... 3 2.4 Summit 1992 Balance Shaft ...................................... .......... Camshaft ............................................... 2 2.4 1993-96 Balance Shaft ...................................... .......... Camshaft ............................................... 2 2.4
1 2

1 .......... ..... T159 Hours .. ..... T204 1 .......... ..... T159 Hours .. ..... T230 1 .......... ..... T168 Hours .. ..... T230

1 .......... ..... T159 Hours .. ..... T204 1 .......... ..... T168 Hours .. ..... T230

1 .......... ..... T159 Hours .. ..... T204 1 .......... ..... T168 Hours .. ..... T230

Courtesy of DaimlerChrysler Corp.

Fig. 1: Aligning Camshaft Timing Belt Marks

Balance shaft labor time included in camshaft labor time. With Air Conditioning, add .2 hours. With Power Steering, add .2 hours. With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Loosen left front wheel lug nuts, then raise and support vehicle with jackstands. Remove left front wheel and tire assembly. Remove left front inner splash shield through the wheel well. Remove coolant reservoir. Support engine with jack and wooden block placed under the oil pan. Remove right side engine mount. 2) Remove accessory drive belts and pulleys. Remove timing belt upper and lower front covers. Rotate crankshaft in normal direction of rotation, and align timing marks. See Fig. 1. Remove auto-tensioner assembly, then remove camshaft timing belt. 3) Remove crankshaft sprocket bolt, then crankshaft sprocket and ange. Remove balance shaft timing belt tensioner pulley bolt, then remove tensioner pulley. Remove balance shaft timing belt. Ensure balance shaft (silent shaft) sprocket and crankshaft sprocket timing marks are properly aligned. See Fig. 2. Installation 1) Align crankshaft and balance shaft sprocket timing marks with the marks on the timing case. See Fig. 2. Install balance shaft timing belt over crankshaft and balance shaft sprockets. When installing timing belt, be sure tension side of belt has no slack. Install balance shaft belt tensioner. Assemble tensioner so that pulley is to the left of the installation bolt and pulley ange is facing the front of engine. 2) Raise the tensioner toward belt by hand. Apply sufficient pressure so that tension side of belt is taut, then tighten tensioner bolt. Ensure that tensioner does not rotate with bolt as it is tightened, as excessive tension will be placed on the belt. Ensure that timing marks are still
Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Balance Shaft Marks aligned, then check belt tension. See Fig. 2. There should be approximately .20-.28 (5.0-7.0 mm) slack on tension side of belt when belt is moved by hand. 3) Install crankshaft sprocket ange with the raised side facing outward, then install crankshaft sprocket. Measure protrusion of auto-tensioner plunger from tensioner housing. Protrusion should be .47 (11.9 mm). Position timing belt tensioner in a soft-jawed vise, then carefully compress plunger. After plunger has been compressed, insert a .055 (1.4 mm) pin or wire through tensioner body to hold plunger in place. 4) Remove auto-tensioner from vise and install on engine. Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. With oil pump sprocket timing marks aligned, remove plug from side of engine and insert a screwdriver, with a shaft diameter of .31 (8.0 mm), into the hole. See Fig. 3. If screwdriver can be inserted 2.4 (61.0 mm) or more, alignment is correct. 5) If screwdriver can only be inserted .8-1 (20.3-25.4 mm), rotate oil pump sprocket one revolution and realign timing marks. Ensure screwdriver can be inserted 2.4 (61.0 mm) or more. Leave screwdriver inserted in hole until after timing belt has been installed. 6) Install camshaft timing belt, rst over crankshaft sprocket, then oil pump sprocket, idler pulley, camshaft sprocket and tensioner pulley. Hold belt so there is no slack on tension side. Apply counterclockwise

204

CHRYSLER, EAGLE & MITSUBISHI


2.4L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolts ............................................................................................. 18 (25) Right Side Engine Mount Bolt/Nuts .......................................................................... 42 (58) Through-Bolt Attaching Nuts ..................................................................................... 25 (34) Through-Bolt Nut ....................................................................................................... 51 (70) INCH Lbs. (N.m) Tensioner Pulley Bolt ............................................................................................... 31 (3.5) Timing Belt Front Cover Bolts ...................................................... .............. 84-108 (9.6-12) Water Pump Pulley Bolts ......................................................................................... 78 (8.9)

force on camshaft sprocket to aid in tensioning belt. Ensure that all timing marks remain aligned. Carefully position timing belt tensioner pulley against timing belt, then tighten center bolt. Rotate crankshaft pulley 1/4 turn counterclockwise, then turn clockwise, aligning crankshaft and camshaft timing marks. 7) Loosen tensioner pulley retaining bolt, then position socket tool and a suitable torque wrench to the pulley. Tighten to specication. See TORQUE SPECIFICATIONS. Tighten retaining bolt while holding the pulley in position. Install set screw tool through left hand engine support bracket. Engine may need to be raised slightly to install set screw tool. Tighten set screw tool until it contacts tensioner arm, then tighten tool slightly more. Remove pin or wire retaining auto-tensioner plunger, then remove set screw tool. 8) Rotate engine in the clockwise direction two turns. After approximately 15 minutes, measure auto-tensioner plunger protrusion from tensioner housing. Plunger protrusion should be .15-.18 (3.8-4.6 mm). See Dimension A in illustration. See Fig. 4. If protrusion is not within limits, readjust timing belt tension. 9) Install timing belt lower and upper front covers, and tighten bolts to specication. Install crankshaft pulley and water pump pulley, and tighten attaching bolts to specication. 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 specication. See TORQUE SPECIFICATIONS. After completing installation of engine mount, remove jack and wooden block supporting engine. Install coolant reservoir. Install left front inner splash shield. Install left front wheel and tire assembly, then lower vehicle. Connect negative battery cable.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Holding Silent Shaft In Stationary Position (Typical)

Courtesy of DaimlerChrysler Corp.

Fig. 4: Measuring Auto Tensioner Protrusion

DAEWOO
1.6L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC Lanos 1999-2002 ................................................
1

205

Labor Time

Belt Part No.

2.3 Hours .. ..... T310

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

3) Rotate water pump until the adjust arm pointer on the automatic tensioner is aligned with the pointer on the automatic tensioner bracket. See Fig. 8. Final tighten water pump bolts. See TORQUE SPECIFICATIONS. 4) Remove crankshaft sprocket center bolt. Install power steering pump (if equipped). Tighten bolts to specication. Install timing belt covers. Install crankshaft pulley. Tighten center bolt to specication. 5) Install power steering pump pulley (if removed). Install accessory drive belts. Install right front splash shield. Install right front wheel. Install air lter housing. Connect air intake temperature sensor connector. Connect negative battery cable. Adjust the drive belts to correct tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends replacing the belt at 60,000 miles, except in California. In California, inspect the belt at 60,000 miles and replace the belt at 102,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air lter housing. 2) Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove accessory drive belts. See Fig. 1. 3) Remove power steering pump pulley bolts (if equipped). Remove power steering pump pulley. Remove crankshaft pulley center bolt. Remove crankshaft pulley. Lower vehicle. 4) Remove upper and lower timing belt covers. See Fig. 2. Remove power steering pump mount bolts (if equipped). Set power steering pump aside with hoses attached. 5) Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6) Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3. Ensure camshaft sprocket timing marks face each other. See Fig. 4. CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7) Slightly loosen water pump bolts. Using Timing Belt Adjuster (J-42492), rotate water pump counterclockwise to relieve tension on the timing belt. See Fig. 5. Remove timing belt. Installation 1) Ensure crankshaft and camshaft timing marks are still aligned. Install the timing belt. See Fig. 6. Turn water pump clockwise until the adjust arm pointer on the automatic tensioner aligns with the notch on the automatic tensioner bracket. See Fig. 7. Tighten water pump bolts. 2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Loosen water pump bolts.

Courtesy of Daewoo Motor America, Inc.

Fig. 1: Removing A/C Compressor Drive Belt

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Timing Belt Covers

206

DAEWOO
1.6L 4-Cylinder DOHC (Cont.)

Courtesy of Daewoo Motor America, Inc.

Fig. 3: Aligning Crankshaft Sprocket Timing Marks


Courtesy of Daewoo Motor America, Inc.

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

Courtesy of Daewoo Motor America, Inc. Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Camshaft Sprocket Timing Marks

Fig. 6: Identifying Timing Belt Routing

DAEWOO
1.6L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

207

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 49 (68) Crankshaft Pulley Center Bolt Step 1 ...................................................................................................................... 70 (95) Step 2 .................................................................................................................... Plus 30 Step 3 .................................................................................................................... Plus 15 Power Steering Pump Mount Bolt ............................................................................ 18 (25) Power Steering Pump Pulley Bolt ............................................................................ 18 (25) Timing Belt Automatic Tensioner Bolt ....................................................................... 18 (25) Water Pump Bolt ....................................................................................................... 10 (89) Wheel Lug Nuts ...................................................................................................... 88 (120) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10)

Courtesy of Daewoo Motor America, Inc.

Fig. 7: Aligning Timing Belt Tensioner With Notch

Courtesy of Daewoo Motor America, Inc.

Fig. 8: Aligning Timing Belt Tensioner With Pointer

208

DAEWOO
2.0L 4-Cylinder DOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC Nubira 1999-2002 ................................................. 1.8 Hours ... ..... T309 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends replacing the belt at 72,000 miles, except in California. In California, inspect the belt at 60,000 miles and replace the belt at 102,000 miles.

REMOVAL & INSTALLATION


Courtesy of Daewoo Motor America, Inc.

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

Fig. 1: Supporting Engine Assembly

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air lter housing. 2) Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3) Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4) Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1. Remove engine mount bracket from timing belt end of engine. See Fig. 2. 5) Remove front timing belt cover. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6) Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3. Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4. CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7) Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 5. Remove timing belt. Installation 1) Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6. Turn the timing belt tensioner clockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS. 2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3) If timing belt tensioner is correctly aligned, install timing belt cover. Install the engine mount bracket on the timing belt end of engine. Install crankshaft pulley. Install serpentine accessory drive belt. Install right front splash shield. Install right front wheel. 4) Install air lter housing. Connect air intake temperature sensor connector. Connect negative battery cable.
Courtesy of Daewoo Motor America, Inc.

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Engine Mount Bracket

Fig. 3: Aligning Crankshaft Sprocket Timing Marks

DAEWOO
2.0L 4-Cylinder DOHC (Cont.)

209

Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Camshaft Sprocket Timing Marks


Courtesy of Daewoo Motor America, Inc.

Fig. 6: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 .................................................................................................................... Plus 60 Step 3 .................................................................................................................... Plus 15 Crankshaft Pulley Bolt ............................................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................... 96 (130) Step 2 ............................................................................................................... Plus 40-50 Engine Mount Bracket Bolt ....................................................................................... 44 (60) Timing Belt Idler Pulley Bolt/Nut ............................................................................... 18 (25) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Water Pump Bolt ....................................................................................................... 15 (20) Wheel Lug Nuts ...................................................................................................... 88 (120) INCH Lbs. (N.m)
Courtesy of Daewoo Motor America, Inc.

Timing Belt Cover Bolt ................................................................................................ 53 (6)

Fig. 5: Locating Timing Belt Tensioner

210

DAEWOO
2.2L 4-Cylinder DOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. DOHC Leganza 1999-2002 ................................................. 1.8 Hours ... ..... T305 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends replacing the belt at 72,000 miles, except in California. In California, inspect the belt at 60,000 miles and replace the belt at 102,000 miles.

REMOVAL & INSTALLATION


Courtesy of Daewoo Motor America, Inc.

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

Fig. 1: Supporting Engine Assembly

TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove resonator from throttle body. Remove air lter housing. 2) Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. 3) Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. 4) Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1. Remove engine mount bracket from timing belt end of engine. See Fig. 2. 5) Remove power steering hose clamp bolt, and position hose away from timing belt cover. Remove front timing belt cover. See Fig. 3. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). 6) Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 4. Align camshaft sprocket timing marks with notches on valve cover. See Fig. 5. CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover. 7) Loosen the automatic tensioner bolt. Use an Allen wrench to rotate tensioner and relieve tension on timing belt. See Fig. 6. Remove timing belt. Installation 1) Ensure crankshaft and camshaft timing marks are still aligned. Install the timing belt. See Fig. 7. Turn the timing belt tensioner counterclockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt to specication. See TORQUE SPECIFICATIONS. 2) Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 3) If timing belt tensioner is correctly aligned, install timing belt cover. See Fig. 3. Install the engine mount bracket on the timing belt end of engine. Position power steering hose in place, and install clamp bolt. Install crankshaft pulley. Install serpentine accessory drive belt. 4) Install right front splash shield. Install right front wheel. Install air lter housing and resonator. Connect air intake temperature sensor connector. Connect negative battery cable.

Courtesy of Daewoo Motor America, Inc.

Fig. 2: Removing Engine Mount Bracket

Courtesy of Daewoo Motor America, Inc.

Fig. 3: Identifying Front Timing Belt Cover & Bolts

DAEWOO
2.2L 4-Cylinder DOHC (Cont.)

211

Courtesy of Daewoo Motor America, Inc.

Fig. 4: Aligning Crankshaft Sprocket Timing Mark

Courtesy of Daewoo Motor America, Inc.

Fig. 7: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 .................................................................................................................... Plus 60 Step 3 .................................................................................................................... Plus 15 Crankshaft Pulley Bolt ............................................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................... 96 (130) Step 2 ............................................................................................................... Plus 40-50 Engine Mount Bracket Bolt ....................................................................................... 44 (60) Timing Belt Idler Pulley Bolt/Nut ............................................................................... 18 (25) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Water Pump Bolt ....................................................................................................... 15 (20) Wheel Lug Nuts ...................................................................................................... 88 (120) INCH Lbs. (N.m) Power Steering Hose Clamp Bolt .............................................................................. 71 (8) Timing Belt Cover Bolt ................................................................................................ 53 (6)

Courtesy of Daewoo Motor America, Inc.

Fig. 5: Aligning Camshaft Sprocket Timing Marks

Courtesy of Daewoo Motor America, Inc.

Fig. 6: Identifying Timing Belt Tensioner

212

DAIHATSU
1.0L 3-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.0L 3-Cyl. Charade 1988-92 ....................................................


1

1.8 Hours .. ..... T178

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Daihatsu Motor Co., LTD.

REMOVAL & INSTALLATION


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

Fig. 1: Removing Engine Front Mounting Bracket Nuts

TIMING BELT
Removal 1) Disconnect negative battery cable. Loosen accelerator cable lock nut. Remove accelerator cable from throttle body and clamp. Remove vent hose from valve cover. Remove air cleaner assembly, and mark all hoses for installation reference. 2) Remove alternator electrical connector. On models equipped with A/C, loosen idler pulley mounting nut. Loosen adjusting bolt, and remove drive belt. On all models, remove alternator drive belt. 3) Remove right lower engine cover. Using a wooden block and jack, apply slight pressure to oil pan to release pressure from front mounts. Remove front mount bracket-to-mount nuts. Remove front mount bracket-to-cylinder head bolts. Remove the 3 front engine mounting bracket-to-cylinder head attaching bolts. See Figs. 1 and 2. Slightly lower jack and remove front mount bracket. 4) Remove water pump pulley. Working from left side fenderwell, place socket on crankshaft pulley bolt, and rotate crankshaft so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on ywheel aligns with mating mark on bellhousing. See Fig. 3. 5) Remove oil lter cap. Ensure exhaust valve rocker on No. 1 cylinder is free. If rocker is not free, rotate crankshaft 360 degrees (one turn), and align timing marks. 6) Insert screwdriver through bellhousing to hold ring gear, and remove crankshaft pulley retaining bolt. Remove crankshaft pulley. Remove upper and lower timing belt covers. Remove ange on front of crankshaft pulley. See Fig. 4. 7) If reusing timing belt, mark belt rotation direction. Loosen idler pulley bolt. Position pulley as far left as possible, and tighten pulley bolt. Remove timing belt. Remove idler pulley and spring. 8) If replacing belt pulleys, remove crankshaft belt pulley and ange. 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 specication. See TIMING BELT PULLEY SPECIFICATIONS table. 3) Inspect all belt pulleys for wear in belt areas. Measure diameter of crankshaft and camshaft belt pulleys. Replace pulleys if measurements are not to specication.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 2: Removing Cylinder Head Mounting Bracket

Courtesy of Daihatsu Motor Co., LTD.

Fig. 3: Aligning Flywheel Timing Marks

Courtesy of Daihatsu Motor Co., LTD.

Fig. 4: Installing Crankshaft Pulley & Flanges

DAIHATSU
1.0L 3-Cylinder (Cont.)
TIMING BELT PULLEY SPECIFICATIONS Application Specication 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 specication. See TORQUE SPECIFICATIONS. Install crankshaft belt pulley and inner ange in proper direction. See Fig. 4. 2) Install idler pulley and tension spring. Position pulley as far left as possible. Align camshaft and crankshaft mating marks. See Fig. 5. Install timing belt on engine. If installing used belt, ensure it is installed in original rotation direction. If installing new belt, align the mark on back of belt with mating mark on each pulley. 3) After belt is installed, loosen idler pulley to apply spring tension on idler pulley. Temporarily tighten idler pulley bolt. 4) Temporarily install bolt in crankshaft and rotate crankshaft COUNTERCLOCKWISE 2 complete revolutions until No. 1 piston is at TDC. The F mark on camshaft drive pulley should be toward top when No. 1 piston is at TDC. 5) Loosen idler pulley bolt to apply spring tension against timing belt. Tighten idler pulley bolt to specication. Ensure all timing marks align. 6) Install outer ange on crankshaft pulley, with protruding side toward crankshaft belt pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

213

Courtesy of Daihatsu Motor Co., LTD.

Fig. 5: Aligning Crankshaft & Camshaft Mating Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 22-33 (30-44) Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98) Timing Belt Tensioner Bolt ............................................................ ................. 25-33 (34-44) Water Pump Bolts ........................................................................................... 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Cover Bolts ................................................................ ..................... 18-36 (2-4) Water Pump Pulley Bolt ................................................................ ..................... 53-80 (6-9)

214

DAIHATSU
1.3L & 1.6L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.3L 4-Cyl. Charade 1989-92 .................................................... 1.6L 4-Cyl. Rocky 1990-92 ....................................................
1

1.8 Hours .. ..... T181

2.3 Hours .. ..... T182

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (1.3L) 1) Disconnect negative battery cable. Remove air conditioner drive belt and idler assembly (if equipped). Remove air conditioner compressor, leaving hoses attached. 2) Remove power steering pump from engine. Mark and remove all hoses attached to air cleaner. Remove air cleaner. Remove oil pressure switch wire harness brackets, and pull wire toward throttle body. 3) Loosen water pump pulley bolts. Remove water pump pulley and belt. Slightly raise engine, and disconnect engine mount bracket and insulators. Remove service hole cover to access crankshaft pulley bolts. See Fig. 1. Remove crankshaft pulley by removing 4 small attaching bolts. 4) Remove upper and lower timing belt covers. See Fig. 2. Rotate engine until F mark on camshaft sprocket aligns with timing mark on cylinder head cover. See Fig. 3. If reusing belt, mark arrow on belt to indicate direction of rotation. 5) Loosen timing belt tensioner bolt, and move tensioner away from belt. Tighten timing belt tensioner. Remove timing belt from engine. Remove cylinder head cover.
Courtesy of Daihatsu Motor Co., LTD.

Fig. 2: Identifying Timing Belt Components (1.3L)

Courtesy of Daihatsu Motor Co., LTD.

Fig. 3: Locating Timing Belt Alignment Marks 3) Remove timing belt cover. Rotate engine until F mark on camshaft sprocket aligns with timing indicator on cylinder head cover. See Fig. 3. If reusing belt, mark arrow on belt to indicate direction of rotation. 4) Loosen timing belt tensioner bolt, and move tensioner away from belt. Tighten timing belt tensioner, and remove timing belt from engine. Inspection (All Models) 1) Inspect timing belt for wear and defects. Check timing belt tensioner for smooth rotation. Ensure tensioner contact surface is clean and not damaged. Check camshaft for smooth rotation. Check sides of belt. If belt side is damaged, check sprocket ange. 2) Check for dirt or contamination on sprocket teeth. Measure sprocket diameter. Camshaft sprocket should be 4.717 (119.8 mm). Crankshaft sprocket should be 2.335 (59.37 mm). Clean and/or repair as necessary.

Courtesy of Daihatsu Motor Co., LTD.

Fig. 1: Locating Service Hole Cover (Charade) Removal (1.6L) 1) Disconnect negative battery cable. Remove air cleaner assembly. Loosen and remove drive belts. Remove radiator reserve tank. Disconnect clutch cable clamps from upper radiator shroud. 2) Disconnect fan clutch. Remove radiator fan shroud and fan clutch. See Fig. 4. Remove water pump pulley and belt. Remove crankshaft pulley attaching bolts and remove pulley. Remove 8 timing belt cover bolts.

DAIHATSU
1.3L & 1.6L 4-Cylinder (Cont.)

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 deect 0.2 (5 mm) with a pushing force of 1.8-3.5 lbs. (0.8-1.6 kg). To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Daihatsu Motor Co., LTD. Courtesy of Daihatsu Motor Co., LTD.

Fig. 4: Identifying Timing Belt Components (1.6L) Installation (All Models) 1) Install crankshaft timing belt sprocket (if removed). Ensure recessed side of crankshaft sprocket ange faces engine block. Ensure crankshaft sprocket timing notch (drilled mark) aligns with timing indicator on engine. See Fig. 3. Tighten crankshaft timing belt sprocket bolt to 65-72 ft. lbs. (88-98 N.m). 2) Install camshaft timing belt sprocket (if removed). Tighten camshaft sprocket bolts to 11-16 ft. lbs. (15-22 N.m). Apply Sealant (Three Bond 1104) or equivalent, to cylinder head near camshaft bearing cap contact areas. Install cylinder head cover. Ensure camshaft and crankshaft sprockets are aligned. See Fig. 3. 3) Install timing belt on sprockets. If installing used belt, ensure there are 35 teeth between sprocket timing notches (drilled marks), and belt rotates in same direction. If installing new belt, align marks on belt with timing notches (drilled marks) on sprockets. See Fig. 3. Loosen ten-

Fig. 5: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Idler Pulley Bolt ...................................................................... ................. 23-35 (31-47) Camshaft Sprocket Bolts ................................................................................ 11-16 (15-22) Crankshaft Pulley Bolts ................................................................. ................. 15-22 (20-30) Crankshaft Sprocket Bolt .............................................................. ................. 65-72 (88-98) Timing Belt Tensioner Bolt ............................................................ ................... 2-32 (30-44) Water Pump Bolts ........................................................................................... 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Cover Bolts ................................................................ ..................... 18-35 (2-4) Water Pump Pulley Bolt ................................................................ ..................... 53-80 (6-9)

216

EAGLE
2.2L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. Medallion 1989 ........................................................... 2.3 Hours ... ..... T140 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove hood. Disconnect negative battery cable. Drain coolant and discharge A/C system. Remove grille, radiator support and facia panel. Disconnect cooling fan and thermoswitch wires. Remove radiator, cooling fan and A/C condenser. 2) Loosen power steering pump belt. Remove timing belt cover. Loosen serpentine drive belt adjustment bolt and nut. Loosen belt and remove from water pump pulley. Remove water pump pulley bolt and pulley. Remove water pump attaching bolts. Remove water pump, gasket, timing belt and timing belt tensioner. Installation 1) Use feeler gauge to measure clearance between intermediate shaft cover and timing belt tensioner. Clearance should be .004 (.10 mm). See Fig. 1. Turn adjusting screw to adjust clearance. Position camshaft sprocket timing index in line with static timing mark. Position crankshaft so No. 1 piston is at TDC of compression stroke. Remove plug in cylinder block, and insert TDC Rod (Mot. 861) into TDC hole in crankcase. Install timing belt. See Fig. 2. 2) Position timing belt cover over sprockets and check camshaft timing mark with index on cover. Remove TDC rod and install plug in cylinder block. Rotate camshaft clockwise 2 complete revolutions. DO NOT rotate counterclockwise. Remove timing belt cover and loosen timing belt tensioner bolts a maximum of 1/4 turn. 3) Spring-loaded timing belt tensioner will automatically adjust to correct position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004 (.10 mm). Tighten lower timing belt tensioner bolt. Tighten upper bolt. Test belt tension with Tension Gauge (Ele 343). Deection should be .216-.276 (5.5-7.0 mm). Install water pump with new gasket. Loosen timing belt tensioner bolts and allow tensioner spring to tighten timing belt. Retighten timing belt tensioner bolts. 4) Install timing belt cover, water pump pulley and water pump pulley bolt. Reverse removal procedures to complete installation. Adjust the drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 1: Checking Timing Belt Tensioner Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 37 (50) Crankshaft Pulley Bolt ............................................................................................. 96 (130)
Courtesy of DaimlerChrysler Corp.

Fig. 2: Installing Timing Belt

FIAT
1.3L & 1.5L 4-Cylinder
TIMING BELT APPLICATION Application
1

217

Labor Time

Belt Part No.

1.3L 4-Cyl. 128 1973-78 ..................................................... 1979 ........................................................... X1/9 1974-78 ..................................................... 1.5L 4-Cyl. Strada 1979-82 ..................................................... X1/9 1979-83 .....................................................
1

2.3 Hours ... ..... T018 2.4 Hours ... ..... T018 2.3 Hours ... ..... T018

2.0 Hours ... ..... T069 2.0 Hours ... ..... T069

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Fiat Motor Co.

REMOVAL & INSTALLATION


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

Fig. 1: Aligning Timing Marks 3) Remove valve cover and check that camshaft lobes of No. 4 cylinder are pointing up. Remove distributor. Loosen idler pulley lock nut. Remove timing belt starting at idler pulley. Installation (X1/9) 1) Install timing belt making sure that teeth are properly engaged in sprockets. Start installation of timing belt at crankshaft pulley. Release idler pulley lock nut and retighten after tension is on belt. NOTE: Never allow engine to rotate backwards, or slack will develop in belt and belt will jump timing. 2) Rotate engine 2 turns in direction of engine rotation. Loosen idler pulley lock nut to ensure all slack is removed. Retighten lock nut. Rotate engine until No. 4 cylinder is in ring position (cam lobe up). Install remaining components in reverse of removal order. Adjust drive belts to proper tension.

TIMING BELT
Removal (128 & Strada) 1) Disconnect negative battery cable. Remove right guard and loosen timing belt cover retaining screws, from under vehicle. Remove timing belt cover. Check timing by aligning index marks on top and bottom of camshaft sprocket with index marks on engine mounting and upper case. See Fig. 1. Index on crankshaft sprocket should be in alignment with index on crankshaft seal case. 2) Put vehicle in low gear, and apply hand brake to prevent crankshaft from turning. Remove fan belt, loosen tensioner pulley retaining nut and relieve tension. Remove timing belt. Installation (128 & Strada) Install new belt, making sure belt and sprocket teeth engage correctly. Tighten pulley support nut. Recheck timing. Install remaining components. Adjust drive belts to proper tension. Removal (X1/9) 1) Disconnect negative battery cable. Rotate No. 4 cylinder into ring position at top dead center. Position transmission into 4th gear, to prevent crankshaft from turning. Apply parking brake. CAUTION: If camshaft is turned independently of engine, valves may hit pistons, causing engine damage. 2) Remove right guard from under engine. Remove timing belt cover. Loosen alternator and remove alternator/water pump drive belt. Loosen air pump and remove drive belt.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 61 (85) Crankshaft Pulley/Sprocket Nut ............................................................................ 101 (137) Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45)

218

FIAT
1.6L & 1.8L 4-Cylinder
REMOVAL & INSTALLATION
1

TIMING BELT APPLICATION Application 1.6L 4-Cyl. 124 1971-74 1.8L 4-Cyl. Brava 1974-78 124 1974-78 131 1975-78
1

Labor Time

Belt Part No.

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

..................................................... 1.9 Hours ... ..... T020

TIMING BELT
..................................................... 2.4 Hours ... ..... T020 ..................................................... 1.9 Hours ... ..... T020 ..................................................... 1.9 Hours ... ..... T020 Removal 1) Disconnect negative battery cable. Drain cooling system and remove upper radiator hose. Remove upper section of air duct. Remove spark plugs. Rotate crankshaft until marks on both camshaft sprockets are aligned with xed pointer on front of engine. See Fig. 1 or 2. Number 4 piston should now be at TDC ring position. Place transmission in 4th gear and apply parking brake to prevent crankshaft from turning. CAUTION: Do not turn crankshaft or camshafts independent of each other, as valves may hit pistons. NOTE: Any time tension is relieved from timing belt, timing belt must be replaced.

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends 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
1.6L & 1.8L 4-Cylinder (Cont.)
2) Remove lower engine protection plate. Remove all drive belts. Disconnect coolant extension union at cylinder head. Loosen timing belt idler pulley nut and mounting bracket bolt, and release timing belt tension. On 1.6L engines before No. 42577, pry pulley to release tension. Tighten pulley nut and bracket bolt, and remove belt. Installation 1) Install timing belt, making sure not to move sprockets. Ensure hole in auxiliary shaft pulley is lined up with tensioner pulley bolt. 2) To adjust timing belt tension, loosen idler pulley tensioner nut and allow pulley to tension timing belt. Rotate crankshaft pulley 2 full turns and recheck timing marks. Tighten tensioner nut and bracket bolt. Adjust drive belts to proper tension.

219

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 87 (118) Tensioner Nut ............................................................................................................ 33 (45)

Courtesy of Fiat Motor Co.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks (1.8L)

220

FIAT
2.0L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. Brava 1979-81 .................................................... Spider 2000 1979-82 ....................................................
1

2.4 Hours .. ..... T068 3.1 Hours .. ..... T068

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 30,000 miles.

REMOVAL & INSTALLATION


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

CAUTION: Timing belts must not be reused once tension is relieved. Crankshaft and/or camshafts must not be turned with belt removed due to resultant valve and/or piston damage.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

TIMING BELT
Removal 1) Disconnect negative battery cable and drain cooling system. Remove spark plugs and set engine to re (TDC) on No. 4 cylinder. Crankshaft and camshaft timing marks must be aligned with indicators. See Fig. 1. Remove upper radiator hose from T union, then unbolt and remove union from the cylinder head. 2) Remove hot air hose from exhaust manifold to air intake. Remove all drive belts from crankshaft pulley. Remove water pump pulley bolts and remove pulley. Remove outer timing belt cover. 3) Lock crankshaft to prevent turning and remove crankshaft pulley. Remove lower timing cover. Loosen belt tensioner to release belt tension. Remove timing belt. Installation Turn auxiliary sprocket to align hole in sprocket with sprocket bolt and spring retaining bolt. See Fig. 2. Install belt and adjust tensioner, then turn crankshaft 2 full turns, and recheck tension and timing. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 87 (118) Timing Belt Tensioner Nut ........................................................................................ 33 (45)
Courtesy of Fiat Motor Co.

Fig. 2: Identifying Sprocket Alignment For Timing Belt Installation

FORD
1.3L 4-Cylinder
TIMING BELT APPLICATION Application 1.3L 4-Cyl. Aspire 1994-97 Festiva 1988-89 1990-93
1

221

Labor Time

Component Belt Kit No. Part No.

VIN H .............................. .............................. ..............................


1

2.0 Hours .. .. TCK185 .. ..... T185 2.0 Hours .. .. TCK141 .. ..... T141 2.0 Hours .. .. TCK185 .. ..... T185

1 1

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For Aspire, the manufacturer recommends the belt be replaced every 60,000 miles on Federal vehicles, and 105,000 miles on California vehicles. For Festiva, the manufacturer recommends the belt be replaced every 60,000 miles.

Courtesy of Ford Motor Co.

Fig. 1: Removing Right Inner Fender Panel

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory belts. Remove water pump pulley. Remove right inner fender panel to gain access to crankshaft pulley. See Fig. 1. Remove outer crankshaft pulley attaching bolts, then outer stiffener and spacer. Remove inner pulley and baffle plate. Remove bolts retaining upper and lower cover halves to engine front. Remove both covers. See Fig. 2. NOTE: Always rotate engine in direction of normal operation. Rotating crankshaft backwards may cause belt to jump timing. 2) Mark timing belt direction of rotation for installation reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley, spring, and spring cover. Remove timing belt. CAUTION: Never twist, turn inside out, or bend timing belt. Keep belt away from grease and oil. 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 specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
Courtesy of Ford Motor Co.

Fig. 2: Locating Timing Belt Upper & Lower Covers

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 29-40 (39-54) Camshaft Pulley Bolt ..................................................................... ................... 9-13 (12-17) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Crankshaft Pulley Bolts ................................................................. ................. 10-13 (12-17) Crankshaft Sprocket Bolt ............................................................................ 80-87 (108-118) Power Steering Adjuster Nut ........................................................ ................. 27-38 (37-52) Timing Belt Tensioner Adjuster Bolt ............................................. ................. 14-19 (19-26) Water Pump Pulley Bolts .............................................................. ................. 36-45 (49-61) INCH Lbs. (N.m) Camshaft Cover ................................................................................................ 71-97 (8-11) Timing Belt Cover Bolt ...................................................................................... 71-97 (8-11) Valve Cover Bolt ........................................................................... ..................... 44-79 (5-9) Fig. 3: Aligning Timing Marks
Courtesy of Ford Motor Co.

222

FORD
1.6L 4-Cylinder DOHC
Labor Time Component Belt Kit No. Part No. Tighten tension pulley to specication. See TORQUE SPECIFICATIONS. Rotate engine 2 full turns. Verify timing mark alignment. 4) Measure timing belt tension between camshaft pulleys. Belt deection should be 0.33-0.45 (8.5-11.5 mm). See Fig. 3. If incorrect, loosen tension pulley and repeat procedure. If correct tension cannot be achieved, replace tension spring. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. DOHC Capri 1991-94 ............................... 3.6 Hours ... .. TCK179 .. ..... T179 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front tire and wheel assembly. Remove right front splash guard. Lower vehicle. Remove spark plugs and set No. 1 cylinder to TDC of compression stroke. Remove accessory drive belts. Remove dipstick. Remove water pump pulley. Remove crankshaft pulley, damper and baffle plate. See Fig. 1. 2) Remove upper timing belt cover. Remove center and lower timing belt covers. Remove timing belt tension spring. Loosen timing belt tension pulley. Support engine with oor jack. Remove right engine mount. After marking timing belt direction of rotation, remove timing belt. See Fig. 1.
Courtesy of Ford Motor Co.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components Installation 1) Ensure sprockets, tensioner, and idler pulleys are clean and not worn, deformed, or damaged. Align timing marks on camshafts and crankshaft. Intake cam should have letter I aligned with arrow on belt cover. Exhaust cam should have letter E aligned with arrow on belt cover. Crankshaft key should align with arrow. See Fig. 2. CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with solvents. Wipe them clean only. 2) Unloaded free length of timing belt tension spring should be 2.315 (58.8 mm). Replace spring as necessary. Tighten tension pulley with tension spring fully extended. If reusing timing belt, install belt in original direction of rotation. Keep tension on opposite side of tensioner as tight as possible. 3) Rotate crankshaft 2 full turns. Inspect alignment of timing marks. If any mark is not aligned, remove timing belt and reset timing. Loosen tension pulley retaining bolt to allow tension spring to tighten belt. Fig. 3: Checking Timing Belt Tension

Courtesy of Ford Motor Co.

TECHNICAL SERVICE BULLETIN REVISION


NOTE: Information on revised service procedure is from Ford technical service bulletin 94-17-5; August 24, 1994. This bulletin supercedes 94-15-10; July 21, 1993.

SWISH NOISE FROM TIMING BELT


Issue Some 1990 1.6L and 1.6L engines built up to 10/1/1990 may exhibit a swish noise from the timing belt. This is caused be a belt guide plate that does not maintain correct timing belt alignment. Action A revised timing belt guide plate and pulley boss is available to correct the noise. See Fig. 4. This procedure will also require replacement of the crankshaft and associated hardware.

FORD
1.6L 4-Cylinder DOHC (Cont.)
This procedure is also recommended when replacing a damaged crankshaft to prevent timing belt noise. When replacing the timing belt and crankshaft, all associated parts MUST be replaced as a set. See TIMING BELT PULLEY PARTS (1990) table. The crankshaft pulley center bolt listed in the TORQUE SPECIFICATIONS table is the revised bolt torque. Use Crankshaft Pulley Holder (T92C-6316-AH). TIMING BELT PULLEY PARTS (1990) Application Part No. Crankshaft ...................................................... .................................................. F1JY-6303-A Crankshaft Accessory Pulley (With FEAD Belt) With A/C & Power Steering ........................................................................ F1JY-6A312-A Crankshaft Damper Pulley (With V Belt) Generator & Water Pump ........................................................................... F1JY-6A312-A Crankshaft Pulley Boss w/Pin ...................................................................... F1CZ-6C337-A Crankshaft Pulley Plate ................................. ................................................. F1CZ-6378-A Crankshaft Timing Pulley ............................... ................................................. F1CZ-6306-B Oil Pan Gasket .............................................. ................................................. F1CZ-6701-B Oil Pump Assembly ....................................... ................................................. F2CZ-6600-A Oil Pump Body-To-Inlet Tube Gasket ........... ................................................. E7GZ-6626-A Oil Pump-To-Cylinder Block Gasket ............. ................................................. E7G7-6659-A Timing Pulley Bolt .......................................... ............................................... F1CZ-6A340-A Timing Pulley Key .......................................... ............................................... F1CZ-6B316-B

223

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 29-40 (39-54) Camshaft Pulley Bolt ..................................................................... ................. 37-45 (49-61) Crankshaft Pulley Bolts ................................................................. ................. 10-13 (12-17) Crankshaft Pulley Center Bolt ................................................................ 115-123 (157-167) Power Steering Adjuster Nut ........................................................ ................. 27-38 (37-52) Timing Belt Tensioner Adjuster Bolt ............................................. ................. 14-19 (19-26) INCH Lbs. (N.m) Camshaft Cover ................................................................................................ 71-97 (8-11) Timing Belt Cover Bolt ...................................................................................... 71-97 (8-11) Valve Cover Bolt ........................................................................... ..................... 44-79 (5-9) Water Pump Pulley Bolt .................................................................................... 71-97 (8-11)

Courtesy of Ford Motor Co.

Fig. 4: Identifying New & Old Style Crankshaft & Timing Belt Pulley

224

FORD
1.6L & 1.9L 4-Cylinder SOHC
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.6L 4-Cyl. SOHC Escort, EXP, LN7 & Lynx 1981-85 ............................... Tracer (Includes Canadian) 1987-90 ............................... 1.9L 4-Cyl. SOHC Escort & EXP 1985-90 ............................... 1991 Thru: 3-25-91 ................... From: 3-26-91 .................. 1992-96 ............................... Lynx 1985-87 ............................... Tracer 1991 Thru: 3-25-91 ................... From: 3-26-91 .................. 1992-96 ...............................
1

2.2 Hours ... .. TCK067 .. ..... T067 2.0 Hours ... .. TCK141 .. ..... T141

2.2 Hours ... .. TCK067 .. ..... T067 2.3 Hours ... .. TCK067 .. ..... T067 2.3 Hours ... .. TCK194 .. ..... T194 2.3 Hours ... .. TCK194 .. ..... T194 2.2 Hours ... .. TCK067 .. ..... T067
Courtesy of Ford Motor Co.

2.3 Hours ... .. TCK067 .. ..... T067 2.3 Hours ... .. TCK194 .. ..... T194 2.3 Hours ... .. TCK194 .. ..... T194

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles. CAUTION: The 1.6L and 1985-91 1.9L engines are interference engines. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

Courtesy of Ford Motor Co.

Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory drive belt. Remove timing belt cover. Rotate crankshaft clockwise, and align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 1. Ensure crankshaft sprocket timing mark aligns with oil pump housing timing mark. 2) Loosen timing belt tensioner bolt. See Figs. 2, 3 and 4. Pry timing belt tensioner away from timing belt, and tighten tensioner bolt. Remove spark plugs. Support engine with oor jack. Remove engine mount at timing belt end of engine. 3) Raise and support vehicle. Remove right front splash shield. Remove retaining bolt and crankshaft pulley. Remove timing belt. CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. If camshaft must be rotated, install crankshaft pulley and position crankshaft with cylinder No. 1 at 90 degrees BTDC. Installation 1) Install timing belt over sprockets in counterclockwise direction, starting at crankshaft. CAUTION: Maintain tension on timing belt between crankshaft and camshaft sprockets when installing belt over remaining sprockets. 2) Loosen belt tensioner bolt. Allow belt tensioner to apply tension on timing belt. Rotate crankshaft 2 full revolutions clockwise and realign timing marks. DO NOT rotate crankshaft counterclockwise. See Figs. 5, 6 and 7. Tighten belt tensioner bolt to specication. To install remaining components, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Fig. 3: Releasing Timing Belt Tension (Except Tracer)

FORD
1.6L & 1.9L 4-Cylinder SOHC (Cont.)

225

Courtesy of Ford Motor Co.

Fig. 4: Exploded View Of Timing Belt & Components


Courtesy of Ford Motor Co.

Fig. 6: Installing Timing Belt (Tracer)

Courtesy of Ford Motor Co.

Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)

Courtesy of Ford Motor Co.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30) Belt Tensioner Bolt ........................................................................ ................. 17-22 (23-30) Crankshaft Pulley Bolt ................................................................................. 81-96 (110-130) Power Steering Pump Bolt ........................................................... ................. 30-41 (41-56) Water Pump Bolt ........................................................................... ................. 15-22 (20-30) INCH Lbs. (N.m) Timing Belt Cover Nut .................................................................. ..................... 44-62 (5-7) Valve Cover Bolt ........................................................................... ................. 44-106 (5-12)

Fig. 7: Aligning Crankshaft Sprocket Timing Marks (Tracer)

226

FORD
1.6L & 2.0L 4-Cylinder Bobcat, Capri & Pinto
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. Capri 1972 .......................................................... 2.0L 4-Cyl. Bobcat 1974 .......................................................... Capri 1971-74 .................................................... Pinto 1971-74 ....................................................
1

1.3 Hours .. ..... T013

1.3 Hours .. ..... T013 1.3 Hours .. ..... T013 1.3 Hours .. ..... T013

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. Fig. 1: Checking Camshaft Timing
Courtesy of Ford Motor Co.

REMOVAL & INSTALLATION


TIMING BELT
Removal Disconnect negative battery cable. Remove accessory drive belts. Ensure that crankshaft is at TDC of No. 1 cylinder compression stroke. See Fig. 1. Remove camshaft belt cover. Loosen belt tensioner adjustment bolt and force tensioner to one side to relieve belt tension. Hold tensioner in this position, and tighten bolt to hold tensioner. Lift belt off sprockets. NOTE: DO NOT rotate crankshaft or camshaft with belt removed. Installation Place new belt over sprockets and loosen tensioner adjustment bolt to place tension on belt. Rotate crankshaft 2 complete turns to place timing marks in proper position and to remove all slack from belt. Torque tensioner adjustment bolt and pivot bolt to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tensioner ................................................................................ ................. 32-36 (42-48) Crankshaft Pulley .......................................................................... ................. 39-43 (54-60) Timing Belt Cover ......................................................................... ..................... 7-9 (10-12) Water Pump Bolts 8 mm ........................................................................................... ................. 12-15 (15-21) 10 mm ......................................................................................... ................. 26-31 (35-41)

FORD
1.8L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 1.8L 4-Cyl. Escort & Tracer 1991-96 ..............................
1

227

Labor Time

Component Belt Kit No. Part No.

2.8 Hours .. .. TCK179 .. ..... T179

2) Remove middle and lower timing belt covers. Rotate crankshaft clockwise until No. 1 piston is at TDC. Ensure camshaft timing marks are aligned. See Figs. 2 and 3. 3) Remove crankshaft pulley and hub. See Fig. 4. Mark direction of timing belt rotation if timing belt is to be reused. Loosen timing belt tensioner bolt, and remove timing belt. CAUTION: DO NOT rotate camshafts with timing belt removed, as engine damage could result. Installation 1) Temporarily position belt tensioner with spring fully extended, and tighten tensioner bolt. Ensure timing marks on crankshaft sprocket and oil pump align. See Fig. 5. CAUTION: Ensure I and E camshaft sprocket timing marks are facing up. Camshaft sprockets may be stamped with more than one mark. 2) Ensure camshaft sprocket timing marks are still aligned. See Figs. 2 and 3. Install timing belt. If reusing timing belt, ensure belt is installed in original direction of rotation. 3) Loosen tensioner bolt. Position tensioner so slack is removed from timing belt. Tighten tensioner bolt. Rotate crankshaft clockwise 2 full revolutions. Ensure all timing marks are aligned. If timing marks are not aligned, remove timing belt and repeat timing belt tensioning procedure. 4) Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft timing mark with tension set mark (at approximately 10 oclock position). See Fig. 5. Loosen tensioner bolt. Apply tension to the tensioner. Tighten tensioner bolt to 27-38 ft. lbs. (37-52 N.m).

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
NOTE: Mark direction of timing belt rotation if timing belt is to be reused. Removal 1) Disconnect negative battery cable. Remove accessory drive belts. Remove upper timing belt cover. See Fig. 1. Remove water pump pulley. Raise and support vehicle. Remove right front wheel. Remove right upper and lower splash shield.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

228

FORD
1.8L 4-Cylinder DOHC (Cont.)

5) Rotate crankshaft clockwise 2 1/6 revolutions. Ensure timing marks align. If timing marks are not aligned, repeat installation procedure. Measure timing belt deection by applying 22 lbs. (10 kg) of pressure on timing belt at a point halfway between camshaft sprockets. See Fig. 6. 6) Timing belt deection should be .35-.45 (8.9-11 mm). If deection is not within specication, loosen tensioner bolt. Using a pry tool, tighten or loosen tensioner to obtain proper timing belt deection. Tighten tensioner bolt. 7) To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30) Belt Tensioner Bolt ........................................................................ ................. 17-22 (23-30) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Crankshaft Sprocket Bolt ............................................................................ 80-87 (109-118) Power Steering Pump Bolt ........................................................... ................. 30-45 (40-62) Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-52) Water Pump Bolt ........................................................................... ................. 15-22 (20-30) INCH Lbs. (N.m) Timing Belt Cover Nut .................................................................. ..................... 44-61 (5-7) Valve Cover Bolt ........................................................................... ................. 48-106 (5-12)
Courtesy of Ford Motor Co.

Fig. 4: Identifying Crankshaft Pulley & Guide Plates

Courtesy of Ford Motor Co.

Fig. 5: Aligning Crankshaft Sprocket Timing Marks

Courtesy of Ford Motor Co.

Fig. 2: Aligning Timing Marks

Courtesy of Ford Motor Co.

Fig. 6: Checking Timing Belt Deection

Courtesy of Ford Motor Co.

Fig. 3: Identifying Camshaft Sprocket Timing Marks

FORD
2.0L 4-Cylinder Diesel
TIMING BELT APPLICATION Application
1

229

Labor Time

Belt Part No.

NOTE: DO NOT allow crankshaft to rotate with timing belt removed. Installation 1) Align camshaft and crankshaft sprockets with their respective timing marks. See Figs. 1 and 2. Remove tensioner spring from front timing belt upper cover pocket, and install in tensioner lever slot and over crankcase stud. See Fig. 3. Push tensioner lever as far as possible toward water pump and tighten lock bolt. 2) Install timing belt. With tensioner pulley loose, adjust belt tension by rotating crankshaft pulley in direction of rotation twice until No. 1 cylinder is at TDC (camshaft timing marks aligned). Tighten tensioner lock bolt. Adjust belt tension to 33-44 lbs. (15-20 kg). Remove tensioner spring and place in front cover pocket. 3) Install front upper cover and ywheel timing mark case. Install front timing belt lower cover. Install crankshaft pulley and front timing belt upper cover. Adjust drive belts to proper tension.

2.0L 4-Cyl. Diesel Escort & Lynx 1984-87 Camshaft ................................................ Injection Pump ....................................... Tempo & Topaz 1984-86 Camshaft ................................................ Injection Pump .......................................
1

6.2 Hours ... ..... T103 1.3 Hours ... ..... T102

6.2 Hours ... ..... T103 1.3 Hours ... ..... T102

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 100,000 miles.

REMOVAL & INSTALLATION


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

ENGINE
NOTE: Engine/transaxle must be removed to replace timing belt. The engine/transaxle is removed as an assembly. Removal & Installation 1) Disconnect negative battery cable. Mark hinges for reinstallation and remove hood. Remove air cleaner assembly. Drain coolant. Remove upper and lower radiator hoses. 2) Disconnect wiring at cooling fan. Remove shroud and cooling fan as an assembly. Remove radiator. Discharge A/C system (if equipped). Disconnect hoses at compressor. Remove cable at starter. 3) Disconnect all vacuum lines as necessary. Disconnect clutch cable at transaxle, injection pump throttle linkage, and fuel hoses at engine. 4) Disconnect both engine harness connectors and glow plug relay connectors at dash panel. Connectors are located under plastic shield on dash panel. Remove and save plastic retainer pins. Disconnect alternator connector on right-hand fender apron. 5) Disconnect power steering hoses at pump (if equipped). Remove hose bracket from cylinder head. Attach engine support tool to lifting eye. Raise vehicle. Disconnect exhaust bracket at oil pan. Disconnect both exhaust pipes from manifold. Pull exhaust system from grommets and set aside. Disconnect speedometer cable from transaxle. Disconnect heater hoses at water pump inlet tube and at oil cooler. 6) Disconnect control arms at body. Remove stabilizer bar brackets. Remove half-shaft assemblies and install alignment plugs in differential side gears. On manual transaxle models, remove shift stabilizer bar-totransaxle bolts. Remove shift mechanism-to-shift shaft attaching bolt at transaxle. 7) Remove left-hand rear insulator mount bracket from body bracket. Remove left-hand front insulator-to-transaxle bolts. Lower vehicle. Attach engine hoist to lifting eyes. Remove engine support tool. Disconnect right-hand insulator intermediate bracket from engine bracket and insulator. Remove bracket. Lower engine and transaxle assembly to oor. To install, reverse removal procedures.

Courtesy of Ford Motor Co.

Fig. 1: Cross Section Of 2.0L Diesel Engine

FRONT TIMING BELT


Removal 1) With engine out of vehicle, remove front upper timing belt cover and ywheel timing mark case. 2) Rotate crankshaft in normal direction of rotation to align timing marks of ywheel and front camshaft sprocket with pointers. Loosen tensioner pulley lock bolt to slide timing belt off water pump and camshaft.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

230

FORD
2.0L 4-Cylinder Diesel (Cont.)

Courtesy of Ford Motor Co.

Fig. 3: Installing Front Timing Belt Tensioner Spring

REAR TIMING BELT


Removal 1) Remove rear timing belt cover and ywheel timing mark case. Rotate crankshaft until No. 1 cylinder is at TDC (ywheel timing mark at TDC, camshaft sprocket and injection pump timing marks aligned). See Figs. 4, 5 and 6. 2) Loosen tensioner lock nut. Turn tensioner clockwise with a screwdriver to loosen timing belt. Tighten lock nut and remove timing belt. Installation Install timing belt. See Fig. 7. Adjust belt tension as follows: with tensioner pulley loose, rotate crankshaft twice until ywheel 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 ywheel timing mark case. Adjust drive belts to proper tension. Fig. 6: Aligning Camshaft Timing Marks

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 7: Installing Rear Timing Belt

TORQUE SPECIFICATIONS
Courtesy of Ford Motor Co.

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket (Front & Rear) .......................................................................... 45 (61) Crankshaft Pulley .................................................................................................. 119 (165) CV Hub Nut ................................................................................... ......... 180-200 (244-271) Insulator Bracket-To-Body Bracket Bolts ...................................... ........... 75-100 (102-136) Intermediate Bracket-To-Engine Bracket Bolts ............................. ........... 75-100 (102-136) Roll Restrictor-To-Transaxle Bolts ................................................. ................. 25-45 (35-61) Shifter-To-Input Shaft Bolts ........................................................... ................... 7-10 (10-14) Shift Stabilizer-To-Transaxle Bolts ................................................ ................. 23-35 (31-47) Water Pump ............................................................................................................... 29 (39)

Fig. 4: Aligning Camshaft & Injection Pump Timing Marks

Courtesy of Ford Motor Co.

Fig. 5: Aligning Flywheel Timing Marks

FORD
2.0L 4-Cylinder DOHC Escape
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

231

2.0L 4-Cyl. VIN B Escape 2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Ford Motor Co.

Fig. 1: Removing Valve Cover

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory drive belt. Remove air cleaner outlet pipe. Disconnect ignition wires from spark plugs. Remove spark plugs. Disconnect throttle cable and cruise control actuator cable. On 2002-04 models, disconnect the catalyst monitor and heated oxygen sensor connectors, and detach the connectors from the bracket. Remove wiring harness anchors from valve cover studs, and position the wiring harness aside. On all models, remove valve cover. See Fig. 1. 2) Remove catalytic converter. Remove coolant tube bolt and nut. Position coolant tube to side. Remove right front wheel and tire assembly. Remove right lower splash shield. 3) Rotate crankshaft to just before No. 1 cylinder TDC. See Fig. 2. Remove stud and install Crankshaft TDC Timing Peg (303-574). See Fig. 3. NOTE: Make sure second notch in pulley is indexed to lower cylinder block. See Fig. 2. 4) Rotate crankshaft clockwise against peg to bring it to TDC. Loosen water pump pulley bolts. 5) Loosen crankshaft pulley bolt. Rotate tensioner and remove accessory drive belt. Remove crankshaft pulley. Remove bolts and lower timing belt cover. See Fig. 4. Install Engine Support Bar (303-F072). See Fig. 5. 6) Remove ground strap and engine mount upper bracket. See Fig. 6. Remove upper timing belt cover studs. Disconnect the knock sensor connector from upper timing cover, if necessary. Remove upper timing belt cover bolts and cover. See Fig. 7. NOTE: Installation of Camshaft Alignment Tool (303-465) into exhaust camshaft may require camshafts to be rotated slightly clockwise. 7) Remove water pump pulley and accessory drive belt idler pulley. Install Camshaft Alignment Tool (303-465) and align camshafts. See Fig. 8. 8) Raise and support vehicle. Remove engine mount lower bracket. See Fig. 9. 9) Loosen timing belt tensioner pulley, and allow it to slide down to bottom of its travel. If timing belt is going to be reused, mark direction of rotation for installation reference. Slide timing belt off of camshaft and crankshaft sprockets.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks Before TDC

Courtesy of Ford Motor Co.

Fig. 3: Removing Stud For Installation Of Crankshaft TDC Timing Peg (303-574)

Courtesy of Ford Motor Co.

Fig. 4: Removing Lower Timing Belt Cover

232

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

Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.

Fig. 9: Removing Engine Mount Lower Bracket Fig. 5: Installing Engine Support Bar (303-F072) Installation 1) Slide crankshaft pulley onto crankshaft. Ensure crankshaft position is at No. 1 TDC by rotating it clockwise against Crankshaft TDC Timing Peg (303-574). Ensure second notch in pulley is indexed to lower cylinder block. See Fig. 2. Remove crankshaft pulley. 2) Ensure timing belt tensioner is installed correctly with tab positioned in slot in inner timing cover. See Fig. 10. 3) Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension. Adjust timing belt tensioner by using a 6-mm Allen wrench to rotate adjuster counterclockwise and align marks. See Figs. 11 and 12. Tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. 4) Install front engine mount lower bracket. Install accessory drive belt idler pulley. Install water pump pulley, and hand tighten bolts. Install timing belt covers. Install crankshaft pulley. Tighten water pump pulley bolts to specication. See TORQUE SPECIFICATIONS. 5) Install splash shield, then wheel and tire assembly. Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install engine mount upper bracket and ground strap. Remove Engine Support Bar (303-F072). Install coolant tube and catalytic converter. Remove Camshaft Alignment Tool (303-465). 6) Install valve cover and spark plugs. On 2002-04 models, connect wiring harness anchors to valve cover studs. Install and reconnect the catalyst monitor and heated oxygen sensor connectors. On all models, reconnect accelerator cable and cruise control actuator cable. Install ignition wires, air cleaner outlet pipe and accessory drive belt. Reconnect negative battery cable.

Courtesy of Ford Motor Co.

Fig. 6: Removing Engine Mount Upper Bracket

Courtesy of Ford Motor Co.

Fig. 7: Removing Upper Timing Belt Cover

Courtesy of Ford Motor Co.

Fig. 10: Installing Timing Belt Tensioner

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Tool (303-465)

FORD
2.0L 4-Cylinder DOHC Escape (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

233

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt On Sprockets

Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45) Camshaft Sprocket Bolts .......................................................................................... 50 (68) Catalytic Converter Bracket Bolts ............................................................................. 18 (25) Coolant Tube Attachments ........................................................................................ 15 (20) Crankshaft Pulley Bolt ............................................................................................. 85 (115) Engine Mount Lower Bracket Nuts .......................................................................... 37 (50) Engine Mount Upper Bracket Bolt ........................................................................................................................... 57 (77) Nuts .......................................................................................................................... 72 (98) Studs ........................................................................................................................ 25 (34) Exhaust Camshaft Center Plug ................................................................................ 27 (37) Ground Strap ............................................................................................................. 25 (34) Spark Plugs ............................................................................................................... 11 (15) Stud (For Crankshaft TDC Timing Peg) ................................................................... 18 (25) Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Water Pump Pulley Bolt ............................................................................................ 18 (25) Wheel Lug Nuts ...................................................................................................... 98 (133) INCH Lbs. (N.m) Timing Belt Cover Bolts Inner ......................................................................................................................... 89 (10) Lower ......................................................................................................................... 62 (7) Upper ......................................................................................................................... 71 (8) Splash Shield Bolts ..................................................................................................... 80 (9) Valve Cover Bolts ........................................................................................................ 80 (9)

Courtesy of Ford Motor Co.

Fig. 12: Adjusting Timing Belt Tensioner

234

FORD
2.0L 4-Cylinder DOHC, VIN 3 Contour & Mystique (1995-97)
4) Install lower timing belt cover. Apply Silicone Gasket Sealer (F1AZ 9562-A) or equivalent to crankshaft keyway. Install crankshaft pulley. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 5) Ensure crankshaft timing marks are aligned. See Fig. 1. Loosen timing belt tensioner pulley, and allow spring to pull pulley against timing belt. Remove camshaft alignment tool. Rotate crankshaft clockwise 2 full revolutions. 6) Tighten timing belt tensioner pulley to specication. See TORQUE SPECIFICATIONS. Align crankshaft timing marks. See Fig. 1. Ensure camshafts are still aligned by installing Camshaft Alignment Tool (T94P-6256-CH) on rear of camshafts. If crankshaft and camshaft alignment is correct, continue with installation procedure. 7) If camshaft alignment tool cannot be installed on camshafts with crankshaft at TDC, hold camshaft sprocket with Camshaft Sprocket Holding Tool (T74P-6256-B) or spanner wrench. Loosen, but do not remove, camshaft sprocket center bolt. Rotate camshafts until camshaft alignment tool can be installed on rear of camshafts. Crankshaft MUST remain at TDC when aligning camshafts. Tighten camshaft sprocket center bolts to specication. 8) Install timing belt covers. Install crankshaft pulley. Tighten bolt to specication. Install valve cover. Install spark plugs. 9) Install upper front engine mount. Remove engine support tool. Install water pump pulley. Install serpentine belt idler pulley and serpentine bolt. 10) Install coolant recovery reservoir. To complete installation, reverse removal procedure.

TIMING BELT APPLICATION Application Labor Time Timing Belt Belt Kit No. Part No.

2.0L 4-Cyl. Contour & Mystique 1995-97 ............................... 2.2 Hours ... .. TCK258 .. ..... T258 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Noting position for installation reference, disconnect secondary wires from spark plugs. Remove spark plugs. 2) Disconnect negative battery cable. Remove air intake resonators. Remove power steering pressure hose bracket from lifting eye, and position aside. 3) Support engine from above using Three Bar Engine Support (D88L-6000-A) or equivalent. Remove upper timing belt cover. 4) Mark position of upper front engine mount before removal. Remove upper front mount. If equipped, disconnect coolant level sensor connector from coolant recovery reservoir. Remove retainers attaching recovery reservoir, and position aside. Remove upper front mount insulator. 5) Loosen water pump pulley bolts. Remove serpentine drive belt. Remove drive belt idler pulley from alternator mounting bracket. Remove water pump pulley. 6) Remove center timing belt cover. Raise and support vehicle. Remove crankshaft pulley. See Fig. 3. Remove lower timing belt cover. Remove valve cover. 7) Temporarily install crankshaft pulley. Rotate crankshaft to align timing mark on block with larger notch on pulley. See Fig. 1. Use Camshaft Alignment Tool (T94P-6256-CH) or equivalent to align camshafts. See Fig. 2. Install tool in slots on camshafts at rear of engine. 8) Loosen timing belt tensioning pulley. See Fig. 4. Move pulley to relieve tension on timing belt, and retighten pulley. If reusing timing belt, mark direction of rotation before removal. Remove timing belt. Installation 1) Temporarily install crankshaft pulley. Ensure crankshaft pulley timing marks are aligned. See Fig. 1. Ensure camshaft alignment tool is still installed. 2) Install tensioner and retaining bolt (if necessary). Remove crankshaft pulley. 3) Install timing belt on crankshaft sprocket. Working in a clockwise direction, install timing belt around camshaft sprockets. Ensure timing belt span between crankshaft sprocket and exhaust camshaft is not loose. Ensure timing belt is aligned on all sprockets.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 2: Installing Camshaft Alignment Tool

FORD
2.0L 4-Cylinder DOHC, VIN 3 Contour & Mystique (1995-97) (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

235

Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt .................................................... ................. 15-22 (20-30) Alternator Mounting Bolt ............................................................... ................. 30-41 (41-56) Camshaft Sprocket Bolt ................................................................ ................. 47-53 (64-72) Crankshaft Pulley Bolt ................................................................................. 81-89 (110-121) Serpentine Belt Idler Pulley Bolt .............................................................................. 35 (48) Timing Belt Tensioner Bolt ............................................................ ................. 26-30 (35-40) Upper Front Engine Mount Nuts .................................................. ................. 52-70 (70-95) Water Pump Bolt ........................................................................... ................. 12-15 (16-20) INCH Lbs. (N.m) Center Timing Belt Cover Bolt ...................................................... ..................... 53-71 (6-8) Lower Timing Belt Cover Bolt ....................................................... ..................... 53-71 (6-8) Spark Plug ..................................................................................... ............. 106-156 (12-18) Upper Timing Belt Cover Bolt ....................................................... ..................... 27-44 (3-5) Valve Cover ................................................................................... ..................... 53-71 (6-8) Water Pump Pulley Bolt ................................................................ ............... 89-124 (10-14)

Courtesy of Ford Motor Co.

Fig. 3: Exploded View Of Timing Belt Components

Courtesy of Ford Motor Co.

Fig. 4: Identifying Timing Belt Tensioner

236

FORD
2.0L 4-Cylinder DOHC, VIN 3 Cougar, Contour & Mystique (1998-02)

TIMING BELT APPLICATION Application 2.0L 4-Cyl. VIN 3 Cougar 1999 Before 3/28/99 .................. After 3/29/99 ..................... 2000-02 ............................... Contour & Mystique 1998 .................................... 1999 Before 3/28/99 .................. After 3/29/99 ..................... 2000 .................................... Labor Time Component Belt Kit No. Part No. CAUTION: DO NOT pull the spark plug cable when removing the spark plug connectors. If necessary, remove the ignition cables from the ignition coil to avoid kinking the cables. Turn the spark plug connectors slightly before removing to loosen the seal. 8) Disconnect throttle cable and cruise control cable from engine appearance cover. Disconnect solenoid valve electrical connector (1), and remove the engine appearance cover (2). See Fig. 6. Pull off the spark plug connectors in line with the spark plugs. Remove the PCV hose. Loosen 10 valve cover bolts from the outside to the inside, working diagonally. See Fig. 7. Remove the valve cover. 9) Remove the spark plugs. Turn the engine to TDC on cylinder No. 1. To remove the tension on timing belt, unscrew the timing belt tensioner bolt (1) 4 turns. See Fig. 8. Position the tensioner so the locating tab (2) is at approximately the 4 oclock position. Line up the hex key slot (3) in the tensioner adjusting washer with the pointer that is located behind the pulley. 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. See Fig. 9. Loosen, but do not remove, exhaust camshaft sprocket bolt (2). Loosen, but do not remove, intake camshaft sprocket bolt (3). Remove timing belt.

3.2 Hours ... .. TCK294 .. ..... T294 3.2 Hours .... TCK294A . ..... T294 3.2 Hours .... TCK294A . ..... T294 3.2 Hours ... .. TCK294 .. ..... T294 3.2 Hours ... .. TCK294 .. ..... T294 3.2 Hours .... TCK294A . ..... T294 3.2 Hours .... TCK294A . ..... T294

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998-00 model years, the manufacturer recommends the belt be inspected every 120,000 miles. Replace, if necessary. For 2001-02 model year, the manufacturer recommends the belt be replaced every 120,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove engine undercover, if equipped. Remove engine splash shield from right wheelwell. 2) Loosen, but do not remove, water pump pulley bolts. If accessory drive belt is to be reused, mark belt with arrow to indicate direction of rotation. Turn accessory drive belt tensioner clockwise, and remove accessory drive belt. See Fig. 1. 3) Remove water pump pulley. Remove serpentine belt idler pulley. Using access hole in bottom of transaxle case to stop rotation of engine, remove crankshaft pulley/vibration damper. CAUTION: Removal of lower timing belt cover is necessary to avoid damage to timing belt. 4) Remove lower timing belt cover. See Fig. 2. Working from under vehicle, loosen center bolt of left-hand and right-hand engine support insulators 2 turns. DO NOT remove center bolts. 5) Lower vehicle. Remove coolant reservoir tank with hoses attached, and set aside. Disconnect cruise control cable (if equipped) from coolant reservoir. CAUTION: Use a block of wood between oil pan and oor jack, or oil pan may be damaged. 6) Position oor jack under engine. Raise engine slightly to release pressure from mounting insulator on front of engine. Marking installed position for installation reference, remove engine front support insulator from timing belt end of engine. See Fig. 3. 7) Remove power steering pressure hose bracket from engine lifting eye, and position aside. Remove the timing belt upper cover bolts, but leave the timing belt cover in its installed position. See Fig. 4. Remove the timing belt center cover/front engine mounting bracket. See Fig. 5. Remove the timing belt upper and center covers.

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

Courtesy of Ford Motor Co.

Fig. 2: Identifying Lower Front Timing Cover Bolts

FORD
2.0L 4-Cylinder DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)

237

Courtesy of Ford Motor Co.

Fig. 3: Removing & Installing Front Support Insulator

Courtesy of Ford Motor Co.

Fig. 7: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co.

Fig. 4: Locating Upper Front Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 8: Removing Tension From Timing Belt

Courtesy of Ford Motor Co.

Fig. 5: Locating Center Timing Cover Bolts


Courtesy of Ford Motor Co.

Fig. 9: Identifying Camshaft Sprocket Holding/Removing Tool

Courtesy of Ford Motor Co.

Fig. 6: Removing & Installing Appearance Cover

238

FORD
2.0L 4-Cylinder DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)
11) Attach the timing belt center cover/front engine mounting bracket. See Fig. 5. Install the valve cover. See Fig. 7. Tighten the valve cover bolts in 2 stages: Step 1: 18 INCH lbs. (2 N.m). Step 2: 62 INCH lbs. (7 N.m). NOTE: Check the seating of the timing belt upper cover gasket and correct it if necessary. 12) Install the timing belt upper cover. See Fig. 4. Install the front engine mount. Connect the Power Assisted Steering (PAS) reservoir. Install the coolant expansion tank. 13) Install the power steering pipe bracket to the engine lift eye. Install the front support insulator. See Fig. 3. Remove the oor jack. 14) Install the coolant expansion tank. Attach the cruise control cable (if equipped) to the coolant expansion tank. Raise and support the vehicle. NOTE: Verify that the center bolt is centered in the support insulator. 15) Tighten the center bolt of the right engine support insulator. Tighten the center bolt of the left engine support insulator. Install the lower part of the engine front cover. See Fig. 2. Tighten front cover bolts to specication. See TORQUE SPECIFICATIONS. NOTE: Use the access hole in the bottom of transaxle case to stop engine rotating. 16) Install the crankshaft pulley/vibration damper and tighten to specication. See TORQUE SPECIFICATIONS. Install the accessory drive belt. See Fig. 1. Note the accessory drive belt direction mark if belt is being reused. Install the belt idler pulley. Install the water pump pulley. 17) Tension the belt tensioner clockwise, and position the accessory drive belt in place. Tighten the water pump pulley bolts to specication. See TORQUE SPECIFICATIONS. 18) Install the right front lower splash shield. Install the engine splash shield (if equipped). Lower the vehicle. Install the right front wheel, and tighten nuts to specication. See TORQUE SPECIFICATIONS. 19) Connect the negative battery cable. Check the uid levels and correct as necessary. Check the routing of the vacuum hoses and wiring and secure them with cable ties. 20) When battery is disconnected, some abnormal driveability symptoms may occur until the PCM relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to complete a relearn cycle.

NOTE: To achieve proper timing belt tension, camshaft sprocket bolts must be loosened enough to permit sprockets to turn freely on camshafts. With cam sprocket bolts loose and cylinder No. 1 at TDC, crankshaft must be rotated to TDC in clockwise direction (install camshaft alignment tool in cam slots). Cylinders No. 1 and 4 are at TDC when Woodruff key points straight up. Installation 1) Rotate the crankshaft clockwise to TDC cylinder No. 1. Remove the blanking plug, completely screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to TDC. See Fig. 10. 2) Turn the camshafts to ignition position on cylinder No. 1, and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH) into the camshafts. See Fig. 11. NOTE: DO NOT kink or bend the timing belt less than a diameter of 1.38 (35 mm). DO NOT rotate the crankshaft, and check that it is still resting against the timing pin. The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation. 3) Starting from the crankshaft timing belt pulley and working counterclockwise, position a NEW timing belt in place while keeping it under tension. See Fig. 12. 4) Apply tension to the timing belt. Incorrect timing belt tension will cause incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. See Fig. 13. 5) Position the hex key slot in the tensioner adjusting washer to the 4 oclock position. Tighten the attaching bolt (3) enough to seat the tensioner rmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 0.24 (6 mm) hex key. 6) Tension the timing belt, working counterclockwise. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment). See Fig. 14. 7) While holding the adjusting washer in position, tighten the bolt to specication. See TORQUE SPECIFICATIONS. DO NOT tighten the camshaft timing pulley bolts against the camshaft alignment plate. Use the camshaft sprocket holding tool to prevent movement. See Fig. 9. The crankshaft must remain at TDC on cylinder No. 1. Tighten the bolts of the camshaft timing pulleys to specication. 8) Unscrew and remove crankshaft timing peg. Remove camshaft alignment plate from the camshafts. Turn the crankshaft 2 revolutions in the normal direction of rotation. Check the valve timing by inserting the crankshaft timing peg. Correct it if necessary. 9) Screw in crankshaft timing peg and make sure that the crankshaft is touching it. Insert camshaft alignment plate into the camshafts. If necessary, loosen the timing pulleys and correct the camshaft alignment. Remove the crankshaft timing peg and camshaft alignment plate. Screw in and tighten the blanking plug. 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 specication. See TORQUE SPECIFICATIONS. Push in the spark plug connector until it engages. Install appearance cover, and tighten bolts to specication. Connect solenoid valve electrical connector and press in rubber seal. Connect throttle and cruise control cables to appearance cover. Put the upper timing belt cover together with the center timing belt cover in place.

Courtesy of Ford Motor Co.

Fig. 10: Aligning Crankshaft Timing Marks

FORD
2.0L 4-Cylinder DOHC, VIN 3 Cougar, Contour & Mystique (1998-02) (Cont.)

239

Courtesy of Ford Motor Co.

Fig. 11: Installing Camshaft Alignment Tool

Courtesy of Ford Motor Co.

Fig. 14: Setting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Intake ....................................................................................................................... 50 (68) Exhaust Step 1 .................................................................................................................... 44 (60) Step 2 .................................................................................................................. 89 (120) Center Bolt-Left & Right-Hand Support Insulator Bolts ......................................... 89 (120) Crankshaft Pulley Bolt ............................................................................................. 85 (115) Engine Front Support Insulator Bolt/Nut .................................................................. 61 (83) Engine Lifting Eye With Coolant Hose Brackets ..................................................... 13 (18) Exhaust Camshaft Center Blanking Plug ................................................................. 27 (37) Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40) Spark Plugs ............................................................................................................... 11 (15) Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25) Water Pump Bolt ....................................................................................................... 13 (18) Water Pump Pulley Bolt ............................................................................................ 18 (24) Wheel Lug Nut ........................................................................................................ 94 (128) INCH Lbs. (N.m) Lower Engine Front Cover Bolt .................................................................................. 71 (8) Timing Belt Tensioner Spring Retaining Pin ............................................................ 89 (10) Upper Engine Front Cover Bolt ................................................................................ 89 (10) Valve Cover Step 1 ........................................................................................................................ 18 (2) Step 2 ........................................................................................................................ 62 (7) Valve Cover Appearance Cover ................................................................................. 62 (7)

Courtesy of Ford Motor Co.

Fig. 12: Identifying Timing Belt Installed Position

Courtesy of Ford Motor Co.

Fig. 13: Applying Pre-Tension To Timing Belt

240

FORD
2.0L 4-Cylinder DOHC, VIN 3 Escort & ZX2
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. DOHC, VIN 3 Escort 1998 .................................... 1999 Before 2/9/99 .................... After 2/10/99 ..................... 2000-02 ............................... ZX2 2000-03 ...............................

2.8 Hours ... .. TCK294 .. ..... T294 2.8 Hours ... .. TCK294 .. ..... T294 2.8 Hours .... TCK294A . ..... T294 2.8 Hours .... TCK294A . ..... T294 2.8 Hours .... TCK294A . ..... T294

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of Ford Motor Co.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998-00 model years, the manufacturer recommends the belt be inspected every 120,000 miles. Replace, if necessary. For 2001-03 model year, the manufacturer recommends the belt be replaced every 120,000 miles.

Fig. 1: Installing Crankshaft TDC Timing Peg

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal 1) Disconnect negative battery cable. Remove spark plugs. Raise and support vehicle. Remove catalytic converter. Remove splash shield. Rotate crankshaft to TDC of No. 1 cylinder. Install TDC Timing Peg (T97P-6000-A) in hole at lower right of block. See Fig. 1. Rotate crankshaft clockwise against timing peg. See Fig. 2. Lower vehicle. 2) Drain cooling system. Loosen water pump pulley bolts. Remove accessory drive belt. Remove drive belt idler pulley from generator mounting bracket. Remove bolts and position A/C compressor out of the way. Remove water pump pulley. 3) . Disconnect wiring connector at Variable Camshaft Timing (VCT) solenoid. Disconnect crankcase ventilation hose from tting on valve cover. Position accelerator and speed control cables aside. Disconnect spark plug wires from spark plug wire brackets on valve covers. Remove bolt, nut and front support isolator damper. Remove upper timing belt cover. Remove valve cover bolts in a diagonal pattern working inward. Remove valve cover and gasket. 4) Raise and support vehicle. Remove center timing belt cover. Remove crankshaft pulley. Remove lower timing belt cover. Use Camshaft Alignment Timing Tool (T94P-6256-CH) to align camshafts. Install tool in slots on camshafts at rear of engine. See Fig. 3. 5) Loosen timing belt tensioning pulley bolt. Disconnect tensioner tab from timing cover back plate to relieve tension on timing belt. If reusing timing belt, mark direction of rotation before removal. Remove timing belt. CAUTION: Do not use camshaft alignment tool to hold camshafts in place when removing or installing camshaft sprocket bolts, or damage to camshaft ears may result. Use open-end wrench to keep camshaft from rotating. 6) Remove camshaft alignment tool. Remove bolt and intake camshaft timing sprocket. Remove VCT oil plug, bolt and exhaust camshaft sprocket. Installation 1) Ensure crankshaft pulley timing marks are aligned. See Fig. 2. Use Camshaft Alignment Timing Tool (T94P-6256-CH) to align camshafts. Install tool in slots on camshafts at rear of engine. See Fig. 3.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 3: Installing Camshaft Alignment Timing Tool Ensure camshafts are aligned. Install intake timing sprocket and loosely install bolt. Rotate oil control bushing one complete turn and check for binding. Position bushing with single hole in 12 oclock position. CAUTION: The VCT sprocket has a rectangular tab on the backside of the sprocket which must align with the hole on the front face of the thrust bushing. Failure to align may result in poor engine performance. 2) Install NEW exhaust sprocket O ring. Install exhaust sprocket. Ensure tab on sprocket engages hole in oil control bushing. Loosely install sprocket bolt. Loosely install timing belt tensioner. Install timing

FORD
2.0L 4-Cylinder DOHC, VIN 3 Escort & ZX2 (Cont.)
belt. See Fig. 4. Engage timing belt tensioner tab into upper timing cover backplate. Using 6-mm Allen wrench, adjust timing belt tensioner until marks are aligned. See Fig. 5. Tighten bolt to 17-20 ft. lbs. (22-28 N.m). NOTE: Camshaft must be held stationary with an open end wrench. DO NOT use alignment tool to hold camshaft in position, as damage to camshaft may occur. 3) Tighten intake camshaft sprocket bolt to 50 ft. lbs. (68 N.m). Tighten exhaust camshaft sprocket bolt to 36 ft. lbs. (50 N.m). Remove camshaft alignment tool and timing peg. Retighten exhaust camshaft sprocket bolt to 85-92 ft. lbs. (115-125 N.m). Install Variable Cam Timing (VCT) oil plug, if necessary. 4) Ensure second crankshaft timing mark is aligned with raised mark on oil pan. Position crankshaft just prior to TDC. Install TDC timing peg. See Fig. 1. Rotate crankshaft clockwise against peg. Ensure camshafts are aligned. If crankshaft and camshaft are misaligned, repeat procedure until alignment is correct. 5) When alignment is correct, complete installation by reversing removal procedure. When installing valve cover, clean gasket mating surfaces before installing NEW gasket. Install and tighten valve cover bolts in a diagonal pattern starting from the inside working outward. See Fig. 6. Tighten all nuts and bolts to specication. See TORQUE SPECIFICATIONS.

241

Courtesy of Ford Motor Co.

Fig. 6: Identifying Valve Cover Torque Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Intake ....................................................................................................................... 50 (68) Exhaust .................................................................................................................. 88 (120) Catalytic Converter Bracket Bolts ............................................................................... ................. 41-47 (55-64) To-Exhaust Manifold Bolts .......................................................... ................. 41-47 (55-64) To-Muffler Pipe Flange Bolts ...................................................... ................. 34-39 (46-54) Crankshaft Pulley Bolt ................................................................................. 81-89 (110-120) Crossmember Bolts ....................................................................... ............... 69-93 (94-126) Engine Front Support Isolator Nut & Bolt .................................... ................. 50-68 (67-93) Exhaust Camshaft (VCT) Sprocket Plug .................................................................. 27 (37) Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 35 (40) Spark Plugs ................................................................................... ................. 10-12 (13-17) Timing Belt Idler Pulley Bolt ..................................................................................... 35 (48) Timing Belt Tensioner Bolt ............................................................ ................. 17-20 (22-28) Water Pump Bolt ....................................................................................................... 17 (24) Wheel Lug Nut Alloy Wheel ................................................................................. ........... 74-100 (100-135) Steel Wheel ................................................................................................. 66-87 (89-117) INCH Lbs. (N.m) Splash Shield Assembly .................................................................................... 62-97 (7-11) Timing Belt Backplate Bolt ................................................................................ 80-97 (9-11) Timing Belt Cover Bolt Center .......................................................................................... ..................................... 1 Lower ......................................................................................................................... 61 (7) Upper ........................................................................................... ..................... 27-44 (3-5) Valve Cover Bolt ........................................................................... ..................... 54-70 (6-8) Valve Cover Appearance Cover ................................................................................. 62 (7)
1

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Fig. 4: Identifying Timing Belt Installed Position

Tighten bolts to 10 ft. lbs. (13 N.m).

Courtesy of Ford Motor Co.

Fig. 5: Index Marks For Timing Belt Tensioner

242

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2.0L 4-Cylinder DOHC, VIN 3 Focus
Labor Time Component Belt Kit No. Part No. Position the tensioner so the locating tab (2) is at approximately the 4 oclock position. Line up the hex key slot (3) in the tensioner adjusting washer with the pointer that is located behind the pulley. 7) Remove the timing belt. Loosen the camshaft pulley retaining bolts. Prevent sprocket from turning using the Cam Sprocket Holding/ Removing Tool (303-098, T74P-6256-B). See Fig. 7.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC, VIN 3 Focus 2000-04 ............................... 2.8 Hours .... TCK294A . ..... T294 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

TIMING BELT
NOTE: The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Coolant Hose Remover (412-108) to remove coolant and ventilation hoses. Owing to special model variants, some steps DO NOT apply to all vehicles. These are clearly marked in the text. If necessary, cut the cable tie and install new on installation. NOTE: Numbers in parenthesis refer to numbers in gures. Removal 1) Disconnect the negative battery cable. Raise and support the vehicle. Remove the drive belt cover. Mark the drive belt running direction. Loosen the bolts on the water pump pulley (1). See Fig. 1. 2) Slacken the drive belt by turning tensioner clockwise. Remove the drive belt. Remove the water pump belt pulley (2). Remove the multi-groove belt idler pulley (3). Remove the crankshaft pulley/vibration damper. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt. 3) Remove the lower timing belt cover. See Fig. 2. Lower the vehicle. Remove the coolant expansion tank and lay it to one side. Remove the Power Assisted Steering (PAS) reservoir and lay it to one side. Position the jack with the wooden block under the oil pan, and raise so that the front engine mounting is free from load. NOTE: Mark the position of the engine mounting. 4) Remove the front engine mounting. Remove the timing belt upper cover bolts, but leave the timing belt cover in its installed position. See Fig. 3. Remove the timing belt center cover/front engine mounting bracket. See Fig. 4. Remove the timing belt upper cover. CAUTION: DO NOT pull the spark plug cable when removing the spark plug connectors. If necessary, remove the ignition cables from the ignition coil to avoid kinking the cables. Turn the spark plug connectors slightly before removing to loosen the seal. Pull off the spark plug connectors in line with the spark plugs. 5) Pull off the spark plug connectors. Remove the PCV hose. Loosen 10 valve cover bolts from the outside to the inside, working diagonally. See Fig. 5. Remove the valve cover. Remove the spark plugs. 6) Turn the engine to TDC on cylinder No. 1. Remove the tension on timing belt. Unscrew the timing belt tensioner bolt 4 turns (1). See Fig. 6.

Courtesy of Ford Motor Co.

Fig. 2: Identifying Lower Front Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 3: Locating Upper Front Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 4: Locating Center Timing Cover Bolts

FORD
2.0L 4-Cylinder DOHC, VIN 3 Focus (Cont.)

243

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 counterclockwise and insert the locating tab (1) into the slot in the rear timing cover. See Fig. 12. 5) Position the hex key slot (2) in the tensioner adjusting washer to the 4 oclock position. Tighten the attaching bolt (3) enough to seat the tensioner rmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 0.24 (6 mm) hex key. 6) Tension the timing belt, working counterclockwise. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment). See Fig. 13. 7) While holding the adjusting washer in position, tighten the bolt to specication. 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 specication. 8) Unscrew and remove crankshaft timing peg. Remove camshaft alignment plate from the camshafts. Turn the crankshaft 2 revolutions in the normal direction of rotation. Check the valve timing by inserting the crankshaft timing peg. Correct it if necessary: Screw in crankshaft timing peg and make sure that the crankshaft is touching it. Insert camshaft alignment plate into the camshafts. If necessary, loosen the timing pulleys and correct the camshaft alignment. Remove the crankshaft timing peg and camshaft alignment plate. 9) Screw in and tighten the blanking plug to specication. CAUTION: Use a blunt object (such as a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors. Push on the spark plug connectors, keeping them in line with the spark plugs. NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 0.20-0.39 (5-10 mm). 10) Install the valve cover. See Fig. 5. Tighten the valve cover bolts in 2 stages: Step 1: 18 INCH lbs. (2 N.m). Step 2: 62 INCH lbs. (7 N.m). Attach the PCV hose. Coat the spark plug thread with Never Seize. Screw in the spark plugs. Tighten spark plugs to specication. See TORQUE SPECIFICATIONS. 11) Push in the spark plug connector until it engages. Put the upper timing belt cover together with the center timing belt cover in place. Attach the timing belt center cover/front engine mounting bracket. See Fig. 4. NOTE: Check the seating of the timing belt upper cover gasket, and correct it if necessary. 12) Install the timing belt upper cover. See Fig. 3. Install the front engine mount. Connect the Power Assisted Steering (PAS) reservoir. Install the coolant expansion tank. 13) Pull the jack out towards the front of the vehicle. Raise and support the vehicle. Install the lower timing belt cover. See Fig. 2. Attach the crankshaft pulley/vibration damper and tighten to specication. See TORQUE SPECIFICATIONS. 14) Install the drive belt. If reusing drive belt note the direction previously recorded in removal procedure. See Fig. 1. Attach the multi-groove belt idler pulley (3). Install but DO NOT tighten the water pump pulley bolts (1). Install the drive belt by turning the tensioner (2) clockwise and tensioning it.

Courtesy of Ford Motor Co.

Fig. 5: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co.

Fig. 6: Removing Tension From Timing Belt

Courtesy of Ford Motor Co.

Fig. 7: Identifying Cam Sprocket Holding/Removing Tool NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts. Installation 1) Turn the camshafts to ignition position on cylinder No. 1 and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into the camshafts. See Fig. 8. Rotate the crankshaft clockwise to TDC cylinder No. 1. See Fig. 9. NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up. 2) Remove the blanking plug. Completely screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to TDC. See Fig. 10. CAUTION: DO NOT kink or bend the timing belt less than a diameter of 1.38 (35 mm). DO NOT rotate the crankshaft, and check that it is still resting against the timing pin.

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15) Tighten the bolts on the water pump pulley to specication. Attach the drive belt cover. Lower the vehicle. Connect the negative battery cable. Check uid levels and correct if necessary. Check the routing of vacuum hoses and cables, and secure them with cable ties. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Timing Tool

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt

Courtesy of Ford Motor Co.

Fig. 9: Aligning Crankshaft Timing Marks

Courtesy of Ford Motor Co.

Fig. 12: Applying Pre-Tension To Timing Belt

Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.

Fig. 13: Setting Timing Belt Tension

Fig. 10: Installing Crankshaft Position Timing Peg

FORD
2.0L 4-Cylinder DOHC, VIN 3 Focus (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24) Camshaft Sprocket Bolt Intake & Exhaust ..................................................................................................... 50 (68) Crankshaft Pulley Bolt ............................................................................................. 85 (115) Engine Front Support To-Engine Bracket Nut ............................................................................................ 59 (80) To-Frame Bolts ........................................................................................................ 35 (48) Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40) Spark Plugs ............................................................................................................... 11 (15) Timing Belt Idler Pulley Bolt ..................................................................................... 17 (23) Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25) Water Pump Pulley Bolt ............................................................................................ 18 (24) Wheel Lug Nuts ...................................................................................................... 94 (128) INCH Lbs. (N.m) Center Timing Belt Cover Bolt ...................................................... ..................... 53-71 (6-8) Lower Timing Belt Cover Bolt ..................................................................................... 62 (7) Upper Timing Belt Cover Bolt ..................................................................................... 8 (71) Valve Cover Bolts Stage 1 ...................................................................................................................... 18 (2) Stage 2 ...................................................................................................................... 62 (7)

245

246

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2.0L 4-Cylinder DOHC, VIN 5 Focus
Labor Time Component Belt Kit No. Part No. 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. 6) Pull off the spark plug connectors. Remove the PCV hose. Loosen 10 valve cover bolts from the outside to the inside, working diagonally. See Fig. 9. Remove the valve cover. Remove the spark plugs. NOTE: At TDC the crankshaft keyway is in the 12 oclock 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 intake camshaft pulley blanking plug. See Fig. 10. Using an open-ended wrench to prevent the camshaft from rotating, loosen the camshaft pulley retaining bolts. 8) Remove the tension on timing belt. Unscrew the timing belt tensioner bolt 4 turns (1). See Fig. 11. 9) Position the tensioner so the locating tab (2) is at approximately the 4 oclock position. Line up the hex key slot (3) in the tensioner adjusting washer with the pointer that is located behind the pulley. Remove the timing belt.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC, VIN 5 Focus 2002-04 ............................... 2.8 Hours .... TCK294A . ..... T294 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: The camshaft must be held stationary with an openended wrench or a suitable pair of locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur. NOTE: The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Coolant Hose Remover (412-108) to remove coolant and ventilation hoses. Owing to special model variants, some steps DO NOT apply to all vehicles. These are clearly marked in the text. If necessary, cut the cable tie and install new on installation. NOTE: Numbers in parenthesis refer to numbers in gures. Removal 1) Disconnect the negative battery cable. Raise and support the vehicle. Remove the drive belt cover. Mark the drive belt running direction. Loosen the bolts on the water pump pulley (1). See Fig. 1. 2) Slacken the drive belt by turning tensioner clockwise. Remove the drive belt. Remove the water pump belt pulley (2). Remove the multi-groove belt idler pulley (3). Remove the crankshaft pulley/vibration damper. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt. 3) Remove the lower timing belt cover. See Fig. 2. Lower the vehicle. Remove the coolant expansion tank and lay it to one side. Remove the Power Assisted Steering (PAS) reservoir and lay it to one side. Position the jack with the wooden block under the oil pan, and raise so that the front engine mounting is free from load. NOTE: Mark the position of the engine mounting. 4) Remove the front engine mounting. Remove the accessory drive belt idler pulley. Remove the timing belt upper cover bolts, but leave the timing belt cover in its installed position. See Fig. 3. Remove the timing belt center cover/front engine mounting bracket. See Fig. 4. Remove the timing belt upper cover. 5) Detach the retaining clips (1). Detach the coolant pipe from the retaining clip (2). See Fig. 5. Remove the ignition coil pack cover (3). Remove the engine upper cover. See Fig. 6. Disconnect the Variable Cam Timing (VCT) valve electrical connector. See Fig. 7.
Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 1: Removing & Installing Accessory Drive Belt

Fig. 2: Identifying Lower Front Timing Cover Bolts

Courtesy of Ford Motor Co.

Fig. 3: Locating Upper Front Timing Cover Bolts

FORD
2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)

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

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 5: Identifying Ignition Coil Pack Cover

Fig. 9: Locating Crankcase Ventilation Hose & Valve Cover Bolts

Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.

Fig. 10: Locating Intake Camshaft Pulley Blanking Plug

Fig. 6: Locating Engine Upper Cover

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 7: Locating Variable Cam Timing Valve Electrical

Fig. 11: Removing Tension From Timing Belt

248

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2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)
Attach the PCV hose. Coat the spark plug thread with Never Seize. Screw in the spark plugs. Tighten spark plugs to specication. See TORQUE SPECIFICATIONS. 11) Push in the spark plug connector until it engages. Connect the VCT valve electrical connector. Install the engine cover. Attach the retaining clips. Attach the coolant pipe to the retaining clip. Install the ignition coil pack cover. Put the upper timing belt cover together with the center timing belt cover in place. Attach the timing belt center cover/front engine mounting bracket. See Fig. 8. NOTE: Check the seating of the timing belt upper cover gasket, and correct it if necessary. 12) Install the timing belt upper cover and tighten bolts to specication. See Fig. 3. Install the accessory drive belt idler and tighten bolt to specication. Install the front engine mount and tighten bolts to specication. Connect the Power Assisted Steering (PAS) reservoir. Install the coolant expansion tank. 13) Pull the jack out towards the front of the vehicle. Raise and support the vehicle. Install the lower timing belt cover. See Fig. 2. Attach the crankshaft pulley/vibration damper and tighten to specication. See TORQUE SPECIFICATIONS. 14) Install the drive belt. If reusing drive belt note the direction previously recorded in removal procedure. See Fig. 1. Attach the multi-groove belt idler pulley (3). Install but DO NOT tighten the water pump pulley bolts (1). Install the drive belt by turning tensioner (2) clockwise and tension it. 15) Tighten the bolts on the water pump pulley to specication. Attach the drive belt cover. Lower the vehicle. Connect the negative battery cable. Check uid levels and correct if necessary. Check the routing of vacuum hoses and cables, and secure them with cable ties. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

NOTE: DO NOT tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts. Installation 1) Turn the camshafts to ignition position on cylinder No. 1 and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH), into the camshafts. See Fig. 12. Remove the blanking plug. Completely screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to TDC. See Fig. 13. NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up. 2) Rotate the crankshaft clockwise to TDC cylinder No. 1. See Fig. 14. Make sure that the crankshaft contacts the timing peg. CAUTION: DO NOT kink or bend the timing belt less than a diameter of 1.38 (35 mm). DO NOT rotate the crankshaft, and check that it is still resting against the timing pin. NOTE: The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation. 3) Position a NEW timing belt in place and starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension. See Fig. 15. 4) Apply tension to the timing belt. Incorrect timing belt tension will cause incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab (1) into the slot in the rear timing cover. See Fig. 16. 5) Position the hex key slot (2) in the tensioner adjusting washer to the 4 oclock position. Tighten the attaching bolt (3) enough to seat the tensioner rmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 0.24 (6 mm) hex key. 6) Tension the timing belt, working counterclockwise. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment). See Fig. 17. 7) While holding the adjusting washer in position, tighten the bolt to specication. 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 specication. 8) Unscrew and remove crankshaft timing peg. Remove camshaft alignment plate from the camshafts. Turn the crankshaft 2 revolutions in the normal direction of rotation. Check the valve timing by inserting the crankshaft timing peg. Correct it if necessary: Screw in crankshaft timing peg and make sure that the crankshaft is touching it. Insert camshaft alignment plate into the camshafts. If necessary, loosen the timing pulleys and correct the camshaft alignment. Remove the crankshaft timing peg and camshaft alignment plate. 9) Screw in and tighten the blanking plug to specication. 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. NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 0.20-0.39 (5-10 mm). 10) Install the valve cover. See Fig. 9. Tighten the valve cover bolts in 2 stages: Step 1: 18 INCH lbs. (2 N.m). Step 2: 62 INCH lbs. (7 N.m).

Courtesy of Ford Motor Co.

Fig. 12: Installing Camshaft Alignment Timing Tool

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Fig. 13: Installing Crankshaft Position Timing Peg

FORD
2.0L 4-Cylinder DOHC, VIN 5 Focus (Cont.)

249

Courtesy of Ford Motor Co.

Fig. 17: Setting Timing Belt Tension


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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Bolt ................................................................................. 35 (48) Blanking Plug (Cylinder Block Oil Gallery) .............................................................. 18 (24) Blanking Plug (Intake Camshaft Pulley Blanking Plug) ........................................... 17 (37) Camshaft Sprocket Bolt Exhaust .................................................................................................................... 50 (68) Intake ..................................................................................................................... 89 (120) Crankshaft Pulley Bolt ............................................................................................. 85 (115) Engine Front Mount Bracket ..................................................................................... 37 (50) Engine Front Support To-Engine Bracket Bolts .......................................................................................... 59 (80) To-Frame Bolts/Nuts ................................................................................................ 35 (48) Serpentine Drive Belt Idler Pulley Bolt ..................................................................... 30 (40) Spark Plugs ............................................................................................................... 11 (15) Timing Belt Idler Pulley Bolt ..................................................................................... 17 (23) Timing Belt Tensioner Attaching Bolt ........................................................................ 18 (25) Water Pump Pulley Bolt ............................................................................................ 18 (24) Wheel Lug Nuts ...................................................................................................... 94 (128) INCH Lbs. (N.m) Center Timing Belt Cover Bolt ...................................................... ..................... 53-71 (6-8) Engine Cover ............................................................................................................. 89 (10) Lower Timing Belt Cover Bolt ..................................................................................... 62 (7) Upper Timing Belt Cover Bolt ................................................................................... 10 (89) Valve Cover Bolts Stage 1 ...................................................................................................................... 18 (2) Stage 2 ...................................................................................................................... 62 (7)

Fig. 14: Aligning Crankshaft Timing Marks

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Fig. 15: Installing Timing Belt

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Fig. 16: Applying Pre-Tension To Timing Belt

250

FORD
2.0L 4-Cylinder SOHC, VIN P
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cylinder SOHC, VIN P Escort 1997-02 ............................... 2.2 Hours ... .. TCK283 .. ..... T283 Tracer 1997-99 ............................... 2.2 Hours ... .. TCK283 .. ..... T283 Focus 2000-04 ............................... 2.2 Hours ... .. TCK283 .. ..... T283 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of Ford Motor Co.

Fig. 2: Identifying Timing Belt Tensioner Removal (Focus) 1) Disconnect negative battery cable. Detach coolant expansion tank, and set to one side. Remove power steering uid reservoir from shock tower, and set aside with hoses attached. 2) Raise and support vehicle. Remove the accessory drive belt splash shield. Lower the vehicle. Using a 3/8 inch square drive breaker bar in the hole provided, rotate the tensioner clockwise to relieve tension, and remove serpentine drive belt. NOTE: Remove power steering pump, if necessary. 3) Hold power steering pump pulley stationary, and remove power steering pump center nut. Remove power steering pump pulley. Remove power steering pump mounting nuts. Set power steering pump aside with hoses attached. 4) Raise and support vehicle. Remove right front wheel. CAUTION: When removing spark plug connectors, do not pull on ignition wire. If necessary, remove ignition coil plug to avoid bending ignition wire. Turn spark plug connector slightly before removing to loosen gasket. 5) Remove the crankshaft pulley and vibration damper. Lower vehicle. Noting position for reassembly reference, disconnect spark plug secondary cables from spark plugs using a straight movement. Remove the two ignition wire separators from the valve cover, if necessary. 6) Noting position for reassembly reference, remove spark plugs. Place jack under engine to support weight. Remove front engine mount and timing belt cover from timing belt end of engine. Remove engine mount bracket from timing belt end of engine. 7) Turn the crankshaft so that timing marks are aligned. See Fig. 1. Loosen timing belt tensioner. Using an 8-mm hex wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit to lock tensioner in place. See Fig. 2. If reusing old belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Installation 1) Ensure timing marks are still aligned. Install timing belt in a counterclockwise direction starting at crankshaft sprocket. Keep slack out of belt span from crankshaft to camshaft sprocket while installing timing belt over camshaft. If reusing old belt, ensure it is installed in original direction of rotation. 2) Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. If not correct, readjust timing belt. 3) Install engine mount bracket and timing belt cover to engine. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install engine mount to engine and frame. Tighten nuts and bolts to specication. Remove jack from under engine. 4) Install spark plugs in cylinders from which they were removed (new spark plugs may be installed in any cylinder). Using a blunt object (such as a plastic cable tie), coat inside of spark plug connector with silicone grease to a depth of 5-10 mm. Install spark plug connectors using a straight movement. Raise vehicle. Install crankshaft pulley and vibration damper. Tighten center bolt to specication. Position drive belt on crankshaft pulley.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Up to 2000 model year, the manufacturer recommends that the timing belt be inspected at 120,000 miles. Replace, if necessary. For 2001-2004 model years, the manufacturer recommends that the timing belt be replaced at 120,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal (Escort & Tracer) 1) Disconnect negative battery cable. Place cylinder No. 1 to TDC of compression stroke. Remove accessory drive belt and tensioner. Remove timing belt cover. Raise and support vehicle. Remove right hand splash shield. Remove crankshaft pulley. Align timing marks. See Fig. 1. 2) Loosen timing belt tensioner. Using an 8-mm hex wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit to lock tensioner in place. See Fig. 2. If reusing old belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks Installation 1) Ensure timing marks are still aligned. Install timing belt in a counterclockwise direction starting at the crankshaft. If reusing old belt, ensure it is installed in original direction of rotation. Keep belt span between crankshaft and camshaft tight while installing timing belt over camshaft. 2) Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. To complete installation, reverse removal procedure.

FORD
2.0L 4-Cylinder SOHC, VIN P (Cont.)
5) Install lower drive belt cover. Install right front wheel. Lower vehicle. Install power steering pump, if removed. Install power steering pump pulley. Tighten center bolt to specication. See TORQUE SPECIFICATIONS. Install serpentine drive belt. Install power steering uid reservoir and coolant expansion tank. Connect negative battery cable. TORQUE SPECIFICATIONS (FOCUS)

251

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ESCORT & TRACER) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................................ 70-85 (95-115) Crankshaft Pulley Bolt ................................................................................. 81-96 (110-130) Engine Mounting Bracket Bolts .................................................... ................. 31-42 (41-57) Power Steering Pump Mount Bolt ................................................................................... ................. 15-22 (20-30) Pulley Bolt ................................................................................... ................. 15-22 (20-30) Spark Plugs ............................................................................................................... 11 (15) Timing Belt Tensioner Bolt ............................................................ ................. 15-22 (20-30) Water Pump Bolts ......................................................................... ................. 15-22 (20-30) Wheel Lug Nuts ............................................................................................ 66-86 (89-117) INCH Lbs. (N.m) Splash Shield Assembly Bolts .......................................................................... 71-97 (8-11) Timing Belt Cover Bolts .................................................................................... 71-97 (8-11)

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 77 (105) Crankshaft Pulley Bolt ............................................................................................. 89 (120) Engine Mount Bracket-To-Engine ................................................................................................... 35 (48) To-Engine Nuts ........................................................................................................ 59 (80) To-Frame Bolts ........................................................................................................ 35 (48) Power Steering Pump Mount Bolt ............................................................................................................... 17 (23) Pulley Bolt ............................................................................................................... 35 (47) Spark Plugs ............................................................................................................... 11 (15) Timing Belt Cover Bolts Lower ........................................................................................... ..................................... 1 Upper ....................................................................................................................... 35 (48) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Wheel Lug Nut ........................................................................................................ 94 (128) INCH Lbs. (N.m) Valve Cover Bolts ........................................................................................................ 80 (9)
1

Tighten bolt to 89 INCH lbs. (10 N.m).

252

FORD
2.0L & 2.2L 4-Cylinder Probe
REMOVAL & INSTALLATION
Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. Probe 1993-97 .............................. 2.2L 4-Cyl. Probe 1989-92 ..............................
1

2.8 Hours .. .. TCK228 .. ..... T228

TIMING BELT
1

2.3 Hours .. .. TCK134 .. ..... T134 CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed. Damage to valve/piston may result. Removal 1) Disconnect negative battery cable. Remove accessory drive belts. Remove spark plug wires and valve cover. Install Three Bar Engine Support (014-00750) or equivalent. Slightly raise engine with a jack. Remove right engine mount. Remove dipstick bolt. Remove upper timing belt cover. See Fig. 1 or 2. 2) Remove water pump pulley. Raise and support vehicle. Remove right front wheel. Remove right upper and lower splash shield. Remove crankshaft pulley and crankshaft pulley guide plate. Remove lower timing belt cover. Temporarily install crankshaft pulley bolt. NOTE: Mark direction of timing belt rotation if reusing belt. 3) Rotate crankshaft clockwise and align crankshaft sprocket timing notch with line on oil pump. Ensure camshaft sprocket timing marks align. See Fig. 3 or 4. Install Camshaft Pulley Holder (T92C-6256-AH) or equivalent. Using an Allen wrench, turn timing chain tensioner and remove tensioner spring. Remove timing belt.

With Air Conditioning, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For the 2.0L engine, the manufacturer recommends the belt be replaced at every 60,000 miles, except in California. For California 2.0L engine, replace belt at 105,000 miles. For the 2.2L engine, the manufacturer recommends the belt be replaced at every 60,000 miles.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt Components (2.0L)

FORD
2.0L & 2.2L 4-Cylinder Probe (Cont.)

253

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt Components (2.2L)

Courtesy of Ford Motor Co.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks (2.2L)

Courtesy of Ford Motor Co.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (2.0L) Installation 1) Install timing belt. Rotate tensioner clockwise with an Allen wrench, and install tensioner spring. See Fig. 1 or 5. Ensure timing marks on crankshaft sprocket and engine block align. 2) Remove camshaft pulley holder, and ensure camshaft sprocket timing marks are still aligned. Rotate crankshaft clockwise 2 full revolutions. Ensure all timing marks align. 3) If timing marks do not align, remove timing belt. Repeat previous two steps. To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt .................................................... ................. 18-26 (24-35) Alternator Mounting Bolt ............................................................... ................. 27-38 (37-52) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Crankshaft Sprocket Bolt ........................................................................ 116-123 (157-167) Tensioner Bolt ................................................................................ ................. 27-38 (37-52) Water Pump Bolt ........................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................... 61-87 (8-10) Valve Cover ................................................................................... ..................... 53-62 (6-7) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
Courtesy of Ford Motor Co.

Fig. 5: Locating Timing Belt Tensioner & Spring (2.2L)

254

FORD
2.0L & 2.3L 4-Cylinder 1974-94 Except Probe
REMOVAL & INSTALLATION
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate engine clockwise and position cylinder No. 1 on TDC of compression stroke. Ensure O mark on crankshaft pulley aligns with O mark on outer timing belt cover. 2) Looking through plug hole of outer timing belt cover, ensure camshaft sprocket timing mark aligns with cover pointer. See Fig. 1. 3) Remove fan guard, cooling shroud, cooling fan and fan shroud. Remove drive belt, water pump pulley and automatic belt tensioner. Discharge A/C system (if equipped) using approved refrigerant recovery equipment. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. Drain cooling system. Remove upper radiator hose. Remove thermostat housing and gasket. 4) Remove retaining bolt and crankshaft pulley. Remove hub assembly retaining bolt from crankshaft. Remove outer timing belt cover. Ensure camshaft sprocket timing mark aligns with cover pointer. See Fig. 1. 5) Loosen belt tensioner bolts. Using Camshaft Belt Tensioner (T74P-6254-A) or equivalent, release spring tension on belt tensioner. Rotate belt tensioner away from timing belt and tighten bolts. 6) Remove retaining bolts and pull crankshaft sensor from dowel pins. See Fig. 1. Remove hub assembly and belt guide. Note direction of belt guide installation. Remove timing belt. Installation 1) Install crankshaft sprocket (if removed) with recessed area toward crankshaft. See Fig. 1. Install belt guide with at side toward camshaft sprocket. Install camshaft sprocket with timing mark outward. CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt. 2) Install NEW camshaft sprocket bolt, and tighten to specication while holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS. 3) Align camshaft sprocket timing mark with pointer. Properly position crankshaft so timing mark aligns with notch in front cover casting. See Fig. 2. Install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner bolt, allowing tension to be applied on timing belt. NOTE: It may be necessary to push belt tensioner against timing belt, as spring tension may not move belt tensioner against timing belt. 4) Remove one spark plug from each cylinder. Rotate engine clockwise (viewed from front of engine) 2 complete revolutions. Tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Ensure all timing marks align properly. See Figs. 1 and 3. Install belt guide on crankshaft. 5) Install crankshaft sensor over dowel pins. Tighten long crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). Rotate crankshaft counterclockwise approximately 45 degrees so outer vane of hub assembly does not engage with crankshaft sensor positioner. 6) Install hub assembly and crankshaft pulley. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install crankshaft sensor positioner. See Fig. 4. Rotate crankshaft clockwise approximately 90 degrees so outer vane of hub assembly engages with crankshaft sensor positioner. Tighten short crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). 7) To install remaining components, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 8) Disconnect heater hose from tting on thermostat housing to bleed air from cooling system when lling. Fill cooling system with Ford Coolant (E2FZ-19549-AA), or equivalent, until coolant ows from tting. Install heater hose. Rell radiator. Adjust drive belts to proper tension.

2.0L 4-Cyl. OHC Ranger 1983-88 .............................. 1 2.2 2.3L 4-Cyl. OHC Aerostar 1987 ................................... 2 2.2 Bobcat & Pinto 1974-80 .............................. 3 2.0 Cougar 1981 ................................... 2 1.3 1984-86 .............................. 2 1.3 Courier 1977-82 .............................. 3 2.2 Fairmont & Zephyr 1978-83 .............................. 3 1.6 Granada 1981-82 .............................. 3 1.6 LTD & Marquis 1983 ................................... 3 1.6 1984-86 .............................. 3 1.5 Merkur XR4Ti 1985-89 .............................. 2 1.5 Mustang, Mustang II & Capri 1974-91 .............................. 3 1.6 1992 With Round Tooth Sprockets .................... 2 2.0 With Square Tooth Sprockets .................... 2 2.0 Mustang 1993 ................................... 3 2.0 Ranger 1983-91 .............................. 4 1.6 1992 With Round Tooth Sprockets .................... 4 1.6 With Square Tooth Sprockets .................... 4 1.6 1993-94 .............................. 4 1.6 Thunderbird 1983-88 .............................. 3 1.3
1

Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK014 .. ..... T014

Hours .. ...... ..... ...... ..... T210 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK210 .. ..... T210 Hours .. .. TCK014 .. ..... T014

Hours .. .. TCK210 .. ..... T210 Hours .. .. TCK014 .. ..... T014 Hours .. .. TCK210 .. ..... T210 Hours .. .. TCK014 .. ..... T014

2 3 4

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours. With Air Conditioning, add 1.0 hours. With Air Conditioning, add .5 hours. With Air Conditioning, add .9 hours. With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

FORD
2.0L & 2.3L 4-Cylinder 1974-94 Except Probe (Cont.)

255

Courtesy of Ford Motor Co.

Fig. 4: Positioning Crankshaft Sensor

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auxiliary Shaft Sprocket Bolt ........................................................ ................. 29-40 (39-54) Belt Tensioner Adjusting Bolt .............................................................................. ................. 14-22 (19-30) Pivot Bolt ..................................................................................... ................. 29-40 (39-54) Camshaft Plug ............................................................................... ................. 12-18 (16-24) Camshaft Sprocket Bolt 1 .............................................................. ................. 52-70 (71-95) Crankshaft Pulley-To-Hub Assembly Bolt ..................................... ................. 15-22 (20-30) Water Pump Bolt 2 ......................................................................... ................. 14-21 (19-29) Water Pump Pulley Bolt ................................................................ ................. 14-22 (19-30) INCH Lbs. (N.m) Auxiliary Shaft Cover Bolt ............................................................. ................. 72-108 (8-12) Auxiliary Shaft Retainer Plate Bolt ............................................... ................. 72-108 (8-12) Camshaft Retainer Thrust Plate Box ............................................ ................. 72-108 (8-12) Outer Timing Belt Cover Bolt ....................................................... ................. 72-108 (8-12) Valve Cover Bolt ............................................................................................... 60-96 (6-11)
1 2

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

Install NEW bolt. DO NOT reuse bolt. Apply thread sealant on bolt threads.

Courtesy of Ford Motor Co.

Fig. 2: Positioning Crankshaft

Courtesy of Ford Motor Co.

Fig. 3: Aligning Camshaft & Oil Pump Timing Marks

256

FORD
2.3L 4-Cylinder Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.3L 4-Cyl. Diesel Ranger 1985-87 Balance Shaft ........................................ Camshaft ...............................................
1

1 1

1.6 Hours .. ..... T092 1.6 Hours .. ..... T091

With Air Conditioning, add .9 hours. With Power Steering, add .5 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

Fig. 1: Locating Silent Shaft Timing Belt Tensioner Nut

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove drive belts. Remove 5 upper front timing belt cover retaining bolts. Remove upper front cover. Remove cooling fan and shroud. Remove water pump pulley. Remove crankshaft pulley attaching bolt. Rotate crankshaft until No. 1 piston is at TDC on compression stroke. 2) Remove vibration damper using Damper Remover (T58P-6316-D) or equivalent. Remove 5 lower front timing belt cover attaching bolts and remove cover. Loosen timing belt tensioners and remove belts. Mark direction of rotation on timing belts before removal. 3) Check timing belts for missing teeth, cracking or excessive wear. Replace timing belt if necessary. Camshaft/injection pump timing belt must be removed to access silent shaft timing belt. NOTE: DO NOT loosen nut near timing scale unless removing silent shaft timing belt. This nut is for silent shaft timing belt tensioner. Loosening this nut may change silent shaft timing belt tension. See Fig. 1. Installation 1) Fabricate timing belt tensioner, using a pivot nut from rear brake adjuster and bar stock. See Fig. 2. Release tension on tensioner spring using belt tensioner. Rotate tensioner toward water pump and tighten top bolt. 2) Install camshaft/injection pump timing belt. Ensure belt is installed to rotate in original rotation. Maintain tension on belt. Loosen top tensioner bolt to tension timing belt. See Figs. 3 and 4. Tighten tensioner hold-down bolts. To complete installation, reverse removal procedure. See Figs. 5 and 6. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co.

Fig. 2: Timing Belt Tensioner

Courtesy of Ford Motor Co.

Fig. 3: Removing Tensioner Bolt Access Cover

FORD
2.3L 4-Cylinder Diesel (Cont.)

257

Courtesy of Ford Motor Co.

Fig. 4: Loosening Belt Tensioner Bolts


Courtesy of Ford Motor Co.

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

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 47-54 (64-73) Crankshaft Pulley Bolts ................................................................. ......... 123-137 (167-186) Injection Pump Sprocket Nut ........................................................ ................. 40-50 (54-68) Silent Shaft Sprocket Bolt ............................................................. ................. 25-28 (34-39) Timing Belt Tensioner Nut ............................................................ ................. 16-21 (22-29) INCH Lbs. (N.m) Front Case Bolts ........................................................................... ............. 108-120 (12-14) Rocker Cover Bolts ....................................................................... ..................... 48-60 (5-7) Silent Shaft Chamber Cover Bolts ............................................... ..................... 36-48 (4-5)

Courtesy of Ford Motor Co.

Fig. 5: Identifying Timing Mark Alignment

258

FORD
2.3L 4-Cylinder Gasoline
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 2.3L 4-Cyl. Ranger 1995-97 ..............................


1

1.6 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours. With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove spark plugs. Ensure crankshaft is set at TDC, and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. See Fig. 1. Remove fan guard. Remove fan shroud and position aside. Remove fan retaining screws, and remove fan and shroud. Rotate drive belt tensioner and remove belt. 2) Remove cooling fan and water pump pulley. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Remove A/C compressor and position aside. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. 3) Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and slowly release tension. See Fig. 2. Pry tensioner away from timing belt and tighten bolt to hold tensioner in place. Remove timing belt.

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components CAUTION: Always rotate engine in direction of normal rotation (clockwise as viewed from front of engine). Reverse rotation may cause timing belt to jump time, causing engine damage. Installation 1) Ensure crankshaft is set at TDC, and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. See Fig. 1. 2) Install NEW timing belt. Loosen tensioner bolt. Allow tensioner to adjust itself, and retighten bolt. Rotate crankshaft clockwise 2 complete revolutions to remove slack from belt. 3) Loosen tensioner bolt. Allow tensioner to adjust itself and retighten bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolts .................................................................. ................. 15-21 (21-28) Alternator Bracket Bolts ................................................................ ................. 30-40 (41-54) Alternator Retaining Bolts ............................................................. ................. 30-40 (41-54) Camshaft Sprocket Bolt ................................................................ ................. 50-71 (68-96) Cooling Fan Bolts .......................................................................... ................. 13-16 (17-23) Crankshaft Damper Bolt ................................................................ ......... 103-133 (140-180) Oil Pump Sprocket Bolt ................................................................ ................. 28-40 (38-54) Timing Belt Tensioner Adjusting Bolt ............................................ ................. 14-21 (35-45) Timing Belt Tensioner Pivot Bolt .................................................. ................. 28-40 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12) Spark Plug ..................................................................................... ................. 80-177 (9-20) Valve Cover Bolt ............................................................................................. 80-115 (9-13)

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

FORD
2.5L 4-Cylinder
TIMING BELT APPLICATION Application 2.5L 4-Cyl. Ranger 1998-01 ..............................
1

259

Labor Time

Component Belt Kit No. Part No.

1.6 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours. With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998-00 model years, the manufacturer recommends the belt be inspected at 120,000 miles and replaced if necessary. For 2001 model year, the manufacturer recommends the belt be replaced at 120,000 miles. Fig. 1: Aligning Timing Marks

Courtesy of Ford Motor Co.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect battery ground cable. Remove exhaust side spark plugs. 2) Remove fan shroud bolts and fan shroud, and position aside. Loosen, but do not remove, water pump pulley bolts. Remove accessory drive serpentine belt. 3) Remove fan and clutch assembly retaining screws. Remove fan and clutch assembly. Remove fan shroud. Remove water pump pulley. 4) On models with A/C, discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C compressor from mounting bracket. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. 5) Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. 6) Rotate crankshaft in normal direction of rotation so that No. 1 cylinder is at TDC of compression stroke. Align camshaft, crankshaft and oil pump timing marks. See Fig. 1. Crankshaft keyway should be pointing straight up, and circle on crankshaft sprocket must align with notch in engine front cover. 7) Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and pivot bolt. Slowly release spring tension. Pry tensioner away from timing belt, and tighten bolt to hold tensioner in place. Remove timing belt. Installation 1) Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. 2) Install timing belt on crankshaft sprocket, oil pump sprocket and then the camshaft sprocket. Loosen timing belt tensioner bolt. 3) Allow tensioner to adjust itself against timing belt. DO NOT tighten belt tensioner. Slowly rotate crankshaft clockwise 2 complete turns clockwise (as viewed from front of engine) so No. 1 cylinder is at TDC of compression stroke. 4) Recheck timing alignment marks. If timing marks are not aligned, reposition timing belt. Repeat timing belt tensioning procedure. 5) Tighten timing belt tensioner adjusting and pivot bolts to specication. See TORQUE SPECIFICATIONS. Install crankshaft pulley. Tighten center bolt to specication. 6) Install timing belt cover. Install exhaust side spark plugs. Install A/C compressor mounting bracket to engine. Install A/C compressor to mounting bracket. To complete installation, reverse removal procedure. Recharge A/C system, if necessary.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mount Bolts ....................................................... ................. 15-21 (21-28) A/C Compressor Mounting Bracket-To-Engine M8 Bolt .................................................................................................................... 18 (25) M10 Bolt & Stud ...................................................................................................... 35 (48) Alternator Bracket Bolts ................................................................ ................. 30-40 (41-54) Alternator Retaining Bolts ............................................................. ................. 30-40 (41-54) Camshaft Sprocket Bolt ................................................................ ................. 52-70 (70-95) Cooling Fan-To-Water Pump Bolts ............................................... ................. 13-16 (17-23) Crankshaft Damper Bolt ................................................................ ........... 93-121 (125-165) Oil Pump Sprocket Bolt ................................................................ ................. 28-40 (38-54) Timing Belt Tensioner Adjusting Bolt ............................................ ................. 14-21 (35-45) Timing Belt Tensioner Pivot Bolt .................................................. ................. 28-40 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12) Spark Plug ..................................................................................... ................. 80-177 (9-20) Valve Cover Bolt ............................................................................................. 80-115 (9-13)

260

FORD
2.5L V6
REMOVAL & INSTALLATION
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.5L V6 Probe 1993-97 ....................................................


1

TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal 1) Disconnect negative battery cable. Disconnect engine coolant temperature sensor and temperature gauge sender connectors from coolant elbow. Disconnect crankshaft position sensor connector. See Fig. 1. Remove accessory drive belts. Raise and support vehicle. 2) Remove A/C belt tensioner bracket. Remove crankshaft damper bolt using Crankshaft Pulley Holder (T92C-6316-AH) or equivalent. Remove crankshaft damper. Remove 2 timing belt cover bolts from behind crankshaft damper. Remove timing belt cover lower bolts. Using Power Steering Pump Pulley Remover (D85L-6000-A) or equivalent, remove power steering pump pulley.

4.0 Hours .. ..... T214

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles for Federal vehicles and 105,000 miles for California vehicles.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

FORD
2.5L V6 (Cont.)
3) Using Water Pump Pulley Remover (T92C-631 2-AH) or equivalent, remove water pump pulley bolts and pulley. Lower vehicle. Remove oil dipstick tube. Remove upper timing belt cover bolts. Remove A/C-alternator belt idler bracket. Remove left timing belt cover, then right cover. 4) Remove 3 nuts and through-bolt from right engine mount. Remove right engine mount. Align crankshaft timing sprocket by turning crankshaft in normal direction of engine rotation only. Remove timing belt tensioner arm by removing lower and then upper tensioner arm bolts. 5) Mark direction of timing belt rotation if reusing belt. Using an Allen wrench, loosen timing belt tensioner bolt. Remove timing belt. CAUTION: DO NOT rotate camshafts or crankshaft with timing belt removed, as engine damage could result. Inspection 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure upper and lower timing belt idlers rotate freely. Replace damaged components. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. 3) Measure timing belt tensioner rod protrusion (free length) from end of rod to edge of housing. See Fig. 2. Replace timing belt tensioner if distance is not .55-.63 (14-16 mm).

261

Installation 1) Place timing belt tensioner in a press, using a at washer to prevent damage to timing belt tensioner plug. 2) Compress automatic belt tensioner until hole in piston aligns with second hole in housing. Insert a .06 (1.5 mm) diameter pin, or drill through hole to keep piston in compressed position. See Fig. 2. 3) Ensure camshafts and crankshaft timing marks align. See Fig. 3. Turn crankshaft counterclockwise until crankshaft timing sprocket is offset from TDC by one tooth. See Fig. 4. Install timing belt. 4) Turn crankshaft clockwise until crankshaft timing mark is back to TDC. This should put slack on tensioner portion of belt. Install automatic timing belt tensioner, and tighten bolts to specication. See TORQUE SPECIFICATIONS. Remove pin from automatic tensioner. 5) Turn crankshaft 2 complete revolutions. Recheck timing marks to ensure timing is still correct. See Fig. 3. To complete installation, reverse removal procedure. Tighten bolts to specication. Check ignition timing. Adjust drive belts to proper tension.

Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.

Fig. 4: Positioning Crankshaft For Removing Slack From Timing Belt

Fig. 2: Checking & Compressing Automatic Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 28-38 (38-51) A/C Compressor Bracket-To-Cylinder Block Bolt ......................... ................. 28-38 (38-51) Camshaft Sprocket Bolt ................................................................ ........... 90-103 (122-140) Crankshaft Pulley Bolt ............................................................................. 116-122 (157-165) Engine Mount Nuts ....................................................................... ............... 54-76 (73-103) Engine Mount Through-Bolts ........................................................................ 50-68 (86-116) Front Suspension Crossmember Bolt ........................................... ............... 69-93 (94-126) Knock Sensor ................................................................................ ................. 14-25 (20-34) Power Steering Pump Bracket Bolt .............................................. ................. 24-33 (32-46) Spark Plug ....................................................................................................... 11-16 (15-23) Tensioner Pulley Bolt .................................................................... ................. 27-33 (37-45) Timing Belt Tensioner Bolt ............................................................ ................. 28-32 (38-43) Water Pump Bolt ........................................................................... ................. 14-18 (19-24) Wheel Lug Nut .............................................................................................. 65-87 (88-118) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................... 71-88 (8-10) Valve Cover Bolt ........................................................................... ..................... 43-78 (5-8) Water Pump Pulley Bolt ................................................................ ................... 71-88 (8-10)

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft To TDC

262

FORD
3.0L V6 SOHC Villager
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 3.0L V6 SOHC Villager (Mercury) 1993 ................................... 1994-98 ..............................
1

1 1

3.6 Hours .. .. TCK104 .. ..... T104 3.6 Hours .. .. TCH249 .. ..... T249

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 105,000 miles. This application is not an interference engine.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Timing Belt & Sprocket crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets. 3) Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock nut. Rotate crankshaft clockwise at least 2 revolutions. 4) Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to timing belt between right camshaft sprocket and tensioner. Hold tensioner in position with Allen wrench, and loosen tensioner lock nut. 5) Place a .0138 (.351 mm) feeler gauge at tensioner pulley and timing belt, and rotate crankshaft until feeler gauge is centered between tensioner pulley and timing belt. See Fig. 3. Tighten tensioner lock nut to specication. See TORQUE SPECIFICATIONS. 6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression stroke. Measure timing belt deection halfway between camshaft sprockets. 7) If deection is not .51-.59 (13-15 mm), readjust timing belt tension. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove covers from below engine. Drain cooling system. Remove right front wheel and engine side cover. Remove accessory drive belts. Remove crankshaft pulley bolt and pulley. 2) Remove upper radiator hose and water inlet hose. Remove A/C compressor idler pulley and bracket. Remove water pump pulley. Remove upper and lower timing belt front covers. See Fig. 1. 3) Temporarily install crankshaft pulley bolt so crankshaft can be rotated. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until marks on camshaft sprockets align with marks on timing belt upper rear cover, and mark on crankshaft sprocket aligns with mark on front cover housing. See Fig. 2. 4) Loosen timing belt tensioner nut. Release tension on belt. Remove timing belt. Check timing belt tensioner, spring and timing belt.

Courtesy of Ford Motor Co.

Fig. 3: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88) Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133) Rocker Shaft Bolts ........................................................................ ................. 13-16 (16-20) Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58) Water Pump Bolt ........................................................................... ................. 13-16 (16-20) INCH Lbs. (N.m) Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Timing Belt Components Installation 1) Ensure cylinder No. 1 is at TDC of compression stroke. See Fig. 2. Install tensioner and return spring if removed. If return spring stud was removed, apply thread lock sealant to threads before installing stud. Insert an Allen wrench into hole in tensioner, turn tensioner fully clockwise, and temporarily tighten lock nut. 2) Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and

FORD
3.0L & 3.2L V6 SHO
TIMING BELT APPLICATION Application Labor Time Belt Part No.

263

3.0L V6 SHO Taurus 1989-95 ..................................................... 3.0 Hours ... ..... T248 3.2L V6 SHO Taurus 1993-95 ..................................................... 3.0 Hours ... ..... T248 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 100,000 miles.

Courtesy of Ford Motor Co.

Fig. 2: Locating Crankshaft Pulley Timing Marks

REMOVAL & INSTALLATION


TIMING BELT
Removal (3.0L SHO) 1) Remove battery. Remove engine roll damper, located near timing belt cover. Disconnect ignition control module. Remove intake manifold crossover tube. See Fig. 1. Remove accessory drive belts. Remove alternator belt tensioner pulley and bracket. 2) Remove water pump tensioner pulley. Disconnect crankshaft sensor wiring assembly at lower timing belt cover. Remove upper timing belt cover. Ensure transaxle is in Neutral. 3) Rotate crankshaft until No. 1 piston is at TDC. Ensure White mark on crankshaft damper aligns with 0 mark on lower timing belt cover, and camshaft timing marks align with marks on timing belt cover. See Fig. 2. 4) Raise and support vehicle. Remove right front wheel and splash shield. Using Puller (T67L-3600-A) or equivalent, remove crankshaft damper. Remove timing belt covers. Disconnect crankshaft position sensor wire and grommet from slot near water pump. 5) Ensure timing marks align. See Fig. 3. If reusing timing belt, place reference mark on timing belt, camshaft sprockets, and crankshaft sprocket. Mark direction of belt rotation for reassembly reference. 6) Loosen timing belt tensioner lock nut. Rotate tensioner pulley 180 degrees clockwise using 6-mm Allen wrench. See Fig. 4. Tighten lock nut to hold tensioner in unloaded position. Lower vehicle. Remove timing belt. Fig. 3: Aligning Timing Marks

Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 1: Exploded View Of Intake Manifold & Brackets


Courtesy of Ford Motor Co.

Fig. 4: Adjusting Timing Belt Tension (3.0L SHO)

264

FORD
3.0L & 3.2L V6 SHO (Cont.)
4) Mount Timing Belt Tensioner Tool (T93P-6254-B) or equivalent, using power steering pump bracket bolt holes. Using INCH-lb. torque wrench and Torque Wrench Attachment (T93P-6254-A) or equivalent, rotate tensioner clockwise to 4.3 INCH lbs. (.5 N.m). Tighten belt tensioner bolt. Remove tensioner tool. Tighten bolts to specication. 5) Raise and support vehicle. Install timing belt guide and lower timing belt cover. Install crankshaft damper. Rotate crankshaft clockwise 60 degrees until White mark on crankshaft damper aligns with 0 mark on lower timing belt cover. 6) Ensure camshaft timing marks align with timing belt cover marks. See Fig. 3. Ensure crankshaft sensor wiring is properly routed. Install remaining timing belt covers. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

NOTE: To prevent timing belt whine on models with 3.0L engine and manual transaxle, the timing belt must be correctly tensioned. The revised tensioning procedure is from Ford technical service bulletin 95-22-10; November 6, 1995. Installation (3.0L SHO) 1) Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks align with timing belt cover marks, and crankshaft sprocket timing mark aligns with mark on oil pump housing. See Fig. 3. 2) Install timing belt on crankshaft, and route around left camshaft and onto right camshaft sprockets. Ensure used timing belt is installed in original direction of rotation. Loosen timing belt tensioner lock nut and leave nut loose. 3) Raise and support vehicle. Install center timing belt cover and ensure crankshaft sensor wiring is properly routed. Install lower timing belt cover. Install crankshaft damper. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 4) Rotate crankshaft until Yellow mark on crankshaft damper aligns with 0 mark on lower timing belt cover. See Fig. 2. 5) Remove plastic access cover in lower timing belt cover. Tighten timing belt tensioner lock nut to 25-37 ft. lbs. (34-50 N.m). Install plastic access cover. 6) Rotate crankshaft clockwise 60 degrees until White mark on crankshaft damper aligns with 0 mark on lower timing belt cover. Lower vehicle. 7) Ensure camshaft timing marks align with timing belt cover marks. See Fig. 3. Install upper timing belt cover. Install intake manifold crossover tubes. Connect ignition electrical connector. 8) Install splash shield and right front wheel. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. Removal (3.2L SHO) 1) Remove battery. Remove engine roll damper, located near timing belt cover. Disconnect ignition control module. Remove intake manifold crossover tube. See Fig. 1. Remove serpentine drive belt and tensioner. 2) Remove upper and lower idler pulleys. Using a strap wrench to hold power steering pump pulley, remove power steering pump pulley nut and pulley. Remove upper and center timing belt covers. Disconnect crankshaft sensor wiring assembly at lower timing belt cover. 3) Ensure transaxle is in Neutral. Rotate crankshaft until No. 1 piston is at TDC. Ensure White mark on crankshaft damper aligns with 0 mark on lower timing belt cover, and camshaft timing marks align with marks on timing belt cover. See Fig. 3. 4) Raise and support vehicle. Remove right front wheel and splash shield. Using Puller (T67L-3600-A), remove crankshaft damper. Remove lower timing belt cover. Remove timing belt guide located in front of crankshaft sprocket. Ensure timing marks align. See Fig. 3. 5) If reusing timing belt, place reference mark on timing belt, camshaft sprockets, and crankshaft sprocket. Mark direction of belt rotation for reassembly reference. Slowly loosen timing belt tensioner bolt and remove tensioner. Lower vehicle. Remove timing belt. Installation (3.2L SHO) 1) Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks align with timing belt cover marks, and crankshaft sprocket timing mark aligns with mark on oil pump housing. See Fig. 3. Place timing belt tensioner in a soft-jawed vise. Compress tensioner until hole in tensioner rod aligns with hole in tensioner housing. Install a 1.5-mm Allen wrench through hole, and lock tensioner in retracted position. See Fig. 5. 2) Install timing belt on crankshaft, and route belt around left camshaft and onto right camshaft sprockets. Ensure used timing belt is installed in original direction of rotation. 3) Install timing belt tensioner while pushing tensioner pulley toward belt. Install rubber grommets between tensioner and oil pump. See Fig. 6. Remove Allen wrench from tensioner. If installing used belt, skip the next step. If installing new timing belt, go to next step.

Courtesy of Ford Motor Co.

Fig. 5: Compressing Timing Belt Tensioner (3.2L SHO)

Courtesy of Ford Motor Co.

Fig. 6: Installing Rubber Grommets (3.2L SHO)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolts ................................................................... ................. 15-18 (20-24) Camshaft Timing Belt Sprocket Bolt ............................................ ................. 15-18 (20-24) Engine Damper Bracket Bolt ........................................................ ................. 21-30 (28-41) Idler Pulley Nut .............................................................................. ................. 25-37 (34-50) Intake Manifold Crossover Tube Bolt ............................................................. 11-16 (15-22) Timing Belt Upper Cover Bolt (3.2L) ............................................ ................. 12-17 (16-23) Timing Belt Tensioner Arm Nut (3.2L) .......................................... ................. 27-37 (36-50) Timing Belt Tensioner Bolt (3.2L) ................................................. ................. 12-17 (16-23) Timing Belt Tensioner Lock Nut (3.0L) ......................................... ................. 25-37 (34-50) Water Pump Pulley Bolt ................................................................ ................. 12-17 (16-23) Wheel Lug Nut .......................................................................................... 85-105 (115-142) INCH Lbs. (N.m) Camshaft Sensor Bolt ....................................................................................... 62-97 (7-11) Crankshaft Sensor ......................................................................... ..................... 18-27 (2-3) Timing Belt Cover Bolt (3.0L) ........................................................................... 62-97 (7-11) Valve Cover Bolt ........................................................................... ............... 89-142 (10-16)

GENERAL MOTORS
1.4L & 1.6L 4-Cylinder
TIMING BELT APPLICATION Application
1

265

Labor Time

Belt Part No.

1.4L 4-Cyl. Acadian & Chevette 1976 ........................................................... 1977 ........................................................... 1.6L 4-Cyl. Acadian, Chevette, T-1000 & 1000 1976 ........................................................... 1977-78 ..................................................... 1979-87 .....................................................
1

Be sure gauge nger is engaged in slot between teeth of timing belt. Use 1/4 Allen wrench on idler pulley to obtain correct tension. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. TIMING BELT ADJUSTMENT SPECIFICATIONS Belt Size Operating Range Specication 3/4 (19 mm) ................. 50-80 Lbs. (110-176 kg) .................... 63-77 Lbs. (140-160 kg)

1.4 Hours ... ..... T037 1.4 Hours ... ..... T039

1.4 Hours ... ..... T037 1.4 Hours ... ..... T039 1.4 Hours ... ..... T061

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove radiator upper mounting panel. On A/C equipped vehicles, remove upper half of fan shroud. Remove drive belts and engine fan. Remove front cover retaining screws and nuts. Remove cover. Rotate crankshaft until timing mark on pulley is at zero degrees (No. 1 cylinder at TDC). Remove A/C compressor and brackets, if necessary. 2) Insert 1/8 drill bit or rod through hole in upper rear cover and through hole in camshaft drive sprocket. This is provided to verify camshaft timing. Remove timing belt front and lower cover. Loosen idler pulley, and allow pulley to rotate clockwise. See Fig. 1. Remove timing belt from sprockets.
Courtesy of General Motors Corp.

Fig. 2: Identifying Sprocket Timing Marks

Courtesy of General Motors Corp.

Fig. 3: Adjusting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of General Motors Corp.

Fig. 1: Locating Timing Belt Idler Pulley Installation 1) With No. 1 piston at TDC, install belt on sprockets and use 1/4 Allen wrench to move idler pulley counterclockwise until all slack is removed from belt. Tighten idler pulley bolt. Rotate crankshaft clockwise a minimum of one revolution. Stop with No. 1 piston at TDC. See Fig. 2. DO NOT let timing belt back up. 2) Use belt tension gauge between camshaft sprocket and idler pulley. See TIMING BELT ADJUSTMENT SPECIFICATIONS table. See Fig. 3.

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts ........................................................................................ 75 (101) Crankshaft Pulley Bolt ........................................................................................... 100 (135) Idler Pulley Bolts ....................................................................................................... 15 (20) Water Pump Bolts ..................................................................................................... 15 (20) INCH Lbs. (N.m) Front Cover (Nuts & Bolts) ......................................................................................... 70 (8)

266

GENERAL MOTORS
1.6L 4-Cylinder Aveo
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. Aveo 2004 ........................................................... 1.5 Hours ... ..... T310 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect the negative battery cable. Disconnect the Intake Air Temperature (IAT) sensor connector. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. 2) Remove the air lter housing bolts and housing. 3) Remove the right front wheel. Remove the right front splash shield. 4) Remove the accessory drive belt. Remove the crankshaft pulley bolt and pulley. See Fig. 1. 5) Remove the upper front timing belt cover bolts and cover. See Fig. 2. Remove the lower front timing belt cover bolts and cover. Remove the power steering mounting bolts, if equipped. 6) Install the crankshaft pulley bolt. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover. See Fig. 3. 7) Slightly loosen the coolant pump retaining bolts. Using the Timing Belt Adjuster (J-42492-A or KM-421-A), rotate the coolant pump counterclockwise to release the tension on the timing belt. See Fig. 4. Remove the timing belt behind the power steering pump. See Fig. 5.

Courtesy of General Motors Corp.

Fig. 2: Removing Front Timing Belt Covers

Courtesy of General Motors Corp.

Fig. 3: Aligning Crankshaft Timing Mark

Courtesy of General Motors Corp.

Fig. 1: Removing Crankshaft Pulley Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulleys for worn bearings. Installation 1) Align the timing mark on the crankshaft gear to the notch on the bottom of the rear timing belt cover. See Fig. 3. Align the timing marks on the camshaft gears. See Fig. 6. Install the timing belt. See Fig. 5. 2) Using the Timing Belt Adjuster (J-42492-A or KM-421-A), rotate the coolant pump clockwise. See Fig. 4. Rotate the coolant pump clockwise until the adjust arm of the timing belt automatic tensioner is aligned to the notch in the timing belt automatic tensioner bracket. See Fig. 7.

Courtesy of General Motors Corp.

Fig. 4: Rotating Coolant Pump Using Timing Belt Adjuster

GENERAL MOTORS
1.6L 4-Cylinder Aveo (Cont.)

267

Courtesy of General Motors Corp.

Fig. 7: Aligning Automatic Tensioner With Bracket Notch

Courtesy of General Motors Corp.

Fig. 5: Removing & Installing Timing Belt 3) Tighten the coolant pump retaining bolts. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt. Loosen the coolant pump retaining bolts. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket. See Fig. 8. 4) Tighten the coolant pump retaining bolts to specication. See TORQUE SPECIFICATIONS. 5) Remove the crankshaft pulley bolt. Install the upper and lower front timing belt covers and bolts. See Fig. 2. Tighten the bolts to specication. See TORQUE SPECIFICATIONS. 6) Install the crankshaft pulley and bolt. See Fig. 1. Tighten the bolt to specication. See TORQUE SPECIFICATIONS. 7) Install the accessory drive belt, if equipped. Install the right front splash shield. Install the right front wheel. Tighten wheel lug nuts to specication. See TORQUE SPECIFICATIONS. 8) Install the air lter housing and bolts. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 9) Connect the air intake tube and breather tube to the throttle body. Connect the IAT sensor connector. Connect the negative battery cable.

Courtesy of General Motors Corp.

Fig. 8: Aligning Automatic Tensioner With Bracket Pointer

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt Step 1 1 .................................................................................................................... 70 (95) Step 2 2 ............................................................................................................ Tighten 30, Then An Additional 15 Wheel Lug Nuts ...................................................................................................... 88 (120) INCH Lbs. (N.m) Air Filter Housing Bolts ............................................................................................... 71 (8) Coolant Pump Retaining Bolts .................................................................................. 89 (10) Lower & Upper Front Timing Belt Cover Bolts ........................................................ 89 (10)
1 2

Tighten using torque wrench. Tighten using Angle Meter (J-45059) or Angular Torque Gauge (KM-470-B).

Courtesy of General Motors Corp.

Fig. 6: Aligning Camshaft Timing Marks

268

GENERAL MOTORS
1.6L 4-Cylinder LeMans
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.6L 4-Cyl. LeMans 1988-89 ............................... 1990 With Tensioner Pulley ..... W/O Tensioner Pulley ..... 1991-93 ...............................
1

2.0 Hours ... .. TCK148 .. ..... T148 2.0 Hours ... ...... ..... ...... ..... T203 2.0 Hours ... .. TCK148 .. ..... T148 2.0 Hours ... ...... ..... ...... ..... T203

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


CAUTION: For 1990-93 models, this application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory drive belts. Remove power steering pump and lines. Remove crankshaft pulley. Remove timing belt covers starting with upper cover. CAUTION: Rotate engine and align reference mark on crankshaft and camshaft sprockets with reference mark on lower timing belt cover before removing belt. Use proper reference mark. Reference marks may be difficult to locate. 2) Rotate engine to align timing marks on crankshaft and camshaft sprockets with reference mark on lower timing belt cover. See Fig. 1. Loosen water pump bolt to release belt tension. Remove timing belt. Installation 1) Install timing belt. Align all timing marks. Carefully rotate water pump to remove slack from timing belt. Tighten water pump bolts. 2) Using Belt Tension Gauge (J-26486-B) or equivalent, measure belt tension between water pump and camshaft sprocket. Adjust belt tension to 35 lbs. (16 kg). To install remaining components, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 41 (56) INCH Lbs. (N.m) Timing Belt Cover Bolt (Front & Rear) .................................................................... 88 (10) Water Pump Bolt ......................................................................................................... 71 (8)
Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt & Pulley Alignment

GENERAL MOTORS
1.6L 4-Cylinder Nova
TIMING BELT APPLICATION Application 1.6L 4-Cyl. Nova DOHC 1988 ................................. SOHC 1985-88 ............................
1

269

Labor Time

Component Belt Kit No. Part No.

3.1 Hours .. ...... ..... ............ T112 3.1 Hours .. .. TCK070 .. ..... T070

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours. With Cruise Control, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits.
Courtesy of General Motors Corp.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Camshaft Sprockets (DOHC)

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove fan shroud on models with power steering. On models with air conditioning, loosen idler pulley nut, adjusting bolt and remove drive belt. On DOHC models, raise and support vehicle and remove right front wheel and right side engine undercover. 2) Remove radiator and air cleaner assembly. If equipped with cruise control, remove actuator and ignition coil. Remove drive belts, fan, water pump drive pulley and valve cover with gasket. Set No. 1 piston at TDC on compression stroke. On DOHC models, use jack to raise engine slightly, then remove right side engine mount through-bolt and mount. Remove crankshaft pulley No. 2 (power steering only). 3) Using puller, remove crankshaft pulley. Remove upper and lower engine front cover mount bolts, gasket and covers. Mark timing belt location. Loosen idler pulley mount bolt, position pulley at far left and retighten mount bolt. Remove timing belt. Installation 1) Loosen timing belt idler pulley mount bolt, move pulley as far left as possible and retighten bolt. If reusing old belt, align marks made during removal. Install belt with arrow pointing in direction of rotation. DO NOT bend or twist belt. Release idler pulley and place tension on belt. 2) If installing new belt, align camshaft(s) timing marks and crankshaft timing marks. See Figs. 1 and 2. Install timing belt. Release idler pulley and place tension on belt. 3) After installing new or used belt, slowly turn crankshaft 2 revolutions clockwise. Recheck timing marks. Adjust belt tension and deection. See Fig. 3. Belt tension should be 4.4 lbs. (2 kg), with a deection of .24-.28 (6-7 mm) on 8-valve engines and .16 (4 mm) on 16-valve engines. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 2: Identifying Timing Belt & Pulley Alignment

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 34 (46) Crankshaft Pulley Bolt 8-Valve ................................................................................................................... 87 (117) 16-Valve ............................................................................................................... 137 (186) Timing Belt Idler Mount Bolt ......................................................... ................. 26-36 (36-49)

Courtesy of General Motors Corp.

Fig. 3: Locating Timing Belt Deection Points

270

GENERAL MOTORS
1.8L 4-Cylinder Diesel
Labor Time Belt Part No. 3) Finger tighten tensioner bolts in sequence to prevent movement of tensioner pulley. See Fig. 3. Tighten camshaft pulley bolt. Remove injection pump gear lock bolt. Remove xing plate on end of camshaft. 4) Install damper pulley on hub and check that No. 1 cylinder is at TDC. DO NOT turn crankshaft if adjustment is needed. Be sure mark on injection pump pulley aligns with mark on plate. See Fig. 1. Fixing plate should t smoothly into slot at rear of camshaft. Remove xing plate. 5) Loosen tensioner pulley and plate bolts. Concentrate belt looseness on tensioner and tighten bolts in sequence. See Fig. 3. Belt tension should be checked at point between camshaft gear and injection pump gear using Belt Tension Gauge (J-29771) or equivalent. Belt tension should be 46-63 lbs. (20-28 kg). 6) Remove damper pulley and install belt holder in position away from timing bolt. Install by-pass hose, dust covers, and damper pulley. Install cooling fan, belt and pulley. Install fan shroud. Rell system with coolant and connect battery. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Diesel Acadian (Canadian) 1981-85 .................................................... Chevette 1981-86 ....................................................
1

3.1 Hours .. ..... T076 3.1 Hours .. ..... T076

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove fan shroud, V-belt and pulley. Remove upper dust cover. Disconnect by-pass hose. 2) With No. 1 piston at TDC of compression stroke, check that timing mark on injection pump pulley is in alignment with front plate pointer. Align injector gear by inserting 8 mm x 1.25 mm bolt through gear alignment hole and front ange plate. See Fig. 1. 3) Remove valve cover. Attach Fixing Plate (J-29761), or equivalent, to slot in rear of camshaft. This will prevent camshaft from rotating. Remove damper pulley and timing belt holder. Recheck to be sure No. 1 cylinder is at TDC. 4) Remove lower dust cover and timing belt holder. Remove tension spring from behind front plate, next to injection pump. Loosen tension pulley and plate bolts. Remove timing belt.

Courtesy of General Motors Corp.

Fig. 2: Identifying Timing Belt Installation Sequence

Courtesy of General Motors Corp.

Fig. 3: Identifying Tension Pulley Bolt Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ................................................................................................. 55 (75) Damper Pulley Bolt ................................................................................................... 12 (20) Tension Pulley Center Bolt .............................................................................................................. 54 (73) Side Bolts ................................................................................................................ 15 (20) Water Pump Bolts ..................................................................................................... 15 (20)

Courtesy of General Motors Corp.

Fig. 1: Locating Injection Pump Gear Alignment Marks & Lock Bolt Installation 1) Remove bolt attaching camshaft gear. Using Gear Puller (J-22888) or equivalent, remove cam gear. Reinstall cam gear loosely so it can be turned by hand. Install timing belt in proper sequence. See Fig. 2. 2) Belt should be properly tensioned between pulleys. Cogs on belt and pulley should engage properly. Crankshaft should not be turned. Concentrate belt looseness on tension pulley. Depress tension pulley with nger and install tension spring.

GENERAL MOTORS
1.8L 4-Cylinder Gasoline
TIMING BELT APPLICATION Application
1

271

Labor Time Component Belt Kit No. Part No.

1.8L 4-Cyl. OHC Firenza 1982-86 ............................... J2000 1982 .................................... Skyhawk 1982-86 ............................... Sunbird 1985-86 ............................... 2000 1983 .................................... 2000 Sunbird 1984 ....................................
1

2.7 Hours ... .. TCK081 .. ..... T081 2.7 Hours ... .. TCK081 .. ..... T081 2.7 Hours ... .. TCK081 .. ..... T081 2.7 Hours ... .. TCK081 .. ..... T081 2.7 Hours ... .. TCK081 .. ..... T081 2.7 Hours ... .. TCK081 .. ..... T081

2) Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent, check belt tension between water pump and camshaft sprocket. Initial new belt tension should be 38 lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16 kg). 3) Reassemble components and run engine to operating temperature (thermostat open). As new belt takes a set position, substantial tension loss will occur. After belt has been run, recheck tension with gauge on belt. 4) If belt tension is incorrect, loosen water pump bolts and rotate pump until correct tension is obtained. Hot timing belt tension specication is 30 lbs. (13 kg). 5) DO NOT leave tension gauge on belt during retightening, or reading will be inaccurate. Tighten water pump bolts. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove belts, brackets and shields necessary to gain access to crankshaft pulley. Remove timing belt front cover. 2) Rotate crankshaft so timing mark on crankshaft pulley lines up with 10 BTDC mark on indicator scale. Mark on camshaft sprocket must align with mark on camshaft carrier. Remove crankshaft pulley. 3) Remove timing probe holder. Verify timing marks are aligned, and loosen water pump retaining bolts to remove timing belt. Installation 1) Install new timing belt on sprockets. Install crankshaft pulley and check for alignment of timing marks. Using Adjuster (J-33039) or equivalent, rotate water pump clockwise until slack is removed from timing belt. Tighten water pump bolts. See Fig. 1. NOTE: If new timing belt has been installed, check nal tension with engine at operating temperature. If new head gasket is installed, cylinder head must be retightened AFTER initial warmup. Timing belt tension MUST then be rechecked.
Courtesy of General Motors Corp.

Fig. 1: Adjusting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 34 (45) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 20 (27) Crankshaft Sprocket Retaining Bolt .............................................. ........................ 115 (156) Timing Belt Rear Cover Bolt ..................................................................................... 19 (25) Water Pump Retaining Bolts .................................................................................... 19 (25) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ......................................................................................... 72 (8) Timing Belt Front Cover Bolt ...................................................................................... 60 (7)

272

GENERAL MOTORS
2.0L 4-Cylinder
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. OHC Firenza 1987-88 ............................... Grand Am 1987-88 ............................... 1989 .................................... LeMans 1989 1st Design ........................ 2nd Design ....................... 1990 .................................... Skyhawk 1987-88 ............................... Sunbird 1987-88 ............................... 1989-94 ...............................
1

2.7 Hours ... ...... ..... ...... ..... T081 2.7 Hours .... TCK081A . ..... T081 2.7 Hours ... .. TCK163 .. ..... T163

2.7 Hours .... TCK081A . ..... T081 2.7 Hours ... .. TCK163 .. ..... T163 2.7 Hours ... .. TCK163 .. ..... T163 2.7 Hours .... TCK081A . ..... T081 2.7 Hours .... TCK081A . ..... T081 2.7 Hours ... .. TCK163 .. ..... T163

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.
Courtesy of General Motors Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Exploded View Of Timing Belt & Components

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal (1987-88) 1) Disconnect negative battery cable. Remove belts, brackets and shields necessary to gain access to crankshaft pulley. Remove timing belt front cover. See Fig. 1. 2) Rotate crankshaft so timing mark on crankshaft pulley lines up with 10 degrees BTDC mark on indicator scale. Mark on camshaft sprocket must align with mark on camshaft carrier. Remove crankshaft pulley. 3) Remove timing probe holder. Verify timing marks are aligned, and loosen water pump retaining bolts to remove timing belt. Installation (1987-88) 1) Install new timing belt on sprockets. Install crankshaft pulley and check for alignment of timing marks. Using Adjuster (J-33039) or equivalent, rotate water pump clockwise until slack is removed from timing belt. Tighten water pump bolts. See Fig. 2. NOTE: If new timing belt has been installed, check nal tension with engine at operating temperature. If new head gasket is installed, cylinder head must be retightened AFTER initial warmup. Timing belt tension MUST then be rechecked. 2) Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent, check belt tension between water pump and camshaft sprocket. Initial new belt tension should be 38 lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16 kg). 3) Reassemble components and run engine to operating temperature (thermostat open). As new belt takes a set position, substantial tension loss will occur. After belt has been run, recheck tension with gauge on belt. 4) If belt tension is incorrect, loosen water pump bolts and rotate pump until correct tension is obtained. Hot timing belt tension specication is 30 lbs. (13 kg). 5) DO NOT leave tension gauge on belt during retightening, or reading will be inaccurate. Tighten water pump bolts to specication. See TORQUE SPECIFICATIONS. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 2: Adjusting Timing Belt Tension Removal (1989-94) 1) Disconnect negative battery cable. Remove serpentine belt, brackets, and shields necessary to gain access to crankshaft pulley. Remove front timing belt cover. See Fig. 1. 2) Remove crankshaft pulley. Loosen water pump retaining bolts. Using Timing Belt Adjuster (J-33039-A) or equivalent, rotate water pump to release timing belt tension. Remove timing belt. Installation (1989-94) 1) To install camshaft and crankshaft sprockets (if removed), reverse removal procedure. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. 2) Rotate crankshaft and camshaft clockwise to align timing marks on sprockets with marks on rear cover. Install new timing belt on sprockets. Ensure belt has tension on it between the camshaft sprocket and crankshaft sprocket. NOTE: Adjust timing belt with engine coolant temperature at 68F (20C). 3) Using timing belt tension adjuster, rotate water pump clockwise until tensioner contacts the high torque stop. See Fig. 3. Slightly tighten water pump retaining bolts.

GENERAL MOTORS
2.0L 4-Cylinder (Cont.)
4) Using crankshaft sprocket bolt, rotate engine clockwise 2 revolutions to fully seat timing belt. Rotate water pump eccentric counterclockwise until hole in tensioner arm aligns with hole in base. 5) Tighten water pump bolts to specication. See TORQUE SPECIFICATIONS. Ensure tensioner holes remain in alignment as stated. Ensure all timing marks are properly aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

273

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley-To-Sprocket Bolt 1987-88 .................................................................................................................... 20 (27) 1989-92 .................................................................................................................... 15 (20) Serpentine Belt Tensioner Bolt ................................................................................. 35 (47) Timing Belt Tensioner Bolt ........................................................................................ 18 (24) Water Pump Bolt ....................................................................................................... 18 (24) INCH Lbs. (N.m) Camshaft Carrier Cover Bolt .................................................................................... 84 (10) Timing Belt Cover Bolt ................................................................................................ 62 (7)

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Tensioner (1989-94)

274

GENERAL MOTORS
3.0L V6
Labor Time Component Belt Kit No. Part No. NOTE: Do not move camshafts with belt removed. Do not remove Camshaft Holders (J42069) with timing belt removed. 11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.

TIMING BELT APPLICATION Application

3.0L V6 DOHC Catera 1997-98 ............................... 2.6 Hours ... .. TCK285 .. ..... T285 1999-01 ............................... 2.6 Hours .... TCK285A . ..... T285 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 100,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Precautions 1) When servicing timing belt, always turn crankshaft in normal direction of rotation (clockwise). 2) Install timing belt with engine at room temperature. 3) Never remove timing belt without rst setting camshaft gears and crankshaft drive gear to TDC and locking them in place. 4) Guide marks on timing belt are to aid in timing belt installation. If guide marks cannot be identied, 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 20F (28C), visually inspect timing belt for cracks. If there are cracks present, DO NOT reuse the belt. Replace belt. If belt is okay and reused, DO NOT clear the cold start counter. Removal 1) Disconnect negative battery cable. Remove air intake resonator and ducting from throttle body. 2) Raise and support vehicle. Remove lower front splash shield. Remove AIR injection crossover pipe clamps and bushing nut from front cover. See Fig. 1. Separate air injection crossover pipe from hoses and front cover. 3) Lower vehicle. Remove air injection crossover pipe from front cover. 4) Loosen, but do not remove, water pump pulley bolts. Loosen, but do not remove, power steering pump pulley bolts. Remove A/C compressor hose strap from AIR injection crossover bracket. Remove accessory drive serpentine belt. 5) Release plastic retaining tabs, and remove wiring harness channel cover from front of engine. Move wiring harness out of way. 6) Remove water pump pulley bolts and pulley. Remove power steering pump pulley bolts and pulley. Remove accessory drive serpentine belt tensioner. 7) Remove front timing belt cover. Remove 6 harmonic balancer-tocrankshaft bolts. Remove harmonic balancer. It is NOT necessary to remove crankshaft center bolt. 8) Rotate crankshaft clockwise to 60 degrees before TDC. See Fig. 2. Ensure timing marks are not 180 degrees from TDC. 9) Install Crankshaft Holder (J42069-10) and rotate crankshaft clockwise until holder contacts water pump. See Fig. 3. Secure moveable lever of tool to water pump pulley ange. Camshaft timing marks should be aligned with marks on rear cover. See Fig. 4 or 5. If not aligned, crankshaft is 180 degrees (one half turn) off. 10) To lock camshafts in place, install Camshaft Gear Holders (J42069-1 and J42069-2). See Fig. 6. It may be necessary to loosen timing belt idler pulley and turn eccentric until holder can be inserted.

Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt Front Cover Components

Courtesy of General Motors Corp.

Fig. 2: Positioning Crankshaft At 60 Degrees BTDC

Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

GENERAL MOTORS
3.0L V6 (Cont.)

275

Courtesy of General Motors Corp.

Fig. 6: Installing Camshaft Gear Holders NOTE: Timing belt conguration changed in mid-1999 model year. For both designs, use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For early design (up to mid-1999), use the remaining 3 White marks on the timing belt. For later design (mid-1999 to present), use the remaining 3 Yellow marks on the timing belt. Correct belt application MUST be used on each engine design. 2) Lower vehicle. Route timing belt around tensioner, right bank (passengers side) camshaft gears, idler pulley, and left bank (drivers side) camshaft pulleys. Ensure timing belt marks are aligned with marks on camshaft sprockets and notches on rear timing belt cover. Keep timing belt taut between idler pulley and left bank camshaft pulleys. See Fig. 4 or 5. 3) Ensure timing belt tension is taut (no slack). Measure timing belt deection midway between left bank camshafts (viewed from rear of engine) and left side idler pulley (viewed from rear of engine). See Fig. 8. Deection should be no more than 0.40 (10 mm). If initial timing belt deection is okay, go to TIMING BELT TENSION ADJUSTMENT. If timing belt deection is not correct, go to TIMING BELT DEFLECTION ADJUSTMENT.

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks (Up To 1999 Early Design)

Courtesy of General Motors Corp.

Fig. 5: Aligning Timing Belt Marks With Rear Cover Marks (From 1999 Late Design) Inspection Check timing belt for excessive wear, cracks, or missing teeth. Inspect timing belt tensioner and idler pulleys for worn bearings. Replace as necessary. NOTE: Install timing belt at room temperature. NEW timing belts are marked with direction of rotation arrow and mating marks. Make sure belt is installed with arrows pointing in correct direction of rotation. Installation 1) To install timing belt, remove crankshaft holder. Raise and support vehicle. Start installation of belt at crankshaft pulley. Install timing belt with double dash marks aligned with oil pump and drive gear marks. See Fig. 7. Install Timing Belt Holder (J42069-30) or equivalent plastic wedge to hold belt against crankshaft sprocket.

Courtesy of General Motors Corp.

Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley Timing Belt Deection Adjustment 1) If timing belt deection adjustment is necessary, loosen left (drivers) side idler pulley bolt. (This is NOT the idler pulley positioned between camshaft sprockets in top, center of engine). Turn left idler pulley counterclockwise until high point of eccentric nut is in about 12 oclock position. See Fig. 5. Snug idler pulley bolt while holding eccentric so it does not move. Go to next step.

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 CAMSHAFTS).

Courtesy of General Motors Corp.

Fig. 8: Measuring Timing Belt Deection 2) Apply additional tension to timing belt by loosening bolt for idler pulley located between camshaft sprockets (top, center of engine). Rotate high point of eccentric to 9 oclock position. Tighten idler pulley bolt while holding eccentric so it does not rotate. Go to TIMING BELT TENSION ADJUSTMENT. Timing Belt Tension Adjustment Loosen timing belt tensioner lock nut. Turn tensioner eccentric counterclockwise to full stop. Turn eccentric back until reference mark is .039 (1 mm) from belt tension setting ange. See Fig. 9. Tighten timing belt tensioner lock nut until snug. Lock nut will be nal tightened after nal adjustments are made. Go to CHECKING CAMSHAFT SPROCKET ALIGNMENT.

Courtesy of General Motors Corp.

Fig. 10: Installing Checking Gauge On Camshaft Sprockets NOTE: When readjusting timing belt tension, Crankshaft Holder (J42069-10) must be in position on engine. Timing Belt Readjustment (Left Bank Camshafts) 1) If timing belt readjustment is required, always start with left bank (drivers side) camshafts rst. Install Checking Gauge (J42069-20) to left bank camshafts. 2) Loosen idler pulley on drivers side of engine. This is idler pulley below camshaft sprockets. Using Wrench (J42069-40) or equivalent, turn idler pulley eccentric COUNTERCLOCKWISE until timing marks on camshaft sprockets and checking gauge are in alignment. High point of idler pulley eccentric should be in about the 12 oclock position. Tighten idler pulley bolt while holding eccentric from turning. 3) Remove checking gauge and crankshaft holder. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degree BTDC. Install Crankshaft Holder (J42069-10) to crankshaft drive gear. Rotate crankshaft to secure lever of holder to water pump ange. Install Checking Gauge (J42069-20) to left bank camshafts. If camshaft sprockets are now properly aligned, go to TIMING BELT READJUSTMENT (RIGHT BANK CAMSHAFTS). If not, repeat readjustment procedure. Timing Belt Readjustment (Right Bank Camshafts) 1) If timing belt readjustment is required, always start with left bank (drivers side) camshafts rst. Install Checking Gauge (J42069-20) to right bank (passengers side) camshafts. 2) Loosen bolt on idler pulley that is located in the center and below the left bank and right bank camshafts. 3) Using Wrench (J42069-40) or equivalent, turn idler pulley eccentric COUNTERCLOCKWISE until timing marks on camshaft sprockets and checking gauge are in alignment. High point of idler pulley eccentric should be in about the 9 oclock position. Tighten idler pulley bolt while holding eccentric from turning. 4) Remove checking gauge and crankshaft holder. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degree BTDC. Install Crankshaft Holder (J42069-10) to crankshaft drive gear. Rotate crankshaft to secure lever of holder to water pump ange. Install Checking Gauge (J42069-20) to right bank camshafts. If camshaft sprockets are now properly aligned, go to FINAL TIMING BELT TENSIONING & INSTALLATION. If not, repeat readjustment procedure.

Courtesy of General Motors Corp.

Fig. 9: Adjusting Timing Belt Tension (New Design Engine Shown; Early Design Engine Is Similar) Checking Camshaft Sprocket Alignment 1) Ensure timing belt alignment marks are still aligned with reference points on camshaft sprockets and rear timing belt cover. Remove all locking tools from camshafts and timing belt. 2) Rotate crankshaft clockwise 2 revolutions, stopping at 60 degrees before TDC mark. See Fig. 2. Install Crankshaft Holder (J42069-10) to crankshaft ange. Secure moveable lever of tool to water pump pulley ange. NOTE: Alignment marks on timing belt will no longer align with camshaft sprocket marks after one or more crankshaft revolutions. 3) Ensure crankshaft timing mark aligns with mark on oil pump housing. Ensure camshaft timing marks align with notches on rear cover.

GENERAL MOTORS
3.0L V6 (Cont.)
Final Timing Belt Tensioning & Installation 1) To set nal timing belt tension, loosen timing belt tensioner eccentric lock nut. Turn timing belt eccentric counterclockwise to full stop. Turn tensioner back until reference mark is .079-.157 (2-4 mm) ABOVE reference mark on ange. See Fig. 9. Tighten tensioner eccentric lock nut to specication. See TORQUE SPECIFICATIONS. 2) If timing belt idler pulley bolts were loosened, nal tighten them to specication. Inspect high points of timing belt tensioner eccentrics. Left side idler pulley (viewed from rear of engine) eccentric high point should be in about the 12 oclock position. Top center idler pulley eccentric high point should be in about the 9 oclock position. See Fig. 5. 3) Remove crankshaft holding tool. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degrees before TDC mark. Install Crankshaft Holder (J42069-10) to crankshaft drive gear. 4) Turn crankshaft clockwise until lever of holder rmly contacts water pump pulley ange. Secure moveable lever of tool to water pump pulley ange. 5) Ensure camshaft timing marks align with notches on rear cover and crankshaft timing mark align with mark on oil pump housing. Use Checking Gauge (J42069-20) to inspect alignment of left bank and right bank camshaft gears. 6) Adjust timing belt position, if necessary. Ensure all tools are removed from engine. Install timing belt front cover. Install crankshaft harmonic balancer. Tighten bolt to specication. 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.

277

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 ........................................................................................................... Additional 60 Step 3 ........................................................................................................... Additional 15 Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................. 184 (250) Step 2 ........................................................................................................... Additional 45 Step 3 ........................................................................................................... Additional 15 Generator Bolt ........................................................................................................... 30 (40) Power Steering Pump Pulley Bolt ............................................................................ 15 (20) Serpentine Drive Belt Tensioner Bolt ....................................................................... 30 (40) Timing Belt Idler Pulley Bolt ..................................................................................... 30 (40) Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40) Timing Belt Tensioner Eccentric Lock Nut ............................................................... 15 (20) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ...................................................................................... 71 (8) Water Pump Pulley Bolt .............................................................................................. 71 (8)

278

GENERAL MOTORS
3.2L V6
Labor Time Belt Part No. on camshaft gears should be aligned with corresponding notches on rear timing belt cover, and marks on crankshaft sprocket and oil pump housing should align. See Fig. 5. 11) Using crank hub torx socket, rotate crankshaft counterclockwise until 60 degrees BTDC. The 60 degree BTDC point can be identied by index mark on oil pump cover. See Fig. 6. NOTE: Ensure moveable lever is positioned toward crankshaft. 12) Install the Crankshaft Holder (J-42069-10) from Timing Belt Alignment Kit (J-42069) to the crankshaft sprocket with the knurled bolt. See Fig. 7. Using crank hub torx socket, rotate crankshaft clockwise until lever of crankshaft holder rmly contacts water pump pulley ange. Ensure No. 1 cylinder is at TDC. Secure moveable lever of tool to water pump pulley ange. CAUTION: Ensure crankshaft is not 180 degrees off TDC. Reference marks on camshaft gears should be aligned with corresponding notches on rear timing belt cover at this point. If they are not aligned, engine is 180 degrees off. 13) Install the Camshaft Gear Holders (J-42069-1 and J-42069-2) to camshaft gears. See Fig. 8. If either tool does not t into the teeth of the camshaft gears, it may be necessary to loosen the upper idler pulley, and turn the eccentric or camshaft gears until tool can be inserted. 14) Loosen timing belt tensioner nut. Loosen upper idler pulley bolt. Remove lower idler pulley bolt. Remove lower idler pulley and spacer. CAUTION: DO NOT turn camshaft and crankshaft independently after timing belt is removed. If turned, interference may occur among pistons and valves, and related components may be damaged. CAUTION: DO NOT remove the camshaft gear holders from camshaft gears while timing belt is removed. 15) Remove the crankshaft holder from crankshaft sprocket. If belt is to be reused, mark direction of rotation for reinstallation reference. Remove timing belt.

TIMING BELT APPLICATION Application

3.2L V6 CTS 2003-04 ..................................................... 2.4 Hours ... ..... T285 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends that the timing belt be replaced at 100,000 miles or every 96 months, whichever occurs rst.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Using scan tool, inspect the cold start counter (also known as heavy duty register). If there are any cold starts below 20F (28C), visually inspect timing belt for cracks and replace as necessary. If belt is replaced, clear the cold start counter. If belt is not replaced, do not clear the cold start counter. 2) Disconnect air intake duct hose from Mass Airow (MAF)/Intake Air Temperature (IAT) sensor. Remove bolt securing intake air resonator to cooling fan assembly. Disconnect air intake duct hoses from throttle body. Lift intake air resonator from front frame to access the electrical connector and vacuum hoses. Disconnect intake resonance switchover solenoid connector. NOTE: Note vacuum hose routing for reassembly. 3) Disconnect vacuum hoses from the coolant by-pass solenoid, intake plenum switchover solenoid and vacuum brake booster hose. Positioning the surge tank inlet and upper radiator hoses aside, remove intake air resonator. 4) Remove intake plenum air inlet hose clamps and hoses from throttle body. Disconnect fuel pressure regulator atmospheric vent tube from bottom of throttle body. Remove throttle body from intake plenum and crankcase vent adapter, and allow it to be supported by the throttle body inlet heater hose. Remove throttle body O ring seals. 5) Remove 3 bolts holding crankcase vent adapter to intake plenum. Lift crankcase vent adapter from intake plenum, and position aside. See Fig. 1. Disconnect crankcase ventilation dirty air hose retainer from fuel pipe. Remove remote power steering uid reservoir bottom and side mounting bolts, and position aside. 6) Disconnect electrical connector and vacuum hose from switchover valve at rear of plenum. See Fig. 2. Remove bolt holding throttle body heater inlet hose/pipe to intake plenum. Disconnect vacuum brake booster hose from vacuum source. Remove 2 bolts securing Engine Control Module (ECM) bracket to intake plenum. See Fig. 4. 7) Remove intake plenum bolt caps and bolts. Lift intake plenum from intake manifold. Remove intake plenum O ring seals. Mask off intake manifold ports to prevent foreign objects from entering engine. 8) Rotate drive belt tensioner clockwise to release drive belt tension. Slide drive belt from water pump pulley. Allow drive belt tensioner to return to relaxed position. Remove accessory drive belt. Remove drive belt tensioner. Remove water pump pulley. See Fig. 3. 9) Remove power steering pump mounting bolts ONLY. Remove power steering pump from accessory mounting bracket, and position aside. Remove timing belt cover. Remove crankshaft balancer from crankshaft sprocket. 10) Using Crank Hub Torx Socket (J-42098), rotate engine clockwise until No. 1 cylinder is at TDC on the compression stroke. Timing marks

Courtesy of General Motors Corp.

Fig. 1: Removing Crankcase Vent Adapter

GENERAL MOTORS
3.2L V6 (Cont.)

279

Courtesy of General Motors Corp.

Fig. 2: Disconnecting Electrical Connector & Vacuum Hose From Switchover Valve

Courtesy of General Motors Corp.

Fig. 4: Removing & Installing ECM Bracket

Courtesy of General Motors Corp.

Fig. 3: Exploded View Of Timing Belt & Components

280

GENERAL MOTORS
3.2L V6 (Cont.)

Courtesy of General Motors Corp.

Fig. 5: Rotating Crankshaft Clockwise

Courtesy of General Motors Corp.

Fig. 7: Installing Crankshaft Holder & Other Tools

Courtesy of General Motors Corp.

Fig. 6: Positioning Crankshaft At 60 Degrees BTDC Inspection 1) Check if a tooth is broken and/or a tooth root is cracked. Possible causes are a jammed camshaft, damaged camshaft, damaged crankshaft oil seal and/or coolant leak, old age or malfunctioning tensioner. 2) Check if the back surface of the belt is cracked, worn, scratched or scored. Possible causes are excessive cold starts, jammed tensioner, overheated engine or belt cover interference. 3) Check if the side of the belt surface is worn. Possible causes are improper belt installation, overload or misalignment of cam drive components, jammed tensioner, heavy thrust loading against idler guide anges or damaged idler guide. 4) Check if the teeth are worn. Possible causes are poor belt cover sealing, excessive belt tension, jammed tensioner, or rough and/or scored cam sprockets. 5) Check if there is a clean break across the bers. Possible causes are kinked belt before and/or during assembly or foreign material under belt. 6) Check if oil or coolant is impregnated and/or there is a swollen belt. Possible causes are poor oil sealing, coolant leak at pump or poor belt cover seal.

Courtesy of General Motors Corp.

Fig. 8: Installing Locking Tools To Camshaft Gears CAUTION: Install timing belt with engine at room temperature. Ensure directional arrows on timing belt are matched with the clockwise rotation of the crankshaft, or excessive wear and timing belt failure may occur. Installation 1) Starting at crankshaft sprocket, align double dash TDC mark on timing belt with marks on oil pump housing and crankshaft sprocket. Wedge the Timing Belt Holder (J-42069-30) between oil pump housing and timing belt in order to prevent the belt teeth from jumping the crankshaft sprocket teeth. See Fig. 9.

GENERAL MOTORS
3.2L V6 (Cont.)
2) Route timing belt through timing belt tensioner. See Fig. 5. Slip the timing belt through camshaft gears No. 1 and 2 simultaneously, ensuring dash marks on timing belt align with marks on camshaft gears and notches on rear timing belt cover. Route belt through upper idler pulley. Slip belt through camshaft gears No. 3 and 4 simultaneously, ensuring dash marks on timing belt align with marks on camshaft gears and notches on rear timing belt cover. 3) Using Crank Hub Torx Socket (J-42098), rotate crankshaft counterclockwise to 3 degrees BTDC, allowing timing belt to slide on the timing belt holder. See Fig. 10. Install lower idler pulley and spacer with the timing belt. Install lower idler pulley bolt, and tighten to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise back to TDC. 4) Apply tension to timing belt at upper idler pulley by turning high point of eccentric to approximately the 9 oclock position. While holding eccentric with the Wrench (J-42069-40), tighten idler pulley locking bolt until snug. See Fig. 5. 5) To set initial timing belt tension, rotate tensioner eccentric counterclockwise to full stop, then turn eccentric back until reference mark is 0.03 (1 mm) over the ange. See Fig. 11. Tighten tensioner locking nut until snug. 6) Ensure alignment marks on timing belt are aligned with timing marks on camshaft gears, rear timing belt cover and oil pump housing. See Fig. 12. Remove the timing belt holder and the Camshaft Gear Holders (J-42069-1 and J-42069-2) from engine. See Figs. 8 and 9. 7) Using crank hub torx socket, rotate crankshaft clockwise 2 revolutions until No. 1 cylinder is 60 degrees BTDC. See Fig. 6. Install the Crankshaft Holder (J-42069-10) to crankshaft sprocket with the knurled bolt. See Fig. 7. Rotate crankshaft clockwise until lever of the crankshaft holder rmly contacts water pump pulley ange, and secure lever to ange. 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 specication. See TORQUE SPECIFICATIONS. 10) Using the wrench, hold upper idler pulley eccentric in place, and tighten pulley bolt to specication. See Fig. 7. See TORQUE SPECIFICATIONS. Remove the checking gauge from camshaft gears. Remove the crankshaft holder from engine. 11) For nal 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 specication. See TORQUE SPECIFICATIONS. Lightly coat intake plenum O ring seals and crankcase vent adapter seal with clean engine oil. Adjust driving belt tension.

281

Courtesy of General Motors Corp.

Fig. 9: Aligning Timing Belt Marks On Crankshaft Pulley

Courtesy of General Motors Corp.

Fig. 10: Positioning Crankshaft At 3 Degrees BTDC

TIMING BELT ADJUSTMENTS


CAUTION: This procedure must not be performed as a stand-alone operation. NOTE: It is not uncommon to repeat steps and make several engine revolutions to achieve the proper level of timing belt adjustment. Timing Belt Adjustment Check 1) Apply the Checking Gauge (J-42069-20) to the camshaft gears No. 1 and 2. See Fig. 7.
Courtesy of General Motors Corp.

Fig. 11: Adjusting Timing Belt Tension

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 oclock position. See Fig. 7. 2) Tighten the upper idler pulley bolt, while holding the eccentric in place with the wrench to prevent movement. See TORQUE SPECIFICATIONS. Remove the Crankshaft Holder (J-42069-10) and the checking gauge. 3) Rotate the crankshaft in the engine rotational direction (clockwise) 2 revolutions using the Crank Hub Torx Socket (J-42098) until reaching 60 degrees BTDC. See Fig. 6. The 60 degrees BTDC point can be identied by the index mark on the oil pump cover. NOTE: Ensure the moveable lever is positioned toward the crankshaft. 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 rmly contacts the water pump pulley ange. The No. 1 cylinder is at TDC at this point. 5) Secure the moveable lever of the tool to the water pump pulley ange. Ensure that the crankshaft is not 180 degrees off TDC. The reference marks on the camshaft gears should be aligned with the corresponding notches on the rear timing belt cover at this point. If they are not aligned, the engine is 180 degrees off. 6) Install the checking gauge to camshaft gears No. 1 and 2. Inspect the alignment of the marks on the camshaft gears in reference to the marks on the checking gauge. 7) Repeat the procedure again if the marks do not align. If camshaft gears No. 1 and 2 are now properly aligned, go to FINAL TIMING BELT TENSIONING & INSTALLATION. Timing Belt Readjustment (Right Bank Camshafts) 1) Loosen the upper idler pulley bolt. Slacken the timing belt by turning the eccentric on the upper idler pulley clockwise with the Wrench (J-42069-40) until the marks on the camshaft gears and the marks on the Checking Gauge (J-42069-20) are in alignment. The high point of the idler pulley eccentric will be in approximately the 9 oclock position. See Fig. 7. 2) Tighten the upper idler pulley bolt, while holding the eccentric in place with the wrench to prevent movement. See TORQUE SPECIFICATIONS. Remove the Crankshaft Holder (J-42069-10) and the checking gauge. 3) Rotate the crankshaft in the engine rotational direction (clockwise) 2 revolutions using the Crank Hub Torx Socket (J-42098) until reaching 60 degrees BTDC. See Fig. 6. The 60 degrees BTDC point can be identied by the index mark on the oil pump cover. NOTE: Ensure the moveable lever is positioned toward the crankshaft. 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 rmly contacts the water pump pulley ange. The No. 1 cylinder is at TDC at this point. 5) Secure the moveable lever of the tool to the water pump pulley ange. 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.

Courtesy of general motor corps.

Fig. 12: Aligning Timing Belt Marks With Rear Cover Marks

Courtesy of General Motors Corp.

Fig. 13: Inspecting Alignment Of Reference Marks

Courtesy of General Motors Corp.

Fig. 14: Setting Final Timing Belt Tension

GENERAL MOTORS
3.2L V6 (Cont.)
7) Repeat the procedure again if the marks do not align. If camshaft gears No. 1 and 2 are properly aligned, set the nal timing belt tensioner as outlined in FINAL TIMING BELT TENSIONING & INSTALLATION. CAUTION: The following steps are the COMPLETION of adjusting the timing belt, and must not be performed as a stand-alone operation. Final Timing Belt Tensioning & Installation 1) With the Crankshaft Holder (J-42069-10) in place locking the crankshaft at TDC, loosen the timing belt eccentric locking nut. Turn the eccentric counterclockwise to full stop, then back to the following specication: New Belt Until the reference mark is 0.118-0.157 (3-4 mm) above the datum line. See Fig. 14. Used Belt Until the reference is aligned with the datum line. Tighten the timing belt tensioner eccentric locking nut. See TORQUE SPECIFICATIONS. 2) If the timing belt upper idler pulley bolt has not been previously torqued to specication, tighten the timing belt upper idler pulley bolt while holding the eccentric in place with the Wrench (J-42069-40) to prevent movement. See Fig. 7. See TORQUE SPECIFICATIONS. 3) Remove the crankshaft holder and the Checking Gauge (J-42069-20). For nal inspection, once again rotate the crankshaft in the engine rotational direction (clockwise) 2 revolutions using the Crank Hub Torx Socket (J-42098) until reaching 60 degrees BTDC. See Fig. 6. 4) Install the crankshaft holder to the crankshaft sprocket. Rotate the crankshaft in the engine rotational direction (clockwise) using the crank hub torx socket until the lever of the crankshaft holder rmly contacts the water pump pulley ange. 5) Secure the moveable lever of the tool to the water pump pulley ange. 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.

283

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Balancer Bolts ........................................................................................ 15 (20) Drive Belt Tensioner Bolts ........................................................................................ 26 (35) Intake Plenum Bolts .................................................................................................. 15 (20) Lower Idler Pulley Bolt .............................................................................................. 30 (40) Power Steering Pump Mounting Bolts ..................................................................... 26 (35) Timing Belt Tensioner Eccentric Locking Nut .......................................................... 15 (20) Upper Idler Pulley Bolt .............................................................................................. 30 (40) INCH Lbs. (N.m) Crankcase Vent Tube Adapter Bolts .......................................................................... 71 (8) Engine Control Module (ECM) Bracket Bolts ............................................................ 71 (8) Intake Air Resonator Retaining Bolt ........................................................................... 80 (9) Remote Power Steering Fluid Reservoir Mounting Bolts To Cylinder Head ........................................................................ ..................................... 1 To Intake Plenum ...................................................................................................... 80 (9) Throttle Body Bolts ...................................................................................................... 71 (8) Throttle Body Heater Inlet Hose/Pipe Bolt ................................................................. 80 (9) Timing Belt Cover Bolts .............................................................................................. 71 (8) Water Pump Pulley Bolts ............................................................................................ 71 (8)
1

Tighten to 18 ft. lbs. (25 N.m).

284

GENERAL MOTORS
3.4L V6
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

10) Position timing belt tensioner actuator in vise with rod tip (rubber boot end) pointing down. CAUTION: Allow oil to ow towards boot end of actuator for at least 5 minutes prior to relling. NOTE: Tensioner actuator is oil lled. Removal of plug may allow oil to escape. DO NOT remove vent plug. 11) Straighten out a standard paper clip (.032 with no serrations) and form a loop at one end. See Fig. 2. Remove rubber end plug from rear of tensioner actuator. Push paper clip through end of vent plug and into pilot hole. Insert a small screwdriver into the screw slot inside actuator, behind rubber end plug. 12) Retract actuator plunger by rotating screw in a clockwise direction until it is fully retracted. Push on paper clip and slowly rotate screw counterclockwise until paper clip engages. Remove timing belt. NOTE: Remove timing marks from camshaft and intermediate shaft sprockets. 13) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Mark the timing indicator with White paint or equivalent on the crankshaft balancer and front cover. See Fig. 3. 14) Position camshafts so that at spots are UP for installation of Camshaft Hold-Down Tools (J 38613-A). Install Camshaft Hold-Down Tools (J 38613-A) on both camshaft carriers. See Fig. 4. 15) Remove camshaft sprocket center bolts. Note difference between early and late designs. See Fig. 5. Lightly tap on rear of sprockets to remove from camshaft.

3.4L V6 DOHC Cutlass Supreme & Grand Prix 1991-95 ............................... 4.5 1996 .................................... 4.5 Lumina 1991-95 ............................... 4.5 1996-97 ............................... 4.5 Monte Carlo 1995 .................................... 4.5 1996-97 ............................... 4.5
1

Hours ... .. TCK192 .. ..... T192 Hours ... .. TCK273 .. ..... T273 Hours ... .. TCK192 .. ..... T192 Hours ... .. TCK273 .. ..... T273 Hours ... .. TCK192 .. ..... T192 Hours ... .. TCK273 .. ..... T273

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


CAUTION: For 1996-97 models, this application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner and duct assembly. Drain engine coolant. 2) Remove accelerator and cruise control cables from throttle body. Remove fuel rail cover. Relieve fuel pressure. Remove fuel lines from fuel rail. Remove fuel mounting bracket. 3) Remove heater hose and bracket from lower intake manifold. Remove PCV valve and vacuum line from throttle body. Remove electrical connectors from EGR valve, canister purge solenoid and MAP sensor. Remove vacuum lines from upper intake manifold tee. 4) Remove wiring loom bracket for rear spark plug wires. Remove upper intake manifold. Remove coolant recovery tank. Remove serpentine drive belt and drive belt tensioner. 5) Siphon uid from power steering pump. Disconnect power steering lines and remove power steering pump. 6) On 1991-93 vehicles only, reposition Powertrain Control Module (PCM) out of way. Remove PCM mounting bracket. On 1994-95 vehicles only, disconnect PCM connectors and secure out of way. 7) On all vehicles, note position for reassembly reference and remove spark plug wires from spark plugs. Remove wiring harness cover at right side (passenger) strut tower. Remove fuel line bracket. 8) Remove timing belt covers. Remove breather hose from rear camshaft cover and crankcase vent from breather manifold. Remove camshaft carrier covers. NOTE: Actuator assembly uses a tapered bushing between the actuator and mounting base. DO NOT lose or damage the bushing when removing the actuator assembly. 9) Remove side plate bolts securing timing belt tensioner actuator. Rotate actuator assembly from tensioner pulley socket and out of mounting base. Remove timing belt tensioner pulley. See Fig. 1.
Courtesy of General Motors Corp.

Fig. 1: Identifying Timing Belt Assembly Components

GENERAL MOTORS
3.4L V6 (Cont.)

285

Courtesy of General Motors Corp.

Fig. 2: Reworking Paper Clip

Courtesy of General Motors Corp.

Fig. 5: Identifying Camshaft Timing Sprocket Designs Inspection 1) To determine if timing belt length is within specications, measure tensioner actuator from centerline of tensioner actuator to end of rubber boot. See Fig. 6. If measurement is 3.2-3.7 (80.5-94.0 mm) for a used belt, the belt is in acceptable range. Replace belt is measurement is more than 3.7 (94 mm). 2) Inspect belt teeth and back side of belt for cracks, tears or other damage. Inspect components for excessive wear or unusual conditions. Note any evidence of oil or other uid intrusion.

Courtesy of General Motors Corp.

Fig. 6: Measuring Timing Belt Tensioner Actuator Length


Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks

Courtesy of General Motors Corp.

Fig. 4: Installing Camshaft Hold-Down Tools (J 38613-A)

286

GENERAL MOTORS
3.4L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 96 (130) Crankshaft Balancer Bolt ........................................................................................ 79 (107) Crankshaft Pulley Bolt ............................................................................................... 37 (50) EGR Valve Bolts ....................................................................................................... 18 (25) Front Cover Bolts Large Bolts .............................................................................................................. 35 (47) Small Bolts .............................................................................................................. 18 (25) Intermediate Shaft Belt Sprocket Bolt .................................................................... 96 (130) Serpentine Belt Tensioner Bolt ................................................................................. 33 (45) Timing Belt Actuator Side Plate Bolt ........................................................................ 20 (27) Timing Belt Tensioner Pulley Bolt ............................................................................. 37 (50) Timing Chain Tensioner Bolt ..................................................................................... 18 (25) Upper Intake Manifold Bolts & Nuts ......................................................................... 22 (27) INCH Lbs. (N.m) Camshaft Carrier Cover Bolts ................................................................................... 97 (11) Timing Belt Cover Bolts ............................................................................................ 89 (10) Water Pump Bolt ....................................................................................................... 97 (11)

Installation 1) Install camshaft sprockets with bolts and locks. Tighten bolts nger tight. Install timing belt onto camshaft sprockets in a counterclockwise direction. Continue installing timing belt, making sure timing belt teeth are fully engaged with all sprockets. 2) Install timing belt tensioner pulley. Tighten timing belt tensioner pulley bolt to 37 ft. lbs. (50 N.m). NOTE: If tensioner oil has been lost, ll tensioner with Mobil 1 SAE 5W-30 synthetic engine oii through plug hole. Fill to bottom of plug hole only when plunger is fully retracted and pin is installed. 3) Install rubber end plug in rear of tensioner assembly until ush. Ensure plug is sealed against case. NOTE: Ensure actuator bushings and appropriate holes in side plate are clean. DO NOT lubricate bushings. 4) Install actuator bushing into side plate. Install timing belt actuator and actuator side plate. Tighten side plate bolt to 20 ft. lbs. (27 N.m). 5) Rotate pulley assembly into timing belt a maximum of 11 ft. lbs. (15 N.m) to allow engagement of actuator shaft into pulley pocket arm socket. Pull the paper clip from the actuator. Retighten pulley assembly counterclockwise to seat pulley into belt. 6) Tighten both right hand camshaft sprockets (bank closest to rewall) 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 at 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 at 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. Rell cooling system with 50/50 mix of water and coolant. Open air bleed valve on thermostat housing while lling cooling system. Adjust drive belts to proper tension.

GEO
1.6L 4-Cylinder DOHC Prizm GSI
TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC (VIN 5) Prizm GSI 1990-92 ....................................................
1

287

Labor Time

Belt Part No.

3.1 Hours .. ..... T176

With Power Steering, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be inspected and adjusted at 30,000 mile intervals, and replaced at 60,000 mile intervals.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks hooked portion of spring (not coil length). Replace spring if free length is greater than 1.618 (41.09 mm). See Fig. 3.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Turn front wheels all the way to the right. Remove right front wheel. Remove right lower stone shield from under vehicle. Remove accessory drive belts. 2) Remove center bolt and crankshaft pulley. Lower vehicle. Label spark plug secondary cables for reassembly reference. Disconnect spark plug cables from spark plugs. 3) Remove PCV valve from valve cover. Disconnect accelerator cable from valve cover. Disconnect wiring harness from valve cover. Remove valve covers. 4) Remove windshield washer reservoir. Remove engine wiring harness from upper timing belt cover. 5) Support engine from above using Engine Support Bar (J 28467-A) or equivalent. Remove engine mount through-bolt from mount on timing belt end of engine. 6) Remove water pump pulley. Remove upper, center and lower timing belt covers. See Fig. 1. Remove timing belt guide. Turn crankshaft so that camshaft and crankshaft timing marks are aligned. See Fig. 2. Loosen timing belt idler pulley bolt. Remove timing belt. NOTE: If timing belt is to be reused, mark direction of timing belt rotation. Place mating marks on belt and sprockets for reference.

Fig. 3: Measuring Tensioner Spring Free Length Installation 1) Ensure all timing marks are aligned. See Fig. 2. Install timing belt. If reusing old timing belt, ensure belt is installed in original rotating direction. 2) If removed, install timing belt idler pulley spring. Loosen timing belt idler pulley bolt to allow tension to be applied on timing belt. 3) Temporarily install crankshaft pulley center bolt. Rotate crankshaft clockwise 2 revolutions, to TDC. Ensure all timing marks are aligned. 4) Final tighten timing belt idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Apply about 4.5 lbs. (2.04 kg) of downward pressure to timing belt between camshaft sprockets. Belt deection should be about .16 (4 mm) if timing belt tension is correct. 5) Remove crankshaft bolt. Install timing belt guide. Install upper, center, and lower timing belt covers. Install crankshaft pulley. Tighten center bolt to specication. Install water pump pulley. 6) Install engine mount through-bolt and tighten to specication. Remove engine support bar. Install valve cover with new gaskets. Apply GM Sealant (1052917) or equivalent to valve cover mating surfaces. 7) Install accessory drive belts. Adjust drive belts to proper tension. To install remaining components, reverse removal procedure.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts .......................................................................................... 35 (47) Crankshaft Pulley Bolt ............................................................................................. 87 (118) Engine Mount Through-Bolt ...................................................................................... 64 (87) Timing Belt Idler Pulley Bolt ..................................................................................... 27 (37) Water Pump Pulley Bolt ............................................................................................ 17 (23) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m)
Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components Inspection 1) Inspect timing belt for cracks or damaged teeth. Ensure timing belt is not contaminated with oil. Check belt tensioner pulley for smooth rotation or grease leaks. Replace damaged components. 2) Remove spring from timing belt idler pulley. Check free length of belt tensioner spring. Free length is measured between inside diameters of

Timing Belt Cover Bolt ................................................................................................ 44 (5) Valve Cover Nut .......................................................................................................... 53 (6)

288

GEO
1.6L 4-Cylinder SOHC Storm
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. SOHC Storm 1990-93 ..............................
1

1.5 Hours .. .. TCK177 .. ..... T177

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 30,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator and power steering pump drive belts. Using Engine Support Fixture (J-26900-9) or equivalent, support engine from above. 2) Remove engine mount located at timing belt cover. Rotate crankshaft and position No. 4 cylinder at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with O timing mark on timing belt cover. Remove timing belt cover. See Fig. 1. 3) Ensure locating dowel on camshaft sprocket is at 12 oclock position and timing mark is aligned with cylinder head surface. See Fig. 2. 4) Raise and support vehicle. Remove right side undercover. Remove crankshaft pulley-to-sprocket bolts. See Fig. 1. Remove crankshaft pulley. 5) Lower vehicle. Ensure timing mark (notch) on rear of crankshaft sprocket is aligned with timing mark on oil pump. See Fig. 3. Loosen belt tensioner bolt 1/2 turn. Rotate belt tensioner and remove timing belt. Inspection Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure belt tensioner bearing rotates freely. Replace components if damaged. NOTE: Revised timing belt tensioning procedure is from GEO technical service bulletin 91-487-6A; February 26, 1992. Installation 1) Rotate camshaft so locating dowel on camshaft sprocket is at 12 oclock position and timing mark aligns with cylinder head surface. See Fig. 2. 2) Ensure timing mark (notch) on rear of crankshaft sprocket aligns with timing mark on oil pump. See Fig. 3. Install timing belt over crankshaft sprocket, tensioner pulley, water pump and camshaft sprocket. See Fig. 4. 3) Insert a hex wrench into the tensioner pulley hexagonal hole. Rotate pulley counterclockwise to tension the belt. Hold pulley stationary and temporarily tighten the tensioner pulley bolt. 4) Rotate crankshaft 2 revolutions counterclockwise, and align crankshaft and camshaft timing marks. See Figs. 2 and 3. 5) Loosen belt tensioner pulley bolt. Insert a hex key wrench into tensioner pulley hexagonal hole. Rotate the tensioner pulley counterclockwise to tension the timing belt. Tighten tensioner pulley bolt to 37 ft. lbs. (50 N.m).
Courtesy of General Motors Corp.

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

Fig. 2: Aligning Camshaft Sprocket Timing Marks 6) Rotate crankshaft back to about 50 degrees BTDC and back to TDC of No. 4 cylinder. Align crankshaft sprocket timing mark with mark on oil pump housing. Align camshaft sprocket timing mark with upper surface of cylinder head. 7) Measure timing belt deection by applying 22 lbs. (98 N) of force to belt. See Fig. 5. Defection must be .63-.79 (16-20 mm). If deection is not correct, retension timing belt. Ensure camshaft sprocket is still aligned correctly. 8) Install timing belt cover. Install crankshaft pulley. Install engine undercover. Install right engine mount. Install accessory drive belts. Adjust drive belts to proper tension.

GEO
1.6L 4-Cylinder SOHC Storm (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

289

Application Ft. Lbs. (N.m) Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 17 (23) Crankshaft Sprocket Center Bolt .................................................. .......................... 87 (118) Engine Mount Right Bracket Bolt ................................................................................................... 29 (39) Right Through-Bolt .................................................................................................. 50 (68) Power Steering Pump Bolt ....................................................................................... 15 (20) Timing Belt Tensioner Pulley Bolt ............................................................................. 37 (50) Water Pump Bolt ....................................................................................................... 18 (25) Wheel Lug Nut ........................................................................................................ 87 (118) INCH Lbs. (N.m)
Courtesy of General Motors Corp.

Fig. 3: Locating Crankshaft Sprocket Timing Mark

Crankshaft Pulley-To-Flange Bolt ............................................................................. 89 (10) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Bolt ....................................................................................................... 89 (10)

Courtesy of General Motors Corp.

Fig. 4: Identifying Timing Belt Routing

Courtesy of General Motors Corp.

Fig. 5: Measuring Timing Belt Tension

290

GEO
1.6L & 1.8L 4-Cylinder DOHC Prizm
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC, VIN 6 Prizm (Except GSI) 1989-92 .............................. 1993-97 .............................. 1.8L 4-Cyl. DOHC, VIN 8 Prizm (Except GSI) 1993-97 ..............................
1

1 1

2.2 Hours .. .. TCK036 .. ..... T036 2.2 Hours .. .. TCK236 .. ..... T236

2.2 Hours .. .. TCK235 .. ..... T235

With Air Conditioning, add .4 hours. With Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be inspected and adjusted at 30,000 mile intervals, and replaced at 60,000 mile intervals.

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components TENSIONER SPRING FREE LENGTH SPECIFICATIONS Application Maximum Free Length In. (mm) 1989-92 .......................................................... ................................................... 1.512 (38.4) 1993-94 .......................................................... ................................................... 1.390 (35.3) 1995-97 .......................................................... ................................................... 1.453 (36.9)

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove windshield washer reservoir. 2) On vehicles equipped with cruise control, remove cruise control actuator cover. Disconnect cruise control electrical connector and actuator cable. Remove cruise control actuator from vehicle. 3) On all vehicles, raise and support vehicle. Remove right front wheel. Remove right wheel housing. Loosen, but do not remove, water pump pulley bolts. 4) Lower vehicle. Remove accessory drive belts. Disconnect A/C compressor electrical connector. Remove A/C compressor mounting bolts. Set compressor aside with hoses attached. Remove mounting bracket from engine. 5) Remove wiring harness from valve cover. Noting position for reassembly reference, remove spark plug secondary cables from spark plugs. Remove spark plugs. 6) Remove PCV valve from valve cover. Remove valve cover. Turn crankshaft so that 0 mark on crankshaft pulley aligns with mark on timing case cover. Ensure No. 1 piston is at TDC of compression stroke. If not, turn crankshaft one full revolution. 7) Using Support Fixture (J028467-A) or equivalent, support engine from above. Remove engine mount from timing belt end of engine. Remove water pump pulley. 8) Remove crankshaft pulley. Remove timing belt covers. See Fig. 1. Noting installed position, remove timing belt guide from crankshaft. 9) Remove timing belt tensioner bolt, tensioner and tensioner spring. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth or cracking. Ensure timing belt is not contaminated with oil. Check tensioner pulley for rotation freedom or grease leaks. Replace components if damaged. 2) Check free length of idler pulley spring. Free length is measured between inside edge of hooked portions of spring (not the coil area). See Fig. 2. Replace spring if free length is not as specied. See TENSIONER SPRING FREE LENGTH SPECIFICATIONS table.
Courtesy of General Motors Corp.

Fig. 2: Measuring Timing Belt Tensioner Spring Free Length Installation 1) Ensure all timing marks are still aligned. See Fig. 3. Install timing belt tensioner and spring. Move tensioner to the left and temporarily tighten bolt. 2) Install timing belt. If old timing belt is reused, ensure belt is installed in original rotating direction. Ensure marks on belt align with camshaft and crankshaft sprockets. 3) Loosen timing belt tensioner bolt and allow tension to be applied on timing belt. Rotate crankshaft CLOCKWISE 2 revolutions. DO NOT turn crankshaft counterclockwise. Ensure all timing marks are aligned. Tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. 4) Measure timing belt deection at midway point between camshaft and crankshaft sprockets. See Fig. 4. With 4.4 lbs. (1.9 kg) applied on timing belt, defection should be .20-.24 (5.1-6.9 mm). If belt deection is not within specication, repeat previous step. CAUTION: Ensure all timing marks are aligned once timing belt is adjusted. 5) Install timing belt guide with cupped side facing out. Install timing belt covers, starting with bottom cover. Install crankshaft pulley. Tighten center bolt to specication. 6) Install water pump pulley. Install engine mount. Install engine ground wire (if equipped) to right fender apron. Install valve cover with new gasket. Install spark plugs and spark plug secondary wires. 7) Install PCV valve and wiring harness on valve cover. Install A/C compressor mounting bracket (if removed). Install A/C compressor to bracket. Install accessory drive belts. 8) Install cruise control actuator (if equipped). Install windshield washer reservoir. To install remaining components, reverse removal procedure. Adjust accessory drive belts to proper tension.

GEO
1.6L & 1.8L 4-Cylinder DOHC Prizm (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

291

Application Ft. Lbs. (N.m) A/C Compressor Bracket-To-Engine Bolt ................................................................. 35 (47) A/C Compressor-To-Bracket Bolt .............................................................................. 18 (25) Camshaft Sprocket Bolt ............................................................................................ 43 (59) Crankshaft Pulley Bolt ............................................................................................. 87 (118) Timing Belt Tensioner Bolt ........................................................................................ 27 (37) Water Pump Bolt ....................................................................................................... 11 (15) Water Pump Pulley Bolt ............................................................................................ 17 (23) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 44 (5) Valve Cover Cap Nuts ................................................................................................ 53 (6)

Courtesy of General Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (Typical)

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Marks & Checking Belt Deection

292

GEO
1.6L & 1.8L 4-Cylinder DOHC Storm
Labor Time Belt Part No. 6) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. Loosen timing belt tensioner pulley bolt 1/2 turn. If timing belt is to be reused, mark direction of timing belt rotation, and place reference marks on timing belt and sprockets for installation reference. Remove timing belt. Inspection Inspect timing belt for cracks or damage. Ensure belt is not contaminated with oil. Check belt tensioner pulley for smooth rotation. Replace damaged components. Installation 1) Ensure all timing marks are aligned. See Fig. 1. Install timing belt. If reusing old timing belt, ensure belt is installed in original rotating direction. 2) Install timing belt on crankshaft pulley, then water pump pulley, timing belt idler pulley, exhaust camshaft sprocket, intake camshaft sprocket and timing belt tensioner pulley. See Fig. 2. 3) Loosen belt tensioner bolt to allow tension to be applied on timing belt. Rotate crankshaft clockwise 2 revolutions. Ensure all timing marks are still aligned. Tighten timing belt tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. 4) Install lower timing belt cover. Install engine mount bracket on engine. Install crankshaft pulley and tighten center bolt to specication. Install upper timing belt cover. Install engine mount. 5) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC Storm 1990-91 .................................................... 1.8L 4-Cyl. DOHC Asuna Sunre (Canadian) 1993 .......................................................... Storm 1992-93 ....................................................
1

2.0 Hours .. ..... T169

2.4 Hours .. ..... T205 2.4 Hours .. ..... T205

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory drive belts or serpentine belt. Raise and support vehicle. Remove right splash shield. 2) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. 3) Lower vehicle. Support weight of engine from above or with oor jack. Remove engine mount from timing belt end of engine. Remove timing belt upper cover. On 1.6L engine, remove timing belt lower cover. 4) On 1.8L engine, remove serpentine drive belt idler pulley. Remove exhaust heat shield. Remove power steering pump mounting bolts. Move pump forward to gain access to serpentine drive belt tensioner. Remove serpentine drive belt tensioner from mounting bracket. 5) On 1.6L and 1.8L engines, remove engine mount bracket from timing belt end of engine. Remove timing belt lower cover.

Courtesy of General Motors Corp.

Fig. 2: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 43 (59) Crankshaft Pulley Center Bolt 1.6L ........................................................................................................................ 87 (118) 1.8L ...................................................................................................................... 108 (147) Engine Mount Bracket-To-Engine Bolt ...................................................................... 37 (50) Engine Mount Through-Bolt ...................................................................................... 50 (68) Power Steering Pump Mounting Bolt ....................................................................... 15 (20) Serpentine Drive Belt Tensioner Bolt ....................................................................... 30 (40) Timing Belt Tensioner Pulley Bolt ............................................................................. 31 (42) Water Pump Bolt 1.6L .......................................................................................................................... 11 (15) 1.8L .......................................................................................................................... 18 (24) Wheel Lug Nut ........................................................................................................ 87 (118) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10)
Courtesy of General Motors Corp.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

GEO & ISUZU


1.5L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

293

1.5L 4-Cyl. I-Mark 1985-87 Thru 6/30/86 .............. ... 1 1.5 Hours ... .. TCK118 ........ From 7/1/86 ............... ... 1 1.5 Hours ... .. TCK118 .. ..... 1988-89 ........................ ... 1 1.5 Hours ... .. TCK118 .. ..... Spectrum (Chevrolet) 1985-86 ........................ .. 1, 2 1.5 Hours .. .. TCK118 ........ 1987 Thru 4/30/87 .............. . 1, 2, 3 1.5 Hours . .. TCK118 ........ From 5/1/87 ............... . 1, 2, 3 1.5 Hours . .. TCK118 .. ..... 1988 .............................. . 1, 2, 3 1.5 Hours . ...... ..... ............ Spectrum (Geo) 1989 .............................. .. 2, 4 1.5 Hours .. ...... ..... ...... ..... Sunburst (Canada) 1985-88 ........................ ... 1 1.5 Hours ... .. TCK118 ........
1

T118 T162 T162 T118 T118 T162 T118 T162


Courtesy of General Motors Corp.

T118

3 4

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. With Engine removal, Automatic Transmission Non-Turbo, labor time is 7.7 hours. With Engine removal, Standard Transmission Non-Turbo, labor time is 7.5 hours. With Engine removal, Turbocharger, labor time is 8.2 hours. With Air Conditioning, add .4 hours. With Cruise Control, add .2 hours. With Power Steering, add .4 hours.

Fig. 1: Aligning Crankshaft Sprocket Timing Marks

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of General Motors Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks 3) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT & SPROCKETS


Removal 1) Disconnect negative battery cable. Drain cooling system. Place small piece of wood on jack under oil pan and carefully raise motor. Remove rear side torque rod and right engine mount. Remove body side and engine side mounts. 2) Remove drive belts, crank pulley and timing belt cover. Ensure timing marks are aligned with TDC. Using Crank Holder (J-37376) or equivalent, remove timing belt crankshaft pulley. Conrm crankshaft is at TDC before removing belt. See Fig. 1. Rotate crankshaft so camshaft pulley dowel is at 12 oclock and alignment mark aligns with edge of cylinder head. See Fig. 2. NOTE: The rear of timing belt crankshaft pulley has a small indent which aligns with small triangle on engine block at 12 oclock. 3) Loosen belt tensioner attaching bolt. Insert Allen wrench into pulley tensioner attaching bolt. Loosen timing belt tensioner by rotating pulley clockwise. Remove timing belt. Installation 1) Ensure camshaft pulley mark is aligned with upper surface of head and dowel pin is at 12 oclock position. Ensure Woodruff key of crankshaft is in 12 oclock position. Install timing belt. See Fig. 3. Tighten tensioner bolt, and rotate crankshaft 2 revolutions. 2) Check timing marks. Loosen tensioner bolt and remove slack from timing belt. There must be no slack in the belt after it has been installed.

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ........................................................................................... 108 (147) Timing Belt Tensioner Bolt ........................................................................................ 37 (50) Water Pump Bolts ..................................................................................................... 17 (24) INCH Lbs. (N.m) Timing Cover Bolts .................................................................................................... 86 (10)

294

GEO/CHEVROLET
1.0L 3-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.0L 3-Cyl. Firey (Canadian) 1985-88 ............................... 1989-91 ............................... 1994-95 ............................... 1996-00 ............................... Metro 1989-92 ............................... 1993 .................................... 1993 .................................... 1994-95 ............................... 1996-97 ............................... 1998-00 ............................... Sprint (Includes Canadian) 1985-88 ............................... 1989-91 ...............................
1 2 3

2.2 2.2 2.2 1.8 2.2 2.2 2.2 2.2 2.2 1.8

Hours Hours Hours Hours Hours Hours Hours Hours Hours Hours

... ...... ..... ...... ..... ... .. TCK166 .. ..... ... .. TCK241 .. ..... .... TCK194A . ..... ... .. TCK166 ... .. TCK166 ... .. TCK241 ... .. TCK241 .... TCK194A .... TCK194A

T095 T166 T241 T194

.. ..... T166 .. ... 2 T166 .. ... 3 T241 .. ..... T241 . ..... T194 . ..... T194

2.2 Hours ... ...... ..... ...... ..... T095 2.2 Hours ... ...... ..... ...... ..... T166

With Air Conditioning, add .4 hours. Four bolt sprocket. Five bolt sprocket.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Up to 1997 model year, the manufacturer recommends the belt be replaced at 60,000 mile intervals. For 1998-00 model years, the manufacturer recommends the belt be inspected at 60,000 miles and replaced at 100,000 miles.

Courtesy of General Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (1985-97)

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner. Remove A/C suction pipe bracket (if equipped). Raise and support vehicle. Remove lower right engine undercover. Remove lower generator cover plate. Remove all accessory drive belts. 2) Remove outer bolts retaining crankshaft pulley. Remove crankshaft pulley. DO NOT remove crankshaft pulley center bolt. Remove wire harness from timing belt cover. 3) Remove timing belt cover and seal. See Fig. 1 or 2. Rotate crankshaft and align timing marks. See Fig. 3 or 4. Remove tensioner spring and tensioner stud. Loosen, but DO NOT remove, tensioner bolt. 4) If reusing timing belt, mark rotation direction. Remove belt tensioner, tensioner plate, tensioner spring, spring damper and timing belt. CAUTION: DO NOT rotate crankshaft or camshaft when timing belt is removed, or piston damage may result. Note direction of timing belt guide for installation. Ensure concave side of timing belt guide faces away from timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure tensioner rotates freely. Replace damaged components. CAUTION: Ensure concave side of timing belt guide faces oil pump. Flat side of timing belt guide goes against crankshaft sprocket.
Courtesy of General Motors Corp.

Fig. 2: Exploded View Of Timing Belt & Components (1998-00)

GEO/CHEVROLET
1.0L 3-Cylinder (Cont.)

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 nger tight to allow movement of tensioner. 2) Ensure all timing marks align. See Fig. 3 or 4. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft or crankshaft so timing mark moves more than 90 degrees, or engine damage may occur. See Fig. 5. CAUTION: Install timing belt so arrow on timing belt, or mark made during removal, points in direction of crankshaft rotation. Crankshaft rotates clockwise. 3) Install tensioner spring and spring damper, push tensioner plate upward and tighten tensioner bolt. Install timing belt so arrow on timing belt, or mark made during removal, points in direction of crankshaft rotation. Ensure no slack exists on drive side of timing belt. Loosen tensioner bolt and allow spring tension to remove slack in timing belt. Tighten tensioner bolt. 4) Rotate crankshaft 2 revolutions clockwise to ensure all slack is removed from timing belt. Tighten tensioner stud and tensioner bolt. See TORQUE SPECIFICATIONS. Ensure all timing marks are aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks (1985-97)

Courtesy of General Motors Corp.

Fig. 5: Rotating Camshaft & Crankshaft

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt 12 mm ..................................................................................................................... 21 (29) 14 mm ..................................................................................................................... 33 (45) Crankshaft Pulley-To-Crankshaft Bolt ....................................................................... 12 (16) Tensioner Bolt ............................................................................................................ 20 (27) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 97 (11) Timing Belt Tensioner Stud ....................................................................................... 97 (11) Valve Cover Bolt ......................................................................................................... 44 (5) Water Pump Bolt 1995-97 .................................................................................................................... 97 (11) 1998-00 .................................................................................................................. 115 (13)

Courtesy of General Motors Corp.

Fig. 4: Aligning Timing Marks (1998-00)

296

GEO/CHEVROLET
1.3L 4-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.3L 4-Cyl. Firey (Canadian) 1995-97 ............................... 1998-00 ............................... Metro 1992-93 ............................... 1994 .................................... 1995-97 ............................... 1998-01 ...............................
1

2.6 Hours ... .. TCK272 .. ..... T272 2.6 Hours ... ...... ..... ...... ..... T194 2.6 2.6 2.6 2.6 Hours Hours Hours Hours ... ...... ..... ...... ..... ... ...... ..... ...... ..... ... .. TCK272 .. ..... ... ...... ..... ...... ..... T095 T243 T272 T194

With Air Conditioning, add .4 hours.


Courtesy of General Motors Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 2: Locking Flywheel In Position

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Up to 1997 model year, the manufacturer recommends the belt be replaced at 60,000 mile intervals. For 1998-01 model years, the manufacturer recommends the belt be inspected at 60,000 miles and replaced at 100,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right side fender apron extension. Do not push center pin in too far, as it may fall into fender. 2) Remove alternator/water pump drive belt and water pump pulley. Lock ywheel and loosen crankshaft pulley outer bolts. See Figs. 1 and 2. It is NOT necessary to remove crankshaft pulley center bolt. Remove crankshaft pulley. 3) Remove timing belt outside cover. Rotate crankshaft to align camshaft and crankshaft timing marks. See Fig. 3 or 4. Loosen tensioner bolt and stud. Push tensioner plate fully upward and temporarily tighten tensioner bolt. Remove timing belt from sprockets.

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Marks (1992-97) tensioner. Install tensioner assembly. Hand tighten tensioner bolt. Plate movement in upward direction should cause tensioner to move in same direction. 2) On 1992-97 models only, remove air cleaner and valve cover, then completely loosen all valve screws and lock nuts on intake and exhaust rocker arms. Turn camshaft pulley clockwise until timing mark on pulley aligns with V mark on belt inside cover. See Fig. 3. 3) Turn crankshaft pulley bolt clockwise until punch mark on sprocket aligns with arrow mark on oil pump case. See Fig. 3. 4) Install timing belt on sprockets with drive-side of belt free of any slack when tensioner plate is pushed up with ngers. Loosen tensioner bolt and allow tensioner to remove slack in timing belt. Skip the next step to continue. NOTE: On 1998-01 models, camshaft sprocket is marked with a raised E for a timing mark. 5) On 1998-01 models, ensure camshaft and crankshaft timing marks are still aligned. See Fig. 4. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft

Courtesy of General Motors Corp.

Fig. 1: Using Screwdriver To Lock Flywheel Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components. NOTE: Ensure tensioner plate moves when tensioner is moved toward timing belt. If tensioner plate does not move, ensure lug is engaged in hole on rear of tensioner. Installation 1) Ensure that tensioner rotates smoothly. Install tensioner plate on tensioner. Lug of tensioner plate must t in hole of

GEO/CHEVROLET
1.3L 4-Cylinder (Cont.)

297

Courtesy of General Motors Corp.

Fig. 5: Identifying Water Pump-To-Oil Case Seal

Courtesy of General Motors Corp.

Fig. 4: Identifying Timing Marks (1998-01) or crankshaft more than 90 degrees, or engine damage may result. Install timing belt. Ensure no slack exists on drive side of timing belt. Loosen tensioner bolt and allow tensioner to remove slack in timing belt. Go to next step. 6) Turn crankshaft 2 rotations clockwise to take up slack. Ensure timing marks are still aligned. Tighten tensioner adjustment stud nut and tensioner bolt. Ensure seal is between water pump and oil pump case. See Fig. 5. Install timing belt outside cover. 7) On 1992-97 models, rotate crankshaft to position camshaft lobe and rocker arm to adjust valve lash. See Fig. 6. Ensure clearance is .010 (.25 mm) at intake valves, and .011 (.28 mm) at exhaust valves. To adjust clearance, turn adjusting screw until correct clearance is obtained. Tighten lock nut to 11-13.5 ft. lbs. (15-18 N.m). 8) On all models, to complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of General Motors Corp.

Fig. 6: Adjusting Valve Lash (1992-97)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt (1998-01) .............................................................................. 12 (16) Crankshaft Sprocket Bolt 1992-97 .................................................................................................................. 79 (110) 1998-01 .................................................................................................................. 96 (130) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Valve Adjustment Lock Nut ............................................................................. 11-13 (15-18) Water Pump Pulley Bolt ............................................................................................ 18 (24) INCH Lbs. (N.m) Crankshaft Pulley Bolt (1992-97) .................................................. ............................ 97 (11) Tensioner Stud .......................................................................................................... 97 (11) Timing Belt Cover Nut/Bolts ..................................................................................... 97 (11) Valve Cover Nuts ........................................................................................................ 44 (5)

298

GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 8-Valve
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. SOHC, VIN U Tracker & Sunrunner (Asuna & Pontiac, Canada) 1989-95 .............................. 1 3.6 Hours .. .. TCK164 .. ..... T164
1

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of General Motors Corp.

Fig. 2: Locking Camshaft During Sprocket Removal

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove accessory drive belts. Remove cooling fan, fan shroud and water pump pulley. Remove outer bolts retaining crankshaft pulley. 2) Remove 5 crankshaft pulley-to-sprocket bolts. Remove crankshaft pulley. DO NOT remove center bolt from crankshaft pulley. The center bolt holds crankshaft sprocket to crankshaft. 3) Remove timing belt cover and seal. See Fig. 1. Loosen tensioner stud, and remove tensioner spring from tensioner plate and tensioner screw. 4) If reusing timing belt, mark timing belt with arrow to indicate rotation direction. Remove timing belt.

Inspection Inspect timing belt for damaged teeth or cracking. Ensure timing belt is not contaminated with oil. Check tensioner for freedom of rotation. Replace components if damaged. Installation 1) If tensioner was removed, install tensioner plate on tensioner. Ensure lug of tensioner plate engages in hole on rear of tensioner. Install tensioner, tensioner plate and tensioner spring on engine block. Tighten tensioner bolt nger tight to allow movement of tensioner. CAUTION: Ensure tensioner plate moves when tensioner is moved toward timing belt. If tensioner plate does not move, ensure lug engages in tensioner bolt. 2) Remove valve cover. Loosen all valve adjusting screws fully before installing timing belt. Ensure camshaft rotates freely during belt tension adjustment. Rotate camshaft clockwise, and align timing mark on camshaft sprocket with V timing mark on timing belt inside cover. See Fig. 3. 3) Rotate crankshaft clockwise, and align timing mark on crankshaft sprocket with timing mark on oil pump housing. See Fig. 3. Install timing belt on engine. If installing old belt, ensure arrow on timing belt aligns with direction of crankshaft rotation. Ensure no slack exists on side of timing belt opposite tensioner. 4) Install tensioner spring to tensioner plate and tensioner screw. Finger tighten tensioner stud. Rotate crankshaft 2 revolutions clockwise to ensure all slack is removed from timing belt. 5) Ensure camshaft and crankshaft timing marks are still aligned. Tighten tensioner stud to specication. Tighten tensioner bolt to specication. See TORQUE SPECIFICATIONS. Ensure all timing marks align. 6) Adjust valve lash between rocker arm adjusting screw and valve stem. See VALVE LASH SPECIFICATIONS table. Turn crankshaft so No. 1 piston is at TDC of compression stroke. Ensure camshaft timing mark is aligned with V timing mark on rear timing belt cover. 7) Adjust valve lash on No. 1 and No. 2 intake valves. Adjust valve lash on No. 1 and No. 3 exhaust valves. Rotate crankshaft one full revolution (360 degrees). Adjust remaining intake and exhaust valves. 8) Install timing belt cover. Install crankshaft pulley. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. VALVE LASH SPECIFICATIONS Valve Clearance (Cold) In. (mm) Clearance (Hot) In. (mm) Intake ................ ............ .051-.067 (.13-.17) ............ ........................... .009-.011 (.23-.27) Exhaust ............. .......... .0063-.0075 (.15-.19) .......... ....................... .0102-.0114 (.25-.29)

Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

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

299

Application Ft. Lbs. (N.m) A/C Compressor 8 mm Bolt ................................................................................................................ 21 (29) 10 mm Bolt .............................................................................................................. 33 (45) Crankshaft Pulley-To-Sprocket Bolts ........................................................................ 12 (16) Power Steering Pump Mounting Bolt ....................................................................... 21 (29) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Valve Adjusting Screw Locknut ................................................................................. 13 (17) INCH Lbs. (N.m) Fan Clutch Nuts ........................................................................................................ 97 (11) Tensioner Stud .......................................................................................................... 97 (11) Timing Belt Cover Bolt .............................................................................................. 97 (11) Valve Cover Bolt ......................................................................................................... 44 (5) Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of General Motors Corp.

Fig. 3: Aligning Timing Marks

300

GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 16-Valve
Labor Time Component Belt Kit No. Part No.
3

TIMING BELT APPLICATION Application

1.6L 4-Cyl. SOHC, VIN 6 Tracker & Sunrunner (Canadian) 1994-02 .............................. 1 4.0 Hours .. .. TCK212 .. ...
1

T212

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove cooling fan nuts and fan shroud fasteners. Remove accessory drive belts. 2) Raise and support vehicle. Remove front skid plate (if equipped). Remove 2 lower radiator shroud bolts. Remove 5 outer bolts retaining crankshaft pulley to crankshaft. Remove crankshaft pulley. DO NOT remove center bolt from crankshaft pulley. The center bolt holds crankshaft sprocket to crankshaft. NOTE: It may be necessary to drain cooling system and disconnect upper radiator hose to remove fan shroud. 3) Lower vehicle. On models with air conditioning, remove A/C suction line bracket bolts from radiator support. On all models, remove upper radiator shroud bolts and remove radiator shroud with cooling fan and water pump pulley. 4) Disconnect wiring harness from timing belt cover. Remove timing belt cover. See Fig. 1. 5) Rotate crankshaft clockwise to align crankshaft and camshaft timing marks. Stamped E on camshaft sprocket must face up and align with mark on rear cover. See Fig. 2. 6) Loosen timing belt tensioner pulley center bolt and stud nut. See Fig. 3. Remove tensioner spring. Push tensioner plate upward to relieve tension on timing belt. 7) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: DO NOT rotate crankshaft or camshaft when timing belt is removed, or piston damage may result. Inspection Inspect timing belt for damaged teeth or cracking. Ensure timing belt is not contaminated with oil. Check tensioner for freedom of rotation. Replace components if damaged. Installation 1) If tensioner was removed, install tensioner plate, spring, and tensioner pulley on engine. Tighten tensioner bolt and stud nut nger tight to allow movement of tensioner. 2) Ensure camshaft and crankshaft timing marks are still aligned. Install timing belt. If reusing old belt, ensure it is installed in original rotation direction. 3) Loosen timing belt tensioner bolt and nut so it places tension on belt. Rotate crankshaft clockwise 2 revolutions. Ensure timing marks still align. See Fig. 2. 4) Tighten tensioner stud nut and tensioner pulley bolt to specication. 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, rell and bleed air from system.
Courtesy of General Motors Corp.

Fig. 1: Exploded View of Timing Belt & Components

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Marks

GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 16-Valve (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

301

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 44 (60) Crankshaft Pulley Center Bolt ................................................................................ 81 (110) Crankshaft Pulley-To-Crankshaft Bolt ....................................................................... 12 (16) Front Skid Plate Bolt ................................................................................................. 40 (55) Power Steering Pump Mounting Bolt ....................................................................... 21 (29) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) INCH Lbs. (N.m) Cooling Fan-To-Pulley Nut ........................................................................................ 97 (11) Timing Belt Cover Bolt .............................................................................................. 89 (10) Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11)

Courtesy of General Motors Corp.

Fig. 3: Identifying Timing Belt Tensioner Assembly

302

HONDA
1.2L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.2L 4-Cyl. Civic 1974 .......................................................... 1975-79 ....................................................
1 2

1 2

1.5 Hours .. ..... T028 2.0 Hours .. ..... T028

With Air Conditioning, add .9 hours. With Air Conditioning, add .4 hours. Where Cruise Control interferes, add .3 hours. Where Power Steering Interferes, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove wheelwell splash shield. Remove air conditioning compressor adjustment pulley, complete with bracket drive belt. Remove remaining accessory drive belt(s). Remove valve cover. Remove water pump pulley and crankshaft pulley. See Fig. 2. Ensure that cylinder No. 1 is at TDC of compression stroke and camshaft is aligned with mark. See Fig. 3. 2) Remove upper timing belt cover from cylinder head. Remove lower timing belt cover from engine block. Loosen (do not remove) timing belt adjusting and pivot bolts. Slide belt off pulleys. Installation To install, reverse removal procedure, using care not to excessively bend or twist timing belt. Do not expose belt to engine oil, as this will cause belt rubber to swell. Install belt in same direction of rotation to prevent premature wear or failure. Adjust drive belts to proper tension.
Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Camshaft Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Pulley Bolt .......................................................................................................... 17 (23) Alternator Adjustment Bolt ....................................................................................................... 17 (23) Through-Bolt ............................................................................................................ 33 (45) Crankshaft Pulley Bolt ............................................................................................... 61 (81) Engine Support Bolts/Nut .......................................................................................... 40 (55) Side Bracket .............................................................................................................. 33 (45) Timing Belt Tensioner Bolt ........................................................................................ 33 (45) INCH Lbs. (N.m) Timing Belt Cover .................................................................................................... 84 (9.7) Valve Cover .............................................................................................................. 84 (9.7)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft Timing Marks

HONDA
1.3L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

303

1.3L 4-Cyl. Civic 1980-83 Canada .......................... ... US .................................. ... 1984-85 ............................ ... 1986-87 ............................ ... Civic CRX 1984 ................................. ...
1

1 1 1

2.0 2.0 2.0 1 2.0


1

Hrs. Hrs. Hrs. Hrs.

... ...... ..... ...... ..... ... ...... ..... ...... ..... ..... 2521610 .. ..... ..... 2521610 .. .....

T028 T073 T099 T161

2.0 Hrs. ..... 2521610 .. ..... T099

With Air Conditioning, add .4 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

Fig. 1: Exploded View Of Timing Belt & Components (1980-83)

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove wheelwell splash shield. Remove A/C compressor or adjusting pulley and bracket. Remove A/C belt. Remove accessory drive belts. Remove engine support bolts and nut. Remove side mount rubber. Rotate crankshaft counterclockwise to position No. 1 cylinder to TDC of compression stroke. 2) Remove engine valve cover and upper timing belt cover. See Fig. 1 or 3. Ensure camshaft timing marks are aligned with valve cover surface, and UP or ROUND mark is upward. See Fig. 4 or 5. 3) Remove crankshaft pulley. Remove lower timing belt cover from engine block. Loosen timing belt tensioner to relieve timing belt tension. 4) If timing belt is being reused, mark direction of belt rotation before removing. Remove timing belt from camshaft and crankshaft gears. Inspection Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Replace as necessary. Installation 1) Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks are aligned with valve cover surface and UP or ROUND mark is upward. See Fig. 4 or 5. CAUTION: Belt tension must be adjusted when engine temperature is cold. 2) Install timing belt. Use care not to excessively bend or twist belt. Ensure belt is installed in original direction of rotation. Belt tension must be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on belt. Tighten tensioner adjustment bolt to specication. See TORQUE SPECIFICATIONS. 3) Install washer on crankshaft bolt with at side toward the pulley. See Fig. 1 or 3. Tighten retaining bolt to specication. Reverse removal procedure to complete installation. Tighten all bolts to specication. See TORQUE SPECIFICATIONS. Valve cover bolts must be tightened in proper sequence. See Fig. 2. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying Valve Cover Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Adjustment Bolt ........................................................................................ 17 (23) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Pulley Bolt ................................................................................................. 27 (37) Crankshaft Pulley Bolt 1980-83 .................................................................................................................... 61 (81) 1984-87 .................................................................................................................. 83 (112) Timing Belt Adjuster Bolt .......................................................................................... 35 (48) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 84 (9) Valve Cover Bolt ..................................................................................................... 108 (12) Valve Cover Nut .......................................................................................................... 84 (9) Water Pump Bolt ..................................................................................................... 108 (12)

304

HONDA
1.3L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1984-87)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Marks (1980-83)

HONDA
1.3L 4-Cylinder (Cont.)

305

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (1984-87)

306

HONDA
1.5L 4-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.5L 4-Cyl. Civic CVCC 1975 ................................. ..... 1976-79 ............................ ..... Civic 1980-83 ............................ ..... 1984-85 ............................ ..... 1986-87 ............................ ..... 1988-95 ............................ ..... Civic CRX 1984-85 ............................ ..... 1986-87 ............................ ..... Civic VX 1992-95 ............................ ..... Civic Del Sol 1993-95 Exc. VX .......................... ..... VX .................................. .....
1

2.0 Hrs ..... ...... ..... ...... ..... T036 2.0 Hrs ..... .. TCK041 .. ..... T041 2.0 2.0 2.0 2.0 Hrs Hrs Hrs Hrs ..... ...... ..... ...... ..... ..... .. TCK161 .. ..... ..... .. TCK161 .. ..... ..... .. TCK143 .. ..... T041 T099 T161 T143

2.0 Hrs ..... .. TCK161 .. ..... T099 2.0 Hrs ..... .. TCK161 .. ..... T161 2.0 Hrs ..... ...... ..... ...... ..... T223

2.0 Hrs ..... .. TCK143 .. ..... T143 2.0 Hrs ..... ...... ..... ...... ..... T223

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. Where Cruise Control interferes, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for 1975-89 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-94 models, the manufacturer recommends the belt be replaced at 90,000 mile intervals. For 1995 models, the manufacturer recommends the belt be replaced at 90,000 mile intervals for normal service and 60,000 miles for severe service.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt Components (1975-83) 3) Remove valve cover. Remove upper timing belt cover. Remove crankshaft pulley. Loosen timing belt tension adjuster bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjuster bolt. Disengage timing belt from pulleys. See Fig. 1, 3 or 4. Installation (1980-95) 1) Ensure No. 1 cylinder is at TDC of compression stroke. Install timing belt onto crankshaft pulley, tension adjuster pulley, water pump pulley, and camshaft sprocket. DO NOT bend or twist belt excessively. Ensure crankshaft pulley timing mark aligns with pointer on lower timing belt cover. See Fig. 2, 5, 6, 7 or 8. 2) Adjust timing belt tension. See TIMING BELT ADJUSTMENT. Before installing valve cover gasket, apply non-hardening sealant to rounded surfaces of front and rear camshaft caps. To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (1975-79) Disconnect negative battery cable. Remove wheelwell splash shield. Remove A/C compressor adjusting pulley together with bracket and A/C belt. Remove alternator bracket and belt. Remove engine support bolts and nut. Remove rubber mount. Remove valve cover. Remove crankshaft pulley. Remove upper timing belt cover from cylinder head and remove lower timing belt cover from engine block. Ensure that No. 1 cylinder is at TDC on compression stroke with camshaft aligned with marks. Remove timing belt. Installation (1975-79) Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 1 and 2. Reverse removal procedure, using care not to excessively twist or bend belt. Adjust drive belts to proper tension. Removal (1980-95) 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Remove splash shield. Remove power steering pump, leaving hoses attached. Remove A/C belt idler pulley bracket and belt. Remove alternator belt. Remove power steering pump bracket. 2) Remove cruise control actuator (if equipped). Remove power steering reservoir bracket. Remove engine mount nuts. Loosen engine mount bolt. Pivot side engine mount cushion aside.

TIMING BELT ADJUSTMENT


CAUTION: Always adjust timing belt tension with engine cold. 1) Remove cylinder head cover. Remove upper timing belt cover. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Loosen but do not remove, timing belt adjuster bolt. See Fig. 9. 2) Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to create tension on timing belt. Tighten adjuster bolt to specication. Retighten crankshaft pulley bolt to specication if it loosened during crankshaft rotation. See TORQUE SPECIFICATIONS.

HONDA
1.5L 4-Cylinder (Cont.)

307

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Timing Marks (1975-83)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt Components (1984-91)

308

HONDA
1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

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

HONDA
1.5L 4-Cylinder (Cont.)

309

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Timing Marks (1984-87)

310

HONDA
1.5L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

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

HONDA
1.5L 4-Cylinder (Cont.)

311

Courtesy of American Honda Motor Co., Inc. 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)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt SOHC 1975-79 .................................................................................................................. 22 (30) 1980-95 .................................................................................................................. 28 (33) Crankshaft Pulley Bolt 1 SOHC ................................................................................................................... 134 (185) Power Steering Pump Bracket Bolt .......................................................................... 33 (45) Timing Belt Adjuster Bolt .......................................................................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10) Water Pump Bolt ..................................................................................................... 108 (12)
1

Lubricate bolt threads. Do not lubricate washer or washer mating surface of bolt.

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Timing Marks (1992-95)

312

HONDA
1.6L 4-Cylinder DOHC
1

TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC Civic 1999-00 .............................. Civic Del Sol 1994-97 ..............................
1

Labor Time Component Belt Kit No. Part No.

2.0 Hours .. .. TCK227 .. ..... T227 2.0 Hours .. .. TCK227 .. ..... T227

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. With Cruise Control, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 3. Set intake and exhaust camshaft pulleys to TDC. The TDC marks should align with each other with UP marks pointing up. See Fig. 3. 2) Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, intake camshaft pulley, and exhaust camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulleys remained aligned with TDC marks. 3) Loosen and retighten adjusting bolt to tension timing belt. Install lower and middle covers. Install crankshaft pulley. Tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys. CAUTION: Always adjust timing belt tension with engine cold. 4) To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). See Fig. 1. Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. 5) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. When installing valve cover gasket, apply liquid gasket to 8 corners where gasket meets camshafts. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1994 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service and 60,000 miles for severe service. For 1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 33 (44) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Pulley Center Bolt .................................................................................... 41 (56) Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177) Engine Mount Bracket Nuts ...................................................................................... 54 (74) Engine Mount Bracket-To-Engine Bolts .................................................................... 40 (54) Power Steering Pump Bracket Bolt .......................................................................... 33 (44) Power Steering Pump-To-Bracket Bolts ................................................................... 17 (24) Timing Belt Adjusting Bolt ......................................................................................... 40 (54) Water Pump Bolt (10 x 1.25 mm) ............................................................................ 33 (44) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nuts 2 .................................................................................................... 89 (10) Water Pump Bolt (6 x 1.0 mm) .............................................................................. 106 (12)
1 2

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) If the radio has a theft protection circuit, be sure to get the customers code before disconnecting battery. Disconnect negative battery cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Remove power steering pump and hang out of way, leaving hoses connected. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. 2) Use jack to support engine. Working from front of engine, remove engine mount bracket nuts and bracket. Remove power steering pump lower bracket and heat shield from engine. Remove the crankshaft pulley. 3) Remove valve cover. Remove middle and lower covers. See Fig. 2. Loosen timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys.

Lubricate bolt threads and bottom shoulder of bolt head. Tighten nuts in 2-3 steps, starting from center outward.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Setting Crankshaft Pulley to TDC

HONDA
1.6L 4-Cylinder DOHC (Cont.)

313

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Installation Sequence

Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

314

HONDA
1.6L 4-Cylinder SOHC, 1976-95
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.6L 4-Cyl. Accord (Includes Canadian) 1976-78 ............................... 1979-83 ............................... Civic 1988-91 ............................. 1992 Except Si .......................... Si ....................................... 1993-95 ............................... Civic del Sol 1993-95 ............................... Civic CRX 1988-91 ............................... Prelude 1980-82 Canada ............................. USA ...................................
1

2.0 Hours ... .. TCK041 .. ..... T041 2.0 Hours ... ...... ..... ...... ..... T041 2.0 Hours ... .. TCK145 .. ..... T145 2.0 Hours ... .. TCK145 .. ..... T145 2.0 Hours ... .. TCK224 .. ..... T224 2.0 Hours ... .. TCK224 .. ..... T224 2.0 Hours ... .. TCK224 .. ..... T224 2.0 Hours ... .. TCK145 .. ..... T145

2.1 Hours ... ...... ..... ...... ..... T041 2.0 Hours ... ...... ..... ...... ..... T041

Courtesy of American Honda Motor Co., Inc.

With Air Conditioning, add .4 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

Fig. 1: Locating Timing Belt Adjuster Bolt

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for 1976-89 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-94 models, normal replacement interval is at 90,000 miles. For 1995 models, recommended replacement interval is 90,000 for normal service and 60,000 for severe service.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect battery negative cable. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Remove wheelwell splash shield. Remove power steering pump if necessary, leaving hoses attached. 2) Remove A/C belt idler pulley bracket if necessary, and belt. Remove alternator belt. Remove power steering pump bracket if necessary. Remove water pump pulley if not cam-driven. Remove cruise control actuator (if equipped). 3) Remove power steering reservoir bracket if necessary. Use jack to support engine, and then remove engine mount nuts. Loosen engine mount bolt. Pivot side engine mount-cushion aside. CAUTION: Crankshaft pulley bolt may stick to the crankshaft threads when properly torqued. A properly torqued pulley bolt may require up to two or three times the installation torque to remove. 4) Remove valve cover. Remove upper timing belt cover. Insert the appropriate crank pulley holder into the pulley. Support crank pulley holder handle with a jack stand or transmission jack to get the weight of
Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components (Accord & Prelude) the car working for you. Use a high-strength, long-handled, breaker bar with an impact socket to remove the bolt (which has right-hand threads). Remove crankshaft pulley.

HONDA
1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

315

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1992-95 Civic) 5) Remove lower timing belt cover bolts and timing belt cover. Remove crankshaft position sensor from oil pump (if equipped). Loosen tension adjuster bolt pivot bolt 180 degrees (if equipped). Loosen timing belt tension adjuster bolt 180 degrees. See Fig. 1. Push tensioner to release belt tension. Retighten tension adjuster bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. See Figs. 2 and 3. Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke. On Civic models, crankshaft keyway will be at 12 oclock position, and sprocket groove or mark will align with pointer on oil pump housing. See Fig. 4. On Accord and Prelude models, pointer on crankcase will align with marks on ywheel. See Fig. 5 or 6. 2) Install timing belt onto crankshaft pulley, tension adjuster pulley, water pump pulley (if cam-driven), and camshaft sprocket. DO NOT bend or twist belt excessively. Take note of spacer installation. See Figs. 2 and 3. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft timing marks are still aligned. 3) Adjust timing belt tension. See TIMING BELT ADJUSTMENT. Before installing valve cover gasket, apply non-hardening sealant to rounded surfaces of front and rear camshaft caps. To complete installation, reverse removal procedure. Ensure beveled edge of crankshaft pulley is away from pulley surface. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

316

HONDA
1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (Civic)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Aligning Crankshaft & Camshaft Timing Marks (Prelude)


Courtesy of American Honda Motor Co., Inc.

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

HONDA
1.6L 4-Cylinder SOHC, 1976-95 (Cont.)
TIMING BELT ADJUSTMENT
1) Remove valve cover. Remove upper timing belt cover. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove timing belt tensioner adjustment bolt access plug(s) in lower timing belt cover. Loosen but do not remove, timing belt adjuster bolt. See Figs. 1 and 2. 2) Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to create tension on timing belt. Tighten adjuster bolt. Retighten crankshaft pulley bolt to specication if it loosened during crankshaft rotation. See TORQUE SPECIFICATIONS.

317

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt Accord & Prelude .................................................................................................... 22 (30) Civic, Civic del Sol & Civic CRX ............................................................................ 27 (38) Crankshaft Pulley Bolt 1 1976-78 Accord ........................................................................... ................. 58-65 (79-88) 1979-83 Accord & 1980-82 Prelude ........................................... .......................... 83 (115) 1988 Civic & Civic CRX ....................................................................................... 83 (115) 1989-91 Civic & Civic CRX ................................................................................ 119 (165) 1992-95 Civic & Civic del Sol ............................................................................ 134 (185) Power Steering Pump Bracket Bolt .......................................................................... 33 (45) Timing Belt Adjuster Bolt 1976-78 Accord 2 ......................................................................... ................. 29-33 (39-45) 1979-83 Accord & 1980-82 Prelude 2 ..................................................................... 22 (30) 1988-95 Civic, Civic del Sol & Civic CRX ............................................................. 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10) Water Pump Bolt Accord & Prelude .................................................................................................. 108 (12)
1 2

Lubricate bolt threads but do not lubricate washer or mating surface of bolt. Pivot bolt and adjuster bolt.

318

HONDA
1.6L 4-Cylinder SOHC, 1996-00
Labor Time Component Belt Kit No. Part No. 4) Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump. Loosen the timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. See Fig. 2. Inspection 1) Inspect timing belt tensioner pulley for worn bearing. Replace as necessary. NOTE: The following revised timing belt tensioner information is from Honda technical service bulletin 96-057; August 4, 1998. 2) If there was a customer complaint of a whine or chirping noise from the front of the engine at idle, or just above idle, this may be caused by a timing belt that is tensioned too tight. A revised timing belt tensioner and spring are available for all 1996, 1997 and some 1998 engines. 3) The timing belt tensioner kit is available under part number 14520-P2A-305. Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 3. 2) Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 4. 3) Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing mark are aligned with TDC marks. 4) Loosen and retighten adjusting bolt to tension timing belt. Install lower cover. Install crankshaft pulley. Tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys. CAUTION: Always adjust timing belt tension with engine cold. 5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. 6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. SOHC Civic 1996-00 .............................. Civic Del Sol 1996-97 ..............................
1

2.0 Hours .. .. TCK224 .. ..... T224 2.0 Hours .. .. TCK224 .. ..... T224

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. With Cruise Control, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1996 vehicles, manufacturer recommends replacing belt at 90,000 miles for normal service and 60,000 miles for severe service. For 1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. 2) Remove engine oil dipstick. Remove power steering pump, and set aside with hoses attached. Remove timing belt upper cover and A/C drive belt idler pulley bracket. 3) Use jack to support engine. Working from front of engine, remove engine mount bracket nuts. Remove crankshaft pulley. Remove lower cover and dipstick tube.

HONDA
1.6L 4-Cylinder SOHC, 1996-00 (Cont.)

319

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Timing Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

320

HONDA
1.6L 4-Cylinder SOHC, 1996-00 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 17 (24) Alternator Adjusting Bolt ............................................................................................ 17 (24) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Pulley Center Bolt .................................................................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 ...................................................................................................................... 14 (20) Step 2 .......................................................................................... ........ Plus 90 Clockwise Engine Mount Bracket Nuts ...................................................................................... 54 (74) Power Steering Pump Bracket Bolt .......................................................................... 17 (24) Power Steering Pump Lock Bolt .............................................................................. 17 (24) Timing Belt Tensioner Adjusting Bolt ........................................................................ 33 (45) INCH Lbs. (N.m)
Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft TDC Mark & Oil Pump Mark

CKF Sensor Bolt ..................................................................................................... 106 Engine Lower Splash Shield ..................................................................................... 89 Timing Belt Cover Bolt .............................................................................................. 89 Water Pump Bolt ..................................................................................................... 106
1

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

Lubricate bolt threads and bolt head shoulder.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Bolt

HONDA
1.7L 4-Cylinder SOHC
TIMING BELT APPLICATION Application 1.7L 4-Cyl. SOHC Civic 2001-04 ....................................................
1

321

Labor Time

Belt Part No.

2.7 Hours .. ..... T312

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 110,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

timing belt between camshaft pulley and water pump pulley. Autotensioner should move smoothly. Replace auto-tensioner if it does not move smoothly. Using socket on small allen at side of auto-tensioner, move auto tensioner to remove tension from timing belt, and remove timing belt. See Fig. 6. Installation 1) Clean timing belt pulleys and covers. Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 7. 2) Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 8. 3) Install timing belt counterclockwise in this sequence: timing belt drive pulley, tensioner pulley, water pump pulley, and camshaft pulley. See Fig. 9. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing marks are aligned with TDC marks. 4) Install CKP sensor, side engine mount bracket, lower timing belt cover, and crankshaft pulley. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley. CAUTION: Always adjust timing belt tension with engine cold. 5) Turn crankshaft pulley so No. 1 piston is at TDC (White TDC mark on crankshaft pulley aligns with pointer on cover). See Fig. 1. 6) Ensure camshaft pulley marks are aligned at TDC. See Fig. 8. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine lower splash shield. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. Remove front wheels. Remove splash shield. Remove power steering adjusting plate mounting bolts and lock nut, then remove power steering pump belt and pump without disconnecting hoses. Remove alternator. 2) Remove four (4) ignition coils, throttle cable clamps and harness holder from cylinder head cover. Remove cylinder head cover. See Fig. 2. 3) Holding crankshaft pulley with Holder Handle (07JAB-001020A) and Holder Attachment (07MAB-PY3010A), use a heavy duty 19-mm socket and breaker bar to remove pulley bolt. See Fig. 3. Support engine with a jack and wood block under oil pan. Remove upper engine bracket from timing belt end of engine. 4) Remove grommet from upper timing belt cover, and disconnect TDC sensor connector. Remove both upper and lower timing belt covers. See Fig. 4. 5) Remove side engine mount bracket. Remove CKP sensor from oil pump without disconnecting connector. See Fig. 5. Check autotensioner before removing belt. Apply a force of 22 ft. lbs. (98 N.m) to

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Aligning Crankshaft Pulley TDC Marks

322

HONDA
1.7L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Removing Crankshaft Pulley

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing Timing Belt Covers

HONDA
1.7L 4-Cylinder SOHC (Cont.)

323

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Removing CKP Sensor From Oil Pump


Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Camshaft TDC Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Removing Tension From Timing Belt

Courtesy of American Honda Motor Co., Inc.

Fig. 9: Identifying Timing Belt Installation Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 17 (24) Alternator Adjusting Bolt ............................................................................................ 17 (24) Alternator Mount Bolt ................................................................................................ 33 (45) Auto Tensioner Mounting Bolt ................................................................................... 33 (44) Camshaft Pulley Center Bolt .................................................................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 .................................................................................................................. 181 (245) Step 2 .......................................................................................... ........ Plus 90 Clockwise Engine Side Mount Bracket Nuts ............................................................................. 33 (44) Engine Upper Bracket Nuts ...................................................................................... 40 (54) Power Steering Pump Bracket Bolt .......................................................................... 17 (24) Power Steering Pump Lock Bolt .............................................................................. 17 (24) INCH Lbs. (N.m) CKP Sensor Bolt ..................................................................................................... 106 Engine Lower Splash Shield ..................................................................................... 89 Harness Holder & Cable Clamps ............................................................................. 89 Timing Belt Cover Bolt .............................................................................................. 89 Water Pump Bolt ..................................................................................................... 106
1

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Crankshaft TDC Mark & Oil Pump Mark

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

Lubricate bolt threads and bolt head shoulder.

324

HONDA
1.8L 4-Cylinder
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Accord 1979-83 1984-85 Prelude 1979-82 1983-85 1986-87
1

............................ ... ............................ ... ............................ ... ............................ ... ............................ ...

1 1

2.0 Hrs. ... ...... ..... ...... ..... T041 2.0 Hrs. ... .. TCK160 .. ..... T094

1 1

2.0 Hrs. ... ...... ..... ...... ..... T041 2.0 Hrs. ... .. TCK160 .. ..... T094 1 2.0 Hrs. ... .. TCK160 .. ..... T160

With Air Conditioning, add .4 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

Fig. 1: Exploded View Of Timing Belt & Components (1979-83 Accord & 1979-82 Prelude)

TIMING BELT
Removal (1979-83 Accord & 1979-82 Prelude) 1) Disconnect negative battery cable. Remove engine support bolts and nuts. Remove side rubber mount. Remove side mount bracket. Remove cruise control actuator. Remove engine splash guard. Remove water pump drive belt, water pump pulley and crankshaft pulley. See Fig. 1. Remove alternator, belt, A/C compressor and belt. CAUTION: Crankshaft pulley bolt may stick to the crankshaft threads when properly torqued. A properly torqued pulley bolt may require up to two or three times the installation torque to remove. 2) Remove valve cover. Ensure cylinder No. 1 is at TDC of compression stroke and camshaft is aligned to mark. See Fig. 2. Remove upper timing belt cover from cylinder head. Remove crankshaft pulley. Remove lower timing belt cover from engine block. Loosen, but do not remove, timing belt adjusting and pivot bolts. If reusing belt, mark direction of belt rotation. Slide belt off pulleys. Inspection (1979-83 Accord & 1979-82 Prelude) Inspect timing belt for wear or rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Replace as necessary. Installation (1979-83 Accord & 1979-82 Prelude) To install, reverse removal procedure, using care not to excessively bend or twist belt. If reinstalling old belt, install belt so same direction of rotation will be maintained. Adjust drive belts to proper tension. Removal (1984-85 Accord & 1983-87 Prelude) 1) Disconnect negative battery cable. Remove engine support bolts and nuts. Remove side rubber mount. Remove side mount bracket. Remove cruise control actuator. Remove engine splash guard. Remove water pump drive belt, water pump pulley. Remove alternator, belt, A/C compressor and belt. Rotate crankshaft counterclockwise to position No. 1 cylinder to TDC of compression stroke. Remove all drive belts. 2) Remove engine valve cover and upper timing belt cover. See Fig. 1 or 3. Ensure camshaft timing marks are aligned with valve cover surface, and UP or ROUND mark is upward. See Fig. 2, 4 or 5.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks (1979-83 Accord & 1979-82 Prelude)

HONDA
1.8L 4-Cylinder (Cont.)

325

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Exploded View Of Timing Belt & Components (1984-85 Accord & 1983-87 Prelude) CAUTION: Crankshaft pulley bolt may stick to the crankshaft threads when properly torqued. A properly torqued pulley bolt may require up to two or three times the installation torque to remove. 3) Remove crankshaft pulley. Remove lower timing belt cover from engine block. Loosen timing belt tensioner to relieve timing belt tension. 4) If timing belt is being reused, mark direction of belt rotation before removing. Remove timing belt from camshaft and crankshaft gears. Inspection (1984-85 Accord & 1983-87 Prelude) Inspect timing belt for wear or rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Replace as necessary. Installation (1984-85 Accord & 1983-87 Prelude) 1) Ensure cylinder No. 1 is at TDC of compression stroke. Ensure camshaft timing marks are aligned with valve cover surface, and UP or ROUND mark is upward. See Fig. 2, 4 or 5. 2) Install timing belt. Use care not to excessively bend or twist belt. Ensure belt is installed in original direction of rotation. Belt tension must be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on belt. Tighten tensioner adjustment bolt to specication. See TORQUE SPECIFICATIONS.

326

HONDA
1.8L 4-Cylinder (Cont.)

Courtesy of American Honda Motor Co., Inc.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (1984-85 Accord) CAUTION: Belt tension must be adjusted when engine temperature is cold. 3) Install washer on crankshaft bolt with at side toward the pulley. Tighten retaining bolt to specication. See TORQUE SPECIFICATIONS. Reverse removal procedure to complete installation. Tighten all bolts to specication. Apply non-hardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. Adjust drive belts to proper tension.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks (1983-87 Prelude)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt 1979-83 Accord & 1980-82 Prelude ....................................................................... 22 (23) 1984-85 Accord & 1983-87 Prelude ....................................................................... 27 (37) Crankshaft Pulley Bolt 1 .......................................................................................... 83 (115) Power Steering Pump Bracket Bolt .......................................................................... 33 (45) Timing Belt Adjuster Bolt 1979-83 Accord & 1980-82 Prelude 2 ..................................................................... 22 (23) 1984-85 Accord & 1983-87 Prelude ....................................................................... 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10) Water Pump Bolt ..................................................................................................... 108 (12)
1 2

Lubricate bolt threads but do not lubricate washer or mating surface of bolt. Pivot bolt and adjuster bolt.

HONDA
2.0L 4-Cylinder CR-V
TIMING BELT APPLICATION Application 2.0L 4-Cyl. CR-V 1997-01 ..............................
1

327

Labor Time

Component Belt Kit No. Part No.

2.7 Hours .. .. TCK184 .. ..... T184

With Air Conditioning, add .3 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Installation 1) Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 3. 2) Set intake and exhaust camshaft pulleys to TDC. The TDC marks should align with cylinder head surface with UP marks pointing up. See Fig. 3. 3) Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, exhaust camshaft pulley, and intake camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Check that crankshaft and camshaft pulleys remained aligned with TDC marks. 4) Loosen and retighten adjusting bolt to tension timing belt. Install lower and middle covers. Install crankshaft pulley. Tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley. CAUTION: Always adjust timing belt tension with engine cold. 5) To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). See Fig. 1. Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. 6) Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. 7) To complete installation, reverse removal procedure. When installing cylinder head cover gasket, apply liquid gasket (Part No. 08718-0001 or -0003) to 8 corners where gasket meets camshafts. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt .................................................................. 33 (44) Alternator Adjusting Lock Nut ................................................................................... 17 (24) Alternator Mount Bolt ................................................................................................ 33 (45) Camshaft Pulley Center Bolt .................................................................................... 27 (37) Crankshaft Pulley Bolt 1 ........................................................................................ 130 (177) Engine Mount Bracket Nuts ...................................................................................... 54 (74) Engine Underguard Bar Bolts ................................................................................... 17 (24) Power Steering Pump Bracket Bolt .......................................................................... 33 (44) Power Steering Pump Lock Bolt .............................................................................. 17 (24) Power Steering Pump-To-Bracket Bolts ................................................................... 17 (24) Timing Belt Adjusting Bolt ......................................................................................... 40 (54) INCH Lbs. (N.m) Cylinder Head Cover Nuts 2 ...................................................................................... 89 Engine Lower Splash Shield ..................................................................................... 89 Timing Belt Cover Bolt .............................................................................................. 89 Water Pump Bolt ..................................................................................................... 106
1 2

TIMING BELT
Removal 1) Disconnect battery negative cable. Remove engine guard bar and lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Remove cruise control actuator and vacuum tank from left side fenderwell (if equipped), and hang out of way. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. 2) Use jack to support engine. Working from front of engine, remove engine mount bracket nuts and bracket. Remove the crankshaft pulley. 3) Remove cylinder head cover. Remove middle and lower covers. See Fig. 2. Loosen timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys.

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

Lubricate bolt threads and bottom shoulder of bolt head. Tighten nuts in 2-3 steps, starting from center outward.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Setting Crankshaft Pulley To TDC

328

HONDA
2.0L 4-Cylinder CR-V (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Aligning Crankshaft & Camshaft TDC Marks

HONDA
2.0L 4-Cylinder SOHC Accord & Prelude
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

329

2.0L 4-Cyl. SOHC Accord 1986-89 ............................ ... Prelude 1985 ................................. ... 1986-87 ............................ ... 1988-90 ............................ ...
1

2.7 Hrs. ... .. TCK160 .. ..... T160

1 1

2.7 Hrs. ... .. TCK160 .. ..... T094 2.7 Hrs. ... .. TCK160 .. ..... T160 1 2.7 Hrs. ... ...... ..... ...... ..... T144

With Air Conditioning, add .3 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1985-89 vehicles, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles. For 1990 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles.

REMOVAL & INSTALLATION


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

Fig. 1: Exploded View Of Timing Belt & Components (Except 1988-90 Prelude)

TIMING BELT
Removal (Except 1988-90 Prelude) 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove drive belts. Remove left engine mount bolts/nuts, engine mount and bracket. Remove cruise control actuator (if equipped). 2) Remove splash shield. Remove power steering adjusting pulley. Remove power steering pump with hoses attached, and set aside. Remove alternator. Remove A/C compressor (if equipped). Remove engine valve cover and upper timing belt cover. See Fig. 1. Ensure timing marks align and UP mark is facing upward. See Fig. 2. 3) Remove crankshaft pulley. Remove lower timing belt cover. If timing belt is going to be reused, mark belt rotation direction before removing. Loosen timing belt tensioner adjustment bolt. Push tensioner to release belt tension, retighten adjustment bolt. Remove timing belt. Inspection (Except 1988-90 Prelude) Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear. Inspect water pump for excessive bearing play or coolant leakage. Replace as necessary. Installation (Except 1988-90 Prelude) 1) Ensure cylinder No. 1 is still at TDC. Install timing belt on sprockets. DO NOT excessively bend or twist belt. Ensure arrow on used belt points in original rotation direction. 2) Adjust timing belt tension by rotating crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Loosen, but do not remove, timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specication. See TORQUE SPECIFICATIONS. 3) Apply non-hardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. To complete installation, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Removal (1988-90 Prelude) 1) Turn crankshaft counterclockwise (as viewed from timing belt end of engine) so that No. 1 cylinder is at TDC of compression stroke. Ensure TDC mark (White paint) is at rear of engine on transaxle mating ange. See Fig. 2.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks (1985-87 Prelude Shown; Others Are Similar)

330

HONDA
2.0L 4-Cylinder SOHC Accord & Prelude (Cont.)

2) Remove engine lower splash shield. Support weight of engine from above or with oor 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 specication. See TORQUE SPECIFICATIONS. 3) Loosen, but DO NOT remove, timing belt adjusting bolt through access hole in timing belt cover. See Fig. 4. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to tension timing belt. Tighten adjusting bolt to 31 ft. lbs. (43 N.m). Install upper timing belt cover. Install valve cover. 4) Install generator, power steering pump and A/C compressor. Install accessory drive belts and adjust to proper tension. Install engine mount and cruise control actuator.

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Adjusting Timing Belt Tension (1988-90 Prelude)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE) Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Adjustment Bolt ........................................................................... 51 (69) Alternator Bracket Bolt .............................................................................................. 18 (24) Camshaft Pulley Bolt ................................................................................................. 27 (37) Crankshaft Pulley Bolt ........................................................................................... 108 (146) Timing Belt Adjuster Bolt .......................................................................................... 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 84 (9) Valve Cover Nut .......................................................................................................... 84 (9) Water Pump Bolt ..................................................................................................... 106 (12) TORQUE SPECIFICATIONS (1988-90 PRELUDE) Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt ................................................................................ 18 (25) Camshaft Pulley Bolt ................................................................................................. 27 (37) Crankshaft Pulley Bolt ........................................................................................... 108 (146) Engine Mount-To-Engine Nut .................................................................................... 47 (65) Generator Lower Mount Bolt .................................................................................... 33 (45) Generator Upper Mount Bolt .................................................................................... 20 (27) Power Steering Pump Upper Mount Bolt ................................................................. 20 (27) Timing Belt Adjuster Bolt .......................................................................................... 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10) Water Pump Bolt ..................................................................................................... 106 (12)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Identifying Timing Belt Installed Position (1988-90 Prelude)

HONDA
2.0L & 2.1L 4-Cylinder DOHC Prelude
TIMING BELT APPLICATION Application 2.0L 4-Cyl. Prelude 1988-91 2.1L 4-Cyl. Prelude 1990-91
1

331

Labor Time

Component Belt Kit No. Part No.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

DOHC ............................ ... DOHC ............................ ...


1

3.3 Hrs. ... .. TCK142 .. ..... T142

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for 1988-89 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-91 models, the manufacturer recommends belt be replaced every 90,000 miles.

3.3 Hrs. ... .. TCK142 .. ..... T142

With Air Conditioning, add .5 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

332

HONDA
2.0L & 2.1L 4-Cylinder DOHC Prelude (Cont.)

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove drive belts. Remove left engine mount bolts/nuts, engine mount and bracket. Remove cruise control actuator (if equipped). 2) Remove engine splash shield. Remove power steering adjusting pulley. Remove power steering pump with hoses attached, and set aside. Remove alternator. 3) Remove A/C compressor (if equipped). Remove engine valve cover and upper timing belt cover. See Fig. 1. Ensure timing marks align, and UP marks on camshaft sprockets are positioned at the top. See Fig. 2. 4) Remove crankshaft pulley. Remove lower timing belt cover. If reusing timing belt, mark belt rotation direction before removing. Loosen timing belt tensioner adjustment bolt, and push tensioner to release belt tension. Tighten adjustment bolt and remove timing belt. Inspection Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Inspect water pump for excessive bearing play or coolant leakage. Replace if necessary. Installation 1) Ensure cylinder No. 1 is still at TDC. Install timing belt on sprockets. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. 2) Adjust timing belt tension by rotating crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Loosen, but do not remove, timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specication. See TORQUE SPECIFICATIONS. 3) To complete installation, reverse removal procedure. Apply nonhardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Adjustment Bolt ........................................................................... 20 (27) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Pulley Bolt ................................................................................................. 27 (37) Crankshaft Pulley Bolt ........................................................................................... 108 (146) Power Steering Adjustment Nut ................................................................................ 31 (42) Power Steering Pump Bracket Bolt .......................................................................... 33 (45) Timing Belt Adjustment Bolt ...................................................................................... 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 90 (10) Valve Cover Nut ........................................................................................................ 90 (10) Water Pump Bolt ..................................................................................................... 108 (12)

HONDA
2.2L 4-Cylinder DOHC Prelude
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

333

2.2L 4-Cyl. DOHC (H22A) Prelude 1993-01 Balancer Shaft Belt ...... .......... 1 .......... .. TCK186 .. ..... T186 Camshaft Timing Belt .. ... 1 3.3 Hrs. ... .. TCK186 .. ..... T226
1

Balancer shaft belt included in camshaft belt labor time. With Air Conditioning, add .5 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1993-94 vehicles, the manufacturer recommends camshaft and balancer shaft belts be replaced at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997-01 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

4) Install auto-tensioner on engine with stopper in place. Install timing belt around crankshaft drive pulley, adjusting pulley, water pump, exhaust camshaft pulley, then intake camshaft pulley. Ensure crankshaft and camshaft pulleys remain aligned at TDC. 5) Remove the auto-tensioner stopper. Install balancer belt drive pulley. Temporarily install lower cover, crankshaft pulley, and crankshaft pulley bolt. Tighten bolt. 6) Rotate crankshaft about 5-6 times counterclockwise so that timing belt positions on the pulleys. Place crankshaft and camshaft pulleys at TDC positions. If either crankshaft or camshaft pulley is not positioned at TDC, timing belt will have to be repositioned. 7) Remove crankshaft pulley and lower cover. Loosen belt tension adjusting nut about one turn. Verify balancer belt adjuster moves freely. Retighten tension adjusting nut. 8) Remove sealing bolt from maintenance hole in side of engine block. See Fig. 5. Insert a 6 x 100 mm bolt into maintenance hole to lock rear balancer shaft in place. Ensure bolt inserts at least 2.9 (74 mm). Align groove on front balancer shaft with pointer on oil pump housing. See Fig. 6. 9) Install balancer belt. Loosen adjusting nut to tension balancer belt. Remove 6 x 100 mm bolt from side of engine block. Install sealing bolt. 10) Install lower cover and crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. 11) Turn crankshaft pulley about one turn counterclockwise. Tighten belt tension adjusting nut. Install rubber seal around adjusting nut. Install accessory drive belts, and adjust tension. 12) Install middle cover. When installing cylinder head cover gasket, apply liquid gasket (Part No. 08718-001 or -0003) to 8 corners where gasket meets camshafts. Reverse removal procedure to complete installation.

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 ange. 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 oor jack. Remove engine side mount and bracket from front of engine. Remove dipstick tube from front of engine. Remove cylinder head cover. 4) Remove middle timing belt cover. See Fig. 2. Remove crankshaft pulley. Loosen belt tension adjusting nut. Push belt tensioner to release tension from balancer belt. Tighten adjusting nut. Remove balancer shaft and camshaft timing belts. Inspection With belt or belt covers removed, inspect belts for wear, cracks, or oil soaking. Inspect belt teeth for wear. Replace belt if worn, oil soaked, or cracked. Inspect water pump for leaks. Installation 1) Remove balancer belt drive pulley. Ensure crankshaft drive pulley TDC (White) mark is aligned with pointer on oil pump housing. See Fig. 3. Align camshaft pulleys at TDC position. See Fig. 1. 2) Remove the auto-tensioner from front of engine. Place auto-tensioner in soft-jawed vise with maintenance bolt facing up. See Fig. 4. DO NOT grip housing. 3) Remove maintenance bolt from top of auto-tensioner. Use a atbladed screwdriver to compress auto-tensioner to bottomed out position. Place stopper on auto-tensioner. Rell any oil that may have spilled out, and install maintenance bolt with new gasket.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Identifying Camshaft & Crankshaft TDC Marks

334

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

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Compressing Auto-Tensioner


Courtesy of American Honda Motor Co., Inc.

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

HONDA
2.2L 4-Cylinder DOHC Prelude (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

335

Application Ft. Lbs. (N.m) Alternator Mount Bolt ................................................................................................ 33 (45) Auto-Tensioner Mount Bolts ...................................................................................... 16 (22) Balance Shaft Pulley Bolt ......................................................................................... 22 (30) Camshaft Pulley Bolt ................................................................................................. 37 (51) Crankshaft Pulley Bolt ......................................................................................... 1 181 (245) Maintenance Hole Sealing Bolt ................................................................................ 22 (29) Power Steering Pump Bolt/Lock Nut ........................................................................ 16 (22) Timing Belt Tension Adjusting Nut ............................................................................ 33 (45) INCH Lbs. (N.m) Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8) Cylinder Head Cover Nut .......................................................................................... 90 (10) Timing Belt Cover Bolt ............................................................................................ 106 (12) Water Pump Bolt ..................................................................................................... 106 (12)
1

Lubricate bolt threads and underside of bolt shoulder.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning & Locking Balancer Shaft

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Aligning Balancer Shaft Pulley

336

HONDA
2.2L 4-Cylinder SOHC Odyssey
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. RA1 Odyssey 1995-97 Balance Shaft ............... .......... 1 .......... .. TCK186 .. ..... T186 Camshaft ....................... ... 2 2.7 Hrs. ... .. TCK186 .. ..... T187
1 2

Balance shaft belt included in camshaft belt labor time. With Air Conditioning, add .3 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

Fig. 1: Exploded View Of Timing Belt, Balance Belt & Related Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount. 2) Remove cylinder head cover. See Fig. 1. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 2. Loosen timing belt tensioner adjuster nut 145-180 degrees. See Fig. 3. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tensioner adjuster nut. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. Installation Ensure cylinder No. 1 is at TDC of compression stroke. See Figs. 4 and 5. Install timing belt in sequence shown. See Fig. 6. Tighten bolts to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

HONDA
2.2L 4-Cylinder SOHC Odyssey (Cont.)

337

Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks Fig. 3: Loosening Tensioner Adjusting Nut

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt ............................................................................................ 28 (38) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Power Steering Pump Mounting Nut ........................................................................ 16 (22) Timing Belt Adjuster Bolt .......................................................................................... 49 (67) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............. 86-104 (7.2-8.7) Valve Cover Nut ....................................................................................................... 86 (9.8)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

338

HONDA
2.2L & 2.3L 4-Cylinder DOHC & SOHC
Labor Time Component Belt Kit No. Part No. 3) Support engine. Remove 2 rear bolts from engine center support beam. Lower engine enough to permit removal of lower timing belt cover. Remove rubber seal from belt tension adjuster nut. Remove lower timing belt cover. CAUTION: DO NOT rotate crankshaft or camshaft when removing timing belts. 4) Lock timing belt adjuster arm into position by installing one lower cover retaining bolt. Loosen belt tension adjuster bolt. See Fig. 5. Push belt tensioner to release tension from belt. Tighten adjuster bolt. Remove balance shaft and camshaft timing belts. Inspection With belt or belt covers removed, inspect belts for wear, cracks, or oil soaking. Inspect belt teeth for wear. Replace belt if worn, oil soaked, or cracked. Installation 1) Align White mark on ywheel or drive plate (explate) with pointer on block. Ensure camshaft(s) is at TDC for No. 1 cylinder. See Fig. 1, 2 or 3. Install camshaft timing belt. See Fig. 6. Align rear timing balance shaft belt pulley by inserting a 6 x 100 mm bolt 2.9 (74 mm) into alignment access hole. Align groove on front balance shaft pulley with pointer on oil pump body. See Fig. 7. 2) Adjust timing belt tension by rotating crankshaft counterclockwise until No. 1 piston is at TDC of compression stroke. Loosen, but do not remove, timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specication. See TORQUE SPECIFICATIONS. 3) Reverse removal procedure to complete installation. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. SOHC Accord 1990-93 Balance Shaft ............... .......... 1 .......... .. TCK186 .. ..... Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... 1994-95 EX Model Balance Shaft ............. .......... 1 .......... ...... ..... ...... ..... Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... ..... Except EX Model Balance Shaft ............. .......... 1 .......... .. TCK186 .. ..... Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... 1996-97 W/VTEC Balance Shaft ............. .......... 1 .......... ...... ..... ...... ..... Camshaft ..................... ... 1 3.1 Hrs. ... ...... ..... ...... ..... W/O VTEC Balance Shaft ............. .......... 1 .......... .. TCK186 .. ..... Camshaft ..................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... Prelude 1992-96 Balance Shaft ............... .......... 1 .......... .. TCK186 .. ..... Camshaft ....................... ... 1 3.1 Hrs. ... .. TCK186 .. ..... 2.3L 4-Cyl. DOHC Prelude 1992-96 Balance Shaft ............... .......... 1 .......... .. TCK216 .. ..... Camshaft ....................... ... 1 3.3 Hrs. ... .. TCK216 .. .....
1

T186 T187

T186 T244 T186 T187

T186 T244 T186 T187

T186 T187

T186 T216

Balance shaft belt included in camshaft belt labor time. With Air Conditioning, add .5 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-94 vehicles, the manufacturer recommends camshaft and balance shaft belts be replaced at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TIMING & BALANCE SHAFT BELTS


Removal 1) Disconnect negative battery cable. Position crankshaft with cylinder No. 1 at TDC of compression stroke. See Fig. 1, 2 or 3. Disconnect battery negative cable. Remove splash shield. Remove cruise control actuator, leaving cable connected. Remove power steering pump, leaving hoses connected. 2) Disconnect alternator wiring. Remove wiring harness from valve cover. Remove alternator and A/C belts (if equipped). Remove valve cover and upper timing belt cover. Remove side engine mount. Remove engine oil dipstick and tube. Remove crankshaft pulley. See Fig. 4.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Positioning Camshaft Sprocket for Valve Adjustment (2.2L SOHC Accord)

HONDA
2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

339

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Removing & Installing Crankshaft Pulley (Typical)

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Positioning Camshaft Sprocket for Valve Adjustment (2.2L SOHC Prelude)

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Positioning Camshaft Sprockets for Valve Adjustment (Prelude 2.3L DOHC)

340

HONDA
2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Locating Timing Belt Adjuster Nut (Typical)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Removing & Installing Timing & Balance Shaft Belts

HONDA
2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

341

Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 37 (50) Alternator Bracket Adjuster Bolt ................................................................................ 16 (22) Alternator Bracket Bolt .............................................................................................. 33 (45) Balance Shaft Pulley Bolt ......................................................................................... 22 (30) Camshaft Pulley Bolt 2.2L DOHC .............................................................................................................. 37 (51) 2.2L SOHC & 2.3L .................................................................................................. 27 (37) Crankshaft Pulley Bolt ........................................................................................... 184 (250) Power Steering Belt Adjuster Nut ................................................. ............................ 11 (15) Power Steering Pump Bracket Bolt .......................................................................... 33 (45) Power Steering Pump Mounting Bolt ....................................................................... 16 (22) Shift Cable Bracket Bolt ............................................................................................ 16 (22) Timing Belt Tension Adjuster .................................................................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................................................................ 108 (12) Valve Cover Nut ........................................................................................................ 90 (10) Water Pump Bolt ..................................................................................................... 108 (12)

Fig. 7: Aligning Balancer Belt Driven Pulley

342

HONDA
2.3L 4-Cylinder SOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.3L 4-Cyl. F23A, SOHC Accord 1998-02 Balance Shaft ...................................... .......... 1 .......... ..... Camshaft ............................................... 2 3.1 Hours .. ..... Odyssey 1998 Balance Shaft ...................................... .......... 1 .......... ..... Camshaft ............................................... 2 3.3 Hours .. .....
1 2

T186 T244

T186 T244

Balance shaft belt included in camshaft belt labor time. With Air Conditioning, add .5 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if vehicle is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balancer Belt & Related Components

TIMING & BALANCER SHAFT BELTS


Removal 1) Disconnect negative battery cable, then positive battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Raise and support vehicle. Remove front tires. Remove engine lower splash shield. 2) Remove accessory drive belts. Remove alternator terminal and connector. Remove alternator and alternator bracket. Use a jack, with cushion between oil pan and jack, to support engine. Remove upper bracket. Remove dipstick tube from front of engine. 3) Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Figs. 1 and 2. 4) Insert a 6-mm timing cover bolt through the hole in the end of the timing belt adjuster arm. This will temporarily lock the arm in place. 5) Loosen belt tensioner adjusting nut about one turn. See Fig. 3. Push outer balancer shaft belt tensioner pulley up to take tension off of the balancer belt. Retighten belt tensioner adjusting nut. Remove balancer shaft belt. 6) Loosen belt tensioner adjusting nut about one turn. See Fig. 3. Push camshaft timing belt tensioner pulley down to take tension off of camshaft timing belt. Retighten belt tensioner adjusting nut. Remove camshaft timing belt. Installation 1) Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by aligning dimple on timing belt drive pulley with pointer on oil pump housing. See Fig. 4. Ensure camshaft pulley TDC marks are aligned. See Fig. 5. 2) Install camshaft timing belt counterclockwise in sequence shown. See Fig. 6. Loosen and retighten tensioner adjusting nut to tension camshaft timing belt. Install balancer belt drive pulley and lower cover. Install crankshaft pulley. Install bolt. 3) Rotate crankshaft pulley COUNTERCLOCKWISE about 5-6 turns so timing belt positions on pulley. Set No. 1 piston at TDC of compression

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers stroke. Loosen belt tensioner adjusting nut about one turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt tensioner adjusting nut to specication. See TORQUE SPECIFICATIONS. 4) Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC position. Ensure camshaft UP mark is facing up. If it is not, timing belt will have to be repositioned.

HONDA
2.3L 4-Cylinder SOHC (Cont.)

343

Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

Fig. 3: Loosening Tensioner Adjusting Nut 5) Remove crankshaft pulley and lower cover. Set timing belt drive pulley to TDC position. 6) Lock camshaft timing belt adjuster arm in place by installing a 6 x 10 mm timing cover bolt. Loosen belt tensioner adjusting nut about one turn. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push balancer belt tensioner up, then retighten belt tensioner adjusting nut. 7) Remove sealing bolt from maintenance hole on side of engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end of 6 x 100 mm bolt. Install 6 x 100 mm bolt into sealing bolt hole to lock balancer shaft in place. 8) Align front balancer shaft pulley groove with pointer on oil pump housing. See Fig. 8. Install balancer belt. Loosen tensioner adjusting nut about one turn to tension balancer shaft belt. Remove 6 x 100 mm bolt from rear of balancer shaft. Install sealing bolt with new washer. 9) Temporarily install crankshaft pulley and bolt. Turn crankshaft pulley about one turn counterclockwise, then tighten tensioner adjusting nut. Remove the 6 x 10 mm bolt that locked camshaft timing belt adjuster arm in place. 10) Remove crankshaft pulley. Install lower cover with new gasket or liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 11) Install dipstick tube with new O ring. When installing cylinder head cover gasket, apply liquid gasket (Part No. 08718-0001 or -0003) to 4 corners where gasket meets camshafts. 12) Install alternator and harness. Install accessory drive belts. Install engine mount bracket to engine and frame. Connect negative and positive battery cables. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

344

HONDA
2.3L 4-Cylinder SOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 8: Locking Balancer Shaft In Place

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Adjusting Lock Nut ................................................................................... 16 (22) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt ............................................................................................ 43 (59) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Block Sealing Bolt ........................................................................................ 22 (29) Engine Bracket-To-Engine Side Mount Nut/Bolt Accord ...................................................................................................................... 40 (54) Engine Side Mount Through-Bolt Odyssey ................................................................................................................... 47 (64) Engine Side Mount-To-Bracket Nut/Bolt Odyssey ................................................................................................................... 47 (64) Power Steering Pump Mounting Nut ........................................................................ 16 (22) Timing Belt Tensioner Adjusting Nut ........................................................................ 33 (44) INCH Lbs. (N.m) Cylinder Head Cover Nut ......................................................................................... 86 (9.8) Dipstick Tube Bolt ................................................................................................... 106 (12) Engine Lower Splash Shield ..................................................................................... 89 (10) Timing Belt Cover Bolt ............................................................................................ 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Aligning Balancer Belt Drive Pulley

HONDA
2.6L 4-Cylinder
TIMING BELT APPLICATION Application
1

345

Labor Time Component Belt Kit No. Part No.

2.6L 4-Cyl. Passport 1994-96 A/T .................................... 1.6 Hours ... .. TCK147 .. ..... T147 M/T .................................... 1.6 Hours ... .. TCK147 .. ..... T147
1

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Fig. 1: Aligning Timing Marks TIMING SPROCKET SPECIFICATIONS Application Standard In. (mm) Limit In. (mm) Camshaft ............................... .......... 5.202 (132.03) ................................. 5.198 (131.93) Crankshaft ............................. ........... 2.574 (65.33) .................................... 2.570 (65.23) Oil Pump ............................... .......... 4.485 (113.84) .......... ....................... 4.481 (113.74) Installation 1) Pull tensioner fully toward water pump side, and temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on compression stroke by rotating crankshaft until keyway aligns with mark on front crankshaft seal housing (12 oclock). 2) Rotate camshaft until timing mark on cam gear (arrow) aligns with mark on upper camshaft cover (notch). See Fig. 1. 3) Position timing belt over crankshaft sprocket, oil pump sprocket, camshaft sprocket and tensioner in that order. Ensure belt is positioned in sequence given and without slack between sprockets. Loosen tensioner pulley adjusting bolt, allowing spring tension to tighten belt. Tighten adjusting bolt temporarily. 4) Temporarily install crankshaft pulley bolt and rotate crankshaft 2 complete revolutions in opposite direction of engine rotation, until marks on crankshaft and front oil seal retainer are aligned again. See Fig. 1. Loosen tensioner lock bolt, allowing tensioner spring to fully adjust tension. Tighten tensioner lock bolt. 5) Install timing belt covers. To complete installation, reverse removal procedures. Tighten all bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction. Removal 1) Disconnect negative battery cable. Remove all necessary air ducts. Position No. 1 cylinder at TDC of compression stroke. Align timing marks. See Fig. 1. Remove fan and fan shroud. Remove accessory drive belts. Remove water pump pulley. If necessary, remove radiator and splash guard. 2) Prevent engine from rotating, and remove crankshaft timing pulley. Remove upper and lower timing belt covers. See Fig. 2. Remove spring from tension pulley. Loosen adjusting bolt, and move pulley toward water pump. Remove timing belt. CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft, or damage may result. Inspection 1) Handle timing belt carefully. Avoid twisting or kinking belt. Do not allow belt to become contaminated by water, oil, dirt or other contaminates. Inspect belt for cracks or damage. Replace, if necessary. 2) Measure tensioner pulley spring length and force. Spring length should not exceed 2.76 (70.2 mm), and spring force should not be less than 197-343 lbs. (27-48 kg). Replace tensioner pulley spring if not within specication. 3) Check timing sprockets. See TIMING SPROCKET SPECIFICATIONS table. Replace, if necessary.

346

HONDA
2.6L 4-Cylinder (Cont.)

Courtesy of Isuzu Motor Co.

Fig. 2: Exploded View of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 43 (58) Crankshaft Pulley Bolt ............................................................................................. 90 (122) Front Cover ............................................................................................................... 14 (19) Tensioner Pulley Bolts ......................................................................................................................... 18 (24) Nut ........................................................................................................................... 10 (14) Water Pump Bolt ....................................................................................................... 14 (19)
Courtesy of Isuzu Motor Co.

INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 53 (6)

Fig. 3: Installing Belt Guide

HONDA
2.7L V6
TIMING BELT APPLICATION Application
1

347

Labor Time

Belt Part No.

2.7L V6 Accord 1996-97 ..................................................... 4.0 Hours ... ..... T263


1

With Air Conditioning, add .3 hours. With Cruise Control, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Inspection Inspect camshaft and crankshaft seals, and replace if leaking. Inspect timing belt for wear or rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Installation 1) Clean timing belt covers and ensure No. 1 piston is at TDC of compression stroke. Ensure crankshaft and camshaft pulleys are at TDC, and install timing belt in sequence shown. See Fig. 2. 2) To adjust timing belt, rotate crankshaft clockwise 5-6 revolutions to seat belt, and then rotate crankshaft until No. 1 piston is at TDC of compression stroke. Loosen adjusting bolt 180 degrees, then retighten adjusting bolt. See Fig. 2. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1996 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove front wheels and splash shield. Support engine with cushioned jack. Remove 3 bolts attaching side engine mount to engine, then loosen mount center bolt and pivot mount out of way. 2) Remove A/C, P/S and alternator belt. Remove dipstick and pipe. Remove crankshaft pulley. Remove timing belt covers. See Fig. 1. 3) If timing belt is being reused, mark direction of belt rotation before removing. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. See Fig. 2. 4) Loosen timing belt adjusting bolt 180 degrees, and push tensioner to remove tension from timing belt. Retighten adjusting bolt and remove timing belt.

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Identifying TDC Marks, Timing Belt Adjusting Bolt & Installation Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt 8 mm Bolts .............................................................................................................. 16 (22) 10 mm Bolts ............................................................................................................ 33 (44) A/C Idler Pulley Center Nut ...................................................................................... 33 (44) Alternator Bracket Bolts 8 mm Bolts .............................................................................................................. 16 (22) 10 mm Bolts ............................................................................................................ 33 (44) Camshaft Pulley Bolts ............................................................................................... 23 (31) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Mount Bolts ................................................................................................... 43 (59) Idler Pulley Center Nut ............................................................................................. 33 (44) Timing Belt Adjuster Bolt .......................................................................................... 31 (42) INCH Lbs. (N.m) Dipstick Bracket Bolts ................................................................................................. 84 (9) Timing Belt Cover Bolts .............................................................................................. 84 (9)

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing & Installing Lower & Upper Timing Belt Covers

348

HONDA
3.0L & 3.5L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

3.0L V6 (J30A1) Accord 1998-00 .............................. 1 4.4 Hours .. . 2 TCK286 . ..... 2001-02 .............................. 1 4.4 Hours .. ...... ..... ...... ..... 2003-04 .............................. 1 4.0 Hours .. ...... ..... ...... ..... 3.5L V6 (J35A1 & J35A4) Odyssey 1999-04 .............................. 1 4.0 Hours .. ...... ..... ...... ..... Pilot 2003-04 ............................... 4.0 Hours ... ...... ..... ...... .....
1

T286 T286 T329

T286 T286

With Cruise Control, add .3 hours. With Power Steering, add .3 hours. Timing component kit does not include camshaft tensioner hydraulic assembly.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Removing Crankshaft Pulley Bolt NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING. CAUTION: Handle auto-tensioner carefully so oil does not spill or leak out. Replace any oil that may leak out. Capacity is 0.22 . oz. (6.5 ml.). 3) Hold auto-tensioner with maintenance bolt pointing up. Remove maintenance bolt. See Fig. 5. Clamp auto-tensioner in soft-jawed vise. DO NOT grip auto-tensioner housing. Insert at-bladed screwdriver into maintenance hole. Place stopper on auto-tensioner while turning screwdriver clockwise to compress tensioner to bottom. 4) Replace any oil that may have spilled out of auto-tensioner. Reinstall maintenance bolt with NEW gasket. Ensure no oil is leaking around maintenance bolt, then reinstall auto-tensioner onto engine with stopper in place. NOTE: When compressing sealed auto-tensioners, compression pressure should not exceed 2200 lbs. (9800 N). 5) Place sealed auto-tensioner in press. SLOWLY compress tensioner until pin can be inserted through tensioner body, and insert pin. See Fig. 6. Install auto-tensioner onto engine. 6) Install battery clamp bolt into back cover. On 2003-04 Accord and Pilot, apply liquid thread lock to idler pulley bolt and loosely install idler pulley. On all models, install timing belt in counterclockwise direction in the following sequence: Crankshaft pulley, idler pulley, front camshaft pulley, water pump pulley, rear camshaft pulley and tension adjust pulley. See Fig. 7. Ensure crankshaft and camshaft pulleys remained aligned with marks on back cover. Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. 7) Remove stopper or pin from auto-tensioner. Remove battery clamp bolt from back cover. Install engine mount bracket to the front of engine (above water pump pulley). If removed, install timing belt guide plate with concave surface facing out. Install lower cover, then upper front and rear covers. Install crankshaft pulley. Lubricate crankshaft pulley bolt threads and install bolt. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 8) Rotate crankshaft about 5-6 turns clockwise to position timing belt on pulleys. Ensure crankshaft and camshaft pulleys are aligned at TDC. Crankshaft pulley White mark should be aligned with pointer on front cover. Remove rubber plugs from upper covers to check camshaft pulley positions. 9) If either camshaft is not at TDC, remove timing belt and readjust position. To complete installation, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110F, or under 20F).

REMOVAL & INSTALLATION


CAUTION: The 3.0L is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT
Removal 1) Disconnect negative battery cable. Turn crankshaft pulley so that No. 1 piston is at TDC on compression stroke. White mark on crankshaft pulley should align with pointer on front cover. Remove right front wheel, if necessary. Remove lower engine splash shield. Remove the generator and power steering pump drive belts. 2) Support engine with a jack and wood block under the oil pan. Remove ground cable (if necessary), then remove engine side mount bracket. Remove dipstick tube from front of engine. Using Holder, remove crankshaft pulley. See Fig. 1. 3) Remove upper and lower timing belt covers. See Fig. 2. If reusing timing belt, mark direction of belt rotation for installation reference. 4) Remove one of the battery clamp bolts from battery tray. Grind threaded end of bolt to a partial point (about 45 degree chamfer). Thread battery bolt into rear cover to hold timing belt adjuster in installed position. Hand tighten ONLY. See Fig. 3. 5) Remove engine mount bracket from front of engine (above water pump pulley). On 2003-04 Accord and Pilot, remove idler pulley bolt and idler pulley, then remove timing belt. On all other models, loosen timing belt idler pulley bolt 5-6 turns and remove timing belt. Installation 1) Ensure that engine is at TDC. Align dimple on timing belt drive pulley with pointer on oil pump. See Fig. 4. Align camshaft pulleys with pointers on back covers. 2) Remove battery clamp bolt from back cover. Remove the timing belt auto-tensioner. For auto-tensioner with removable bolt, go to next step. For models with sealed auto-tensioner, go to step 5). For identication, see Figs. 5 and 6.

HONDA
3.0L & 3.5L V6 (Cont.)

349

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner

350

HONDA
3.0L & 3.5L V6 (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Compressing Auto-Tensioner (2000-03 Odyssey & Pilot)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Center Bolt 1 .............................................................................. 67 (90) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Mount Bracket (Front) 10 x 1.25 mm Bolts ................................................................................................ 33 (44) 6 x 1.0 mm Bolt .......................................................................... ..................................... 2 Engine Side Mount Bracket 10 x 1.25 mm Bolts 3 .............................................................................................. 33 (44) 12 x 1.25 mm Bolts ................................................................................................ 40 (54) Idler Pulley Bolt ......................................................................................................... 33 (44) Power Steering Pump Lock Nut ............................................................................... 17 (24) Power Steering Pump Mount Bolt ............................................................................ 17 (24) INCH Lbs. (N.m) Auto-Tensioner Maintenance Bolt ............................................................................... 71 (8) Auto-Tensioner Mount Bolts .................................................................................... 106 (12) Dipstick & Tube 4 ..................................................................................................... 106 (12) Ground Cable Bolt .................................................................................................. 106 (12) Lower Engine Splash Shield Bolts ......................................................................... 106 (12) Timing Belt Cover Bolts .......................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)
Courtesy of American Honda Motor Co., Inc.
1 2 3 4

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

Fig. 5: Compressing Auto-Tensioner (Accord & 1999 Odyssey)

Apply engine oil to bolt threads. Tighten bolt to 106 INCH lbs. (12 N.m). Tighten these bolts rst. Use a NEW O ring.

HONDA
3.2L V6 DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No.

351

3.2L V6 Passport 1998-02 ..................................................... 3.2 Hours ... ..... T303 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 75,000 miles for 1998-99 model years. For 2000-02 model year vehicles, recommended replacement interval is 100,000 miles.
Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks 3) Align timing mark on left hand (driver side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around water pump pulley and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys. 4) Install timing belt around idler pulley and tensioner pulley. Temporarily install crankshaft pulley, and tighten center bolt by hand. Turn pulley clockwise slightly to give some belt slack between the crankshaft sprocket and right hand camshaft sprocket. NOTE: It will take about 220 lbs. (100 kg) to compress timing belt tensioner rod. 5) Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. 6) Install tensioner on engine with locking pin in place. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove locking pin from timing belt tensioner. Remove clips from camshaft and crankshaft sprockets. 8) Rotate crankshaft 2 turns clockwise. Ensure timing marks are still aligned. 9) Remove crankshaft pulley and install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6. 10) Install crankshaft pulley. Tighten center bolt to specication. See TORQUE SPECIFICATIONS. Install cooling fan pulley. Install power steering pump. Install cooling fan. Install serpentine drive belt idler pulley and tensioner assemblies. Install radiator fan shroud. Connect negative battery cable.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove serpentine drive belt. 2) Remove cooling fan and drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. 3) Remove power steering pump with hoses attached, and set aside. Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, remove crankshaft pulley. 4) Remove timing belt covers. Rotate crankshaft to align timing marks. See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be at TDC. 5) If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt. CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation. Installation 1) Align groove on crankshaft sprocket with mark on oil pump. See Fig. 2. Install timing belt on crankshaft pulley, aligning White dotted line on belt with timing mark on crankshaft pulley. Secure belt to sprocket with spring clip. 2) Align timing mark on right hand (passenger side) camshaft sprocket with alignment mark on valve cover. See Fig. 3. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip.

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

352

HONDA
3.2L V6 DOHC (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Installing Timing Belt Cover Bushings


Courtesy of American Honda Motor Co., Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 72 (98) Cooling Fan Pulley Bolt ............................................................................................ 16 (22) Crankshaft Pulley Bolt ........................................................................................... 123 (167) Power Steering Pump Bolt M8 Bolt .................................................................................................................... 16 (22) M10 Bolt .................................................................................................................. 34 (46) Timing Belt Cover Bolt .............................................................................................. 14 (19) Timing Belt Idler Pulley Bolt ..................................................................................... 38 (52) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42) Water Pump Bolt ....................................................................................................... 18 (25)

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

HYUNDAI
1.5L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 1.5L 4-Cyl. Accent 1996-97 ....................................................
1

353

Labor Time

Belt Part No.

7) Ensure belt cog will reach half the width of timing belt tensioner bolt on slot-side of belt tensioner. Install crankshaft ange. Install timing belt cover. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

1.8 Hours .. ..... T282

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1996 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1997 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Loosen, but do not remove water pump pulley bolts. Remove all accessory drive belts. Remove pulleys from crankshaft and water pump. CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removal. 2) Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Fig. 1. 3) If reusing old belt, place mark on belt to indicate direction of belt rotation. Loosen timing belt tensioner bolts, and move tensioner inward toward water pump. Temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearing. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Move timing belt tensioner toward water pump and tighten bolt. Install crankshaft sprocket (if removed) with chamfer (ange) toward engine. 2) Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. 3) Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Fig. 1. CAUTION: Slot-side timing belt tensioner bolt must be tightened before pivot-side to prevent belt tensioner from rotating, causing belt to be over-tightened. 4) Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 2. Tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. 5) Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. Loosen pivot-side bolt and then slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specication. See TORQUE SPECIFICATIONS. 6) To check belt tension, hold belt tensioner and timing belt together and apply slight thumb pressure (about 11 lbs.) at center point of belt tensioner. See Fig. 2. Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Courtesy of Hyundai Motor Co.

Fig. 2: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ............... 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt ........................................................ 103-111 (140-150) Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150) Timing Belt Idler Pulley Bolt ......................................................... ................. 32-41 (43-55) Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

354

HYUNDAI
1.5L 4-Cylinder SOHC
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.5L 4-Cyl. Accent 1995-99 2000-02 Excel 1986-89 1990-94 Scoupe 1991-93 1994-95
1 2

............................ ... ............................ ... ............................ ... ............................ ... ............................ ... ............................ ...

1 2

1.8 Hrs. ... .. TCK191 .. ..... T191 2.0 Hrs. ... ...... ..... ...... ..... T324 2.2 Hrs. ... .. TCK073 .. ..... T073 2.2 Hrs. ... .. TCK128 .. ..... T128 2.2 Hrs. ... .. TCK128 .. ..... T128 2.2 Hrs. ... .. TCK191 .. ..... T191

1 1

1 1

With Air Conditioning, add .2 hours. With Air conditioning, add .2 hour (1995-99) or .3 hour (2000-02). With Power Steering, add .2 hour.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1986-96 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1997-02 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles. Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove all accessory drive belts. Remove pulleys from crankshaft and water pump. CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removal. 2) Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Figs. 1 and 2. 3) If reusing old belt, place mark on belt to indicate direction of belt rotation. Move tensioner inward toward water pump, and temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner for worn bearing. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 1 and 2. Move timing belt tensioner toward water pump and tighten bolt. 2) Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. 3) Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Figs. 1 and 2.
Courtesy of Hyundai Motor Co.

Fig. 2: Locating Camshaft & Crankshaft Sprocket Marks CAUTION: Slot-side timing belt tensioner bolt must be tightened before pivot-side to prevent belt tensioner from rotating, causing belt to be over-tightened. 4) Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 3. Tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. 5) Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. Loosen pivot-side bolt, and then slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specication. See TORQUE SPECIFICATIONS. 6) To check belt tension, hold belt tensioner and timing belt together and apply slight thumb pressure (about 11 lbs.) at center point of belt tensioner. See Fig. 3. 7) Ensure belt cog will reach half the width of timing belt tensioner bolt on slot-side of belt tensioner. Install timing belt cover. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

HYUNDAI
1.5L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

355

Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ............... 59-74 (80-100) Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150) Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt ................................................................ ............. 106-133 (12-15)

Courtesy of Hyundai Motor Co.

Fig. 3: Checking Timing Belt Tension

356

HYUNDAI
1.6L 4-Cylinder DOHC 2001-04
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. Accent 2001-04 ....................................................


1

2.0 Hours .. ..... T282

With Air Conditioning, add .3 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be inspected every 30,000 miles. Manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Loosen, but do not remove water pump pulley bolts. Remove all accessory drive belts. Remove pulleys from crankshaft and water pump. CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removal. 2) Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Fig. 1. 3) If reusing old belt, place mark on belt to indicate direction of belt rotation. Loosen timing belt tensioner bolts, and move tensioner inward toward water pump. Temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearing. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Move timing belt tensioner toward water pump and tighten bolt. Install crankshaft sprocket (if removed) with chamfer (ange) toward engine. 2) Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. 3) Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Fig. 1. CAUTION: Slot-side timing belt tensioner bolt must be tightened before pivot-side to prevent belt tensioner from rotating, causing belt to be overtightened. 4) Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 2. Tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. 5) Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. To check belt tension, hold belt tensioner and timing belt together and apply slight thumb pressure (about 11 lbs.) at center point of belt tensioner. See Fig. 2. 6) Ensure belt cog will reach half the width of timing belt tensioner bolt on slot-side of belt tensioner. Install crankshaft ange. Install timing belt cover. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Courtesy of Hyundai Motor Co.

Fig. 2: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ............... 59-74 (80-100) Crankshaft Sprocket Center Bolt ............................................................ 103-111 (140-150) Timing Belt Idler Pulley Bolt ......................................................... ................. 32-41 (43-55) Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

HYUNDAI
1.6L & 1.8L 4-Cylinder DOHC 1992-95
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

357

1.6L 4-Cyl. DOHC Elantra 1992 ................................. ... 1 3.0 Hrs. ... .. 1993-95 Balance Shaft ............... .......... 2 .......... .. Camshaft ....................... ... 1 3.0 Hrs. ... .. 1.8L 4-Cyl. DOHC Elantra 1993-95 Balance Shaft ............... .......... 2 .......... .. Camshaft ....................... ... 1 3.0 Hrs. ... ..
1

TCK165 .. ..... T165 TCK165 .. ..... T168 TCK165 .. ..... T165

Compressing Automatic Tensioner 1) Check if plug at bottom of tensioner protrudes past tensioner housing. If plug protrudes past housing, place a washer over plug to prevent plug from contacting vise when pushing rod into tensioner housing. Place tensioner assembly in a soft-jawed vise. 2) SLOWLY squeeze rod back into automatic tensioner. Replace tensioner if rod can be retracted easily into automatic tensioner. Align holes in rod and automatic tensioner body. See Fig. 4. Insert drill bit or pin through holes to retain rod in retracted position. NOTE: If right (viewed from rear of engine) balance shaft sprocket was removed, ensure right balance shaft spacer is installed with chamfer toward engine. Before installation, apply light coat of engine oil to spacer. Installation (Balance Shaft Belt) 1) Ensure crankshaft sprocket and right side balance shaft sprocket timing marks are aligned with marks on oil pump housing. See Fig. 5. Install balance shaft belt. If removed, install balance shaft tensioner pulley and center bolt. 2) Install balance shaft belt (timing belt B). No slack should be present in belt. Lift tensioner toward belt so that large part of center eccentric is to the left and above the center bolt. See Fig. 6. 3) While tightening balance shaft tensioner center bolt, ensure tensioner and sprockets DO NOT rotate. Ensure timing marks are still aligned. Check belt tension by applying nger pressure to side of belt opposite tensioner. See Fig. 6. Deection should be .20-.28 (5-7 mm). If not, readjust belt tension. 4) Install crankshaft ange and outer sprocket. Install ange in correct direction to prevent damage to timing belt. See Fig. 7. Installation (Camshaft Timing Belt) 1) If crankshaft sprocket was removed, ensure sprocket, spacer and ange are installed correctly. See Fig. 8. 2) Remove automatic tensioner from vise, and install onto engine with wire in place. Install tensioner arm. Position tensioner pulley so that pin holes are left of center bolt. See Fig. 9. Temporarily tighten camshaft tension pulley center bolt. CAUTION: The same camshaft sprocket is used on intake and exhaust camshafts. Each has two timing marks. Both camshaft sprockets are positioned correctly when the center dowel pin holes face up (12 oclock position). 3) Rotate camshaft sprockets so dowel pins face up and timing marks on sprockets align. See Fig. 2. Inner marks on sprockets should be aligned with cylinder head surface. When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. When installing timing belt, compensate for rotation. 4) Rotate crankshaft, and align timing marks on crankshaft and oil pump sprockets. If installing old timing belt, ensure it is installed in original direction of rotation. 5) Install timing belt on tensioner pulley and crankshaft sprocket. Hold belt in place using left hand. Pull belt around oil pump sprocket using right hand. Pull belt around idler pulley. 6) Install timing belt around intake camshaft sprocket. Ensure exhaust timing mark on camshaft sprocket aligns with cylinder head surface. See Fig. 2. Using both hands, install timing belt around exhaust camshaft sprocket. 7) Rotate tensioner pulley in toward timing belt until belt does not sag. Temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are still aligned. 8) To adjust camshaft belt tension, rotate crankshaft 1/4 turn counterclockwise, and then rotate until No. 1 cylinder is at TDC. Loosen center bolt on camshaft belt tensioner pulley. 9) Install Socket Wrench (MD998752) into pin holes offset to left center of pulley. See Fig. 10. Using INCH-lb. torque wrench and socket wrench, apply a clockwise torque of 23-25 INCH lbs. (2.6-2.8 N.m) on tensioner pulley. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 31-40 ft. lbs. (42-54 N.m). DO NOT allow pulley to rotate while tightening center bolt.

TCK167 .. ..... T168 TCK167 .. ..... T167

With Air Conditioning, add .2 hours. With Power Steering, add .3 hours. Balance shaft belt included in camshaft belt labor time.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove cover from under engine (if equipped). Support engine weight with oor jack. Remove engine mount located near timing belt cover. Remove all accessory drive belts. Remove water pump pulley and crankshaft pulley. Remove timing belt covers and gaskets, noting bolt lengths and locations. CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 2) Rotate engine clockwise to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 2. Remove automatic tensioner. Place mark on timing belt to indicate direction of belt rotation. Remove timing belt. 3) On models equipped with balance shaft, remove outer crankshaft sprocket. See Fig. 1. Align oil pump sprocket timing mark with mark on oil pump case. See Fig. 2. CAUTION: Leave screwdriver inserted in block until timing belt is installed. This will lock left side balance shaft in correct position. 4) Remove plug at left side of cylinder block. See Fig. 3. Insert screwdriver to hold left balance shaft in place. Screwdriver should insert at least 2.4 (60 mm) into hole. If not, rotate oil pump sprocket one full turn and align timing mark. Ensure screwdriver inserts correct amount. 5) Loosen balance belt tensioner bolt. Remove balance belt. Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. 2) Check end of automatic tensioner rod for wear. Measure distance from end of automatic tensioner rod to top of automatic tensioner housing. Distance should be .47 (12 mm). If out of specication, replace automatic tensioner.

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 clearance, an alternate method can be used. Install Set Screw (09244-28000) until it contacts tensioner arm. 13) Turn set screw inward, counting number of turns until tensioner arm contacts automatic tensioner housing. Set screw should rotate 2 1/2-3 turns inward if belt tension is correct. Repeat timing belt tensioning procedure until correct distance is obtained. Remove set screw. 14) Install rubber plug in rear timing belt cover. To complete installation, reverse removal procedure. Ensure timing belt cover bolts are installed in proper location. See Fig. 13. Adjust drive belts to proper tension.

NOTE: If engine is in vehicle, it may be necessary during tensioner pulley adjustment to jack up engine slightly for clearance. 10) Install Set Screw (09244-28000) or equivalent, in left engine support bracket until screw end contacts tensioner arm. See Fig. 11. Turn set screw further until wire can be removed from automatic tensioner. Remove set screw. 11) Rotate crankshaft clockwise 2 complete revolutions, and leave in this position for approximately 15 minutes. After 15 minutes, measure distance between bottom of tensioner arm and top of automatic tensioner body (automatic tensioner rod extension). Distance should be .15-.18 (3.8-4.5 mm). See Fig. 12, Dimension A. Repeat timing belt tensioning procedure until correct distance is obtained. If correct distance can be measured, go to step 14). If correct distance CANNOT be measured, go to next step.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)

HYUNDAI
1.6L & 1.8L 4-Cylinder DOHC 1992-95 (Cont.)

359

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Crankshaft & Balance Shaft Sprockets

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 6: Checking Balance Shaft Tension Pulley Alignment

Courtesy of Hyundai Motor Co.

Fig. 3: Holding Silent Shaft In Stationary Position

Courtesy of Hyundai Motor Co.

Fig. 7: Installing Flange & Crankshaft Sprocket (Engines With Balance Shaft Belt)

Courtesy of Hyundai Motor Co.

Fig. 4: Retracting Automatic Tensioner Rod

Courtesy of Hyundai Motor Co.

Fig. 8: Installing Flange & Crankshaft Sprocket (Engines Without Balance Shaft Belt)

360

HYUNDAI
1.6L & 1.8L 4-Cylinder DOHC 1992-95 (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 9: Installing Tensioner Pulley

Courtesy of Hyundai Motor Co.

Fig. 13: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

Fig. 10: Adjusting Camshaft Belt Tension

Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100) Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30) Crankshaft Sprocket Center Bolt ................................................................ 80-94 (110-130) Front Cover Bolt 8 x 30 mm Bolt ........................................................................... ................. 20-26 (27-35) Except 8 x 30 mm Bolt ............................................................... ................. 14-20 (19-27) Idler Pulley Bolt ............................................................................. ................. 22-30 (30-42) Tensioner Pulley Bracket Bolt ....................................................... ................. 12-19 (17-26) Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (43-55) Timing Belt Cover Left Lower Rear .......................................................................... ................. 22-30 (30-42) Except Left Lower Rear .............................................................. ..................................... 1
1

Courtesy of Hyundai Motor Co.

Tighten to 89-106 INCH lbs. (10-12 N.m).

Fig. 11: Removing Timing Belt Automatic Tensioner Lock Wire

Courtesy of Hyundai Motor Co.

Fig. 12: Measuring Timing Belt Tensioner Protrusion

HYUNDAI
1.8L & 2.0L 4-Cylinder DOHC 1996-04 (Except Sonata & 2004 Elantra)
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

361

1.8L 4-Cyl. DOHC Elantra 1996-98 .............................. 1 2.4 Hours .. .. TCK278 .. ..... Tiburon 1997 ................................... 1 2.4 Hours .. .. TCK278 .. ..... 2.0L 4-Cyl. DOHC Elantra 1999-01 ............................... 2.8 Hours ... .. TCK284 .. ..... 2002-03 ............................... 2.8 Hours ... ...... ..... ...... ..... Tiburon 1997 .................................... 3.0 Hours ... ...... ..... ...... ..... 1998-01 ............................... 3.0 Hours ... .. TCK284 .. ..... 2003-04 ............................... 3.0 Hours ... ...... ..... ...... .....
1

T278 T278

T284 T284 T284 T284 T284

With Air Conditioning, add .2 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Inspection Check belt teeth for cracks, damage, and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and worn bearings. Replace components if damaged. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. Outer marks on sprockets should be aligned with rocker cover surface. Verify timing chain timing mark alignment, if necessary. See Fig. 2. Install timing belt tensioner pulley. Install timing belt. If reusing old belt, ensure belt is installed in original direction of rotation. 2) Loosen timing belt tensioner bolt, allowing tensioner pulley to contact belt. Tighten timing belt tensioner pulley bolt. Rotate crankshaft one turn clockwise. Realign camshaft and crankshaft timing marks. 3) Adjust timing belt tension until .15-.24 (4-6 mm) deection is present midway between idler pulley and camshaft sprocket, with a force of 4.4 lbs. (2 kg) applied to belt. 4) Rotate engine clockwise 2 revolutions. Ensure timing marks are still aligned and proper belt tension still exists. Install timing belt covers. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belt to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer requires that the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.
Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Timing Chain Marks

REMOVAL & INSTALLATION


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

TECHNICAL SERVICE BULLETIN


TIMING BELT NOISE: FRONT CASE
Description Some 1999-00 Elantras and Tiburons produced before Sept. 22, 1999 may exhibit an unusual noise at the front of the engine. The noise may be caused by the timing belt rubbing against the front of the engine. Some timing belt idler pulley mounting surfaces were machined incorrectly. This can cause the timing belt to ride off of the timing belt sprockets and into the front cover. Service Procedure If this condition exists, the forward edge of the timing belt will shredded and the inside of the upper timing belt cover will be worn. Replace the front case, idler pulley, timing belt and any other damaged components. NOTE: This information is from the Hyundai technical service bulletin 00-20-002-1; May, 2000.

TIMING BELT
NOTE: On some models, engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt. Removal 1) Remove all drive belts and drive pulleys from crankshaft and water pump. Remove generator bolt, if necessary. Remove crankshaft pulley and water pump pulley. 2) Remove timing belt covers and gaskets, noting bolt lengths and locations. DO NOT rotate engine counterclockwise, as viewed from timing belt side of engine. Remove timing belt tensioner pulley. 3) Rotate engine clockwise to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 1. If reusing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ............. 74-89 (100-120) Crankshaft Pulley Bolt ................................................................... ......... 125-133 (170-180) Front Case Bolts ........................................................................... ................. 14-20 (20-27) Generator Brace Mounting Bolt .................................................... ................. 14-20 (20-27) Generator Support Bolt/Nut .......................................................... ................. 14-18 (20-25) Timing Belt Idler Bolt .................................................................... ................. 31-41 (43-55) Timing Belt Tensioner Bolt ............................................................ ................. 31-41 (43-55) Water Pump Bolt 1996-97 ............................................................................................................ 9-11 (12-15) 1998-04 ........................................................................................ ................. 14-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................... 71-86 (8-10) Water Pump Pulley Bolt ................................................................ ................... 71-86 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Belt Marks

362

HYUNDAI
2.0L 4-Cylinder DOHC Elantra
Labor Time Belt Part No. Remove the PCV hose and breather hose. See Fig. 15. Remove the cylinder head cover. See Fig. 16. CAUTION: Be careful not to damage the cylinder head and valve lifter with the wrench. 19) Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt and camshaft sprocket. See Fig. 17. Inspection Check belt teeth for cracks, damage, and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and worn bearings. Replace components if damaged. Installation 1) Install the camshaft sprocket and tighten the bolt to specication. See TORQUE SPECIFICATIONS. Temporarily install the camshaft sprocket bolt. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolt. See Fig. 17. 2) Install cylinder head cover. See Fig. 16. Install the PCV hose and breather hose. See Fig. 15. Install the accelerator cable to the cylinder head cover. See Fig. 14. Install the spark plug cable. 3) Install the crankshaft sprocket. See Fig. 13. 4) Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No. 1 piston placed at top dead center and its compression stroke. See Figs. 18 and 19. 5) Install the idler pulley and tighten the bolt to the specied torque. See Fig. 12. See TORQUE SPECIFICATIONS. 6) Temporarily install the timing belt tensioner with plain washer. See Fig. 20. 7) Install belt so as not to give slack at each center of shaft. Install timing belt starting with crankshaft sprocket, idler pulley, camshaft sprocket to timing belt tensioner. See Fig. 21. 8) Temporarily fasten tensioner pulley by center bolt to add force at belt. 9) Adjust timing belt tension: Rotate crankshaft in regular direction (clock wise view from front) through angle equivalent to two teeth (18) of camshaft sprocket. See Fig. 22. Give tension to timing belt by rotating tensioner in arrow direction with tool and set timing belt not to give slack to tension side. Tighten tensioner bolt. Recheck the belt tension. See Fig. 23. When the tension side of timing belt is pushed horizontally with a moderate force, 5 ft. lbs. (20 N.m). The timing belt cog end sags in 0.16-0.24 (4-6 mm). 10) Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark. 11) Install the timing belt lower cover. See Fig. 9. See TORQUE SPECIFICATIONS. 12) Install the ange and crankshaft pulley. See Fig. 7. See TORQUE SPECIFICATIONS. Make sure that crankshaft sprocket pin ts the small hole in the pulley. 13) Install the timing belt upper cover. See Fig. 5. 14) Install the coolant pump pulley. 15) Install power steering belt. 16) Install air compressor bolt. 17) Install alternator belt. 18) Install the stay plate. See Fig. 4. See TORQUE SPECIFICATIONS. Install engine mount bracket. See Fig. 3. See TORQUE SPECIFICATIONS. 19) Install right side cover. See Fig. 2. 20) Install right front wheel. 21) Install engine cover. See Fig. 1.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. DOHC Elantra 2004 ..........................................................
1

2.4 Hours .. ..... T284

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer requires that the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: On some models, engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt. Removal 1) Remove the engine cover. See Fig. 1. 2) Remove right front wheel. 3) Remove right side cover. See Fig. 2. NOTE: Place wooden block between the jack and engine oil pan. 4) Set the jack to the engine oil pan. Remove the engine mount bracket. See Fig. 3. Remove the stay plate. See Fig. 4. 5) Temporarily loosen the water pump pulley bolts. 6) Remove alternator belt. 7) Remove air compressor belt. 8) Remove power steering belt. 9) Remove water pump pulley. 10) Remove timing belt upper cover. See Fig. 5. 11) Turn the crankshaft pulley, and align its groove with timing mark T on the timing belt cover. See Fig. 6. 12) Remove the crankshaft pulley bolt and crankshaft pulley. See Fig. 7. 13) Remove the crankshaft ange. See Fig. 8. 14) Remove the timing belt lower cover. See Fig. 9. NOTE: If the timing belt is reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before. 15) Remove the timing belt tensioner and timing belt. See Figs. 10 and 11. 16) Remove the bolt and timing belt idler. See Fig. 12. 17) Remove the crankshaft sprocket. See Fig. 13. 18) Remove the cylinder head cover: Remove the spark plug cable. Remove the accelerator cable from the cylinder head cover. See Fig. 14.

HYUNDAI
2.0L 4-Cylinder DOHC Elantra (Cont.)

363

Courtesy of Hyundai Motor Co.

Fig. 4: Removing & Installing Stay Plate


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Fig. 1: Removing & Installing Engine Cover

Courtesy of Hyundai Motor Co.

Fig. 5: Removing & Installing Timing Belt Upper Cover

Courtesy of Hyundai Motor Co.

Fig. 2: Removing & Installing Side Cover

Courtesy of Hyundai Motor Co.

Fig. 6: Identifying Timing Marks


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Fig. 3: Removing & Installing Engine Mount Bracket

364

HYUNDAI
2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 7: Removing & Installing Crankshaft Pulley


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Fig. 10: Removing Timing Belt Tensioner

Courtesy of Hyundai Motor Co.

Fig. 8: Removing Crankshaft Flange

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Fig. 11: Removing Timing Belt

Courtesy of Hyundai Motor Co.

Fig. 9: Removing & Installing Timing Belt Lower Cover


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Fig. 12: Removing & Installing Timing Belt Idler

HYUNDAI
2.0L 4-Cylinder DOHC Elantra (Cont.)

365

Courtesy of Hyundai Motor Co.

Fig. 13: Removing & Installing Crankshaft Sprocket


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Fig. 16: Removing & Installing Cylinder Head Cover

Courtesy of Hyundai Motor Co.

Fig. 14: Removing & Installing Accelerator Cable

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Fig. 17: Removing & Installing Camshaft Sprocket

Courtesy of Hyundai Motor Co.

Fig. 15: Locating PCV Hose & Breather Hose

366

HYUNDAI
2.0L 4-Cylinder DOHC Elantra (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 20: Installing Timing Belt Tensioner


Courtesy of Hyundai Motor Co.

Fig. 18: Locating Camshaft Sprocket Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 19: Locating Crankshaft Sprocket Timing Marks

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Fig. 21: Locating Timing Belt Components

HYUNDAI
2.0L 4-Cylinder DOHC Elantra (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

367

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ............. 74-89 (100-120) Crankshaft Pulley Bolt ................................................................... ......... 125-133 (170-180) Idler Pulley Bolt ............................................................................. ................. 32-40 (43-55) Engine Mount Nuts 14mm Nut .................................................................................... ................. 37-48 (50-65) 17mm Nut .................................................................................... ................. 44-59 (60-80) Generator Brace Mounting Bolt .................................................... ................. 14-20 (20-27) Generator Support Bolt/Nut .......................................................... ................. 14-18 (20-25) Stay Plate Bolt .............................................................................. ................. 31-41 (43-55) Timing Belt Idler Bolt .................................................................... ................. 31-41 (43-55) Timing Belt Tensioner Bolt ............................................................ ................. 31-41 (43-55) Water Pump Bolt ........................................................................... ................. 14-20 (20-27)
Courtesy of Hyundai Motor Co.

INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................... 71-86 (8-10) Water Pump Pulley Bolt ................................................................ ................... 71-86 (8-10)

Fig. 22: Adjusting Camshaft Sprocket

Courtesy of Hyundai Motor Co.

Fig. 23: Adjusting Timing Belt Tension

368

HYUNDAI
2.0L 4-Cylinder Sonata
Labor Time Component Belt Kit No. Part No. 5) Replace automatic tensioner assembly if rod can be easily pushed into automatic tensioner. While automatic tensioner is in vise, align holes in end of tensioner rod and housing. Install pin through holes to lock tensioner in position. Installation 1) Align timing marks on balance shaft sprockets with timing marks on engine case. Install balance shaft timing belt and crankshaft ange. Install crankshaft ange in correct direction. See Fig. 5. 2) Position balance shaft tensioner so that the center of the pulley is to the left and above the tensioner bolt. See Hold tensioner tightly against belt. Tighten tensioner pulley bolt without letting tensioner rotate. 3) To check balance shaft belt tension, depress belt with nger midway between sprockets (opposite tensioner pulley). Deection should be between .20-.29 (57 mm). If not, readjust belt tension. 4) Place crankshaft sprocket on crankshaft. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 5) Ensure screwdriver is still installed through left side of cylinder block to hold balance shaft in place. Install automatic tensioner on engine block with rod locked in place. 6) Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 1. Outer marks on sprockets should be aligned with cylinder head surface. NOTE: The same camshaft sprockets are installed on intake and exhaust camshafts. Timing marks are correctly aligned when dowel pin holes are facing straight up. 7) Align crankshaft sprocket timing marks and oil pump sprocket timing marks. See Fig. 1. Install timing belt around tensioner pulley and crankshaft sprocket. Hold timing belt on tensioner pulley using left hand. Pulling belt with right hand, install belt around oil pump sprocket. 8) Install belt around idler pulley. Align timing mark on exhaust camshaft sprocket with top of cylinder head. Pulling belt with both hands, install it around exhaust camshaft sprocket. 9) Gently raise tensioner pulley so belt does not sag. Position timing belt tensioner pin holes so that they face up. Temporarily tighten center bolt. See Fig. 6. 10) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, and then rotate clockwise until No. 1 cylinder is at TDC. Ensure all timing marks are aligned. 11) Loosen center bolt on tensioner pulley. Note location of pin holes in tensioner pulley. 12) Using INCH-lb. torque wrench and Socket Wrench (09224-28100), apply a torque of 22-24 INCH lbs. (2.6-2.8 N.m) on tensioner pulley. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to specication. See Fig. 7. See TORQUE SPECIFICATIONS. 13) Install Set Screw (09244-28000), or equivalent, in left engine support bracket until set screw end contacts tensioner arm. Rotate set screw further until locking pin can be removed from automatic tensioner. See Fig. 6. Remove set screw. 14) Rotate crankshaft clockwise 2 complete revolutions. Allow engine to sit in this position for about 15 minutes. Measure distance between tensioner arm and automatic tensioner body. Distance should be .15-.18 (3.8-4.5 mm). See Fig. 8, Dimension A. If distance is incorrect, repeat timing belt tensioning procedure. If distance is okay, go to step 17). 15) If distance between automatic tensioner and tensioner arm cannot be measured easily, use this alternate method. Install Set Screw (09244-28000) until it contacts tensioner arm. 16) Rotate set screw inward while counting number of turns until tensioner arm contacts automatic tensioner housing. Turn set screw 2 1/2-3 turns to correctly tension belt. Remove set screw. 17) Install rubber plug in rear timing belt cover. Install timing belt covers. Install timing belt cover bolts in correct locations. See Fig. 9. 18) To complete installation, reverse removal procedure. Apply sealant to contact areas on semi-circular packing and rocker cover before installing. Ensure correct bolts are installed in proper location in timing belt covers. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC Sonata 1992-98 Balance Shaft ............... .......... 1 .......... .. TCK167 .. ..... T168 Camshaft ......................... 2 3.8 Hours .. .. TCK167 .. ..... T167
1 2

Balance shaft belt included in camshaft belt labor time. With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove all drive belts. Remove crankshaft pulley and water pump pulley. Remove upper and lower timing belt covers, noting bolt lengths and locations. 2) Turn crankshaft clockwise and align timing marks so No. 1 cylinder is at TDC. Timing marks on camshaft sprockets should be aligned at upper surface of cylinder head. See Fig. 1. Camshaft sprocket dowel pins should face upward. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, mark direction of belt rotation before removing. 3) Remove timing belt automatic tensioner. See Fig. 2. Mark timing belt to indicate original direction of rotation. Remove timing belt. 4) Remove balance shaft access plug from cylinder block. Insert Phillips screwdriver to block left balance shaft. See Fig. 3. Balance shaft is correctly locked in place if screwdriver can be inserted at least 2.36 (60 mm). If not, rotate oil pump sprocket so screwdriver can be inserted to correct depth. 5) Loosen balance shaft belt tensioner bolt. Remove front crankshaft sprocket and ange. Remove balance shaft timing belt. Inspection 1) Check belt teeth for damage and oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is not cracked, separated or showing canvas ber. 2) Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. 3) Inspect automatic tensioner for leaks. Check rod end of automatic tensioner for wear. Measure distance from tensioner rod end to tensioner housing. Distance should be .47 (12 mm). If not, replace automatic tensioner. NOTE: If plug at bottom of tensioner protrudes past tensioner housing, place a washer over plug to prevent contacting vise when pushing rod into tensioner housing. 4) Retract rod into tensioner housing by placing automatic tensioner assembly in a soft-jawed vise. Close vise SLOWLY to push rod back into tensioner. See Fig. 4.

HYUNDAI
2.0L 4-Cylinder Sonata (Cont.)

369

Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Marks

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt & Related Components

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Fig. 3: Locking Left Balance Shaft In Place

370

HYUNDAI
2.0L 4-Cylinder Sonata (Cont.)

Courtesy of Hyundai Motor Co. Courtesy of Hyundai Motor Co.

Fig. 8: Measuring Auto Tensioner Protrusion

Fig. 4: Retracting Automatic Tensioner Rod

Courtesy of Hyundai Motor Co.

Fig. 5: Installing Crankshaft Flange

Courtesy of Hyundai Motor Co.

Fig. 9: Installing Timing Belt Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Automatic Tensioner Bolt .............................................................. ................. 15-20 (20-27) Balance Shaft Sprocket Bolt ......................................................... ................. 32-36 (43-49) Balance Shaft Tensioner Retaining Bolt ......................................................... 11-16 (15-22) Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 15-22 (20-30) Crankshaft Sprocket Center Bolt ................................................................ 81-96 (110-130) Front Tensioner Pulley Bolt ........................................................... ................. 32-41 (43-55) Idler Pulley Bolt ............................................................................. ................. 25-31 (34-42) Oil Pump Sprocket Nut ................................................................. ................. 37-44 (50-60) Water Pump Mounting Bolt ............................................................................... 9-11 (12-15) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 6: Tensioning Camshaft Timing Belt

Courtesy of Hyundai Motor Co.

Fig. 7: Adjusting Timing Belt Tensioner Pulley

HYUNDAI
2.4L 4-Cylinder DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No.

371

2.4L 4-Cylinder DOHC Sonata 1999-03 Balance Shaft Belt ................................ 1 3.0 Hours .. ..... Camshaft Belt ........................................ 2.4 Hours ... ..... Santa Fe 2001-04 Balance Shaft Belt ................................ 1 3.1 Hours .. ..... Camshaft Belt ........................................ 2.3 Hours ... .....
1

T314 T313

T314 T313

Includes camshaft belt.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, inspect timing belt at 60,000 miles, and replace as necessary.
Courtesy of Hyundai Motor Co.

REMOVAL & INSTALLATION


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

Fig. 1: Identifying Timing Belt Alignment Marks

TIMING & COUNTERBALANCE SHAFT BELTS


CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. Removal 1) Remove drive belts and drive pulleys from crankshaft and water pump. Remove timing belt covers. To align timing marks, rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks align with upper surface of rocker cover. Dowel pin of camshaft sprocket should be pointing upward. See Figs. 1 and 2. 2) Remove timing belt auto tensioner. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Remove camshaft sprockets. 3) Remove plug at left side of block and insert a screwdriver to hold left counterbalance shaft in position. Screwdriver will have to be inserted at least 2.36 (60 mm). Remove oil pump sprocket nut and sprocket. See Fig. 2. 4) Loosen right counterbalance shaft sprocket mounting bolt. Remove tensioner B and timing belt B. See Fig. 2. Remove crankshaft sprocket B from crankshaft. Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Check sprockets and pulleys for wear, cracks or damage. Replace components if necessary. 2) Measure protrusion of auto tensioner rod. From end of housing, auto tensioner rod should extend .55 (14 mm) on Sonata or .57 (15 mm) on Santa Fe. Replace auto tensioner rod, if not within specication. 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 ange is properly positioned. Lightly oil outer surface of spacer, and then install spacer onto right counterbalance shaft, with rounded edge of spacer inward. 2) Install counterbalance shaft sprocket. Tighten ange bolt tightly by hand. Align timing marks on each sprocket and on front case.

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components 3) When installing timing belt B, ensure there is no slack in tension side. Install tensioner B in center of pulley of left side of mounting bolt, and in pulley ange toward front of engine. See Fig. 3. Align timing mark of right counterbalance shaft sprocket with timing mark on front case.

372

HYUNDAI
2.4L 4-Cylinder DOHC (Cont.)

4) To tighten timing belt B, lift tensioner B so tension side is pulled tight. Tighten bolt to secure tensioner B. DO NOT turn shaft, or belt will be over-tightened. 5) Ensure timing marks are aligned. Ensure center of span on tension side of timing belt B can be depressed by hand. Ensure belt deection is .20-.30 (5-7 mm). 6) Install crankshaft sprocket ange and sprocket. Ensure ange is mounted in proper direction, with chamfered side toward block. Install special washer and sprocket bolt to crankshaft. Tighten sprocket bolt to specication. See TORQUE SPECIFICATIONS. 7) Insert long screwdriver through plug hole in left side of cylinder block to hold counterbalance shaft in position. Install oil pump sprocket, and tighten nut to specication. See TORQUE SPECIFICATIONS. Install camshaft sprockets, and tighten bolts. See TORQUE SPECIFICATIONS. 8) If auto tensioner rod is fully extended, place it in soft-jawed vise, and compress rod until hole in rod lines up with hole in auto tensioner housing. Insert stiff wire to hold rod in this position. Install auto tensioner, leaving wire in place. CAUTION: If timing marks on camshaft sprockets do not line up properly, DO NOT rotate sprocket more than 2 teeth in either direction, or valve and piston will touch. If necessary, remove and reposition camshaft sprocket. 9) Install crankshaft sensor. Set timing marks of camshaft sprockets with notches on upper side of rocker cover and dowel pins straight up. Align crankshaft sprocket timing marks. Align oil pump sprocket timing marks. 10) Install timing belt around tensioner pulley and crankshaft sprocket. Secure belt onto tensioner pulley by hand. Pull other side of belt, and install it around oil pump sprocket. Install belt around idler pulley. 11) Install belt around intake camshaft sprocket. Turn exhaust camshaft sprocket one tooth clockwise to align its timing mark with cylinder head top surface. Pull belt with both hands, and install around exhaust camshaft sprocket. 12) Gently raise tensioner pulley so belt will not sag, and then temporarily tighten center bolt. Ensure timing mark of each sprocket is still aligned. Remove wire from auto tensioner. 13) Rotate crankshaft 2 complete turns clockwise. Leave in this position for about 15 minutes. Measure auto tensioner protrusion A (distance between tensioner arm and auto tensioner body). Ensure auto tensioner protrusion is .24-.31 (6-8 mm). See Fig. 4. Install timing belt lower cover and upper cover. Note proper location of each bolt. See Fig. 5 or 6.

Courtesy of Hyundai Motor Co.

Fig. 4: Measuring Auto Tensioner Protrusion

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Fig. 5: Identifying Timing Belt Cover Bolts (Santa Fe & 2002-03 Sonata)

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Fig. 3: Installing Tensioner B

HYUNDAI
2.4L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

373

Application Ft. Lbs. (N.m) Auto Tensioner Bolt ....................................................................... ................. 14-20 (20-27) Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100) Crankshaft Damper Mounting Bolt ......................................................... 116-123 (157-167) Crankshaft Pulley-To Crankshaft Sprocket Bolt ........................... ................. 14-22 (20-30) Front Case Bolt ............................................................................. ................. 14-20 (20-27) Front Case Plug Cap .................................................................... ................. 14-20 (20-27) Tensioner Arm Assembly ............................................................... ................. 12-19 (17-26) Tensioner Pulley Bolt .................................................................... ................. 31-40 (42-54) Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27) Timing Belt Cover Bolts Lower & Upper Cover ................................................................. ..................................... 1 Rear Left Cover Lower ......................................................................................... ................. 22-30 (30-42) Upper ......................................................................................... ..................................... 2 Right Rear Cover ........................................................................ ..................................... 2 Timing Belt Idler Pulley Bolt Sante Fe & 2002-04 Sonata ...................................................................... 22-30 (30- 42) All Other Models ......................................................................... ................. 33-40 (45-55) Water Pump Mounting Bolt Sante Fe & 2002-04 Sonata ...................................................... ................. 14-20 (20-27) All Other Models ........................................................................................... 11-15 (15-22)
Courtesy of Hyundai Motor Co.

INCH Lbs. (N.m) Valve Cover Bolts .......................................................................... ................... 71-89 (8-10) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
1 2

Fig. 6: Identifying Timing Belt Cover Bolts (1999-01 Sonata)

Tighten to 71-89 INCH lbs. (8-10 N.m). Tighten to 89-106 INCH lbs. (10-12 N.m).

374

HYUNDAI
2.4L 4-Cylinder SOHC
REMOVAL & INSTALLATION
Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application

2.4L 4-Cyl. SOHC Sonata 1989-91 Balance Shaft ............... .......... 1 .......... .. TCK124 .. ..... T159 Camshaft ......................... 2 2.7 Hours .. .. TCK124 .. ..... T124
1 2

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all drive belts and crankshaft pulley. Remove upper timing belt cover and gasket. Remove timing belt lower cover and gasket, noting bolt lengths and locations. See Fig. 1. 2) Remove crankshaft sprocket bolt access cover. Remove crankshaft sprocket bolt and washer. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. See Fig. 2. Loosen front timing belt tensioner adjustment bolt, and move tensioner toward water pump. 3) Tighten bolt to secure tensioner. Remove front timing belt. Remove camshaft sprocket. Remove oil pump sprocket access plug from cylinder block. Insert 8-mm Phillips screwdriver to block left silent (counterbalance) shaft. See Fig. 3. Remove oil pump sprocket nut to remove sprocket. 4) Remove front crankshaft sprocket and ange. 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.

Balance Shaft Belt included in Camshaft Belt labor time. With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

HYUNDAI
2.4L 4-Cylinder SOHC (Cont.)

375

Courtesy of Hyundai Motor Co.

Fig. 4: Positioning Timing Belt Crankshaft Flange

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Front Timing Belt

Courtesy of Hyundai Motor Co.

Fig. 5: Aligning Rear Timing Belt Marks


Courtesy of Hyundai Motor Co.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley-To-Sprocket Bolt .............................................. ................. 14-22 (19-30) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41) Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27) Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54) INCH Lbs. (N.m) Crank Angle Sensor Nut ............................................................... ................. 84-108 (9-12) Timing Belt Cover Bolt Left Lower Rear Cover Bolt ........................................................ ..................... 44-61 (5-7) All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Fig. 3: Blocking Left Silent Shaft Inspection Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner for damage. Check belt tensioner for signs of grease leakage or roughness in tensioner rotation. Replace components if damaged. Installation 1) Install rear timing belt gear on crankshaft. Install spacer to right silent shaft with chamfer of spacer facing toward engine block. Properly install ange on crankshaft. See Fig. 4. Install rear belt and align rear belt marks. See Fig. 5. Install crankshaft gear, camshaft timing belt, washer and bolt. Align timing marks. See Fig. 2. 2) Install rear tensioner. Hold tensioner tight against belt while tightening bolts. Depress belt with nger to ensure deection is between .20-30 (5-7 mm). Install camshaft and oil pump sprocket (if removed). Tighten camshaft sprocket retaining bolt to specication while holding hexagon area of camshaft. See TORQUE SPECIFICATIONS. 3) Install belt tensioner, tension spring and spacer. Ensure spring is properly engaged against front case. Rotate tensioner toward water pump, and temporarily tighten retaining bolts. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 2. Install timing belt on crankshaft. 4) Apply pressure on tension side of belt while installing belt on camshaft sprocket. Loosen tensioner to allow spring pressure to timing belt. Rotate camshaft sprocket clockwise until timing mark is offset by 2 teeth to apply tension on belt. Ensure all timing marks are aligned. Tighten tensioner bolt. 5) Tighten tensioner spacer. To check belt tension, apply slight thumb pressure to measure deection between camshaft and oil pump sprocket. Belt deection should be .55 (14 mm). To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

376

HYUNDAI
3.0L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

3.0L V6 Sonata 1990-98 ............................ ...


1

3.1 Hrs. ... .. TCK139 .. ..... T139

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer requires the belt be replaced every 60,000 miles, except for 1998 California vehicles. For 1998 California vehicles, timing belt replacement is recommended, but not required at 60,000 miles.

Courtesy of Hyundai Motor Co.

Fig. 1: Identifying Engine Support Loosening & Tightening Sequence Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner for worn bearing. Installation 1) Align camshaft and crankshaft timing marks. See Fig. 3. If tensioner spring has been removed, install spring on tensioner so hook faces away from engine block. 2) Route timing belt on crankshaft sprocket, and then onto rear camshaft sprocket. Run timing belt under water pump pulley, over front camshaft sprocket, and then over tensioner pulley. 3) Apply force counterclockwise to rear camshaft sprocket, applying tension to right side of belt. Ensure timing marks are aligned. 4) Loosen tensioner bolt, allowing tensioner to take up slack in left side of timing belt. Tighten tensioner bolt. Rotate crankshaft 2 turns clockwise. 5) Realign timing marks. Measure timing belt tension using belt tension gauge midway between crankshaft and camshaft sprockets, on side opposite tensioner. For new belt, tension should be 57-84 lbs. (26-38 kg). 6) Install ange on crankshaft sprocket with at side facing timing belt. Install front timing belt cover. Install crankshaft pulley and tighten bolt to specication. See TORQUE SPECIFICATIONS. 7) Install engine support bolts and tighten in sequence. See Fig. 1. To complete installation, reverse removal procedure. Tighten nuts and bolts to speccation. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Support engine oil pan with jack and block of wood. Remove all drive belts. Remove power steering pump with hoses connected, and set aside. Remove engine mount on timing belt end of engine. Remove engine support bracket bolts in sequence. Slowly remove reamer bolt. See Fig. 1. NOTE: Reamer bolt may sometimes become seized on engine support bracket. Remove reamer bolt carefully without damaging threads. 2) Ensure engine is on No. 1 cylinder compression stroke and timing marks are aligned. Remove crankshaft pulley and timing belt covers. See Fig. 2. 3) Rotate crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3. Loosen timing belt tensioner bolt and pivot tensioner counterclockwise. Lock tensioner in retracted position. If reusing timing belt, mark rotation direction on belt. Remove timing belt.

HYUNDAI
3.0L V6 (Cont.)

377

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100) Crankshaft Sprocket Bolt .............................................................. .......... 111-118 (150-160) Timing Belt Tensioner Bolt ............................................................ ................. 16-22 (22-30) Water Pump Bolt Headmark 4 Bolt ........................................................................................... 9-11 (12-15) Headmark 7 Bolt ....................................................................... ................. 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

Courtesy of Hyundai Motor Co.

Fig. 3: Aligning Timing Belt Marks

378

HYUNDAI
3.5L V6 DOHC
Labor Time Belt Part No. CAUTION: Before removing the engine mounting bracket support the engine oil pan with a jack or equivalent. 5) Remove the engine mounting bracket. See Fig. 1. 6) Disconnect the connectors from the timing belt upper cover and remove the upper cover. 7) Remove the drive belt and loosen the 2 alternator mounting nuts (14 mm) and 2 bolts (12 mm) connecting the engine support bracket. 8) Loosen the 5 engine support bracket bolts. 9) Remove the engine support bracket bolt by moving the engine up and down slightly and remove the bracket upward. NOTE: Rotate the crankshaft clockwise and align the timing mark to set the No.1 cylinders piston to TDC (compression stroke). See Fig. 2. At this time, the timing marks of the camshaft sprocket and cylinder head cover should coincide with each other. 10) Remove the auto tensioner. See Fig. 3. NOTE: If you plan to use the timing belt again, mark the rotation direction on the belt so you reinstall it correctly. 11) Unbolt the tensioner to remove the timing belt. Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary.

TIMING BELT APPLICATION Application 3.5L V6 DOHC XG350 2004 ..........................................................


1

4.0 Hours .. ..... T323

Includes Upper and Lower Timing Covers removal and installation.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, inspect timing belt at 60,000 miles, and replace as necessary.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove the wheel of passenger side. 2) Remove the side cover. 3) Remove the engine cover. 4) Disconnect the power steering hose xing on the engine mounting bracket.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components

HYUNDAI
3.5L V6 DOHC (Cont.)

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 rod is aligned with set hole in the cylinder. Insert a set pin through the auto tensioner body and rod. Leave the set pin installed in the auto tensioner. 5) Install auto tensioner to oil pump case. NOTE: In this step, No. 1 piston is in TDC (Compression stroke). CAUTION: Do not insert ngers. 6) Align the timing marks of each sprocket and install the timing belt in this order: Crankshaft sprocket. Idler pulley. Exhaust camshaft sprocket (left). Intake camshaft sprocket (left). Water pump pulley. Intake camshaft sprocket (right). Exhaust camshaft sprocket (right). Tensioner pulley.

Courtesy of Hyundai Motor Co.

Fig. 2: Rotating Crankshaft

Courtesy of Hyundai Motor Co.

Fig. 3: Removing Auto Tensioner

Courtesy of Hyundai Motor Co.

Fig. 4: Aligning Camshaft Timing Marks

380

HYUNDAI
3.5L V6 DOHC (Cont.)

7) After installing the timing belt, reconrm the timing mark. 8) Pull out the set pin of auto tensioner. NOTE: Rotate the crankshaft two rotations clockwise and measure the projected load of auto tensioner in the TDC (#1 piston compression stroke) after 5 minutes. Check for projected length of 3.8-4.5 mm. See Fig. 8. Check again to verify the timing marks of each sprocket are within specied position. 9) Install the engine support bracket. 10) Install the timing belt cover. 11) Install the alternator and drive belt. 12) Install the engine mounting bracket. 13) Install the side cover. 14) Install the wheel of passenger side.

Courtesy of Hyundai Motor Co.

Fig. 7: Camshaft Sprocket Initial Installation

Courtesy of Hyundai Motor Co.

Fig. 8: Checking Timing Belt Tensioner Projected Length

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Hyundai Motor Co.

Fig. 5: Identifying Crankshaft Sprocket Components

Application Ft. Lbs. (N.m) Auto Tensioner Fixed Bolt ............................................................. ................. 15-20 (20-27) Camshaft Sprocket Bolt ................................................................................ 66-81 (90-110) Crankshaft Pulley Bolt ................................................................... ......... 133-140 (180-190) Drive Belt Pulley Bolt .................................................................... ................. 26-41 (35-55) Drive Belt Tensioner Bolt/Nut ........................................................ ................. 33-37 (45-50) Timing Belt Cover Bolt 6 mm ........................................................................................... ..................................... 1 8 mm ........................................................................................... ................. 15-20 (20-27) Timing Belt Idler Pulley Bolt ......................................................... ................. 37-44 (50-60) Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 26-41 (35-55) Timing Belt Tensioner Pulley Bolt ................................................. ................. 32-41 (43-55)
1

Tighten bolts to 89-106 INCH lbs. (10-12 N.m).

Courtesy of Hyundai Motor Co.

Fig. 6: Aligning Crankshaft Sprocket Timing Marks

HYUNDAI & KIA


2.5L V6 DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No.

381

2.5L V6 DOHC Optima 2001 .......................................................... 1 2.4 Hours .. ..... T315 Sonata 1999-01 ..................................................... 2.6 Hours ... ..... T315
1

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles, except in California. For California Sonata models, inspect timing belt at 60,000 miles, and replace as necessary. For California Optima models, inspect timing belt at 60,000 miles and 90,000 miles, and replace belt at 105,000 miles.

REMOVAL & INSTALLATION


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

Fig. 1: Identifying Timing Belt Components & Aligning Belt Timing Marks (this will result in valves touching pistons). If camshaft sprocket is accidentally rotated more than 3 teeth, rotate crankshaft counterclockwise 3 teeth before rotating camshaft sprocket. 3) Compress timing belt auto tensioner, and install set pin to hold in retracted position. Install timing belt auto tensioner to front case. Align timing marks of each sprocket and install timing belt around pulleys and sprockets in the following order: crankshaft sprocket, idler pulley, left intake cam sprocket, water pump pulley, right intake cam sprocket and tensioner pulley. See Fig. 1. 4) Pull set pin from timing belt auto tensioner to apply tension to timing belt. Adjust tension and seat timing belt by rotating crankshaft 2 complete revolutions clockwise. Check auto tension pin extended length. Extended length should be .24-.32 (6.1-8.1 mm). If length is greater than specication, belt is stretched. Install NEW timing belt. Ensure sprocket timing marks are properly aligned. If marks are not properly aligned, repeat installation procedure. 5) Install engine mount bracket and insulator. Install upper and lower timing belt covers. Install all external pulleys. Rotate auto tensioner arm about 14 degrees clockwise, and install serpentine drive belt onto pulleys. See Fig. 2. Release tensioner. Tensioner indicator mark should be between range marks. See Fig. 3. If tensioner indicator is not within range marks, replace serpentine drive belt. Install engine cover.

TIMING BELT
Removal 1) Remove engine trim cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove water pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. 2) Support engine with padded jack, and remove engine mount insulator and bracket in front of timing belt. Rotate engine clockwise to align timing mark so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks line up with marks on upper surface of rocker cover. See Fig. 1. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt auto tensioner. Remove timing belt. Inspection Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Check sprockets and pulleys for wear, cracks or damage. Replace components if necessary. Installation 1) Install idler pulley onto pin spring pressed into water pump boss. Install tensioner arm and at washer to cylinder block. Install pulley on tensioner arm. 2) Before installing timing belt, ensure camshaft and crankshaft timing marks are aligned. See Fig. 1. If timing marks are not aligned, DO NOT turn camshaft sprockets more than 3 teeth in either direction to align

382

HYUNDAI & KIA


2.5L V6 DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 3: Identifying Tensioner Mark Location

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Arm Bolt ............................................................... ................. 26-40 (35-55) Camshaft Sprocket Bolt ................................................................................ 65-80 (90-110) Crankshaft Pulley Bolt ................................................................... ......... 130-138 (180-190) Drive Belt Pulley Bolt .................................................................... ................. 26-40 (35-55) Drive Belt Tensioner Bolt .............................................................. ................. 14-20 (20-27) Timing Belt Assembly Auto Tensioner Fixed Bolt ........................................................... ................. 14-20 (20-27) Auto Tensioner Pulley Bolt .......................................................... ................. 31-40 (43-55) Idler Pulley Bolt ........................................................................... ................. 36-43 (50-60) Water Pump Mounting Bolt ............................................................................. 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Assembly Cover Bolt ................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)

Courtesy of Hyundai Motor Co.

Fig. 2: Identifying Drive Belt Routing & Pulley Locations

HYUNDAI & KIA


2.7L V6 DOHC
TIMING BELT APPLICATION Application 2.7L V6 Optima 2002-04 Santa Fe 2001-04 Sonata 2002-04 Tiburon 2003-04
1 2

383

Labor Time

Belt Part No.

....................................................

2.4 Hours .. ..... T315

..................................................... 2.6 Hours ... ..... T315 .................................................... ....................................................


1

2.4 Hours .. ..... T315 2.7 Hours .. ..... T315

With Air Conditioning, add .2 hours. With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, for all models except Optima, inspect timing belt at 60,000 miles, and replace as necessary. For Optima, inspect timing belt at 60,000 miles and 90,000 miles, and replace at 105,000 miles.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt Components

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: To prevent pistons from contacting valves, DO NOT rotate camshaft or crankshaft with timing belt removed. Removal 1) Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, drive belt idler pulley, drive belt tensioner pulley, and crankshaft pulley. See Fig. 1. 2) Remove timing belt covers. If necessary, support engine using wooden block on jack, and remove engine mounting insulator and engine mount bracket. Rotate crankshaft clockwise until engine is on No. 1 cylinder compression stroke. Ensure camshaft timing marks are aligned. See Fig. 2. 3) If reusing timing belt, mark direction of rotation on belt. Remove timing belt auto tensioner. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulleys for worn bearings. Installation 1) Install idler pulley onto roll pin pressed into water pump boss. Install tensioner arm and at washer onto cylinder block. Install pulley onto tensioner arm. 2) Before installing timing belt, ensure camshaft and crankshaft timing marks are aligned. See Fig. 2. If timing marks are not aligned, DO NOT turn camshaft sprockets more than 3 teeth in either direction to align (this will result in valves touching pistons). If camshaft sprocket is accidentally rotated more than 3 teeth, rotate crankshaft counterclockwise a bit before rotating camshaft sprocket. 3) Compress timing belt auto tensioner, and install set pin to hold in retracted position. Install timing belt auto tensioner onto front case. Align timing marks of each sprocket, and install timing belt around pulleys and sprockets as follows: crankshaft sprocket, idler pulley, left intake camshaft sprocket, water pump pulley, right intake camshaft sprocket and tensioner pulley. See Fig. 2.

Courtesy of Hyundai Motor Co.

Fig. 2: Aligning Timing Belt Marks 4) Pull set pin from timing belt auto tensioner to apply tension to timing belt. Adjust tension and seat timing belt by rotating crankshaft 2 complete revolutions clockwise. Check auto tension pin extended length after 5-minute wait. Extended length should be .24-.32 (6.1-8.1 mm). If length is greater than specication, belt is stretched. Install NEW timing belt. Ensure sprocket timing marks are properly aligned. If marks are not properly aligned, repeat installation procedure. 5) Install engine mount bracktet and mounting insulator, if necessary. Install upper and lower timing belt covers. Install all external pulleys. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Rotate auto tensioner arm about 14 degrees clockwise, and install serpentine drive belt onto pulleys. See Fig. 3. Release tensioner. Tensioner indicator mark should be between range marks. See Fig. 4. If tensioner indicator is not within range marks, replace serpentine drive belt. Install engine cover.

384

HYUNDAI & KIA


2.7L V6 DOHC (Cont.)

Courtesy of Hyundai Motor Co.

Fig. 4: Identifying Tensioner Mark Location

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Fixed Bolt ............................................................. ................. 14-20 (20-27) Camshaft Sprocket Bolt ................................................................................ 65-80 (90-110) Crankshaft Sprocket Bolt .............................................................. ......... 130-138 (180-190) Drive Belt Pulley Bolt .................................................................... ................. 25-40 (35-55) Drive Belt Tensioner Bolt .............................................................. ................. 14-20 (20-27) Engine Mount Bracket Bottom Bolt (3) ........................................ ................. 43-58 (60-80) Engine Mount Bracket Stud Santa Fe, Sonata & Tiburon ....................................................... ................. 22-29 (30-40) Engine Mount Insulator Bolt Optima ......................................................................................................... 65-80 (90-110) Santa Fe, Sonata & Tiburon ....................................................... ................. 29-40 (40-55) Power Steering Pump ................................................................... ................. 12-19 (17-26) Timing Belt Idler Pulley Bolt ......................................................... ................. 36-43 (50-60) Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 25-40 (35-55) Timing Belt Tensioner Pulley Bolt ................................................. ................. 31-40 (43-55) Water Pump Bolt ............................................................................................. 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

Courtesy of Hyundai Motor Co.

Fig. 3: Drive Belt Routing & Pulley Locations

HYUNDAI & KIA


3.0L & 3.5L V6 DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No.

385

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.

3.0L V6 DOHC XG300 2001 ........................................................... 4.0 Hours ... ..... 3.5L V6 DOHC Amanti 2004 ........................................................ ........ N/A ........ ..... Sedona 2002-04 .................................................... 1 3.1 Hours .. ..... Sorento 2003-04 .................................................... 1 3.1 Hours .. ..... XG350 2002-03 ..................................................... 4.0 Hours ... .....
1

T322

TIMING BELT
T323 T323 T323 T323 Removal 1) Disconnect negative battery cable. Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 or 2. NOTE: Rotate crankshaft clockwise and align timing mark to set No. 1 cylinder to TDC on compression stroke. 2) Ensure timing marks of camshaft sprocket and cylinder head cover are matching. See Fig. 5. On Sedona, support engine with jack and remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3. NOTE: If timing belt is to be reused, mark rotational direction on belt for reinstallation reference. 3) Unbolt timing belt tensioner pulley, and remove timing belt. CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the compression stroke and the corresponding camshaft on the same cylinder head is rotated 180 degrees while the timing belt is removed, intake and exhaust valves may contact each other.

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For Sorento, the manufacturer recommends the belt be inspected every 20,000 miles, and replaced at 40,000 miles (severe service) or 60,000 miles (normal service). For all other models, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, inspect timing belt at 60,000 miles, and replace as necessary.

Courtesy of Hyundai Motor Co.

Fig. 1: Exploded View Of Timing Belt & Components (Amanti, Sedona, XG300 & XG350)

386

HYUNDAI & KIA


3.0L & 3.5L V6 DOHC (Cont.)

Courtesy of Kia Motors America, Inc.

Fig. 2: Exploded View Of Timing Belt & Components (Sorento) Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened Black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary. Installation 1) Install timing belt idler pulley to engine support lower bracket. Install tensioner arm, shaft and washer to cylinder block. Tighten tensioner arm bolt to specication. See TORQUE SPECIFICATIONS. CAUTION: Use care to avoid bending crankshaft sensing blade of crank angle sensor. 2) Install crankshaft sprocket and align timing mark. See Fig. 4. Install camshaft sprocket and adjust installation positions as shown. See Figs. 5 and 6. Install auto tensioner to oil pump case. Ensure that auto tensioner set pin is completely assembled. Align timing marks of each sprocket. 3) Install timing belt in this order: crankshaft sprocket, idler pulley, left exhaust camshaft sprocket, left intake camshaft sprocket, water pump pulley, right intake camshaft sprocket, right exhaust camshaft sprocket, and tensioner pulley. 4) Ensure timing marks are correctly aligned. Install tensioner pulley. Pull set pin from auto tensioner. 5) Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Measure projected load of auto tensioner in TDC. Ensure projected length is .15-.18 (3.8-4.5 mm). See Fig. 7. Recheck timing marks at each sprocket to ensure each sprocket is in correct position. If not, repeat installation of timing belt and auto tensioner.
Courtesy of Hyundai Motor Co.

Fig. 3: Removing Auto Tensioner

Courtesy of Hyundai Motor Co.

Fig. 4: Aligning Crankshaft Sprocket Timing Marks

HYUNDAI & KIA


3.0L & 3.5L V6 DOHC (Cont.)

387

Courtesy of Hyundai Motor Co.

Fig. 5: Aligning Camshaft Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Fixed Bolt ............................................................. ................. 15-20 (20-27) Camshaft Sprocket Bolt Amanti, Sedona & Sorento ......................................................... ................. 58-72 (79-98) XG300 & XG350 ......................................................................................... 66-81 (90-110) Crankshaft Pulley Bolt ................................................................... ......... 133-140 (180-190) Drive Belt Pulley Bolt .................................................................... ................. 26-41 (35-55) Drive Belt Tensioner Bolt/Nut Amanti .......................................................................................... ................. 25-40 (34-54) Except Amanti ............................................................................. ................. 33-37 (45-50) Timing Belt Cover Bolt 6-mm ............................................................................................ ..................................... 1 8-mm ............................................................................................ ................. 15-20 (20-27) Timing Belt Tensioner Arm Fixed Bolt .......................................... ................. 26-41 (35-55) Timing Belt Tensioner Pulley Bolt ................................................. ................. 32-41 (43-55) Timing Belt Idler Pulley Bolt ......................................................... ................. 37-44 (50-60)
1

Courtesy of Hyundai Motor Co.

Fig. 6: Camshaft Sprocket Initial Installation

Tighten bolts to 89-106 INCH lbs. (10-12 N.m).

Courtesy of Hyundai Motor Co.

Fig. 7: Checking Timing Belt Tensioner Projected Length

388

INFINITI
3.0L V6 J30
REMOVAL & INSTALLATION
Labor Time Belt Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application

3.0L V6 J30 1993 ........................................................... 4.4 Hours ... ..... T180 1994-97 ..................................................... 4.4 Hours ... ..... T251 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

TIMING BELT
NOTE: Crankshaft position sensor is mounted on front of exhaust camshaft on driver side. Crankshaft position sensor removal may be required for timing belt cover removal. Mark location of crankshaft position sensor before removing to ensure proper installation during reassembly. Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove lower engine cover. Drain radiator and cylinder block. Remove air intake ducts, radiator, drive belts, cooling fan assembly and

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

INFINITI
3.0L V6 J30 (Cont.)
starter. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove coolant inlet and outlets for access to timing belt cover. Remove upper and lower timing belt covers. See Fig. 1. 2) Install a 6 x 16 mm stopper bolt on automatic tensioner to prevent tensioner from pushing outward. See Fig. 2. Rotate engine so No. 1 cylinder is at TDC on compression stroke (No. 1 cylinder is front cylinder on right side when viewed from rear of engine). Ensure timing marks on camshaft sprockets and crankshaft sprocket are aligned. See Fig. 3. Remove bolts and automatic tensioner. Remove timing belt. DO NOT rotate crankshaft or camshafts with timing belt removed, or engine damage may result.

389

Fig. 3. Remove all spark plugs. Install timing belt with White marks on timing belt aligned with timing mark on crankshaft sprocket and camshaft sprockets. Ensure arrow on timing belt points toward front of engine. CAUTION: Ensure stopper bolt is removed before adjusting clearance on automatic tensioner, or stopper bolt and automatic tensioner may be damaged. 2) Remove stopper bolt from automatic tensioner. Using vise, adjust tensioner arm on automatic tensioner so .16 (4.0 mm) clearance exists between pusher and tensioner arm. See Fig. 4. Once correct clearance is obtained, reinstall stopper bolt. Install automatic tensioner on cylinder block with bolts nger 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 specication in sequence. See Fig. 4. See TORQUE SPECIFICATIONS. 4) Rotate crankshaft 120 degrees counterclockwise. Loosen automatic tensioner retaining bolts and nut 1/2 turn. Rotate automatic tensioner back as far as possible. Rotate crankshaft clockwise until No. 1 cylinder is at TDC on compression stroke and all timing marks are aligned. See Fig. 5. 5) Using Push-Pull Gauge (J-38387) or equivalent and Hook (KV10112000) or equivalent, push end of pusher on automatic tensioner inward against timing belt with a force of 13.2 lbs. (6 kg). See Fig. 6. Tighten automatic tensioner retaining nut and then the bolts to specication 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 specication. See Fig. 7. Using belt tension plate and push-pull gauge, check timing belt deection at mid-way distance between sprockets and idler pulleys using 11 lbs. (5 kg) force. See Fig. 7. Timing belt deection should be .24-.28 (6.0-7.0 mm). 7) If timing belt deection is not within specication, repeat steps 3)-6) until proper timing belt deection is obtained. Ensure automatic tensioner retaining nut and bolts are tightened to specication. See TORQUE SPECIFICATIONS. Remove stopper bolt from automatic tensioner. NOTE: If timing belt deection does not meet specication, 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. 9) To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Installing Stopper Bolt On Automatic Tensioner

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Aligning Timing Marks Inspection Inspect timing belt for cracks, worn teeth or oil contamination. Inspect crankshaft sprocket and camshaft sprockets for damaged teeth. Inspect automatic tensioner for signs of oil leakage around the shaft that pushes the pulley outward. Check all idler pulleys for smooth rotation. Replace components if damaged. CAUTION: Timing belt must be installed so White marks on timing belt align with timing mark on crankshaft sprocket and camshaft sprockets. Arrow on timing belt must point toward front of engine. DO NOT bend or twist timing belt during installation. Installation 1) Ensure crankshaft sprocket, camshaft sprockets, idler pulleys and timing belt are dry and clean. Ensure No. 1 cylinder is at TDC of compression stroke and all timing marks are still aligned. See

Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Adjusting Automatic Tensioner Clearance & Identifying Bolt/Nut Tightening Sequence

390

INFINITI
3.0L V6 J30 (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 7: Fabricating Belt Tension Plate & Checking Timing Belt Deection

TORQUE SPECIFICATIONS
Courtesy of Nissan Motor Co., U.S.A.

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt/Nut ........................................................ ................. 12-15 (16-20) Camshaft Sprocket Bolt Exhaust .......................................................................................................... 11-14 (15-19) Intake ........................................................................................... ............. 91-97 (123-132) Crankshaft Position Sensor Brackets ........................................... ................. 12-15 (16-20) Crankshaft Pulley Bolt ................................................................... ......... 159-174 (216-236) Engine Mount-To-Frame Nut ......................................................... ................. 41-49 (56-66) Idler Pulley Nut .............................................................................. ................. 32-43 (45-58) Water Pump Bolt ........................................................................... ................. 12-15 (16-20) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt ................................................................................. Timing Belt Cover Bolt Rear Cover Bolt ........................................................................................................ Upper & Lower .......................................................................................................... Valve Cover Bolt/Screw Exhaust Camshaft Cover .......................................................................................... Intake Camshaft Cover ............................................................................................. 44 (5) 53 (6) 27 (3) 71 (8) 27 (3)

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Nissan Motor Co., U.S.A.

Fig. 6: Adjusting Automatic Timing Belt Tensioner

INFINITI
3.0L V6 M30
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

391

3.0L V6 M30 1990-92 ............................... 4.0 Hours ... .. TCK104 .. ..... T104 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

2) Remove A/C drive belt idler bracket. Disconnect coolant inlet hose from thermostat housing. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove front upper and lower timing belt covers. See Fig. 1. 3) Temporarily install crankshaft pulley retaining bolt. Using crankshaft pulley retaining bolt, rotate crankshaft until No. 1 cylinder is at TDC on compression stroke and all timing marks are aligned See Fig. 2. Loosen timing belt tensioner retaining nut. Rotate timing belt tensioner to release timing belt tension. Remove timing belt. NOTE: No. 1 cylinder is front cylinder on left when viewed from front of engine. CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed, or engine damage may result. Inspection Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure timing belt tensioner rotates smoothly. Inspect tensioner spring for damage. Replace components if damaged. Installation 1) Ensure No. 1 cylinder is TDC on compression stroke and all timing marks are aligned. See Fig. 2. Install timing belt tensioner and tensioner spring (if removed). If tensioner spring stud was removed from cylinder block, apply thread sealant to threads before installing. 2) Rotate timing belt tensioner fully outward (away from timing belt area), and temporarily tighten retaining nut. Align White marks on timing belt with timing marks on camshaft and crankshaft sprocket, and install timing belt.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine covers. Drain cooling system. Remove radiator, cooling fan and accessory drive belts. Remove water pump pulley, spark plugs and distributor cover. Remove fresh air tube from rocker arm cover.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

392

INFINITI
3.0L V6 M30 (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks & Checking Belt Tension CAUTION: Install timing belt with arrow pointing toward timing belt cover. With timing belt installed, 40 teeth should be between timing marks on right and left camshafts, and 43 teeth between timing mark on left camshaft sprocket and timing mark on crankshaft sprocket. See Fig. 2. 3) Using an Allen wrench, hold tension on timing belt tensioner and loosen retaining nut. Rotate timing belt tensioner clockwise 70-80 degrees, and tighten retaining nut. Rotate crankshaft clockwise 2 full revolutions, and realign timing marks so No. 1 cylinder is at TDC on compression stroke. Apply 22 lbs. (10 kg) of pressure on timing belt at midway point between timing belt tensioner and camshaft sprocket. See Fig. 1. 4) Loosen timing belt tensioner retaining nut while maintaining pressure on timing belt tensioner using an Allen wrench. Insert a .0138 (.350 mm) thick and 1/2 wide feeler gauge between timing belt tensioner and timing belt. Perform rst 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 specication. See TORQUE SPECIFICATIONS. 6) Rotate crankshaft clockwise and remove feeler gauge. Rotate crankshaft clockwise 2 full revolutions, and realign timing marks so No. 1 cylinder is at TDC on compression stroke. Timing belt deection 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 specication. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension.
Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Checking Timing Belt Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Locating Plate Bolt ....................................................... ................. 58-65 (79-88) Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88) Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133) Crossmember-To-Body Bolt .......................................................... ................. 32-41 (43-56) Timing Belt Tensioner Nut ............................................................ ................. 32-43 (43-58) Water Pump Bolt ........................................................................... ................. 12-15 (16-20) INCH Lbs. (N.m) Rocker Arm Cover Bolt ................................................................. ....................... 9-27 (1-3) Timing Belt Cover Bolt .................................................................. ..................... 27-44 (3-5)

INFINITI, MERCURY & NISSAN


3.3L V6 SOHC
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

393

3.3L V6 VG33E & VG33ER (SOHC) Frontier 1999-04 .............................. 1 3.1 Hours .. .. TCK249 .. ..... Pathnder 1996-00 .............................. 1 3.3 Hours .. .. TCK249 .. ..... QX4 1997-00 ............................... 3.9 Hours ... .. TCK249 .. ..... Quest 1999-02 .............................. 1 2.6 Hours .. .. TCK249 .. ..... Villager 1999-02 ............................... 2.6 Hours ... ...... ..... ...... ..... Xterra 2000-04 .............................. 1 3.1 Hours .. .. TCK249 .. .....
1

T249 T249 T249 T249 T249 T249


Courtesy of Nissan Motor Co., U.S.A.

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

Fig. 1: Setting Crankshaft To TDC NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Frontier, Pathnder, QX4 & Xterra) 1) Disconnect negative battery cable. Remove the engine undercover. Drain coolant and remove the radiator. Remove engine cooling fan and water pump pulley. Remove accessory drive belts. Remove spark plugs. 2) Remove distributor protector. Remove A/C compressor drive belt idler bracket. Remove fresh air intake tube from rocker cover. Remove thermostat housing hose. 3) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. See Fig. 1. Remove crankshaft pulley bolt and remove crankshaft pulley. Remove front upper and lower timing belt covers. See Fig. 2. 4) Align punch mark on left camshaft sprocket with punch mark on timing belt upper rear cover. Align punch mark on crankshaft sprocket with notch on oil pump housing. See Fig. 3. Install crankshaft pulley bolt so that crankshaft can be rotated. 5) Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and remove timing belt. Inspection (Frontier, Pathnder, QX4 & Xterra) Check timing belt for cracks and broken or worn teeth. Check belt tensioner for smooth turning. Check condition of tensioner spring. Replace parts as necessary. Installation (Frontier, Pathnder, QX4 & Xterra) 1) Install timing belt when engine is cold. Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft sprocket mark should align with mark on rear cover. See Fig. 5. If removed, install timing belt tensioner and tensioner spring. NOTE: If stud for tensioner spring is removed, apply thread sealant to stud threads before installing. 2) Turn tensioner clockwise fully outward with hexagon wrench, and temporarily tighten lock nut. Align White lines on timing belt with punch marks on camshaft sprockets and crankshaft sprocket. See Fig. 6. Point

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Exploded View Of Timing Belt & Components arrow on timing belt toward front belt cover. There should be 40 teeth between left and right camshaft sprockets, and 43 teeth between left camshaft sprocket and crankshaft sprocket. 3) If engine was overhauled or reassembled (rocker covers removed), go to step 6). If only the timing belt was replaced, go to next step. 4) Loosen tensioner lock nut. Using hex wrench, turn tensioner clockwise and counterclockwise at least 2 times. Tighten tensioner lock nut. Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1 cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to belt (downward direction) midway between camshaft sprockets. Belt deection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension. 5) Install lower and upper belt covers. Install crankshaft pulley. Tighten bolt to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING. Adjust drive belts to proper tension. 6) Loosen rocker shaft bolts to relieve belt tension caused by camshafts. Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock nut. Rotate crankshaft clockwise at least 2 revolutions. 7) Slowly return cylinder No. 1 to TDC of compression stroke. Using Push/Pull Gauge (J-38387), apply 22 lbs. (10 kg) of pressure to timing belt between right camshaft sprocket and tensioner. Hold tensioner in position with Allen wrench, and loosen tensioner lock nut.

394

INFINITI, MERCURY & NISSAN


3.3L V6 SOHC (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 5: Positioning Camshaft & Crankshaft Sprockets

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Aligning Camshaft & Crankshaft Punch Marks

Courtesy of Nissan Motor Co., U.S.A.

Fig. 6: Installing Timing Belt


Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Loosening Timing Belt Tensioner Nut 8) Place a .0206 (.5 mm) feeler gauge under tensioner pulley between pulley and timing belt, and rotate crankshaft clockwise until feeler gauge is centered between tensioner pulley and timing belt (timing belt will move about 2.5 teeth). See Fig. 7. Tighten tensioner lock nut to specication. See TORQUE SPECIFICATIONS. 9) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions, then slowly set cylinder No. 1 at TDC of compression stroke. While applying 22 lbs. (10 kg) of pressure, measure timing belt deection halfway between camshaft sprockets. If deection is not .51-.59 (13-15 mm), repeat steps 6)-8). To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING. Adjust drive belts to proper tension. Removal (Quest & Villager) 1) Raise and support vehicle. Remove the engine undercover. Remove right side wheel and engine side cover. Drain coolant from radiator. Remove accessory drive belts. 2) Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. See Fig. 1. Remove crankshaft pulley bolt, and remove crankshaft pulley using a gear puller.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 7: Adjusting Timing Belt 3) Remove upper radiator hose and water inlet hose from timing belt end of engine. Remove A/C compressor drive belt idler bracket. Remove water pump pulley. Remove breather pipe from timing belt front upper cover. Remove front upper and lower belt covers. See Fig. 2. 4) Align punch mark on left camshaft sprocket with punch mark on timing belt upper rear cover. Align punch mark on crankshaft sprocket with notch on oil pump housing. See Fig. 3. Temporarily install crankshaft pulley bolt so that crankshaft can be rotated. 5) Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and remove timing belt.

INFINITI, MERCURY & NISSAN


3.3L V6 SOHC (Cont.)
NOTE: After removing timing belt, DO NOT turn crankshaft or camshaft separately, or valves will strike pistons. Inspection (Quest & Villager) Check timing belt for cracks and broken or worn teeth. Check belt tensioner for smooth turning. Check condition of tensioner spring. Replace parts as necessary. Installation (Quest & Villager) 1) Install timing belt when engine is cold. Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft sprocket mark should align with mark on rear cover. See Fig. 5. If removed, install timing belt tensioner and tensioner spring. NOTE: If stud for tensioner spring is removed, apply thread sealant to stud threads before installing. 2) Turn tensioner clockwise fully outward with hexagon wrench, and temporarily tighten lock nut. Align white lines on timing belt with punch marks on camshaft sprockets and crankshaft sprocket. See Fig. 6. Point arrow on timing belt toward front belt cover. There should be 40 teeth between left and right camshaft sprockets, and 43 teeth between left camshaft sprocket and crankshaft sprocket. 3) Loosen tensioner lock nut. Using hex wrench, turn tensioner clockwise and counterclockwise at least 2 times. Tighten tensioner lock nut. Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1 cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to belt (downward direction) midway between camshaft sprockets. Belt deection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension. 4) Install lower and upper belt covers. Install crankshaft pulley. Tighten bolt to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING. Adjust drive belts to proper tension.

395

Courtesy of Nissan Motor Co., U.S.A.

Fig. 9: Locating Heater Core Inlet Hose (Frontier, Pathnder, QX4 & Xterra) lbs. (8-12 N.m). If removed, apply sealant to threads of cylinder block drain plugs, and tighten to 25-33 ft. lbs. (34-44 N.m). Install reservoir tank, if necessary. Tighten air relief plug to 62-71 INCH lbs. (7-8 N.m). See Fig. 8. Reattach upper radiator hose at engine side. 2) Set vehicle heater controls to full HOT and heater ON positions. Turn ignition on (engine off) to activate heater mode. Install Coolant Rell Tool (J-45695) by installing radiator cap adapter onto radiator neck opening. Attach gauge body assembly with rell tube and venturi assembly to radiator cap adapter. See Fig. 10. CAUTION: Compressed air supply must be equipped with an air dryer. 3) Insert rell hose into coolant mixture container that is placed at oor level. Ensure ball valve is in closed position. Install air hose to venturi assembly, and adjust air pressure to 80-120 psi (5.6-8.4 kg/cm2). 4) The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process, open ball valve on rell hose slightly. Coolant will be visible rising in rell hose. Once rell hose is full of coolant, close the ball valve. This will purge any air trapped in rell hose. 5) Continue to draw vacuum until gauge reaches 28 inches of vacuum. In high altitude locations, the gauge may not reach 28 inches. See VACUUM GAUGE SPECIFICATIONS table. VACUUM GAUGE SPECIFICATIONS Altitude Above Sea Level Vacuum Gauge Reading 0-328 Ft. (0-100 m) ....................................... ....................................................... 28 Inches 984 Ft. (300 m) ............................................. ....................................................... 27 Inches 1641 Ft. (500 m) ........................................... ....................................................... 26 Inches 3281 Ft. (1000 m) ........................................................................................... 24-25 Inches 6) When vacuum gauge has reached specied amount, disconnect air hose and wait 20 seconds to see if the system loses any vacuum. If vacuum level drops, repair system as necessary and repeat steps 3)-5). Recheck for leaks. CAUTION: DO NOT allow coolant container to get too low when lling, or air will be drawn into cooling system. 7) Place coolant container (with rell hose inserted) at same level as top of radiator. Open ball valve on rell hose so the coolant will be drawn up to ll 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 specied level. See COOLING SYSTEM SPECIFICATIONS table. Run engine to warm up the cooling system, and top up as necessary before installing radiator cap.

COOLING SYSTEM BLEEDING


Frontier, Pathnder, QX4 & Xterra (1999-02) 1) If vehicle is equipped with manual A/C, move temperature control lever to full HOT position. If vehicle is equipped with automatic A/C, turn ignition on. Remove air relief plug on intake manifold collector. See Fig. 8. On Pathnder, remove heater hose from heater core inlet. See Fig. 9. On all models, ll radiator slowly until coolant starts to drip from air relief plug. Tighten air relief plug to 61-69 INCH lbs. (7-8 N.m). On Pathnder, install heater hose to heater core inlet. 2) On all models, ll radiator and coolant reservoir tank to MAX mark. Install and tighten radiator cap. Start and run engine until warm. Run engine at 3000 RPM for at least 10 seconds (repeat 2-3 times). Stop engine and allow it to cool. Rell radiator and coolant reservoir as necessary. 3) Repeat previous step at least 3 times with temperature control lever at several different positions between full COLD and full HOT positions. System is full when water noise is no longer heard at heater core and coolant level no longer drops.

Courtesy of Nissan Motor Co., U.S.A.

COOLING SYSTEM SPECIFICATIONS Application Specication Engine Coolant Capacity (Without Reservoir Tank) .................... ...... 10 3/4 Qts. (10.15L) Reservoir Tank ................................................................................................... 7/8 Qt. (0.8)

Fig. 8: Locating Air Relief Plug (Frontier, Pathnder, QX4 & Xterra) Frontier & Xterra (2003-04) 1) Ensure radiator is completely empty of coolant and water. Install radiator drain plug, and tighten to 71-106 INCH

396

INFINITI, MERCURY & NISSAN


3.3L V6 SOHC (Cont.)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 11: Holding Negative Pressure Relief Valve Open (Quest & Villager)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Nissan Motor Co., U.S.A.

Fig. 10: Installing Coolant Rell Tool (J-45695) Quest & Villager 1) Install radiator drain plug. If removed, apply sealant to threads of cylinder block drain plug and tighten to 25-33 ft. lbs. (34-44 N.m). Slowly add coolant through radiator ller neck allowing several minutes for air to escape. Add uid until ller neck is full. 2) Continue adding coolant while gently moving upper radiator hose up and down until coolant no longer lowers in ller neck. Place wire under radiator ller cap negative pressure relief valve. See Fig. 11. Install radiator cap. Disconnect coolant reservoir hose from radiator neck overow port. 3) Attach clear hose to modied one gallon bottle. Using locking pliers, clamp hose. Fill bottle with coolant and hang it from hood latch. Remove locking pliers and let coolant ow 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 specication. 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 airow to head/feet position. On vehicles with automatic heater, set temperature controls to 90F and fan speed to HIGH. 6) Remove locking pliers. Start and run engine at 1500 RPM, until cooling fan turns on. 7) On all models, stop engine. Fill coolant reservoir to MAX mark. Remove modied one gallon bottle. Lower vehicle. Let engine cool down. Remove radiator cap and remove wire from negative pressure valve. Fill radiator as necessary and reinstall radiator cap. Fill reservoir as necessary and install reservoir cap. Check for leaks.

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88) Crankshaft Pulley Bolt ............................................................................. 141-156 (191-211) Spark Plugs ................................................................................... ................. 14-22 (20-29) Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58) Water Pump Bolt ........................................................................... ................. 12-15 (16-20) Wheel Lug Nut Quest ........................................................................................................... 72-87 (98-118) INCH Lbs. (N.m) Cooling Fan & Water Pump Pulley Bolts ..................................... ................... 52-89 (6-10) Radiator Mounting Bolts ................................................................ ............... 34-42 (3.8-4.8) Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

ISUZU
1.6L & 1.8L 4-Cylinder Gasoline
TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC I-Mark 1989 .................................... Impulse 1990-92 Non-Turbo ............ 1991-92 Turbo .................... Stylus 1991 .................................... 1.6L 4-Cyl. SOHC Stylus 1991-93 ............................... 1.8L 4-Cyl. SOHC Impulse 1992 .................................... Stylus 1992-93 ...............................
1

397

Labor Time

Component Belt Kit No. Part No.

2.0 Hours ... ...... ..... ...... ..... T169 2.0 Hours ... ...... ..... ...... ..... T169 2.4 Hours ... ...... ..... ...... ..... T169 2.0 Hours ... ...... ..... ...... ..... T169

1.5 Hours ... .. TCK177 .. ..... T177

2.4 Hours ... ...... ..... ...... ..... T205 2.4 Hours ... ...... ..... ...... ..... T205

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING. Fig. 1: Aligning Timing Marks (DOHC)

Courtesy of Isuzu Motor Co.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


CAUTION: The 1991-93 1.6L (SOHC) engine used in the Stylus is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Isuzu Motor Co.

TIMING BELT
Removal (DOHC) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove upper timing belt cover. Support engine. Remove engine mounting bracket located at timing belt cover. Rotate crankshaft and position No. 1 cylinder at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 timing mark on timing belt cover. 2) Ensure timing marks on camshaft sprockets are aligned with cylinder head surface. See Fig. 1. Disconnect front exhaust pipe. Remove bolts attaching torque rod bracket to cylinder block. Remove bolt attaching torque rod to vehicle frame. Remove torque rod and bracket as an assembly. 3) Remove engine stiffener brace. See Fig. 2. Remove ywheel dust cover. Hold ywheel while removing crankshaft pulley bolt. Remove crankshaft pulley. Remove lower timing belt cover. 4) Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 1. Loosen tensioner pulley bolt 1/2 turn. Rotate tensioner pulley clockwise. Mark timing belt direction of rotation if reusing old belt. Remove timing belt. Inspection (DOHC) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure tensioner pulley and idler pulley rotate freely. Replace components if damaged. Installation (DOHC) 1) Rotate camshafts so timing marks align with cylinder head surface. Install 6 mm bolts in lock bolt holes to secure camshafts. Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 1. Install timing belt in the following order: over crankshaft sprocket, water pump, idler pulley, exhaust camshaft, intake camshaft and belt tensioner. Ensure no slack exists in belt. See Fig. 3.

Fig. 2: Removing Engine Stiffener Brace 2) Loosen bolt and allow tensioner pulley to apply tension on timing belt. Hold tensioner pulley, and tighten tensioner pulley bolt. CAUTION: On new timing belts, push tensioner pulley sightly inward to apply more pressure on timing belt. On used timing belts, allow only spring tension to be applied to timing belt. 3) Rotate crankshaft 2 revolutions in direction of engine rotation. Ensure all timing marks align. Rotate crankshaft 60 degrees. Measure timing belt deection at midpoint between camshaft sprockets. Ensure timing belt defection is within specication. See TIMING BELT DEFLECTION SPECIFICATIONS table. If belt deection is not within specication, repeat the last two steps. CAUTION: Ensure timing marks align after belt adjustment. 4) To install remaining components, reverse removal procedure. See Fig. 4. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. TIMING BELT DEFLECTION SPECIFICATIONS Application In. (mm) DOHC New Belt ................................................................................................... .28-.33 (7.1-8.4) Used Belt ................................................................................................ .35-.41 (8.9-10.4) SOHC New Or Used Belt ...................................................................................... .63-.79 (16-20)

398

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

Courtesy of Isuzu Motor Co. Courtesy of Isuzu Motor Co.

Fig. 5: Aligning Timing Marks (SOHC) Installation (SOHC) 1) Rotate camshaft so timing mark aligns with cylinder head surface. Ensure dowel pin on camshaft pulley is in the up position. See Fig. 5. Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 5. Install timing belt in the following order: over crankshaft sprocket, camshaft pulley, water pump and belt tensioner. See Fig. 6. 2) Insert a hex wrench into belt tensioner. Rotate tensioner pulley counterclockwise to tension belt. Hold tensioner pulley, and tighten pulley bolt. Rotate crankshaft back to approximately 50 degrees BTDC and back to TDC for No. 4 cylinder. Ensure all timing marks align. Measure timing belt deection. See Fig. 7. Ensure timing belt defection is within specication. See TIMING BELT DEFLECTION SPECIFICATIONS table. If belt deection is not within specication, repeat this step. 3) To install remaining components, reverse removal procedure. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Fig. 3: Routing Timing Belt (DOHC)

Courtesy of Isuzu Motor Co.

Fig. 4: Tightening Sequence For Valve Cover Bolts (DOHC) Removal (SOHC) 1) Disconnect negative battery cable. Support engine. Remove right side engine mount. Remove alternator and power steering pump drive belts. Ensure engine is supported. Remove engine mounting bracket located at timing belt cover. 2) Remove crankshaft pulley bolts. Remove crankshaft pulley from crankshaft pulley hub. Remove timing belt cover. Rotate crankshaft and position No. 4 cylinder at TDC of compression stroke. Ensure timing mark on camshaft pulley aligns with cylinder head. See Fig. 5. 3) Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 5. Loosen tensioner pulley bolt. Rotate tensioner pulley to loosen timing belt tension. Mark timing belt direction of rotation if reusing belt. Remove timing belt. Inspection (SOHC) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure tensioner pulley rotates freely. Replace components if damaged.
Courtesy of Isuzu Motor Co.

Fig. 6: Routing Timing Belt (SOHC)

ISUZU
1.6L & 1.8L 4-Cylinder Gasoline (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

399

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 43 (58) Crankshaft Pulley Bolt DOHC .................................................................................................................. 109 (148) SOHC ....................................................................................................................... 62 (84) Idler Pulley Bolt ......................................................................................................... 31 (42) Left Engine Mount Bolt ............................................................................................. 51 (69) Power Steering Pump Bolt ........................................................... ............................ 11 (15) Right Engine Mount Bolt ......................................................................................... 89 (121) Right Engine Mount Nut ........................................................................................... 37 (50) Right Engine Mount Through-Bolt ............................................................................ 51 (69) Tensioner Pulley Bolt DOHC ...................................................................................................................... 31 (42) SOHC ....................................................................................................................... 37 (50) Water Pump Bolt ....................................................................................................... 17 (23) Wheel Lug Nut ........................................................................................................ 87 (118)
Courtesy of Isuzu Motor Co.

INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10)

Fig. 7: Checking Timing Belt Tension (SOHC)

400

ISUZU
1.8L 4-Cylinder Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Diesel I-Mark 1981-84 ....................................................
1

3.1 Hours .. ..... T076

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Fig. 2: Camshaft Fixing Plate

Courtesy of Isuzu Motor Co.

TIMING BELT & VALVE TIMING


Removal 1) Disconnect negative battery cable. Remove lower engine cover. Drain engine coolant. Remove fan shroud, fan, drive belt and pulley. Remove crankshaft pulley. Remove upper timing belt cover. Remove coolant by-pass hose. 2) With piston of No. 1 cylinder at TDC of compression stroke, check that timing marks on injection pump sprocket and front plate are aligned. Lock sprocket in place by inserting a bolt through sprocket and into block. See Fig. 1. 3) Remove air cleaner and PCV valve hose. Remove valve cover. Loosen adjusting screws on rocker arms to relieve tension on camshaft. Lock camshaft in place by installing Fixing Plate (J-29761), or equivalent, in slot at rear of camshaft. See Fig. 2. 4) Ensure that No. 1 piston is still at TDC, then remove crankshaft pulley. Remove lower timing belt cover. Remove timing belt holder. See Fig. 3. Remove tension spring located behind front plate. Loosen tensioner pulley and pivot bolts. Remove timing belt.

Courtesy of Isuzu Motor Co.

Fig. 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 xing 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 xing plate ts smoothly into slot at rear of camshaft, then remove xing plate. Loosen tensioner pulley pivot bolts, and take up timing belt slack. Tighten tensioner pulley center bolt, then tighten pivot bolts. Using Tension Gauge (J-29771) or equivalent, check for 47-64 lbs. (21-29 kg) tension between camshaft and injection pump sprockets. 5) Remove crankshaft pulley and install timing belt holder. Ensure that timing belt holder does not rub against timing belt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Injection Pump Timing Marks Installation 1) Remove camshaft sprocket center bolt. Using Puller (J-29801) or equivalent, remove camshaft sprocket. Install sprocket on camshaft. Lightly tighten center bolt so that sprocket can be turned smoothly by hand. Starting at crankshaft sprocket and working in a counterclockwise direction, engage new timing belt over each sprocket and pulley. Check that belt is properly engaged on all sprockets and pulleys. See Fig. 4.

ISUZU
1.8L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

401

Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................................................ ................. 43-50 (58-68) Crankshaft Pulley ............................................................................................ 11-18 (15-24) Injection Pump Timing Pulley ....................................................... ................. 42-52 (57-71) Tensioner Pulley Center Bolt .................................................................................. ................. 47-64 (64-87) Pivot Bolt ....................................................................................................... 11-18 (15-24)

Courtesy of Isuzu Motor Co.

Fig. 4: Identifying Timing Belt Installation Sequence

Courtesy of Isuzu Motor Co.

Fig. 5: Locating Tensioner Pulley

402

ISUZU
2.0L, 2.3L & 2.6L 4-Cylinder
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

2.0L 4-Cyl. Turbo Impulse 1985-89 A/T ................................. ... M/T ................................. ... 2.3L 4-Cyl. Amigo 1989-93 A/T ................................. ... M/T ................................. ... Impulse 1988-89 A/T ................................. ... M/T ................................. ... Pickup 1986-95 A/T ................................. ... M/T ................................. ... Trooper II 1986-87 A/T ................................. ... M/T ................................. ... 2.6L 4-Cyl. Amigo 1989-94 A/T ................................. ... M/T ................................. ... Pickup 1988-95 A/T ................................. ... M/T ................................. ... Rodeo 1991-97 A/T ................................. ... M/T ................................. ... Trooper 1990-91 A/T ................................. ... M/T ................................. ... Trooper II 1988-89 A/T ................................. ... M/T ................................. ...
1

1 1

3.6 Hrs. ... ...... ..... ...... ..... T121 3.4 Hrs. ... ...... ..... ...... ..... T121

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.

1 1

1.9 Hrs. ... .. TCK122 .. ..... T122 1.6 Hrs. ... .. TCK122 .. ..... T122

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction. Removal 1) Disconnect negative battery cable. Remove all necessary air ducts. Position No. 1 cylinder at TDC of compression stroke. Align timing marks. See Fig. 1. Remove fan and fan shroud. Remove accessory drive belts. Remove water pump pulley. If necessary, remove radiator and splash guard. 2) Prevent engine from rotating, and remove crankshaft timing pulley. Remove upper and lower timing belt covers. See Fig. 2. Remove spring from tension pulley. Loosen adjusting bolt and move pulley toward water pump. Remove timing belt. CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft, or damage may result.

3.6 Hrs. ... .. TCK122 .. ..... T122 1 3.4 Hrs. ... .. TCK122 .. ..... T122
1 1

1.9 Hrs. ... .. TCK122 .. ..... T122 1.6 Hrs. ... .. TCK122 .. ..... T122

1 1

1.9 Hrs. ... .. TCK122 .. ..... T122 1.6 Hrs. ... .. TCK122 .. ..... T122

1 1

1.9 Hrs. ... .. TCK147 .. ..... T147 1.6 Hrs. ... .. TCK147 .. ..... T147

1 1

1.9 Hrs. ... .. TCK147 .. ..... T147 1.6 Hrs. ... .. TCK147 .. ..... T147

1 1

1.9 Hrs. ... .. TCK147 .. ..... T147 1.6 Hrs. ... .. TCK147 .. ..... T147

1 1

1.9 Hrs. ... .. TCK147 .. ..... T147 1.6 Hrs. ... .. TCK147 .. ..... T147

1 1

1.9 Hrs. ... .. TCK147 .. ..... T147 1.6 Hrs. ... .. TCK147 .. ..... T147

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Marks

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

403

Courtesy of Isuzu Motor Co.

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

404

ISUZU
2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 43 (58) Crankshaft Pulley Bolt ............................................................................................. 90 (122) Front Cover ............................................................................................................... 14 (19) Tensioner Pulley Bolts ......................................................................................................................... 18 (24) Nut ........................................................................................................................... 10 (14) Water Pump ............................................................................................................... 14 (19)
Courtesy of Isuzu Motor Co.

INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 53 (6)

Fig. 3: Installing Belt Guide

ISUZU
2.2L 4-Cylinder Diesel
TIMING BELT APPLICATION Application
1

405

Labor Time

Belt Part No.

2.2L 4-Cyl. Diesel LUV (Chevrolet) 1981-82 ..................................................... Pickup (Isuzu) 1983-85 ..................................................... PUP 1981-87 ..................................................... S10 & S15 Pickup (Chevrolet/GMC) 1983-85 ..................................................... Trooper II 1984-87 .....................................................
1

2.7 Hours ... ..... T075 2.7 Hours ... ..... T075 2.7 Hours ... ..... T075 1.0 Hours ... ..... T075 2.7 Hours ... ..... T075
Courtesy of Isuzu Motor Co.

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. Fig. 2: Removing Tension Spring

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove battery. Remove fan, fan shroud, top radiator hose and drive belts. Remove 4 crankshaft pulley bolts and crankshaft pulley. Remove timing belt covers. See Fig. 1. 2) Remove tension spring. See Fig. 2. Position No. 1 cylinder at TDC of compression stroke. Ensure injection pump and camshaft sprocket timing marks are aligned. See Fig. 3. Remove injection pump pulley ange bolts, and remove ange. Remove tensioner spring without using excess force on spring. Remove tension pulley nut and tensioner assembly. Remove timing belt.

Courtesy of Isuzu Motor Co.

Fig. 3: Identifying Timing Belt Sprocket Alignment Installation 1) Ensure that timing marks on injection pump, camshaft sprockets, crankshaft pulley and timing pointer are aligned. See Fig. 4. Install timing belt over crankshaft sprocket, camshaft sprocket and injection pump sprocket. 2) Install tensioner assembly so that end of tensioner is in contact with 2 pins on timing pulley housing. See Fig. 5. Hand tighten nut. Install tension spring. Tighten nut to 22-36 ft. lbs. (30-49 N.m). Turn crankshaft 2 complete revolutions in normal direction of rotation, then turn crankshaft 90 degrees past TDC. Loosen tensioner nut completely, and allow tensioner to take up slack. Tighten nut. 3) Install and tighten injection pump pulley ange. Ensure hole in ange lines up with triangular timing mark on pump sprocket. See Fig. 6. Turn crankshaft 2 more turns, bringing No. 1 cylinder to TDC on compression stroke. Check timing mark alignment. Check timing belt tension with Tension Gauge (J-29771) or equivalent. Tension should be 33-55 lbs. (15-25 kg). Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of Isuzu Motor Co.

Fig. 1: Removing Timing Belt Covers

406

ISUZU
2.2L 4-Cylinder Diesel (Cont.)

Courtesy of Isuzu Motor Co. Courtesy of Isuzu Motor Co.

Fig. 6: Aligning Injection Pump Timing Marks

Fig. 4: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................................ 72-87 (98-118) Crankshaft Sprocket Bolt .............................................................. ......... 124-151 (168-205) Injection Pump Timing Pulley Bolt ................................................ ................. 42-52 (57-71) Tension Spring Nut ........................................................................ ................. 22-36 (30-49) Timing Belt Tensioner Bolts .......................................................... ............. 79-94 (107-127)

Courtesy of Isuzu Motor Co.

Fig. 5: Installing Timing Belt Tensioner

ISUZU
2.2L 4-Cylinder DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No.

407

2.2L 4-Cyl. DOHC Amigo 1998-00 Auto. Trans. ........................................... 1 1.9 Hours .. ..... Man. Trans. ............................................ 1 1.6 Hours .. ..... Rodeo 1998-03 Auto. Trans. ........................................... 1 1.9 Hours .. ..... Man. Trans. ............................................ 1 1.6 Hours .. ..... Rodeo Sport 2001-03 Auto. Trans. ............................................ 1.9 Hours ... ..... Man. Trans. ............................................. 1.6 Hours ... .....
1

T305 T305

T305 T305

T305 T305

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.
Courtesy of Isuzu Motor Co.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998 vehicles, the manufacturer recommends the belt be replaced every 75,000 miles. For 1999-00 vehicles, the manufacturer recommends the belt be replaced every 100,000 miles for normal service, or 75,000 miles for severe service. For 2001-03 vehicles, the manufacturer recommends the belt be replaced every 75,000 miles for normal service, or 60,000 miles for severe service.

Fig. 1: Aligning Timing Marks 4) Remove camshaft locking tool. Turn crankshaft 2 turns in normal direction of rotation until No. 1 cylinder is at TDC. Check alignment of timing belt tensioner pointer. If marks do NOT align, repeat timing belt tensioning procedure. 5) Install timing belt cover. Install engine harness cover. Connect engine harness electrical connectors. To complete installation, reverse removal procedure.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove serpentine drive belt. Remove engine wiring harness cover, and disconnect 3 connectors from left rear side of engine compartment. 2) Remove 4 crankshaft pulley bolts, and remove pulley from crankshaft. It is NOT necessary to remove the crankshaft center bolt. Remove engine harness cover from front of engine. 3) Remove timing belt cover. If reusing old belt, place mark on belt to indicate direction of belt rotation. 4) Rotate crankshaft clockwise so camshaft and crankshaft timing marks are aligned. See Fig. 1. Remove timing belt tensioner pulley bolt, and remove timing belt tensioner. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearings. NOTE: Do not turn crankshaft in a counterclockwise direction, or tensioner setting will not be correct. Installation 1) Install timing belt tensioner, and temporarily tighten bolt. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Place Camshaft Locking Tool (J-43037) between camshafts to prevent movement. 2) Install timing belt on engine. If reusing old belt, install belt in original position. Ensure there is no slack in belt. Loosen tensioner pulley center bolt. Move timing belt tensioner toward belt. NOTE: Adjust timing belt tension with engine cold. 3) To tension timing belt, align timing belt tensioner arrow in correct position for new or used belt. See Fig. 2. Tighten timing belt tensioner bolt to specication. See TORQUE SPECIFICATIONS.
Courtesy of Isuzu Motor Co.

Fig. 2: Adjusting Timing Belt Tension

408

ISUZU
2.2L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1 Step 1 ...................................................................................................................... 36 (50) Step 2 ........................................................................................................... Additional 60 Step 3 (1998-00 Engines Only) ................................................................... Additional 15 Crankshaft Pulley-To-Sprocket Bolt .......................................................................... 14 (20) Crankshaft Sprocket Center Bolt 1 Step 1 .................................................................................................................... 94 (130) Step 2 ........................................................................................................... Additional 45 Timing Belt Idler Pulley Bolt ..................................................................................... 18 (25) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Water Pump Bolt ....................................................................................................... 18 (25) INCH Lbs. (N.m) Engine Harness Cover-To-Engine .............................................................................. 52 (6) Timing Belt Cover Bolt ................................................................................................ 52 (6)
1

Replace bolt if loosened or removed.

ISUZU
2.2L 4-Cylinder Oasis
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

409

2.2L 4-Cyl. RA1 Oasis 1996-97 Balancer Shaft .............. .......... 1 .......... .. TCK186 .. ..... T186 Camshaft ....................... ... 2 2.7 Hrs. ... .. TCK186 .. ..... T187
1 2

Balancer shaft belt included in camshaft belt labor time. With Air Conditioning, add .3 hours. With Power Steering, add .3 hours

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1996 vehicles, the manufacturer recommends the belt be replaced every 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if vehicle is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balance Belt & Related Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. 2) Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Using a jack with block of wood to support engine, remove side engine mount. 3) Remove cylinder head cover. See Fig. 1. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 2. Loosen timing belt tension adjusting nut 145-180 degrees. See Fig. 3. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tension adjuster nut. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. Installation Ensure cylinder No. 1 is at TDC of compression stroke. See Figs. 4 and 5. Install timing belt in sequence shown. See Fig. 6. Tighten bolts to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers

410

ISUZU
2.2L 4-Cylinder Oasis (Cont.)

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

Courtesy of American Honda Motor Co., Inc.

Fig. 3: Loosening Tensioner Adjusting Nut

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence

Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt ............................................................................................ 28 (38) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Power Steering Pump Mounting Nut ........................................................................ 16 (22) Timing Belt Adjuster Bolt .......................................................................................... 49 (67) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............. 86-104 (7.2-8.7) Valve Cover Nut ....................................................................................................... 86 (9.8)

ISUZU
2.3L 4-Cylinder Oasis
TIMING BELT APPLICATION Application 2.3L 4-Cyl. F23A, SOHC Oasis 1998-99 Balancer Shaft ...................................... Camshaft ...............................................
1

411

Labor Time

Belt Part No.

1 1

2.7 Hours .. ..... T186 2.7 Hours .. ..... T244

Balance shaft belt included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if vehicle is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

REMOVAL & INSTALLATION


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

TIMING & BALANCER SHAFT BELTS


Removal 1) Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Raise and support vehicle. Remove engine lower splash shield. 2) Remove accessory drive belts. Remove alternator terminal and connector. Remove alternator and alternator bracket. Using a jack with a block of wood to support engine, remove side engine mount from front of engine. Remove dipstick tube from front of engine. 3) Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Figs. 1 and 2. 4) Insert a 6-mm timing cover bolt through the hole in the end of the timing belt adjuster arm. This will temporarily lock the arm in place. 5) Loosen belt tension adjusting nut about one turn. See Fig. 3. Push outer balancer shaft belt tensioner pulley up to take tension off of the balancer belt. Retighten belt tension adjusting nut. Remove balancer shaft belt. 6) Loosen belt tension adjusting nut about one turn. See Fig. 3. Push camshaft timing belt tensioner pulley down to take tension off of camshaft timing belt. Retighten belt tension adjusting nut. Remove camshaft timing belt. Installation 1) Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by aligning dimple on timing belt drive pulley with pointer on oil pump housing. See Fig. 4. Ensure camshaft pulley TDC marks are aligned. See Fig. 5. 2) Install camshaft timing belt in sequence shown. See Fig. 6. Loosen and retighten tensioner adjusting nut to tension camshaft timing belt. Install balancer belt drive pulley and lower cover. Install crankshaft pulley. Install bolt. 3) Rotate crankshaft pulley COUNTERCLOCKWISE about 5-6 turns so timing belt positions on pulley. Set No. 1 piston at TDC of compression stroke. Loosen belt tensioner adjusting nut about one turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt tensioner adjusting nut to specication. See TORQUE SPECIFICATIONS. 4) Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC position. Ensure camshaft UP mark is facing up. If they are not, timing belt will have to be repositioned.
Courtesy of American Honda Motor Co., Inc.

Fig. 1: Exploded View Of Timing Belt, Balancer Belt & Related Components

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Removing & Installing Timing Belt Covers 5) Remove crankshaft pulley and lower cover. Set timing belt drive pulley to TDC position. 6) Lock camshaft timing belt adjuster arm in place by installing a 6 x 10 mm timing cover bolt. Loosen belt tension adjusting nut about one turn. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push balancer belt tensioner up, then retighten belt tensioner adjusting nut.

412

ISUZU
2.3L 4-Cylinder Oasis (Cont.)

Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.

Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark

Fig. 3: Loosening Tensioner Adjusting Nut 7) Remove sealing bolt from maintenance hole on side of engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end of 6 x 100 mm bolt. Install 6 x 100 mm bolt into maintenance hole to lock balancer shaft in place. 8) Align front balancer shaft pulley groove with pointer on oil pump housing. See Fig. 8. Install balancer belt. Loosen tensioner adjusting nut about one turn to tension balancer shaft belt. Remove 6 x 100 mm bolt from rear of balancer shaft. Install sealing bolt with new washer. 9) Temporarily install crankshaft pulley and bolt. Turn crankshaft pulley about one turn counterclockwise, then tighten tensioner adjusting nut. Remove the 6 x 10 mm bolt that locked camshaft timing belt adjuster arm in place. 10) Remove crankshaft pulley. Install lower cover with new gasket or liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 11) Install dipstick tube with new O ring. When installing cylinder head cover gasket, apply liquid gasket (Part No. 08718-0001 or -0003) to 4 corners where gasket meets camshafts. 12) Install alternator and harness. Install accessory drive belts. Install engine mount bracket to engine and frame. Connect negative battery cable. Adjust drive belts to proper tension.

Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks

ISUZU
2.3L 4-Cylinder Oasis (Cont.)

413

Courtesy of American Honda Motor Co., Inc.

Fig. 6: Identifying Timing Belt Installation Sequence


Courtesy of American Honda Motor Co., Inc.

Fig. 8: Aligning Balancer Belt Drive Pulley

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt ................................................................................... 33 (45) Alternator Adjusting Lock Nut ................................................................................... 16 (22) Alternator Bracket Bolt .............................................................................................. 33 (45) Camshaft Sprocket Bolt ............................................................................................ 43 (59) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Block Sealing Bolt ........................................................................................ 22 (29) Engine Bracket-To-Engine Side Mount Nut/Bolt ...................................................... 40 (54) Engine Side Mount Through-Bolt ............................................................................. 47 (64) Engine Side Mount-To-Bracket Nut/Bolt ................................................................... 47 (64) Power Steering Pump Mounting Nut ........................................................................ 16 (22) Timing Belt Tensioner Adjusting Nut ........................................................................ 33 (44) INCH Lbs. (N.m) Cylinder Head Cover Nut ......................................................................................... 86 (9.8) Dipstick Tube Bolt ................................................................................................... 106 (12) Engine Lower Splash Shield ..................................................................................... 89 (10) Timing Belt Cover Bolt ............................................................................................ 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

Courtesy of American Honda Motor Co., Inc.

Fig. 7: Locking Balancer Belt Shaft In Place

414

ISUZU
3.2L V6 1992-97
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 3.2L V6 DOHC Trooper 1992-95 ............................ . 3.2L V6 SOHC Rodeo 1993-97 .............................. Trooper 1992-97 ..............................
1

2.6. Hours . ...... ..... ...... ..... T220

2.8 Hours .. .. TCK221 .. ..... T221 2.8 Hours .. .. TCK221 .. ..... T221

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.
Courtesy of Isuzu Motor Co.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 3: Aligning Camshaft Timing Marks (SOHC)

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove cooling fan assembly. Remove all accessory drive belts. 2) Remove fan pulley assembly. Remove crankshaft pulley bolt. Using Puller (J-8614-01) or equivalent, remove crankshaft pulley. Remove oil cooler hose from timing cover. Remove timing belt cover. Align all timing marks prior to belt removal. See Figs. 1-4. Remove belt tensioner pusher and timing belt.

Courtesy of Isuzu Motor Co.

Fig. 4: Aligning Crankshaft Timing Marks (All Models) CAUTION: To ensure correct timing belt installation, ensure direction of rotation arrows are pointing in proper direction. If timing belt is being reused, install belt in original direction of rotation. 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 specication. See TORQUE SPECIFICATIONS. 3) Loosen tensioner pulley bolt. Apply pressure on belt by rotating tensioner. Tighten tensioner pulley bolt to specication.. See TORQUE SPECIFICATIONS. Remove pin from timing belt tensioner pusher. 4) Remove pinch clips from timing belt (if used). Install crankshaft pulley, tightening center bolt nger 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 specication, 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 specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Timing Belt Sprockets (DOHC)

Courtesy of Isuzu Motor Co.

Fig. 2: Aligning Camshaft Timing Marks (DOHC)

ISUZU
3.2L V6 1992-97 (Cont.)

415

Courtesy of Isuzu Motor Co.

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)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ................................................................................................. 41 (56) Camshaft Sprocket Bolt ............................................................................................ 41 (56) Crankshaft Pulley Bolt ........................................................................................... 123 (167) Fan Pulley Bolt .......................................................................................................... 16 (22) Front Plate Bolt ......................................................................................................... 14 (19) Idler Arm Retaining Bolt ............................................................................................ 33 (44) Power Steering Pump Bolt ....................................................................................... 34 (46) Timing Belt Cover Bolt .............................................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................................................................. 32 (43) Timing Belt Tensioner Pusher Bolt ........................................................................... 14 (19) Upper Intake Manifold Bolt ....................................................................................... 18 (24) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ....................................................................................... 87 (10) Cooling Fan Assembly Nut ......................................................................................... 69 (8)

416

ISUZU
3.2L & 3.5L V6 DOHC, 1998-04
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 3.2L V6 Amigo 1998-00 .................................................... Rodeo 1998-04 .................................................... Rodeo Sport 2001-03 .................................................... 3.5L V6 Axiom 2002-04 .................................................... Rodeo 2004 .......................................................... Trooper 1998-02 .................................................... VehiCROSS 1999-01 ....................................................
1

3.2 Hours .. ..... T303 3.2 Hours .. ..... T303 3.2 Hours .. ..... T303

3.2 Hours .. ..... T303 3.2 Hours .. ..... T303 2.4 Hours .. ..... T303 2.0 Hours .. ..... T303
Courtesy of Isuzu Motor Co.

Fig. 1: Aligning Camshaft Timing Marks (3.2L Shown; 3.5L Is Similar)

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1998 models, the manufacturer recommends the belt be replaced every 75,000 miles. For all other models, the manufacturer recommends the belt be replaced at 100,000 miles for normal service, and 75,000 miles for severe service.
Courtesy of Isuzu Motor Co.

REMOVAL & INSTALLATION


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

Fig. 2: Aligning Crankshaft Timing Marks NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation. Installation 1) Align grove on crankshaft sprocket with mark on oil pump. See Fig. 2. Install timing belt on crankshaft pulley, aligning White dotted line on belt with timing mark on crankshaft pulley. Secure belt to sprocket with spring clip. 2) Align timing mark on right hand (passenger side) camshaft sprocket with alignment mark on valve cover. See Fig. 3. It may require up to 4 revolutions of camshaft pulley to achieve alignment of all timing marks. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip. 3) Align timing mark on left hand (driver side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around water pump pulley, and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install spring clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys. 4) Install timing belt around idler pulley and tensioner pulley. Temporarily install crankshaft pulley. Turn crankshaft pulley clockwise slightly to give some belt slack between the crankshaft sprocket and right hand camshaft sprocket. NOTE: It will take about 220 lbs. (100 kg) to compress timing belt tensioner rod. 5) Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. 6) Install tensioner on engine with locking pin in place. Tighten bolts to specication. See TORQUE SPECIFICATIONS.

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Relieve tension on serpentine drive belt tensioner and remove serpentine drive belt. 2) Remove 4 cooling fan assembly mounting nuts and remove cooling fan assembly. Remove cooling fan drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. 3) On Rodeo, remove power steering pump with hoses attached, and set aside. On all models, using Crankshaft Holder (J-8614-01) or equivalent, hold crankshaft from turning and remove crankshaft pulley bolt. Remove crankshaft pulley. 4) Disconnect harness connector from right side timing belt cover (if equipped). Remove timing belt covers. Remove fan bracket (if equipped). 5) On all models, rotate crankshaft to align timing marks. See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be at TDC. 6) If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt. CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up.

ISUZU
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 specication (if equipped). Install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6. 10) Install crankshaft pulley. Using Crankshaft Holder (J-8614-01) or equivalent, hold crankshaft from turning and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 11) On Rodeo, install power steering pump. On all models, Install cooling fan pulley and cooling fan assembly. Install serpentine drive belt idler pulley and tensioner assemblies. Install serpentine belt. 12) Install radiator fan shroud. Install air cleaner assembly. Connect negative battery cable.

417

Courtesy of Isuzu Motor Co.

Fig. 5: Installing Locking Pin In Timing Belt Tensioner

Courtesy of Isuzu Motor Co. Courtesy of Isuzu Motor Co.

Fig. 6: Installing Timing Belt Cover Bushings

Fig. 3: Installing Timing Belt On Right Hand Camshaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 72 (98) Cooling Fan Bracket Bolts ........................................................................................ 16 (22) Cooling Fan Pulley Bolt ............................................................................................ 16 (22) Cooling Fan & Clutch Assembly ................................................... ..................................... 1 Crankshaft Pulley Bolt ........................................................................................... 123 (167) Power Steering Pump Bolt M8 Bolt .................................................................................................................... 16 (22) M10 Bolt .................................................................................................................. 34 (46) Timing Belt Cover Bolt .............................................................................................. 14 (19) Timing Belt Idler Pulley Bolt ..................................................................................... 38 (52) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ................................................................... 31 (42) Water Pump Bolt ....................................................................................................... 18 (25)
1

Tighten cooling fan and clutch assembly nuts to 89 INCH lbs. (10 N.m).

Courtesy of Isuzu Motor Co.

Fig. 4: Installing Timing Belt On Left Hand Camshaft Sprocket

418

KIA
1.5L & 1.6L 4-Cylinder DOHC 2001-04
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.5L 4-Cyl. Rio 2001-02 1.6L 4-Cyl. Rio 2003-04
1

DOHC ..................................................... 1.9 Hours ... ..... T318 DOHC ....................................................


1

1.9 Hours .. ..... T318

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, inspect timing belt at 60,000 miles and 90,000 miles, and replace belt at 105,000 miles.

Courtesy of Kia Motors America, Inc.

Fig. 1: Removing & Installing Accessory Drive Belt

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Loosen power steering lock bolts and nuts, and remove tension from power steering and air conditioning compressor drive belt. Remove power steering and air conditioning drive belt. See Fig. 1. 2) Loosen and remove generator bolts. Remove water pump pulley. Remove crankshaft pulley and timing belt guide plate. Remove upper and lower timing belt covers. 3) Turn crankshaft so that timing mark on crankshaft sprocket is aligned with timing mark on engine. See Figs. 2 and 3. Ensure I mark on intake camshaft sprocket is aligned with mark on cylinder head cover, and E mark on exhaust camshaft sprocket is aligned with mark on cylinder head cover. See Fig. 4. CAUTION: DO NOT move camshaft or crankshaft once timing marks have been correctly positioned. 4) Loosen tensioner pulley lock bolt. See Fig. 5. While protecting timing belt with a rag, remove tensioner pulley. If belt is to be reused, mark direction of timing belt rotation for proper reinstallation. Remove timing belt. Inspection Replace timing belt if it is contaminated with oil or grease. Check belt for wear, fraying or other damage. Inspect idler pulley and tensioner pulley for uneven wear and smooth bearing operation. Inspect camshaft sprockets and crankshaft sprocket for broken teeth or damage. NOTE: Replace tensioner spring whenever timing belt is replaced. Replace any component that shows damage or excessive wear. Installation 1) Install tensioner pulley. Pull tensioner pulley to its furthest point, and tighten lock bolt. Check that timing mark on crankshaft sprocket is aligned with timing mark on engine. See Figs. 2 and 3. Ensure that camshaft sprockets are aligned with marks on cylinder head cover. See Fig. 4. 2) Install timing belt onto crankshaft sprocket rst, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and nally, tensioner pulley. See Fig. 6. Ensure there is no looseness in belt between idler pulley and exhaust camshaft sprocket, or between intake and exhaust camshaft sprockets.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Crankshaft Timing Mark (1 Of 2)

Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Crankshaft Timing Mark (2 Of 2) 3) Loosen tensioner pulley lock bolt, and allow tensioner spring to apply tension to timing belt. DO NOT add additional tension. Tighten tensioner pulley lock bolt to specication. See TORQUE SPECIFICATIONS. 4) Rotate crankshaft two full turns (clockwise only), and align timing mark on crankshaft sprocket with timing mark on engine block. See Fig. 6. Ensure that marks on camshaft sprockets align with marks on cylinder head cover. See Figs. 2, 3 and 4. If marks do not align, remove timing belt and repeat process from tensioner installation. 5) Measure timing belt deection by applying moderate pressure midway between camshaft sprockets. If deection is not 0.39-0.50 (11-13 mm) with 22 lbs. (10 kg) of force applied, repeat installation process from tensioner installation.

KIA
1.5L & 1.6L 4-Cylinder DOHC 2001-04 (Cont.)
6) Install lower and upper timing belt covers, timing belt guide plate and crankshaft pulley. Install water pump pulley. Tighten all bolts to specication. 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.

419

Courtesy of Kia Motors America, Inc. Courtesy of Kia Motors America, Inc.

Fig. 6: Identifying Rotation & Routing Of Timing Belt

Fig. 4: Locating Camshaft Sprocket & Cylinder Head Cover Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ................................................................... ................... 9-13 (12-17) Crankshaft Sprocket Bolt ............................................................................ 80-87 (108-118) Timing Belt Guide Plate Bolt ........................................................ ................... 9-13 (12-17) Timing Belt Tensioner Pulley Lock Bolt ........................................ ................. 28-38 (38-51) Water Pump Pulley Bolt ................................................................ ................... 9-13 (12-17) INCH Lbs. (N.m) Timing Belt Cover Bolts .................................................................................... 70-97 (8-11)

Courtesy of Kia Motors America, Inc.

Fig. 5: Locating Timing Belt Components

420

KIA
1.6L & 1.8L 4-Cylinder DOHC 1995-97
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. Sephia 1996-97 .............................. 1.8L 4-Cyl. Sephia 1995-97 ..............................
1

2.4 Hours .. .. TCK179 .. ..... T179

2.4 Hours .. .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of Kia Motors America, Inc.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On California models, the manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For all other models, the manufacturer recommends the belt be replaced every 60,000 miles.

Fig. 2: Aligning Camshaft Sprocket Timing Marks Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary. Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt pulled tight on right side (facing engine), route belt around camshaft sprockets. 2) Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2 complete turns. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 3) Check timing belt deection. Check timing belt deection with 22 lbs. (10 kg) of pressure applied to belt. Timing belt deection should be .36-45 (9.0-10.7 mm). If timing belt deection is not within specication, repeat timing belt tensioning procedure or replace tensioner spring. If timing belt deection is within specication, reverse removal procedure to complete installation. 4) Before installing valve cover, apply silicone sealer to areas next to front camshaft journals and rear distributor mounting cap. Also apply thin bead of silicone sealer around spark plug holes on underside of valve cover. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley. Remove crankshaft pulley bolts, and remove pulley only. 2) Remove upper and lower timing belt covers. See Fig. 1. Disconnect spark plug wires and remove spark plugs. Rotate crankshaft clockwise until No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprockets and crankshaft sprocket timing marks align. See Fig. 2. 3) If timing belt is to be reused, mark direction of timing belt rotation. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully extended. Remove timing belt.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Center Bolt ................................................................ 116-123 (157-167) Spark Plug ..................................................................................... ................. 14-17 (19-23) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................................................... ............. 106-152 (12-17) Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11) Valve Cover Bolt ........................................................................... ............... 44-78 (5.0-8.8) Water Pump Pulley Bolt ................................................................................. 69-97 (7.8-11)

Courtesy of Kia Motors America, Inc.

Fig. 1: Identifying Timing Belt Covers

KIA
1.6L & 1.8L 4-Cylinder SOHC
TIMING BELT APPLICATION Application 1.6L 4-Cyl. Sephia 1994-95 .............................. 1.8L 4-Cyl. Sephia 1996-97 ..............................
1

421

REMOVAL & INSTALLATION


Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

2.0 Hours .. .. TCK185 .. ..... T185

TIMING BELT
1

2.0 Hours .. .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On California models, the manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For all other models, the manufacturer recommends the belt be replaced every 60,000 miles.

Removal 1) Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley. Remove crankshaft pulley bolts, and remove pulley only. See Fig. 1. Remove upper and lower timing belt covers. Disconnect spark plug wires and remove spark plugs. Rotate crankshaft clockwise until No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket and crankshaft sprocket timing marks align. See Fig. 2. 2) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully extended. Remove timing belt. Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.

Courtesy of Kia Motors America, Inc.

Fig. 1: Exploded View of Timing Belt & Components

422

KIA
1.6L & 1.8L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60) Crankshaft Pulley Lock Bolt .................................................................... 116-123 (157-167) Spark Plug ..................................................................................... ................. 14-17 (19-23) Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ......................................................................................... 71 (8) Crankshaft Pulley Bolt ................................................................... ............. 106-152 (12-17) Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11) Water Pump Pulley Bolt ................................................................................. 69-97 (7.8-11)

Installation 1) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 2. Install belt around crankshaft sprocket. Keeping belt pulled tight on right side (facing engine), route belt around camshaft sprocket. 2) Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2 complete turns. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 3) Rotate crankshaft clockwise 2 more turns, and check timing belt deection. Check timing belt deection with 22 lbs. (10 kg) of pressure applied to belt, midway between camshaft and crankshaft pulleys, on side opposite tensioner. Timing belt deection should be .43-51 (10.9-13.0 mm). 4) If timing belt deection is not within specication, repeat procedure or replace tensioner spring. If timing belt deection is within specication, reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Timing Marks

KIA
1.8L 4-Cylinder DOHC 1998-04
TIMING BELT APPLICATION Application 1.8L 4-Cyl. DOHC Sephia 1998-01 .................................................... Spectra 2000-04 ....................................................
1

423

Labor Time

Belt Part No.

2.4 Hours .. ..... T302 2.4 Hours .. ..... T302

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On California models, the manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For all other models, the manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Kia Motors America, Inc.

Fig. 2: Aligning Camshaft Timing Marks

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove all accessory drive belts. Remove generator bolts. Remove water pump pulley. Remove crankshaft pulley bolt, and remove pulley and timing belt guide plate. See Fig. 1. 2) Remove upper and lower timing belt covers. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure camshaft sprockets and crankshaft sprocket timing marks align. See Figs. 2 and 3. Camshaft sprocket I and E marks must face up and align with marks on rear timing belt cover. 3) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt tensioner pulley. See Fig. 4. Remove timing belt.

Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Crankshaft Timing Marks

Courtesy of Kia Motors America, Inc. Courtesy of Kia Motors America, Inc.

Fig. 4: Timing Belt Tensioner & Idler Pulley

Fig. 1: Removing Timing Belt Guide Plate

424

KIA
1.8L 4-Cylinder DOHC 1998-04 (Cont.)

Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner and idler pulley bearings for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary. NOTE: Manufacturer recommends replacing timing belt tensioner spring whenever timing belt is replaced. See Fig. 5. Installation 1) Install tensioner pulley with NEW spring. Move tensioner away from timing belt, and tighten center bolt. Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 2 and 3. 2) Install timing belt around crankshaft sprocket. If reusing old belt, ensure belt is installed in original direction of rotation. Keeping belt pulled tight on right side (facing engine), route belt around idler pulley, camshaft sprockets, and tensioner pulley. 3) Loosen timing belt tensioner center bolt, and allow spring to apply tension on belt. Tighten tensioner center bolt. Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 4) Check timing belt deection with 22 lbs. (10 kg) of downward pressure applied to belt, midway between camshaft sprockets. Timing belt deection should be .36-.45 (9.0-11 mm). 5) If timing belt deection is not within specication, repeat timing belt tensioning procedure. If timing belt deection is within specication, install timing belt covers. Install crankshaft and water pump pulleys. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 5: Cross Section of Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Bolt ........................................... ............. 106-152 (12-17) Timing Belt Cover Bolt ................................................................................... 69-97 (7.8-11) Water Pump Pulley Bolt ................................................................ ............. 106-152 (12-17)

KIA
2.0L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 2.0L 4-Cyl. Sportage 1995-02 ..............................
1

425

Labor Time

Component Belt Kit No. Part No.

3.2 Hours .. .. TCK281 .. ..... T281

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On California models, the manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For all other models, the manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Kia Motors America, Inc.

REMOVAL & INSTALLATION


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

Fig. 2: Aligning Crankshaft Pulley Timing Marks

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove 2 air ducts mounting bolts from radiator. Loosen fresh air duct clamp at intake housing. Remove hose at resonance chamber. Remove fresh air duct. Remove cooling fan shroud. Remove cooling fan clutch-to-pulley nuts. 2) Remove accessory drive belts. Remove cooling fan and pulley. Remove lower engine splash guard. Remove crankshaft pulley from crankshaft. It is NOT necessary to remove center bolt. Remove upper and lower timing belt covers. See Fig. 1. 3) Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 2 and 3. Camshaft I and E marks should align with marks on rear cover. 4) Loosen tensioner pulley bolt. Pivot tensioner pulley outward to remove tension from timing belt, then retighten tensioner lock bolt. See Fig. 4. Mark timing belt rotation direction if old belt is to be reinstalled. Remove timing belt.
Courtesy of Kia Motors America, Inc.

Fig. 3: Aligning Camshaft Pulley Mating Marks

Courtesy of Kia Motors America, Inc.

Fig. 4: Loosening Tensioner


Courtesy of Kia Motors America, Inc.

Fig. 1: Exploded View Of Timing Belt & Components

426

KIA
2.0L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Center Bolt ........................................................ ................. 35-48 (47-65) Cooling Fan Clutch-To-Pulley Nuts ........................................................................... 24 (32) Crankshaft Center Bolt ............................................................................ 116-123 (157-167) Crankshaft Pulley-To-Crankshaft Bolts ......................................... ................... 9-13 (12-17) Generator Mount Bolts Top Generator Bolt .................................................................................................. 16 (22) Bottom Generator Bolt ............................................................................................ 32 (45) Power Steering Pump Bolts .......................................................... ................. 27-34 (37-46) Timing Belt Idler Pulley Bolt ......................................................... ................. 27-38 (37-52) Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-52) Water Pump Bolt ....................................................................................................... 16 (22) INCH Lbs. (N.m) Cooling Fan Shroud Bolts ........................................................................................... 74 (8) Fresh Air Duct Mounting Bolts ................................................................................. 89 (10) Timing Belt Cover Bolts ................................................................ ................... 61-87 (7-10)

Installation 1) Ensure crankshaft and camshaft pulleys are still aligned. See Fig. 3. Install timing belt so that there is no looseness at tension side, and at camshaft pulleys. If reusing old belt, ensure belt is installed in original direction of rotation. Loosen tensioner pulley bolt. 2) Turn crankshaft 2 revolutions in normal direction of rotation. Check that timing marks are correctly aligned. If timing marks are not correctly aligned, remove belt and realign. After realigning belt, repeat rotation prodecure. 3) Turn crankshaft to align S mark of exhaust camshaft pulley with rear cover seal plate mating mark. Tighten tensioner pulley bolt. 4) Check that belt deection is .30-.33 (7.5-8.5 mm) with 22 lbs. (10 kg) of downward pressure on belt, midway between two camshaft pulleys. 5) Install timing belt guide plate with at side toward belt. Install timing belt covers. 6) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

KIA
2.0L 4-Cylinder SOHC
TIMING BELT APPLICATION Application 2.0L 4-Cyl. SOHC Sportage 1995 ..........................................................
1

427

Labor Time

Belt Part No.

2.3 Hours .. ..... T264

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On California models, the manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. For all other models, the manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Fig. 1: Identifying Timing Belt & Related Components

Courtesy of Kia Motors America, Inc.

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 deection is .43-.51 (11-13 mm) at 22 lbs. (10 kg) pressure on belt between camshaft pulley and crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Kia Motors America, Inc.

Fig. 2: Camshaft Pulley Mating Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Belt Lock Bolts ............................................................ ................. 24-30 (32-42) Cooling Fan Assembly .............................................................................................. 27 (37) Cooling Fan Nuts ...................................................................................................... 16 (22) Crankshaft Damper Bolts ........................................................................................ 132 (15) Timing Belt Tensioner Lock Bolt ................................................... ................. 27-38 (37-52) INCH Lbs. (N.m) Cooling Fan Shroud Bolts ........................................................................................... 74 (8) Fresh Air Duct Mounting Bolts ................................................................................. 84 (10) Timing Belt Cover Bolts ............................................................................................ 84 (10)
Courtesy of Kia Motors America, Inc.

Fig. 3: Crankshaft Pulley Mating Marks

428

KIA
2.4L 4-Cylinder DOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 2.4L 4-Cyl. DOHC Optima 2001-04 Balance Shaft ...................................... Camshaft .............................................
1

1, 2 1, 2

2.3 Hours . ..... T314 2.6 Hours . ..... T313

Balance Shaft Belt labor time included in camshaft belt labor time. With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, inspect timing belt at 60,000 miles and 90,000 miles, and replace at 105,000 miles.

REMOVAL & INSTALLATION


Courtesy of Hyundai Motor Co.

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

Fig. 1: Identifying Timing Belt Alignment Marks

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). Removal 1) Disconnect negative battery cable. Remove drive belts and drive pulleys from crankshaft and water pump. Remove timing belt covers. To align timing marks, rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks align with upper surface of rocker cover. Dowel pin of camshaft sprocket should be pointing upward. See Fig. 1. 2) Remove timing belt auto tensioner. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Remove camshaft sprockets. 3) Remove plug at left side of block, and insert a screwdriver to hold left counterbalance shaft in position. Screwdriver will have to be inserted at least 2.36 (60 mm). Remove oil pump sprocket nut and sprocket. See Fig. 2. 4) Loosen right counterbalance shaft sprocket mounting bolt. Remove tensioner B and timing belt B. See Fig. 2. Remove crankshaft sprocket B from crankshaft. Inspection 1) Check belt teeth for cracks, damage and oil contamination. Inspect sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Check sprockets and pulleys for wear, cracks or damage. Replace components if necessary. 2) Measure protrusion of auto tensioner rod. Auto tensioner rod should extend .57 (14.5 mm) from end of housing. See Fig. 3. Replace auto tensioner rod if not within specication. 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 ange is properly positioned. Lightly oil outer surface of spacer, and then install spacer to right counterbalance shaft, with rounded edge of spacer inward. 2) Install right counterbalance shaft sprocket. Tighten ange bolt tightly by hand. Align timing marks on each sprocket and on front case. See Fig. 4. 3) When installing timing belt B, ensure there is no slack in tension side. Install tensioner B in center of pulley on left side of mounting bolt, and in pulley ange toward front of engine. See Fig. 5. Align timing mark of right counterbalance shaft sprocket with timing mark on front case.

Courtesy of Hyundai Motor Co.

Fig. 2: Exploded View Of Timing Belt Components 4) To tighten timing belt B, lift tensioner B so tension side is pulled tight. Tighten bolt to secure tensioner B. DO NOT turn shaft, or belt will be over-tightened.

KIA
2.4L 4-Cylinder DOHC (Cont.)

429

Courtesy of Hyundai Motor Co.

Fig. 4: Identifying Front Case Timing Marks


Courtesy of Hyundai Motor Co.

Fig. 3: Measuring Auto Tensioner Protrusion 5) Ensure timing marks are aligned. Ensure center of span on tension side of timing belt B can be depressed by hand. Ensure belt deection is .20-.30 (5-7 mm). 6) Install crankshaft sprocket ange and sprocket. Ensure ange is mounted in proper direction, with chamfered side toward block. Install special washer and sprocket bolt to crankshaft. Tighten sprocket bolt to specication. See TORQUE SPECIFICATIONS. 7) Insert long screwdriver through plug hole in left side of cylinder block to hold counterbalance shaft in position. Install oil pump sprocket, and tighten nut to specication. See TORQUE SPECIFICATIONS. Install camshaft sprockets, and tighten bolts. 8) If auto tensioner rod is fully extended, place it in soft-jawed vise, and compress rod until hole in rod lines up with hole in auto tensioner housing. Insert stiff wire to hold rod in this position. Install auto tensioner, leaving wire in place. CAUTION: If timing marks on camshaft sprockets do not line up properly, DO NOT rotate sprocket more than 2 teeth in either direction, or valve and piston will touch. If necessary, remove and reposition camshaft sprocket. 9) Install crankshaft sensor. Set timing marks of camshaft sprockets with notches on upper side of rocker cover and dowel pins straight up. Align crankshaft sprocket timing marks. Align oil pump sprocket timing marks. 10) Install timing belt in order around crankshaft sprocket, oil pump sprocket, idler pulley, exhaust camshaft sprocket, intake camshaft sprocket and tensioner pulley. 11) Gently raise tensioner pulley so belt will not sag, and then temporarily tighten center bolt. Ensure timing mark of each sprocket is still aligned. Remove wire from auto tensioner. 12) Rotate crankshaft 2 complete turns clockwise. Leave in this position for about 5 minutes. Measure auto tensioner protrusion A (distance between tensioner arm and auto tensioner body). Ensure auto tensioner protrusion is .22-.35 (6-9 mm). See Fig. 3. Install timing belt lower cover and upper cover.

Courtesy of Hyundai Motor Co.

Fig. 5: Installing Tensioner B

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Bolt ....................................................................... ................. 15-20 (20-27) Block Plug Cap ............................................................................. ................. 15-20 (20-27) Camshaft Sprocket Bolt ................................................................ ............... 58-72 (80-100) Crankshaft Pulley Bolt ................................................................... ................. 15-22 (20-30) Crankshaft Sprocket Bolt ............................................................................ 80-94 (110-130) Oil Pump Sprocket Nut ................................................................. ................. 36-43 (50-60) Timing Belt Cover Bolts Lower & Upper Cover Bolt ......................................................... ..................................... 1 Left Rear Cover Bolt Lower ......................................................................................... ................. 22-30 (30-41) Upper ......................................................................................... ..................................... 2 Right Rear Cover Bolt ................................................................. ..................................... 2 Timing Belt Idler Pulley Bolt ......................................................... ................. 33-40 (45-54) Timing Belt Tensioner Pulley Bolt ................................................. ................. 31-40 (42-54) Timing Belt Tensioner Pulley Bracket Bolt ................................... ................. 17-20 (23-27) Water Pump Mounting Bolt ............................................................................. 11-15 (15-20) INCH Lbs. (N.m) Rocker Cover Bolt ......................................................................... ................... 71-89 (8-10) Valve Cover Bolts .......................................................................... ................... 71-89 (8-10) Water Pump Pulley Bolt ................................................................ ................... 71-89 (8-10)
1 2

Tighten bolts to 71-89 INCH lbs. (8-10 N.m). Tighten bolts to 89-108 INCH lbs. (10-12 N.m).

430

LANCIA
1.8L 4-Cylinder
Labor Time Belt Part No. Installation 1) Align reference mark on crankshaft pulley with timing mark on Locking Fixture (88013039) or equivalent. When both marks correspond exactly, cylinders No. 1 and 4 will be at TDC. Fixture reference hole should also line up with ancillary drive shaft reference hole. Check alignment by inserting dowel pin. 2) Install timing belt. Unlock the belt stretcher bolt while applying pressure to the belt. Tighten bolt and nut to 33 ft. lbs. (45 N.m). Once tensioning bolt is torqued, remove locking xture. Turn the crankshaft a few times, partially release the belt stretcher, and nally relock it properly. Install timing reference pointers bracket. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Beta 1976-78 ....................................................


1

2.7 Hours .. ..... T020

With Air Conditioning, add .6 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 25,000 miles.

VALVE TIMING
To check valve timing, turn crankshaft until reference mark on sheave aligns with long mark on timing gear cover. See Fig. 2. Check that the holes in camshaft gears (one in each) are aligned with reference marks on front camshaft bearings. See Fig. 2. If adjustment is necessary, use Locking Fixture (88013039) or equivalent, as instructed under TIMING BELT.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove timing gear cover, spark plugs, and valve covers. Install Handles (88013344), or equivalent, on ywheel. 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 xture to cylinder head. Remove belt tensioner nut and bolt, and release tension from belt. Remove timing belt.

Courtesy of lancia motors, inc.

Fig. 2: Locating Valve Timing Reference Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Nuts ............................................................................................ 16 (22) Timing Belt Tensioner ................................................................................................ 33 (45)

Fig. 1: Aligning Camshaft Timing Marks With Bearing Reference Marks

LAND ROVER
2.5L KV6 DOHC, 2002-04
TIMING BELT APPLICATION Application Labor Time Belt Part No.

431

2.5L KV6 VIN 2 Freelander 2002-04 Front Belt ............................................... 5.6 Hours ... ..... T327 Rear Belts ............................................ .......... 1 .......... ..... T326
1

Engine set (front/rear timing belts) labor time is 6.8 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

engine steady away from top arm. Install wooden block to jack, position jack under engine sump to support engine. 3) Remove nut and 4 bolts securing engine top arm bracket to right hydramount and to engine front mounting bracket. See Fig. 3. Release power steering pipe support bracket from hydramount and position pipe aside. Remove top arm. 4) Remove 4 bolts securing engine mounting bracket to engine front plate and remove bracket. See Fig. 4. Using a 3/8 square drive socket bar, raise ancillary drive belt tensioner and release drive belt from alternator pulley. Release and remove ancillary drive belt from remaining pulleys.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends that belts be replaced every 72,000 miles or 72 months whichever is sooner. If any timing belt is removed for other repairs, manufacturer requires replacement of timing belt if mileage has exceeded 45,000 miles.

COMPONENT LOCATION
NOTE: Freelander 2.5L KV6 engine is equipped with 3 timing belts. For location of timing belts and related components, see Fig. 1.

Courtesy of Land Rover North America, Inc.

Fig. 2: Removing Upper Right Engine Steady

Courtesy of Land Rover North America, Inc.

Fig. 3: Removing Top Engine Arm Bracket


Courtesy of Land Rover North America, Inc.

Fig. 1: Locating Timing Belts & Related Components (2.5L KV6)

REMOVAL & INSTALLATION


WARNING: This application is an interference engine. DO NOT rotate camshafts or crankshaft when timing belt is removed, or engine damage may occur.

NOTE: Examine drive belt for signs of wear. A drive belt with cracked ribs is acceptable. A drive belt that has loose or missing parts of ribs must be changed. Installation 1) Clean pulley grooves and tensioner pulley running surface. Install new drive belt to crankshaft pulley. Raise belt tensioner and connect drive belt to steering pump, alternator and compressor pulleys. Ensure drive belt is correctly located in pulley grooves. 2) Position engine mounting front bracket to engine front plate and tighten bolts to specication. See TORQUE SPECIFICATIONS. Position top arm to front engine mounting bracket, install and tighten bolts to specication. 3) Lower and remove jack supporting engine. Position power steering pipe support bracket to hydramount. Install nut securing top arm to right hydramount and tighten to specication. See TORQUE SPECIFICATIONS.

ANCILLARY DRIVE BELT


Removal 1) Disconnect battery ground lead. Remove underbelly panel. See UNDERBELLY PANEL. Remove engine acoustic cover. See ENGINE ACOUSTIC COVER. 2) Remove bolt securing upper right engine steady to top arm. See Fig. 2. Loosen bolt securing upper right engine steady to body, pivot

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 bers. 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 rectied. Removal 1) Disconnect battery ground lead. Remove ancillary drive belt. See ANCILLARY DRIVE BELT. Remove right front road wheel. Remove 3 bolts securing right splash shield to body and remove shield. 2) Remove 3 bolts securing camshaft left rear timing belt cover and remove cover. See Fig. 7. 3) On vehicles up to 2003, remove intake manifold chamber to gain access to right rear timing belt cover. See INTAKE MANIFOLD CHAMBER. Remove 2 bolts securing right rear timing belt cover heat shield and remove heat shield. Remove 3 bolts securing right rear timing belt cover and remove cover. See Fig. 7. CAUTION: DO NOT use camshaft gear bolts or timing belt to rotate crankshaft. DO NOT use arrow on oil pump body as a timing reference. 4) Using a socket on crankshaft pulley bolt, rotate crankshaft in a clockwise direction. Align the engine SAFE position notch on crankshaft pulley with the ARROW on front mounting plate and timing marks aligned on the rear camshaft gears. See Fig. 8. CAUTION: Ensure hole immediately adjacent to side of lower crankcase is used. 5) Insert timing pin LRT-12-232 through hole in lower crankcase, ensuring pin is located in hole in drive plate. See Fig. 9. Remove bolt securing Power Assisted Steering (PAS) pipe to engine front mounting plate. Remove 3 Torx screws securing PAS pump pulley and remove pulley. Remove 3 bolts securing PAS pump to front mounting plate and tie pump aside. 6) Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal. Disconnect connector from alternator. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate and remove alternator. 7) Remove Torx screw securing idler pulley to front mounting plate and remove pulley. See Fig. 6. Loosen bolt securing lower engine steady to front subframe. See Fig. 10. Remove bolt securing lower engine steady to sump mounting, release lower engine steady from sump mounting. CAUTION: Ensure crankshaft does not rotate during crankshaft pulley removal.
Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 4: Locating Engine Mounting Front Bracket & Ancillary Drive Belt Tensioner 4) Position engine upper right steady to top arm, install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Tighten bolt securing engine upper right steady to body to specication. 5) Install underbelly panel. See UNDERBELLY PANEL. Install engine acoustic cover. See ENGINE ACOUSTIC COVER. Connect battery ground lead.

ENGINE ACOUSTIC COVER


Removal & Installation 1) Loosen clip and disconnect fresh air intake hose from acoustic cover. See Fig. 5. Loosen clip and disconnect air intake hose from Mass Air Flow (MAF) sensor. Release 2 turnbuckles securing acoustic cover to left camshaft cover. Release retaining strap and remove acoustic cover. 2) To install, position and secure engine acoustic cover. Connect air intake and air bypass hoses, secure clip. Connect fresh air intake hose to acoustic cover and tighten clip screw.

Fig. 5: Removing & Installing Engine Acoustic Cover

8) Remove 3 bolts securing camshaft timing belt front covers and remove covers. See Fig. 6. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. See Fig. 11. Remove tools LRT-12-161 and LRT-12-199 from crankshaft pulley and remove pulley.

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)
NOTE: It is not necessary to discharge A/C system. 9) Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner. See Fig. 4. Note position of heat shield on A/C compressor and remove 3 bolts securing A/C compressor to front mounting plate and cylinder block. Release A/C compressor and heat shield and position aside. 10) Remove bolt securing dipstick tube to cylinder block. Depress and hold down dipstick tube locking collar, remove dipstick tube from engine sump. Remove rubber blanking plug from around camshaft front timing belt tensioner assembly. See Fig. 12. Remove 3 bolts securing engine front mounting plate and lifting bracket to cylinder block. Remove bolt securing lifting bracket to right cylinder head and remove lifting bracket. 11) Remove 2 bolts securing Intermediate Reduction Drive (IRD) support bracket to engine front mounting plate. Remove 5 bolts and 2 pillar bolts securing engine front mounting plate to cylinder block. See Figs. 6 and 13. With care, release and remove front mounting plate from engine. NOTE: If holes in body and plunger are not aligned, move tensioner backplate using a suitable broad bladed screwdriver; this will move plunger sufficiently to enable pin to be inserted. 12) Insert a suitable 1.5-mm diameter pin through hole in tensioner body and into hole in plunger. See Fig. 14. CAUTION: Exercise great care when removing bolts, DO NOT apply excessive torque. If bolts appear to be seized, apply suitable anti-seize lubricant prior to removing bolts. DO NOT loosen Allen screw securing tensioner pulley. 13) Remove and discard 2 Patchlok bolts securing tensioner to cylinder block and remove tensioner. See Fig. 14. CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed and cylinder heads installed. 14) If camshaft timing belt is to be reinstalled, mark direction of rotation on timing belt before removal. With care, ease camshaft timing belt from gears using ngers only and remove timing belt. CAUTION: Special tools must be installed when tightening or loosening gear retaining bolts, otherwise damage to camshafts may occur. 15) Remove and discard left and right exhaust camshaft cap seals. See Fig. 15. Position tools LRT-12-196 to left and right front intake camshaft gears and into end of each exhaust camshaft. See Fig. 16. 16) Remove and discard bolts retaining front intake camshaft gears to camshafts. Remove tools LRT-12-196 from both intake camshaft gears and exhaust camshafts. Remove camshaft drive gears and hub assemblies. NOTE: Following front or rear timing belt installation, it is possible that, after rotating engine and positioning crankshaft pulley to SAFE position, the timing marks on rear timing gears may be misaligned. This misalignment is acceptable provided that the timing belt installation procedure was carried out correctly. CAUTION: If sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and then thoroughly washed in clean solvent before retting. Because of the porous construction of sintered material, oil impregnated in the gears will emerge and contaminate the belt. Installation 1) Clean camshaft gears and hubs, crankshaft gear, tensioner and water pump pulleys. Install hubs to camshaft gears and install gears to camshafts. Install NEW bolts and tighten sufficiently to allow gears to rotate without tipping.

433

NOTE: To prevent timing belt from disengaging from crankshaft gear during installation, install a suitable wedge between the belt and oil pump belt guard. 2) Position timing belt to crankshaft gear. Install tool LRT-12-197 into each exhaust camshaft in turn. See Fig. 17. Using assistance, rotate each exhaust camshaft slightly clockwise and align timing marks on left and right rear camshaft gears. See Fig. 18. Remove tool LRT-12-197 from exhaust camshaft. Install tools LRT-12-175 to left and right rear camshaft gears. CAUTION: Timing gears MUST NOT be rotated counterclockwise more than one tooth. 3) Rotate both front intake camshaft gears fully clockwise as viewed from front of engine. Using ngers only, install front timing belt to gears, starting at the crankshaft gear and working in a counterclockwise direction. Keep belt run as tight as possible and turn camshaft gears only a minimum amount counterclockwise to install timing belt. CAUTION: Ensure timing belt tensioner plunger is contacting underside of tensioner backplate. 4) Position an Allen key in tensioner backplate and hold tensioner pulley against timing belt. See Fig. 19. With assistance, position tensioner, install NEW Patchlok bolts and tighten to specication. See TORQUE SPECIFICATIONS. Remove tools LRT-12-175 from rear timing belt gears. CAUTION: Special tools must be installed when tightening or loosening gear retaining bolts, otherwise damage to camshafts may occur. 5) Install tools LRT-12-196 to intake camshaft front gears and into end of each exhaust camshaft. See Fig. 16. Tighten front intake camshaft gear bolts in 2 stages to specication. See TORQUE SPECIFICATIONS. 6) Remove tools LRT-12-196 from both intake camshaft gears and exhaust camshafts. Remove wedge from between drive belt and oil pump belt guard. Remove 1.5-mm diameter pin from tensioner. Install rubber blanking plug around tensioner. Remove timing pin LRT-12-232. CAUTION: The sealing edge of cap seal and mating face must be clean and dry. 7) Clean exhaust camshaft front cap seal locations and install NEW cap seals. Position engine front mounting plate and maneuver plate into position. Install bolts but DO NOT tighten at this stage. Install bolts securing front mounting plate to cylinder block and Intermediate Reduction Drive (IRD) bracket, but DO NOT tighten at this stage. 8) Tighten bolts in sequence shown and to specication by numbers indicated. See Fig. 20. See TORQUE SPECIFICATIONS. 9) Position engine lifting bracket, install bolts securing lifting bracket and front mounting plate to cylinder block and right cylinder head. Tighten M10 bolts and M8 bolt to specication. See TORQUE SPECIFICATIONS. 10) Clean end of dipstick tube. Position dipstick tube to sump and cylinder block, instal bolt and tighten to specication. See TORQUE SPECIFICATIONS. Position A/C compressor to front mounting plate and cylinder block, align heat shield, install and tighten bolts to specication. 11) Clean lower timing belt cover. Position lower timing belt cover, install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Clean crankshaft pulley. Install crankshaft pulley to crankshaft gear and ensure that indent on pulley locates over lug on crankshaft gear. Install crankshaft pulley bolt and washer. Position LRT-12-161 with LRT-12-199 tools into crankshaft pulley bolt and tighten to specication. See Fig. 11. 12) Remove tools LRT-12-161 and LRT-12-199 from crankshaft pulley bolt. Clean ancillary drive belt tensioner. Position ancillary belt tensioner, install bolts and tighten to specication. See TORQUE SPECIFICATIONS.

434

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 6: Locating Front Timing Belt Components (2.5L) 13) Clean left and right front timing belt covers. Position left and right front timing belt covers, install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Clean idler pulley, position pulley to engine front mounting plate and tighten Allen bolt to specication. 14) Position alternator to front mounting plate. Install bolts and nut securing alternator to front mounting plate and tighten to specication. See TORQUE SPECIFICATIONS. Connect alternator connector. Connect battery lead to alternator, install and tighten nut to specication and install terminal cover. 15) Position PAS pump to front mounting plate, install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Position PAS pipe to engine front mounting plate, install and tighten bolt to specication. Clean PAS pump pulley mating faces. Position PAS pump pulley, install and tighten Torx screws to specication. 16) Position lower engine steady to sump mounting, install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Tighten bolt securing lower engine steady to subframe to specication. 17) Clean rear timing belt covers. Position rear timing belt covers, install and tighten bolts to specication. Position rear timing belt right cover heat shield, install bolts and tighten M6 bolt and M8 bolt to specications. 18) Install intake manifold chamber. See INTAKE MANIFOLD CHAMBER. Install right road wheel and tighten nuts to specication. Install ancillary drive belt. See ANCILLARY DRIVE BELT.

INTAKE MANIFOLD CHAMBER


Removal (Up To 2003 Model Year) 1) Disconnect battery ground lead. Remove vacuum enhancer. Remove engine acoustic cover. See ENGINE ACOUSTIC COVER. Release enhancer from support clips. Disconnect connector from solenoid valve, if equipped. Release and disconnect servo pipe. Release clip and disconnect from intake hose. Release and remove enhancer assembly from intake manifold. WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent re and explosion. 2) Position absorbent cloth around fuel feed pipe connection to collect spillage. Pull back rubber sleeve on fuel pipe connector, release connector and disconnect fuel pipe from fuel rail pipe. See Fig. 21. Install plugs to open connections to prevent contamination. 3) Release clip and disconnect hose from purge control valve. Install plugs to open connections to prevent contamination. Disconnect con-

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

435

Courtesy of Land Rover North America, Inc.

Fig. 9: Inserting Timing Pin LRT-12-232 Through Lower Crankcase Hole

Courtesy of Land Rover North America, Inc.

Fig. 7: Removing Rear Timing Belt Covers

Courtesy of Land Rover North America, Inc.

Fig. 10: Locating Lower Engine Steady At Front Subframe

Courtesy of Land Rover North America, Inc.

Fig. 8: Aligning Front & Rear Timing Marks nector from purge control valve. Depress locking collar and release vacuum hose from Idle Air Control Valve (IACV) housing. Disconnect connector from Throttle Position (TP) sensor. 4) Depress locking collars and release vacuum/breather hose from purge control valve and left camshaft cover. See Fig. 22. Release clip securing hose to T piece and remove hose. Depress locking collars and release vacuum/breather hoses from throttle body, left and right camshaft cover and remove hose.

Courtesy of Land Rover North America, Inc.

Fig. 11: Removing Or Installing Crankshaft Pulley Bolt 5) Disconnect connectors from IAT and MAF sensors. See Fig. 23. Disconnect engine breather pipe from intake hose. Disconnect injector air supply pipe from intake hose. Disconnect connector from throttle body. See Fig. 24. Release clip and remove intake hose and MAF sensor assembly. Disconnect cruise control actuator vacuum pipe.

436

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 12: Removing Rubber Blanking Plug From Front Timing Belt Tensioner
Courtesy of Land Rover North America, Inc.

Fig. 14: Locking Timing Belt Tensioner Before Removal

Courtesy of Land Rover North America, Inc. Courtesy of Land Rover North America, Inc.

Fig. 13: Removing Engine Front Mounting Plate 6) Depress locking collar and disconnect brake servo hose from intake manifold chamber. See Fig. 25. Disconnect connectors from Variable Intake System (VIS) motors. Remove 2 screws securing engine harness brackets to intake manifold chamber and position harness aside. 7) Remove 2 bolts securing intake manifold chamber rear support brackets to right camshaft cover. Remove 4 bolts securing intake manifold chamber to left intake manifold. Release and raise intake manifold chamber from intake manifolds. Release 3 locking clips and disconnect 3 connectors from right plug top coils. 8) Release 2 clips securing right plug top coil harness to intake manifold camber rear support brackets. Remove intake manifold chamber. Remove and discard seals from intake manifold chamber and O rings from right intake manifold. Installation 1) Clean seal faces on intake manifold chamber and intake manifolds. Install NEW O rings to right intake manifold and NEW seals to manifold chamber. Position intake manifold chamber, secure right coil harness clips in intake manifold chamber support brackets. 2) Connect connectors to plug top coils and secure with locking clips. Align intake manifold chamber to intake manifolds, install and tighten bolts to specication. See TORQUE SPECIFICATIONS.

Fig. 15: Removing Left Side Exhaust Camshaft Cap Seal, Right Side Is Similar

Courtesy of Land Rover North America, Inc.

Fig. 16: Positioning LRT-12-196 To Left Side Camshafts, Right Side Is Similar

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

437

Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 20: Engine Front Mounting Plate-To-Cylinder Block & IRD Bracket Tightening Sequence

Fig. 17: Installing LRT-12-197 Tools To Front Of Exhaust Camshafts

Courtesy of Land Rover North America, Inc.

Fig. 21: Locating Fuel Pipe Connector (Up To 2003)


Courtesy of Land Rover North America, Inc.

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

Courtesy of Land Rover North America, Inc.

Courtesy of Land Rover North America, Inc.

Fig. 22: Locating Purge Control Valve & Left Camshaft Cover Vacuum/Breather Hoses (Up To 2003) 4) Connect engine breather pipe. Connect connectors to IAT and MAF sensors. Connect brake servo vacuum hose to intake manifold chamber. Connect vacuum/breather hoses to left and right camshaft covers and to throttle body. Connect cruise control actuator vacuum pipe.

Fig. 19: Installing Front Timing Belt Tensioner 3) Align intake manifold chamber support brackets to right camshaft cover, install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Position engine harness brackets to intake manifold chamber, 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 operation. Ensure that all necessary precautions are taken to prevent re 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 contamination. 2) Release and disconnect EVAP hose from purge control valve. Install plugs to open connections to prevent contamination. Disconnect connector from purge control valve. Disconnect connector from Idle Air Control Valve (IACV). 3) Remove clip securing vacuum/breather pipe to engine air intake hose and disconnect vacuum/breather pipe from air intake hose. See Fig. 27. Discard clip. Install plugs to open connections to prevent contamination. Depress locking collars and release vacuum/breather pipe from left camshaft cover, right camshaft cover link pipe and intake manifold chamber. 4) Remove pipe. Install plugs to open connections to prevent contamination. Disconnect connector from IAT and MAF sensors. See Fig. 28. Disconnect connector from throttle body. Remove clip securing intake hose to throttle body. Remove intake hose and MAF sensor assembly. Discard clip. 5) Release harness and fuel feed pipe from clip on intake manifold chamber. Disconnect connectors from Variable Intake System (VIS) motors. Remove 2 screws securing engine harness brackets to intake manifold chamber and position harness aside. Remove 2 bolts securing intake manifold chamber rear support brackets to right camshaft cover. 6) Remove 4 bolts securing intake manifold chamber to left intake manifold. Release 3 locking clips and disconnect 3 connectors from right plug top coils. See Fig. 29. Release and raise intake manifold chamber from intake manifolds. Release 2 clips securing right plug top coil harness to intake manifold chamber support brackets. Remove intake manifold chamber. Remove and discard seals from intake manifold chamber and O rings from right intake manifold.

Courtesy of Land Rover North America, Inc.

Fig. 23: Locating IAT & MAF Sensors (Up To 2003)

Courtesy of Land Rover North America, Inc.

Fig. 24: Removing Intake Hose & MAF Sensor (Up To 2003)

Courtesy of Land Rover North America, Inc.

Fig. 25: Locating VIS Motors Connectors & Brake Servo Hose (Up To 2003) 5) Connect vacuum/breather hoses to left camshaft cover, T piece and purge control valve. Connect connector to purge control valve. Connect EVAP hose to purge control valve. Connect fuel hose to fuel rail pipe, install rubber sleeve over hose connector. Remove absorbent cloth.

Courtesy of Land Rover North America, Inc.

Fig. 26: Locating Fuel Pipe & EVAP Hose Connections (From 2003)

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

439

Courtesy of Land Rover North America, Inc.

2) Align intake manifold chamber support brackets to right camshaft cover, install and tighten bolts to specication. 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 bres. 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 rectied. Removal 1) Disconnect battery ground lead. Remove underbelly panel. See UNDERBELLY PANEL. On left side, remove engine acoustic cover. See ENGINE ACOUSTIC COVER. Remove 3 bolts securing left rear timing belt cover and remove cover. See Fig. 7. 2) On vehicles up to 2003, remove intake manifold chamber to gain access to right rear timing belt cover. See INTAKE MANIFOLD CHAMBER. On all vehicles, remove 2 bolts securing right rear timing belt cover heat shield and remove heat shield. See Fig. 7. Remove 3 bolts securing right rear timing belt cover and remove cover. CAUTION: DO NOT use camshaft gear bolts or timing belt to rotate crankshaft. DO NOT use arrow on oil pump body as a timing reference. 3) Using a socket on crankshaft pulley bolt, rotate crankshaft in a clockwise direction. Align the engine SAFE position notch on crankshaft pulley with the ARROW on front mounting plate and timing marks aligned on the rear camshaft gears. See Fig. 8. CAUTION: Ensure hole immediately adjacent to side of lower crankcase is used. 4) Insert timing pin LRT-12-232 through hole in lower crankcase, ensuring pin is located in hole in drive plate. See Fig. 9. CAUTION: DO NOT turn crankshaft or camshafts while rear timing belt is removed.

Courtesy of Land Rover North America, Inc.

Fig. 28: Disconnecting IAT & MAF Sensors Connectors (From 2003)

Courtesy of Land Rover North America, Inc.

Fig. 29: Releasing Plug Top Coil Connector (From 2003) Installation 1) Clean seal faces on intake manifold chamber and intake manifolds. Install NEW O rings to right intake manifold and NEW seals to intake manifold chamber. Position intake manifold chamber, secure right coil harness clips in intake manifold chamber support brackets. Align intake manifold chamber to intake manifolds, install and tighten bolts to specication.

5) Remove and discard front exhaust camshaft cap seal from cylinder head. See Fig. 15. Position LRT-12-175 to rear camshaft gears. See Fig. 30. Remove and discard bolts securing gears to camshafts. Remove rear camshaft gears, timing belt and special tool as an assembly. CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed and cylinder heads installed. 6) If camshaft timing belt is to be reinstalled, mark direction of rotation on timing belt. Remove LRT-12-175 from camshaft gears and remove timing belt from gears.

440

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)

Courtesy of Land Rover North America, Inc.

Fig. 31: Rear Camshaft Gear Positions For Installation


Courtesy of Land Rover North America, Inc.

Fig. 30: Positioning LRT-12-175 To Rear Camshaft Gears (Left Shown; Right Is Similar) NOTE: Following front or rear timing belt installation, it is possible that after rotating engine and positioning crankshaft pulley to the SAFE position, timing marks on rear timing gears may be misaligned. This misalignment is acceptable provided that timing belt reinstalling procedure was carried out correctly. CAUTION: If sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and then thoroughly washed in clean solvent before reinstalling. Because of the porous construction of sintered material, oil impregnated in gears will emerge and contaminate belt. Installation 1) Clean camshaft gears and mating faces on camshafts. Place gears inverted on a at surface, with the locating lugs on the gears facing each other. See Fig. 31. 2) Keeping timing marks aligned, position timing belt onto gears. Position LRT-12-195 between gears, turn center nut sufficiently to spread drive belt. Invert gears and timing belt and position LRT-12-175 to camshaft gears. See Fig. 32. 3) Check that locating lugs are still aligned and remove LRT-12-195 from between camshaft gears. Install LRT-12-198 alignment pins into end of each camshaft. See Fig. 33. Position timing belt and gears over LRT-12-198 and locate gears onto camshafts. 4) Position LRT-12-197 into front end of exhaust camshaft. See Fig. 17. With assistance, using a 30-mm socket on LRT-12-197, turn exhaust camshaft clockwise sufficiently to align camshaft gears to drive slots in each camshaft. 5) Remove LRT-12-198 alignment pins and install NEW camshaft gear retaining bolts. See Fig. 34. Tighten camshaft gear bolts to specication. See TORQUE SPECIFICATIONS. 6) Remove LRT-12-175 from camshaft gears. Remove LRT-12-197 from front end of exhaust camshaft. Clean exhaust camshaft cap seal recess and install NEW cap seal. See Fig. 15. Remove timing pin LRT-12-232 from lower crankcase. 7) Install splash shield and secure with bolts. Install right road wheel and tighten nuts to specication. See TORQUE SPECIFICATIONS. Clean rear timing belt cover. Position rear timing belt cover, install bolts and tighten to specication. 8) Install engine acoustic cover. See ENGINE ACOUSTIC COVER. Install underbelly panel. See UNDERBELLY PANEL. Connect battery earth lead.

Courtesy of Land Rover North America, Inc.

Fig. 32: Installing LRT-12-195 & LRT-12-175 To Rear Camshaft Gears

Courtesy of Land Rover North America, Inc.

Fig. 33: Installing Rear Camshaft Gears To Camshafts 2) Remove 4 screws securing wheel arch liners to bumper valance, if equipped. Remove 2 bolts securing rear of underbelly panel. Remove 6 bolts securing underbelly panel frame. Remove underbelly panel. 3) To install, position underbelly panel. Install bolts securing underbelly panel frame and tighten to specication. See TORQUE SPECIFICATIONS. Install bolts securing rear of underbelly panel and tighten to specication. 4) Install and tighten screws securing wheel arch liners to bumper valance, if equipped. Install and tighten screws securing bumper valance to brackets. Remove stands and lower vehicle.

UNDERBELLY PANEL
Removal & Installation 1) Raise and support front of vehicle. DO NOT work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Remove 2 screws securing bumper valance to underbelly panel brackets.

LAND ROVER
2.5L KV6 DOHC, 2002-04 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

441

Courtesy of Land Rover North America, Inc.

Fig. 34: Installing NEW Camshaft Gear Retaining Bolts

Application Ft. Lbs. (N.m) A/C Compressor-To-Front Mounting Plate & Cylinder Block ................................... 18 (25) Alternator-To-Front Mounting Plate ........................................................................... 33 (45) Ancillary Drive Belt Tensioner Bolts ......................................................................... 18 (25) Camshaft Rear Gear Bolts 1 Stage 1 .................................................................................................................... 20 (27) Stage 2 ........................................................................................ ..................... 90 Further Crankshaft Pulley Bolt ........................................................................................... 118 (160) Engine Lifting Bracket & Front Mounting Plate Bolts-To-Engine Block M8 ............................................................................................................................ 18 (25) M10 .......................................................................................................................... 33 (45) Engine Lower Steady-To-Subframe Bolt ................................................................ 74 (100) Engine Lower Steady-To-Sump Mounting Bolt ...................................................... 74 (100) Engine Mounting Bracket-To-Engine Front Plate Bolts ........................................... 33 (45) Engine Upper Right Steady-To-Top Arm Bolts ....................................................... 74 (100) Engine Upper Right Steady-To-Body Bolt .............................................................. 74 (100) Engine Front Mounting Plate-To-Cylinder Block & IRD Bracket 2 M10 Bolt No. 1 ........................................................................................................ 18 (25) M12 Bolts No. 2, 3, 4, 6 & 7 ................................................................................. 63 (85) M10 Bolt No. 5 ........................................................................................................ 33 (45) Heat Shield Rear Timing Belt Right Cover Bolts M6 ................................................................................................................................ 7 (9) M8 ............................................................................................................................ 18 (25) Idler Pulley-To-Engine Front Mounting Plate Allen Bolt ........................................... 33 (45) Intake Camshaft Front Gear Bolts Stage 1 .................................................................................................................... 20 (27) Stage 2 ........................................................................................ ..................... 90 Further Intake Manifold Chamber-To-Intake Manifolds Bolts ............................................... 13 (18) Intake Manifold-To-Cylinder Head Nuts & Bolts ...................................................... 18 (25) PAS Pipe-To-Engine Front Mounting Plate Bolt ...................................................... 18 (25) PAS Pipe Support Bracket-To-Right Hydramount Nut ............................................. 63 (85) Road Wheel Lug Nuts ............................................................................................ 85 (115) Timing Belt Front Tensioner Plunger Patchlok Bolts ............................................... 18 (25) Top Arm Bracket-To-Engine Front Plate & Right Mounting Bracket Bolts ......................................................................................................... 74 (100) Top Arm-To-Right Hydramount Nut ........................................................................... 63 (85) Underbelly Panel Frame Bolts .................................................................................. 33 (45) INCH Lbs. (N.m) Battery Lead-To-Alternator .......................................................................................... 71 (8) Battery Lead-To-Starter Solenoid .............................................................................. 88 (10) Dipstick Tube-To-Sump & Cylinder Block Bolt ........................................................... 80 (9) Fuel Rail-To-Intake Manifold Bolts .............................................................................. 80 (9) Ground Lead-To-Right Camshaft Cover Bolt ............................................................. 80 (9) Intake Manifold Chamber Support Brackets-To-Right Camshaft Cover Bolts ............................................................................................................... 88 (10) PAS Pump Pulley Torx Screws .................................................................................. 80 (9) Timing Belt Front Cover Bolts .................................................................................... 35 (4) Timing Belt Front Cover Backplate-To-Cylinder Block Bolts 3 ................................... 80 (9) Timing Belt Rear Cover Backplate-To-Cylinder Block Bolts 3 .................................... 80 (9) Timing Belt Rear Cover Bolts ..................................................................................... 35 (4) Underbelly Rear Panel Bolts ...................................................................................... 71 (8)
1 2 3

NEW bolts must be installed. Tighten bolts in sequence to specied torque value for each bolt. See Fig. 20. Apply sealant No. STC50552 to bolt threads.

442

LEXUS
2.5L & 3.0L V6 1990-98
TIMING BELT
Labor Time Component Belt Kit No. Part No. Removal (2.5L & 1992-93 3.0L V6) 1) Disconnect negative battery cable. Remove cruise control actuator and vacuum pump. Remove power steering reservoir with hoses attached, and secure them aside. Raise and support vehicle. Remove right front wheel. Remove right lower engine cover. Remove all drive belts. 2) Remove top braces on right engine mount at timing belt cover. Slightly raise engine to remove weight from right engine mount. Remove retaining bolts/nuts and right engine mount assembly. Remove spark plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right engine mount bracket. See Fig. 1. Note bolt length and location of No. 2 timing belt cover bolts for reassembly reference. CAUTION: If timing belt is to be reused, mark direction of timing belt rotation and location on camshaft sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover. 3) Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets are aligned with timing marks on No. 3 timing belt cover. See Fig. 2. Remove retaining bolts and timing belt tensioner. 4) Install Camshaft Sprocket Holder (09278-54012), or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets.

TIMING BELT APPLICATION Application

2.5L V6 ES 250 1990-91 ............................... 3.8 Hours ... .. TCK157 .. ..... T157 3.0L V6 ES 300 1992-93 ............................... 3.0 Hours ... .. TCK200 .. ..... T200 1994-98 ............................... 3.0 Hours ... ...... ..... ...... ..... T257 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months for severe operating conditions.

REMOVAL & INSTALLATION


WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

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

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
5) Using Pulley Holder (09213-54014) or equivalent, and Handle (09330-00021), hold crankshaft pulley, and remove retaining bolt. If timing belt is to be reused, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. 6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft to rotate. Remove No. 1 timing belt cover and gasket. If timing belt is to be reused, mark direction of belt rotation, and place reference marks on timing belt and crankshaft sprocket for reassembly reference. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide and timing belt. Remove idler pulleys (if necessary).

443

6) Remove retaining bolts, timing belt tensioner and dust boot. Remove crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder (09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets.

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

Fig. 3: Aligning Timing Marks (1994-98 3.0L) Inspection (2.5L & 3.0L V6) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body. Press rod against solid surface. Replace timing belt tensioner if rod moves. 2) Measure timing belt tensioner rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 4. On 2.5L engines, replace timing belt tensioner if distance is not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace timing belt tensioner if distance is not .394-.413 (10.01-10.49 mm).
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L) Removal (1994-98 3.0L V6) 1) Disconnect negative battery cable. Remove coolant reservoir. Raise and support vehicle. Remove right side front wheel. Remove right lower engine cover. Remove accessory drive belts. 2) Remove engine stabilizer rod, engine mounting bracket and right engine mount brace (located near timing belt cover). Remove the alternator bracket for access to timing belt covers. Remove No. 2 timing belt cover. See Fig. 1. 3) Use Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, to hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover. See Fig. 1. 4) Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. 5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees).

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

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion Installation (2.5L & 1992-93 3.0L V6) 1) Install No. 1 idler pulley (if removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining bolt. Install and tighten retaining bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates smoothly. 2) Install timing belt on crankshaft sprocket with installation mark on timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2. Install timing belt guide with cupped side away from crankshaft sprocket. Install No. 1 timing belt cover and gasket. Align crankshaft key with key groove of crankshaft pulley, and install crankshaft pulley. Tighten retaining bolt to specication.

444

LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Installation (1994-98 3.0L V6) 1) Install timing belt plate. Install and tighten bolt to specication. Install No. 1 and No. 2 idler pulleys (if removed). Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. 3) Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. See Fig. 6. Ensure front mark is pointing toward timing belt end of engine. CAUTION: Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. Ensure front mark is pointing toward timing belt end of engine. 4) Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then on No. 1 idler pulley. Using press, apply pressure on rod of timing belt tension until rod is retracted, and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 5. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 5) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 6) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. Using new gaskets, install No. 1 and No. 2 timing belt covers. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

CAUTION: If reusing timing belt, ensure timing mark on crankshaft sprocket is aligned with reference mark placed on timing belt, and timing belt is installed in original direction of rotation. 3) Install No. 2 idler pulley. Tighten retaining bolt to specication. Ensure idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. 4) Rotate right camshaft so knock pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. 5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket. 6) Using camshaft sprocket holder, slightly rotate left camshaft sprocket, and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft reference mark on timing belt with timing mark on right camshaft sprocket. Install right camshaft sprocket on camshaft with ange side toward cylinder head. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. 7) Using camshaft sprocket holder, slightly rotate right camshaft sprocket so knock pin hole in camshaft sprocket aligns with knock pin hole in camshaft. Install knock pin in right camshaft. Install right camshaft sprocket retaining bolt, and tighten it to specication. See TORQUE SPECIFICATIONS. 8) Place washer on bottom side of timing belt tensioner. Using press, apply pressure on rod of timing belt tension until rod is retracted, and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 5. Release press, and install dust boot on timing belt tensioner. Install timing belt tensioner. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. 9) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft sprockets align with those on No. 3 timing belt cover. See Fig. 2. CAUTION: Crankshaft must always be rotated clockwise. DO NOT rotate crankshaft counterclockwise. 10) To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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

Fig. 5: Retracting Timing Belt Tensioner Rod

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

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

LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.5L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Crossmember-To-Body Bolt .......................................................................... 29 (39) Engine Mount Through-Bolt ...................................................................................... 64 (87) Engine Mount-To-Engine Crossmember Bolt ........................................................... 54 (73) Idler Pulley Bolt No. 1 Idler Pulley .................................................................................................... 25 (34) No. 2 Idler Pulley .................................................................................................... 29 (39) Idler Pulley Support Bolt ........................................................................................... 13 (18) Right (Timing Belt Side) Engine Mount Bolt ........................................................................................................................... 47 (64) Nut Bracket Side .......................................................................................................... 38 (52) Body Side .............................................................................................................. 65 (88) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 14 (19) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ..................................................................................... 65 (7) Valve Cover Nut .......................................................................................................... 52 (6) TORQUE SPECIFICATIONS (3.0L V6)

445

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 94 (127) Crankshaft Pulley Bolt ........................................................................................... 159 (215) Front Engine Mount-To-Crossmember Bolt Toyota Motor Corporation Bolt ................................................................................ 59 (80) Toyota Motor Manufacturing Bolt ............................................................................ 49 (66) Front Engine Mount-To-Cylinder Block Bolt ............................................................. 47 (64) Power Steering Pump Bolt ....................................................................................... 31 (42) Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43) Pulsation Damper ...................................................................................................... 24 (33) Right Engine Mount Brace Bolt ................................................................................ 23 (31) Stabilizer Bar Link-To-Lower Control Arm Nut ......................................................... 29 (39) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt ............................................................................................ 25 (34) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ........................................................................... No. 3 Timing Belt Cover Bolt .................................................................................. Timing Belt Plate Bolt .............................................................................................. Valve Cover Bolt ...................................................................................................... Water Pump Bolt/Nu ................................................................................................ 75 75 71 71 71 (8.5) (8.5) (8.0) (8.0) (8.0)

446

LEXUS
3.0L 6-Cylinder 1993-97
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

3.0L 6-Cyl. GS 300 1993-97 ..................................................... 3.4 Hours ... ..... T215 SC 300 1993-97 ..................................................... 3.4 Hours ... ..... T215 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months for severe operating conditions.

REMOVAL & INSTALLATION


TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal 1) Disconnect battery cables and remove battery. Drain cooling system. Place reference mark on fan clutch and water pump for reassembly reference. Remove drive belt, cooling fan, fan clutch and water pump pulley. 2) Remove radiator and lower engine cover. Remove oil ller 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. 6) Using Handle (09330-00021) or equivalent, and Pulley Holder (09213-70010), or equivalent, hold crankshaft pulley and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. 7) Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide. CAUTION: If reusing timing belt, place reference mark on timing belt and crankshaft sprocket for reassembly reference. 8) Remove timing belt. Remove bolt, idler pulley and plate washer (if necessary). Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. 3) Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. 4) Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. Replace timing belt tensioner if distance is not .315-.343 (8.00-8.80 mm).
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

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

Fig. 2: Aligning Timing Marks NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner.

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

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) Install idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely.

LEXUS
3.0L 6-Cylinder 1993-97 (Cont.)
2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 1. Install timing belt on crankshaft sprocket. CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align and timing belt is installed in original direction of rotation. 3) Install timing belt guide with cupped side away from crankshaft sprocket and at side against timing belt. Install gaskets and No. 1 timing belt cover. 4) Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 5) If installing camshaft sprocket, align hole in camshaft sprocket with dowel pin in camshaft. Install camshaft sprocket. Hold camshaft sprocket with sprocket holder, and tighten bolt to specication. See TORQUE SPECIFICATIONS. 6) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 7) Using sprocket holder, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft sprockets align and timing belt is installed in original direction of rotation. 8) Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 3. 9) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 4. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise. 10) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. 11) Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. 12) To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. Adjust drive belts to proper tension.

447

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 36 (49) Nut ........................................................................................................................... 22 (30) Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Distributor Housing Bolt ............................................................................................ 13 (18) Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Power Steering Pump Bolt ........................................................................................................................... 29 (39) Nut ........................................................................................................................... 32 (43) Power Steering Pump Pulley Nut ............................................................................. 32 (43) Pulsation Damper ...................................................................................................... 29 (39) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt/Nut ................................................................................................ 13 (18) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4) Valve Cover Bolt ...................................................................................................... 52 (5.9)

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

Fig. 4: Retracting Timing Belt Tensioner Rod

448

LEXUS
3.0L 6-Cylinder 1998-04
REMOVAL & INSTALLATION
Labor Time Belt Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application 3.0L 6-Cyl. GS 300 1998-04 IS 300 2001-04 SC 300 1998-00 2JZ-GE ..................................................... 3.4 Hours ... ..... T215 ..................................................... 3.2 Hours ... ..... T215 ..................................................... 3.4 Hours ... ..... T215

TIMING BELT
Removal 1) Raise and support vehicle. Remove engine undercover. Drain cooling system. 2) On IS 300 M/T, remove drive belt tensioner absorber. On GS 300 and all IS 300 models, remove air cleaner inlet, air cleaner, and MAF assembly. Remove radiator and electric cooling fan assembly. On 1998-99 models, rotate serpentine drive belt tensioner COUNTERCLOCKWISE and remove belt. Tensioner bolt has LEFT-HAND threads. On 2000-04 models, rotate tensioner CLOCKWISE to remove serpentine belt.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

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

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS
3.0L 6-Cylinder 1998-04 (Cont.)
3) On SC 300, remove battery and battery tray. Drain coolant. Remove lower fan shroud. Remove radiator. Loosen 4 nuts holding fan clutch to water pump. Rotate serpentine drive belt tensioner bolt CLOCKWISE, and remove drive belt. Remove cooling fan, fan clutch, and water pump pulley. 4) On all models, remove power steering pump front bracket. Remove pump with hoses attached, and hang out of way. Remove No. 2 and No. 3 timing belt covers and gaskets. See Fig. 1. Being careful not to drop bolts inside timing belt cover, remove serpentine drive belt tensioner. 5) Using Handle (09330-00021) and Pulley Holder (09213-70011) or equivalent to hold crankshaft pulley, loosen crankshaft pulley bolt. Rotate crankshaft CLOCKWISE so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Figs. 2 and 3. 6) Timing marks on camshaft timing pulleys must align with timing marks on No. 4 timing belt cover. See Fig. 2. If not, rotate crankshaft CLOCKWISE one complete revolution (360 degrees). CAUTION: Crankshaft must be correctly positioned by aligning sub-timing mark (60 degree mark BTDC) with 0 mark on timing belt cover to prevent valves from contacting pistons. 7) Rotate crankshaft pulley 60 degrees COUNTERCLOCKWISE. Align sub-timing mark with 0 mark on timing belt cover. See Fig. 3, STEP 1. Ensure the dot marks of camshaft timing pulleys are aligned with the timing marks of No. 4 timing belt cover. See Fig. 3, STEP 2. CAUTION: If reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft timing pulley for reassembly reference. 8) DO NOT allow the crankshaft pulley to rotate. Remove crankshaft pulley bolt. 9) Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. 10) Remove crankshaft pulley using gear puller. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference (at 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.

449

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

Fig. 3: Aligning Sub-Timing Marks Fig. 2: Aligning Camshaft Timing Marks Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner pulley for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.

450

LEXUS
3.0L 6-Cylinder 1998-04 (Cont.)
9) Ensure timing marks on camshaft timing pulleys align with timing marks on timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. If timing marks are not aligned, remove timing belt and reinstall. 10) Tighten crankshaft pulley bolt to specication. Install drive belt tensioner. Install No. 2 and No. 3 timing belt covers. To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. 11) Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING.

NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Hold timing belt tensioner body, and press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .315-.346 (8.00-8.80 mm). 3) On IS 300 M/T, compress and extend drive belt tensioner absorber rod. If there is abnormal resistance or operation, replace as necessary.

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

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. NOTE: The engine should be cold before adjusting timing marks. 2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft timing pulley with timing mark on oil pump body. See Fig. 3, STEP 3. Clean oil or water off of crankshaft timing pulley, and install timing belt on crankshaft timing pulley and around idler pulley. CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft timing pulley align, and timing belt is installed in original direction of rotation. 3) Install timing belt guide with cupped side away from crankshaft timing pulley and at side against timing belt. Install gasket and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. 4) Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is aligned with 0 timing mark of No. 1 timing belt cover. See Fig. 3, STEP 4. Temporarily install crankshaft pulley bolt. CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft timing pulleys align and timing belt is installed in original direction of rotation. 5) If necessary, use spanner wrench to rotate camshaft timing pulleys so timing marks on camshaft timing pulleys align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft timing pulleys. Ensure tension exists on timing belt between camshaft timing pulleys. 6) Using press, SLOWLY apply pressure of 220-2205 lbs. (981-9807 N) on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 5. 7) Install 1.5 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 5. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner with 2 bolts. Alternately tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft CLOCKWISE. DO NOT rotate crankshaft COUNTERCLOCKWISE. 8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft CLOCKWISE 2 full revolutions from TDC to TDC.

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

Fig. 5: Retracting Timing Belt Tensioner Rod

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Timing Pulley Bolt .................................................................................... 60 (81) Crankshaft Pulley Bolt ........................................................................................... 243 (330) Drive Belt Tensioner Absorber Nut (IS 300 M/T) ..................................................... 14 (20) Drive Belt Tensioner Bolt .......................................................................................... 15 (21) Fan Clutch-To-Water Pump Nut (SC 300) ............................................................... 12 (16) Idler Pulley Bolt ....................................................................................................... 1 26 (35) Power Steering Pump Front Bracket Bolts Bottom Bolt .............................................................................................................. 38 (52) Top Bolts (2) ............................................................................................................ 43 (58) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 15 (21) INCH Lbs. (N.m) Fan-To-Fan Clutch Nuts (SC 300) .......................................................................... 65 (7.5) Timing Belt Cover Bolts .............................................................................................. 71 (8) Timing Belt Plate Bolt ................................................................................................. 71 (8)
1

Apply Loctite 242 or equivalent to bolt threads.

LEXUS
3.0L V6 1999-03
TIMING BELT APPLICATION Application 3.0L V6 1MZ-FE ES 300 1999-01 ............................... 2002-03 ............................... RX 300 1999-01 ............................... 2002-03 ...............................
1

451

Labor Time

Component Belt Kit No. Part No.

3.0 Hours ... ...... ..... ...... ..... T257 3.0 Hours ... ...... ..... ...... ..... T257 4.4 Hours ... . 1 TCK257 . ..... T257 4.4 Hours ... ...... ..... ...... ..... T257

Timing belt component kit does not include camshaft tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 90,000 miles or 72 months.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

REMOVAL & INSTALLATION


WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

Fig. 1: Exploded View Of Timing Belt & Components

TIMING BELT
Removal (ES 300) 1) Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. 2) Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers. 3) Using Pulley Holder (09213-54015) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and No. 2 timing belt covers and gaskets. See Fig. 1. Remove transverse engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. NOTE: Always turn crankshaft clockwise, as viewed from timing belt side of engine. 4) Temporarily install crankshaft pulley bolt and washer in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 5) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove crankshaft pulley bolt. 6) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 7) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing downward. Remove timing belt in the following sequence: No. 1 idler pulley, right camshaft sprocket (rewall side), No. 2 idler pulley, left camshaft sprocket (front of vehicle side), left camshaft sprocket (front of vehicle side), water pump pulley, then crankshaft sprocket.

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

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks Inspection (ES 300) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Check water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing downward. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves. 3) Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 4. Replace timing belt tensioner if distance is not .394-.425 (10.01-10.8 mm).

452

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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 specication. 10) Using new gaskets, install No. 1 and No. 2 timing belt covers. Ensure there are no gaps in gasket. Cut off any excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 12) Install generator bracket. Install engine mounting bracket No. 2 (right side) and engine moving control rod. Install fender apron seal and right front wheel. 13) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Connect engine ground strap. Adjust drive belts to proper tension.

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

Fig. 3: Identifying Timing Belt Reference Marks & Front Mark

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

Fig. 5: Retracting Timing Belt Tensioner Rod Removal (RX 300) 1) Remove the outer cowl top panel along with ventilation louvers and windshield wiper arm assembly. See Fig. 6. Remove shock tower suspension brace. Raise and support vehicle. 2) Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Remove cruise control actuator from right side of engine compartment. 3) Disconnect engine coolant reservoir hose from water outlet, if necessary. Disconnect ground strap connectors. 4) Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers. 5) Using Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove transverse engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. NOTE: Always turn crankshaft clockwise, as viewed from timing belt side of engine. 6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 7) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove crankshaft pulley bolt. 8) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation.

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion NOTE: Engine should be cold when installing timing belt. Installation (ES 300) 1) Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 3) Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. 4) Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket (front of vehicle side), No. 2 idler pulley, right camshaft sprocket (rewall side), and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. 5) Using press, SLOWLY apply about 200-2200 lbs. of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 5. Align holes in housing and push rod to hold rod in retracted position. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft clockwise 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body.

LEXUS
3.0L V6 1999-03 (Cont.)
9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing downward. Remove timing belt.

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4) Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket (front of vehicle side), No. 2 idler pulley, right camshaft sprocket (rewall 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 specication. See TORQUE SPECIFICATIONS. 7) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft clockwise 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Fig. 2. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cupped side facing outward. Install transverse engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Using new gaskets, install No. 1 and No. 2 timing belt covers. Ensure there are no gaps in gasket. Cut off excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. 12) Install generator bracket. Connect engine ground strap. Install engine mounting bracket No. 2 (right side) and engine moving control rod. Install cruise control actuator (if equipped). 13) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ES 300 ................................................................................................................... 94 (125) RX 300 Left Hand (Front End Of Vehicle Side) .............................................................. 94 (125) Right Hand (Firewall Side Of Vehicle) ................................................................. 65 (88) Crankshaft Pulley Bolt ........................................................................................... 159 (215) Engine Mounting Bracket (Right Side) Bolts ........................................................... 47 (64) Engine Moving Control Rod Bolts Inboard Bolt (Small) Except 2002-03 ES 300 ........................................................................................ 23 (32) 2002-03 ES 300 .................................................................................................... 17 (23) All Other Bolts ......................................................................................................... 47 (64) Generator Adjusting Lock Bolt .................................................................................. 13 (18) Generator Bracket-To-Engine Bolts .......................................................................... 21 (28) Generator Pivot Bolt .................................................................................................. 41 (56) Power Steering Pump Bolt ....................................................................................... 32 (43) Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43) Shock Tower Brace-To-Shock Tower Nuts (RX 300) ............................................... 59 (80) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt .......................................................................................... 1 25 (34) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Transverse Engine Mount Bracket-To-Engine Bolts ................................................ 21 (28) Wheel Lug Nut ........................................................................................................ 76 (103) Wiper Arm Nuts (RX 300) ........................................................................................ 18 (24) INCH Lbs. (N.m) Timing Belt Cover Bolts ........................................................................................... 76 (8.5) Timing Belt Plate Bolt ................................................................................................. 71 (8) Water Pump Bolt/Nut .................................................................................................. 71 (8)
1

Fig. 6: Exploded View Of Outer Cowl Top Panel (RX 300) Inspection (RX 300) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing downward. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves. 3) Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 4. Replace timing belt tensioner if distance is not .394-.425 (10.01-10.8 mm). Installation (RX 300) 1) Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 3) Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. NOTE: Engine should be cold when installing timing belt.

Apply Loctite 242 or equivalent to bolt threads.

454

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Labor Time Belt Part No. 6) Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one complete revolution. Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot. See Fig. 2. Using Sprocket Holder (09278-54012) or equivalent, slightly rotate right camshaft sprocket clockwise to release tension on timing belt. Remove timing belt from camshaft sprockets. 7) Using Pulley Holder (09213-70010) or equivalent and Handle (0933000021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. On LS 400, remove bolts/nuts and fan bracket. On SC 400, remove bolts/nuts and hydraulic pump. On all models, remove No. 1 timing belt cover, gaskets, timing belt cover spacer and gasket. See Fig. 2. 8) Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. Remove timing belt. Remove bolt, idler pulleys and plate washer (if necessary). CAUTION: If reusing timing belt, ensure installation mark exists at crankshaft sprocket. If installation mark does not exist, place installation mark on timing belt and crankshaft sprocket.

TIMING BELT APPLICATION Application

4.0L V8 1UZ-FE LS 400 1990-97 ..................................................... 4.5 Hours ... ..... T190 SC 400 1992-97 ..................................................... 4.8 Hours ... ..... T190 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-94 model years, although the manufacturer does not recommend a specic scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months for severe operating conditions. For 1995-97 model years, the manufacturer recommends the belt be replaced at 90,000 miles for normal service and 60,000 miles for severe service.

REMOVAL & INSTALLATION


TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal 1) Remove battery. Remove lower engine cover Drain cooling system. On LS 400, remove air duct located above top of radiator and air cleaner cover. Remove air cleaner assembly. Remove V-bank cover. Remove drive belt, fan clutch assembly and fan pulley. On SC 400, rotate drive belt tensioner counterclockwise. Remove drive belt. Remove coolant reservoir. 2) On all models, remove radiator. Remove A/C compressor with hoses attached, and secure aside. Remove air intake pipe between air cleaner hose and throttle body. Remove upper spark plug wiring cover. Remove engine wiring covers located near valve covers. Remove No. 3 (upper) timing belt covers. Remove spark plug wire clamps. Disconnect spark plug wires from distributor caps. 3) Disconnect high-tension wire from ignition coils. Remove spark plug wires and clamps. See Fig. 1. Remove bolt, plate and drive belt idler pulley. Remove left (drivers side) ignition coil. Disconnect cam position sensor electrical connector from clamp on No. 2 timing belt cover. Remove bolts, No. 2 timing belt covers and gaskets. See Fig. 2. It may be necessary to remove coolant pipe to access No. 2 timing belt covers. 4) Remove bolts, distributor caps and rotors. Mark component location for reassembly reference. Disconnect electrical connector at distributor housings. Remove bolts and distributor housings. See Fig. 2. Remove alternator, drive belt tensioner and spark plugs. CAUTION: If reusing timing belt, ensure the 4 installation marks exist on timing belt. If installation marks do not exist, place installation mark on timing belt, all sprockets and edge of fan bracket (LS 400) or hydraulic pump (SC 400). 5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on left side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Fig. 3.

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

Fig. 1: Removing/Installing Spark Plug Wires & Retainers Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .413-.453 (10.50-11.50 mm).

LEXUS
4.0L V8 1990-97 (Cont.)

455

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

Fig. 2: Exploded View Of Timing Belt & Components

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. 9) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specication. See TORQUE SPECIFICATIONS.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

CAUTION: Always rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise. 10) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets align with timing marks on timing belt rear plate. See Fig. 3. If timing marks are not aligned, remove timing belt and reinstall. To install remaining components, reverse removal procedure. 11) Ensure distributor housings are installed in correct location according to identication mark on front of distributor housing. Right distributor housing (viewed from rear of engine) contains an R identication mark. Left distributor housing contains an L identication mark. 12) Install rotors so rotor protrusion aligns with camshaft sprocket groove. See Fig. 7. Ensure spark plug wires are properly positioned and installed in retainers. See Fig. 1. Tighten all bolts/nuts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Fig. 3: Checking Camshaft Timing Mark Alignment

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Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) Install No. 1 idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Install No. 2 idler pulley and bolt. Tighten bolt to specication. Ensure idler pulleys are clean and rotate smoothly. Ensure idler pulley bracket moves freely. 2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. Install timing belt on crankshaft sprocket so CR installation mark on timing belt aligns with dot on crankshaft sprocket. See Fig. 5. Install timing belt on No. 1 and then No. 2 idler pulley. 3) Install timing belt guide with cupped side away from crankshaft sprocket. Flat side should be against timing belt. Install gasket and timing belt cover spacer. Install gaskets and No. 1 timing belt cover. On LS 400, install fan bracket. Install and tighten bolts/nuts to specication. See TORQUE SPECIFICATIONS. 4) On SC 400, install hydraulic pump. Install and tighten bolts/nuts to specication. On all models, align crankshaft key with key groove of crankshaft pulley. Using hammer and Pulley Installer (09223-46011) or equivalent, install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. CAUTION: Ensure camshaft sprocket is installed with identication mark facing forward, toward timing belt end of engine. Identication mark is located on camshaft sprocket, below timing belt area. Right camshaft sprocket contains an R identication mark, and left camshaft sprocket contains an L identication mark. 5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Using sprocket holder, rotate camshaft sprockets and align timing marks on camshaft sprockets with timing marks on timing belt rear plate. See Fig. 3. Align installation mark on timing belt with end of fan bracket (LS 400) or hydraulic pump (SC 400). 6) Ensure timing mark on camshaft sprockets align with timing mark on timing belt rear plate. See Fig. 3. Align installation mark on timing belt with timing mark on left camshaft sprocket. See Fig. 3. Install timing belt on left camshaft sprocket. 7) Ensure timing mark on left camshaft sprocket still aligns with timing mark on timing belt rear plate. Ensure tension exists on timing belt between left camshaft sprocket and crankshaft sprocket. Ensure timing mark on right camshaft sprocket still aligns with timing mark on timing belt rear plate.

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

Fig. 5: Identifying Timing Belt Installation Marks

LEXUS
4.0L V8 1990-97 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

457

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

Fig. 6: Retracting Timing Belt Tensioner Rod

Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 36 (49) Nut ........................................................................................................................... 22 (30) Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Distributor Housing Bolt ............................................................................................ 13 (18) Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Power Steering Pump Bolt ........................................................................................................................... 29 (39) Nut ........................................................................................................................... 32 (43) Pulsation Damper ...................................................................................................... 29 (39) Power Steering Pump Pulley Nut ............................................................................. 32 (43) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt/Nut ................................................................................................ 13 (18) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt .............................................................................. 57 (6.4) Valve Cover Bolt ...................................................................................................... 52 (5.9)

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

Fig. 7: Installing Rotors

458

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4.0L V8 1998-00
Labor Time Belt Part No. CAUTION: If reusing timing belt, check that there are 3 mating marks on belt to show installed position on crankshaft and camshaft timing pulleys. If marks are missing, place installation mating marks on timing belt and camshaft and crankshaft pulleys. Also, mark belt with arrow to indicate original direction of rotation. 8) Using Pulley Holder (09213-70010) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Loosen, but do not remove crankshaft pulley bolt. 9) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on left side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Fig. 3. 10) Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one complete revolution. 11) Rotate crankshaft clockwise about 50 degrees clockwise. Place timing mark on crankshaft pulley in line with centers of crankshaft pulley bolt and No. 2 timing belt idler pulley bolt. See Fig. 4. CAUTION: If timing belt is disengaged, having crankshaft at incorrect angle can cause piston to contact valves while removing crankshaft pulley. 12) Without moving crankshaft pulley, remove pulley bolt. Alternately loosen 2 bolts, and remove timing belt tensioner. DO NOT hold timing belt tensioner with push rod facing downward. See Fig. 1. 13) Using spanner wrench, slightly rotate right side camshaft pulley clockwise to relieve tension on timing belt. Remove timing belt from camshaft pulleys. 14) On GS 400, remove power steering pump pulley bolt and pulley. On all models, remove generator. Remove serpentine drive belt tensioner. Using gear puller, remove crankshaft pulley without rotating crankshaft. 15) Remove No. 1 timing belt cover. See Fig. 5. Noting installed direction for reassembly reference, remove timing belt guide from end of crankshaft. Remove timing belt cover spacer. 16) If reusing timing belt, place mating mark on timing belt and crankshaft timing pulley. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation and oil seal leakage. Replace idler pulleys if defective. CAUTION: Never hold timing belt tensioner facing downward. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if there are excessive oil leaks. 3) Hold timing belt tensioner body with push rod facing UPWARD. Press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 6. Replace timing belt tensioner if distance is not .413-.453 (10.50-11.50 mm). Inspect water pump for leaks or worn bearing.

TIMING BELT APPLICATION Application

4.0L V8 1UZ-FE GS 400 1998-00 ..................................................... 4.5 Hours ... ..... T298 LS 400 1998-00 ..................................................... 4.5 Hours ... ..... T298 SC 400 1998-00 ..................................................... 4.8 Hours ... ..... T298 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal 1) Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove air cleaner inlet. Remove V bank cover from top of engine. Remove air cleaner assembly and intake air connector pipe. 2) On all models, drain engine coolant. Remove upper radiator hose. 3) On GS 400 and LS 400, remove serpentine drive belt by turning drive belt tensioner pulley bolt counterclockwise. Tensioner pulley bolt is LEFT HAND threaded. On SC 400, turn serpentine drive belt tensioner bolt CLOCKWISE to relieve tension. 4) On LS 400, remove fan, fan clutch and fan pulley. On GS 400, remove electric cooling fan assembly. On SC 400, disconnect hydraulic fan motor pressure and return pipes from fan. Disconnect cooling fan inlet pipe and reservoir tank from fan shroud. 5) On all models, remove the radiator assembly. Remove No. 2 drive belt idler pulley. See Fig. 1. Disconnect camshaft position sensor wiring connector from No. 3 left side belt cover. Move engine wiring harness out of way, and remove No. 3 left side (driver side) belt cover. See Fig. 1. 6) On GS 400 and LS 400, disconnect power steering air hose from clamp on No. 3 right side belt cover. On LS 400, disconnect coolant reservoir-to-engine pipe from in front of No. 3 right side belt cover. On all models, remove No. 3 right side (passenger side) belt cover. See Fig. 1. 7) Remove A/C compressor from engine mount with hoses attached. Move A/C compressor out of way. On GS 400, remove No. 1 drive belt idler pulley and mount from engine. See Fig. 1. On LS 400, remove fan bracket from front of engine. On SC 400, remove fan hydraulic pump from front of engine. See Fig. 2.

LEXUS
4.0L V8 1998-00 (Cont.)

459

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

Fig. 1: Exploded View Of Timing Belt Covers (GS 400 Shown; Others Are Similar)

460

LEXUS
4.0L V8 1998-00 (Cont.)

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

Fig. 4: Setting Crankshaft At 50 Degrees ATDC


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

Fig. 2: Timing Belt Components (LS 400 & SC 400)

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Fig. 3: Aligning Crankshaft & Camshaft Timing Marks Installation 1) Install No. 1 idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. 2) If removed, install No. 2 idler pulley and bolt. Tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Ensure idler pulley bracket moves freely. NOTE: Engine should be cold when installing timing belt. 3) Clean any oil or water off of crankshaft timing pulley. DO NOT use solvent. Temporarily install timing belt on crankshaft timing pulley, No. 1 idler pulley, and No. 2 idler pulley. If reusing old belt, ensure mating mark on timing belt aligns with mark on crankshaft timing pulley. 4) Install timing belt guide in original direction on end of crankshaft. Install gasket and timing belt cover spacer. Install gaskets and No. 1 timing belt cover.

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

Fig. 5: Exploded View Of Timing Belt & Idler Pulleys

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

Fig. 6: Measuring Timing Belt Tensioner Rod Protrusion 5) Without rotating crankshaft, align crankshaft key with key groove of crankshaft pulley. Using hammer and Pulley Installer (09223-46011) or equivalent, install crankshaft pulley.

LEXUS
4.0L V8 1998-00 (Cont.)
6) Install serpentine drive belt tensioner. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install generator. On GS 400, install power steering pump pulley. On all models, ensure crankshaft is still at 50 degrees ATDC position. See Fig. 4. 7) Ensure camshaft timing pulleys are still aligned with mating marks on rear plate. See Fig. 3. Clean camshaft timing pulleys (do not use solvent). Install timing belt on left side (drivers side) camshaft pulley. If reusing old timing belt, ensure mating mark on belt aligns with mark on left side camshaft pulley. 8) Using spanner wrench, turn left side camshaft pulley until there is tension on timing belt between crankshaft timing pulley and left side camshaft pulley. 9) Install timing belt on right side camshaft pulley. If reusing old belt, ensure mating mark on belt aligns with mark on right side camshaft pulley. Ensure there is tension on timing belt between left side and right side camshaft pulleys. 10) Using press, SLOWLY apply about 200-2205 lbs. of pressure on push rod of timing belt tensioner until rod is retracted. Ensure timing belt tensioner is held with push rod facing upward. Holes in push rod and housing must be aligned. See Fig. 7. 11) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 7. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise. 12) Remove hexagon wrench from timing belt tensioner. Temporarily install crankshaft pulley bolt. Slowly rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets align with timing marks on timing belt rear plate. See Fig. 3. If timing marks are not aligned, remove timing belt and reinstall. 13) Tighten crankshaft pulley bolt to specication. On GS 400, install No. 1 drive belt idler pulley. On LS 400, install fan bracket. On SC 400, install fan hydraulic pump and attach lines. 14) On all models, install A/C compressor. Install No. 2 timing belt cover. Install No. 3 timing belt covers. Connect camshaft position sensor electrical connectors. Install serpentine drive belt idler pulley. 15) Install radiator assembly. Install air cleaner assembly. Fill and bleed cooling system. Start engine and open heater water valve. Maintain engine speed at 2000-2500 RPM until engine is warm. Stop engine. When engine is cool, rell coolant reservoir.

461

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 36 (49) Nut ........................................................................................................................... 22 (30) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Fan Bracket-To-Engine Bolts (LS 400) 12 mm Head ........................................................................................................... 12 (16) 14 mm Head ........................................................................................................... 24 (32) Generator Pivot & Lock Bolt ..................................................................................... 29 (39) Hydraulic Pump-To-Engine Bolts (SC 400) 12 mm Head ........................................................................................................... 12 (16) 14 mm Head ........................................................................................................... 24 (32) No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS 400) 12 mm Head ........................................................................................................... 12 (16) 14 mm Head ........................................................................................................... 24 (32) No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16) No. 1 Timing Belt Idler Pulley Pivot Bolt ............................................................... 1 25 (35) No. 2 Timing Belt Idler Pulley Bolt ........................................................................... 25 (35) Power Steering Pump Bolt ........................................................................................................................... 29 (39) Nut ........................................................................................................................... 32 (43) Power Steering Pump Pulley Center Nut GS400 ...................................................................................................................... 32 (43) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 19 (26) Water Pump Bolt GS 400 & SC 400 .................................................................................................. 15 (21) LS 400 ..................................................................................................................... 13 (18) INCH Lbs. (N.m) Camshaft Timing Pulley Bolt ................................................................................... 66 (7.5) No. 3 Camshaft Belt Cover Bolts ............................................................................ 66 (7.5)
1

Use Loctite 242 on bolt threads.

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

Fig. 7: Retracting Timing Belt Tensioner Rod

462

LEXUS
4.3L V8 GS 430 & LS 430
Labor Time Belt Part No. 7) Rotate crankshaft clockwise so cylinder No. 1 is about 50 degrees after TDC on compression stroke. Cylinder No. 1 is front cylinder on left side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Fig. 3. 8) Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one complete revolution (360 degrees). CAUTION: If the timing belt is disengaged with the crankshaft pulley at the wrong angle, this can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley, causing damage. Always set the crankshaft pulley at the correct angle. 9) Rotate crankshaft CLOCKWISE about 50 degrees. Place timing mark on crankshaft pulley in line with centers of crankshaft pulley bolt and No. 2 timing belt idler pulley bolt. See Fig. 3. NOTE: When re-using timing belt: If the installation marks have disappeared, before removal of the timing belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys. NOTE: When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt, secure one of them with string. Place matchmarks on the timing belt and right side camshaft timing pulley. 10) Without moving crankshaft pulley, remove pulley bolt. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold timing belt tensioner with push rod facing DOWN. See Fig. 1. 11) Using spanner wrench, slightly rotate right side camshaft sprocket CLOCKWISE to relieve tension on timing belt. Remove timing belt from camshaft sprockets. 12) Remove camshaft timing sprockets, power steering pump pulley and generator. Remove serpentine drive belt tensioner. Using gear puller, remove crankshaft pulley without rotating crankshaft. 13) Remove No. 1 timing belt cover. See Fig. 4. Noting installed direction for reassembly reference, remove timing belt guide from end of crankshaft. Remove timing belt cover spacer. 14) If not present, place mating mark on timing belt and crankshaft timing sprocket. Remove timing belt. NOTE: Note size and location of idler pulley bolts for reassembly reference. 15) If necessary, use a 10-mm hexagon wrench to remove No. 1 idler pulley bolt, idler pulley and plate washer. To remove No. 2 idler pulley, remove the bolt and idler pulley. To remove crankshaft timing sprocket, use Puller (0995050013). Do not turn the timing pulley during removal.

TIMING BELT APPLICATION Application

4.3L V8 3UZ-FE GS 430 2001-04 ..................................................... 4.5 Hours ... ..... T298 LS 430 2001-04 ..................................................... 4.5 Hours ... ..... T298 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove air cleaner inlet. Remove V bank cover from top of engine. On 2001-03 LS 430, also remove engine room side covers. On all models, remove air cleaner assembly and intake air connector pipe. 2) Remove serpentine drive belt by turning drive belt tensioner pulley bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND threads. 3) Remove radiator hoses and disconnect ECM outlet duct. Disconnect electric cooling fan wiring connectors and ECT switch connector for cooling fan. Disconnect automatic transmission oil cooler hoses from radiator. Remove upper radiator supports, and remove radiator and cooling fan assembly. 4) Remove No. 2 drive belt idler pulley. See Fig. 1. Remove water by-pass pipe from left side No. 3 timing belt cover. Remove No. 3 left side timing belt cover. See Fig. 1. On 2004 LS 430, disonnect power steering hoses from clamp on No. 3 right side timing belt cover. On all models, remove No. 3 right side timing belt cover and No. 2 timing belt cover. 5) Remove A/C compressor from engine with hoses attached. Move A/C compressor out of way. Remove No. 1 drive belt idler pulley. See Fig. 1. CAUTION: If reusing timing belt, check that there are 3 mating marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 2. If marks are missing, place installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original direction of rotation. 6) Using Pulley Holder (09213-70010 or 09213-70011) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Loosen, but do not remove crankshaft pulley bolt.

LEXUS
4.3L V8 GS 430 & LS 430 (Cont.)

463

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

Fig. 1: Exploded View Of Timing Belt & Components

464

LEXUS
4.3L V8 GS 430 & LS 430 (Cont.)

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

Fig. 2: Locating Timing Belt Installation Marks

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

Fig. 4: Exploded View Of Timing Belt & Idler Pulleys 3) Hold timing belt tensioner body with push rod facing UPWARD. Press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 5. Replace timing belt tensioner if distance is not .374-.413 (9.50-10.50 mm). Inspect water pump for leaks or worn bearing.

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

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

Fig. 3: Aligning Crankshaft Pulley & Camshaft Timing Marks Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation and oil seal leakage. Replace idler pulleys if defective. CAUTION: Never hold timing belt tensioner facing downward. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if there are excessive oil leaks.

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) If removed, install crankshaft timing sprocket by aligning sprocket set key with key groove of sprocket. Using Special Tool (09223-46011) and a hammer, tap in timing sprocket with ange side INWARD. See Fig. 6. 2) If removed, install No. 1 timing belt idler pulley, plate washer and pivot bolt. Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. 3) If removed, install No. 2 timing belt idler pulley and bolt. Tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Ensure idler pulley bracket moves smoothly.

LEXUS
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 specication. See TORQUE SPECIFICATIONS. CAUTION: Check that crankshaft pulley timing mark is aligned with centers of crankshaft pulley and No. 2 timing belt idler pulley bolt. 6) Install camshaft timing sprockets by aligning camshaft timing tube knock pin with pin groove of timing sprocket. Attach timing sprocket to camshaft timing tube with L or R marks facing FORWARD. Install bolts and tighten to specication. See TORQUE SPECIFICATIONS. 7) Ensure camshaft timing sprockets are still aligned with mating marks on rear plate. See Fig. 3. Clean camshaft timing sprockets (do not use solvent). Install timing belt on left side camshaft sprocket. If reusing old timing belt, ensure mating mark on belt aligns with mark on left side camshaft sprocket. 8) Using spanner wrench, turn left side camshaft sprocket COUNTERCLOCKWISE until there is tension on timing belt between crankshaft timing sprocket and left side camshaft sprocket. 9) Install timing belt on right side camshaft sprocket. If reusing old belt, ensure mating mark on belt aligns with mark on right side camshaft sprocket. Ensure there is tension on timing belt between left side and right side camshaft sprockets. 10) Using press, slowly apply about 200-2205 lbs. (981-9807 N) of pressure on push rod of timing belt tensioner until rod is retracted. Ensure timing belt tensioner is held with push rod facing upward. Holes in push rod and housing must be aligned. See Fig. 7. 11) Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 7. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specication. 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 specication. See TORQUE SPECIFICATIONS. Install No. 1 drive belt idler pulley. 14) Install A/C compressor, No. 2 timing belt cover, No. 3 timing belt cover and connect Camshaft Position (CMP) sensor electrical connectors. Install No. 2 drive belt idler pulley. 15) Install radiator assembly. Fill cooling system. Bleed cooling system and check for leaks. See COOLING SYSTEM BLEEDING. To install remaining components, reverse removal procedure. Tighten all bolts/ nuts to specication. See TORQUE SPECIFICATIONS.

465

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

Fig. 6: Installing Crankshaft Timing Sprocket

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

Fig. 7: Retracting Timing Belt Tensioner Rod

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

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

Fig. 8: Checking Timing Marks

466

LEXUS
4.3L V8 GS 430 & LS 430 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 36 (49) Nut ........................................................................................................................... 21 (29) Crankshaft Sprocket Bolt ...................................................................................... 181 (245) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Generator Pivot & Lock Bolt ..................................................................................... 29 (39) No. 1 Drive Belt Idler Pulley Bolts 12 mm Head ........................................................................................................... 12 (16) 14 mm Head ........................................................................................................... 24 (32) No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 25 (35) No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16) Power Steering Pump Bolt ........................................................................................................................... 29 (39) Nut ........................................................................................................................... 32 (43) Power Steering Pump Pulley Center Nut ................................................................ 32 (43) Spark Plug ................................................................................................................. 13 (18) Timing Belt Idler Pulley Bolts ................................................................................. 1 25 (35) Timing Belt Tensioner Bolt ........................................................................................ 19 (26) Water Pump Bolt, Nut Or Stud Bolt ......................................................................... 13 (18) INCH Lbs. (N.m) Air Cleaner Assembly Bolts ........................................................................................ 41 (5) Air Cleaner Inlet Bolts ................................................................................................. 41 (5) Camshaft Timing Sprocket Bolts ............................................................................. 66 (7.5) No. 1 & No.3 Timing Belt Cover Bolts .................................................................... 66 (7.5) Radiator Support Nuts ......................................................................................... 119 (13.5) V Block Cover ........................................................................................................... 41 (5)
1

Apply Loctite 242 or equivalent on threads of No. 1 idler pulley bolt.

LEXUS
4.3L V8 SC 430
TIMING BELT APPLICATION Application Labor Time Belt Part No.

467

4.3L V8 SC 430 2002-04 ..................................................... 3.6 Hours ... ..... T298 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

CAUTION: If reusing timing belt, check that there are 3 mating marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 3. If marks are missing, place installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original direction of rotation. 7) Using crankshaft damper bolt, rotate crankshaft CLOCKWISE so cylinder No. 1 is about 50 degrees BTDC on compression stroke. Ensure timing marks on crankshaft sprocket and oil pump body are aligned. See Fig. 4. 8) Turning hexagon wrench head portion of camshaft, align timing marks on camshaft sprockets with timing marks on timing belt rear plates. See Fig. 5. If timing marks are not aligned, rotate crankshaft CLOCKWISE one complete revolution (360 degrees). CAUTION: If the timing belt is disengaged with the crankshaft sprocket at the wrong angle, this can cause the piston head and valve head to come into contact with each other when you remove the camshaft sprocket, causing damage. Always set the crankshaft sprocket at the correct angle. 9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCKWISE about 50 degrees. See Fig. 6. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold timing belt tensioner with push rod facing DOWN. See Fig. 1. 10) Using spanner wrench, slightly rotate right side camshaft sprocket COUNTERCLOCKWISE to relieve tension on timing belt. See Fig. 7. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation and oil seal leakage. Replace idler pulleys if defective. CAUTION: Never hold timing belt tensioner with push rod facing DOWN. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if there are excessive oil leaks. 3) Hold timing belt tensioner body with push rod facing UPWARD. Press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 8. Replace timing belt tensioner if distance is not .374-.413 (9.50-10.50 mm). Inspect water pump for leaks or worn bearing, and replace as necessary.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove air cleaner inlet. Remove V bank cover from top of engine. Remove intake air connector pipe. 2) Remove radiator hoses and oil cooler tubes from radiator. Remove air cleaner assembly. Disconnect electric cooling fan wiring connectors. Remove upper radiator supports, and remove radiator and cooling fan assembly. 3) Remove serpentine drive belt by turning drive belt tensioner pulley bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND threads. 4) Remove power steering pump assembly with hoses attached, and position out of way. Remove generator. Remove A/C compressor from engine with hoses attached. Move A/C compressor out of way. NOTE: Note size and location of idler pulley bolts for reassembly reference. 5) Remove No. 2 right side timing belt cover. See Fig. 1. Remove water by-pass pipe from No. 3 left side timing belt cover. Remove No. 3 left side timing belt cover. Remove No. 2 timing belt cover sub-assembly. Remove serpentine drive belt tensioner. Remove No. 1 drive belt idler pulley. 6) Using Pulley Holder (09213-70011) and Handle (09330-00021), remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt cover. See Fig. 2. Noting installed direction for reassembly reference, remove timing belt guide (Crankshaft Position (CKP) sensor plate) from end of crankshaft.

468

LEXUS
4.3L V8 SC 430 (Cont.)

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

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS
4.3L V8 SC 430 (Cont.)

469

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

Fig. 4: Aligning Crankshaft Timing Marks

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

Fig. 5: Aligning Camshaft Timing Marks

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

Fig. 2: Exploded View Of Timing Belt & Idler Pulleys

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

Fig. 6: Aligning Crankshaft Sprocket For Timing Belt Removal

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

Fig. 3: Locating Timing Belt Installation Marks

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

Fig. 7: Removing Timing Belt

470

LEXUS
4.3L V8 SC 430 (Cont.)

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

Fig. 8: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) Turn camshaft and set No. 1 cylinder to TDC. Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 9. To ease installation of timing belt, turn left camshaft sprocket CLOCKWISE 1/2 tooth and turn right camshaft sprocket CLOCKWISE one tooth. See Fig. 10. Turn crankshaft CLOCKWISE to align timing marks of crankshaft sprocket and oil pump body. See Fig. 11. 2) Face the front mark (arrow) on timing belt forward. While aligning installation marks on timing belt with mark on appropriate sprocket, install timing belt in the following sequence: a) Crankshaft sprocket b) Idler No. 2 c) Left camshaft sprocket d) Water pump pulley e) Right camshaft sprocket f) Idler No. 1 See Fig. 3. 3) Using press, slowly apply about 220-2205 lbs. (100-1000 kg) of pressure on push rod of timing belt tensioner until rod is retracted. Ensure timing belt tensioner is held with push rod facing UPWARD. Holes in push rod and housing must be aligned. See Fig. 12. 4) Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 12. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft CLOCKWISE as viewed from front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE. 5) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. Ensure all timing marks are aligned. See Figs. 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 specication. See TORQUE SPECIFICATIONS. Using Replacer (09223-46011) and a hammer, tap in crankshaft pulley, aligning sprocket set key with key groove of sprocket. Using Pulley Holder (09213-70011) and Handle (09330-00021), install crankshaft sprocket bolt. Tighten crankshaft sprocket bolt to specication. 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 specication. See TORQUE SPECIFICATIONS. Fill cooling system, and check for leaks. See COOLING SYSTEM BLEEDING.

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

Fig. 9: Aligning Camshaft Sprocket Timing Marks

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

Fig. 10: Positioning Camshaft Sprockets For Timing Belt Installation

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

Fig. 11: Aligning Crankshaft Sprocket Timing Marks

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

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

Fig. 12: Retracting Timing Belt Tensioner Rod

LEXUS
4.3L V8 SC 430 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

471

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

Fig. 13: Installing Timing Belt Guide

Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 36 (49) Nut ........................................................................................................................... 21 (29) Crankshaft Sprocket Bolt ...................................................................................... 181 (245) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Generator Pivot & Lock Bolt ..................................................................................... 29 (39) No. 1 Drive Belt Idler Pulley Bolts 12-mm Head ............................................................................................................ 12 (16) 14-mm Head ............................................................................................................ 24 (32) No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 29 (39) No. 2 Timing Belt Cover Sub-Assembly Bolt ........................................................... 12 (16) Power Steering Pump Bolt ........................................................................................................................... 29 (39) Nut ........................................................................................................................... 32 (43) Spark Plug ................................................................................................................. 13 (18) Timing Belt Idler Pulley Bolt ................................................................................... 1 25 (35) Timing Belt Tensioner Bolt ........................................................................................ 19 (26) Water Pump Bolt ....................................................................................................... 13 (18) INCH Lbs. (N.m) 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

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

Fig. 14: Installing No. 2 Timing Belt Cover Sub-Assembly

Apply Loctite 242 or equivalent to No. 1 idler pulley bolt threads.

472

LEXUS & TOYOTA


3.3L V6 2004
Labor Time Belt Part No. CAUTION: If timing belt is disengaged, having crankshaft pulley at wrong angle can cause piston and valve to come in contact with each other when you remove crankshaft or camshaft pulleys, causing damage. Always set crankshaft pulley at correct angle. 8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing DOWN. Remove timing belt in the following sequence: a) No. 1 idler pulley b) Right camshaft sprocket (rewall side) c) No. 2 idler pulley d) Left camshaft sprocket (front of vehicle side) e) Water pump pulley f) Crankshaft sprocket

TIMING BELT APPLICATION Application 3.3L V6 3MZ-FE Camry 2004 ........................................................... Camry Solara 2004 ........................................................... ES 330 2004 ........................................................... Highlander 2004 ........................................................... RX 330 2004 ........................................................... Sienna 2004 ...........................................................

3.0 Hours ... ..... T257 3.0 Hours ... ..... T257 3.0 Hours ... ..... T257 2.5 Hours ... ..... T257 4.4 Hours ... ..... T257 4.0 Hours ... ..... T257

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT
Removal (Camry, Camry Solara & ES 330) 1) Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. 2) Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers. 3) Using Pulley Holder (09213-54015) or equivalent and Handle (09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft pulley bolt. Using puller and crankshaft pulley bolt, remove crankshaft pulley. Remove No. 2 timing belt cover and gasket. See Fig. 1. Remove right side engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. NOTE: Always turn crankshaft clockwise, as viewed from timing belt side of engine. 4) Temporarily install crankshaft pulley bolt and washer in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 5) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt rear cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution (360 degrees). Remove crankshaft pulley bolt. 6) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3. If not, place mating mark on belt where timing belt contacts crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 7) Turning crankshaft pulley, set cylinder No. 1 to about 60 degrees BTDC. See Fig. 4.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components Inspection (Camry, Camry Solara & ES 330) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Check water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing DOWN. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing UP. Press rod against solid surface. Replace timing belt tensioner if push rod moves. NOTE: Engine should be cold when installing timing belt. Installation (Camry, Camry Solara & ES 330) 1) Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE until timing mark on crankshaft sprocket is about 60 degrees BTDC. See Fig. 4.

LEXUS & TOYOTA


3.3L V6 2004 (Cont.)

473

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 (rewall side) No. 1 idler pulley If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. 5) Using press, SLOWLY apply about 200-2200 lbs. of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 5. Align holes in housing and push rod to hold rod in retracted position. Install 1.5 mm hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with appropriate timing mark on No. 3 timing belt rear cover. See Fig. 2. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cup facing out. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. 10) Using new gaskets, install No. 1 and No. 2 timing belt covers. Ensure there are no gaps in gasket. Cut off any excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 12) Install generator bracket. Install engine mounting bracket No. 2 (right side) and engine moving control rod. Install fender apron seal and right front wheel. 13) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Connect engine ground strap. Adjust drive belts to proper tension.

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

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

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

Fig. 3: Identifying Timing Belt Reference Marks & Front Mark

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

Fig. 4: Aligning Crankshaft For Removal/Installation Of Timing Belt

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

Fig. 5: Retracting Timing Belt Tensioner Rod

474

LEXUS & TOYOTA


3.3L V6 2004 (Cont.)
2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft COUNTERCLOCKWISE until timing mark on crankshaft sprocket is about 60 degrees BTDC. See Fig. 4. CAUTION: If timing belt is disengaged, having crankshaft pulley at wrong angle can cause piston and valve to come in contact with each other when you remove crankshaft or camshaft pulleys, causing damage. Always set crankshaft pulley at correct angle. 3) Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt rear cover. See Fig. 2. NOTE: Engine should be cold when installing timing belt. 4) Install timing belt in following order: Crankshaft sprocket Water pump pulley Left camshaft sprocket (front of vehicle side) No. 2 idler pulley Right camshaft sprocket (rewall side) No. 1 idler pulley If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. 5) Using press, SLOWLY apply about 200-2200 lbs. of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 5. Align holes in housing and push rod. Install 1.5 mm hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt rear cover. See Fig. 2. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cup facing out. On RX330, place wooden block on jack and jack up engine enough to install right side engine mounting bracket. On all models, Install engine mounting bracket on front of cylinder block. Install nut on engine mounting insulator. Install and tighten bolts and nut to specication. See TORQUE SPECIFICATIONS. 10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure there are no gaps in gasket. Cut off excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. 12) Install generator bracket. Connect engine ground strap. Install engine mounting bracket No. 2 (right side) and engine moving control rod. Install cruise control actuator (if equipped). 13) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Removal (Highlander, Sienna & RX 330) 1) Remove windshield wiper arms, cowl top ventilator louver sub-assembly and windshield wiper link assembly. Remove cowl top panel outer sub-assembly. See Fig. 6. 2) Raise and support vehicle. Remove right front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. 3) Remove engine moving control rod and engine mounting bracket No. 2 (right side), located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers. 4) Using Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. On RX330, remove nut and separate engine mounting insulator. Place wooden block on jack and jack up engine enough to remove right side engine mounting bracket. On Highlander and Sienna, lifting engine is not required. On all models, Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing belt side of engine. 5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 6) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution (360 degrees). Remove crankshaft pulley bolt. 7) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 3. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 8) Turning crankshaft pulley COUNTERCLOCKWISE, set cylinder No. 1 to about 60 degrees BTDC. See Fig. 4. CAUTION: If timing belt is disengaged, having crankshaft pulley at wrong angle can cause piston and valve to come in contact with each other when you remove crankshaft or camshaft pulleys, causing damage. Always set crankshaft pulley at correct angle. 9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing DOWN. Remove timing belt in following sequence: a) No. 1 idler pulley b) Right camshaft sprocket (rewall side) c) No. 2 idler pulley d) Left camshaft sprocket (front of vehicle side) e) Water pump pulley f) Crankshaft sprocket Inspection (Highlander, Sienna & RX 330) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing downward. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves. Installation (Highlander, Sienna & RX 330) 1) Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly.

LEXUS & TOYOTA


3.3L V6 2004 (Cont.)

475

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

Fig. 6: Exploded View Of Outer Cowl Top Panel (Highlander & RX-330)

476

LEXUS & TOYOTA


3.3L V6 2004 (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 92 (125) Crankshaft Pulley Bolt ........................................................................................... 162 (220) Engine Mounting Bracket (Right Side) Bolts ........................................................... 21 (28) Engine Mounting Stay Bolts ..................................................................................... 47 (64) Engine Moving Control Rod Bolts Inboard Bolt (Small) ................................................................................................ 17 (23) All Other Bolts ......................................................................................................... 47 (64) Generator Adjusting Lock Bolt .................................................................................. 13 (18) Generator Bracket-To-Engine Bolts .......................................................................... 21 (28) Generator Pivot Bolt .................................................................................................. 43 (58) Power Steering Pump Bolt ....................................................................................... 32 (43) Power Steering Pump Bracket-To-Cylinder Head Bolt ............................................ 32 (43) Timing Belt Idler Pulleys No. 1 Idler Pulley Pivot Bolt ................................................................................. 1 25 (34) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Wheel Lug Nut ........................................................................................................ 76 (103) Wiper Arm Nuts ......................................................................................................... 18 (24) INCH Lbs. (N.m) Timing Belt Cover Bolts ........................................................................................... 75 (8.5) Timing Belt Plate Bolt ................................................................................................. 71 (8) Water Pump Bolt/Nut .................................................................................................. 71 (8) Wiper Link Assembly Bolts ......................................................................................... 62 (7)
1

Apply Loctite 242 or equivalent to bolt threads.

LEXUS & TOYOTA


4.7L V8 Except GX 470 & 4Runner
TIMING BELT APPLICATION Application 4.7L V8 Land Cruiser 1998-04 ..................................................... LX 470 1998-04 ..................................................... Sequoia 2001-03 ..................................................... Tundra 2000-03 ..................................................... Labor Time Belt Part No.

477

4.5 Hours ... ..... T298 4.5 Hours ... ..... T298 3.6 Hours ... ..... T298 3.6 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 crankshaft pulley at the correct angle. 8) On 1998-2002 models only, using crankshaft pulley bolt, rotate crankshaft CLOCKWISE (viewed from front of engine) about 50 degrees ATDC. This will align crankshaft pulley groove with centerline of crankshaft pulley bolt and No. 2 idler pulley bolt. See Fig. 4. This prevents valves from contacting pistons. On all models, remove crankshaft pulley bolt. NOTE: When re-using timing belt: If the installation marks have disappeared, before removal of the timing belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys. NOTE: When replacing timing belt tensioner only: To maintain meshing of the timing pulley and timing belt, secure one of them with string. Place matchmarks on the timing belt and passengers side camshaft timing pulley. 9) Alternately loosen bolts, and remove timing belt tensioner and dust boot. Using spanner wrench in holes in camshaft sprocket, slightly rotate passengers side camshaft sprocket CLOCKWISE to release timing belt tension. Remove timing belt from camshaft sprockets. 10) Remove serpentine drive belt tensioner. See Fig. 1. Remove generator. Without letting crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1 timing belt cover. Noting direction of timing belt guide for installation reference, remove timing belt guide (Crankshaft Position (CKP) sensor plate) and timing belt cover spacer. Remove timing belt. CAUTION: DO NOT use solvent to clean crankshaft or camshaft sprockets. Wipe clean only. Inspection (Land Cruiser & LX 470) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. NEVER hold timing belt tensioner with push rod facing DOWN. 2) Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. 3) Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 5. Replace timing belt tensioner if distance is not 0.413-0.453 (10.5-11.5 mm). Inspect water pump for leaks or bearing failure. NOTE: Install timing belt with engine cold.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal (Land Cruiser & LX 470) 1) Raise and support vehicle. Remove oil pan protector. Remove lower engine cover. Drain cooling system. Remove battery clamp cover. Remove V bank cover located on top of engine. Remove air cleaner assembly with air intake hose that goes to throttle body. 2) Loosen 4 bolts/nuts holding uid coupling to cooling fan bracket. See Fig. 1. Remove serpentine drive belt, cooling fan uid coupling assembly, and fan pulley. 3) Remove radiator assembly. Remove pulley bolt, cover plate and drive belt idler pulley. Remove No. 3 timing belt cover from front of passengers side camshaft. 4) Disconnect engine wiring harness clamps for access to No. 3 timing belt cover at front of drivers side camshaft. Disconnect electrical connectors from Camshaft Position (CMP) sensor on No. 3 timing belt cover. Remove No. 3 timing belt cover. See Fig. 1. 5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C compressor with hoses attached, and set aside. Remove cooling fan bracket. CAUTION: If reusing timing belt, ensure installation mark exists at crankshaft and camshaft sprockets. If installation mark does not exist, place mating marks on timing belt and crankshaft sprocket. See Fig. 3. Also, place arrow on belt indicating direction of rotation. 6) Using Pulley Holder (09213-70010 or 09213-70010) and Handle (09330-00021), hold crankshaft pulley. Loosen crankshaft pulley bolt. 7) Rotate crankshaft CLOCKWISE (viewed from front of engine) so crankshaft pulley groove aligns with 0 timing mark on No. 1 (lower) timing belt cover. See Fig. 2. Ensure timing marks on camshaft sprockets align with marks on the timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution. Realign crankshaft pulley groove with 0 timing mark on No. 1 (lower) timing belt cover.

Installation (Land Cruiser & LX 470) 1) If No. 1 idler pulley was removed, apply Loctite 242 or equivalent to bolt threads. Ensure pulley bracket moves freely. 2) Install timing belt on crankshaft sprocket. If reusing old belt, ensure match marks made on removal are properly aligned. 3) Place timing belt around No. 1 and No. 2 idler pulleys. Install gasket and timing belt cover spacer. Install timing belt guide with cupped side facing out away from crankshaft sprocket. 4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with key in crankshaft. Tap crankshaft pulley until seated on crankshaft. 5) Install serpentine drive belt tensioner. Install generator. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Ensure timing mark on crankshaft pulley aligns with timing mark 0 of No. 1 (lower) timing belt cover. See Fig. 4.

478

LEXUS & TOYOTA


4.7L V8 Except GX 470 & 4Runner (Cont.)

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

Fig. 2: Aligning Crankshaft Timing Marks

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

Fig. 3: Locating Timing Belt Alignment Marks

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

Fig. 1: Exploded View Of Timing Belt & Components

LEXUS & TOYOTA


4.7L V8 Except GX 470 & 4Runner (Cont.)

479

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

Fig. 4: Positioning Crankshaft Pulley

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

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

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion 6) Ensure timing mark on drivers side camshaft sprocket is correctly aligned. See Fig. 6. Install timing belt on drivers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. Rotate drivers side camshaft sprocket COUNTERCLOCKWISE until tension exists on timing belt between crankshaft sprocket and drivers side camshaft sprocket. 7) Ensure passengers side camshaft sprocket timing mark is still aligned. Install timing belt on passengers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. See Fig. 6. 8) Using press, SLOWLY apply about 220-2200 lbs. (100-1000 kg) of pressure on timing belt tensioner rod until rod is retracted and holes in rod and housing are aligned. See Fig. 7. Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. 9) Release press and install dust boot on timing belt tensioner. Install timing belt tensioner on engine. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: When checking valve timing, only rotate crankshaft CLOCKWISE as viewed from front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE. 10) Remove 1.27 mm hexagon wrench from timing belt tensioner. To check valve timing, rotate crankshaft pulley CLOCKWISE 2 full revolutions from TDC to TDC. Crankshaft pulley groove must align with 0 timing mark on No. 1 (lower) timing belt cover. 11) With crankshaft at TDC position, ensure camshaft sprockets align with timing marks on rear plates. If installing old belt, ensure belt matching marks are aligned with camshaft sprockets. If timing marks are not aligned, timing belt will have to be removed and repositioned. 12) Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install radiator. Install cooling fan assembly. 13) To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING.

Fig. 6: Installing Timing Belt On Camshaft Sprocket

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

Fig. 7: Retracting Timing Belt Tensioner Rod Removal (Except Land Cruiser & LX 470) 1) Raise and support vehicle. Remove engine undercover. Drain cooling system. Remove radiator assembly. Remove throttle body cover. Remove intake air connector assembly. 2) Loosen 4 bolts holding uid coupling to cooling fan bracket. See Fig. 1. Remove serpentine drive belt, cooling fan uid coupling assembly, and fan pulley. 3) Remove power steering pump from engine with hoses attached, and secure out of way. Remove serpentine drive belt idler pulley. Remove No. 3 timing belt cover from front of passengers side camshaft. 4) Disconnect engine wiring harness clamps for access to No. 3 timing belt cover at front of drivers side camshaft. Disconnect electrical connectors from camshaft position sensor on No. 3 timing belt cover. Remove No. 3 timing belt cover. See Fig. 1. 5) Remove oil cooler pipe. Remove No. 2 timing belt cover. Remove A/C compressor with hoses attached, and set aside. Remove cooling fan bracket.

480

LEXUS & TOYOTA


4.7L V8 Except GX 470 & 4Runner (Cont.)
3) Place timing belt around No. 1 and No. 2 idler pulleys. Install gasket and timing belt cover spacer. Install timing belt guide with cupped side away from crankshaft sprocket. 4) Install No. 1 timing belt cover. Align groove of crankshaft pulley with key in crankshaft. Using Crankshaft Front Oil Seal Replacer (SST 09223-46011) and a hammer, tap crankshaft pulley until seated on crankshaft. 5) Install serpentine drive belt tensioner. Install generator. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Ensure the crankshaft pulley groove aligns with 0 timing mark on No. 1 timing belt cover. See Fig. 2. 6) Ensure timing mark on drivers side camshaft sprocket is correctly aligned. See Fig. 6. Install timing belt on drivers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. Rotate drivers side camshaft sprocket COUNTERCLOCKWISE until tension exists on timing belt between crankshaft sprocket and drivers side camshaft sprocket. 7) Ensure passengers side camshaft sprocket timing mark is still aligned. Install timing belt on passengers side camshaft sprocket. If reusing old belt, ensure installation marks are aligned. See Fig. 6. 8) Using press, SLOWLY apply about 220-2200 lbs. (100-1000 kg) of pressure on timing belt tensioner rod until rod is retracted and holes in rod and housing are aligned. See Fig. 7. Install a 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. 9) Release press and install dust boot on timing belt tensioner. Install timing belt tensioner on engine. Install and alternately tighten bolts to specication. CAUTION: When checking valve timing, only rotate crankshaft CLOCKWISE as viewed from front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE. 10) Remove 1.27 mm hexagon wrench from timing belt tensioner. To check valve timing, rotate crankshaft pulley CLOCKWISE 2 full revolutions from TDC to TDC. Crankshaft pulley groove must align with 0 timing mark on No. 1 (lower) timing belt cover. 11) With crankshaft at TDC position, ensure camshaft sprockets align with timing marks on rear plates. If installing old belt, ensure belt installation marks are aligned with camshaft sprockets. If installation marks are not aligned, timing belt will have to be removed and repositioned. 12) Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install fan bracket. Install A/C compressor. Install No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install radiator. Install cooling fan assembly. 13) To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING.

CAUTION: If reusing timing belt, ensure installation marks exist at crankshaft and camshaft sprockets on timing belt. If installation marks do not exist, place matching marks on timing belt before removing timing belt. See Fig. 3. Also, place arrow on belt indicating direction of rotation. 6) Using Pulley Holder (09213-70011) and Handle (09330-00021), hold crankshaft pulley. Loosen crankshaft pulley bolt. 7) Rotate crankshaft CLOCKWISE (viewed from front of engine) so crankshaft pulley groove aligns with 0 timing mark on No. 1 (lower) timing belt cover. See Fig. 2. 8) Ensure timing marks on camshaft sprockets align with marks on the timing belt rear plates. See Fig. 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution. Realign crankshaft pulley groove with 0 timing mark on No. 1 (lower) timing belt cover). Remove crankshaft pulley bolt. NOTE: When re-using timing belt: If the installation marks have disappeared, before removal of the timing belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys. NOTE: When replacing timing belt tensioner only: To maintain meshing of the timing pulley and timing belt, secure one of them with string. Place matchmarks on the timing belt and passengers side camshaft timing pulley. 9) Remove generator. Alternately loosen bolts, and remove timing belt tensioner and dust boot. Using spanner wrench in holes in camshaft sprocket, slightly rotate passengers side camshaft sprocket CLOCKWISE to release timing belt tension. Remove timing belt from camshaft sprockets. 10) Remove serpentine drive belt tensioner. See Fig. 1. Without letting crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1 timing belt cover. Noting direction of timing belt guide for installation reference, remove timing belt guide (crankshaft position sensor plate) and timing belt cover spacer. Remove timing belt. CAUTION: DO NOT use solvent to clean crankshaft or camshaft sprockets. Wipe clean only. Inspection (Except Land Cruiser & LX 470) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Check timing belt cover gaskets and condition of covers. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. NEVER hold timing belt tensioner with push rod facing DOWN. 2) DO NOT allow tensioner push rod to face downward. Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. 3) Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 5. Replace timing belt tensioner if distance is not 0.413-0.453 (10.5-11.5 mm). Inspect water pump for leaks or bearing failure. NOTE: Install timing belt with engine cold. Installation (Except Land Cruiser & LX 470) 1) If idler pulleys were removed, apply Loctite 242 or equivalent to bolt threads. Install idler pulleys and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure pulley bracket moves freely. 2) Install timing belt on crankshaft sprocket. If reusing old belt, ensure installation marks (made on removal) are properly aligned with crankshaft pulley.

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

LEXUS & TOYOTA


4.7L V8 Except GX 470 & 4Runner (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Mount Bolt ................................................................................ 36 (49) Air Intake Chamber Bolt/Nut ..................................................................................... 13 (18) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Cooling Fan Bracket 12-mm Head ............................................................................................................ 12 (16) 14-mm Head ............................................................................................................ 24 (32) Cooling Fan Fluid Coupling-To-Cooling Fan Bracket Except Sequoia ....................................................................................................... 16 (21) Sequoia .................................................................................................................... 21 (29) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Drive Belt Idler Pulley Bolt ....................................................................................... 27 (37) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Generator Land Cruiser & LX 470 1998-02 .................................................................................................................. 29 (39) 2003-04 10-mm Bolt & Nut ............................................................................................... 29 (39) 8-mm Nut ............................................................................................................. 16 (11) Sequoia 10-mm Bolt & Nut ................................................................................................. 29 (39) 8-mm Nut ............................................................................................................... 16 (11) Tundra ...................................................................................................................... 29 (39) No. 1 & No. 2 Idler Pulley Bolt .............................................................................. 1 25 (35) No. 2 Timing Belt Cover Bolt ................................................................................... 12 (16) Power Steering Pump Land Cruiser, LX 470 & Sequoia ........................................................................... 13 (17) Tundra Bolt & Nut .............................................................................................................. 33 (44) Stud Bolt ................................................................................................................ 16 (22) Radiator Bracket-To-Body Bolt .................................................................................. 12 (18) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 19 (26) Water Pump Stud Bolt & Nut ....................................................................................................... 13 (18) Bolt ........................................................................................................................... 15 (21) INCH Lbs. (N.m) Fan Shroud ............................................................................................................... 44 (5.0) No. 1 & No. 3 Timing Belt Cover Bolt .................................................................... 66 (7.5) Radiator Mounting Bolt ........................................................................................... 106 (12) V Bank Cover Bolt ................................................................................................. 66 (7.5)
1

481

Apply Loctite 242 or equivalent to idler pulley bolt threads.

482

LEXUS & TOYOTA


4.7L V8 GX 470 & 4Runner
Labor Time Belt Part No. CAUTION: If the timing belt is disengaged with the crankshaft sprocket at the wrong angle, this can cause the piston head and valve head to come into contact with each other when you remove the camshaft sprocket, causing damage. Always set the crankshaft sprocket at the correct angle. 9) Using crankshaft damper bolt, rotate crankshaft COUNTERCLOCKWISE about 50 degrees. See Fig. 5. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. DO NOT hold timing belt tensioner with push rod facing DOWN. See Fig. 1. 10) Using spanner wrench, slightly rotate right side camshaft sprocket COUNTERCLOCKWISE to relieve tension on timing belt. See Fig. 6. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation and oil seal leakage. Replace idler pulleys if defective. CAUTION: Never hold timing belt tensioner with push rod facing DOWN. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if there are excessive oil leaks. 3) Hold timing belt tensioner body with push rod facing UP. Press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 7. Replace timing belt tensioner if distance is not .440-.480 (11.20-12.20 mm). Inspect water pump for leaks or worn bearing, and replace as necessary. Installation 1) Turn camshaft and set No. 1 cylinder to TDC. Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 8. To ease installation of timing belt, turn left camshaft sprocket CLOCKWISE 1/2 tooth and turn right camshaft sprocket CLOCKWISE one tooth. See Fig. 9. Turn crankshaft CLOCKWISE to align timing marks of crankshaft sprocket and oil pump body. See Fig. 10. 2) Face the front mark (arrow) on timing belt forward. While aligning installation marks on timing belt with mark on appropriate sprocket, install timing belt in the following sequence: a) Crankshaft timing sprocket b) Idler pulley No. 2 c) Left camshaft sprocket d) Water pump pulley e) Right camshaft sprocket f) Idler pulley No. 1 See Fig. 2. 3) Using press, slowly apply about 220-2205 lbs. (100-1000 kg) of pressure on push rod of timing belt tensioner until rod is retracted. Ensure timing belt tensioner is held with push rod facing upward. Holes in push rod and housing must be aligned. See Fig. 11. 4) Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 11. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft CLOCKWISE as viewed from front of engine. DO NOT rotate crankshaft COUNTERCLOCKWISE. 5) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. Ensure all timing marks are aligned. See Figs. 3 and 4. If timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft damper bolt. Install timing belt guide. See Fig. 12.

TIMING BELT APPLICATION Application

4.7L V8 GX 470 2003-04 ..................................................... 3.5 Hours ... ..... T298 4Runner 2003-04 ..................................................... 3.5 Hours ... ..... T298 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove air cleaner hose assembly. Remove V bank cover from top of engine. Remove 11 clips, and remove upper radiator support seal. 2) Remove serpentine drive belt by turning drive belt tensioner pulley bolt COUNTERCLOCKWISE. Tensioner pulley bolt has LEFT-HAND threads. 3) Remove 2 oil cooler hoses from fan shroud. Remove 3 bolts, and separate fan shroud from radiator. Remove 4 nuts, and separate fan w/uid coupling from engine. Remove fan shroud and fan w/uid coupling assembly from vehicle. 4) Remove power steering pump assembly with hoses attached, and position out of way. Remove generator. Remove A/C compressor from engine with hoses attached. Move A/C compressor out of way. NOTE: Note size and location of idler pulley bolts for reassembly reference. 5) Remove No. 2 idler pulley. See Fig. 1. Remove oil cooler pipe. Disconnect Camshaft Position (CMP) sensor connector and wires, and remove No. 3 left side timing belt cover. Remove No. 3 right side timing belt cover. Remove No. 2 timing belt cover. Remove serpentine drive belt tensioner. Remove cooling fan bracket assembly. 6) Using Pulley Holder (09213-70011) and Handle (09330-00021), remove crankshaft pulley bolt. Using Crankshaft Pulley and Gear Puller Set (09950-50013), remove crankshaft pulley. Remove No. 1 timing belt cover. See Fig. 1. Noting installed direction for reassembly reference, remove timing belt guide from end of crankshaft. CAUTION: If reusing timing belt, check that there are 3 mating marks on belt to show installed position on crankshaft and camshaft timing sprockets. See Fig. 2. If marks are missing, place installation mating marks on timing belt and camshaft and crankshaft sprockets. Also, mark belt with arrow to indicate original direction of rotation. 7) Using crankshaft damper bolt, rotate crankshaft CLOCKWISE so cylinder No. 1 is about 50 degrees BTDC on compression stroke. Ensure timing marks on crankshaft sprocket and oil pump body are aligned. See Fig. 3. 8) Turning hexagon wrench head portion of camshaft, align timing marks on camshaft sprockets with timing marks on timing belt rear plates. See Fig. 4. If timing marks are not aligned, rotate crankshaft CLOCKWISE one complete revolution.

LEXUS & TOYOTA


4.7L V8 GX 470 & 4Runner (Cont.)

483

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

Fig. 2: Locating Timing Belt Installation Marks

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

Fig. 3: Aligning Crankshaft Timing Marks

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

Fig. 4: Aligning Camshaft Timing Marks

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

Fig. 1: Exploded View Of Timing Belt & Components

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

Fig. 5: Aligning Crankshaft Sprocket For Timing Belt Removal

484

LEXUS & TOYOTA


4.7L V8 GX 470 & 4Runner (Cont.)

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 Timing Belt Installation

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

Fig. 7: Measuring Timing Belt Tensioner Rod Protrusion 6) Install timing belt No. 1 cover, and tighten bolts to specication. 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 specication. 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 specication. See TORQUE SPECIFICATIONS. Fill cooling system, and check for leaks. See COOLING SYSTEM BLEEDING.

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

Fig. 10: Aligning Crankshaft Sprocket Timing Marks

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

Fig. 11: Retracting Timing Belt Tensioner Rod

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

Fig. 8: Aligning Camshaft Sprocket Timing Marks

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

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

Fig. 12: Installing Timing Belt Guide

LEXUS & TOYOTA


4.7L V8 GX 470 & 4Runner (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

485

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

Fig. 13: Installing No. 2 Timing Belt Cover

Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................................................................... 34 (47) Nut ........................................................................................................................... 18 (25) Cooling Fan Bracket Bolt 12-mm ...................................................................................................................... 12 (16) 14-mm ...................................................................................................................... 24 (32) Crankshaft Sprocket Bolt ...................................................................................... 181 (245) Drive Belt Tensioner Bolt/Nut .................................................................................... 12 (16) Fan W/Fluid Coupling Nut ........................................................................................ 21 (29) Generator Bolt ........................................................................................................................... 29 (39) M8 Nut ..................................................................................................................... 11 (16) M10 Nut ................................................................................................................... 29 (39) No. 2 Drive Belt Idler Pulley Bolt ............................................................................. 29 (39) Power Steering Pump Bolt/Nut ................................................................................. 32 (43) Timing Belt Idler Pulley Bolt ................................................................................... 1 25 (35) Timing Belt Tensioner Bolt ........................................................................................ 19 (26) Water Pump Bolt ....................................................................................................... 13 (18) INCH Lbs. (N.m) Camshaft Timing Sprocket Bolt ............................................................................... 66 (7.5) Fan Shroud Bolts ........................................................................................................ 44 (5) Timing Belt Cover Bolt ............................................................................................. 66 (7.5) Oil Cooler Pipe Bolt/Nut ........................................................................................... 66 (7.5) V Bank Cover ........................................................................................................ 66 (7.5)
1

Apply Loctite 242 or equivalent to No. 1 idler pulley pivot bolt threads.

486

MAZDA
1.5L 4-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.5L 4-Cyl. Protege 1995-97 ............................... 2.4 Hours ... .. TCK266 .. ..... T266 1998 Up To Engine No. 194742 ..................... 2.4 Hours ... .. TCK266 .. ..... T266 From Engine No. 194743 ..................... 2.4 Hours ... .. TCK266 .. ..... T308
1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.
Courtesy of Mazda Motors Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks Installation 1) Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). Align timing marks on camshaft sprocket and crankshaft. See Fig. 2. Ensure crankshaft timing mark is at TDC of compression stroke. Install belt around crankshaft sprocket. Working in a counterclockwise direction, route belt around pulleys and camshaft sprocket. 2) Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. 3) Letter Z on camshaft pulley and pin on crankshaft pulley boss should face upward. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 4) Check timing belt deection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 3. Ensure timing belt deection is .28-.35 (7.0-9.0 mm). 5) Ensure grooves on valve cover are free of oil, water, and dirt. Using new valve cover gasket, install valve cover. Tighten valve cover bolts in sequence. See Fig. 1. To complete installation, reverse removal procedure.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right side cover and undercover. 2) Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary. Remove crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub. 3) Remove spark plug wires. Remove valve cover bolts in reverse order of tightening sequence. See Fig. 1. Remove valve cover. Remove dipstick tube. 4) Remove upper timing belt cover. Support engine with jack. Remove engine mount bracket from timing belt end of engine. If timing belt is to be reused, mark timing belt rotation direction. Ensure timing marks on camshaft and crankshaft sprockets are aligned. See Fig. 2. 5) Remove lower and middle timing belt covers. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt.

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Deection

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Crankshaft Pulley-To-Pulley Boss Bolt ......................................... ................... 9-13 (12-18) Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167) Timing Belt Tensioner Bolt ............................................................ ................. 27-38 (37-51) Wheel Lug Nuts ...................................................................................................... 80 (110) INCH Lbs. (N.m)
Courtesy of Mazda Motors Corp.

Timing Belt Adjuster Bolt .................................................................................. 71-97 (8-11) Timing Cover Bolt ............................................................................................. 71-97 (8-11) Valve Cover Bolt ............................................................................................... 62-97 (7-11)

Fig. 1: Identifying Valve Cover Bolt Tightening Sequence Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring free length. Specied length is 2.80 (71 mm). Replace parts as necessary.

MAZDA
1.6L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 1.6L 4-Cyl. DOHC Protege 1999-01 ....................................................
1

487

Labor Time

Belt Part No.

2.7 Hours .. ..... T308

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1999-00 vehicles, the manufacturer recommends belt replacement interval at 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001 vehicles, inspect timing belt at 60,000 and replace at 105,000 miles, UNLESS the vehicle is operated in outside temperatures under 0F (-18C). Under this condition, replace timing belt at 60,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove camshaft position sensor from left side (exhaust) of engine. Remove ignition coils. Remove valve cover. 2) Remove accessory drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Groove in crankshaft pulley should align with T mark on timing belt cover. 3) Remove crankshaft pulley from pulley boss. See Fig. 1. Note installed position, and remove plate from pulley boss. Holding crankshaft, loosen crankshaft pulley boss bolt. 4) Support engine with jack or from above with support bar. Remove engine mount from timing belt end of engine. 5) Remove timing belt covers. See Fig. 1. If timing belt is to be reused, mark timing belt rotation direction. 6) Ensure camshaft and crankshaft timing marks are aligned correctly. See Fig. 2. Pulley boss position pin on crankshaft should be facing up. If not, rotate crankshaft until marks are aligned. Remove crankshaft pulley boss. 7) Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt. Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 2.43 (61.8 mm). Replace parts as necessary. Installation 1) Install tensioner spring with damper rubber closing face on side away from tensioner. See Fig. 3. 2) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 2. Temporarily secure tensioner with spring fully extended. Install belt around crankshaft sprocket, idler pulley, exhaust camshaft, intake camshaft, then tensioner. 3) Temporarily install crankshaft pulley boss and bolt. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Rotate crankshaft clockwise almost 2 complete turns. 4) Remove the crankshaft pulley boss bolt and pulley boss. Ensure the crankshaft timing belt pulley mark is aligned with tensioner set mark. See Fig. 4. If not, rotate crankshaft to align. 5) While holding timing belt tensioner, tighten lock bolt to specication. See TORQUE SPECIFICATIONS. 6) Install crankshaft boss, and tighten bolt to specication. See TORQUE SPECIFICATIONS. Turn crankshaft clockwise 2 revolutions. Face pin on crankshaft pulley boss straight up. Ensure camshaft
Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks sprocket timing marks are correctly aligned. See Fig. 2. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 7) Check timing belt deection with 22 lbs. (10 kg) of downward pressure applied to belt, midway between camshaft sprockets. Timing belt deection should be 0.24-0.29 (6.0-7.5 mm). If not, readjust timing belt tension. 8) To complete installation, reverse removal procedure. When installing valve cover, tighten valve cover bolts in correct sequence. See Fig. 5. 9) Adjust air gap between crankshaft plate and Crankshaft Position (CKP) sensor. With a plate tooth directly centered over CKP sensor, air gap should be 0.020-0.059 (0.5-1.54 mm). Adjust accessory drive belts to proper tension.

488

MAZDA
1.6L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60) Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167) Engine Mount Nut/Bolt .................................................................. ................. 44-59 (59-80) Engine Mount-To-Engine Bolt ....................................................... ................. 50-68 (67-93) Idler Pulley Bolt ............................................................................. ................. 28-38 (38-52) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52) INCH Lbs. (N.m) Camshaft Position Sensor Bolt ......................................................................... 69-95 (8-11) Crankshaft Position Sensor Bolt ....................................................................... 69-95 (8-11) Crankshaft Pulley-To-Pulley Boss Bolt ......................................... ....... 109-151 (12.3-17.1) Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11) Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 3: Installing Timing Belt Tensioner Spring

Courtesy of Mazda Motors Corp.

Fig. 4: Aligning Timing Belt At Tensioner Set Mark

Courtesy of Mazda Motors Corp.

Fig. 5: Identifying Valve Cover Bolt Tightening Sequence

MAZDA
1.6L & 1.8L 4-Cylinder 1986-95
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

489

1.6L 4-Cyl. DOHC MX-3 1994-95 ................................ MX-5 Miata 1990-93 ............................ ... 323 1988-89 ............................ ... 1.6L 4-Cyl. SOHC MX-3 1992-93 ............................ ... 323 1986 ................................. ... 1987-89 ............................ ... 1990-94 ............................ ... 1.8L 4-Cyl. DOHC Protege 1990-94 ............................ ... 1.8L 4-Cyl. SOHC Protege 1990-94 ............................ ...
1

2.9 Hrs .... .. TCK179 .. ..... T179 3.0 Hrs. ... .. TCK179 .. ..... T179 2.8 Hrs. ... ...... ..... ...... ..... T149

2.0 Hrs. ... .. TCK185 .. ..... T185

1 1

2.0 Hrs. ... ...... ..... ...... ..... T123 2.0 Hrs. ... .. TCK141 .. ..... T141 1 2.0 Hrs. ... .. TCK185 .. ..... T185
1

2.8 Hrs. ... .. TCK179 .. ..... T179

2.0 Hrs. ... .. TCK185 .. ..... T185

Courtesy of Mazda Motors Corp.

With Air Conditioning add .2 hours. With Power Steering, add .2 hours.

Fig. 1: Exploded View Of Timing Belt & Components (MX-5 Miata)

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1992 and earlier model years, the manufacturer recommends the belt be replaced every 60,000 miles. For 1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal (MX-5 Miata) 1) Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner lter housing. Remove splash shield. 2) Remove drive belt(s) and water pump pulley. See Fig. 1. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub. 3) Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See Fig. 2. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt. Removal (MX-3, Protege & 323) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash panels. 2) Remove drive belts and water pump pulley. See Fig. 3, 4 or 5. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub. 3) Remove timing belt covers. If timing belt is to be reused, mark timing belt rotation direction. Align timing marks on camshaft sprocket(s). See Figs. 2 and 6. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Camshaft Timing Marks (DOHC Engines) Inspection (All Models) Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary. Installation (All Models) 1) Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). Align timing marks on camshaft sprocket(s). See Figs. 2 and 6. Ensure crankshaft timing mark is at TDC. Install belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around camshaft sprocket(s). 2) Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. 3) On all engines, check timing belt deection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 7. Ensure timing belt deection is within specication. See TIMING BELT DEFLECTION table. Adjust drive belts to proper tension.

490

MAZDA
1.6L & 1.8L 4-Cylinder 1986-95 (Cont.)

TIMING BELT DEFLECTION


1 Deection In. (mm) Application 1986-89 .......................................................... ......................................... .47-.51 (11.9-13.0) 1990-95 DOHC ........................................................... ........................................... .35-.45 (9.0-11.5) SOHC ........................................................... ......................................... .43-.51 (11.0-13.0) 1

Deection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 7.

Courtesy of Mazda Motors Corp.

Fig. 5: Exploded View Of Timing Belt & Components (DOHC Except MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 3: Exploded View Of Timing Belt & Components (1989 SOHC)

Courtesy of Mazda Motors Corp.

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

Courtesy of Mazda Motors Corp.

Fig. 4: Exploded View Of Timing Belt & Components (1990 & Later SOHC)

MAZDA
1.6L & 1.8L 4-Cylinder 1986-95 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

491

Application Ft. Lbs. (N.m) A/C Compressor Bracket MX-5 Miata .................................................................................................... 11-16 (15-22) MX-3, Protege & 323 .................................................................. ................. 17-26 (23-35) Alternator Top Bolt ........................................................................ ................. 27-38 (37-52) Camshaft Sprocket Bolt ................................................................ ................. 36-45 (49-61) Crankshaft/Timing Belt Sprocket Bolt 1986-91 ...................................................................................................... 80-87 (109-118) 1992-95 .................................................................................................. 116-123 (157-167) Power Steering Pump-To-Bracket Bolt MX-3, Protege & 323 .................................................................. ................. 27-38 (37-52) Timing Belt Tensioner Bolt DOHC .......................................................................................... ................. 27-38 (37-52) SOHC ........................................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Camshaft/Rocker Cover Bolt DOHC & SOHC (Top) ................................................................. ..................... 43-78 (5-9) SOHC (Timing Belt Cover-To-Camshaft Cover) ............................................. 69-95 (8-11) Crankshaft Pulley Bolts ................................................................. ............. 109-152 (12-17)

Courtesy of Mazda Motors Corp.

Fig. 7: Measuring Timing Belt Deection

492

MAZDA
1.8L 4-Cylinder BP Engine
Labor Time Component Belt Kit No. Part No. 10) Install pulley boss on crankshaft to temporarily tighten with pulley lock bolt. Ensure timing marks on camshaft sprockets and crankshaft sprockets are aligned. See Fig. 3. 11) Loosen timing belt tensioner lock bolt. Move tensioner away from belt with spring fully expanded, and tighten lock bolt. Remove timing belt.

TIMING BELT APPLICATION Application

1.8L 4-Cyl. DOHC MX-5 Miata 1994-97 ............................ ... 1999-00 ............................ ... 2001-04 ............................ ... Protege 1995-98 ............................ ...
1

1 1

2.6 Hrs. ... .. TCK179 .. ..... T179 2.5 Hrs. ... .. TCK179 .. ..... T179 1 2.7 Hrs. ... .. TCK179 .. ..... T179
1

2.4 Hrs. ... .. TCK179 .. ..... T179

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: Engine identication code is on machined pad at left rear end of engine, at transmission mating ange. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1994-96 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1997-98 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999-00 vehicles, the replacement interval is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001-04 MX-5 Miata, the replacement interval is 60,000 miles.
Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (1994-00 MX-5 Miata) Removal (Protege) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash shield from wheelwell. 2) Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley from crankshaft pulley boss. See Fig. 4. 3) Remove spark plug wires from spark plugs. Remove valve cover. Remove dipstick pipe. Remove upper timing belt cover. If timing belt is to be reused, mark timing belt rotation direction. 4) Support engine from above, and remove engine mount bracket from timing belt end of engine. Remove middle and lower timing belt covers. 5) Holding crankshaft stationary, remove crankshaft pulley boss. Align timing marks on crankshaft and camshaft sprocket(s). See Fig. 3. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt. Inspection (All Models) 1) Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner and idler pulley bearing for looseness or roughness of rotation. Replace parts as necessary. 2) Inspect tensioner spring for stretching. Replace tensioner spring if free length is not greater than 2.33 (59.2 mm). Free length is measured between inside edges of hooked portions of spring.

REMOVAL & INSTALLATION


TIMING BELT
Removal (MX-5 Miata) 1) Disconnect negative battery cable. Drain cooling system. Remove front strut bar and strut brackets, if equipped. 2) Disconnect Intake Air Temperature (IAT) sensor harness connector. Remove air cleaner cover and necessary air hoses or pipes. Remove drive belt(s). 3) Remove Camshaft Position (CMP) sensor, if equipped. Remove Crankshaft Position (CKP) sensor. 4) Remove high tension leads and ignition coil(s). Remove spark plugs. 5) Remove upper radiator hose and by-pass hoses from thermostat housing. See Fig. 1 or 2. 6) If equipped with an control valve and pipe, remove oil pipe and cover with a shop rag to prevent oil spill. Remove Oil Control Valve (OCV) case. 7) Remove water pump pulley, crankshaft pulley and crankshaft position sensor plate. See Fig. 1 or 2. 8) Remove crankshaft pulley from crankshaft pulley boss. Remove plate with crankshaft pulley. Ensure crankshaft pulley boss locating pin faces straight up. Holding crankshaft pulley boss stationary, remove crankshaft pulley boss bolt. Remove pulley boss. 9) Remove upper, middle, and lower timing belt covers. If timing belt is to be reused, mark timing belt with arrow to indicate rotation direction.

MAZDA
1.8L 4-Cylinder BP Engine (Cont.)

493

Courtesy of Mazda Motors Corp.

Fig. 2: Exploded View Of Timing Belt & Components (2001-04 MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks

494

MAZDA
1.8L 4-Cylinder BP Engine (Cont.)

Courtesy of Mazda Motors Corp.

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

MAZDA
1.8L 4-Cylinder BP Engine (Cont.)
Installation (All Models) 1) Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). See Fig. 3. Align timing marks on camshaft sprocket(s). Timing mark on intake camshaft sprocket is an I; timing mark on exhaust camshaft is an E. 2) Install timing belt tensioner spring with damper rubber closing face away from tensioner. See Fig. 5. Temporarily secure the timing belt tensioner with tensioner spring fully expanded. 3) Install timing belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around idler pulley, camshaft sprocket(s), and tensioner pulley. Ensure there is no slack in belt between crankshaft sprocket, idler pulley, and camshaft sprockets. 4) Temporarily install the crankshaft pulley boss and bolt. Rotate crankshaft about 2 turns in direction of normal engine rotation. Align timing belt pulley boss mark with tensioner set mark for correct timing belt tension adjustment. See Fig. 6. 5) Holding crankshaft stationary, remove the crankshaft pulley boss and bolt. Ensure the crankshaft and camshaft timing marks are still aligned. Loosen timing belt tensioner lock bolt to apply tension to timing belt. Without moving tensioner, tighten tensioner lock bolt to specication. See TORQUE SPECIFICATIONS. 6) Install crankshaft pulley boss, and nal tighten bolt to specication. 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 deection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 7. Ensure timing belt deection is .35-.45 (8.5-11.5 mm). 8) To install remaining components, reverse removal procedure. While installing valve cover gasket, apply light bead of silicone sealer to 6 corners where gasket meets ends of camshafts. Tighten all valve cover bolts in the correct sequence. See Fig. 8. CAUTION: When installing OCV case, do not damage O ring of OCV adopter on camshaft cap, or it may cause hydraulic leakage. When installing oil pipe, no load should be applied on any connection part, or it may cause oil leakage. 9) On MX-5 Miata, install OCV case using several steps to tighten bolts to specication in the sequence shown. See Fig. 9. Install OCV lter so that it aligns with the projected part on ange 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, ll and bleed cooling system. Fill with 50/50 mix of water and coolant. To bleed system, ll system. Run engine at 2500 RPM for 5 minutes. Run engine at 3000 RPM for 5 minutes. Recheck coolant level and ll as necessary. On Protege, check ignition timing.

495

Courtesy of Mazda Motors Corp.

Fig. 6: Aligning Timing Belt At Tensioner Set Mark

Courtesy of Mazda Motors Corp.

Fig. 7: Measuring Timing Belt Deection

Courtesy of Mazda Motors Corp.

Fig. 8: Identifying Valve Cover Bolt Tightening Sequence

Courtesy of Mazda Motors Corp. Courtesy of Mazda Motors Corp.

Fig. 5: Installing Timing Belt Tensioner Spring

Fig. 9: Identifying OCV Case Bolts Tightening Sequence (MX-5 Miata)

496

MAZDA
1.8L 4-Cylinder BP Engine (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Pivot Bolt ...................................................................... ................. 28-38 (38-51) Alternator Top Bolt ........................................................................ ................. 14-18 (19-25) Camshaft Sprocket Bolt ................................................................ ................. 37-44 (50-60) Crankshaft Pulley Boss Bolt ................................................................... 116-123 (157-167) Crankshaft Pulley-To-Pulley Boss ................................................. ................... 9-13 (12-18) Engine Mount Bracket Nuts (Protege) ......................................... ............... 55-77 (75-104) Idler Pulley Bolt ............................................................................. ................. 28-38 (38-51) Ignition Coil Mounting Bolt (1999-00) ........................................... ................. 14-18 (19-24) Spark Plugs ..................................................................................................... 11-16 (15-22) Strut Bar Bolt ................................................................................. ................. 12-16 (16-22) Strut Bar Bracket Nut .................................................................... ................. 22-27 (30-37) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51) Wheel Lug Nut (Protege) .............................................................. ............... 66-94 (89-127) INCH Lbs. (N.m) Ignition Coil Mounting Bolt (2001-2004) ........................................................... 70-95 (8-11) Radiator Drain Plug ....................................................................... ................. 7-10 (0.7-1.1) Timing Belt Cover Bolt ...................................................................................... 71-97 (8-11) Valve Cover Bolt Except 2001-03 MX-5 Miata ....................................................... ..................... 43-78 (5-9) 2001-03 MX-5 Miata ....................................................................................... 71-97 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 10: Installing OCV Filter (MX-5 Miata)

Courtesy of Mazda Motors Corp.

Fig. 11: Identifying Top Oil Pipe Bolt Tightening Sequence (MX-5 Miata)

Courtesy of Mazda Motors Corp.

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

MAZDA
1.8L 4-Cylinder FP Engine
TIMING BELT APPLICATION Application 1.8L 4-Cyl. DOHC Protege 1999-00 ....................................................
1

497

Labor Time

Belt Part No.

CAUTION: Crankshaft position sensor rotor is on rear of crankshaft pulley. DO NOT damage rotor when removing crankshaft pulley. 3) Remove crankshaft pulley and guide plate (large washer). Loosen valve cover bolts in 2-3 steps. See Fig. 2. Remove valve cover and gasket. 4) Remove dipstick tube. Remove upper and lower timing belt covers. Support engine from above. Remove engine mount at timing belt end of engine. 5) If reusing timing belt, mark arrow on belt to indicate direction of rotation. Install crankshaft pulley bolt nger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 3. 6) Turn tensioner clockwise with a hex wrench to relieve spring tension, and then disconnect spring. Remove timing belt. Remove tensioner and idler pulley (if necessary). Inspection Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44 (36.6 mm). Replace parts as necessary. Installation 1) Install tensioner, and idler pulley (if removed). Temporarily tighten tensioner with spring fully retracted. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 3. 2) Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler side of timing belt.

2.4 Hours .. ..... T316

With Air Conditioning, add .2 hours.

NOTE: Engine code is stamped on machined pad on lower left end of engine, on transaxle mating ange. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The replacement is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove Crankshaft Position (CKP) and Camshaft Position (CMP) sensors from front of engine. 2) Remove accessory drive belt. Remove the water pump pulley. See Fig. 1. Rotate crankshaft so No. 1 cylinder is on TDC of compression stroke.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt Components

498

MAZDA
1.8L 4-Cylinder FP Engine (Cont.)
5) To install remaining components, reverse removal procedure. Tighten valve cover bolts in correct sequence. See Fig. 4. Install water pump pulley with stamped F mark away from engine. Adjust drive belts to proper tension. 6) Inspect crankshaft position sensor air gap. Air gap between outer edge of crankshaft pulley rotor tooth and center of CKP sensor should be 0.029-0.059 (0.5-1.5 mm). Air gap is not adjustable. If gap is incorrect, check for damaged parts.

Courtesy of Mazda Motors Corp.

Fig. 2: Identifying Valve Cover Bolt Loosening Sequence

Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Valve Cover Bolt Tightening Sequence

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 37-44 (50-60) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167) Timing Belt Idler Pulley Bolt ......................................................... ................. 28-38 (38-52) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52) INCH Lbs. (N.m) CKP & CMP Sensor Bolts ................................................................................ Timing Belt Covers ........................................................................ ................... Valve Cover Bolts .......................................................................... ................... Water Pump Pulley Bolts .................................................................................. 71-97 (8-11) 61-87 (7-10) 62-89 (7-10) 71-97 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks 3) Complete timing belt installation on slack (tensioner) side. Allow tensioner to ride against timing belt. Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft timing marks are still correctly aligned. If not, timing belt will have to be removed and repositioned. 4) If all timing marks are okay, turn tensioner clockwise by using a hex wrench. Connect tensioner spring to pin on engine block. Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing marks are still aligned.

MAZDA
1.8L V6
TIMING BELT APPLICATION Application 1.8L V6 MX-3 1992-93 .................................................... MX-3 (Canadian) 1995 ..........................................................
1

499

REMOVAL & INSTALLATION


Labor Time Belt Part No.

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain coolant. Raise and support vehicle, and remove right front wheel. Remove lower engine covers. Remove accessory drive belts. Remove water pump pulley. Remove drive belt idler pulley bracket. See Fig. 1. Disconnect necessary clamps and power steering pressure switch connector to remove power steering reservoir. Remove retaining bolts and power steering reservoir with hoses attached, and secure reservoir aside. 2) Remove retaining nut and power steering pump pulley. Remove retaining bolts and power steering pump with hoses attached, and secure pump aside. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. CAUTION: DO NOT damage crank angle sensor rotor on rear of crankshaft pulley during crankshaft pulley removal. 3) Unplug crank angle sensor, and unclip wires from oil dipstick tube. Remove oil dipstick and oil dipstick tube. Remove crank angle sensor harness bracket. Remove engine wiring harness, located along top of timing belt cover. Support engine using hoist or oor jack. Remove right front wheel. Remove through-bolt, retaining nuts and right (timing belt side) engine mount. Remove retaining bolts, timing belt covers and gaskets. See Fig. 1.

3.8 Hours .. ..... T214 3.8 Hours .. ..... T214

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1992 model year, the manufacturer recommends the belt be replaced every 60,000 miles. For 1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

500

MAZDA
1.8L V6 (Cont.)
CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation. 3) Push outward at bottom of timing belt tensioner, and install lower retaining bolt in timing belt tensioner. Tighten both timing belt tensioner retaining bolts to specication. Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If timing marks are not aligned, repeat entire timing belt installation procedure. 4) Check timing belt deection by applying 22 lbs. (10 kg) of force at designated area on timing belt. Check timing belt deection. See Fig. 5. Timing belt deection should be .24-.31 (6.0-8.0 mm). If timing belt deection is not within specication, replace timing belt tensioner. 5) Install timing belt covers using NEW gaskets. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. See Fig. 6. Tighten fasteners to specication. Adjust drive belts to proper tension.

4) Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. Ensure grove on crankshaft sprocket aligns with indicator on oil pump body. See Fig. 2. 5) If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Hold timing belt tensioner and remove lower retaining bolt rst, then remove upper bolt. Remove timing belt tensioner. Remove No. 2 timing belt pulley and timing belt. Remove No. 1 idler pulley and tensioner pulley (if necessary).

Courtesy of Mazda Motors Corp. Courtesy of Mazda Motors Corp.

Fig. 4: Retracting Timing Belt Tensioner Rod

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys No. 1 and No. 2 and tensioner pulley rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion from end of rod to edge of the housing. See Fig. 3. Replace timing belt tensioner if distance is not .550-.630 (13.97-16.00 mm).

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion Installation 1) Place timing belt tensioner in a press using a at washer to prevent damage to timing belt tensioner. See Fig. 4. Compress tensioner rod until holes in rod and housing are aligned and install .06 (1.5 mm) diameter pin through holes in housing and rod to hold rod in retracted position. See Fig. 4. 2) Install timing belt tensioner on cylinder block with the upper retaining bolt only; do not fully tighten upper bolt. Install No. 2 idler pulley, and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure all timing marks align. See Fig. 2. Install timing belt on sprockets. Ensure all slack is on tensioner side. Ensure the timing belt fully engages all sprockets.

Courtesy of Mazda Motors Corp.

Fig. 5: Measuring Timing Belt Deection

MAZDA
1.8L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

501

Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 27-38 (37-52) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-166) No. 1 Idler Pulley Bolt .................................................................. ................. 28-38 (38-52) No. 2 Idler Pulley Bolt .................................................................. ................. 28-38 (38-52) Power Steering Pump Bracket Bolt .............................................. ..................................... 1 Power Steering Pump Pulley Nut ................................................. ................. 49-69 (66-93) Right (Timing Belt Side) Engine Mount Nut ............................................................................................... ............... 55-75 (74-102) Through-Bolt ................................................................................ ................. 50-68 (67-92) Tensioner Pulley Bolt .................................................................... ................. 28-32 (38-44) Timing Belt Tensioner Bolt ............................................................ ................. 14-19 (19-26) Water Pump Bolt ........................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Crank Angle Sensor Bracket Bolt ..................................................................... 69-95 (8-11) Cylinder Block Valley Cover Bolt ...................................................................... 69-95 (8-11) Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11) Valve Cover Bolt 2 ......................................................................... ..................... 43-78 (5-9) Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
1

Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs. (31-46 N.m.). Tighten lower bolt on front of bracket to 14-19 ft. lbs. (19-26 N.m). Tighten rear bracket-to-cylinder block bolt to 24-33 ft. lbs. (32-45 N.m). Tighten bolts to specication in sequence. See Fig. 6.

Courtesy of Mazda Motors Corp.

Fig. 6: Identifying Valve Cover Bolt Installation Sequence

502

MAZDA
2.0L 4-Cylinder Diesel
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

2.0L 4-Cyl. Diesel 626 1984-85 Camshaft ................................................ 1.9 Hours ... ..... T103 Injection Pump ....................................... 1.0 Hours ... ..... T102
1

With Air Conditioning add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 100,000 miles. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

REMOVAL & INSTALLATION


TIMING BELT (FRONT)
Removal 1) Disconnect negative battery cable. Remove right side splash shield (if equipped). Remove drive belts and crankshaft pulley. Remove timing belt covers and rubber seals. Turn crankshaft in a clockwise direction until mark on front camshaft pulley and front seal plate timing mark align. Loosen tensioner lock bolt, and push tensioner as far back as it will go. Snug tensioner lock bolt. 2) Remove torque bracket from right fender apron. If reusing timing belt, mark an arrow on timing to indicate direction of travel, then remove timing belt. Check belt for premature wear, missing teeth, or cracks. Check turning smoothness of belt tensioner. Installation 1) Ensure that timing mark on camshaft pulley is aligned with mark on front seal plate. Make sure that notch on crankshaft pulley is aligned with timing mark on oil pump housing. See Fig. 1. 2) If tensioner was removed, install tensioner, lock bolt, and spring. Push tensioner as far left as it will go. Snug tensioner lock bolt. Install timing belt. Release tensioner lock bolt, and allow tensioner to contact belt. 3) Turn crankshaft in a clockwise direction (as viewed from front) for 2 complete revolutions. Tighten tensioner lock bolt. Check timing marks on front camshaft and crankshaft pulleys. 4) Check timing belt deection using 22 lbs. (10 kg) of force between front camshaft and water pump pulleys. Deection should be .413-.472 (10.49-11.99 mm) Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

Courtesy of Mazda Motors Corp.

Fig. 1: Aligning Front Camshaft & Crankshaft Pulley Timing Marks 3) Install rear timing belt on injection pump pulley, around tensioner, and then on camshaft pulley. Remove bolts securing injection pump pulley. Loosen tensioner lock nut until tension is applied on belt. Turn crankshaft in a clockwise direction for 2 complete revolutions. 4) Check timing marks on rear camshaft and injection pump pulleys. See Fig. 2. Tighten tensioner lock nut. Check timing belt deection using 22 lbs. (10 kg) of force between injection pump and camshaft pulleys. Deection should be 0.375 (9.53 mm). Install rear timing belt cover. Adjust drive belts to proper tension.

TIMING BELT (REAR)


Removal 1) Remove rear timing belt cover. Turn crankshaft to align rear camshaft pulley with rear seal plate timing mark. Loosen belt tensioner lock nut. Rotate belt tensioner clockwise, using a screwdriver, as far as it will go. Snug tensioner lock nut. 2) If reusing timing belt, mark an arrow on timing belt to indicate direction of travel. Remove rear timing belt. Check belt for premature wear, missing teeth, or cracks. Check turning smoothness of belt tensioner. Installation 1) Check timing marks on rear camshaft and injection pump pulleys. See Fig. 2. Secure injection pump pulley to engine using two 8 x 1.5 x 45 mm bolts. CAUTION: DO NOT remove bolts securing injection pump pulley at this time. Remove bolts after installing timing belt. 2) If tensioner was removed, install tensioner lock nut and spring in fully released position. Rotate belt tensioner clockwise, using a screwdriver, as far as it will go. Snug tensioner lock nut.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Rear Camshaft & Injection Pump Pulley Timing Marks

MAZDA
2.0L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 41-48 (56-65) Crankshaft Pulley Bolts ................................................................. ................. 17-24 (23-33) Fuel Injection Pump Pulley Bolts ................................................. ................. 43-51 (58-69) Timing Belt (Front) Pulley Bolt ............................................................... 116-123 (157-167) Timing Belt Tensioner Bolt Front ............................................................................................. ................. 23-34 (31-46) Rear ............................................................................................. ................. 15-20 (20-27) Water Pump Bolts ......................................................................... ................. 23-34 (31-46) INCH Lbs. (N.m) Rear Cover Bolts ........................................................................... ..................... 60-84 (7-9)

503

504

MAZDA
2.0L 4-Cylinder DOHC Except Tribute
Labor Time Component Belt Kit No. Part No. For 1997-98 gasoline engine model years, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999-00 gasoline engine model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001-03 gasoline engine models, the manufacturer recommendsinspecting the belt at 60,000 miles and replaced at 105,000 miles, UNLESS the vehicle is operated in temperatures under 0F (-18C). Under this condition, replace belt at 60,000 miles.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. MX-6 1993-97 Protege 2001-03 Protege5 2002-03 626 1993-02
1

DOHC ............................ ... ............................ ... ............................ ... ............................ ...


1

2.5 Hrs. ... .. TCK228 .. ..... T228 2.4 Hrs. ... .. TCK228 .. ..... T228 2.4 Hrs. ... .. TCK228 .. ..... T228 2.5 Hrs. ... .. TCK228 .. ..... T228

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove Crankshaft Position (CKP) and Camshaft Position (CMP) sensors from front of engine (if equipped). See Fig. 1. Remove spark plugs. 2) Remove accessory drive belts. Leaving hoses attached, remove power steering pump and position aside. Remove the water pump pulley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on TDC of compression stroke.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1993 model year, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 gasoline engine model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Courtesy of Mazda Motors Corp.

Fig. 1: Locating Camshaft & Crankshaft Position Sensor

MAZDA
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 nger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 5. 7) Turn tensioner clockwise using a Allen wrench to relieve spring tension, and then disconnect spring from the hook pin. See Fig. 6. Remove timing belt. Remove crankshaft sprocket, tensioner and idler pulley (if necessary).

505

Courtesy of Mazda Motors Corp.

Fig. 3: Removing Crankshaft Pulley

Courtesy of Mazda Motors Corp.

Fig. 2: Removing Engine Front Components

506

MAZDA
2.0L 4-Cylinder DOHC Except Tribute (Cont.)
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 specication in correct sequence. See Fig. 13. Adjust drive belts to proper tension. 6) Inspect crankshaft position sensor air gap. Air gap between outer edge of crankshaft pulley rotor tooth and center of CKP sensor should be 0.029-0.059 (0.5-1.5 mm). See Fig. 14. Air gap is not adjustable. If gap is incorrect, check for damaged parts.

Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Valve Cover Bolt Loosening Sequence

Courtesy of Mazda Motors Corp.

Fig. 5: Aligning Camshaft & Crankshaft Timing Marks Fig. 7: Inspecting Timing Belt

Courtesy of Mazda Motors Corp.

Courtesy of Mazda Motors Corp.

Courtesy of Mazda Motors Corp.

Fig. 6: Removing Tensioner Spring CAUTION: Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Inspection Check timing belt for cracks, peeling, abrasion or other damage. See Fig. 7. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44 (36.6 mm). Measure spring free length from inside edge to inside edge of hooked portion of spring. See Fig. 8. Replace parts as necessary. Install the tensioner. Rotate tensioner. See Fig. 9. If tensioner rotates with no resistance or does not rotate, replace tensioner. Installation 1) Ensure all timing marks are aligned. See Fig. 10. 2) Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler pulley side of timing belt.

Fig. 8: Measuring Tensioner Spring Free Length

Courtesy of Mazda Motors Corp.

Fig. 9: Checking Timing Belt Tensioner

MAZDA
2.0L 4-Cylinder DOHC Except Tribute (Cont.)

507

Courtesy of Mazda Motors Corp.

Fig. 13: Identifying Valve Cover Bolt Tightening Sequence

Courtesy of Mazda Motors Corp.

Fig. 10: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Mazda Motors Corp.

Fig. 14: Measuring Crankshaft Position Sensor-To-Crankshaft Pulley Air Gap

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Courtesy of Mazda Motors Corp.

Fig. 11: Installing Tensioner Spring To Hook Pin

Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 37-44 (50-60) Crankshaft Pulley Bolt ............................................................................. 116-122 (157-166) Engine Mount Nut ......................................................................... ............... 55-77 (75-104) Timing Belt Idler Pulley Bolt ......................................................... ................. 28-38 (38-51) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-51) INCH Lbs. (N.m) CKP & CMP Sensor Bolts ............................................................ ............. 70-90 (7.9-10.7) Dipstick Tube Bolt ......................................................................... ............. 70-90 (7.9-10.7) Timing Belt Covers ........................................................................ ............. 70-95 (7.9-10.7) Valve Cover Bolts .......................................................................... ............... 61-87 (6.9-9.8) Water Pump Pulley Bolts .............................................................. ............. 70-95 (7.9-10.7)

Courtesy of Mazda Motors Corp.

Fig. 12: Identifying Sealant Locations

508

MAZDA
2.0L 4-Cylinder DOHC Tribute
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC Tribute 2001-04 ............................... 3.8 Hours .... TCK294A . ..... T294 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Ford Motor Co.

Fig. 1: Removing Valve Cover

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner outlet pipe. Remove spark plugs. Disconnect cruise control actuator cable. Disconnect accelerator cable. If necessary, disconnect catalyst monitor and heated HO2S sensor connectors, and detach from bracket. Remove wiring harness anchors from valve cover studs, and position wiring harness aside. Remove valve cover. See Fig. 1. 2) Raise and support vehicle. Remove right wheel. Remove right lower splash shield. Remove catalytic converter. Remove coolant tube bolt and nut. Position coolant tube to side. 3) Rotate crankshaft to just before No. 1 cylinder TDC. See Fig. 2. Remove stud and install Crankshaft TDC Timing Peg (303-574). See Fig. 3. NOTE: Ensure second notch in pulley is indexed to lower cylinder block. See Fig. 2. 4) Rotate crankshaft clockwise against peg to bring it to TDC. Loosen water pump pulley bolts. Loosen crankshaft pulley bolt. Rotate tensioner and remove accessory drive belt. 5) Remove crankshaft pulley. Remove bolts and lower timing belt cover. See Fig. 4. 6) Lower vehicle. Install Engine Support Bar (303-F072). See Fig. 5. 7) Remove ground strap and engine mount upper bracket and studs. See Fig. 6. Disconnect knock sensor electrical connector, if necessary. Remove upper timing belt cover bolts and cover. See Fig. 7. NOTE: Installation of Camshaft Alignment Tool (303-465) into exhaust camshaft may require camshafts to be rotated slightly clockwise. 8) Remove water pump pulley and accessory drive belt idler pulley. Install Camshaft Alignment Tool (303-465) and align camshafts. See Fig. 8. 9) Raise and support vehicle. Remove engine mount lower bracket. See Fig. 9. 10) Loosen timing belt tensioner pulley, and allow it to slide down to bottom of its travel. Slide timing belt off of camshaft and crankshaft sprockets. CAUTION: DO NOT reuse old timing belt. Replace with a NEW belt. Installation 1) Slide crankshaft pulley onto crankshaft. Ensure crankshaft position is at No. 1 TDC by rotating it clockwise against Crankshaft TDC Timing Peg (303-574). Ensure second notch in pulley is indexed to lower cylinder block. See Fig. 2. Remove crankshaft pulley. 2) Lower vehicle. Ensure timing belt tensioner is installed correctly with tab positioned in slot in inner timing cover. See Fig. 10. 3) Install new timing belt onto timing belt sprockets. See Fig. 11. Adjust timing belt tensioner using a 6-mm Allen wrench to rotate adjuster
Courtesy of Ford Motor Co.

Courtesy of Ford Motor Co.

Fig. 2: Aligning Crankshaft Timing Marks Before TDC

Fig. 3: Removing Stud For Installation Of Crankshaft TDC Timing Peg (303-574)

Courtesy of Ford Motor Co.

Fig. 4: Removing Lower Timing Belt Cover

MAZDA
2.0L 4-Cylinder DOHC Tribute (Cont.)

509

Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.

Fig. 9: Removing Engine Mount Lower Bracket Fig. 5: Installing Engine Support Bar (303-F072) counterclockwise and align marks. See Fig. 12. Tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. 4) Raise and support vehicle. Install front engine mount lower bracket. Install accessory drive belt idler pulley. Install water pump pulley, but hand tighten only. Install timing belt covers. Install crankshaft pulley, but hand tighten only. Rotate tensioner and install accessory drive belt. Tighten crankshaft pulley and water pump pulley bolts to specication. See TORQUE SPECIFICATIONS. 5) Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install engine mount upper bracket and ground strap. Remove Engine Support Bar (303-F072). Install coolant tube and catalytic converter. 6) Install right splash shield and wheel. Remove Camshaft Alignment Tool (303-465). To complete installation, reverse removal procedure. Reconnect negative battery cable.

Courtesy of Ford Motor Co.

Fig. 6: Removing Engine Mount Upper Bracket

Courtesy of Ford Motor Co.

Fig. 10: Installing Timing Belt Tensioner

Courtesy of Ford Motor Co.

Fig. 7: Removing Upper Timing Belt Cover

Courtesy of Ford Motor Co.

Fig. 11: Installing Timing Belt On Sprockets

Courtesy of Ford Motor Co.

Fig. 8: Installing Camshaft Alignment Tool (303-465)

510

MAZDA
2.0L 4-Cylinder DOHC Tribute (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt ..................................................................... 35 (45) Coolant Tube Attachments ........................................................................................ 15 (20) Crankshaft Pulley Bolt ............................................................................................. 85 (115) Engine Mount Lower Bracket Nuts .......................................................................... 37 (50) Engine Mount Upper Bracket Bolt ........................................................................................................................... 57 (77) Nuts .......................................................................................................................... 72 (98) Exhaust Camshaft Center Plug ................................................................................ 27 (37) Ground Strap Nut ...................................................................................................... 25 (34) Spark Plugs ............................................................................................................... 11 (15) Stud (For Crankshaft TDC Timing Peg) ................................................................... 18 (24) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Upper Timing Belt Cover Studs ................................................................................ 25 (34) Water Pump Pulley Bolt ............................................................................................ 18 (24) INCH Lbs. (N.m) Lower Timing Belt Cover Bolts ................................................................................... Splash Shield Bolts ..................................................................................................... Upper Timing Belt Cover Bolts ................................................................................... Valve Cover Bolts ........................................................................................................ 62 80 71 80 (7) (9) (8) (9)

Courtesy of Ford Motor Co.

Fig. 12: Adjusting Timing Belt Tensioner

MAZDA
2.0L & 2.2L 4-Cylinder SOHC
TIMING BELT APPLICATION Application
1

511

Labor Time Component Belt Kit No. Part No.

2.0L 4-Cyl. SOHC B2000 1986 Thru: Chassis No. 568707 ........................ 2.6 From: Chassis No. 568708 ........................ 2.6 1987 ....................................... 2.6 626 1983 ....................................... 1.6 626 Coupe 1984-85 Thru: VIN JM1GC221E1617 .............. 1.6 From: VIN JM1GC221E16176 ............ 1.6 626 Hatchback 1984-85 Thru: VIN JM1GC241E1 ..... 1.6 From: VIN JM1GC241E1 .... 1.6 626 Sedan 1984-85 Thru: VIN JM1GC221E1635511 ......... 1.6 From: VIN JM1GC221E1635511 ......... 1.6 1986-87 .................................. 1.6 2.2L 4-Cyl. Non-Turbo & Turbo B2200 1987-93 .................................. 2.6 MX-6 1988-92 .................................. 2.3 626 1988-92 .................................. 2.3
1

arrow on timing belt to indicate direction of travel. Remove tensioner lock bolt, tensioner and spring. Remove timing belt. On 2.2L engines, measure free length of tensioner spring. Replace spring if free length is not 2.48 (63 mm). See Fig. 3. NOTE: Never twist, turn inside out, or bend timing belt.

Hrs. ... ...... ..... ............ T113 Hrs. ... ...... ..... ............ T117 Hrs. ... .. TCK117 ........ T117 Hrs. ... ...... ..... ...... ..... T088

Hrs. ... ...... ..... ...... ... Hrs. ... ...... ..... ...... ...

T088 T113

Hrs. ... ...... ..... ...... ... Hrs. ... ...... ..... ...... ...

2 3

T088 T113

Hrs. ... ...... ..... ...... ...

T088

Hrs. ... ...... ..... ...... ... 3 T113 Hrs. ... .. TCK117 ........ T117

Hrs. ... .. TCK134 .. ..... T134 Hrs. ... .. TCK134 .. ..... T134 Hrs. ... .. TCK134 .. ..... T134

2 3

With Air Conditioning add .2 hours. With Power Steering, add .2 hours. With square tooth sprocket. With round tooth sprocket.

Courtesy of Mazda Motors Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Timing Belt Reference Marks & Deection (2.0L)

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Courtesy of Mazda Motors Corp.

TIMING BELT
Removal 1) Disconnect negative battery cable. On B2200 models, drain cooling system. Radiator removal may be required. Remove cooling fan and shroud. Remove distributor from front housing. Remove cooling fan pulley and bracket. Remove secondary air pipe assembly (carbureted engines). 2) On all models, remove all accessory drive belts. Remove crankshaft pulley. Remove timing belt covers. Remove baffle plate located in front of crankshaft sprocket. Note direction of baffle plate installation. Align camshaft pulley with front housing timing mark. See Fig. 1 or 2. Mark an

Fig. 2: Aligning Timing Marks (2.2L) Installation 1) Align camshaft pulley with front housing timing mark. Align crankshaft pulley with pointer on oil pump body. See Fig. 1 or 2. Install tensioner, lock bolt and tensioner spring. Position timing belt tensioner to its limit of travel toward the intake manifold side, and partially tighten lock bolt. 2) Install timing belt onto crankshaft pulley and then camshaft pulley. Install timing belt from tension side (right side, as viewed from engine front). If timing belt is being reused, ensure that arrow is pointing in direction of travel.

512

MAZDA
2.0L & 2.2L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.0L) Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 35-48 (47-65) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167) Timing Belt Tensioner Bolt ............................................................ ................. 28-38 (38-52) Torque Stopper Bolts .................................................................... ................. 45-56 (61-76) INCH Lbs. (N.m) Timing Belt Covers ........................................................................ ................... 61-87 (7-10) Valve Cover ................................................................................... ..................... 26-35 (3-4) TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo) Application Ft. Lbs. (N.m) Coolant Inlet Pipe Bolt .................................................................. ................. 14-19 (19-26) Crankshaft Sprocket Bolt ........................................................................ 116-123 (157-167) Timing Belt Idler Pulley ................................................................. ................. 27-38 (37-52) Timing Belt Tensioner Lock Bolt ................................................... ................. 27-38 (37-52) Water Pump Bolt ........................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Sprocket Bolt ........................... ............... 109-152 (13-7) Rocker Cover Bolt ......................................................................... ..................... 26-35 (3-4) Timing Belt Cover ......................................................................... ................... 61-87 (7-10)

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Free Length of Tensioner Spring 3) Loosen tensioner lock bolt to apply tension. To apply equal tension to each side of timing belt, turn crankshaft 2 revolutions in direction of travel. Tighten tensioner lock bolt. Check for proper alignment of timing marks. 4) Check for proper belt tension by measuring amount of deection midway between idler pulley and camshaft sprocket. Belt deection should be .30-.33 (7.6-8.4 mm) when force of 22 lbs. (10 kg) is applied. See Fig. 1 or 2. Repeat adjustment if deection is not within specication. 5) Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

MAZDA
2.3L 4-Cylinder
TIMING BELT APPLICATION Application 2.3L 4-Cyl. B2300 1994 ................................... 1995-97 ..............................
1

513

Labor Time

Component Belt Kit No. Part No.

1 1

1.7 Hours .. .. TCK210 .. ..... T210 1.7 Hours .. .. TCK276 .. ..... T276

With Air Conditioning add .9 hours. With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Ensure crankshaft is set at TDC and camshaft sprocket timing mark is aligned with cover pointer. See Fig. 1. Disconnect negative battery cable. 2) Drain cooling system and remove upper radiator hose. Remove alternator. Loosen water pump pulley bolts. Remove accessory drive belt(s). Remove spark plugs to ensure belt does not jump time during rotation. 3) Remove cooling fan and water pump pulley. Remove crankshaft pulley, hub and belt guide. Remove crankshaft position sensor. Remove dipstick and pipe. Remove timing belt cover retaining bolt. Release 8 cover interlocking tabs. Remove timing belt cover. Loosen timing belt tensioner pulley bolt. See Fig. 2. Pry tensioner away from timing belt, and tighten bolt to hold tensioner in place. Remove timing belt.

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components CAUTION: Always rotate engine in direction of normal rotation (clockwise as viewed from front of engine). Installation 1) Ensure crankshaft is set at TDC and camshaft sprocket timing mark is aligned with cover pointer. See Fig. 1. Install belt guide with at side toward the camshaft sprocket. See Fig. 2. 2) Install timing belt. Loosen tensioner bolt, allowing tensioner to apply pressure on belt. Tighten tensioner bolt. Rotate crankshaft clockwise 2 complete turns to remove slack from belt. 3) Loosen tensioner bolt. Apply additional pressure to tensioner, as spring pressure is insufficient. Retighten tensioner lock bolt. To complete installation, reverse removal procedure. Fill and bleed cooling system. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 50-71 (68-96) Crankshaft Damper Bolt ................................................................ ......... 103-133 (140-180) Water Pump Bolt 1 ......................................................................... ................. 14-21 (19-29) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12) Valve Cover Bolt ............................................................................................... 62-97 (7-11)
1

Apply sealant to bolt threads.

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

514

MAZDA
2.3L V6
Labor Time Belt Part No. 4) Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. The crankshaft and camshaft timing marks should align. See Fig. 2. 5) If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Hold timing belt tensioner and remove lower retaining bolt rst, then remove upper bolt. Remove timing belt tensioner. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Inspect timing belt auto tensioner for signs of oil leakage. Replace timing belt auto tensioner if oil leakage exists. Measure timing belt auto tensioner rod protrusion from end of rod to edge of the housing. See Fig. 3. Replace timing belt auto tensioner if distance is not .563-.594 (14.3-15.1 mm). NOTE: The following information on repairing the front engine oil leaks is from Mazda technical service bulletin MT0596-07; May, 1996. 2) Oil leaking from the front of the engine on 1995-96 models may be caused by the No. 3 engine mount bracket stud. See Fig. 4. To repair the oil leak, remove No. 3 engine mount bracket. Remove mounting stud from engine. Clean all threads thoroughly. Apply Loctite PST Pipe Sealant with Teon (No. 565) to stud threads. Install stud on engine block. Installation 1) Place timing belt auto tensioner in a press using a at washer to prevent damage to timing belt tensioner. See Fig. 5. Using no more than 2200 lbs. of pressure, compress tensioner rod until holes in rod and housing are aligned. Install a .055-.063 (1.4-1.6 mm) diameter pin through holes in housing and rod to hold rod in retracted position. See Fig. 5. 2) Install timing belt on sprockets and around idler pulleys in the sequence shown. See Fig. 6. Ensure all slack is on tensioner pulley side. Install timing belt auto tensioner. Tighten timing belt auto tensioner bolts to specication. See TORQUE SPECIFICATIONS. Ensure all timing marks align. See Fig. 2. CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation. 3) Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If timing marks are not aligned, remove and repeat entire timing belt installation procedure. 4) Install timing belt covers using NEW gaskets. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. Install dipstick tube with new O ring. 5) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Check ignition timing. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 2.3L V6 Millenia 1995-02 ....................................................


1

4.5 Hours .. ..... T267

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1995-96 vehicles, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1997-98 vehicles, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999-00 vehicles, the replacement is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001-02 vehicles, the replacement interval is 60,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain coolant. Raise and support vehicle. Remove right front wheel. Remove lower engine covers. Remove accessory drive belts. CAUTION: DO NOT damage crank angle sensor rotor on rear of crankshaft pulley during crankshaft pulley removal. 2) Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove power steering pump pulley. Remove water pump pulley. Remove generator drive belt auto tensioner. See Fig. 1. Remove camshaft position sensor from right hand camshaft. 3) Remove engine oil dipstick and pipe. Remove vacuum pipe. Remove upper radiator hose. Support engine using hoist. Remove No. 3 engine mount and brackets from timing belt end of engine. Remove retaining bolts, timing belt covers and gaskets. Remove power steering belt auto tensioner. See Fig. 1.

MAZDA
2.3L V6 (Cont.)

515

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

516

MAZDA
2.3L V6 (Cont.)

Courtesy of Mazda Motors Corp.

Fig. 5: Retracting Timing Belt Tensioner Rod

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Marks

Courtesy of Mazda Motors Corp.

Fig. 6: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 27-38 (37-52) Camshaft Position Sensor Bolt ..................................................... ................. 14-18 (19-25) Crankshaft Pulley Bolts Center Bolt ............................................................................................ 116-123 (157-166) Except Center Bolt ...................................................................... ................. 19-22 (26-30) Engine Mount Nuts .............................................................................................. ............... 55-77 (75-104) Bolts ............................................................................................. ................. 32-44 (44-60) Generator Drive Belt Auto Tensioner Bolt .................................... ................. 14-18 (19-25) No. 1 & No. 2 Idler Pulley Bolt .................................................... ................. 28-38 (38-52) Power Steering Pump Pulley Nut ................................................. ................. 37-43 (50-58) Tensioner Pulley Pivot Bolt ........................................................... ................. 28-32 (38-44) Timing Belt Auto Tensioner Bolt ................................................... ................. 14-19 (19-26) Water Pump Bolt ........................................................................... ................. 14-19 (19-26) Wheel Lug Nut .............................................................................. ............... 66-94 (89-127) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11) Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)

Courtesy of Mazda Motors Corp.

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

Courtesy of Mazda Motors Corp.

Fig. 4: Locating Engine Mount Bracket Stud

MAZDA
2.5L 4-Cylinder
TIMING BELT APPLICATION Application 2.5L 4-Cyl. B2500 1998-00 ..............................
1

517

Labor Time

Component Belt Kit No. Part No.

1.7 Hours .. .. TCK276 .. ..... T276

With Air Conditioning, add .9 hours. With Power Steering, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be inspected at 120,000 miles and replaced if necessary.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove exhaust side spark plugs. Rotate crankshaft clockwise so No. 1 piston is at TDC of compression stroke. 2) Remove fan shroud. Loosen fan clutch-to-pulley bolts. Remove accessory drive belt. Remove fan clutch and pulley. Remove crankshaft center bolt, and remove crankshaft pulley. 3) Using recycling equipment, recover refrigerant from air conditioning system (if equipped). Disconnect A/C clutch connector from A/C clutch. Remove A/C compressor from mounting bracket. Remove A/C compressor mounting bracket with hoses attached, and position out of way. 4) Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. 5) Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and slowly release tension. See Fig. 2. Pry tensioner away from timing belt, and tighten bolt to hold tensioner in place. 6) If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt.

Courtesy of Ford Motor Co.

Fig. 2: Exploded View Of Timing Belt & Components CAUTION: Always rotate engine in direction of normal rotation (clockwise as viewed from front of engine). Reverse rotation may cause timing belt to jump time, causing engine damage. Installation 1) Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. See Fig. 1. 2) Install timing belt on crankshaft sprocket. Working clockwise, install belt over oil pump sprocket, camshaft sprocket, and tensioner pulley. 3) Loosen tensioner bolt and allow tensioner to adjust itself. Rotate crankshaft clockwise 2 complete revolutions to remove slack from belt. Recheck timing mark alignment. Readjust as necessary. Tighten timing belt tensioner bolts. 4) Install timing belt cover. Install crankshaft pulley. Install A/C compressor bracket with power steering pump. Install A/C compressor and recharge system (if equipped). 5) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Mount Bolts M8 Bolt .................................................................................................................... 18 (25) M10 Bolt .................................................................................................................. 35 (48) A/C Compressor-To-Bracket Bolt .................................................. ................. 16-20 (21-28) Camshaft Sprocket Bolt ................................................................ ................. 52-70 (70-95) Cooling Fan-To-Pulley Bolts .......................................................... ................. 13-16 (17-23) Crankshaft Damper Bolt ................................................................ ........... 92-122 (125-165) Oil Pump Sprocket Bolt ................................................................ ................. 29-41 (40-55) Timing Belt Tensioner Adjusting Bolt ............................................ ................. 35-45 (26-33) Timing Belt Tensioner Pivot Bolt .................................................. ................. 29-41 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt ..................................................... ................. 71-106 (8-12) Spark Plug ....................................................................................................... 80-115 (9-13)

Courtesy of Ford Motor Co.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

518

MAZDA
2.5L V6
Labor Time Component Belt Kit No. Part No. For 1999 626 models and 1999-00 Millenia models, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2000 626 models, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Maine, Massachusetts and Vermont. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001-02 model year, inspect timing belt at 60,000 and replace timing belt at 105,000 miles, UNLESS the vehicle is operated in temperatures that are under 0F (-18C). In this case, replace timing belt at 60,000 miles.

TIMING BELT APPLICATION Application 2.5L V6 Millenia 1995-02 .............................. MX-6 1993-97 .............................. 626 1993-02 ..............................
1

3.4 Hours .. .. TCK214 .. ..... T214 4.0 Hours .. .. TCK214 .. ..... T214 4.0 Hours .. .. TCK214 .. ..... T214

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. On Millenia, raise and support vehicle. Remove right front wheel. Remove lower engine covers. 2) On all models, remove accessory drive belts. Remove water pump pulley. Remove drive belt idler pulley bracket. Remove retaining bolts and power steering pump with hoses attached, and secure pump out of way. Remove spark plugs. CAUTION: DO NOT damage crankshaft position sensor rotor on rear of crankshaft pulley during crankshaft pulley removal. 3) Holding crankshaft stationary, remove the crankshaft pulley retaining bolt. Using gear puller, remove crankshaft pulley.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1993 model year, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1997-98 model years, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

MAZDA
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 oor 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.

519

Courtesy of Mazda Motors Corp.

Fig. 4: Identifying Timing Belt Tensioner Types Installation 1) Place timing belt tensioner in a press using a at washer to prevent damage to timing belt tensioner. See Fig. 5. Using no more than 2200 lbs. of pressure, SLOWLY compress tensioner rod until holes in rod and housing are aligned. Install 0.055 (1.4 mm) diameter pin through holes in housing and rod to hold rod in retracted position. 2) Install timing belt tensioner on cylinder block with the upper retaining bolt only; do not fully tighten upper bolt. CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation. 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 specication. See TORQUE SPECIFICATIONS. Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. 5) Rotate crankshaft 2 full revolutions clockwise (as viewed from timing belt end of engine) from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If timing marks are not aligned, remove and repeat entire timing belt installation procedure. 6) Install right (timing belt side) engine mount. Install timing belt covers using NEW gaskets. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. 7) Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. 8) Check crankshaft position sensor air gap. Gap between center of sensor and outer edge of rotor tooth should be 0.020-0.059 (0.5-1.5 mm). If not, check for damaged components. Air gap is not adjustable.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks Inspection 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys (No. 1 and No. 2) and tensioner pulley rotate freely. Replace damaged components. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. There are 2 types of tensioners used on this engine. See Fig. 4. Replace timing belt tensioner if rod protrusion distance is not as specied. See TIMING BELT TENSIONER ROD PROTRUSION table. 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)

Courtesy of Mazda Motors Corp. Courtesy of Mazda Motors Corp.

Fig. 5: Retracting Timing Belt Tensioner Rod

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion

520

MAZDA
2.5L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-166) Drive Belt Idler Pulley Bracket Bolt .............................................. ................. 14-18 (19-23) No. 1 & No. 2 Idler Pulley Bolt .................................................... ................. 28-38 (38-52) Power Steering Pump Bracket Bolt Millenia 1995-98 ...................................................................................... ................. 23-34 (31-46) 1999-02 ...................................................................................... ..................................... 1 MX-6 & 626 ................................................................................. ................. 28-38 (38-52) Power Steering Pump Pulley Nut ................................................. ................. 37-43 (50-58) Right (Timing Belt Side) Engine Mount Nut (All Models) .......................................................................... ............... 55-75 (74-102) Through-Bolt (626) ...................................................................................... 63-86 (86-116) Tensioner Pulley Bolt .................................................................... ................. 28-32 (38-44) Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25) Water Pump Bolt ........................................................................... ................. 14-18 (19-25) Wheel Lug Nut Millenia ......................................................................................... ............... 66-94 (89-127) INCH Lbs. (N.m) Crankshaft Position Sensor Bracket Bolt ......................................................... 69-95 (8-11) Timing Belt Cover Bolt ...................................................................................... 69-95 (8-11) Water Pump Pulley Bolt .................................................................................... 69-95 (8-11)
1

Courtesy of Mazda Motors Corp.

Fig. 6: Installing Timing Belt

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
3.0L V6 DOHC
TIMING BELT APPLICATION Application
1

521

Labor Time Component Belt Kit No. Part No.

3.0L V6 DOHC 929 1990-91 ............................... 3.9 Hours .... TCK183A . ..... T183 1992-95 ............................... 3.9 Hours ... .. TCK183 .. ..... T183 Serenia (Canadian) 1992-95 ............................... 3.9 Hours ... ...... ..... ...... ..... T183
1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

2) Remove drive belts. Remove A/C and P/S idler pulleys (if equipped). Remove crankshaft pulley, baffle plate (if equipped), and sensor rotor (if equipped). DO NOT damage sensor rotor. Remove coolant by-pass and upper radiator hoses. 3) Remove distributor. Remove timing belt covers and gasket. See Fig. 1. Turn crankshaft to align pulley match marks. See Fig. 2. Remove timing belt upper idler pulley. If reusing timing belt, mark rotation direction. Remove timing belt and timing belt automatic tensioner. Inspection Check automatic tensioner rod projection. Rod should project .47-.55 (12-14 mm) from tensioner body. Replace tensioner if projection is not within specication. Installation 1) Using at washer to prevent damage to tensioner body plug, place automatic tensioner in vise or arbor press. Compress tensioner rod until a pin can be inserted into tensioner rod through hole in tensioner body. Install tensioner with pin installed. CAUTION: DO NOT exceed 2200 lbs (1000 kg) pressure on tensioner rod. 2) Ensure match marks on pulleys align with marks on heads. See Fig. 2. With upper idler pulley removed, install timing belt on pulleys. Keep slack toward automatic tensioner side. Install upper idler pulley. Rotate crankshaft twice in direction of rotation, and ensure match marks still align. Remove automatic tensioner pin, and repeat steps to conrm match marks are still in alignment. 3) Check timing belt deection between right cam pulley and lower idler. Deection should be .20-.28 (5-7 mm) at 22 lbs. (10 kg). If deection is not correct, repeat installation procedure. If deection is still not correct, check for faulty automatic tensioner or stretched timing belt. 4) To complete installation, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust the drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles for Federal vehicles, and 105,000 miles on California vehicles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain engine coolant. Remove spark plug cables and spark plugs. Remove air intake hose. Remove cooling fan and fan shroud.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

522

MAZDA
3.0L V6 DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Bracket Bolt .................................................. ................. 21-29 (29-39) Alternator-To-Bracket Bolt ............................................................. ................. 27-38 (37-52) Camshaft Pulley Bolt Left Head ..................................................................................... ................. 14-18 (19-25) Right Head .................................................................................. ................. 52-59 (71-80) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167) Power Steering Idler Bolt ...................................................................................... ................. 14-18 (19-25) Pulley Nut .................................................................................... ................. 29-43 (39-58) Pump Mount Bolt .......................................................................... ................. 23-34 (31-46) Radiator Bolt .................................................................................. ................. 14-18 (19-25) Timing Belt Lower Idler Bolt ......................................................... ................. 32-45 (43-61) Timing Belt Tensioner Bolt ............................................................ ................. 14-18 (19-25) Timing Belt Upper Idler Bolt ......................................................... ................. 27-38 (37-52) Water Pump Bolt/Nut .................................................................... ................. 14-18 (19-25) INCH Lbs. (N.m) Timing Belt Cover Bolt Right Side Cover (Top 3 Bolts) .................................................. ..................................... 1 All Other Bolts ................................................................................................. 71-97 (8-11) Valve Cover Bolt ........................................................................... ............... 30-39 (3.4-4.4)
1

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Belt Match Marks

Tighten 3 top bolts on right side cover to 14-18 ft. lbs. (19-25 N.m).

MAZDA
3.0L V6 SOHC
TIMING BELT APPLICATION Application
1

523

Labor Time Component Belt Kit No. Part No.

3.0L V6 SOHC MPV 1989-98 ............................ .... 3.0 Hrs. .... .. TCK146 .. ..... T146 929 1988-91 ............................ .... 3.1 Hrs. .... .. TCK146 .. ..... T146
1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1988-93 model years, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1997-98 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Courtesy of Mazda Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove spark plug wires and spark plugs. Remove air intake hose. Remove cooling fan and fan shroud. Remove drive belts. Remove A/C compressor drive belt idler pulley. Remove retaining bolt and crankshaft pulley. Remove coolant bypass and upper radiator hoses. Remove timing belt covers and gaskets. See Fig. 1. Rotate crankshaft and align all timing marks. See Fig. 2. 2) If reusing timing belt, place reference mark on timing belt to indicate direction of timing belt rotation. Remove upper idler pulley. See Fig. 1. Remove timing belt. Remove timing belt tensioner, tensioner pulley and lower idler pulley (if necessary). Inspection 1) Measure timing belt tensioner rod protrusion from end of rod to edge of timing belt tensioner housing. Replace timing belt tensioner if distance is not .47-.55 (12.0-14.0 mm). 2) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys and tensioner pulley rotate freely. Inspect timing belt tensioner for signs of oil leakage. Replace worn components. NOTE: The following information on tensioner pulley inspection is from Mazda technical service bulletin 002/00R; March 9, 2000. 3) During the 60,000 mile inspection or timing belt replacement on MPV, inspect tensioner pulley pivot bushing for a bronze color (wear) on the Teon coating. If the bushing is worn, the tensioner pulley and spacer must be replaced with the timing belt. This is to prevent a torn or jumped timing belt. Installation 1) Install tensioner pulley and lower idler pulley (if removed). Install retaining bolts, and tighten to specication. See TORQUE SPECIFICATIONS. Ensure all pulleys are clean and rotate smoothly.

Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Timing Marks CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure on timing belt tensioner rod. 2) Place timing belt tensioner in press with at washer to prevent damage to timing belt tensioner plug. See Fig. 3. Apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 3. Install pin through holes in housing and rod to hold rod in retracted position. Release press and remove timing belt tensioner. CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation. 3) Install timing belt tensioner on cylinder block with pin installed. Tighten retaining bolts to specication. See TORQUE SPECIFICATIONS. Rotate camshafts and crankshaft to ensure all timing marks are aligned. See Fig. 2. With upper idler pulley removed, install timing belt on crankshaft sprocket, lower idler pulley, left camshaft sprocket, right camshaft sprocket and tensioner pulley in sequence.

524

MAZDA
3.0L V6 SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt .................................................................... ................. 13-20 (18-27) A/C Compressor Bracket-To-Cylinder Block Bolt ......................... ................. 27-38 (37-52) Camshaft Sprocket Bolt ................................................................ ................. 52-59 (71-80) Crankshaft Pulley Bolt ............................................................................. 116-123 (157-167) Lower Idler Pulley Bolt .................................................................. ................. 27-38 (37-52) Power Steering Pump Bolt ........................................................... ................. 23-34 (31-46) Power Steering Pump Pulley Nut ................................................. ................. 29-43 (39-58) Tensioner Pulley Bolt .................................................................... ................. 17-22 (23-30) Timing Belt Cover Bolt 6 mm Bolt .................................................................................... ..................................... 1 10 mm Bolt .................................................................................. ................. 27-38 (37-52) Timing Belt Tensioner Bolt ............................................................ ................. 14-19 (19-26) Upper Idler Pulley Bolt .................................................................. ................. 27-38 (37-52) Water Pump Bolt/Nut .................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Valve Cover Bolt ........................................................................... ..................... 30-39 (3-4)
1

4) Install upper idler pulley. Tighten retaining bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure all timing marks are aligned. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. 5) Remove pin from timing belt tensioner, allowing pressure to be applied to timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure all timing marks are aligned. Check timing belt deection by applying 22 lbs. (10 kg) of force at midpoint between right camshaft sprocket and tensioner pulley. Timing belt deection should be .20-.28 (5.0-7.0 mm). 6) If timing belt deection is not within specication, repeat installation procedure. To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension.

Tighten to 69-95 INCH lbs. (8-11 N.m).

Courtesy of Mazda Motors Corp.

Fig. 3: Retracting Timing Belt Tensioner Rod

MITSUBISHI
1.5L 4-Cylinder SOHC
TIMING BELT APPLICATION Application
1

525

Labor Time Component Belt Kit No. Part No.

1.5L 4-Cyl. Mirage 1985 ................................. .... 1986 Before 5/31/86 ............... .... After 6/1/86 .................... .... 1987-90 ............................ .... 1991-96 ............................ .... 1997-99 ............................ .... 2000-02 ............................ .... Precis 1987-89 ............................ .... 1990-94 ............................ ....
1

2.4 Hrs. .... .. TCK073 .. ..... T073 2.4 2.4 2.4 2.4 2.4 2.4 Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. .... .. TCK073 .. ..... .... ...... ..... ...... ..... .... .. TCK128 .. ..... .... .. TCK191 .. ..... .... .. TCK289 .. ..... .... ...... ..... ...... ..... T073 T073 T128 T191 T289 T289

2.2 Hrs. .... .. TCK073 .. ..... T073 2.2 Hrs. .... .. TCK128 .. ..... T128

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits.
Courtesy of DaimlerChrysler Corp.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Timing Marks (1985-96) Inspection (1985-96) Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective. Installation (1985-96) 1) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. Install timing belt onto crankshaft and camshaft sprockets. Ensure tension side is tight and all timing marks are aligned when camshaft sprocket is rotated. Install crankshaft pulley. Loosen tensioner mounting bolts. See Fig. 2. Ensure timing belt is not out of position and has not jumped a sprocket tooth. Tighten tensioner bolts. CAUTION: If pivot bolt is tightened before side bolt, belt tensioner may rotate, causing belt to be overtightened. 2) Rotate crankshaft one full revolution clockwise, until crankshaft sprocket timing mark aligns with TDC position. Recheck belt tension. To check belt tension, hold belt tensioner and timing belt together. Apply slight thumb pressure at center point of belt tensioner. See Fig. 3. A tension gauge can also be used to check belt tension. See Fig. 4. 3) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1985-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-02 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (1985-96) 1) Disconnect negative battery cable. Remove air cleaner assembly, then disconnect accelerator cable and oxygen lead sensor. Mark position of spark plug wires for installation, then remove wires from spark plugs. Support engine using a suitable engine support bar. Remove left engine mount bracket. Remove all accessory drive belts and pulleys. CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 2) Remove timing belt covers and gaskets, noting bolt lengths and locations as they are removed. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure all timing marks are aligned. See Fig. 1. 3) Loosen timing belt tensioner bolts. Move tensioner inward toward water pump. Temporarily tighten bolt in slot side of tensioner. Remove timing belt from camshaft sprocket. Remove crankshaft pulley, and timing belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Installing Timing Belt Tensioner (1985-96)

526

MITSUBISHI
1.5L 4-Cylinder SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension (1985-96)

Fig. 5: Exploded View Of Timing Belt & Components

Courtesy of DaimlerChrysler Corp.

Fig. 4: Checking Timing Belt Tension (1985-96) Removal (1997-02) 1) Disconnect negative battery cable. Remove under cover. Remove all accessory drive belts. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Holding crankshaft stationary, remove crankshaft pulley. CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 2) Place jack under engine. Support engine so there is no weight on engine mount bracket (timing belt end of engine). On vehicles equipped with A/C, move A/C relay box and drier assembly (hoses attached) out of way to remove engine mount bracket. On all vehicles, remove engine mount bracket-to-engine bolt and nut. Remove engine mount bracketto-body through-bolt. Remove engine mount bracket. 3) Remove water pump pulley. Remove power steering pump and bracket with hoses attached, and secure out of way. Remove oil dipstick tube. Remove timing belt upper and lower covers. See Fig. 5. 4) Rotate crankshaft clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure crankshaft sprocket timing marks are aligned. See Fig. 6. 5) Loosen timing belt tensioner adjusting bolt. Move tensioner toward water pump to relieve tension on timing belt. Temporarily tighten tensioner adjusting bolt. Remove timing belt. Inspection (1997-02) Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective. Installation (1997-02) 1) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 6. If timing belt tensioner and spring were removed, install with tensioner spring in correct position. See Fig. 7.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Aligning Timing Marks (1997-02) 2) Install timing belt onto crankshaft sprocket, camshaft sprocket, and tensioner pulley. Ensure tension side is tight and all timing marks are aligned. See Fig. 6. 3) After installing timing belt, ensure timing belt is tensioned between crankshaft and camshaft sprockets. Check that all timing marks are still aligned. 4) Loosen tensioner adjusting bolt. Rotate crankshaft two full revolutions clockwise, until crankshaft sprocket timing mark aligns with TDC position. Tighten tensioner adjusting bolt. 5) Ensure timing belt teeth are fully seated in camshaft sprocket. Install timing belt covers. Install crankshaft pulley. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 6) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

MITSUBISHI
1.5L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (1985-96 MIRAGE)

527

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1985-91 ........................................................................................ ................. 47-54 (65-75) 1992-96 ........................................................................................ ............... 52-74 (70-100) Crankshaft Pulley Bolt 1991-96 .......................................................................................................... 10-11 (14-15) Crankshaft Sprocket Bolt 1985 ............................................................................................. ................. 37-43 (50-58) 1986-96 ........................................................................................ ............... 52-74 (70-100) Front Cover Bolt 1985-88 ........................................................................................ ................... 9-10 (12-14) Rocker Arm Adjuster Lock Nut 1989-96 ........................................................................................ ................. 10-13 (14-18) Timing Belt Tensioner Bolt 1985-96 ........................................................................................ ................. 14-20 (19-27) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................................................... ............. 108-120 (12-14) Front Cover Bolt ............................................................................ ................. 84-132 (9-15) Fuel Rail Bolt 1992-96 ........................................................................................ ................. 84-108 (9-12) Rocker Cover Bolt ......................................................................... ............... 13-17 (1.5-1.9) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Water Pump Pulley Bolt 1985-88 ........................................................................................ ............. 108-120 (12-14) 1989-96 ........................................................................................ ..................... 72-84 (8-9)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Installing Timing Belt Tensioner (1997-02)

TORQUE SPECIFICATIONS (1991-94 PRECIS) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 48-55 (65-75) Camshaft Thrust Case Bolt .......................................................... ................. 14-20 (19-27) Crankshaft Sprocket Bolt .............................................................. ............... 52-74 (70-100) Front Cover Bolt .............................................................................................. 10-11 (14-15) Timing Belt Tensioner Bolt ............................................................ ................. 15-20 (20-27) INCH Lbs. (N.m) Camshaft Rear Cover Bolts .......................................................... ................... 70-86 (7-10) Rocker Cover Bolt ......................................................................... ............... 13-18 (1.5-2.0) Timing Belt Cover Bolt .................................................................. ............... 86-104 (10-12) TORQUE SPECIFICATIONS (1997-02) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 64 (88) Crankshaft Pulley Center Bolt .............................................................................. 1 93 (125) Engine Mount Bracket-To-Engine ............................................................................. 25 (35) Engine Mount Bracket-To-Engine Bracket Bolt/Nut ....................................................................... 42 (57) Bracket-To-Body Through-Bolt .............................................................................. 2 72 (98) Power Steering Pump Bracket-To-Engine Bolt ........................................................ 16 (22) Timing Belt Tensioner Adjusting Bolt ........................................................................ 17 (24) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt .............................................................................................. 80 (9)
1 2

Apply engine oil to bolt thread before installation. Final tighten with full weight of engine on bolt.

528

MITSUBISHI
1.6L 4-Cylinder SOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.6L 4-Cyl. SOHC Mirage 1985-88 ....................................................
1

2.8 Hours .. ..... T093

With Air Conditioning, add .4 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove splash panel in left side wheel house. Remove air intake duct to air cleaner housing. Noting installed position for reassembly reference, remove spark plug cables from spark plugs. 2) Remove all accessory drive belts. Place jack under engine. Support engine so there is no weight on engine mount bracket (timing belt end of engine). Remove left side engine mount. 3) Remove power steering pump pulley (if equipped). Remove water pump pulley. See Fig. 1. Remove upper timing belt cover. CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 4) Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing mark aligns with mark on under upper cover. See Fig. 2. Holding crankshaft stationary, remove crankshaft pulley. Remove lower timing belt cover. 5) Loosen timing belt tensioner adjusting bolt and nut. Move tensioner inward toward water pump. Temporarily tighten tensioner adjusting bolt. Remove timing belt.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Camshaft Timing Marks Installation 1) If crankshaft sprocket was removed, ensure ange and spacer are correctly installed. See Fig. 3. If timing belt tensioner was removed, ensure end of tensioner spring is seated under water pump housing. See Fig. 4. Move tensioner towards water pump, and temporarily tighten mounting bolt and nut. 2) Ensure crankshaft and camshaft timing marks are aligned. See Fig. 2. Install timing belt onto crankshaft sprocket, and keeping tension tight, install timing belt on camshaft sprocket. 3) After installing timing belt, ensure timing belt is tensioned between crankshaft and camshaft sprockets. Check that all timing marks are still aligned. 4) Loosen tensioner adjusting bolt and nut about one turn so that timing belt tensioner contacts timing belt. Turn crankshaft clockwise by 2 teeth of the camshaft sprocket. See Fig. 5. This is to give adequate tension to the timing belt. DO NOT turn crankshaft counterclockwise. 5) Push timing belt tensioner to the right (as viewed from front of engine) so that belt engages completely with camshaft sprocket without any slack. Tighten tensioner bolt to specication rst, and then the tensioner nut. See TORQUE SPECIFICATIONS. Turn crankshaft one full revolution. 6) Ensure camshaft and crankshaft timing marks are still aligned. To check timing belt nal tension, hold timing belt between thumb and forenger 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 specication. See TORQUE SPECIFICATIONS. 8) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components Inspection Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective.

MITSUBISHI
1.6L 4-Cylinder SOHC (Cont.)

529

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Installing Crankshaft Sprocket, Flange & Spacer

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Checking Timing Belt Tension Adjustment

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Installing Tensioner Spring

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Identifying Timing Belt Cover Bolt Length

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ............... 59-74 (80-100) Crankshaft Pulley Center Bolt ...................................................... ........... 1 80-96 (110-130) Engine Mount To-Engine Bracket Bolt/Nut ......................................................... ................. 37-50 (50-65) Bracket-To-Body Through-Bolt .................................................................... 66-81 (90-110) Timing Belt Tensioner Adjusting Bolt/Nut ................................................................. 17 (24) Vibration Damper-To-Adapter Bolts ................................................................ 11-13 (15-18) INCH Lbs. (N.m) Power Steering Pump Pulley Bolt .............................................................................. 80 (9) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt .............................................................................................. 80 (9)
1

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Camshaft Sprocket Position For Tension Adjustment

Apply engine oil to bolt thread before installation.

530

MITSUBISHI
1.8L & 2.0L 4-Cylinder SOHC
Labor Time Component Belt Kit No. Part No. 3) Remove plug on left side of cylinder block. Insert a screwdriver to keep left silent shaft in position. See Fig. 1. Remove oil pump sprocket. Loosen right silent shaft sprocket mounting bolt until it can be turned by hand. Remove belt tensioner B and timing belt B.

TIMING BELT APPLICATION Application

1.8L 4-Cyl. Cordia & Tredia 1983-84 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... 1985-86 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... 1987-88 Balance Shaft ............... .......... 1 .......... .. TCK158 .. ..... Camshaft ....................... ... 2 3.2 Hrs. ... .. TCK158 .. ..... 2.0L 4-Cyl. Cordia & Tredia 1984 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... 1985-86 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... 1987-88 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 3.2 Hrs. ... ...... ..... ...... ..... Galant 1989-92 Balance Shaft ............... .......... 1 .......... .. TCK155 .. ..... Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK155 .. ..... 1993 Balance Shaft ............... .......... 1 .......... .. TCK232 .. ..... Camshaft ....................... ... 3 3.0 Hrs. ... .. TCK232 .. ..... Pickup 1983-86 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... Camshaft ....................... ... 2 2.3 Hrs. ... ...... ..... ...... ..... 1987-89 Balance Shaft ............... .......... 1 ........... TCK158A . ..... Camshaft ....................... ... 2 2.3 Hrs. .... TCK158A . .....
1

T090 T089 T159 T089 T159 T158

T090 T089 T159 T089 T159 T158


Courtesy of Mitsubishi Motor Sales of America.

T159 T155 T168 T232

Fig. 1: Aligning Camshaft Timing Marks (16-Valve Engine) Inspection (1983-88) Inspect back of belt for hardness, non-elasticity and glossy surface. If no mark is produced when ngernail is forced into it, replace belt. Check for rounded sides on belt, aking, peeling, cracking and separating rubber. Cracks are most evident at base of tooth. Installation (1983-88) 1) Install timing belt B ensuring tension side has no slack. Install tensioner B so only light pressure is on belt. Ensure ange on tensioner is mounted away from engine and ngertighten bolt. Lift tensioner with nger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. 2) Check belt tension by pressing center of tension side inward, using index nger and measuring belt deection. Deection should be .20-.30 (5.0-7.0 mm). Readjust if not within specication. Align camshaft timing belt sprockets with corresponding timing marks. See Fig. 2 or 3. To ensure oil pump sprocket is in correct alignment, insert screwdriver shaft in hole on left side of block. See Fig. 1. 3) If screwdriver cannot be inserted at least 2.4 (60.0 mm), turn oil pump sprocket one revolution and realign marks. Insert screwdriver. Leave screwdriver inserted until timing belt installation is complete. With tensioner secured fully toward water pump, install timing belt in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure tension side of belt has no slack. Loosen tensioner mounting bolt and nut to allow only tensioner spring pressure to tighten belt. 4) Check belt to ensure each tooth is in proper mesh with camshaft sprocket. Tighten slot-side bolt before tightening nut. Otherwise, tension bracket will turn and belt will be too tight. Ensure all timing marks are in correct alignment. Remove screwdriver and install plug in block. Turn crankshaft, clockwise only, one revolution. Loosen mounting nut and bolt to allow tensioner to readjust and tighten slot-side bolt, then tighten nut. 5) Hold belt and seal line of undercover, between thumb and forenger, at center of tension side. Measure clearance between belt and seal line. Clearance should be .55 (14.0 mm). Reverse removal procedure to complete reassembly. Adjust drive belts to proper tension. Removal (1989-93) 1) Disconnect negative battery cable. Remove A/C and power steering hose mounting bracket or oxygen sensor connector bracket from upper engine mount at timing belt cover. Support engine, and remove upper engine mount. Remove all drive belts and drive pulleys from crankshaft and water pump.

T090 T089 T159 T158

Balance Shaft Belt labor time included in Camshaft Belt labor time. With Air Conditioning, add .4 hours. With Power Steering, add .3 hours. With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal (1983-88) 1) Disconnect negative battery cable. On models equipped with A/C, remove upper radiator shroud and cooling fan/clutch assembly. On models equipped with power steering, remove power steering pump and pulley. On all models, position No. 1 cylinder at TDC of compression stroke. Loosen pulley bolts. Remove drive belts. 2) Remove crankshaft, water pump and power steering pulleys. Remove upper and lower front timing belt covers. Relieve camshaft timing belt tensioner pressure and secure tensioner toward water pump. If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove belt. Remove camshaft and crankshaft sprocket bolts. Remove camshaft sprocket, crankshaft sprocket and crankshaft ange.

MITSUBISHI
1.8L & 2.0L 4-Cylinder SOHC (Cont.)

531

3) DO NOT remove screwdriver until timing belt is installed. Install camshaft sprocket. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install front timing belt tensioner, tension spring and spacer(s). Ensure spring is properly engaged against water pump case. Rotate tensioner toward water pump, and temporarily tighten bolts. Ensure timing marks are aligned. See Fig. 2 or 3. 4) If reused, install timing belt in original direction of rotation. Apply pressure on tension side of belt while installing belt on camshaft sprocket. Loosen timing belt tensioner to apply spring pressure to timing belt. Ensure timing marks are still aligned. To apply tension on belt, rotate crankshaft clockwise until camshaft sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten tensioner nut. 5) To check belt tension, apply slight thumb pressure and measure deection between camshaft and oil pump sprocket. Belt deection should be .55 (14 mm). To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 2: Aligning Camshaft Sprocket Timing Marks (8-Valve Engine)

Courtesy of DaimlerChrysler Corp.

Courtesy of DaimlerChrysler Corp.

Fig. 3: Aligning Oil Pump Sprocket 2) Remove drive belt tensioner. Remove upper and lower timing belt covers. Note bolt lengths and locations. Longer (2) bolts are located above crankshaft seal. Remove crankshaft sprocket bolt access cover, crankshaft sprocket bolt and washer. If necessary, remove rocker arm cover for clearance. CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing. 3) Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2 or 3. Loosen timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt and camshaft sprocket. 4) If oil pump sprocket removal is necessary, remove left silent shaft access plug from cylinder block. Insert .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. Remove oil pump sprocket nut and sprocket. Remove front crankshaft sprocket and ange. Note direction and order of installation. Remove rear timing belt tensioner assembly. Remove rear timing belt. Inspection (1989-93) Check belt teeth for cracks, damage and contamination. Inspect sprockets for damage. Check belt tensioner for leakage or roughness in rotation. Replace components as necessary. Installation (1989-93) 1) If reusing rear timing belt, install in original direction of rotation. Ensure timing marks are aligned. See Fig. 4. Install rear timing belt tensioner. Hold tensioner tightly against belt while tightening bolts. Depress belt between sprockets to ensure deection is .20-28 (5-7 mm). Adjust as necessary. 2) Install crankshaft front sprocket. Install oil pump sprocket. Hold left silent shaft using a .31 (8.0 mm) diameter Phillips screwdriver through access hole. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36 (59.9 mm), and rotate oil pump sprocket one revolution. Align timing mark. Insert screwdriver, and ensure it can be inserted at least 2.36 (59.9 mm).

Fig. 4: Aligning Rear Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Automatic Tensioner Bolt .............................................................. ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt 1983-85 .......................................................................................................... 11-15 (15-20) 1986-93 ........................................................................................ ................. 15-21 (20-29) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Damper Pulley Bolt ......................................................................................... 11-13 (15-18) Front Cover Bolts M8 X 30 Bolt ............................................................................... ................. 20-26 (27-35) Except M8 X 30 Bolt .................................................................. ................. 14-20 (19-27) Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41) Rear Timing Belt Tensioner ............................................................................ 11-16 (15-22) Silent Shaft Sprocket Bolt .08 (2.0 mm) Washer ................................................................ ................. 25-29 (34-39) .10 (2.5 mm) Washer ................................................................ ................. 31-35 (42-47) Tensioner Pulley Bracket Bolt ....................................................... ................. 17-20 (23-27) Tensioner Pulley Center Bolt ........................................................ ................. 31-40 (42-54) Timing Belt Cover Bolt Left Lower Rear Cover ............................................................... ................. 22-30 (30-41) All Others ..................................................................................... ..................................... 1 Timing Belt Tensioner Nut 1983-85 ........................................................................................ ................. 16-21 (22-28) 1986-93 ........................................................................................ ................. 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm .......................................................................................... 9-11 (12-15) 8 X 65 mm .................................................................................. ................. 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt All Except Left Lower Rear Cover Bolt ...................................... ................. 84-108 (9-12) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)
1

All except Left Lower Rear Cover Bolt tighten to 84-108 INCH lbs. (9-12 N.m).

532

MITSUBISHI
2.0L 4-Cylinder DOHC
Labor Time Belt Part No. Inspection 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulleys for smooth rotation. Replace if defective. 2) Remove timing belt tensioner adjuster. Check timing belt tensioner adjuster for leaks. Hold timing belt tensioner adjuster upright. Measure rod extension length above edge of housing. See Fig. 9. Length should be .5 (12 mm). If length is not as specied, 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 ngers, lift balancer belt tensioner in direction of arrow. See Fig. 11. CAUTION: When tightening balancer belt tensioner bolt, ensure tensioner does not rotate with the bolt. Allowing it to rotate can cause excessive belt tension. 3) Apply 22-30 INCH lbs. (2.6-4.4 N.m) to balancer belt, then tighten balancer belt tensioner bolt to specication. See TORQUE SPECIFICATIONS. 4) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing marks are aligned. See Fig. 8. 5) Apply about 22 lbs. (10 kg.) of pressure at center (arrow area) between sprockets as shown. See Fig. 12. Ensure belt deection is .20-.27 (5.0-7.0 mm). 6) Clean front of crankshaft. Clean and install crankshaft angle sensing blade and crankshaft timing belt sprocket. Apply engine oil to crankshaft center bolt threads and both sides of washer. Install crankshaft center bolt. 7) Using Special Spanner (MB991367) and Pins (MB991385) to hold crankshaft timing belt sprocket, tighten crankshaft center bolt to specication. See TORQUE SPECIFICATIONS. 8) If timing belt tensioner adjuster was removed and rod is fully extended, slowly compress timing belt tensioner adjuster rod with a vise or press to align timing belt tensioner adjuster rod set hole A with timing belt tensioner adjuster cylinder set hole B. 9) Insert a suitable pin or wire into set hole. Install timing belt tensioner adjuster, and tighten bolts to specication. Install idler pulley, and tighten bolt to specication. See TORQUE SPECIFICATIONS. 10) Ensure timing marks are aligned. See Fig. 3. To ensure oil pump/balancer shaft is properly aligned, remove cylinder block plug, and insert a phillips screwdriver as shown. See Fig. 13. 11) If screwdriver cannot be inserted 2.36 (60.0 mm) or more, remove screwdriver and rotate oil pump/balancer shaft one revolution. Ensure screwdriver can be inserted 2.36 (60.0 mm) or more. Do not remove screwdriver until timing belt is installed. 12) Install timing belt on crankshaft timing belt sprocket, oil pump/ balancer shaft sprocket, and idler pulley in that order. Install timing belt on exhaust camshaft sprocket. Secure timing belt to exhaust camshaft sprocket with paper clamp. 13) Use 2 wrenches on camshaft sprocket bolts to align timing marks on camshaft sprockets with timing marks on valve cover. Install timing belt on intake camshaft sprocket. Secure timing belt to intake camshaft sprocket with paper clamp. 14) Pass timing belt around timing belt tensioner pulley. Apply counterclockwise pressure to intake camshaft. Ensure timing marks are aligned while tension side of belt is tight. Remove paper clamps. 15) Using Tensioner Wrench (MD998767), turn timing belt tensioner in direction shown to apply tension to timing belt. See Fig. 14. Pre-tighten timing belt tensioner pulley bolt. 16) Ensure timing marks are still aligned. Remove Phillips screwdriver installed in step 10). Install cylinder block plug, and tighten to specication. See TORQUE SPECIFICATIONS.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. DOHC Lancer Evolution Turbo 2003-04 Balance Shaft ...................................... .......... 1 .......... ..... T168 Camshaft ............................................. ... 2 3.1 Hrs. ... ..... T167
1

With Air Conditioning, add .2 hour. With Power Steering, add .2 hour.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove undercover and side cover. Remove accessory drive belt. Remove crankshaft pulley bolts. Remove crankshaft pulley. Remove crossmember bar for access to front exhaust pipe. 2) Remove front exhaust pipe. Remove timing belt upper cover. See Figs. 1 and 2. Remove water pump pulley. Remove idler pulley. 3) Remove auto-tensioner. Remove timing belt lower cover. Raise engine and transaxle assembly until its weight is not supported by front engine mount. Remove front engine mount. 4) Rotate crankshaft clockwise to align each timing mark and to set cylinder No. 1 at TDC of compression stroke. See Fig. 3. 5) Remove timing belt under cover rubber plug. See Fig. 4. Screw in Adjusting Bolt (MD998738) until it comes in contact with timing belt tensioner arm. See Fig. 5. CAUTION: Adjusting Bolt will bend if it is screwed in too fast. 6) Gradually screw in adjusting bolt at a rate of 30 degrees per second to align timing belt tensioner adjuster rod set hole A with timing belt tensioner adjuster cylinder set hole B. See Fig. 6. 7) Insert a suitable pin or wire into set hole, and remove adjusting bolt. If timing belt is to be reused, mark rotation direction on belt. Loosen timing belt tensioner pulley mounting bolt, and remove timing belt. See Fig. 7. 8) Disconnect power steering pressure switch connector. Remove power steering pump heat shield. Remove power steering pump with hoses attached, and secure aside. Remove power steering pump bracket. Remove timing belt idler pulley. 9) Remove crankshaft position sensor. Using Special Spanner (MB991367) and Pins (MB991385) to hold crankshaft timing belt sprocket, remove crankshaft center bolt. 10) Using Crankshaft Sprocket Puller (MD998778), remove crankshaft timing belt sprocket. Remove crankshaft angle sensing blade. If balancer belt is to be reused, mark rotation direction on belt. 11) Ensure balancer timing marks are aligned. See Fig. 8. Loosen balancer belt tensioner bolt. Remove balancer belt tensioner. Remove balancer belt.

MITSUBISHI
2.0L 4-Cylinder DOHC (Cont.)

533

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt Components (1 Of 2)

Courtesy of Mitsubishi Motor Sales of America.

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

534

MITSUBISHI
2.0L 4-Cylinder DOHC (Cont.)

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Fig. 6: Retracting Timing Belt Tensioner Adjuster

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Fig. 3: Aligning Timing Marks

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Fig. 7: Identifying Timing Belt Tensioner Pulley Mounting Bolt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Locating Timing Belt Under Cover Hole

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Fig. 8: Aligning Balancer Timing Marks

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Fig. 9: Measuring Tensioner Adjuster Rod Extension Length


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Fig. 5: Inserting Adjusting Bolt

MITSUBISHI
2.0L 4-Cylinder DOHC (Cont.)

535

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Measuring Timing Belt Tensioner Adjuster Retraction CAUTION: When crankshaft is rotated counterclockwise, crankshaft center bolt may loosen. Retighten if it comes loose. 17) Gradually screw in Adjusting Bolt (MD998738) until wire or pin inserted in timing belt tension adjuster set hole lightly moves. Rotate crankshaft 1/4 turn counterclockwise. Rotate crankshaft clockwise until timing marks are aligned. CAUTION: When tightening timing belt tensioner bolt, ensure timing belt tensioner pulley does not rotate. Allowing it to rotate with bolt can cause insufficient timing belt tension. 18) Loosen timing belt tensioner pulley bolt. Using Tensioner Wrench (MD998767) and torque wrench, apply 31 INCH lbs. (3.5 N.m) tension torque, and tighten timing belt tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. 19) Remove wire or pin from timing belt tension adjuster set hole. Remove Adjusting Bolt (MD998738), and install rubber plug into timing belt under cover. Rotate crankshaft clockwise 2 turns, and wait about 15 minutes. 20) Insert wire or pin again, and ensure that it can be pulled out easily. If wire or pin can be easily removed, appropriate tension is applied to timing belt. If wire or pin cannot be easily removed, repeat steps 17)-19). 21) Measure distance A between timing belt tensioner adjuster and timing belt tensioner arm. See Fig. 15. Appropriate timing belt tension is applied when distance is .15-.17 (3.8-4.5 mm). 22) Ensure timing marks are still aligned. To complete installation, reverse removal procedure. Tighten bolts and nuts to specication. When tightening engine mount bolts, ensure weight of engine is on vehicle body. See TORQUE SPECIFICATIONS.

Fig. 12: Checking Balancer Belt Deection

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Fig. 13: Aligning Oil Pump/Balancer Shaft

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Fig. 11: Installing Balancer Belt Tensioner

Fig. 14: Tightening Timing Belt

536

MITSUBISHI
2.0L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84) Balancer Belt Tensioner Bolt ........................................................ ................. 12-16 (16-22) Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98) Crankshaft Center Bolt 1 ....................................................................................... 123 (167) Crankshaft Pulley Bolt ................................................................... ................. 15-21 (20-28) Crossmember Bar Bolt .................................................................. ................. 30-47 (39-59) Cylinder Block Plug ....................................................................... ................. 21-25 (28-33) Drive Belt Auto-Tensioner Center Bolt .................................................................................. ................. 26-40 (34-54) Except Center Bolt ...................................................................... ................. 15-21 (20-28) Engine Mount-To-Body Bolt/Nut 2 ................................................. ............... 66-80 (88-108) Engine Mount-To-Engine Mounting Bracket Nut .......................... ................. 45-55 (60-74) Exhaust Pipe-To-Manifold Bolt ...................................................... ................. 33-41 (45-55) Exhaust Pipe-To-Catalyst Bolt ...................................................... ................. 30-44 (41-59) Power Steering Pump Heat Shield Mounting Bolt ....................... ................. 13-19 (18-26) Power Steering Pump Mounting Bolt ........................................... ................. 27-33 (35-45) Power Steering Pump Bracket Mounting Bolt ............................. ................. 29-43 (40-58) Timing Belt Idler Pulley Mounting Bolt ......................................... ................. 22-30 (29-41) Timing Belt Tensioner Adjuster Mounting Bolt ............................. ................. 15-19 (20-26) Timing Belt Tensioner Arm Mounting Bolt .................................... ................. 14-18 (17-25) Timing Belt Tensioner Pulley Bolt ................................................. ................. 33-39 (45-53) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt ................................................... ............... Exhaust Pipe Hanger Bolt ............................................................................ Timing Belt Cover Bolt .................................................................. ............... Water Pump Pulley Bolt ................................................................ ...............
1 2

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Fig. 15: Checking Timing Belt Tension

69-87 (7.8-9.8) 89-133 (11-15) 90-106 (10-12) 69-87 (7.8-9.8)

Before installing, apply engine oil to threads and bolt ange. Tighten with full weight of engine on vehicle body.

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

537

2.0L 4-Cyl. DOHC (4G6) Eclipse Turbo & Non-Turbo 1990-94 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK167 .. ..... Eclipse Turbo 1995-99 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 2 3.0 Hrs. .......... .... ....... ..... Galant 1989-92 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 3 3.6 Hrs. ... .. TCK167 .. ..... 1993 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 2 3.6 Hrs. ... .. TCK232 .. .....
1 2

T168 T167

For 1995-97 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended but not required at 60,000 miles. In California, replace belt at 100,000 miles, unless previously changed. For 1998-99 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California, Connecticut and Massachusetts. In California, Connecticut and Massachusetts, timing belt replacement is recommended but not required at 60,000 miles. In California, replace belt at 100,000 miles, unless previously changed.

T168 T167

REMOVAL & INSTALLATION


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

T168 T167 T168 T232

TIMING BELT & BALANCE SHAFT BELT


Removal 1) Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2) Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1. Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation. 3) Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover.

Balance Shaft labor time included in Camshaft labor time. With Air Conditioning, add .7 hours. With Power Steering, add .2 hours. With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1989-94 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belts & Components

538

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Belt A Marks (1990-93 Models) NOTE: Camshaft sprocket dowel pins will be in 12 oclock position when timing marks are correctly aligned. 4) Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or 3. Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1. 5) Remove plug from left side of cylinder block. Install a .31 (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4. Screwdriver must go in at least 2.36 (60 mm) or more. If screwdriver will only go in about .79-.98 (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6) To remove timing belt B (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7) Remove crankshaft sensing blade (if equipped). See Fig. 5. Loosen timing belt B tensioner bolt. If reusing timing belt B, mark direction of belt rotation for reassembly reference. Remove timing belt B. Inspection 1) Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists. NOTE: The following revised information for timing belt tensioner inspection is from Mitsubishi technical service bulletin 96-11-006; June, 1996. 2) Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 6. Length should be .47 (12 mm). Apply 22-44 lbs. (10-20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto tensioner.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Belt A Timing Marks (1994-99 Models) Installation 1) Retract rod into auto tensioner housing by placing auto tensioner assembly in a soft-jawed vise. Close vise SLOWLY to push rod back into auto tensioner housing. When pin hole in cylinder aligns with pin hole in rod, insert set pin. Replace tensioner assembly if rod can be retracted easily into housing. Install auto tensioner on engine with set pin in place. 2) Align balance shaft and crankshaft timing marks with rear cover. See Fig. 7 or 8. Install timing belt B on sprockets. If using old belt, install belt in original direction of rotation. Ensure there is no slack in tension side of belt.

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

539

CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions, or timing belt may be damaged. 4) Install crankshaft sensing blade (if equipped) in front of crankshaft sprocket B, with offset in proper direction. See Fig. 10. Install crankshaft sprocket A. Apply light coat of engine oil to crankshaft sprocket bolt threads, and tighten bolt to specication. See TORQUE SPECIFICATIONS. Install idler pulley (if removed). 5) Ensure camshaft, crankshaft and oil pump timing marks are still aligned. See Fig. 2 or 3. Do not remove screwdriver from side of engine block until timing belt is installed. NOTE: Intake and exhaust camshafts use same camshaft sprocket. Camshaft sprockets are provided with 2 timing marks. For exhaust camshaft sprocket, use timing mark on right with dowel pin facing up. On intake camshaft sprocket, use timing mark on the left, with dowel pin hole on top. 6) Rotate camshaft sprocket so dowel pins are upward and away from cylinder head, and timing marks are aligned with cylinder head surface. Timing marks should face each other. See Fig. 2 or 3. 7) Install timing belt on intake camshaft sprocket. Install spring clip to retain timing belt on sprocket. See Fig. 11. Place a wrench on each camshaft sprocket retaining bolt. Rotate camshafts so timing marks align with each other. 8) Install timing belt over exhaust camshaft. Install spring clip to retain timing belt. Install timing belt over idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove spring clips from camshaft sprockets. Go to TIMING BELT TENSION ADJUSTMENT (1990-92) or TIMING BELT TENSION ADJUSTMENT (1993-99).

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Holding Balance Shaft Stationary

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Fig. 5: Timing Belt B (Balance Shaft Belt) Components

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Aligning Timing Belt B (1990-92 Models)

Fig. 6: Inspecting Timing Belt Auto Tensioner CAUTION: Ensure tensioner pulley shaft does not rotate when bolt is tightened, or excessive pressure will be applied to timing belt. 3) Install timing belt B tensioner so center of tensioner pulley is to the left and above of retaining bolt center. See Fig. 9. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner retaining bolt without letting tensioner pulley rotate out of position. Check belt deection at designated area. Belt deection should be .20-.28 (5.0-7.0 mm). Readjust timing belt if belt deection is not within specication.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Aligning Timing Belt B (1993-99 Models) Timing Belt Tension Adjustment (1990-92) 1) Position timing belt tensioner pulley so that the 2 pin holes in the center eccentric are facing to the left (as viewed from timing belt end of engine) of the center bolt. Finger tighten center bolt.

540

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of DaimlerChrysler Corp.

Fig. 9: Installing Timing Belt B Tensioner

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

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Fig. 10: Installing Crankshaft Sprocket & Crankshaft Sensing Blade

Fig. 13: Installing Set Screw On Tensioner Pulley

Courtesy of DaimlerChrysler Corp.

Fig. 11: Installing Timing Belt On Intake Sprockets 2) Remove screwdriver from balance shaft hole in side of engine block. Install plug. 3) Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft 1/4 clockwise until timing marks are aligned again. No. 1 cylinder should be at TDC of compression stroke. 4) Attach Adapter (MD998767) to tensioner pulley eccentric. Attach torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in a clockwise direction. See Fig. 12. With torque applied to eccentric, tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). 5) Insert Set Screw (MD998738) through inner timing belt cover until it contacts tensioner arm. See Fig. 13. Slowly rotate set screw until set pin can be removed. Remove set screw from engine. 6) Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes without turning crankshaft. Measure distance between top of auto tensioner body and tensioner arm. See Fig. 14, Dimension A. The distance should be .15-.18 (3.8-4.5 mm). If distance is incorrect, repeat tensioning procedure until distance is correct. Go to FINAL ASSEMBLY. Timing Belt Tension Adjustment (1993-99) 1) Lift tensioner pulley upward to apply tension on timing belt. The 2 pin holes in the center of the tensioner must face down. See Fig. 13. Screw the Set Screw (MD998738) into engine support bracket until it makes contact with tensioner arm. At that point, screw the set screw in a few more threads and remove the set pin from the auto tensioner. Remove the set screw. Tighten timing belt tensioner pulley center bolt to 35 ft. lbs. (48 N.m). 2) Remove screwdriver from side of engine block, and install plug. To tension timing belt, rotate crankshaft about 1/4 turn counterclockwise, then 1/4 turn clockwise until all timing marks align.

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Fig. 14: Measuring Timing Belt Auto Tensioner Protrusion 3) Loosen tensioner pulley center bolt. Install Adapter (MD998767) or equivalent to tensioner eccentric. Install torque wrench on adapter. See Fig. 15. Starting with eccentric pin holes still facing down, apply 31 INCH lbs. (3.5 N.m) of torque counterclockwise on tensioner pulley. 4) Hold tensioner pulley at specied torque, and tighten tensioner center bolt to specication. DO NOT let tensioner pulley turn with bolt. See TORQUE SPECIFICATIONS. 5) Rotate crankshaft 2 full revolutions clockwise so that timing marks are aligned. Allow engine to stand for 15 minutes without turning crankshaft. Distance between top of auto tensioner housing and tensioner arm should be .15-.18 (3.8-4.5 mm). If distance is incorrect, repeat tensioning procedure until distance is correct. Go to FINAL ASSEMBLY.

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Fig. 15: Adjusting Timing Belt Tension (1993-99)

MITSUBISHI
2.0L 4-Cylinder DOHC Eclipse & Galant (Cont.)
Final Assembly To install remaining components, reverse removal procedure. Ensure proper length bolts are installed in timing belt covers. See TIMING COVER BOLT LENGTH & TORQUE table. See Fig. 16. Adjust the drive belts to proper tension. TIMING COVER BOLT LENGTH & TORQUE Bolt Length INCH Lbs. (N.m) A: 6 x 16 Flange Bolt ................................................................................ 89-106 (10-12) B: 6 x 18 Flange Bolt ................................................................................ 89-106 (10-12) C: 6 x 25 Loose Washer Bolt .................... .......................................................... 58 (6.5) D: 6 x 25 Flange Bolt ................................................................................ 89-106 (10-12) E: 6 x 45 Flange Bolt ................................................................................ 89-106 (10-12)

541

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Bolt ................................................................................................... 17 (24) Balance Shaft Sprocket Bolt ..................................................................................... 33 (46) Camshaft Sprocket Bolt ............................................................................................ 65 (90) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (108-127) Drive Belt Tensioner Pulley Bracket ............................................. ................. 17-20 (23-26) Engine Mount-To-Engine Bolt/Nut (1990-92) ................................ ................. 36-47 (50-65) Engine Mount-To-Engine Bolt/Nut (1993-99) ............................................................ 49 (67) Engine Mount-To-Body Through-Bolt (1990-92) ........................... ................. 43-58 (60-80) Engine Mount-To-Body Through-Bolt (1993-99) ........................................... 72-87 (98-118) Idler Pulley Bolt ......................................................................................................... 27 (38) Timing Belt B (Balance Shaft) Tensioner Bolt ............................................. 11-16 (15-20) Timing Belt Tensioner Pulley Center Bolt ................................................................ 35 (48) Water Pump Bolt ....................................................................................................... 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12) Water Pump Pulley Bolt .............................................................................................. 80 (9)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 16: Installing Timing Belt Cover Bolts

542

MITSUBISHI
2.0L 4-Cylinder SOHC
REMOVAL & INSTALLATION
Labor Time Belt Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. SOHC Lancer 2002-04 ..................................................... 3.1 Hours ... ..... T201
1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

TIMING BELT
Removal 1) Remove left undercover. Raise engine and transaxle assembly until its weight is off front engine mount, and support securely. Remove front engine mount and bracket. 2) Remove drive belts. Using Crankshaft Pulley Holder (MD998719) and End Yoke Holder (MB990767), remove crankshaft pulley bolt. Remove crankshaft pulley. 3) Remove generator belt tension adjustment bracket, power steering pump bracket support and engine support bracket. See Fig. 1. 4) Disconnect crankshaft position sensor electrical connector. Remove upper and lower timing belt covers.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Removing & Installing Timing Belt

MITSUBISHI
2.0L 4-Cylinder SOHC (Cont.)
CAUTION: Only rotate crankshaft clockwise. 5) Rotate crankshaft clockwise to align each timing mark and to set cylinder No. 1 at TDC of compression stroke. See Fig. 2. 6) If timing belt is to be reused, mark rotation direction on belt. Loosen tensioner bolt. Insert a Phillips screwdriver into tensioner arm hole, and pry tensioner away from timing belt. Temporarily tighten tensioner bolt. Remove ange and timing belt. Inspection Inspect timing belt rubber backing for hardening or surface cracks. Check for cracks or peeling of canvas, cracks on belt sides or bottom of teeth. Check for abnormal wear on belt sides and teeth. Check for missing teeth. Check tensioner pulley for smooth rotation without noise or play. Installation 1) Ensure timing marks are aligned. See Fig. 2. Install timing belt on crankshaft sprocket, water pump sprocket, camshaft sprocket, then tensioner. CAUTION: DO NOT rotate crankshaft counterclockwise. 2) Loosen tensioner bolt 1/4 to 1/2 turn. Rotate crankshaft clockwise 2 revolutions. Ensure timing marks are still aligned and teeth in each sprocket are engaged. Tighten tensioner bolt to specication. See TORQUE SPECIFICATIONS. 3) To complete installation, reverse removal procedure. Tighten bolts and nuts to specication. When tightening engine mount bolts, ensure weight of engine is on vehicle body. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

543

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98) Crankshaft Pulley Bolt 1 ................................................................ ......... 131-137 (178-186) Engine Mount Bracket-To-Engine Mount Bolt .............................. ............... 49-75 (67-101) Engine Mount Bracket-To-Engine Support Bracket Nut 2 ............ ................. 45-55 (60-74) Engine Mount-To-Body Bolt 2 ........................................................ ................. 26-40 (34-54) Engine Support Bracket Bolt ........................................................ ................. 32-40 (44-54) Generator Belt Tension Adjustment Bracket Bolt ......................... ................. 16-18 (21-25) Power Steering Pump Bracket Support Bolt ................................ ................. 32-40 (44-54) Timing Belt Tensioner Bolt ............................................................ ................. 15-19 (21-25) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 72-106 (8-12)
1 2

Before installing, apply engine oil to threads and bolt ange. Tighten with full weight of engine on vehicle body.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks

544

MITSUBISHI
2.4L 4-Cylinder DOHC
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.4L 4-Cyl. DOHC Galant 1994 Balance Shaft ............... .......... 1 .......... ...... ..... ...... ..... T168 Camshaft Thru 5/94 ....................... 2 3.9 Hours .. .. TCK256 .. ..... T256 From 6/94 ...................... 2 3.9 Hours .. ...... ..... ...... ..... T230
1

Balance Shaft belt labor time included in Camshaft belt labor time. With Air Conditioning, add .4 hour. With Power Steering, add .3 hour.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Timing Marks

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). Removal 1) Disconnect negative battery cable. Remove protective cover from below engine. Remove A/C and power steering hose mounting bracket. Support engine. Remove upper engine mount located near timing belt cover. Remove all drive belts. Remove tensioner pulley bracket. Remove pulleys from crankshaft, water pump and power steering. 2) Remove drive belt tensioner. Remove upper and lower timing belt cover with gasket. Note bolt lengths and locations. Remove breather hose, PCV hose and center shield from valve cover. Disconnect spark plug wires from spark plugs. 3) Remove rocker cover and semi-circular packing (located at rear of rocker cover). Remove rubber plug. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until all timing marks align and cylinder No. 1 is at TDC of compression stroke. See Fig. 1. 4) Remove automatic tensioner. See Fig. 2. If timing belt is to be reused, mark timing belt to indicate original direction of rotation. Remove timing belt. Remove tensioner pulley, tensioner arm and idler pulley (if necessary). Inspect sprockets for damage. 5) To remove camshaft sprockets, hold camshaft hexagon (between camshaft journals No. 2 and 3) while removing camshaft sprocket bolt. Remove camshaft sprockets. Remove silent shaft access plug from cylinder block. Insert .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Remove oil pump sprocket nut and sprocket. 6) Remove bolt, washer, crankshaft sprocket and ange. Note direction of ange installation. Remove rear timing belt tensioner assembly. Remove rear timing belt.

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Fig. 2: Exploded View Of Timing Belt & Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Holding Silent Shaft In Stationary Position

MITSUBISHI
2.4L 4-Cylinder DOHC (Cont.)
Inspection 1) Check belt teeth for damage and oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is not cracked, separated or showing canvas ber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. 2) Inspect automatic tensioner for leaks. Check rod end of automatic tensioner for wear. Measure distance from tensioner rod end to tensioner housing. Distance should be .47 (11.9 mm). 3) Retract rod into tensioner housing by placing automatic tensioner assembly in a soft-jawed vise. Close vise to push rod back into tensioner. Replace automatic tensioner assembly if rod can be easily pushed into automatic tensioner. 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 nger midway between sprockets. Deection should be .20-.28 (5.0-7.1 mm). Install crankshaft sprocket, oil pump sprocket and camshaft sprocket. Tighten camshaft sprocket bolts to specication while holding hexagon area of camshaft. See TORQUE SPECIFICATIONS. Install idler pulley. 3) Retract automatic tensioner rod into tensioner housing by placing tensioner assembly in a soft-jawed vise. Push rod back into automatic tensioner in small increments until both rod and housing holes are aligned. See Fig. 4. Install a .055 (1.39 mm) diameter wire into holes. Remove automatic tensioner from vise with wire attached. 4) Install tensioner and arm. Install tensioner pulley on tensioner arm. Ensure pin holes of tensioner pulley shaft are left of pulley center bolt. Tighten center bolt. Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 1. Outer marks on sprockets should be aligned with cylinder head surface. 5) When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. Ensure this rotation is compensated for when installing timing belt. Rotate crankshaft and oil pump sprockets to align timing marks. 6) If reusing old timing belt, ensure belt is installed in original direction of rotation. Remove silent shaft access plug from cylinder block. Insert .31 (8.0 mm) diameter Phillips screwdriver. See Fig. 3. If screwdriver can be inserted 2.36 (59.9 mm) or more, timing mark alignment is okay. 7) If screwdriver cannot be inserted at least 2.36 (59.9 mm), remove screwdriver and rotate oil pump sprocket one full turn. Reinsert screwdriver. Leave screwdriver in place until timing belt is installed. Install timing belt on intake camshaft sprocket. Use spring clip to hold belt on sprocket. See Fig. 5. 8) Install wrench on both camshaft sprocket bolts. Install timing belt around exhaust camshaft sprocket while holding camshaft sprocket bolt so timing mark on camshaft sprocket is aligned with timing mark. Install another spring clip on timing belt and camshaft sprocket to hold belt on sprocket. Install timing belt in following sequence: around idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. 9) Remove both spring clips. Rotate tensioner pulley inward toward timing belt until belt does not sag. Temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are aligned. Remove Phillips screwdriver from silent shaft access hole. Install plug. Remove wrench from camshaft sprocket bolts. 10) To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, and then rotate clockwise until cylinder No. 1 is at TDC. Ensure timing marks are aligned. Loosen center bolt on tensioner pulley. Note location of pin holes in tensioner pulley. Using INCH-lb. torque wrench and Socket Wrench (MD998767) or equivalent, apply 22 INCH lbs. (2.6 N.m) on tensioner pulley. See Fig. 6. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 35 ft. lbs. (48 N.m). 11) Install set screw in support bracket until set screw end contacts tensioner arm. See Fig. 7. Rotate set screw further until wire can be removed from automatic tensioner. Remove set screw. Rotate crankshaft clockwise 2 complete revolutions, and allow to remain in this

545

position for about 15 minutes. Measure distance between tensioner arm and automatic tensioner body. Distance should be .15-.18 (3.8-4.5 mm). See Fig. 8, Dimension A. 12) If distance cannot be measured due to lack of clearance, use alternate method. Install set screw until it contacts tensioner arm. Rotate set screw inward while counting number of turns until tensioner arm contacts automatic tensioner housing. Number of turns should be 2 1/2-3 if belt tension is correct. Remove set screw. Install rubber plug in rear timing belt cover. 13) To complete installation, reverse removal procedure. Apply sealant to contact areas on semi-circular packing and rocker cover before installing. Ensure correct bolts are installed in proper location in timing belt covers. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Retracting Automatic Tensioner Rod

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Fig. 5: Installing Timing Belt On Camshaft Sprockets

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Adjusting Timing Belt Tensioner Pulley

546

MITSUBISHI
2.4L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Auto Tensioner Bolt ....................................................................... ................. 14-20 (19-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ................................................................... ................. 14-22 (19-30) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Engine Support Bracket Bolt Front ............................................................................................. ................. 36-51 (49-69) Left ............................................................................................... ................. 22-30 (30-41) Front Cover Bolt ............................................................................ ................. 14-16 (19-22) Front Tensioner Pulley Bolt ........................................................... ................. 31-40 (42-54) Idler Pulley Bolt ............................................................................. ................. 25-30 (34-41) Rear Tensioner Retaining Bolt ........................................................................ 11-16 (15-22) Silent Shaft Sprocket Bolt ............................................................. ................. 31-35 (42-47) Water Pump Bolt Except 8 X 65 mm .................................................................................................. 10 (14) 8 X 65 mm .................................................................................. ................. 15-19 (20-26) INCH Lbs. (N.m) Crankshaft Position Sensor Nut ................................................... ................. 84-108 (9-12) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Valve Cover Bolt ........................................................................... ..................... 24-36 (3-4) Water Pump Pulley Bolt ................................................................ ..................... 72-84 (8-9)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Measuring Timing Belt Adjustment

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Measuring Automatic Tensioner Protrusion

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Installing Crankshaft Sprockets

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander
TIMING BELT APPLICATION Application Labor Time Belt Part No.

547

2.4L 4-Cyl. SOHC, VIN G Lancer 2004 ........................................................... 3.1 Hours ... ..... Outlander 2003-04 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt (2003) ............................. 2.7 Hours ... ..... Camshaft Belt (2004) ............................. 2.7 Hours ... .....
1

T332

2) Remove power steering oil pressure hose clamps. See Fig. 6. Disconnect Crankshaft Position (CKP) sensor connector. Remove upper timing belt cover and water pump pulley. Remove drive belt idler pulley. Remove end cap and drive belt auto-tensioner. Remove lower timing belt cover. Raise engine and transaxle assembly until its weight is off front engine mount, and support securely. Remove engine front mounting bracket. See Fig. 7. Turn crankshaft clockwise, and align each timing mark to set No. 1 cylinder to TDC of its compression stroke. See Fig. 8. CAUTION: Adjusting Bolt (MD998738) can be gradually installed at a rate of a 30-degree turn per second. If Adjusting Bolt (MD998738) is screwed in all at once, timing belt tensioner adjuster rod will not easily retract and adjusting bolt may bend. 3) Remove timing belt under cover rubber plug and install Adjusting Bolt (MD998738). See Fig. 9. Screw in Adjusting Bolt (MD998738) until it comes in contact with timing belt tensioner arm. See Fig. 10. 4) Gradually screw in Adjusting Bolt (MD998738) until timing belt tensioner adjuster rod set hole A aligns with timing belt tensioner adjustor cylinder set hole B. See Fig. 11. Insert a wire or pin through set holes. See Fig. 12. Remove Adjusting Bolt (MD998738). Loosen timing belt tensioner pulley mounting bolt, and remove timing belt. Inspection (Timing Belt) Inspect timing belt for the following conditions: Hardening of rubber backing (rubber backing will be glossy without resilience and leave no indentation when pressing with ngernail). Cracks on rubber back. Cracks or peeling of canvas. Cracks on bottom of ribs. Cracks on belt sides. If any of these conditions are present, replace timing belt. Inspection (Timing Belt Tensioner Adjuster) 1) Check for oil leak from timing belt tensioner adjuster seal, and replace it if leak is detected. 2) Check for wear or damage at tip of timing belt tensioner adjuster rod. Replace as necessary. 3) Hold timing belt tensioner adjuster by hand, and press top end of rod onto metal (e.g., cylinder block) under a pressure of 22-44 lbs. (10-20 kg) to measure movement of rod. Movement should be within 0.039 (1.00 mm) of length when it is free (not pressed) and length when it is pressed. See Fig. 13. If measured value is not within standard value, replace timing belt tensioner adjuster. NOTE: After installing timing belt, apply reverse rotation (counterclockwise rotation) pressure to camshaft sprocket. Recheck to see that each timing mark is in proper location while belt is tight. 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 ts past oil pump balancer shaft. DO NOT remove bolt until timing belt is assembled. 3) Place timing belt on timing belt tensioner pulley and crankshaft drive sprocket. See Fig. 15. Support timing belt with your hand so it does not slide. Place timing belt on engine oil pump sprocket while pulling it with your other hand. Place timing belt on timing belt idler pulley. Place timing belt on camshaft sprocket. 4) Turn timing belt tensioner in direction shown using Tensioner Wrench (MD998767) to apply tension to timing belt. See Fig. 16. Pre-tighten timing belt tensioner pulley. Ensure timing marks are aligned. Remove bolt installed in step 2). Reinstall cylinder block plug and tighten to specication. See TORQUE SPECIFICATIONS. Adjust timing belt tension. 5) Install Adjusting Bolt (MD998738) used when removing timing belt. See Fig. 9. Gradually screw in Adjusting Bolt (MD998738) until wire or pin inserted in timing belt tensioner adjuster slightly moves.

T168 T232 T332

Balance shaft belt labor time included in camshaft belt labor time. Balance shaft belt labor time included in camshaft belt labor time.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends replacing timing belt at 60,000 miles except in California, Vermont and Maine. In these states, manufacturer recommends replacing timing belt at 100,000 miles. If timing belt was already replaced at 60,000 miles, it is not required to be replaced at 100,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: Do not remove tape securing Crankshaft Position (CKP) sensor harness connector and control wiring harness, since control wiring harness may contact power steering pump pulley. See Fig. 1.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Identifying Crankshaft Position Sensor Connector Securing Tape NOTE: If reusing timing belt, draw an arrow indicating rotating direction (clockwise) on back of belt using chalk. NOTE: Crankshaft drive sprocket may also be referred to as crankshaft camshaft sprocket. Removal 1) Remove right side under cover (Outlander shown, Lancer is similar). See Fig. 2. Using 1/2 drive ratchet, turn drive belt autotensioner counterclockwise until it hits stopper. Align hole A and hole B of drive belt auto-tensioner. See Fig. 3. Insert an L-shaped hexagonal wrench through holes. See Fig. 4. This will x drive belt autotensioner in place to allow drive belt removal. Remove crankshaft pulley. See Fig. 5.

548

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Removing Under Covers (Outlander)

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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
2.4L 4-Cylinder Lancer & Outlander (Cont.)

549

6) Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft in clockwise direction until you align each timing mark to set No. 1 cylinder to TDC of its compression stroke. 7) Loosen timing belt tensioner pulley mounting bolt. NOTE: When tightening timing belt tensioner pulley bolts, ensure that timing belt tensioner pulley does not rotate with bolts. Allowing it to rotate with bolts can cause decient 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 specication. See Fig. 17. See TORQUE SPECIFICATIONS. Remove wire or pin inserted into timing belt tensioner. See Fig. 12. Remove Adjusting Bolt (MD998738), and install rubber plug to timing belt under cover. Rotate crankshaft clockwise 2 turns, and leave it for about 15 minutes. 9) Insert wire or pin removed in step 8) into set hole in timing belt tensioner and ensure it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin. If projection of timing belt tensioner adjuster rod is within standard value, appropriate tension is applied. See Fig. 18. Standard value A should be 0.15-0.17 (3.8-4.5 mm). If wire or pin cannot be easily pulled out, repeat steps 5)-8) to reach proper timing belt tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Removing Crankshaft Pulley

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Fig. 6: Removing Timing Belt

550

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)

NOTE: Always check tightening torque of crankshaft pulley center bolt after turning crankshaft pulley center bolt counterclockwise. Retighten if it is loose. 10) Ensure timing marks on sprockets are aligned. 11) Install NEW drive belt auto-tensioner end cap. To complete installation, reverse removal procedures. Tighten nuts and bolts to specication. See TORQUE SPECIFICATIONS.

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Fig. 9: Installing Adjusting Bolt

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Fig. 10: Applying Pressure With Adjusting Bolt Against Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Removing Engine Front Mounting Bracket

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Fig. 11: Aligning Timing Belt Tensioner Adjuster Rod With Cylinder

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Timing Belt Aligning Marks

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Fig. 12: Identifying Timing Belt Tensioner Adjuster Wire Or Pin

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)

551

Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Checking Timing Belt Tensioner Rod Movement

Fig. 16: Pre-Tightening Timing Belt Tensioner Pulley

Courtesy of Mitsubishi Motor Sales of America.

Fig. 17: Tightening Timing Belt Tensioner Pulley Bolt


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Fig. 14: Identifying Oil Pump Balancer Shaft Cylinder Block Plug

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Fig. 18: Checking Timing Belt Tensioner Adjuster Rod Projection

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Fig. 15: Installing Timing Belt

552

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 19: Removing Crankshaft Position Sensor

BALANCER TIMING BELT


NOTE: Before performing balancer timing belt removal procedure, remove timing belt. See REMOVAL under TIMING BELT. NOTE: Crankshaft drive sprocket may also be referred to as crankshaft camshaft sprocket. NOTE: If reusing balancer timing belt, draw an arrow indicating rotating direction (clockwise) on back of belt using chalk. Removal 1) Disconnect Power Steering Pressure (PSP) switch and A/C compressor harness connectors. See Fig. 19. Remove A/C compressor connector clamp. With hose connected, remove power steering pump assembly from bracket. Remove power steering pump bracket. Remove CKP sensor harness connector bracket and CKP sensor. 2) Hold crankshaft drive sprocket using Special Spanner (MB991367 or MB991367-01) and 2 Pins (MB991385 or MIT217213). See Fig. 20. Loosen crankshaft pulley center bolt, and remove crankshaft drive sprocket. It may be necessary to use Crankshaft Sprocket Puller (MD998778). See Fig. 21. 3) Remove crankshaft angle sensing ring. 4) Loosen center bolt on balancer timing belt tensioner pulley. Remove balancer timing belt tensioner pulley. Remove balancer timing belt. Inspection Inspect balancer belt for the following conditions: Hardening of rubber backing (rubber backing will be glossy without resilience and leave no indentation when pressing with ngernail). Cracks on rubber back. Cracks or peeling of canvas. Cracks on bottom of ribs.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 20: Holding Crankshaft Drive Sprocket With Special Spanner (MB991367 Or MB991367-01) & Pins (MB991385 Or MIT217213) Cracks on belt sides. If any of these conditions are present, replace timing belt. Installation (Without Scan Tool) 1) Ensure crankshaft balancer drive sprocket and balancershaft sprocket timing marks are aligned. See Fig. 22. 2) Install balancer timing belt on crankshaft balancer drive sprocket and balancershaft sprocket. There should be no slack on tension side. 3) Loosely install balancer timing belt tensioner so that it is at top left from center of assembling bolt. Ensure pulley ange is at front side of engine. 4) Using your ngers, lift balancer timing belt tensioner in direction of arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to specication. See TORQUE SPECIFICATIONS.

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)

553

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 24: Checking Balancer Belt Deection 5) Connect Belt Tension Meter Set (MB991668) to Scan Tool (MB991502). Connect Battery Harness (MB991704) to scan tool. See Fig. 25.

Fig. 21: Removing Crankshaft Sprocket With Crankshaft Sprocket Puller (MD998778)

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Fig. 22: Aligning Balancer Timing Marks

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Fig. 23: Installing Balancer Belt Tensioner 5) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing marks are aligned. 6) Apply about 22 lbs. (10 kg) of pressure at center (arrow area) between sprockets as shown. See Fig. 24. Ensure belt deection is .20-.27 (5-7 mm). 7) If not within specication, readjust balancer timing belt tension. If measurement is within specication, go to CRANKSHAFT ANGLE SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET. Installation (With Scan Tool) 1) Ensure crankshaft balancer drive sprocket and balancershaft sprocket timing marks are aligned. See Fig. 22. 2) Install balancer timing belt on crankshaft balancer drive sprocket and balancershaft sprocket. There should be no slack on tension side. 3) Loosely install balancer timing belt tensioner so that it is at top left from center of assembling bolt. Ensure pulley ange is at front side of engine. 4) Using your ngers, lift balancer timing belt tensioner in direction of arrow shown. See Fig. 23. Tighten balancer timing belt tensioner bolt to specication. See TORQUE SPECIFICATIONS.

Fig. 25: Identifying Scan Tool & Balancer Timing Belt Deection Measuring Components (MB991668, MB991502 & MB991704) 6) Turn crankshaft clockwise 2 revolutions. Ensure balancer timing marks are aligned. 7) Select BELT TENSION on menu screen of scan tool. 8) Hold Belt Tension Meter Set (MB991668) to middle of balancer timing belt between sprockets (at place indicated by arrow), about 0.40-0.78 (10-20 mm) away from rear surface of belt so that it is perpendicular to belt (within an angle of 15 degrees). See Fig. 26. 9) While performing rest of test, ensure the following conditions are met: Temperature of belt should be as close to normal as possible. Do not allow contaminants such as water or oil to get into microphone. If gusts of wind blow against microphone or if there are any loud sources of noise nearby, values measured by microphone may not correspond to actual values. If microphone is touching belt while measurement is being made, values measured by microphone may not correspond to actual values. 10) Gently tap middle of balancer timing belt between sprockets (place indicated by arrow) with your nger as shown in gure, and measure that vibration frequency of belt is within 76-92 Hz. See Fig. 26.

554

MITSUBISHI
2.4L 4-Cylinder Lancer & Outlander (Cont.)
4) Clean screw hole of crankshaft. 5) Place larger chamfer side of crankshaft pulley washer in direction shown and then assemble on crankshaft pulley center bolt. See Fig. 27. 6) Apply some engine oil to crankshaft pulley center bolt bearing surface and screw. 7) Hold crankshaft drive sprocket using Special Spanner (MB991367 or MB991367-01) and 2 Pins (MB991385 or MIT217213). 8) Tighten crankshaft pulley center bolt to specication. See TORQUE SPECIFICATIONS. 9) After tightening crankshaft pulley center bolt to specication, go to INSTALLATION under TIMING BELT.

TORQUE SPECIFICATIONS
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TORQUE SPECIFICATIONS Fig. 26: Measuring Balancer Timing Belt Deection With Belt Tension Meter Set (MB991668) 11) If measurement is not with 76-92 Hz, readjust balancer timing belt. If measurement is within specication, go to CRANKSHAFT ANGLE SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET. Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt ......................................... ................. 56-62 (74-84) Balancer Timing Belt Tensioner Bolt ............................................ ................. 12-16 (16-22) Camshaft Pulley Bolt ..................................................................... ................. 58-72 (78-98) Crankshaft Center Bolt 1 ......................................................................... 117-123 (157-167) Crankshaft Pulley Bolt ................................................................... ................. 15-21 (20-28) Cylinder Block Plug ....................................................................... ................. 21-25 (28-33) Drive Belt Auto-Tensioner (Center Bolt) Center Bolt .................................................................................. ................. 26-40 (34-54) Except Center Bolt ...................................................................... ................. 13-18 (18-24) Engine Mount-To-Body Bolt/Nut 2 ................................................. ................. 26-40 (34-54) Engine Mount-To-Engine Mounting Bracket Nut .......................... ................. 49-55 (66-74) Power Steering Pump Bracket Mounting Bolt ............................. ................. 29-43 (40-58) Power Steering Pump Mounting Bolt ........................................... ................. 13-19 (18-20) Timing Belt Idler Pulley Mounting Bolt ......................................... ................. 22-30 (29-41) Timing Belt Tensioner Adjuster Mounting Bolt ............................. ................. 15-19 (20-26) Timing Belt Tensioner Arm Mounting Bolt .................................... ................. 14-18 (17-24) Timing Belt Tensioner Pulley Bolt ................................................. ................. 33-39 (43-53) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt ................................................... ............... 69-87 (7.8-9.8) Crankshaft Position Sensor Harness Connector Mounting Bolt .. ............. 107-133 (13-15) Power Steering Pressure Hose Clamp Mounting Bolt ................ ............... 80-132 (10-14) Timing Belt Cover Bolt .................................................................. ............... 90-106 (10-12) Water Pump Pulley Bolt ................................................................ ............... 69-87 (7.8-9.8) Wiring Harness Mounting Bolt ...................................................... ............. 107-124 (13-15)
1 2

CRANKSHAFT ANGLE SENSING BLADE OR CRANKSHAFT DRIVE SPROCKET


Installation 1) Degrease and clean crankshaft angle sensing blade and crankshaft drive sprocket. 2) Degrease and clean crankshaft drive sprocket on installation side of crankshaft. 3) Install crankshaft angle sensing blade and crankshaft drive sprocket in direction shown. See Fig. 27.

Before installing, apply engine oil to threads and bolt ange. Tighten with full weight of engine on vehicle body.

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Fig. 27: Preparing & Installing Crankshaft Angle Sensing Blade Or Crankshaft Drive Sprocket

MITSUBISHI
2.4L 4-Cylinder SOHC 1985-90 Galant & Van
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

555

2.4L 4-Cyl. SOHC Galant 1985-87 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 2 2.7 Hrs. ... .. TCK124 .. ..... Van 1987-90 Balance Shaft Belt ....... .......... 1 .......... ...... ..... ...... ..... Camshaft Belt ............... ... 2 3.2 Hrs. ... .. TCK124 .. .....
1

T159 T124

T159 T124

Balance shaft belt labor time included in camshaft belt labor time. With Air Conditioning, add .4 hours on Galant. With Air Conditioning, add .7 hours on Van. With Power Steering, add .4 hours.

Courtesy of Mitsubishi Motor Sales of America.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 2: Holding Silent Shaft In Stationary Position Installation 1) Lightly oil right silent shaft spacer and insert spacer with chamfered end toward seal. Install right silent shaft sprocket (if removed) and nger-tighten bolt. Align crankshaft sprocket and silent shaft sprocket timing marks with corresponding marks on front case. See Figs. 4 and 5. 2) Install timing belt B, ensuring tension side has no slack. Install tensioner B so only light pressure is on belt. Ensure ange on tensioner is mounted away from engine, and nger-tighten bolt. 3) Lift tensioner with nger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. 4) Check belt tension by pressing center of tension side inward, using index nger and measuring belt deection. Deection should be .20-.30 (5.0-7.0 mm). Readjust if not within specication. 5) Align camshaft timing belt sprockets with corresponding timing marks. See Fig. 6. To ensure oil pump sprocket is in correct alignment, insert screwdriver shaft in hole on left side of block. See Figs. 1 and 2. 6) If screwdriver cannot be inserted at least 2.4 (60.0 mm), turn oil pump sprocket one revolution and realign marks. Insert screwdriver. Leave screwdriver inserted until timing belt installation is complete. Install crankshaft sprocket. See Fig. 7 or 8. 7) With tensioner secured fully toward water pump, install timing belt in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure tension side of belt has no slack. Loosen tensioner mounting bolt and nut to allow only tensioner spring pressure to tighten belt. Check belt to ensure each tooth is in proper mesh with camshaft sprocket. 8) Tighten slot-side bolt before tightening nut. Otherwise, tension bracket will turn and belt will be over-tensioned. Ensure all timing marks are in correct alignment. Remove screwdriver and install plug in block. Turn crankshaft, clockwise only, one revolution. Loosen mounting nut and bolt to allow tensioner to readjust and tighten slot-side bolt, then tighten nut. 9) Hold belt and seal line of undercover, between thumb and forenger, 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.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Position No. 1 cylinder at TDC of compression stroke. Remove crankshaft and water pump pulleys. Remove upper and lower front timing belt covers Relieve camshaft timing belt tensioner pressure, and secure tensioner toward water pump. 2) If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove belt. Remove camshaft and crankshaft sprocket bolts. Remove camshaft sprocket, crankshaft sprocket and crankshaft ange. Remove plug on left side of cylinder block. Insert a screwdriver to keep left silent shaft in position. See Figs. 1 and 2. 3) Remove oil pump sprocket. Loosen right silent shaft sprocket mounting bolt until it can be turned by hand. Remove belt tensioner B and timing belt B. See Fig. 3.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Aligning Oil Pump Sprocket Inspection 1) Inspect back of belt for hardness, non-elastic and having a glossy surface. If no mark is produced when ngernail is forced into it, replace belt. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking and rubber from canvas also indicates belt warrants replacement. Cracks are most evident at base of tooth. 2) Abnormal wear most often occurs on load side of tooth. Fluffy canvas, unclear canvas texture, belt color changed to White from rubber missing, reduced tooth width or a missing tooth warrant belt replacement.

556

MITSUBISHI
2.4L 4-Cylinder SOHC 1985-90 Galant & Van (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Exploded View Of Timing Belt Components

Courtesy of DaimlerChrysler Corp.

Fig. 5: Aligning Rear Timing Belt

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks For Timing Belt B

MITSUBISHI
2.4L 4-Cylinder SOHC 1985-90 Galant & Van (Cont.)

557

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Checking Timing Belt A Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt ............................................... ................. 17-20 (23-27) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ................................................................... ................. 14-22 (19-30) Crankshaft Sprocket Bolt .............................................................. ............. 80-94 (109-127) Engine Support Bracket Bolt Front ............................................................................................. ................. 36-51 (49-69) Left ............................................................................................... ................. 22-30 (30-41) Engine Support Bracket Bolts ....................................................... ................. 29-36 (39-49) Front Cover Bolts .......................................................................... ................. 15-19 (20-26) Front Roll Stopper Bracket Nuts .................................................. ................. 22-36 (30-49) Front Roll Stopper Insulator Nut .................................................. ................. 36-41 (49-56) Left Mounting Bracket-To-Engine Bolts & Nuts ........................... ................. 36-47 (49-64) Rear Roll Stopper Bracket-To-Rear Roll Stopper Insulator Nut .......................................................... ................. 22-29 (30-39) Roll Stopper Stay Bolt .................................................................................. 11-15 (15-20) Rear Roll Stopper-To-No. 2 Crossmember Nuts ..................................................................... ................. 43-58 (58-79) Rear Tensioner Retaining Bolt ...................................................................... 11-16 (15-22) Silent Shaft Sprocket Bolt 1985-87 ........................................................................................ ................. 25-28 (34-38) Timing Belt Tensioner Nut 1986-85 ........................................................................................ ................. 16-21 (22-28) 1987-90 ........................................................................................ ................. 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm .................................................................................................. 10 (14) 8 X 65 mm .................................................................................. ................. 15-19 (20-26) INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Aligning Camshaft Timing Marks

Fig. 7: Installing Crankshaft Sprockets (Galant)

Timing Belt Cover Bolt .................................................................. ................. 22-29 (30-39) Valve Cover Bolt ........................................................................... ................. 84-108 (9-12) Water Pump Pulley Bolt ................................................................ ..................... 48-60 (5-7)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Installing Crankshaft Sprockets (Van)

558

MITSUBISHI
2.4L 4-Cylinder SOHC, VIN G Except Outlander & Lancer
MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE
For 1994-96 and 2001 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles. For 2002-04 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts, Maine and Vermont. In California, Massachusetts, Maine and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles.

TIMING BELT APPLICATION Application Labor Time Belt Part No.

2.4L 4-Cyl. SOHC Eclipse 1996-99 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ....................................... 2 3.0 Hours .. ..... 2000-03 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ....................................... 2 2.7 Hours .. ..... 2004 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ....................................... 2 2.7 Hours .. ..... Galant 1994-98 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ....................................... 2 2.7 Hours .. ..... 1999-03 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ........................................ 3.1 Hours ... ..... 2004 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ........................................ 3.1 Hours ... ..... Montero Sport 1997-99 Balance Shaft Belt .............................. .......... 1 .......... ..... Camshaft Belt ....................................... 2 2.2 Hours .. .....
1

T168 T230 T168 T232 T168 T332

T168 T230 T168 T232 T168 T332

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.

T168 T230

Balance shaft belt labor time included in camshaft belt labor time. With Air Conditioning, add .4 hour for 1994-98 Galant and 1997-99 Montero Sport. With Air Conditioning, add .1 hour for 1996-99 Eclipse. With Power Steering, add .3 hour for 1994-98 Galant.

TIMING BELT
Removal (Eclipse & Galant) 1) Raise and support vehicle. Remove engine splash shield from right side wheelwell. 2) Lower vehicle. Support weight of engine with oor jack. If necessary, remove coolant reservoir. Remove upper engine mount located near timing belt cover. Remove all drive belts. If necessary, remove drive belt tensioner pulley bracket and power steering pump pulley. See Fig. 1. Remove water pump pulley. 3) Remove crankshaft pulley. Noting bolt lengths and locations, remove upper and lower timing belt cover with gasket.

NOTE: Engine VIN is eighth character of vehicle VIN. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Eclipse & Galant)

MITSUBISHI
2.4L 4-Cylinder SOHC, VIN G Except Outlander & Lancer (Cont.)
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing. 4) Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2. 5) Loosen timing belt tensioner center bolt, and move tensioner pulley toward water pump. Tighten center bolt to secure tensioner. Remove front timing belt. Remove tensioner pulley and timing belt auto tensioner. 6) To remove balance shaft belt, remove left balance shaft access plug from cylinder block. Insert .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36 (59.9 mm). Rotate balance shaft one revolution and realign timing mark. 7) If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Holding crankshaft stationary, remove front crankshaft sprocket bolt. Use gear puller to remove crankshaft sprocket from crankshaft. 8) Noting direction of installation, remove crankshaft sensing blade. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION.

559

Installation (Eclipse & Galant) 1) Align crankshaft rear sprocket and balance shaft sprocket timing marks. See Fig. 4. Install balance shaft timing belt. Ensure there is no slack in belt. If reusing old belt, install in original direction of rotation. 2) Install crankshaft sensing blade in correct direction. See Fig. 6. Install crankshaft sprocket. Apply engine oil to threads of crankshaft sprocket bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. 3) Move the balance shaft tensioner pulley so that the center of the tensioner pulley is above and to the left of the centerline of the tensioner center bolt. See Fig. 5. The tensioner pulley ange should face toward the front of the engine. CAUTION: When tightening balance shaft tensioner pulley center bolt, ensure tensioner pulley shaft does not rotate with bolt. This will place excessive tension on bolt. 4) Using your hand, place pressure on balance shaft tensioner pulley in direction of balance shaft timing belt. Loosen balance shaft tensioner pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and tighten balance shaft tensioner pulley center bolt. 5) Press balance shaft belt on side opposite tensioner to check belt deection. See Fig. 4. Balance shaft belt deection should be .20-.28 (5.0-7.0 mm). Adjust as necessary. NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed. 6) Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. Install tensioner pulley. 7) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, oil pump sprocket, then camshaft sprocket. If reusing old timing belt, ensure belt is installed in original direction of rotation. Make sure there is no slack in timing belt between sprockets. 8) Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 7. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt. CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only. 9) Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7. Screw in set screw by hand until tensioner bracket arm makes contact with auto tensioner push rod end. 10) Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. 11) Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specication. 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 specied, repeat timing belt tensioning procedure. 14) Install timing belt covers. Ensure bolts are installed in original locations. See Fig. 9. Continue installation in reverse order of removal procedure. Adjust drive belts to proper tension. Removal (Montero Sport) 1) Drain engine coolant. Remove upper radiator hose. Loosen the cooling fan clutch-to-pulley nuts. Remove accessory drive belts. Remove fan shroud and cooling fan clutch with pulley.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Front Timing Belt Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Locking Balance Shaft

560

MITSUBISHI
2.4L 4-Cylinder SOHC, VIN G Except Outlander & Lancer (Cont.)

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Adjusting Timing Belt Tension

Fig. 4: Aligning Balance Shaft Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Balance Shaft Timing Belt Tensioner

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Timing Belt Cover Bolt Installation Locations 4) Disconnect ignition power transistor and ignition coil connector. Remove ignition coil. Remove timing belt upper cover. 5) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. Remove distributor bracket. See Fig. 10. 6) Remove timing belt lower cover. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2. 7) Loosen timing belt tensioner center bolt, and remove tensioner toward water pump. Tighten center bolt to secure tensioner. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Remove timing belt auto tensioner. 8) To remove balance shaft timing belt, remove left balance shaft access plug from cylinder block. Insert .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36 (59.9 mm). Rotate balance shaft one revolution and realign timing mark. 9) If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft timing belt. Inspect timing belt. See TIMING BELT INSPECTION. Installation (Montero Sport) 1) Align crankshaft sprocket and balance shaft sprocket timing marks. See Fig. 4. Install balance shaft timing belt. If reusing old belt, install in original direction of rotation. 2) Move the balance shaft tensioner pulley so that the center of the tensioner pulley is above and to the left of the centerline of the tensioner center bolt. See Fig. 5. The tensioner pulley ange should face toward the front of the engine. 3) Using your hand, place pressure on balance shaft tensioner pulley in direction of balance shaft timing belt. Loosen balance shaft tensioner pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and tighten balance shaft tensioner pulley center bolt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Installing Crankshaft Sensing Blade (Eclipse & Galant)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Installing Set Screw On Tensioner Pulley CAUTION: Never rotate crankshaft counterclockwise. 2) Rotate crankshaft clockwise so that No. 1 piston is at TDC of compression stroke. Leaving secondary wires attached, remove distributor cap and set aside. 3) Note installed position of distributor and distributor rotor. Unplug distributor electrical connector. Remove distributor housing and set aside.

MITSUBISHI
2.4L 4-Cylinder SOHC, VIN G Except Outlander & Lancer (Cont.)

561

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 specied, repeat timing belt tensioning procedure. 13) Install timing belt lower cover, distributor bracket, and timing belt upper cover. Install distributor, distributor cap, and ignition coil. 14) Install cooling fan clutch, pulley, fan shroud, and upper radiator hose. Continue installation in reverse order of removal procedure. Fill and bleed cooling system. Adjust ignition timing.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Timing Belt & Components (Montero Sport) NOTE: When tightening balance shaft tensioner pulley center bolt, ensure tensioner pulley shaft does not rotate with bolt. This will place excessive tension on belt. 4) Press balance shaft belt on side opposite tensioner to check belt deection. See Fig. 4. Balance shaft belt deection should be .20-.28 (5.0-7.0 mm). Adjust as necessary. 5) Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. 6) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on engine. If reusing old timing belt, ensure belt is installed in original direction of rotation. Make sure there is no slack in timing belt between sprockets. NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed. 7) Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 7. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt. CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only. 8) Install Set Screw (MD998738) into rear timing belt cover. See Fig. 7. Screw in set screw until tensioner bracket arm makes contact with auto tensioner push rod end. 9) Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. 10) Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 8. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specication. See TORQUE SPECIFICATIONS. DO NOT let tensioner pulley turn while tightening center bolt. 11) Remove locking pin from auto tensioner. Remove set screw.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Measuring Timing Belt Auto Tensioner Protrusion

TIMING BELT INSPECTION


1) Inspect back of belt for being hard, non-elastic and having a glossy surface. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking rubber from canvas also indicates that belt should be replaced. Cracks are most evident at base of tooth. 2) Abnormal wear most often occurs on load side of tooth. Fluffy canvas, unclear canvas texture, belt color changed to White from rubber missing, reduced tooth width or a missing tooth warrant belt replacement. 3) Check timing belt and balance shaft belt tensioner pulleys for worn bearings. Replace as necessary. 4) Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 12. Length should be .47 (12 mm). Apply 22-44 lbs. (20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto tensioner.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Inspecting Timing Belt Auto Tensioner

562

MITSUBISHI
2.4L 4-Cylinder SOHC, VIN G Except Outlander & Lancer (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ECLIPSE & GALANT) Application Ft. Lbs. (N.m) Auto Tensioner Bolt ................................................................................................... 18 (24) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24) Crankshaft Sprocket Bolt .............................................................. ........... 1 80-94 (108-127) Drive Belt Tensioner Pulley Bracket Bolt ..................................... ................. 17-20 (23-26) Engine Upper Mount Mount-To-Engine Bracket Nut/Bolt Eclipse (2000-03) ...................................................................... ................. 56-72 (74-98) Galant (1999-03) ................................................................................................... 63 (86) All Other Models ................................................................................................... 49 (67) Mount-To-Body Through-Bolt Eclipse (2000-03) ...................................................................... ................. 51-69 (69-93) Galant (1999-03) ................................................................................................... 60 (81) All Other Models ....................................................................................... 71-85 (98-118) Power Steering Pump Pulley Bolt ............................................................................ 45 (61) Tensioner Pulley Center Bolt Balance Shaft Belt Pulley ....................................................................................... 14 (19) Camshaft Belt Pulley ............................................................................................... 35 (48) Water Pump Bolt ....................................................................................................... 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt 6-mm (Except Flange Bolts) .................................................................................. 78 (8.8) 6-mm (Flange Bolt) ..................................................................... ............... 89-106 (10-12) 8-mm Bolt .............................................................................................................. 120 (14) Water Pump Pulley Bolt ................................................................ ..................... 71-80 (8-9)
1

TORQUE SPECIFICATIONS (MONTERO SPORT) Application Ft. Lbs. (N.m) Auto Tensioner Bolt ................................................................................................... 18 (24) Camshaft Sprocket Bolt ............................................................................................ 65 (90) Crankshaft Drive Belt Pulley Bolt ............................................................................. 18 (24) Distributor Bracket Bolt Except M6 x 18 mm ................................................................... ..................................... 1 M6 x 18 mm ............................................................................................................ 17 (24) Tensioner Pulley Center Bolt Balance Shaft Belt Pulley ....................................................................................... 14 (19) Camshaft Belt Pulley ............................................................................................... 35 (48) Water Pump Bolt ....................................................................................................... 10 (14) INCH Lbs. (N.m) Cooling Fan Clutch-To-Stud Nut ................................................... ............... 89-106 (10-12) Distributor Housing Hold-Down Bolt ............................................. .......................... 115 (13) Timing Belt Cover Lower Cover Bolt ................................................................................................... 78 (8.8) Upper Cover Bolt .................................................................................................... 97 (11) Water Pump Pulley Bolt .......................................................................................... 117 (13)
1

Tighten bolt to 97 INCH lbs. (11 N.m).

Apply engine oil to bolt threads.

MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

563

3.0L V6 SOHC Diamante 1992-96 ............................ ... Galant Sigma 1988-90 ............................ ... Montero (12-Valve Engine) 1989-91 ............................ ... 1992-94 ............................ ... Pickup (4WD) 1990-94 ............................ ... Sigma 1989-90 ............................ ... 3000GT 1997-99 ............................ ...
1

3.8 Hrs. ... .. TCK139 .. ..... T139 3.8 Hrs. ... .. TCK139 .. ..... T139 3.5 Hrs. ... .. TCK139 .. ..... T139 3.5 Hrs. ... .. TCK139 .. ..... T139 3.5 Hrs. ... .. TCK139 .. ..... T139 3.8 Hrs. ... .. TCK139 .. ..... T139 3.5 Hrs. ... .. TCK139 .. ..... T139

2 1

With Air Conditioning, add .4 hours. With Power Steering, add .2 hours. With Air Conditioning, add .5 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1988-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-99 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Removing & Installing Engine Support Bracket

REMOVAL & INSTALLATION


TIMING BELT REMOVAL
Removal (Diamante) 1) Disconnect negative battery cable. Remove left front and left side splash shields. Using engine hoist, lift engine just enough to remove weight from engine mounts. Remove drive belts. Remove A/C tensioner pulley and bracket. CAUTION: Apply spray lubricant on reamer bolt during removal, as bolt is sometimes seized in engine support. 2) Remove engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 1. Remove power steering pump, leaving hoses attached. On 1996 models, remove crankshaft position sensor and right oxygen sensor. Remove crankshaft pulley. On vehicles with ABS, remove overow tank and bracket. 3) On all models, remove engine support bracket. Remove crankshaft pulley. Remove timing belt covers. Remove ange from crankshaft. See Fig. 2. Rotate crankshaft to align all timing marks. See Figs. 3 and 4. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to release belt tension. 4) If reusing timing belt, mark belt to indicate direction of belt rotation. Loosen tensioner bolt. Pry tensioner counterclockwise to relieve belt tension. While holding tensioner, tighten tensioner bolt. Remove timing belt.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View of Timing Belt & Components Removal (Galant) 1) Disconnect negative battery cable. Remove all accessory drive belts. Disconnect connector and pressure hoses at power steering pump. Remove power steering pump with return hose connected. Remove through-bolt from front engine mount.

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 ange. See Fig. 2. Rotate crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to release belt tension. 5) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt and belt tensioner. Removal (Sigma) 1) Disconnect negative battery cable. Remove all accessory drive belts. Disconnect connector and pressure hose at power steering pump. Remove power steering pump with return hose connected. Support engine. Remove through-bolt from front engine mount. Remove front engine mount. NOTE: Apply spray lubricant on reamer bolt during removal, as bolt is sometimes seized in engine support bracket.
Courtesy of DaimlerChrysler Corp.

Fig. 3: Locating Timing Belt & Sprocket

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Aligning Timing Marks CAUTION: Apply spray lubricant on reamer bolt during removal, as bolt is sometimes seized in engine support. 2) Support engine and remove front engine mount. Remove engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 1. 3) Remove A/C tensioner pulley and mounting bracket. Remove No. 1 upper outer cover and gaskets. See Fig. 2. Remove engine support bracket bolts in proper sequence. See Fig. 1. Remove engine support bracket. 4) Remove cover cap and No. 2 upper outer cover and gaskets. Remove under cover. Using Holder (MB990767-01) and Adapter Bolts (MD998719) or equivalent, remove crankshaft pulley. 5) Remove lower outer cover, gaskets and ange. See Fig. 2. Rotate crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to release belt tension. 6) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt and belt tensioner. Removal (Montero & Pickup) 1) Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose. Remove upper radiator shroud. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove power steering pump with pressure and return hoses connected and set aside. 2) Remove power steering pump brackets. Remove A/C tensioner pulley and mounting bracket. Remove A/C compressor with hoses connected and mounting bracket. Remove cooling fan bracket assembly. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 2.

2) Remove A/C tensioner pulley and mounting bracket. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 2. Remove engine support bracket bolts in proper sequence. See Fig. 1. Remove engine support bracket. 3) Remove cover cap and timing belt No. 2 upper outer cover and gaskets. Remove under cover. Using Holder (MB990767-01) and Adapter Bolts (MD998719) or equivalent, remove crankshaft pulley. 4) Remove lower outer cover, gaskets and ange. See Fig. 2. Rotate crankshaft and align all timing marks. See Figs. 3 and 4. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to release belt tension. If timing belt is to be reused, place arrow on belt to indicate rotation direction. Removal (3000GT) 1) Remove engine lower splash shields. Remove cruise control actuator (if equipped) from right side fenderwell. 2) Remove all drive belts. Remove A/C drive belt tensioner pulley assembly. Remove power steering and generator drive belt tensioner pulley bracket. 3) Place oor jack under engine to support weight of engine. Remove engine-to-body mount from timing belt end of engine. 4) Unplug power steering pump pressure switch electrical connector. Remove power steering pump with hoses attached, and set out of way. CAUTION: Reamer bolt may be heat-seized to engine support bracket. Reamer bolt has R marking on bolt head. 5) Remove engine support bracket bolts, in specied sequence, from front of engine. See Fig. 1. Note position of reamer bolt for reassembly reference. 6) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. 7) Remove all timing belt covers. Noting position for reassembly reference, remove front ange from crankshaft. See Fig. 5. 8) Rotate crankshaft to align all timing marks. See Figs. 3 and 4. Loosen belt tensioner bolt. Rotate belt tensioner pulley counterclockwise to relieve belt tension. Tighten tensioner pulley bolt. 9) If reusing timing belt, place arrow on belt to indicate belt running direction. Remove timing belt.

TIMING BELT INSPECTION


All Models Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner for smooth rotation. Replace parts, if defective.

TIMING BELT INSTALLATION


Installation (Diamante) 1) Install timing belt onto crankshaft sprocket, then around left camshaft sprocket, with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft

MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine (Cont.)

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3) Install timing belt. Ensure belt is installed in original direction of rotation and all timing marks are aligned. Install ange on crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. 4) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. 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. 5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining components, reverse removal procedure. Install proper length bolts in timing belt covers and engine support bracket. See Figs. 1 and 6. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Installation (Montero & Pickup) 1) Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. 2) Rotate belt tensioner counterclockwise as far as possible, and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Figs. 3 and 4. 3) Install timing belt on crankshaft sprocket and then left camshaft sprocket with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft sprocket and tensioner. Remove any slack from belt by rotating left and then right camshaft sprockets counterclockwise. Ensure all timing marks are aligned. Install ange on crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. 4) Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner. 5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining components, reverse removal procedure. Install proper length bolts in timing belt covers. See Fig. 7. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. CAUTION: The sealing washer under the cooling system air bleed bolt was reduced to .85 mm from 2.0 mm. The .85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin 96-00-003; February, 1996. 6) Before relling cooling system, remove air bleed bolt on top of thermostat housing. Rell cooling system with 50/50 mix of water and coolant until it overows 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, rell radiator. Installation (Sigma) 1) Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. 2) Rotate belt tensioner counterclockwise as far as possible, and temporarily tighten bolt. Align all timing marks with No.1 cylinder at TDC of compression stroke. See Figs. 3 and 4. 3) Install timing belt on crankshaft sprocket, rear head camshaft sprocket, water pump pulley, front head sprocket and timing belt tensioner. Ensure belt is installed in original direction of rotation and all timing marks are aligned on crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Exploded View Of Timing Belt & Components (3000GT SOHC) sprocket, and tensioner. Apply torque to rear camshaft pulley to tighten belt. Ensure all timing marks are aligned. 2) Install ange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. Using Crankshaft Socket (MD998716-01) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner. Belt tension should be 44-66 lbs. (20-30 kg). 3) Install proper length bolts in timing belt covers. See Fig. 6. Tighten all bolts and nuts to specication. See TORQUE SPECIFICATIONS. NOTE: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt. 4) Install engine support bracket and tighten bolts in sequence. See Fig. 1. Tighten bolts to specication. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of DaimlerChrysler Corp.

Fig. 6: Identifying Timing Belt Cover Bolt Lengths (Diamante, Galant & Sigma) Installation (Galant) 1) Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. 2) Rotate belt tensioner counterclockwise as far as possible, and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Figs. 3 and 4.

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MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Timing Belt Cover Bolt Lengths (3000GT)

TORQUE SPECIFICATIONS
Courtesy of DaimlerChrysler Corp.

TORQUE SPECIFICATIONS (DIAMANTE) Fig. 7: Identifying Timing Belt Cover Bolt Lengths (Montero & Pickup) 4) Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner. 5) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining components, reverse removal procedure. Install proper length bolts in timing belt covers. See Fig. 6. NOTE: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt. 6) Install engine support bracket. Tighten bolts in sequence to specication. See Fig. 1. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Installation (3000GT) 1) Ensure all timing belt marks are aligned. See Figs. 3 and 4. If not already done, loosen tensioner center bolt. Turn tensioner counterclockwise. Temporarily tighten tensioner center bolt. 2) Install timing belt on crankshaft sprocket, left hand camshaft sprocket (side away from tensioner pulley), water pump pulley, right hand camshaft sprocket, and timing belt tensioner. Apply counterclockwise force to right hand camshaft sprocket (camshaft closest to rewall) to remove any belt slack. Ensure all timing marks are still aligned. 3) Install front ange on crankshaft. Loosen timing belt tensioner pulley center bolt. Allow the tensioner spring force to tension timing belt. Turn crankshaft 2 revolutions clockwise. DO NOT turn counterclockwise. 4) Align all timing belt marks. Final tighten tensioner pulley center bolt. Using a belt tension gauge, measure timing belt tension midway between crankshaft sprocket and left hand camshaft sprocket (side opposite belt tensioner pulley). Belt tension should be 46.3-68.3 lbs. (21-31 kg). 5) Install ange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. 6) Install timing belt covers. Install timing belt cover bolts in correct locations. See Fig. 8. NOTE: When installing engine support bracket reamer bolt, tighten it slowly while spraying lubricant on reamer bolt. Reamer bolt has R marking on bolt head. 7) Install crankshaft pulley. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install engine support bracket on engine block. Install bolts in correct location, and tighten in sequence. See Fig. 1. 8) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .......................................................................................... 17 (23) Camshaft Sprocket Bolt ............................................................................................ 66 (90) Crankshaft Pulley Bolt 1991 ....................................................................................................... 108-116 (146-157) 1992-96 ................................................................................................................ 136 (185) Engine Support Bracket Bolt 10 X 40 mm ................................................................................ ................. 47-54 (64-73) Except 10 X 40 mm .................................................................................. 76-83 (103-113) Timing Belt Tensioner Arm Bolt ................................................................................ 31 (42) Timing Belt Tensioner Pulley Nut ............................................................................. 36 (49) Water Pump Bolt ....................................................................................................... 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) TORQUE SPECIFICATIONS (GALANT) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ............................................................................. 108-116 (146-157) Engine Support Bracket Bolt 10 X 40 mm ................................................................................ ................. 25-36 (34-49) 10 X 53 mm ................................................................................ ................. 47-54 (64-73) 12 X 56 mm .............................................................................................. 76-83 (103-113) Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29) Water Pump Bolt ........................................................................... ................. 14-19 (19-26) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12) TORQUE SPECIFICATIONS (MONTERO & PICKUP) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt Montero .................................................................................................. 108-116 (146-157) Pickup .......................................................................................... ......... 130-137 (176-186) Left Engine Support Bracket Bolt ................................................. ................. 15-21 (20-30) Rear Engine Support Bracket Bolt ............................................... ................. 13-18 (18-25) Right Engine Support Bracket Bolt 10 X 22 mm ................................................................................ ................. 25-36 (34-49) 10 X 40 mm ................................................................................ ................. 25-36 (34-49) 12 X 22 mm ................................................................................ ................. 47-61 (64-83) 12 X 32 mm ................................................................................ ................. 47-61 (64-83) Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29) Water Pump Bolt ........................................................................... ................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ................. 84-108 (9-12) Timing Belt Cover Cap Bolt .......................................................... ................. 84-108 (9-12)

MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine (Cont.)
TORQUE SPECIFICATIONS (SIGMA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (79-98) Crankshaft Pulley Bolt ............................................................................. 110-118 (150-160) Engine Mount Bracket Nut ............................................................ ................. 44-57 (60-77) Engine Support Bracket Bolt 10 X 40 mm ................................................................................ ................. 25-36 (34-49) 10 X 53 mm ................................................................................ ................. 47-54 (64-73) 12 X 56 mm 1989 ......................................................................................................... 76-83 (103-113) 1990 ........................................................................................... ................. 47-61 (65-85) Timing Belt Tensioner Bolt ............................................................ ................. 16-21 (22-29) Water Pump Bolt ........................................................................... ................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 90-102 (10-12) TORQUE SPECIFICATIONS (3000GT)

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Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 66 (90) Crankshaft Pulley Bolt ............................................................................. 108-116 (150-160) Engine Mount To-Body Through-Bolt .............................................................................................. 51 (70) To-Engine Support Bracket ......................................................... ............. 72-87 (100-120) Engine Support Bracket-To-Engine Bolt 1 M10 Bolt .................................................................................................................. 51 (70) M12 Bolt ................................................................................................................ 80 (110) Generator/Power Steering Tensioner Pulley Bracket Bolt ....................................... 30 (42) Power Steering Pump Mount Bolt Short Bolt ................................................................................................................. 29 (40) Long, Shoulder Bolt ................................................................................................ 16 (22) Timing Belt Tensioner Pulley Center Bolt .................................... ................. 16-22 (22-30) Water Pump Bolt ....................................................................................................... 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)
1

Spray lubricant on reamer bolt while tightening.

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MITSUBISHI
3.0L V6 SOHC, 24-Valve Engine
Labor Time Component Belt Kit No. Part No. 4) Remove power steering pump belt tensioner. See Fig. 1. Remove upper and lower timing belt covers. Remove engine support bracket from front of engine. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 5) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt tensioner pulley, and remove timing belt. Remove timing belt autotensioner from engine block.

TIMING BELT APPLICATION Application 3.0L V6 SOHC Eclipse 2000-04 .............................. Galant 1999-03 .............................. Montero (24-Valve Engine) 1995-96 .............................. Montero Sport 1997-02 .............................. 2003 ...................................
1 2

3.0 Hours .. .. TCK259 .. ..... T259 3.0 Hours .. .. TCK259 .. ..... T259 3.4 Hours .. .. TCK259 .. ..... T259 2.8 Hours .. .. TCK259 .. ..... T259 2.8 Hours .. ...... ..... ...... ..... T259

1 1

With Air Conditioning, add .3 hours for Montero Sport. With Air Conditioning, add .4 hours for Montero.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1995-96 and 2001 Eclipse and Galant models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2002-04 Eclipse and 2002-03 Galant models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts, Maine and Vermont. In California, Massachusetts, Maine and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles. For 2001-03 Montero Sport models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components (Eclipse & Galant)

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Eclipse & Galant) 1) Disconnect negative battery cable. Raise and support vehicle. Remove engine splash shield from right wheelwell. 2) Remove generator and A/C compressor drive belt. Remove dipstick tube from front of engine. Remove generator with wires attached, and secure out of way. Remove power steering pump drive belt. 3) Lower vehicle. Support weight of engine with jack. Remove engine mount from timing belt end of engine. Using Tensioner Wrench (MB990767) and Crankshaft Pulley Holder Pin (MD998715), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner) Removal (Montero & Montero Sport) 1) Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose from engine. Remove upper radiator shroud. Loosen cooling fan clutch-topulley nuts. Relieve tension on accessory drive belts.

MITSUBISHI
3.0L V6 SOHC, 24-Valve Engine (Cont.)
2) Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove generator with wires attached, and secure out of way. 3) Remove power steering pump with hoses connected, and set aside. Remove A/C compressor with hoses connected, and set aside. Remove A/C compressor bracket. Remove timing indicator bracket. Remove accessory mount assembly. See Fig. 3. 4) Remove upper timing belt upper cover. See Fig. 4. Using Crankshaft Pulley Holder Pin (MD998715) and End Yoke Holder (MD990767) hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 5) Remove lower timing belt cover. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner pulley center bolt. 6) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.

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Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Exploded View Of Timing Belt & Components (Montero & Montero Sport)

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Checking Timing Belt Auto-Tensioner Movement WARNING: Right bank camshaft can turn easily due to applied spring force, so keep ngers out of the way. 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley Socket Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5) For 1999-00 models, loosen tensioner pulley center bolt. Position tensioner pin holes at BOTTOM of tensioner. Install Tensioner Pulley Socket Wrench (MD998767) on tensioner pulley. See Fig. 6. Use a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner stationary. See TORQUE SPECIFICATIONS. 6) For 2001 and later models, loosen tensioner pulley center bolt. Position tensioner pin holes at TOP of tensioner. Install Tensioner Pulley Socket Wrench (MD998767) on tensioner pulley. See Fig. 7. Use a

Fig. 3: Exploded View Of Accessory Mount Assembly (Montero & Montero Sport) Inspection (All Models) 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. 2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner upright. Measure rod protrusion above edge of housing. See Fig. 5. Length should be .47 (12 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto-tensioner. Installation (Eclipse & Galant) 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine.

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MITSUBISHI
3.0L V6 SOHC, 24-Valve Engine (Cont.)
Installation (Montero & Montero Sport) 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) SLOWLY compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. WARNING: Right bank camshaft can turn easily due to applied spring force, so keep ngers out of the way. 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley Socket Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Tensioner Pulley Socket Wrench (MD998767) on tensioner pulley. See Fig. 6. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. 8) Install timing belt covers. Install crankshaft pulley. Install accessory mount assembly on front of engine. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. CAUTION: The sealing washer under the cooling system air bleed bolt was reduced to .85 mm from 2.0 mm. The .85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin 96-00-003; February, 1996.
Courtesy of Mitsubishi Motor Sales of America.

torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque (clockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner stationary. See TORQUE SPECIFICATIONS. 7) On all models, remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 8) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. 9) Install engine support bracket on engine block. Tighten top bolt rst, then working in a counterclockwise direction, tighten the remaining bolts. See Fig. 8. Install timing belt covers. Install crankshaft pulley. Apply engine oil to crankshaft pulley bolt, then tighten bolt to specication. See TORQUE SPECIFICATIONS. 10) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse & Galant; 1995-03 Montero & Montero Sport)

Fig. 7: Adjusting Timing Belt Tension (2001-04 Eclipse & 2001-03 Galant)

9) Before relling cooling system, remove air bleed bolt on top of thermostat housing. Rell cooling system with 50/50 mix of water and coolant until it overows from air bleed bolt hole. Install air bleed bolt with new .85 mm washer (if equipped). 10) Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, rell radiator.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Identifying Engine Support Bracket Tightening Sequence (Eclipse & Galant)

MITSUBISHI
3.0L V6 SOHC, 24-Valve Engine (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ECLIPSE & GALANT) Application Ft. Lbs. (N.m) Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (177-186) Dipstick Tube Bolt ..................................................................................................... 10 (14) Engine Mount To-Engine Support Bracket Nut/Bolt ....................................................................... 63 (86) To-Body Through-Bolt ............................................................................................ 2 61 (83) Engine Support Bracket-To-Engine Bolt ................................................................... 33 (44) Generator Pivot Bolt .................................................................................................. 33 (44) Generator Top Bolt .................................................................................................... 15 (21) Power Steering Pump Belt Tensioner Bolt ............................................................... 33 (44) Timing Belt Tensioner Center Bolt ............................................................................ 35 (48) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Water Pump Bolt M8 Bolt .................................................................................................................... 17 (23) M10 Bolt .................................................................................................................. 30 (41) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................................................................ 106 (12)
1 2

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TORQUE SPECIFICATIONS (MONTERO & MONTERO SPORT) Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt 12 x 100 Bolt ........................................................................................................... 54 (74) All Other Bolts ......................................................................................................... 33 (44) Auto-Tensioner-To-Engine Block Bolt ....................................................................... 18 (24) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Pulley Bolt ......................................................................................... 1 134 (181) Generator ................................................................................................................... 16 (22) M8 Bolt .................................................................................................................... 15 (21) M10 Bolt .................................................................................................................. 30 (51) Power Steering Pump Bolt 1995-96 ........................................................................................ ................. 29-33 (39-44) 1997-03 .................................................................................................................... 17 (24) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Timing Belt Tensioner Center Bolt ............................................................................ 35 (48) Water Pump Bolt ....................................................................................................... 18 (24) INCH Lbs. (N.m) Cooling Fan Clutch-to-Pulley Nut ................................................. ............... 89-106 (10-12) Power Steering Pump Cover Bolt .............................................................................. 43 (5) Radiator Shroud Bolt ................................................................................................... 43 (5) Timing Belt Cover Bolt M6 Bolt .................................................................................................................... 97 (11) M8 Bolt .................................................................................................................. 117 (13) Timing Indicator Bracket Bolt .................................................................................... 97 (11)
1

Apply engine oil to bolt threads before installation. Final tighten bolt with full weight of engine on mount.

Apply engine oil to bolt threads before installation.

572

MITSUBISHI
3.5L V6 DOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 3.5L V6 Montero 1994-96 ....................................................


1

4.4 Hours .. ..... T253

With Air Conditioning, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


Courtesy of Mitsubishi Motor Sales of America.

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

Fig. 1: Exploded View Of Accessory Mount Components

TIMING BELT
NOTE: Ensure timing marks are aligned. Mark timing belt direction of rotation. Removal 1) Disconnect negative battery cable. Drain engine coolant. Remove engine coolant reservoir tank, fan shroud and radiator. 2) Remove generator with wires attached, and secure out of way. Remove battery and battery tray. Remove engine lower splash shields. 3) Remove accessory drive belts. Remove cooling fan clutch assembly. See Fig. 1. Remove cooling fan pulley. Remove A/C compressor with hoses attached, and secure out of way. Remove A/C compressor bracket. 4) Remove power steering pump mount cover. Remove power steering pump with hoses attached, and secure out of way. Remove accessory mount. See Fig. 1. 5) Remove timing belt upper cover. See Fig. 2. Disconnect crankshaft position sensor connector. Using Holder (MB990767) and Bolts (MB998754) or equivalent, hold crankshaft stationary while remove crankshaft pulley center bolt. 6) If reusing timing belt, place arrow on belt to indicate running direction. Rotate crankshaft to align all timing marks. See Fig. 3. Loosen timing belt tensioner center bolt. Remove timing belt and timing belt automatic tensioner. NOTE: Revised auto-tensioner procedure is from Mitsubishi technical service bulletin 96-11-006; June, 1996. Inspection 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. 2) Check timing belt automatic tensioner for leaks. Hold timing belt auto-tensioner upright. Measure rod protrusion above edge of housing. Length should be .461-.484 (11.7-12.3 mm). Apply 40-44 lbs. (18-20 kg) of force to end of rod. If automatic tensioner rod moves more than 0.39 (1 mm), replace the automatic tensioner. Installation 1) Place automatic tensioner assembly in a soft-jawed vise. SLOWLY close vise to press rod back into tensioner until both rod and housing holes are aligned. Install a .055 (1.40 mm) diameter wire or drill bit through both holes. 2) Remove automatic tensioner from vise, and install assembly on engine with wire in place. Install crankshaft sprocket (if removed). Align timing marks on crankshaft and camshaft sprockets. See Fig. 3.

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Fig. 2: Exploded View Of Timing Belt & Components CAUTION: Turning camshaft sprockets while No. 1 piston is at TDC may damage valve and piston. Use care when aligning timing marks. 3) To lower No. 1 piston from TDC and prevent valve and piston contact, turn crankshaft back 3 sprocket teeth (measured at timing mark). See Fig. 4. 4) Starting with left (drivers side) bank of cylinders, verify intake and exhaust camshaft timing marks are correctly aligned with marks on rear timing belt cover. See Fig. 3. Rotate either camshaft sprocket clockwise to align timing marks. WARNING: Use care when aligning timing marks. Camshaft is under valve spring pressure and may rotate suddenly, pinching hand between sprockets. 5) Align camshaft timing marks on right (passengers side) camshaft sprockets. See Fig. 3. Using box end wrenches, hold camshaft sprocket center bolts to prevent sprockets from turning. With right bank camshaft

MITSUBISHI
3.5L V6 DOHC (Cont.)

573

17) Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, rell radiator. 18) To complete installation, reverse removal procedure. Tighten all nuts and bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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Fig. 3: Aligning Timing Marks sprocket timing marks aligned with marks on rear timing belt cover, install timing belt on right bank camshaft sprockets. Hold camshaft sprockets in place with spring clips. See Fig. 5. 6) Install timing belt around water pump pulley. With left bank camshaft sprockets correctly aligned, install timing belt on left hand camshaft sprocket. Secure timing belt onto sprockets with spring clips. 7) Install timing belt on the idler pulley. Realign the crankshaft sprocket timing mark with mark on oil pump housing. Turn crankshaft ONE turn counterclockwise (as viewed from front of engine). Set timing belt on crankshaft sprocket, then onto tensioner pulley. 8) Rotate timing belt tensioner pulley until pin holes are located above center bolt. See Fig. 6. Push tensioner pulley against belt, and temporarily tighten center bolt. Ensure all timing marks are still aligned, and remove spring clips. 9) Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft clockwise until timing marks are realigned. Loosen tensioner center bolt. 10) Using Tensioner Pulley Socket (MD998767) or equivalent, apply approximately 83 INCH lbs. (9.4 N.m) torque to tensioner pulley in a clockwise direction. Holding tensioner pulley to prevent it from turning, nal tighten center bolt to 35 ft. lbs. (48 N.m). Ensure tensioner pulley does not rotate while tightening center bolt. 11) Remove set pin or drill bit from automatic tensioner. Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify wire or drill bit can still be easily removed and installed. 12) Even if set pin or drill bit cannot be easily installed, the automatic tensioner is normal if its push rod protrusion is within .15-.18 (3.8-4.5 mm). Measure push rod protrusion between top of tensioner body and lever arm of tensioner pulley lever. See Fig. 7. 13) If push rod protrusion is out of specication, timing belt tension adjustment will have to be repeated. 14) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. 15) Install generator. Install accessory mount. Install power steering pump and A/C compressor. Install cooling fan. Install accessory drive belts. CAUTION: On later model years, the sealing washer under the cooling system air bleed bolt was reduced to .85 mm from 2.0 mm. The .85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin 96-00-003; February, 1996. 16) Install radiator. Before relling cooling system, remove air bleed bolt on top of thermostat housing. Rell cooling system with 50/50 mix of water and coolant until it overows from air bleed bolt hole. Install air bleed bolt with new .85 mm washer (if equipped).

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Positioning Crankshaft For Timing Belt Installation

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Fig. 5: Securing Timing Belt With Spring Clips

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Fig. 6: Adjusting Timing Belt Tension

574

MITSUBISHI
3.5L V6 DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .......................................................................................... 17 (24) Accessory Mount Bolts 10 x 80 mm ................................................................................. ................. 28-30 (38-41) 10 x 100 mm ............................................................................... ................. 32-34 (43-46) 12 x 100 mm ............................................................................... ................. 53-55 (72-75) Camshaft Sprocket Bolt ............................................................................................ 64 (88) Crankshaft Pulley Center Bolt ...................................................... ......... 130-137 (177-186) Power Steering Pump Bolt ........................................................... ................. 26-30 (38-41) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Timing Belt Tensioner Pulley Bolt ............................................................................. 35 (48) INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Measuring Push Rod Protrusion

Coolant Air Bleed Bolt ....................................................................................... 80-97 (9-11) Cooling Fan-To-Pulley Bolt ........................................................... ............... 89-106 (10-12) Crankshaft Position Sensor ........................................................................................ 80 (9) Radiator Mounting Bolt/Nut ......................................................................................... 62 (7) Timing Belt Cover Bolt .................................................................. ............... 89-106 (10-12)

MITSUBISHI
3.5L V6 SOHC
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

575

3.5L V6 SOHC Diamante 1997-02 .............................. 1 3.4 Hours .. .. TCK287 .. ..... 2003-04 .............................. 1 3.4 Hours .. ...... ..... ...... ..... Montero 1997-00 .............................. 1 3.4 Hours .. .. TCK287 .. ..... 2001-02 ............................... 3.9 Hours ... ...... ..... ...... ..... Montero Sport 1999-00 .............................. 1 2.8 Hours .. ...... ..... ...... ..... 2001-02 .............................. 1 2.8 Hours .. .. TCK287 .. ..... 2003-04 .............................. 1 2.8 Hours .. ...... ..... ...... .....
1

T287 T287 T287 T320 T287 T287 T287

With Air Conditioning, add .4 hour for Montero. With Air Conditioning, add .3 hour for Montero Sport.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt & Components (Diamante)

TIMING BELT
NOTE: Replacement procedure for Diamante includes revised information from Mitsubishi technical service bulletin No. 00-11-005; April, 2000. Removal (Diamante) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove generator with wires attached, and secure out of way. 2) Holding crankshaft pulley stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. 3) Remove timing belt covers. See Fig. 1. Support weight of engine with oor jack. Remove engine mount from front (timing belt end) of engine. Remove engine support bracket from front of engine. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 4) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt tensioner pulley, and remove timing belt. Remove timing belt autotensioner from engine block. Inspect timing belt. See TIMING BELT INSPECTION.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Aligning Timing Marks

576

MITSUBISHI
3.5L V6 SOHC (Cont.)

Installation (Diamante) 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. WARNING: Right bank camshaft can easily turn from applied spring pressure. Be careful not to pinch ngers when installing timing belt. 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Tensioner Pulley Wrench (MD998767)) on tensioner pulley. See Fig. 3. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. For 2000 and earlier models, clearance should be 0.15-0.20 (3.8-5.0 mm). For 2001 and later models, clearance should be 0.20-0.24 (4.8-6.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. 8) Install engine support bracket on engine block. Tighten top bolt rst, 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 specication. See TORQUE SPECIFICATIONS. 9) To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Engine Support Bracket Tightening Sequence (Diamante) 3) Remove cover and power steering pump with hoses connected, and set aside. Remove A/C compressor from bracket (hoses connected), and set aside. Remove A/C compressor bracket. On Montero Sport, remove timing mark indicator plate from front of engine. On all models, remove accessory mount assembly. See Fig. 5. 4) Remove upper timing belt cover. See Fig. 6. Using Crankshaft Pulley Holder Pin (MD998715) and End Yoke Holder (MB990767), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 5) Remove lower timing belt cover. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner pulley center bolt. 6) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove timing belt auto-tensioner. Inspect timing belt. See TIMING BELT INSPECTION.

Courtesy of Mitsubishi Motor Sales of America. Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Adjusting Timing Belt Tension (Except 2001-02 Montero) Removal (1997-00 Montero & 1999-04 Montero Sport) 1) Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose. Remove radiator shroud. Loosen cooling fan clutch-topulley nuts. Relieve tension on accessory drive belts. 2) Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove generator with wires attached, and secure out of way.

Fig. 5: Exploded View Of Accessory Mount Assembly (1997-00 Montero & 1999-04 Montero Sport) Installation (1997-00 Montero & 1999-04 Montero Sport) 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place at washer around plug so it will not contact vise jaw.

MITSUBISHI
3.5L V6 SOHC (Cont.)

577

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Exploded View Of Timing Belt & Components (1997-00 Montero & 1999-04 Montero Sport) CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. WARNING: Right bank camshaft can easily turn from applied spring pressure. Be careful not to pinch ngers when installing timing belt. 3) Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Tensioner Pulley Wrench (MD998767)) on tensioner pulley. See Fig. 3. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure.

8) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install accessory mount assembly on front of engine. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. 9) When lling cooling system, use 50/50 mix of coolant and water. Open bleed screw on top of thermostat housing. Slowly ll cooling system until coolant ows 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, rell 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 airow sensor. See Fig. 7. Remove air cleaner assembly. 2) Remove upper and lower radiator shroud covers. Remove A/T oil cooler hose, and plug hose and radiator nipple to prevent contamination. Remove upper and lower radiator hoses. Remove radiator shroud. Remove accessory drive belt. See Fig. 8. Remove cooling fan and cooling fan pulley. 3) Insert an 1/2 (12.7 mm) breaker bar into the square hole on drive belt auto tensioner, and rotate it clockwise until tensioner touches the stopper. Align hole B with hole A, and insert a 0.20 (5.0 mm) Allen wrench to hold tensioner. See Fig. 9. Remove drive belt auto tensioner. 4) Remove accessory mount stay. See Fig. 8. Remove power steering pump with hoses connected, and set aside. Remove A/C compressor from bracket (hoses connected), and set aside. Remove A/C compressor bracket. Remove cooling fan bracket assembly. Remove accessory mount assembly. 5) Remove upper timing belt cover. See Fig. 10. Using Pulley Holder (MB991800) and Pin B (MD991802), hold crankshaft pulley stationary and remove crankshaft pulley bolt. Remove crankshaft pulley. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 6) Remove timing belt indicator bracket. Remove lower timing belt cover. Remove timing belt auto-tensioner. Turn crankshaft clockwise to align camshaft and crankshaft timing marks, and set the No. 1 cylinder to compression TDC. See Fig. 11. Loosen belt tensioner pulley center bolt. 7) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Inspect timing belt. See TIMING BELT INSPECTION. Installation (2001-02 Montero) 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. WARNING: Right bank camshaft can easily turn from applied spring pressure. Be careful not to pinch ngers when installing timing belt. 3) Ensure all timing marks are still aligned. See Fig. 11. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Using Tensioner Pulley Wrench (MD998767), rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Using Crankshaft Pulley Spacer (MD998769), turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned.

578

MITSUBISHI
3.5L V6 SOHC (Cont.)

5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Tensioner Pulley Wrench (MD998767) on tensioner pulley. See Fig. 12. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. Ensure all timing marks are aligned. 8) Install timing belt covers. See Fig. 10. Install crankshaft pulley. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install accessory mount assembly on front of engine. See Fig. 13. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedures. See Figs. 7 and 8. Adjust drive belts to proper tension. 9) When lling cooling system, use 50/50 mix of coolant and water. Open bleed screw on top of thermostat housing. Slowly ll cooling system until coolant ows 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, rell radiator and coolant reservoir tank.

TIMING BELT INSPECTION


Inspection (All Models) 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. 2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner upright. Measure rod protrusion above edge of housing. See Fig. 14. Length should be .461-.484 (11.7-12.3 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto-tensioner.
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Exploded View Of Air Cleaner Assembly (2001-02 Montero)

MITSUBISHI
3.5L V6 SOHC (Cont.)

579

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Exploded View Of Drive Belt Components (2001-02 Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Removing Drive Belt Auto Tensioner (2001-02 Montero)

580

MITSUBISHI
3.5L V6 SOHC (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Timing Belt Components (2001-02 Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 11: Aligning Timing Marks (2001-02 Montero)

MITSUBISHI
3.5L V6 SOHC (Cont.)
TORQUE SPECIFICATIONS (1997-00 MONTERO & 1999-04 MONTERO SPORT)

581

Courtesy of Mitsubishi Motor Sales of America.

Fig. 12: Adjusting Timing Belt Tensioner (2001-02 Montero)

Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt 12 x 100 Bolt ........................................................................................................... 54 (74) All Other Bolts ......................................................................................................... 33 (44) Auto-Tensioner Bolt ................................................................................................... 18 (24) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Pulley Bolt ......................................................................................... 1 134 (181) Generator Bottom Bolt .............................................................................................. 16 (22) Generator Pivot (Upper) Bolt .................................................................................... 38 (52) Power Steering Pump Bolt ....................................................................................... 17 (24) Timing Belt Idler Pulley Bolt ..................................................................................... 35 (48) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Timing Belt Tensioner Center Bolt ............................................................................ 35 (48) Water Pump Bolt ....................................................................................................... 17 (23) INCH Lbs. (N.m) Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 89-106 (10-12) Power Steering Pump Cover Bolt .............................................................................. 43 (5) Radiator Shroud Bolt ................................................................................................... 43 (5) Timing Belt Cover Bolt .............................................................................................. 97 (11) Timing Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1

Apply engine oil to bolt threads before installation.

TORQUE SPECIFICATIONS (2001-02 MONTERO)


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Fig. 13: Installing Accessory Mount Assembly Bolts (2001-02 Montero)

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Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt Bolt A (10 x 100 mm) .............................................................. ................. 24-36 (33-49) Bolt B (10 x 30 mm) ................................................................ ................. 24-36 (33-49) Bolt C (10 x 100 mm) .............................................................. ................. 26-40 (34-54) Bolt D (12 x 100 mm) .............................................................. ................. 47-61 (65-83) Bolt E (8 x 30 mm) .................................................................. ................. 13-19 (18-26) Bolt F (10 x 106 mm) ............................................................... ................. 26-40 (34-54) Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98) Crankshaft Pulley Bolt ................................................................... ....... 1 131-137 (178-186) Power Steering Pump Bolt ........................................................... ................. 13-19 (18-26) Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49) Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54) Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54) INCH Lbs. (N.m) Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 88-104 (10-12) Radiator Shroud Bolt ..................................................................... ..................... 35-53 (4-6) Timing Belt Cover Bolt .................................................................. ............... 88-104 (10-12) Timing Mark Indicator Plate Bolt .................................................. ............... 88-104 (10-12) Water Pump Pulley Nuts .............................................................. ............... 88-104 (10-12)
1

Fig. 14: Checking Timing Belt Auto-Tensioner Movement

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (DIAMANTE) Application Ft. Lbs. (N.m) Auto-Tensioner Bolt ................................................................................................... 17 (23) Camshaft Sprocket Bolt ............................................................................................ 65 (88) Crankshaft Pulley Bolt ......................................................................................... 1 134 (181) Engine Mount To-Engine Support Bracket Nut/Bolt ........................................................... 73-87 (98-118) To-Body Through-Bolt 2 ............................................................................... 73-87 (98-118) Engine Support Bracket-To-Engine Bolt ................................................................... 33 (44) Generator Pivot Bolt .................................................................................................. 33 (44) Generator Top Bolt .................................................................................................... 15 (21) Power Steering Pump Belt Tensioner Bolt ............................................................... 33 (44) Timing Belt Idler Pulley Bolt ..................................................................................... 33 (44) Timing Belt Tensioner Arm Pivot Bolt ....................................................................... 33 (44) Timing Belt Tensioner Center Bolt ............................................................................ 35 (48) Water Pump Bolt M8 Bolt .................................................................................................................... 17 (23) M10 Bolt .................................................................................................................. 30 (41) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 97 (11) Timing Mark Indicator Plate Bolt .................................................. ............................ 97 (11)
1 2

Apply engine oil to bolt threads before installation.

Apply engine oil to bolt threads before installation. Arrow on engine mount plates must face toward front of vehicle.

582

MITSUBISHI
3.8L V6 SOHC Endeavor & Galant
Labor Time Belt Part No. Inspection 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened back surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. 2) Check timing belt auto-tensioner for leaks. Check for wear or damage at end of rod. Hold timing belt auto-tensioner upright. Measure rod protrusion above edge of housing. See Fig. 4. Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto-tensioner. Installation 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the autotensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. 3) Ensure all timing marks are still aligned. See Fig. 3. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned. 5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Adapter (MD998767) on tensioner pulley. See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.19-0.24 (4.8-6.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. 8) Install timing belt covers. Install crankshaft pulley. Using Pulley Holder (MB991800) and Pins B (MB001802), tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

TIMING BELT APPLICATION Application

3.8L V6 SOHC Endeavor & Galant 2004 ........................................................... 3.0 Hours ... ..... T287 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) On Galant, remove engine cover. On all models, remove skid plate and under cover. Remove accessory drive belts. Using Pulley Holder (MB991800) and Pins B (MB001802), remove crankshaft pulley. 2) Disconnect harness connectors on connector bracket. See Fig. 1 or 2. Remove connector bracket. Remove engine mount support bracket. Remove both upper timing belt covers. 3) Remove tensioner pulley and tensioner bracket. Remove crankshaft position sensor harness clamp. Remove lower timing belt cover. Remove front engine mount and front engine mount bracket. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 4) Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. 5) Loosen belt tensioner pulley center bolt. Remove timing belt. Remove timing belt auto-tensioner.

MITSUBISHI
3.8L V6 SOHC Endeavor & Galant (Cont.)

583

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Timing Belt Components (Endeavor)

584

MITSUBISHI
3.8L V6 SOHC Endeavor & Galant (Cont.)

Courtesy of Mitsubishi Motor Sales of America.

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

MITSUBISHI
3.8L V6 SOHC Endeavor & Galant (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

585

Application Ft. Lbs. (N.m) Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98) Crankshaft Pulley Bolt ................................................................... ....... 1 134-140 (180-190) Engine Mount Bracket-To-Engine Bolt .......................................... ................. 31-37 (42-48) Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49) Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54) Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 97 (11)
1

Apply engine oil to bolt threads before installation.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Checking Timing Belt Auto-Tensioner Movement

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Timing Belt Tension

586

MITSUBISHI
3.8L V6 SOHC Montero
Labor Time Belt Part No. 2) Remove accessory drive belt. Remove cooling fan and pulley. Remove drive belt auto tensioner. Remove accessory mount support. See Fig. 1. 3) Remove power steering pump with hoses connected, and set aside. Remove A/C compressor from bracket (hoses connected), and set aside. Remove A/C compressor bracket. Remove cooling fan bracket. Remove accessory mount assembly. 4) Remove upper timing belt cover. See Fig. 2. Using Pulley Holder (MB991800 or MB991800-01) and Pin (MB991802 or MB991802-01) to hold crankshaft pulley stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine). 5) Remove timing belt indicator bracket. Remove lower timing belt cover. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3. 6) If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Loosen belt tensioner pulley center bolt. Remove timing belt. Remove timing belt auto-tensioner. Inspection 1) Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened back surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. 2) Check timing belt auto-tensioner for leaks. Hold timing belt autotensioner upright. Measure rod protrusion above edge of housing. See Fig. 4. Length should be .461-.484 (11.7-12.3 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto-tensioner.

TIMING BELT APPLICATION Application

3.8L V6 SOHC Montero 2003-04 ..................................................... 3.9 Hours ... ..... T320 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove skid plate and under cover. Drain engine coolant. Remove battery and battery tray. Remove air cleaner and intake air duct. Remove upper radiator hose. Remove radiator shroud. Loosen cooling fan clutch-to-pulley nuts.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 1: Exploded View Of Accessory Mount Assembly

MITSUBISHI
3.8L V6 SOHC Montero (Cont.)

587

Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Checking Timing Belt Auto-Tensioner Movement Installation 1) Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the autotensioner body, place at washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2) Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. 3) Ensure all timing marks are still aligned. See Fig. 3. Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out of timing belt. 4) Loosen the tensioner pulley center bolt. Rotate tensioner pulley against timing belt. Temporarily tighten tensioner pulley center bolt. Turn crankshaft 1/4 turn counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt marks are still aligned.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Aligning Timing Marks

588

MITSUBISHI
3.8L V6 SOHC Montero (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt 1 Bolt A (10 x 100 mm) .............................................................. ................. 24-36 (33-49) Bolt B (10 x 30 mm) ................................................................ ................. 24-36 (33-49) Bolt C (10 x 100 mm) .............................................................. ................. 26-40 (34-54) Bolt D (12 x 100 mm) .............................................................. ................. 47-61 (65-83) Bolt E (8 x 30 mm) .................................................................. ................. 15-19 (20-26) Bolt F (10 x 100 mm) ............................................................... ................. 32-40 (44-54) Auto-Tensioner Bolt ....................................................................... ................. 15-19 (20-26) Camshaft Sprocket Bolt ................................................................ ................. 58-72 (78-98) Cooling Fan Bracket Bolt .............................................................. ................. 24-36 (33-49) Crankshaft Pulley Bolt ................................................................... ....... 2 134-140 (180-190) Power Steering Pump Bolt ........................................................... ................. 13-19 (18-26) Timing Belt Idler Pulley Bolt ......................................................... ................. 30-36 (39-49) Timing Belt Tensioner Arm Pivot Bolt ........................................... ................. 26-40 (34-54) Timing Belt Tensioner Center Bolt ................................................ ................. 32-40 (42-54) INCH Lbs. (N.m) Cooling Fan Clutch-To-Pulley Nut ................................................ ............... 89-106 (10-12) Timing Belt Cover Bolt .............................................................................................. 97 (11)
1 2

5) Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of tensioner. Install Adapter (MD998767) on tensioner pulley. See Fig. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specication while holding tensioner pulley stationary. See TORQUE SPECIFICATIONS. 6) Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions clockwise and align all timing marks. DO NOT rotate counterclockwise. 7) Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To check push rod protrusion, measure clearance between body of auto-tensioner and bottom of tensioner pulley bracket arm. Clearance should be 0.15-0.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. 8) Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install accessory mount assembly on front of engine. 9) To complete installation, reverse removal procedure. When lling cooling system, use 50/50 mix of coolant and water. Open bleed screw on top of thermostat housing. Slowly ll cooling system until coolant ows 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, rell radiator and coolant reservoir tank.

For bolt identication and locations, see Fig. 6. Apply engine oil to bolt threads before installation.

Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Adjusting Timing Belt Tension

Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Identifying Accessory Mount Assembly Bolts

NISSAN
1.5L & 1.6L 4-Cylinder SOHC
TIMING BELT APPLICATION Application
1

589

Labor Time Component Belt Kit No. Part No.

1.5L 4-Cyl. SOHC Sentra 1982-83 ............................ .... 2.8 Pulsar NX (Includes Canadian) 1983-84 ............................ .... 3.0 310 1982 ................................. .... 5.8 1.6L 4-Cyl. SOHC Pulsar & Pulsar NX 1983-88 ............................ .... 2.3 Sentra 1983-88 ............................ .... 2.8
1

Hrs. .... .. TCK077 .. ..... T077 Hrs. .... .. TCK077 .. ..... T077 Hrs. .... .. TCK077 .. ..... T077

Hrs. .... .. TCK077 .. ..... T077 Hrs. .... .. TCK077 .. ..... T077

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View of Timing Belt & Components

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshaft separately with timing belt removed. Valves will contact piston and may cause damage. Removal 1) Disconnect negative battery cable. Place crankshaft on TDC of compression stroke. Remove spark plugs. Remove right front under engine cover and splash cover. Remove accessory drive belts. Remove water pump pulley and crankshaft pulley. On 1988 models, support engine with a jack under oil pan and remove right side engine mount. 2) On all models, remove upper and lower timing belt cover. See Fig. 1. Check timing mark alignment. See Fig. 2. Mark timing belt rotation direction for installation reference. Loosen timing belt tensioner and retain tensioner away from timing belt. Remove timing belt. Remove tensioner and spring (if necessary). See Fig. 1. CAUTION: Camshaft sprockets have 2 marks on them. Ensure the correct mark is aligned. See Fig. 2. Installation 1) Ensure camshaft and crankshaft sprocket timing marks are aligned at TDC on compression stroke. See Fig. 2. Install timing belt tensioner so no tension will be applied to belt during installation (if removed). If installing removed belt, properly position rotation direction mark made at removal. 2) Install timing belt, keeping belt tight on jackshaft and camshaft sprockets side. Loosen tensioner and allow tension to be applied to timing belt. Rotate camshaft sprocket 20 degrees (2 cogs) clockwise. 3) Using a screwdriver, prevent tensioner from turning and tighten tensioner lock nut. Recheck timing mark alignment. Ensure ignition rotor is ring No. 1 cylinder. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (1.5L) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 29-35 (39-48) Crankshaft Pulley Bolt ................................................................... ......... 108-145 (147-197) Crankshaft Pulley Damper Bolt .................................................... ............. 90-98 (123-132) INCH Lbs. (N.m) Camshaft Lockplate ....................................................................... ..................... 35-43 (4-5) Timing Belt Tensioner .................................................................... ..................... 52-70 (6-8) TORQUE SPECIFICATIONS (1.6L) Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ................................................................................ 80-94 (108-127) Timing Belt Tensioner Lock Nut .................... ................................................. 12-15 (16-21) INCH Lbs. (N.m) Camshaft Sprocket Bolt ................................. ........................................... 78-104 (8.8-11.8) Jackshaft Sprocket Bolt ................................. ........................................... 78-104 (8.8-11.8) Timing Belt Cover ......................................................................................... 46-58 (5.2-6.6) Valve Cover Bolt 1st Step ....................................................................................................... 17-35 (1.9-4.0) 2nd Step ..................................................................................................... 35-52 (4.0-5.9) Water Pump Bolt .......................................................................................... 46-58 (5.2-6.6) Water Pump Pulley Bolt ............................................................................. 74-96 (8.4-10.9)

590

NISSAN
1.6L & 1.8L 4-Cylinder DOHC
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

1.6L 4-Cyl. DOHC Pulsar 1987 ........................................................... 3.8 Hours ... ..... T137 1.8L 4-Cyl. DOHC Pulsar NX 1988-89 ..................................................... 3.8 Hours ... ..... T137
1

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose. Remove undertray from right side. Remove accessory drive belts. Remove water pump pulley. 2) Place reference mark on crank angle sensor and timing belt cover for reassembly reference. See Fig. 1. Remove crank angle sensor. Support engine and remove front engine mount support. 3) Remove upper timing belt cover. See Fig. 1. Align timing marks on camshaft sprockets. See Fig. 2. Remove right side inner fender panel. Remove crankshaft pulley and lower timing belt cover. Loosen tensioner pulley nut and release tension. Remove timing belt. 4) Using dial indicator, check camshaft sprocket runout. Replace sprocket if runout exceeds .004 (.10 mm). To remove camshaft sprocket, remove camshaft cover and hold hex area of camshaft. Remove sprocket retaining bolts. See Fig. 3. 5) Remove camshaft sprocket. If crankshaft sprocket requires removal, note direction of sprocket plates prior to removal. See Fig. 1. Remove plates and sprocket. Inspection 1) Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. 2) Check tensioner and idler pulleys for smooth rotation. Inspect tensioner pulley return spring for distortion or corrosion. Installation 1) Install crankshaft sprocket and sprocket plates. Sprocket plates must be installed with at 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 specication. See TORQUE SPECIFICATIONS. Ensure all marks are aligned. Install timing belt covers. 4) Install crankshaft pulley and washer. Install engine mount. Install crank angle sensor and water pump pulley. Ensure reference marks on crank angle sensor are aligned. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 5) Install accessory drive belts. Adjust drive belts to proper tension. Install upper radiator hose and rell cooling system.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Aligning Timing Marks

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Removing Camshaft Sprocket

NISSAN
1.6L & 1.8L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 10-14 (14-19) Crankshaft Pulley Bolt ............................................................................. 105-112 (142-152) Engine Mount Bolt ......................................................................... ................. 29-40 (39-54) Idler Nut ......................................................................................... ................. 23-31 (31-42) Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30) Timing Belt Tensioner Pulley Nut ................................................. ................. 16-22 (22-30) Water Pump Bolt ........................................................................... ................. 12-14 (16-19) INCH Lbs. (N.m) Crank Angle Sensor Bolt .............................................................. ..................... 61-70 (7-8) Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8)

591

592

NISSAN
1.7L 4-Cylinder Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.7L 4-Cyl. Diesel Sentra (Includes Canadian) 1983-87 Camshaft ................................................ 4.0 Hours ... ..... T096 Injection Pump ....................................... 4.2 Hours ... ..... T097
1

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1984-85 models, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986-87 models, the manufacturer recommends the belt be replaced at 60,000 mile intervals.
Courtesy of Nissan Motor Co., U.S.A.

REMOVAL & INSTALLATION


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

Fig. 1: Installing Camshaft Timing Belt

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.

INJECTION PUMP BELT


Removal Disconnect negative battery cable. Remove timing belt cover from rear of engine. Loosen injection timing belt tensioner. Remove injection timing belt. Installation Install injection timing belt. Ensure reference marks are 23 cogs apart. See Fig. 2. Rotate crankshaft 2 revolutions in normal direction of rotation. Tighten tensioner bolt while holding it to keep it from rotating. To complete installation, reverse removal procedure.

Fig. 2: Installing Injection Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 68-75 (18-22) Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132) Front Tensioner Bolt ...................................................................... ................. 27-33 (36-34) Rear Tensioner Bolt ...................................................................... ................. 12-15 (16-21) INCH Lbs. (N.m) Timing Belt Cover Bolts ................................................................ ..................... 27-43 (3-5)

NISSAN
1.8L & 2.0L 4-Cylinder
TIMING BELT APPLICATION Application 1.8L 4-Cyl. Turbo 200SX (Includes Canadian) 1984-87 .............................. 2.0L 4-Cyl. Stanza & Stanza Wagon 1982-89 .............................. 200SX (Includes Canadian) 1984-87 .............................. 1988 ...................................
1

593

Labor Time

Component Belt Kit No. Part No.

2.0 Hours .. ...... ..... ...... ..... T100

4.4 Hours .. .. TCK078 .. ..... T078 2.0 Hours ... TCK078A . ..... T078 2.0 Hours .. .. TCK078 .. ..... T078

1 1

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Timing Belt Alignment Procedure

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1982-85 models, the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986 and later models, the manufacturer recommends the belt be replaced every 60,000 miles.

REMOVAL & INSTALLATION


CAUTION: The 2.0L is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT
Removal (1982-88) 1) Disconnect negative battery cable. Turn crankshaft until No. 1 cylinder is at TDC on compression stroke. Remove cooling fan, radiator shroud and accessory drive belts. NOTE: After timing belt is removed, do not rotate crankshaft or camshaft. 2) Remove upper and lower dust cover mount bolts. Remove upper and lower covers and gaskets. Remove timing belt tensioner, bracket, and timing belt. Removal (1989) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove exhaust side spark plugs. Turn crankshaft until No. 1 cylinder is at TDC on compression stroke. Remove dust cover and undercovers. Remove belts. 2) Support engine with a chain hoist. Remove right side engine mount and bracket. Remove upper and lower timing belt covers and gaskets. Remove timing belt tensioner, bracket and timing belt. Installation (All Models) 1) Do not tighten tensioner bolts to nal specication before drive belt is installed. Install timing belt. Align belt mark to camshaft and crankshaft sprocket marks. See Fig. 1. 2) Tighten belt tensioner and assemble spring. To set spring, hook one end on bolt B side and hook the other end on tensioner bracket pawl. Tighten bolt B, and then bolt A. See Fig. 2. 3) Belt tension will automatically be at the specied value. Install lower front cover with gaskets, and tighten mount bolts. Install plate and front pulley damper. Complete installation by reversing removal procedure. Adjust drive belts to proper tension.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Adjusting Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (1982-88) Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ..................................................................... ................. 10-14 (14-19) Crankshaft Pulley Bolt ............................................................................. 105-112 (142-152) Engine Mount Bolt ......................................................................... ................. 29-40 (39-54) Idler Nut ......................................................................................... ................. 23-31 (31-42) Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30) Water Pump Bolt ........................................................................... ................. 12-14 (16-19) INCH Lbs. (N.m) Crank Angle Sensor Bolt .............................................................. ..................... 61-70 (7-8) Front Cover Bolts .......................................................................... ..................... 27-43 (3-5) Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8) TORQUE SPECIFICATIONS (1989) Application Ft. Lbs. (N.m) Camshaft Lock Plate Bolt ............................................................. ................. 58-65 (78-88) Camshaft Sprocket Bolt ................................................................ ................. 58-65 (78-88) Crankshaft Pulley Bolt ................................................................... ............. 90-98 (123-132) Engine Mount Bolt ......................................................................... ................. 29-40 (39-54) Tensioner Pulley Nut ..................................................................... ................. 16-22 (22-30) INCH Lbs. (N.m) Crank Angle Sensor Bolt .............................................................. ..................... 61-70 (7-8) Front Cover Bolts .......................................................................... ..................... 27-43 (3-5) Rear Timing Belt Cover Bolt ......................................................... ..................... 61-70 (7-8) Water Pump Pulley Bolt ................................................................ ................... 54-86 (6-10)

594

NISSAN
3.0L V6 DOHC
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

3.0L V6 DOHC 300ZX 1990-93 ..................................................... 4.6 Hours ... ..... T180 1994-96 ..................................................... 4.6 Hours ... ..... T251
1

With Air Conditioning, add .3 hours. With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-92 models, the manufacturer recommends the belt be replaced every 60,000 miles. On 1993 convertible models, the manufacturer recommends the belt be replaced every 60,000 miles. On 1993 non-convertible models, the manufacturer recommends the belt be replaced every 105,000 miles. On 1994-96 turbocharged models, the manufacturer recommends the belt be replaced every 60,000 miles. On 1994-96 non-turbocharged models, the manufacturer recommends the belt be replaced every 105,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove engine undercover. Drain coolant from radiator and cylinder block. Remove radiator. Remove accessory drive belts. Remove cooling fan and coupling. Remove starter.

2) Lock ywheel/explate to prevent crankshaft from rotating. Remove crankshaft pulley bolt and pulley. Remove water inlet and outlet hoses. Remove timing belt front covers. Remove spark plugs. 3) Install a stopper bolt (M6 x 16) into timing belt tensioner arm to maintain tensioner position. See Fig. 1. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until timing marks align. Remove timing belt tensioner and timing belt. Inspection Replace timing belt if cracked, worn or saturated with oil or coolant. Replace tensioner if it leaks oil. Installation 1) Ensure cylinder No. 1 is at TDC of compression stroke. See Fig. 1. Measure clearance between tensioner arm and tensioner body (distance pusher rod protrudes from tensioner body). If clearance is .16 (.4 mm), go to step 3). If clearance is not .16 (.4 mm), go to next step. 2) Remove tensioner. Remove stopper bolt. Using a vise, adjust clearance until it is as specied. Install stopper bolt in tensioner to maintain clearance. Install tensioner. Hand-tighten tensioner nut and bolts. 3) Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets. 4) Push tensioner gently toward timing belt to prevent belt from slipping (excessive pressure will overtighten belt). Maintain light pressure on tensioner. 5) Turn crankshaft clockwise 10 degrees. Tighten tensioner bolts and nut. See TORQUE SPECIFICATIONS. Turn crankshaft counterclockwise 120 degrees. Turn crankshaft clockwise until cylinder No. 1 is at TDC of compression stroke. 6) Loosen tensioner nut and bolts 1/2 turn. Move tensioner as far pack as possible. Using Push/Pull Gauge (J-38387) or equivalent, apply 15.2-18.3 lbs. (6.9-8.3 kg) pressure to end of pusher. See Fig. 2. Tighten tensioner nut and bolts. 7) Turn crankshaft 120 degrees clockwise, then turn it 120 degrees counterclockwise to TDC. Fabricate a small steel plate. See Fig. 3. Set plate at each position shown (A, B, C and D).

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Installing Timing Belt & Tensioner

NISSAN
3.0L V6 DOHC (Cont.)
8) Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Measure and record timing belt deection in each position. Divide sum of measurements (A + B + C + D) by 4 to obtain average. 9) Average timing belt deection should be .24-.28 (6-7 mm). If deection is not as specied, repeat steps 4)-8). If timing belt deection is excessive, change amount of pushing force applied in step 6). 10) Remove tensioner stopper bolt. After 5 minutes, ensure clearance between pusher rod and tensioner arm is .138-.205 (3.5-5.2 mm). Check for slippage or misplacement of timing belt at each sprocket. Install timing belt covers. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

595

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts Exhaust ........................................................................................ ................. 10-14 (14-19) Intake ........................................................................................... ............. 90-98 (122-133) Crankshaft Pulley Bolt ................................................................... ......... 159-174 (216-236) Timing Belt Idler Pulley Nut .......................................................... ................. 32-43 (43-58) Timing Belt Tensioner Lock Nut ................................................... ................. 12-15 (16-20) Water Pump Bolt ........................................................................... ................. 12-15 (16-20) INCH Lbs. (N.m) Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Adjusting Timing Belt Tensioner

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Checking Timing Belt Deection

596

NISSAN
3.0L V6 SOHC
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

3.0L V6 SOHC Maxima 1985-88 ............................ ... 1 6.0 Hrs. 1989-91 ............................ .... 5.7 Hrs. 1992-94 With Round Tooth Sprocket .................... .... 5.7 Hrs. With Square Tooth Sprocket .................... .... 5.7 Hrs. Pathnder & Pickup 1986-92 ............................ .... 4.5 Hrs. 1993-94 With Round Tooth Sprocket .................... .... 4.5 Hrs. With Square Tooth Sprocket .................... .... 4.5 Hrs. 1995-96 ............................ .... 4.5 Hrs. Quest 1993-94 With Round Tooth Sprocket .................... .... 3.6 Hrs. With Square Tooth Sprocket .................... .... 3.6 Hrs. 1995-98 ............................ .... 3.6 Hrs. 200SX 1987-88 ............................ .... 4.8 Hrs. 300ZX 1984-89 ............................ .... 6.0 Hrs.
1

... .. TCK104 .. ..... T104 .... .. TCK104 .. ..... T104

.... .. TCK249 .. ..... T249 .... .. TCK104 .. ..... T104 .... .. TCK104 .. ..... T104

.... .. TCK249 .. ..... T249 .... .. TCK104 .. ..... T104 .... .. TCK249 .. ..... T249

Courtesy of Nissan Motor Co., U.S.A.

Fig. 1: Exploded View Of Timing Belt & Components .... .. TCK249 .. ..... T249 .... .. TCK104 .. ..... T104 .... .. TCK249 .. ..... T249 .... .. TCK104 .. ..... T104 .... .. TCK104 .. ..... T104 2) Turn tensioner clockwise and temporarily tighten lock nut. Install timing belt. Align White lines on timing belt with punch mark on camshaft pulleys and crankshaft pulley. Arrow on timing belt must be pointing toward front belt covers. 3) Using Allen wrench, slowly turn tensioner clockwise and counterclockwise 2 or 3 times. When camshafts and crankshaft marks are aligned, tighten tensioner lock nut. See Fig. 2. Ensure that camshaft lobes are correctly positioned. Tighten rocker shaft bolts in 2 stages. 4) Rell and bleed air from cooling system. To complete installation, reverse removal procedures. Adjust drive belts to proper tension.

With Air Conditioning add .3 hours. With Power Steering, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1984-85 models, although the manufacturer does not recommend a specic 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.
Courtesy of Nissan Motor Co., U.S.A.

Fig. 2: Adjusting Timing Belt Removal (Maxima & Quest) 1) Disconnect negative battery cable. Raise and support vehicle. Remove covers from below engine. Drain cooling system. Remove right front wheel and engine side cover. Remove accessory drive belts. Remove crankshaft pulley bolt and pulley. 2) Remove upper radiator hose and water inlet hose. Remove A/C compressor idler pulley and bracket. Remove water pump pulley. Remove upper and lower timing belt front covers. See Fig. 1. 3) Temporarily install crankshaft pulley bolt so crankshaft can be rotated. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until marks on camshaft sprockets align with marks on timing belt upper rear cover, and mark on crankshaft sprocket aligns with mark on front cover housing. See Fig. 3. 4) Loosen timing belt tensioner nut. Release tension on belt. Remove timing belt. Check timing belt tensioner, spring and timing belt. Installation (Maxima & Quest) 1) Ensure cylinder No. 1 is at TDC of compression stroke. See Fig. 3. Install tensioner and return spring if removed. If return spring stud was removed, apply thread lock sealant to threads before installing stud. Insert an Allen wrench into hole in tensioner, turn tensioner fully clockwise, and temporarily tighten lock nut.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (200SX & 300ZX) 1) Disconnect negative battery cable. Release fuel pressure from system. Raise and support vehicle. Remove right wheel and engine side cover (if necessary). Drain cooling system. Remove cooling fan duct. Remove engine coolant reservoir. Remove actuator and remove radiator hoses. Do not allow coolant to contact drive belts. 2) Remove front upper and lower belt covers. See Fig. 1. Remove drive belts and set No. 1 cylinder at TDC of compression stroke. Remove idler bracket of compressor drive belt and crankshaft pulley. Remove timing belt by removing timing belt tensioner and return spring. Inspection (200SX & 300ZX) Visually inspect condition of timing belt. Inspect for cracks, wear, breaks, and oil/coolant saturation. Installation (200SX & 300ZX) 1) Ensure that piston No. 1 is at TDC of compression stroke. Remove valve covers and loosen all rocker shaft bolts. Do not bend timing belt. Install tensioner and return spring.

NISSAN
3.0L V6 SOHC (Cont.)

597

6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression stroke. Measure timing belt deection halfway between camshaft sprockets. If deection is not .51-.59 (13-15 mm), repeat procedure. To complete installation, reverse removal procedure. 7) Rell and bleed air from cooling system. Adjust drive belts to proper tension. NOTE: Manufacturer has revised the timing belt specications 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; valves will contact pistons, resulting in bent valves. Removal (Pathnder & Pickup) 1) Remove covers from below engine. Drain and remove radiator. Remove cooling fan and water pump pulley. Remove accessory drive belts. Remove spark plugs. Remove distributor protector. Remove A/C compressor idler pulley and bracket. 2) Remove fresh air tube from cylinder head cover. Remove thermostat housing coolant hose. Remove crankshaft pulley bolt and pulley. Remove upper and lower timing belt front covers. See Fig. 4. Temporarily install crankshaft pulley bolt to rotate crankshaft. 3) Set cylinder No. 1 at TDC of compression stroke by aligning marks on camshaft sprockets with marks on timing belt upper rear cover, and mark on crankshaft sprocket with mark on front cover housing. See Fig. 5. Loosen timing belt tensioner. Remove timing belt. Check timing belt tensioner, spring and timing belt.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Installing Timing Belt & Sprocket 2) Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets. 3) Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock nut. Rotate crankshaft clockwise at least 2 revolutions. 4) Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to timing belt between right camshaft sprocket and tensioner. Hold tensioner in position with Allen wrench, and loosen tensioner lock nut. 5) Place a .0138 (.351 mm) feeler gauge at tensioner pulley and timing belt, and rotate crankshaft until feeler gauge is centered between tensioner pulley and timing belt. See Fig. 2. Tighten timing belt tensioner lock nut to specication. See TORQUE SPECIFICATIONS.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Removing & Installing Timing Belt Covers

598

NISSAN
3.0L V6 SOHC (Cont.)

Installation (Pathnder & 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 specication. See TORQUE SPECIFICATIONS. 6) Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression stroke. Measure timing belt deection halfway between camshaft sprockets. If deection is not .51-.59 (13-15 mm), repeat steps 4) and 5). To complete installation, reverse removal procedure.

Courtesy of Nissan Motor Co., U.S.A.

Fig. 5: Installing Timing Belt & Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 58-65 (79-88) Crankshaft Pulley Bolt ................................................................... ............. 90-98 (122-133) Rocker Shaft Bolts ........................................................................ ................. 13-16 (16-20) Timing Belt Tensioner Lock Nut/Bolt ............................................ ................. 32-43 (43-58) Water Pump Bolt ........................................................................... ................. 13-16 (16-20) INCH Lbs. (N.m) Timing Belt Cover ......................................................................... ..................... 27-43 (3-5)

OPTIMA
1.6L & 2.0L 4-Cylinder
TIMING BELT APPLICATION Application 1.6L 4-Cyl. Optima (Canadian) 1988-91 .............................. 2.0L 4-Cyl. Optima (Canadian) 1988-89 .............................. 1990-91 ..............................
1

599

Labor Time

Component Belt Kit No. Part No.

2.9 Hours .. ...... ..... ...... ..... T148

1 1

2.9 Hours .. ...... ..... ...... ..... T081 2.9 Hours .. .. TCK163 .. ..... T163

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Courtesy of General Motors Corp.

Fig. 1: Exploded View Of Timing Belt & Components (2.0L) Installation (2.0L) 1) Align timing marks on camshaft and crankshaft sprockets with marks on timing belt rear cover. Place timing belt on camshaft and crankshaft sprockets and tensioner. Use special tool (J-33039-A) or equivalent to rotate water pump eccentric until tensioner touches stop. Slightly tighten water pump attaching bolts. 2) Rotate crankshaft clockwise 2 revolutions. Rotate water pump eccentric counterclockwise until hole in tensioner arm is in line with hole in base. Tighten water pump attaching bolts and make sure tensioner holes are still aligned. To complete installation, reverse removal procedure. Adjust drive belt to proper tension.

REMOVAL & INSTALLATION


TIMING BELT
Removal (1.6L) Disconnect negative battery cable. Remove accessory drive belts. Remove power steering pump. Remove timing belt cover. Remove air cleaner. Mark all hoses for installation reference and disconnect hoses from valve cover. Remove valve cover. Remove timing belt. Installation (1.6L) Align camshaft sprocket mark with mark on rear timing belt cover. Install timing belt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Removal (2.0L) 1) Disconnect negative battery cable. Remove drive belt. Remove power steering pump and bracket. Remove serpentine drive belt tensioner as an assembly. Remove timing belt cover. See Fig. 1. 2) Loosen water pump attaching bolts. On water pump eccentric, use special tool (J-33039-A) or equivalent to release tension. Remove crankshaft pulley. Remove timing belt from camshaft and crankshaft sprockets.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Water Pump Bolts ..................................................................................................... 18 (24)

600

PEUGEOT
1.9L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.9L 4-Cyl. 405 1989-91 DOHC ...................................................... 4.0 Hours ... ..... T188 SOHC ...................................................... 4.0 Hours ... ..... T189 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal (DOHC) 1) Disconnect negative battery cable. Raise and support front of vehicle. Remove A/C compressor drive belt. Remove A/C compressor from mounting bracket with refrigerant hoses attached. Suspend compressor from lower frame at bottom of engine compartment. 2) Remove alternator drive belt, then alternator. Support engine. Remove upper engine mount and two upper cover bolts. Tilt engine and transmission assembly as far as possible. Disconnect wiring harnesses from relay box, then pull up on clip and lift upper cover upward. 3) Remove lower ywheel housing cover. Hold ywheel 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 ywheel locking tool. 4) Rotate engine, using crankshaft pulley bolt, to align crankshaft lock pin hole with engine lock pin hole. See Fig. 1. Insert Peugeot Lock Pin (No.0153-G) or equivalent through crankshaft lock pin holes, remove pin. Insert Peugeot Lock Pins (No. 0153-M) or equivalent through camshaft sprocket lock pin holes. 5) Loosen timing belt tensioner bolts, then turn tensioner to relieve tension on timing belt. Remove timing belt from sprockets. Installation (DOHC) 1) Ensure that camshaft and crankshaft locking pins are in position. See Fig. 1. Install belt in order, observing direction of engine rotation. Start with camshaft sprockets, tensioner, crankshaft sprocket, water pump sprocket and tensioner. See Fig. 2. 2) Lift and tilt engine and transmission assembly as far as possible, then position belt tensioning tool on indicated section of timing belt and lock in position. Rotate tensioner one full turn. Using Peugeot Tensioner Tool (No. 0153-P) or equivalent, rotate tensioner counterclockwise until 19 SEEM units are displayed on belt tensioning tool meter. See Fig. 2. Without changing tensioner position, tighten tensioner bolt to 18 ft. lbs. (25 N.m), then remove belt tensioning meter. 3) Rotate tensioner counterclockwise until 21 SEEM units are displayed on belt tensioning tool meter. See Fig. 2. Without changing tensioner position, tighten tensioner bolt to 18 ft. lbs. (25 N.m). Remove three locking pins and rotate crankshaft two turns in normal direction of engine rotation. 4) Insert Peugeot Lock Pin Tool (0153-G) or equivalent through crankshaft lock pin holes. Both camshaft lock pins should be able to be inserted through lock pin holes without effort. See Fig. 1. If not, timing belt must be removed and reinstalled. 5) Position belt tension tool on timing belt. Meter reading should be between 40-50 SEEM units. If meter reading is not within limits, timing belt must be retensioned. Remove belt tensioning tool, then locking pins. Install lower cover. Lock ywheel in position with Peugeot Lock Tool (J-36358) or equivalent. Install crankshaft pulley. 6) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of Peugeot Motors of America, Inc.

Fig. 1: Installing Camshaft & Crankshaft Sprocket Locking Pins (DOHC)

Courtesy of Peugeot Motors of America, Inc.

Fig. 2: Installing Timing Belt & Tensioning Tool (DOHC) Removal (SOHC) 1) Disconnect negative battery cable. Remove right mud shield. Remove A/C compressor and alternator drive belts. Remove upper timing belt cover. Rotate crankshaft using pulley bolt,

PEUGEOT
1.9L 4-Cylinder (Cont.)
aligning holes in camshaft sprocket and crankshaft pulley for pin installation. Insert Peugeot Locking Pin Tool (No. 0-0163), or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 3 and 4. 2) Remove locking pins. Remove lower ywheel cover. Using Flywheel Stop Tool (No. 91-86) or equivalent, lock ywheel in position. Remove crankshaft pulley retaining bolt and crankshaft pulley. Remove stop tool that was used to lock ywheel in position. 3) Remove upper portion of timing belt lower cover. Remove lower portion of timing belt lower cover. Loosen three timing belt tensioner nuts. Do not remove timing belt tensioner nuts. Push timing belt tensioner away from timing belt to relieve tension. Tighten tensioner retaining bolt next to pulley to hold tensioner in position. 4) Remove timing belt from sprockets.

601

Installation (SOHC) 1) Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. Insert Peugeot Locking Pin Tool (No. 0-0163), or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 3 and 4. 2) Remove crankshaft retaining bolt and pulley. Install timing belt over camshaft sprocket, crankshaft sprocket and water pump sprocket, then position timing belt on tensioner pulley. Ensure timing belt is properly seated on sprockets. Loosen tensioner nut, then turn tensioner square to release spring. 3) Remove locking pins, then tighten tensioner retaining nuts. Rotate crankshaft 2 turns in direction of engine rotation, and bring No. 1 cylinder to TDC of compression stroke. Loosen timing belt tensioner retaining nuts to tension timing belt. After timing belt has tensioned, tighten tensioner retaining bolts. Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. 4) Insert Peugeot Locking Pin Tool (No. 0-0163), or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 3 and 4. If pins are not aligned with holes, timing belt must be removed and reinstalled. Remove crankshaft retaining bolt and pulley. 5) Install lower and upper portions of timing belt lower cover. Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. Using Peugeot Flywheel Stop Tool (No. 91-86) or equivalent, lock ywheel in position, then tighten crankshaft pulley retaining bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts .......................................................................................... 11 (15) Crankshaft Pulley Bolts DOHC ...................................................................................................................... 18 (25) SOHC ........................................................................................... .......................... 81 (111) Timing Belt Tensioner Nut/Bolt DOHC (4 Bolts) ....................................................................................................... 18 (26) SOHC ....................................................................................................................... 12 (16) Upper Engine Mount DOHC ...................................................................................................................... 33 (45)

Courtesy of Peugeot Motors of America, Inc.

Fig. 3: Installing Camshaft Sprocket Timing Pin (SOHC)

Courtesy of Peugeot Motors of America, Inc.

Fig. 4: Installing Crankshaft Sprocket Timing Pin (SOHC)

602

PEUGEOT
2.2L 4-Cylinder
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. 505 1986-91 ..................................................... 2.7 Hours ... ..... T140 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect battery. Drain cooling system including cylinder block. Remove radiator and fan shroud. Remove thermostat housing and auxiliary air device. 2) Align timing marks for crankshaft, camshaft and intermediate shaft. See Fig. 1. Remove crankshaft pulley bolt and pulley. Ensure that crankshaft does not rotate. Remove timing belt cover. Loosen timing belt tensioner bolts, and position tensioner out of way. Remove camshaft pulley and timing belt. Installation 1) Ensure timing marks remain in alignment. See Fig. 1. Remove distributor cap and check rotor position. Distributor rotor must be at a 90-degree angle to the crankshaft. If not, turn intermediate shaft once or twice. 2) Install timing belt, centered on pulleys and tensioner. Loosen belt tensioner mounting bolts, and allow spring to adjust timing belt. Tighten belt tensioner bolts. 3) To complete installation, reverse removal procedures. Crankshaft pulley bolt must be reinstalled using Loctite. Adjust drive belts to proper tension.

Courtesy of Peugeot Motors of America, Inc.

Fig. 1: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts .......................................................................................... 11 (15) Crankshaft Pulley Bolts ........................................................................................... 98 (133) Timing Belt Tensioner Nut/Bolt ................................................................................. 18 (26)

PORSCHE
2.0L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

603

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.

2.0L 4-Cyl. 924 1977-82 ............................... 1.0 Hours ... .. TCK017 .. ..... T017 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

TIMING BELT
Removal Disconnect negative battery cable. Remove accessory drive belts and any components as necessary to access camshaft sprocket cover. Remove camshaft sprocket cover. Align mark on camshaft sprocket with indicator on cylinder head cover. The TDC mark on ywheel and housing must align with each other. Loosen timing belt tensioner. Remove timing belt. Installation To install components, reverse removal procedure. Belt must be tightened until belt can be turned 90 degrees with thumb and index nger at a point midway between crankshaft and camshaft. Adjust drive belts to proper tension.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends that under normal operating conditions, check tension at 2,000 miles, then every 15,000 miles. Replace belt every 45,000 miles.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 58 (79) Crankshaft Pulley .................................................................................................. 180 (245) Tensioner Pulley ........................................................................................................ 29 (39) INCH Lbs. (N.m) Camshaft Sprocket Cover ......................................................................................... 84 (10)

604

PORSCHE
2.5L, 2.7L & 3.0L 4-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

2.5L 4-Cyl. 924 1987-88 Balance Shaft ......................................... Camshaft ................................................ 944 1983-86 Balance Shaft ......................................... Camshaft ................................................ 1987-88 Balance Shaft ......................................... Camshaft ................................................ 1989 Balance Shaft ......................................... Camshaft ................................................ 944S 1987-88 Balance Shaft ......................................... Camshaft ................................................ 2.7L 4-Cyl. 944 1989 Balance Shaft ......................................... Camshaft ................................................ 3.0L 4-Cyl. 944 1989-91 Balance Shaft ......................................... Camshaft ................................................ 968 1992-95 Balance Shaft ......................................... Camshaft ..................................................
1

3.2 Hours ... ..... T293 3.2 Hours ... ..... T107

2.4 Hours ... ..... T293 2.4 Hours ... ..... T107 3.2 Hours ... ..... T293 3.2 Hours ... ..... T107 3.5 Hours ... ..... T293 3.5 Hours ... ..... T107

2) Turn crankshaft clockwise to align camshaft sprocket TDC mark with mark in distributor cap console. See Fig. 2. Ensure mark on upper and lower balance shaft sprockets align with mark on rear timing belt cover. See Fig. 3. 3) The ywheel mark for No. 1 cylinder must also align with cast boss on clutch housing. On 1986 and earlier models, release belt tension. On 1987 and later models, mechanical belt tensioner must be removed. See Fig. 4. Remove balance shaft drive belt. Loosen camshaft belt tensioning sprocket lock nut and then sprocket by turning it clockwise. Remove camshaft timing belt.

3.5 Hours ... ..... T293 3.5 Hours ... ..... T152

3.5 Hours ... ..... T293 3.5 Hours ... ..... T107

Courtesy of Porsche of North America, Inc.

Fig. 1: Loosening Pressure Rod 3.5 Hours ... ..... T293 3.5 Hours ... ..... T152

3.4 Hours ... ..... T293 3.4 Hours ... ..... T152

With Power Steering, add .3 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 45,000 miles.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: When using belt tension gauge, always zero telltale gauge needle after lock pin is engaged (turned counterclockwise). Adjust drive belt tension only on a cold engine. Ensure gauge does not turn on belt and slides remain at on belt surface.

Courtesy of Porsche of North America, Inc.

Fig. 2: Aligning Camshaft Sprocket Timing Mark

TIMING BELT
WARNING: On models equipped with supplemental restraint system (air bags), wait 20 minutes after disconnecting battery before starting repairs. Failure to wait the suggested time may result in air bag deployment and possible personal injury. Removal 1) Disconnect negative battery cable. Remove splash shield. Remove air cleaner assembly with airow sensor. Disconnect vent hose, and position to one side. Remove timing belt cover assembly. Remove distributor cap, and position to one side. Raise and support vehicle. Ensure pressure rod bolts are slightly loose prior to loosening lock nuts. See Fig. 1. Remove accessory drive belts.

Courtesy of Porsche of North America, Inc.

Fig. 3: Aligning Upper Balance Shaft Timing Mark

PORSCHE
2.5L, 2.7L & 3.0L 4-Cylinder (Cont.)

605

Courtesy of Porsche of North America, Inc.

Fig. 4: Removing Mechanical Belt Tensioner Installation (Camshaft Belt) Ensure No. 1 cylinder is at TDC, and that marks on ywheel 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 ywheel and cast clutch housing are aligned. Loosen tensioner adjustment bolts. See Fig. 4. Using thumb pressure, press downward on camshaft belt between water pump pulley and camshaft sprocket. Force camshaft belt against belt cover. NOTE: On 944S, intake camshaft is chain driven from the exhaust camshaft. 2) Repeat procedure twice to ensure free movement of belt idler pivot. Allow idler spring tension to apply tension against belt. Tighten adjustment bolts to 15 ft. lbs. (20 N.m). CAUTION: DO NOT remove balance shaft sprocket mounting bolts to replace drive belt. Handle metal insert drive belts carefully. Mark belt direction of rotation prior to removal if belt is to be reused. Installation (Balance Shaft Belt) Ensure No. 1 cylinder is at TDC, and that marks on ywheel and cast clutch housing are aligned. Align mark on camshaft sprocket with mark on rear drive belt cover. Install balance shaft belt with color coded tooth facing out. See Fig. 6. Adjust drive belts to proper tension. To complete installation, reverse removal procedure. Adjustment 1) For upper shaft, align grove 0 with Woodruff key. For lower shaft, align unmarked grove with Woodruff key. See Fig. 3. Pull out lock pin on tension gauge and push out gauge pin opposite lock pin. Zero telltale needle. 2) Slide tension gauge onto belt. Push in gauge needle until lock pin is heard engaging. Read value from dial gauge. On engine with slotted guide roller, tension should be 2.4-3.0 for both new and used belts. 3) If adjustment is necessary, turn tensioner clockwise to tighten and counterclockwise to loosen. Tighten tensioner nut. After adjusting drive belt tension, adjust idler pulley position. 4) Use Adjusting Gauge (9207) or a .020 (.50 mm) feeler gauge to ensure a .020 (.50 mm) clearance exists between drive belt (at lower balance shaft sprocket) and idler pulley is maintained when upper portion of drive belt is preloaded at .04-.08 (1.0-2.0 mm). 5) Tighten idler pulley. See Fig. 3. If correct gap cannot be reached, rotate idler pulley 180 degrees and repeat adjustment. Tighten mounting nut. Install and adjust poly-rib belt.
Courtesy of Porsche of North America, Inc.

Fig. 5: Identifying Drive Belt Positioning

Courtesy of Porsche of North America, Inc.

Fig. 6: Installing Balance Shaft Drive Belt

606

PORSCHE
2.5L, 2.7L & 3.0L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Balance Shaft Bearing Cover ....................................................... ..................................... 1 Step 1 2 Bolts @ Bearing (8 mm) ....................................................... ............................ 11 (15) Step 2 6 mm ....................................................................................................................... 7 (10) 8 mm ..................................................................................................................... 15 (20) Step 3 2 Bolts @ Bearing (8 mm) ................................................................................... 24 (33) Balance Shaft Sprocket Mounting Bolt .................................................................... 33 (45) Belt Tensioner Mounting Bolt .................................................................................... 33 (45) Camshaft Housing Mounting Bolt ............................................................................. 15 (20) Camshaft Plug (Aluminum) ....................................................................................... 30 (41) Camshaft Sprocket Hex Mounting Bolt ................................................................................................... 33 (45) Polygon Mounting Bolt ................................................................ ................. 47-51 (64-69) INCH Lbs. (N.m) Camshaft Bearing Cap Bolt ........................................................................................ 96 (8) Transport Clamp-to-Camshaft Housing ...................................................................... 96 (8)
1

Check movement of balance shaft between each tightening step.

PORSCHE
4.5L, 4.7L, 5.0L & 5.4L V8
TIMING BELT APPLICATION Application 4.5L V8 928 1978-82 4.7L V8 928 1983-84 5.0L V8 928 1985-86 1987-91 5.4L V8 928 1993-95 Labor Time Belt Part No.

607

..................................................... 4.6 Hours ... ..... T196

..................................................... 4.6 Hours ... ..... T196

..................................................... 5.8 Hours ... ..... T196 ..................................................... 6.5 Hours ... ..... T196

..................................................... 6.5 Hours ... ..... T196

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Porsche of North America, Inc.

Fig. 1: Identifying Camshaft Sprocket & Timing Belt Types

TIMING BELT
NOTE: On 1983 4.5L V8 models, the tooth shape of the timing belt was changed to High Torque Drive (HTD). See Fig. 1. New HTD belts can be used on older engines if sprockets with new tooth shape are installed. NEVER mix sprockets with different tooth shapes. NOTE: When replacing drive belt, ensure proper type is used and new belt teeth match used sprockets. Early design belt uses square-shouldered teeth with belt thickness of .18 (4.5 mm). Late design belt uses round teeth (high torque drive type) with a belt thickness of .22 (5.6 mm). All sprockets must match belt tooth design. Removal 1) Disconnect negative battery cable. Remove air cleaner intake hoses. Remove accessory drive belts. Disconnect cables for throttle, cruise control and automatic transaxle. Remove retainers and clamp on console, and position cable aside. Remove clutch slave cylinder. CAUTION: NEVER operate clutch pedal when slave cylinder is removed. 2) On 4.5L V8, align TDC mark on vibration damper with red indicator on cover. On 4.7L, 5.0L and 5.4L V8, align mark for 45 degrees BTDC on vibration damper with Red needle. Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until timing marks (notches) on camshaft sprockets align with marks cast on camshaft bearing caps. 3) On 4.7L, 5.0L and 5.4L V8, lock crankshaft by installing Porsche Tool (9161/1) or equivalent. Secure tool with slave cylinder mounting bolts. 4) Remove crankshaft pulley mounting bolt, both pulleys, vibration damper and collar. Remove oil dipstick tube. Remove alternator. Remove left upper and center timing belt covers. Loosen timing belt tensioner. Loosen tensioning roller. Remove timing belt. Installation 1) On 4.5L V8, align TDC mark on vibration damper with Red indicator on cover. On 4.7L, 5.0L and 5.4L V8, align mark for 45 degrees BTDC on vibration damper with Red needle. Turn crankshaft
Courtesy of Porsche of North America, Inc.

Fig. 2: Installing Camshaft Drive Belt clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until timing marks (notches) on camshaft sprockets align with marks cast on camshaft bearing caps. NOTE: Manufacturer indicates sufficient clearance exists so pistons and valves will not collide when crankshaft is turned with camshaft timing belt removed. 2) Preload belt by hand and install belt on sprockets in order of crankshaft, oil pump, left camshaft, water pump, right camshaft and tension roller. See Fig. 2. Ensure belt and camshaft sprocket teeth match. If necessary, rotate camshaft counterclockwise until teeth match. Tighten timing belt to specication. Rotate engine 2 revolutions and align cylinder No. 1 at TDC of compression stroke. 3) Check camshaft timing marks for proper alignment and retighten camshaft drive belt. Ensure tester is not turned or pushed during tension measurement. Recheck belt adjustment at least once. Adjust drive belts to proper tension.

608

PORSCHE
4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)

Adjustment 1) With both upper drive belt guards removed, rotate crankshaft (in direction of rotation) and position cylinder No. 1 at TDC of compression stroke. Mark on vibration damper should be in alignment with Red indicator on cover. 2) Ensure each camshaft sprocket timing mark is in alignment with mark cast on camshaft bearing cap. Turn engine over 2 more times until TDC is reached again. 3) Check timing belt for damage and wear. Pull out lock pin, then completely push out gauge pin (opposite lock pin) on Timing Belt Tension Tester (9201) or equivalent. Move telltale to 0 position on gauge. See Fig. 3. 4) Slide tension tester onto belt section between tension roller and lower camshaft sprocket. Ensure measuring pin is resting in belt grove. Push tester down on side closer to tensioner, until gauge needle, resting on air pump bracket, engages. 5) Read measured valve while keeping tester horizontal to belt and free of tension. Tester must not touch plastic cover. Move telltale to 0 position on gauge. 6) Pull out lock pin to disengage gauge needle again. Remove tester from timing belt and read measured value. Correct belt tension if necessary. See TIMING BELT TENSION table. Adjustment screw is located on bottom of engine, at right front side. To adjust, loosen adjustment screw lock nut and turn adjustment screw until tension is correct. Tighten lock nut and turn engine 2 revolutions. Recheck tension adjustment. TIMING BELT TENSION Application Scale Value New Or Used ................................................. .................................................................. 4.5

Courtesy of Porsche of North America, Inc.

Fig. 3: Using Drive Belt Tension Tester

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 lled with engine oil (which is added only after installation on block). Replacement tensioners are not oil lled 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 lling tensioner, damping chamber may be bled by pumping tension roller carrier. Ensure belt is loose and oil ller bolt and bleeder are open. 2) To ll, remove the larger oil ller and open Allen head bleeder screws on tensioner housing. Using an oil can, slowly pour oil into ller hole until air-free oil ows from bleeder hole. 3) Install and tighten ller and bleeder screws. Check uid level after 1000 miles and at 15,000 mile intervals thereafter. To check, remove ller bolt. If oil can be seen, level is okay. If not, add oil as necessary.

Courtesy of Porsche of North America, Inc.

Fig. 4: Exploded View of Timing Belt & Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Mounting Bolt ............................................................................. 14 (20) Camshaft Pulley Mounting Bolt ................................................................................ 33 (45) Front Pulley Mounting Nut ............................................................ ......... 181-188 (250-260)

RENAULT
1.7L 4-Cylinder
TIMING BELT APPLICATION Application
1

609

Labor Time

Belt Part No.

1.7L 4-Cyl. Alliance & Encore 1985-87 ..................................................... 2.3 Hours ......... T119
1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Courtesy of American Motors/Renault Corp.

REMOVAL & INSTALLATION


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

Fig. 1: Identifying Camshaft Sprocket Alignment Marks

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 rst over crankshaft sprocket, then intermediate shaft sprocket, and then camshaft sprocket. See Fig. 2. 2) Position timing belt arrow, indicating direction of rotation between intermediate shaft sprocket and idler pulley. See Fig. 2. Loosen tensioner pulley lock nut, then turn tensioner pulley nut counterclockwise until timing belt is taut. Hold tensioner pulley nut from turning and tighten lock nut. 3) Align timing belt marks with timing mark on camshaft sprocket and crankshaft sprocket. See Fig. 2. Remove TDC tool from crankcase, then rotate crankshaft clockwise, 2 complete revolutions. Reinstall TDC tool through crankcase into crankshaft. Ensure that the camshaft sprocket timing mark is aligned with mark on rear cover plate. See Fig. 1. NOTE: The intermediate shaft sprocket does not have a timing mark. 4) There should be 66 timing belt teeth (cogs) between camshaft sprocket timing mark and crankshaft sprocket timing mark. See Fig. 2. Remove TDC tool and install plug into cylinder block. Check timing belt deection between intermediate shaft sprocket and idler pulley. With belt cold, deection should be .295 (7.49 mm). With belt hot, deection should be .216 (5.48 mm). 5) If deection is excessive, loosen tensioner pulley lock nut, then turn tensioner pulley nut counterclockwise to increase tension or counterclockwise to decrease tension. While holding tensioner pulley lock nut with a suitable wrench, tighten tensioner pulley lock nut to specication. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Courtesy of American Motors/Renault Corp.

Fig. 2: Installing Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Tensioner Pulley Lock Nut ........................................................................................ 30 (41)

610

RENAULT
2.2L 4-Cylinder
Labor Time Belt Part No. Installation & Adjustment 1) Position camshaft sprocket timing index in line with static timing mark. See Fig. 1. Position crankshaft so No. 1 piston is at TDC of compression stroke. Remove plug in cylinder block and insert TDC Rod (Mot. 861), or equivalent, into TDC hole in crankshaft. Install timing belt. See Fig. 2. 2) Position timing belt cover over sprockets and check camshaft timing mark with index on cover. See Fig. 3. Remove TDC rod and install plug in cylinder block. Rotate crankshaft clockwise 2 complete revolutions. DO NOT rotate counterclockwise. Remove timing belt cover and loosen timing belt tensioner bolts a maximum of 1/4 turn. 3) Spring loaded timing belt tensioner will automatically adjust to correct position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004 (.10 mm). See Fig. 4. Tighten bottom timing belt tensioner bolt. Tighten top bolt. Test belt tension with Tension Gauge (Ele. 343) or equivalent. See Fig. 5. Deection should be .216-.276 (5.5-7.0 mm). Install timing belt cover. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application

2.2L 4-Cyl. Fuego 1984-85 ..................................................... 2.2 Hours ... ..... T140 Sportwagon 1984-86 ..................................................... 2.0 Hours ... ..... T140 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove radiator upper support. Remove upper and lower hoses from radiator. Disconnect wiring harness connectors from cooling fan and thermo switch. Remove radiator and A/C condenser as an assembly. 2) Release tension and remove serpentine drive belt. Remove timing belt cover. Remove hose from water pump. Remove water pump pulley bolt and pulley. Remove water pump. 3) Remove timing belt tension spring and plunger from water pump and install them in replacement water pump. Clean gasket mating surfaces. Loosen timing belt tensioner idler bolts. Remove timing belt.

Courtesy of American Motors/Renault Corp.

Fig. 2: Installing Timing Belt

Courtesy of American Motors/Renault Corp.

Fig. 1: Aligning Camshaft & Crankshaft Sprockets

RENAULT
2.2L 4-Cylinder (Cont.)

611

Courtesy of American Motors/Renault Corp.

Fig. 5: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 37 (50) Crankshaft Pulley Bolt ............................................................................................. 96 (130)
Courtesy of American Motors/Renault Corp.

Fig. 3: Identifying Timing Belt Cover TDC Marks

Courtesy of American Motors/Renault Corp.

Fig. 4: Adjusting Intermediate Shaft Cover Clearance

612

SAAB
2.5L & 3.0L V6 1994-97
Labor Time Timing Belt Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.5L V6 900 1994-97 ............................... 2.3 Hours ... ...... ..... ...... ..... T285 3.0L V6 9000 1995-97 ............................... 2.3 Hours ... .. TCK285 .. ..... T285 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Saab-Scania of America, Inc.

Fig. 1: Aligning Camshaft Sprocket Timing Marks

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Move power steering reservoir out of the way, and remove right side engine-to-frame torque arm. Remove the power steering line clamp from the torque arm engine mount. Remove torque arm engine mount. 2) Relieve tension on serpentine belt and remove serpentine belt. Remove the water pump pulley. Remove upper part of alternator air intake. Remove the serpentine belt tensioner. 3) Remove the power steering pump with lines attached, and move out of way. Remove the timing belt cover. Remove the 6 outer bolts from the crankshaft pulley, NOT the center bolt. 4) Turn crankshaft so No. 1 cylinder is at TDC of compression stroke. Ensure marks on camshaft sprockets and timing cover align. See Fig. 1. Install Belt Holder (KM-800-1 and KM-800-2) to hold camshaft sprockets in place. See Fig. 2. 5) If belt is to be reused, mark belt with direction of rotation. Remove timing belt from engine. NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the timing belt. Correct belt marks MUST be used. Installation 1) Ensure crankshaft and camshaft timing marks are still aligned. Install timing belt. Adjust lower roller counterclockwise to belt tension of 205-221 ft. lbs. (275-300 N.m). Adjust tensioning pulley with a hex head wrench until 2 marks are aligned. Tighten bolt. 2) Remove locking tool for camshaft sprockets No. 1 and 2. Adjust upper adjusting roller counterclockwise until No. 2 sprocket moves .03-.07 (1-2 mm) clockwise. Remove camshaft locking tools. 3) Turn engine 2 revolutions in normal direction of rotation. Recheck camshaft and crankshaft timing mark alignment. To complete installation, reverse removal procedure.

Courtesy of Saab-Scania of America, Inc.

Fig. 2: Installing Camshaft Belt Holders

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 37 (50) Crankshaft Pulley Bolt ............................................................................................... 15 (20) INCH Lbs. (N.m) Valve Cover Nuts ...................................................................................................... 86 (10)

SAAB
3.0L V6 DOHC 1999-03
TIMING BELT APPLICATION Application Labor Time Belt Part No.

613

9-5 1999-03 ....................................................... 2.4 Hours ... ..... T285


1

With Air Conditioning, add .2 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends belt be replaced every 90,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Raise vehicle and remove lower spoiler sections. See Fig. 1. 2) Insert a wedge between the oil sump and subframe. Insert a wedge between the gearbox and subframe. 3) Lower car. 4) Remove mass airow sensor with hose. Detach power steering hose from holder. See Fig. 2. 5) Remove right engine attachment with bracket and engine mount. See Fig. 3. 6) Undo retaining bolts from coolant pump pulley and power steering pump pulley. See Fig. 4. 7) Release timing belt tension. See Fig. 5. 8) Remove coolant pump pulley and power steering pump pulley. 9) Remove belt tensioner and generator air intake. Remove timing cover. Remove crankshaft pulley. 10) Turn crankshaft clockwise to align timing marks and set No. 1 cylinder to TDC of its compression stroke. Markings on camshaft sprockets and timing cover must be aligned as must be crankshaft marking. If reusing belt, mark direction of rotation on belt. Install Locking Tool (KM-800-1 and KM-800-2) for camshaft sprockets, and Locking Tool (KM-800-10) for crankshaft. See Fig. 6. 11) Undo tensioning pulley and adjusting rollers. Use Adjusting Wrench (83 94 983) as a counterstay on adjusting rollers. 12) Remove Locking Tool (KM-800-10) from crankshaft. Keep Locking Tools (KM-800-1 and KM-800-2) in place. Remove lower adjusting roller. Remove washer behind roller. Remove timing belt.

Courtesy of Saab-Scania of America, Inc.

Fig. 2: Locating Mass Air Flow Sensor & Power Steering Hose

Courtesy of Saab-Scania of America, Inc.

Fig. 3: Removing Right Engine Attachment With Bracket & Mount Inspection Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Installation 1) Install timing belt using markings on belt and indicated rotation direction. Use Assembly Kit (83 95 006) for camshaft sprockets and camshaft drive belt. Use Adjustment Tool (KM-800-30) to hold belt in place. Adjust tensioning pulley by hand so belt does not disengage. Adjust counterclockwise and check to see that markings on timing belt match markings on camshaft drive and crankshaft. Remove Adjustment Tool (KM-800-30). Install Locking Tool (KM-800-10), position a piece of camshaft belt, and install Belt Tension Meter (83 93 985) to measure belt tension. See Fig. 7.

Courtesy of Saab-Scania of America, Inc.

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 nally 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 specication. See TORQUE SPECIFICATIONS. Use Adjusting Wrench (83 94 983) as a counterstay. Check belt tension again and adjust as necessary. 3) Remove belt-tension meter and piece of toothed belt. 4) Ensure adjusting nut on upper adjusting roller rotates freely and is not tight. Adjust tensioning pulley with a 5-mm Allen key until the two lines on tensioning pulley correspond with each other. Tighten nut to specication. See TORQUE SPECIFICATIONS. 5) Remove Locking Tool for camshaft sprockets No. 1 and 2. Install Adjustment Tool (KM-800-20). Adjust upper adjusting roller counterclockwise with Adjusting Wrench (83 94 983) until markings on camshaft sprocket are aligned with markings on Adjustment Tool (KM-800-20). Use Adjusting Wrench (83 94 983) as a counterstay, and tighten to specication. See TORQUE SPECIFICATIONS. 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 specication. See TORQUE SPECIFICATIONS. 9) Install timing cover and tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Install belt tensioner and generator air intake. Install coolant pump pulley and power steering pump pulley. Use Loctite. Do NOT tighten bolts. 11) Install timing belt. Tighten retaining bolts on pulleys to specication. See TORQUE SPECIFICATIONS. 12) Install right engine attachment with bracket and engine mount. 13) Install power steering hose in holder. Install mass airow sensor with hose. 14) Raise car. Lower engine by carefully removing wedges. Install lower spoiler sections. Lower car.

Courtesy of Saab-Scania of America, Inc.

Fig. 5: Releasing Timing Belt Tension

Courtesy of Saab-Scania of America, Inc.

Fig. 6: Locking Camshaft & Crankshaft Sprockets

Courtesy of Saab-Scania of America, Inc.

Fig. 7: Installing Timing Belt

Courtesy of Saab-Scania of America, Inc.

Fig. 4: Locating Timing Belt Components

SAAB
3.0L V6 DOHC 1999-03 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

615

Application Ft. Lbs. (N.m) Adjuster Roller Bolt ................................................................................................... 30 (40) Camshaft Sprockets .................................................................................................. 30 (40) Crankshaft Pulley ...................................................................................................... 15 (20) Engine Attachment W/Bracket & Engine Mount ................................................... 46.5 (63) Power Steering Pump Retaining Bolts ..................................................................... 15 (20) Upper Adjusting Roller Nut ....................................................................................... 15 (20) INCH Lbs. (N.m) Coolant Pump Retaining Bolts ................................................................................. 70.8 (8) Timing Cover ............................................................................................................ 70.8 (8)
Courtesy of Saab-Scania of America, Inc.

Fig. 8: Measuring Tension Roller Position

616

SATURN
3.0L V6 DOHC L-Series After VIN 578512 & Vue
Labor Time Belt Part No. CAUTION: DO NOT remove Camshaft Holders (J-42069) with timing belt removed. CAUTION: DO NOT rotate crankshaft unless camshafts are properly locked in place, or valves may contact pistons. CAUTION: DO NOT rotate camshafts unless crankshaft in at 60 BTDC, or valves may contact pistons.

TIMING BELT APPLICATION Application

3.0L V6 DOHC VIN B Vue 2002-03 ..................................................... 3.0 Hours ... ..... T285 3.0L V6 DOHC VIN R (After S/N 578512) L300 2002-04 ..................................................... 3.2 Hours ... ..... T285 LW300 2002-03 ..................................................... 3.2 Hours ... ..... T285 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 100,000 mile intervals.

REMOVAL & INSTALLATION


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

Fig. 1: Positioning Crankshaft At 60 BTDC

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. 2) Raise and support vehicle. Remove right front wheel. Remove lower front splash shield. 3) Lower vehicle. Loosen, but DO NOT remove, water pump pulley bolts. Rotate accessory serpentine belt tensioner clockwise using a 15 mm wrench, and remove accessory serpentine belt from pulleys. NOTE: Right engine mount must be removed before accessory drive belt can be removed from vehicle. 4) Install the 3 Bar Engine Support Fixture (SA9105E) and the Engine Support Fixture Adapter (J-43405) to support weight of engine from above or from below with a oor jack. Remove front engine mount (timing belt end of engine) from engine and frame. 5) Remove water pump pulley bolts and pulley. Remove the power steering pump pulley bolts and pulley. Remove accessory drive belt tensioner from engine block. 6) Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic balancer. It is NOT necessary to remove crankshaft center bolt. 7) Remove wiring harness channel from front timing belt cover, and secure away from engine. Remove front timing belt cover. Inspect sealing strip on outer edge of cover for cracks or tears. Replace, if necessary. 8) Rotate crankshaft clockwise to 60 degrees Before Top Dead Center (BTDC). See Fig. 1. 9) Install Crankshaft Locking Tool (J-42069-10). Rotate the crankshaft in the engine rotational direction, clockwise, using the Crank Hub TORX Socket (J-42098) until the No. 1 cylinder is at TDC and tighten the lever arm to the water pump pulley ange. See Fig. 3. NOTE: Ensure timing marks are not 180 degrees from TDC. Camshaft timing marks should be aligned with marks on rear cover. See Fig. 2. 10) To lock camshafts in place, install Camshaft Gear Holders 1-2 (J-42069-1) and 3-4 (J-42069-2). See Fig. 4. It may be necessary to loosen timing belt idler pulley and turn eccentric until holder can be inserted. 11) Loosen timing belt tensioner. Remove timing belt.

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks Inspection Check timing belt for excessive wear, cracks, missing teeth, oil contamination or damage. Inspect timing belt tensioner and idler pulleys for grease leaks or worn bearings. Replace as necessary. CAUTION: DO NOT kink belt or a NEW belt will be required. Installation 1) Remove crankshaft holder. This will ease installation of the timing belt. NOTE: With the camshaft locks installed, verify the distance between the camshaft sprockets with the Green test belt located in the Timing Belt Alignment Kit (J-42069). 2) Starting at the No. 1 and No. 2 camshaft sprockets, route the belt around the No. 1 and No. 2 sprockets while aligning the belt marks to the marks on the sprockets and the rear cover. See Fig. 2. Keeping slack out of belt, route timing belt around tensioner and upper idler pulley.

SATURN
3.0L V6 DOHC L-Series After VIN 578512 & Vue (Cont.)

617

4) With belt rmly 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 ange. Perform the following in sequence: a) Install the camshaft checking gage to cams 3 and 4 and verify the alignment marks are within 0.08 (2 mm) of each other. b) Install the 3 and 4 camshaft lock, if properly aligned. c) Install the camshaft checking gage to cams 1 and 2. 6) Rotate the No. 1 camshaft sprocket counterclockwise to remove the slack between 1 and 2, and 3 and 4 cams. NOTE: Ensure that the camshaft timing marks are to the left (retard) side of the checking gage.
Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

7) Rotate upper timing belt idler pulley counterclockwise so that marks are aligned within 0.08 (2.0 mm) of each other. Install 1-2 camshaft lock after aligning idler pulley. Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. 8) Turn tensioner eccentric until center alignment mark is about 1/8 (3.0 mm) above alignment mark on spring loaded idler pulley. See Fig. 6.

Courtesy of General Motors Corp. Courtesy of General Motors Corp.

Fig. 6: Setting Timing Belt Tension Setting CAUTION: If TDC is passed while rotating crankshaft, DO NOT turn crankshaft counterclockwise. This will take out correct timing belt tension between timing belt tensioner and crankshaft sprocket. To correct for this, rotate crankshaft 2 additional turns. 9) Remove camshaft holders from camshaft sprockets. Remove crankshaft locking tool. Rotate crankshaft 1-3/4 turns clockwise, install crankshaft locking tool and then stop rotating crankshaft at TDC. Secure crankshaft locking tool arm to water pump pulley ange. 10) Install Checking Gauge (J-42069-20) to left hand (drivers side) camshafts. See Fig. 7. Verify marks are within 0.08 (2.0 mm) of each other. Adjust timing belt tensioner so center alignment mark is approximately 1/8 (3.0 mm) above mark on spring loaded idler pulley. Tighten tensioner pulley bolt to specication. 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 specication. See TORQUE SPECIFICATIONS. 12) Install water pump and accessory drive belt idler pulleys. Install accessory drive belt tensioner. Install accessory drive belt. Tighten pulley and idler bolts to specication. Install engine mount. Connect negative battery cable. 13) Raise vehicle. Install splash shield. Install wheel. Lower vehicle and install air cleaner assembly.

Fig. 4: Installing Camshaft Gear Holders NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the timing belt. Correct belt marks MUST be used. 3) Route the belt around the No. 3 and the No. 4 camshaft sprockets while aligning the belt marks to the marks on the sprockets and the rear cover. Route the belt around the crankshaft hub sprockets while aligning the marks on the belt to the marks on the sprockets and the rear cover. See Fig. 5. Hold timing belt in place against crankshaft sprocket using Plastic Wedge (J-42069-30).

Courtesy of General Motors Corp.

Fig. 5: Aligning Timing Belt Marks On Crankshaft Pulley

618

SATURN
3.0L V6 DOHC L-Series After VIN 578512 & Vue (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (L-SERIES) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 ........................................................................................................... Additional 60 Step 3 ........................................................................................................... Additional 15 Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................. 184 (250) Step 2 ........................................................................................................... Additional 45 Step 3 ........................................................................................................... Additional 15 Engine Mount-To-Bracket Bolt .................................................................................. 41 (55) Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55) Generator Bolt ........................................................................................................... 30 (40) Power Steering Pump Pulley Bolt ............................................................................ 15 (20) Serpentine Drive Belt Tensioner Unit Bolt ............................................................... 30 (40) Timing Belt Idler Pulley Torx Bolt ............................................................................. 30 (40) Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40) Timing Belt Tensioner Eccentric Lock Nut ............................................................... 15 (20) Water Pump Bolt ....................................................................................................... 18 (25) Wheel Lug Nut ........................................................................................................ 92 (125) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ...................................................................................... 71 (8) Water Pump Pulley Bolt .............................................................................................. 71 (8) TORQUE SPECIFICATIONS (VUE) Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley ............................................................................. 15 (20) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 ........................................................................................................... Additional 60 Step 3 ........................................................................................................... Additional 15 Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................. 184 (250) Step 2 ........................................................................................................... Additional 45 Step 3 ........................................................................................................... Additional 15 Engine Mount-To-Bracket Bolt .................................................................................. 41 (55) Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55) Generator Bolt ........................................................................................................... 30 (40) Serpentine Drive Belt Tensioner Unit Bolt ............................................................... 30 (40) Timing Belt Idler Pulley Torx Bolt ............................................................................. 30 (40) Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40) Timing Belt Tensioner Eccentric Lock Nut ............................................................... 15 (20) Water Pump Bolt ....................................................................................................... 18 (25) Wheel Lug Nut ........................................................................................................ 92 (125) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ...................................................................................... 71 (8) Water Pump Pulley Bolt .............................................................................................. 71 (8)

Courtesy of General Motors Corp.

Fig. 7: Positioning Timing Belt On Left Hand Camshafts

SATURN
3.0L V6 DOHC L-Series Before VIN 578511
TIMING BELT APPLICATION Application Labor Time Belt Part No.

619

3.0L V6 DOHC VIN R LS2 & LW2 2000 ........................................................... 3.2 Hours ... ..... T285 L300 & LW300 2001 ........................................................... 3.2 Hours ... ..... T285 2002-03 (Before S/N 578511) .................. 3.2 Hours ... ..... T285 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 100,000 mile intervals.

Courtesy of General Motors Corp.

Fig. 1: Positioning Crankshaft At 60 BTDC

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner assembly. 2) Raise and support vehicle. Remove right front wheel. Remove lower front splash shield. NOTE: Right engine mount must be removed before accessory drive belt can be removed from vehicle. 3) Lower vehicle. Loosen, but do not remove, water pump pulley bolts. Loosen, but do not remove, power steering pump pulley bolts. Rotate accessory serpentine belt tensioner clockwise using a 15mm wrench, and remove accessory serpentine belt from pulleys. 4) Support weight of engine from above or below with oor jack. Remove front engine mount (timing belt end of engine) from engine and frame. Remove engine mount bracket from engine block. 5) Remove water pump pulley bolts and pulley. Remove power steering pump pulley bolts and pulley. Remove accessory drive belt tensioner from engine block. 6) Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic balancer. It is NOT necessary to remove crankshaft center bolt. 7) Remove wiring harness channel from front timing belt cover, and secure away from engine. Remove front timing belt cover. Inspect sealing strip on outer edge of cover for cracks or tears. Replace, if necessary. 8) Rotate crankshaft clockwise to 60 degrees before TDC. See Fig. 1. Ensure timing marks are not 180 degrees from TDC. Camshaft timing marks should be aligned with marks on rear cover. See Fig. 2. 9) Install Crankshaft Holder (J42069-10), and rotate crankshaft clockwise until holder contacts the water pump. See Fig. 3. Secure moveable lever of tool to water pump pulley ange. 10) To lock camshafts in place, install Camshaft Gear Holders (J42069-1 and J42069-2). See Fig. 4. It may be necessary to loosen timing belt idler pulley and turn eccentric until holder can be inserted. 11) Loosen timing belt tensioner and idler pulley bolts. If reusing timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. NOTE: DO NOT move camshafts with belt removed. DO NOT remove Camshaft Holders (J42069) with timing belt removed. Inspection Check timing belt for excessive wear, cracks, or missing teeth. Inspect timing belt tensioner and idler pulleys for grease leaks or worn bearings. Replace as necessary.

Courtesy of General Motors Corp.

Fig. 2: Aligning Timing Belt Marks With Rear Cover Marks

Courtesy of General Motors Corp.

Fig. 3: Installing Crankshaft Holder

620

SATURN
3.0L V6 DOHC L-Series Before VIN 578511 (Cont.)

Courtesy of General Motors Corp.

Courtesy of General Motors Corp.

Fig. 4: Installing Camshaft Gear Holders NOTE: Upper timing belt idler pulley uses a narrow .20 (5 mm) thick spacer and a Black bolt. The lower timing belt idler pulley uses a .40 (11 mm) thick spacer and a Silver bolt. Installation 1) To install timing belt, remove crankshaft holder. Using a felt pen, mark the face of the upper and lower timing belt idler pulleys. The mark should line up with point farthest away from the Torx head mounting bolt. See Fig. 5. The idler pulleys provide adjustment by rotating on an eccentric circle around the mounting bolt.

Fig. 6: Aligning Timing Belt Marks On Crankshaft Pulley 5) Install upper idler pulley. Tighten mounting bolt just enough so that the pulley will rotate with slight resistance. Install Timing Belt Holder (J42069-30) or equivalent to crankshaft. Tighten lever arm to water pump pulley ange. 6) Ensure timing belt tension is taut (no slack). Loosen timing belt tensioner lock nut. Turn tensioner eccentric until center alignment mark is about .118 (3 mm) above alignment mark on spring loaded idler pulley. See Fig. 7. Remove plastic wedge holding timing belt against crankshaft sprocket. Tighten timing belt tensioner lock nut until snug. Lock nut will be nal tightened after nal adjustments are made.

Courtesy of General Motors Corp.

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 oclock). See Fig. 5. Temporarily tighten Torx mounting bolt. 8) Adjust lower timing belt idler pulley so that the largest part of the eccentric is above and to the left of the mounting Torx bolt (11 oclock). See Fig. 5. Temporarily tighten Torx mounting bolt. 9) Remove camshaft holders from camshaft sprockets. Install Checking Gauge (J42069-20) to left hand (drivers side) camshafts. See Fig. 8. Pull timing belt between timing belt tensioner and crankshaft sprocket to take up slack between left hand camshaft sprocket and lower idler pulley. 10) Ensure left hand camshaft timing marks are about 1 mm (about the width of the timing marks on the sprockets) on the retard side. See Fig. 8. If they are not, turn lower idler pulley clockwise to allow retard of left hand camshafts. Pull timing belt between timing belt tensioner and crankshaft sprocket to take up slack between left hand camshaft sprocket and lower idler pulley.

Courtesy of General Motors Corp.

Fig. 5: Positioning Timing Belt Idler Pulleys 2) Loosen lower idler pulley mounting bolt just enough so that pulley will rotate with slight resistance. Remove upper timing belt pulley. NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the timing belt. Correct belt marks MUST be used. 3) Install timing belt onto left hand camshafts (as viewed from rear of engine), matching marks on timing belt with corresponding marks on camshaft sprockets. See Fig. 2. Keeping slack out of belt, route timing belt around lower idler pulley and around crankshaft sprocket. Ensure mark on timing belt mates with mark on crankshaft sprocket face. See Fig. 6. 4) Hold timing belt in place against crankshaft sprocket using Plastic Wedge (J42069-30). Route timing belt around right hand camshaft pulleys (as viewed from rear of engine). Ensure timing belt dash marks are aligned with marks on right hand camshaft sprockets.

SATURN
3.0L V6 DOHC L-Series Before VIN 578511 (Cont.)

621

Courtesy of General Motors Corp.

18) Recheck both camshaft timing marks on both banks with Checking Gauge (J42069-20). If timing marks are NOT aligned, readjust timing belt. It is NOT necessary to remove timing belt. If camshaft timing marks are aligned, nal 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 specication. 21) Install water pump and power steering pump pulleys. Install accessory drive belt tensioner. Install accessory drive belt. Tighten pulley and idler bolts to specication. Install engine mount. Connect negative battery cable. 22) Raise vehicle. Install splash shield. Install wheel. Lower vehicle and install air cleaner assembly.

Fig. 8: Positioning Timing Belt On Left Hand Camshafts 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. 11) Remove Crankshaft Holder (J42069-10). Rotate crankshaft clockwise 1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to crankshaft ange, and then stop at TDC. Tighten lever arm to water pump pulley ange. NOTE: Alignment marks on timing belt will no longer align with camshaft sprocket marks after one or more crankshaft revolutions. Timing marks on timing belt are used for initial installation only. 12) Rotate lower timing belt idler pulley counterclockwise until the left hand camshaft timing marks on the sprockets are lined up with marks on the Checking Gauge (J42069-20). While holding lower idler pulley in this position, tighten lower idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m). 13) Remove Crankshaft Holder (J42069-10). Rotate crankshaft 1 3/4 turns clockwise. DO NOT rotate crankshaft counterclockwise. Install Crankshaft Holder (J42069-10) to crankshaft ange, and then stop at TDC. Tighten lever arm to water pump pulley ange. 14) Inspect left hand camshaft timing marks for alignment. Sprocket timing marks should align with marks on rear cover. Realign, if necessary. 15) Remove Checking Gauge (J42069-20) from left hand camshaft sprockets. Install checking gauge on right hand sprockets (passenger side). Install Camshaft Gear Holder (J42069-2, Green) between left hand camshaft sprockets. 16) Turn upper timing belt idler pulley counterclockwise until the right hand camshaft sprocket timing marks are aligned with marks on Checking Gauge (J42069-20). While holding idler pulley eccentric in this position, tighten upper idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m). CAUTION: If TDC is passed while rotating crankshaft, do NOT turn crankshaft counterclockwise. This will take out correct timing belt tension between timing belt tensioner and crankshaft sprocket. To correct for this, rotate crankshaft 2 additional turns. 17) Remove Camshaft Gear Holder (J42069-2, Green) from left hand camshaft sprockets. Remove Crankshaft Holder (J42069-10) from crankshaft. Rotate crankshaft clockwise 1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to crankshaft ange, and then stop at TDC. Tighten lever arm to water pump pulley ange.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ...................................................................................................................... 37 (50) Step 2 ........................................................................................................... Additional 60 Step 3 ........................................................................................................... Additional 15 Crankshaft Harmonic Balancer Bolt ......................................................................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 .................................................................................................................. 184 (250) Step 2 ........................................................................................................... Additional 45 Step 3 ........................................................................................................... Additional 15 Engine Mount Bracket-To-Engine Bolt ...................................................................... 41 (55) Engine Mount-To-Bracket Bolt .................................................................................. 41 (55) Generator Bolt ........................................................................................................... 30 (40) Power Steering Pump Pulley Bolt ............................................................................ 15 (20) Serpentine Drive Belt Tensioner Unit Bolt ............................................................... 30 (40) Timing Belt Idler Pulley Torx Bolt ............................................................................. 15 (20) Timing Belt Tensioner Bracket Bolt .......................................................................... 30 (40) Timing Belt Tensioner Eccentric Lock Nut ............................................................... 15 (20) Water Pump Bolt ....................................................................................................... 18 (25) Wheel Lug Nut ........................................................................................................ 92 (125) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ...................................................................................... 71 (8) Water Pump Pulley Bolt .............................................................................................. 71 (8)

622

SATURN
3.5L V6
Labor Time Belt Part No. Installation 1) Clean the belt pulleys and covers. Rotate the crankshaft and align the Top Dead Center (TDC) mark on the sprocket with the pointer on the oil pump housing. See Fig. 2. 2) Rotate the left camshaft sprocket to TDC by aligning the mark on the sprocket with the pointer on the cover. See Fig. 3. 3) Rotate the right camshaft sprocket to TDC by aligning the mark on the sprocket with the pointer on the cover. See Fig. 4. 4) Install the Timing Belt Tensioner Pulley Retaining Bolt (EN-46331). Screw the timing belt tensioner pulley retaining bolt all the way in by hand, until it contacts the timing belt tensioner. See Fig. 5. 5) Install the belt onto the sprockets. Install the timing belt in a clockwise sequence starting with the tensioner pulley. See Fig. 6. 6) Tighten the idler pulley bolt to specications. See TORQUE SPECIFICATIONS. Remove the Timing Belt Tensioner Retaining Pin (EN-46330) and timing belt tensioner pulley retaining bolt. 7) Install the guide, balancer and bolt. See Fig. 7. Tighten the bolt until snug. Using the Camshaft Sprocket/Balancer Holder (EN-46337), rotate the crankshaft clockwise about 5 or 6 complete revelations to position the timing belt on the sprockets. 8) Align the mark on the sprocket with the pointer on the oil pump housing. See Fig. 2. Inspect the left camshaft sprocket for proper alignment. The TDC mark on the sprocket should align with the pointer on the cover. See Fig. 3. Inspect the right camshaft sprocket for proper alignment. The TDC mark on the sprocket should align with the pointer on the cover. See Fig. 4. 9) Remove the guide, balancer and bolt. See Fig. 7. Install the timing belt cover.

TIMING BELT APPLICATION Application

3.5L V6 Vue 2004 ........................................................... 3.0 Hours ... ..... T329 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 100,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: The Powertrain Control Module (PCM) has to perform the crankshaft position learn process under the following conditions: The crankshaft position (CKP) sensor is removed for replacement or during disassembly. The timing belt is removed for replacement or during disassembly. The CKP Pattern Clear is executed from the Tech II. The PCM is replaced. Removal 1) Remove the air cleaner assembly. Remove the engine drive belt. Remove the right splash shield. Using Camshaft Sprocket/ Balancer Holder (EN-46337), remove the engine balancer. 2) Remove the timing belt cover bolts. Remove the timing belt cover. 3) Using Timing Belt Tensioner Pulley Retaining Bolt (EN-46331), secure the tensioner pulley. See Fig. 1. Loosen the idler pulley bolt about 5 or 6 turns. 4) Remove timing belt from the pulleys.

Courtesy of General Motors Corp.

Fig. 2: Identifying Crankshaft Timing Marks

Courtesy of General Motors Corp.

Fig. 1: Identifying Idler Pulley Bolt

SATURN
3.5L V6 (Cont.)

623

Courtesy of General Motors Corp.

Fig. 5: Identifying Timing Belt Tensioner Pulley Retainer Bolt


Courtesy of General Motors Corp.

Fig. 3: Identifying Left Camshaft Sprocket Timing Mark

Courtesy of General Motors Corp.

Fig. 6: Identifying Timing Belt Alignment

Courtesy of General Motors Corp.

Fig. 4: Identifying Right Camshaft Sprocket Timing Mark

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Timing Belt Idler Pulley Bolt ....................................................................................................... 33 (44) Rear Cover Bolts ..................................................................................................... 16 (22) Tensioner Bolt .......................................................................................................... 18 (25) Tensioner Pulley Bolt .............................................................................................. 18 (25) Tensioner Pulley Nut ............................................................................................... 59 (80) INCH Lbs. (N.m) Timing Belt Auto-Tensioner Bolts ............................................................................ 106 (12) Timing Belt Front Cover Bolts ................................................................................ 106 (12)
Courtesy of General Motors Corp.

Fig. 7: Identifying Balancer Components

624

STERLING
2.5L & 2.7L V6
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

2.5L V6 825 1987-88 ............................... 4.1 Hours ... .. TCK129 .. ..... T129 2.7L V6 827 1989-91 ............................... 4.1 Hours ... .. TCK129 .. ..... T129 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove negative battery cable. Turn crankshaft clockwise to bring No. 1 cylinder to TDC of compression stroke. Remove pulley cover from upper timing belt cover. Remove engine wiring harness clamp from right side of engine compartment. Support front of engine. On right side of engine compartment, remove engine-to-body mount (on front of engine). Remove lower engine splash shield. Remove A/C, power steering, and all other drive belts. 2) Remove alternator. Leaving hoses connected, remove power steering pump and secure out of way. Remove upper timing belt pulley covers. Remove crankshaft pulley. Remove timing belt lower cover. Loosen timing belt tensioner to relieve tension on timing belt. If reusing timing belt, mark direction of belt rotation before removing. Slide belt off pulleys. Check belt for damage, missing teeth, or cracks. Installation 1) Remove spark plugs. Turn crankshaft clockwise to bring No. 1 cylinder to TDC of compression stroke. Advance crankshaft an additional 15 degrees from TDC position. Rotate camshaft pulleys to compression stroke (TDC position) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC position. 2) Push timing belt tensioner to full release position and snug adjuster bolt. Install timing belt over crankshaft pulley, front camshaft pulley, water pump pulley, tensioner and then over rear camshaft pulley. See Fig. 1. Note position of timing belt pulley guides on both sides of crankshaft. Install pulley guides so guides form a V groove for belt to ride in. Loosen timing belt tensioner bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. NOTE: Always adjust timing belt tension with engine cold. 3) Set No. 1 piston to TDC on compression stroke. Rotate crankshaft clockwise 9 teeth on rear camshaft pulley. Blue mark on crankshaft pulley should match pointer on lower cover. Loosen timing belt tensioner bolt. See Fig. 1. 4) Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt. Reverse removal procedure to complete installation. NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.

Courtesy of American Honda Motor Co., Inc.

Fig. 1: Adjusting Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolts .............................................................................................. 16 (22) A/C Compressor Bracket Bolts ................................................................................. 33 (45) Alternator Bracket Bolts ............................................................................................ 33 (45) Alternator Mount Bolts .............................................................................................. 16 (22) Camshaft Pulley Bolts ............................................................................................... 23 (31) Crankshaft Pulley Bolt ........................................................................................... 123 (170) Engine Mount Bolts ................................................................................................... 40 (54) Power Steering Pump Mount Bolt ............................................................................ 33 (45) Timing Belt Tensioner Bolt ........................................................................................ 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................................................................ 86 (10) Valve Cover Bolts .................................................................................................... 106 (12) Water Pump Bolts ................................................................................................... 106 (12)

STERLING
2.5L & 2.7L V6 (Cont.)

625

Courtesy of American Honda Motor Co., Inc.

Fig. 2: Exploded View Of Timing Belt & Components

626

SUBARU
1.2L 3-Cylinder
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

1.2L 3-Cyl. Justy 1987-95 ..................................................... 1.4 Hours ... ..... T135
1

With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator drive belt. Using Pulley Holder (499205500) or equivalent, loosen crankshaft pulley bolts. Rotate engine until No. 3 cylinder is at TDC. Remove crankshaft pulley retaining bolts using access hole in fenderwell housing. 2) Remove outer timing belt cover. Loosen tensioner retaining bolts. Move tensioner toward outside of engine. Tighten bolts to hold tensioner. See Fig. 1. Mark timing belt for direction of rotation. Remove crankshaft belt drive sprocket plate and timing belt. Inspection Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect all drive sprockets for wear in drive belt area. Inspect tensioner for noise and grease leakage. Replace tensioner as necessary. Installation 1) Using Pulley Holder (499205500) or equivalent, rotate camshaft to align camshaft sprocket alignment mark with alignment mark on timing belt cover. See Fig. 2. Install crankshaft belt drive sprocket (if removed) with anged 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 specication. See TORQUE SPECIFICATIONS. Adjust valve clearance. Adjust drive belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 1: Exploded View Of Timing Belt Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ................................................................... ................. 58-72 (78-98) INCH Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................... 97-106 (11.0-12.0) Tensioner Bolt ................................................................................ ............... 50-53 (5.7-6.0) Valve Cover Bolt ........................................................................... ............... 53-71 (6.0-8.0) Water Pump Impeller Bolt ............................................................. ............. 80-89 (9.0-10.0) Fig. 2: Aligning Timing Marks
Courtesy of Subaru of America, Inc.

SUBARU
1.8L & 2.2L 4-Cylinder Impreza & Legacy
TIMING BELT APPLICATION Application 1.8L 4-Cyl. Impreza 1993 ................................... 1994-95 .............................. 1996-97 .............................. 2.2L 4-Cyl. Impreza 1995-96 .............................. 1997 ................................... 1998 ................................... Legacy 1990-93 .............................. 1994-95 .............................. 1996 ................................... 1997-98 ..............................
1

627

Labor Time

Component Belt Kit No. Part No.


2 2

CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992 kg). DO NOT release pressure until stopper pin is completely installed. Installation 1) Ensure timing marks are aligned. Using a press, align holes in belt tension adjuster rod and adjuster body, and push rod into body. DO NOT allow press pressure to exceed 2205 lbs. (992 kg). Install a stopper pin with a diameter of .059 (1.5 mm) through holes in adjuster body and rod. See Fig. 2. 2) Temporarily tighten mount bolts while tension adjuster is pushed completely right. Install belt tensioner. Ensure belt direction of rotation is correct. 3) Install timing belt, being careful not to move sprockets. Install belt idler No. 2 and belt idler. Loosen tension adjuster mount bolts and push tension adjuster completely left. Tighten adjuster mount bolts. 4) Ensure the marks on timing belt and sprockets align. See Fig. 1. Remove stopper from tension adjuster. Remove rocker covers and ensure valve lash adjuster does not contain air. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

1 1

2.2 Hours .. . 2.2 Hours .. . 1 2.8 Hours .. .


1 1

TCK172 . ..... T172 TCK254 . ..... T254 2 TCK254 . ..... T254

2.8 Hours .. . 2 TCK254 . ..... T254 2.8 Hours .. ...... ..... ...... ..... T254 1 2.3 Hours .. ...... ..... ...... ..... T254
1 1

2.8 2.8 1 2.3 1 2.3

Hours Hours Hours Hours

.. . 2 TCK172 . ..... .. . 2 TCK254 . ..... .. . 2 TCK254 . ..... .. ...... ..... ...... .....

T172 T254 T254 T254

With Air Conditioning, add .4 hours. With Power Steering, add .2 hours. Does not include camshaft tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-94 model years, the manufacturer recommends belt be replaced every 60,000 miles. For 1995-97 model years, the manufacturer recommends belt be replaced at 60,000 miles on Federal vehicles, and 105,000 miles on California vehicles.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing & Installing Timing Belt

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator drive belt. Remove crankshaft pulley bolt. Remove crankshaft pulley. If engine is removed from vehicle, crankshaft can be held using Flywheel Stopper (498277000) or equivalent for M/T models, or Drive Plate Stopper (498497000) or equivalent for A/T models. 2) Remove front, left and right timing belt covers. If timing belt is to be reused, mark belt to indicate original direction of rotation before removal. Use Crankshaft Socket (499987500) to turn crankshaft pulley. 3) Align crankshaft and camshaft timing notches with corresponding notches on timing cover and engine block. See Fig. 1. Use White paint to mark timing belt in relation to sprocket timing marks. Loosen tensioner adjuster mounting bolts. Remove belt idler. Remove belt idler No. 2. Remove timing belt. Inspection 1) Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect belt tension adjuster oil seals for leaks. Inspect rod ends for abnormal wear and scratches. Timing belt bend diameter must be greater than 2.36 (60.0 mm). 2) Slight trace of oil at rod oil seal does not indicate a problem. While holding tensioner using both hands, push rod section against oor or wall using a force of 33-110 lbs. (15-50 kg) to ensure rod section does not move. 3) If rod section moves, replace tension adjuster. Measure extension of rod beyond body. Rod extension should be .606-.646 (15.40-16.40 mm). Replace belt tension adjuster if extension of rod is not as specied. Inspect belt tensioner and belt adjuster rod mating surface. Check spacer and tensioner bushing.

Courtesy of Subaru of America, Inc.

Fig. 2: Installing Tension Adjuster Rod Stopper Pin

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ................. 55-61 (75-83) Camshaft Support Bolt .............................................................................................. 12 (16) Crankshaft Pulley Bolt ................................................................... ............... 69-76 (93-103) Timing Belt Idler Bolt .................................................................... ................. 26-32 (35-43) Timing Belt Tension Adjuster Bolt ................................................. ................. 17-20 (23-27) Timing Belt Tensioner Bracket Bolt .............................................. ................. 17-20 (23-27) INCH Lbs. (N.m) Rocker Cover Bolt .................................................................................................... 44 (5.0) Rocker Shaft Support Bolt Long .................................................................................................................... 108 (12.2) Short ....................................................................................................................... 44 (5.0) Timing Belt Cover Bolt ............................................................................................. 44 (5.0) Water Pump Bolt ........................................................................... ......... 89-124 (10.0-14.0)

628

SUBARU
1.8L 4-Cylinder Except Impreza & Legacy
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No. Wagon) .... .. TCK299 .. ..... T299 .... .. TCK299 .. ..... T300

1.8L 4-Cyl. DL, GL & RX (Coupe, Sedan & Station 1985-89 Left Side ........................ .... 2.7 Hrs. Right Side ..................... .... 2.7 Hrs. Loyale 1990-94 Left Side ........................ .... 2.7 Hrs. Right Side ..................... .... 2.7 Hrs. XT 1985-91 Left Side ........................ .... 2.7 Hrs. Right Side ..................... .... 2.7 Hrs.
1

by hand to ensure smooth operation and movement of tensioner. Using Belt Tensioner Wrench (499437000) or equivalent, apply 17-19 ft. lbs. (23-26 N.m) of torque to camshaft sprocket in a counterclockwise direction. 4) While applying torque, tighten tensioner bolts. Ensure all timing marks are aligned. See Figs. 3, 4 and 5. NOTE: After installing left side timing belt, crankshaft is rotated one full turn (360 degrees). This will be the position for installing the right side camshaft belt. The camshaft timing mark for the left side timing belt will now be pointing straight down (6 oclock position). See Fig. 6. 5) To install right (outer) timing belt, rotate crankshaft clockwise 360 degrees and align center line on ywheel with timing mark on ywheel housing. Align camshaft sprocket timing mark with notch in housing. See Figs. 4 and 5. 6) Install right timing belt over crankshaft and camshaft sprockets, keeping slack out of side opposite tensioner. Ensure reused belt is installed in original direction of rotation. Loosen inner tensioner bolt and allow tensioner to apply belt tension. While turning camshaft sprocket counterclockwise, apply 17-19 ft. lbs. (23-26 N.m) of torque using Belt Tension Wrench (499437000) or equivalent. NOTE: When timing belts are properly installed, left side camshaft sprocket timing mark will be pointing DOWN and right side camshaft sprocket timing mark will be pointing UP. Engine timing marks for both camshafts are located on TOP side of rear timing belt covers. See Figs. 4, 5 and 6. 7) While applying torque, tighten inner and then outer tensioner retaining bolts. Ensure all timing marks are aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension.

.... .. TCK299 .. ..... T299 .... .. TCK299 .. ..... T300

.... .. TCK299 .. ..... T299 .... .. TCK299 .. ..... T300

Both Belts. With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 52,500 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove alternator drive belt. Remove water pump pulley. Remove dipstick and tube. Remove crankshaft pulley. If engine is removed from vehicle, crankshaft can be held using Flywheel Stopper (498277000 or equivalent) for M/T models, or Drive Plate Stopper (498497000 or equivalent) for A/T models. CAUTION: If reusing timing belt, mark belt to indicate normal direction of rotation. 2) Remove center, left and right timing belt covers. To remove right side timing belt, loosen tensioner bolts on No. 1 cylinder 1/2 turn, rotate tensioner to release belt tension, and retighten bolts. See Fig. 1. If reusing timing belt, mark belt to indicate normal direction of rotation. Remove timing belt. 3) Loosen left side timing belt tensioner bolts on No. 2 cylinder 1/2 turn. See Fig. 1. Using tensioner wrench, rotate tensioner until belt is slack. Tighten tensioner bolts. If reusing timing belt, mark belt to indicate normal direction of rotation. Remove outer crankshaft sprocket. Remove timing belt. Inspection Inspect timing belt for wear and rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect idler pulleys and tensioners for smooth rotation. Check belt tensioner roller for squareness. See Fig. 2. Replace tensioner if out-of-square exceeds .02 (.5 mm). Installation 1) Install belt tensioners and belt idler. Position belt tensioners to allow belt installation. Install inner (sprocket without dowel pin) and outer crankshaft sprockets on crankshaft. Temporarily install crankshaft pulley. 2) Align center mark on ywheel with mark on ywheel 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 rst on inner crankshaft sprocket and then around oil pump sprocket. Install left timing belt on idler and then camshaft sprocket. 3) If reusing belt, install it in original direction of rotation. Loosen left tensioner retaining bolt to apply tension to timing belt. Push timing belt

Courtesy of Subaru of America, Inc.

Fig. 1: Identifying Timing Belts & Engine Components

SUBARU
1.8L 4-Cylinder Except Impreza & Legacy (Cont.)

629

Courtesy of Subaru of America, Inc.

Fig. 2: Measuring Tensioner Squareness

Courtesy of Subaru of America, Inc.

Fig. 5: Identifying Camshaft Position For Installing Timing Belts (Right Camshaft Sprocket)

Courtesy of Subaru of America, Inc.

Fig. 3: Aligning Flywheel Timing Marks


Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Final Installed Position Of Left Timing Belt Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Idler Bolt ................................................................................. ................. 29-35 (39-47) Belt Tensioner Bolt ........................................................................ ................. 13-15 (18-20) Camshaft Case Bolt ...................................................................... ................. 13-15 (18-20) Crankshaft Pulley Bolt 1 ................................................................ ............... 66-79 (90-107) Oil Pump Pulley Nut ..................................................................... ................. 13-15 (18-20) INCH Lbs. (N.m)
Courtesy of Subaru of America, Inc.

Fig. 4: Identifying Camshaft Position For Installing Timing Belts (Left Camshaft Sprocket)

Camshaft Sprocket Bolt ................................................................ ................... 80-89 (9-10) Camshaft Support Bolt .................................................................. ..................... 53-62 (6-7) Timing Belt Cover Bolt .................................................................. ..................... 35-44 (4-5) Valve Cover Bolt ........................................................................... ..................... 35-44 (4-5) Water Pump Pulley Bolt ................................................................ ................... 80-89 (9-10)
1

Coat bolt threads with oil before installation.

630

SUBARU
2.0L 4-Cylinder DOHC
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.0L 4-Cylinder DOHC (Turbocharged) Impreza 2002-04 ..................................................... 2.4 Hours ... ..... T328 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 105,000 miles.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing Drive Belt Cover

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. 2) Remove accessory drive belt cover. See Fig. 1. Remove accessory drive belts. 3) Hold crankshaft pulley stationary using Crank Pulley Wrench (499977100 or 499977400), and remove crankshaft pulley center bolt. See Fig. 2. Remove crankshaft pulley. 4) Remove timing belt covers. See Fig. 3. 5) Using Crankshaft Socket (499987500), turn crankshaft to align marks on crankshaft sprocket, left side intake camshaft sprocket, left side exhaust camshaft sprocket, right side intake camshaft sprocket and right side exhaust camshaft sprocket with notches on belt cover and cylinder block. See Fig. 4. 6) On manual transmission models, remove timing belt guides from around crankshaft and camshaft pulleys. See Fig. 5. 7) On all models, if reusing old belt, check for timing and rotation marks on timing belt before removing. If marks are missing or worn off, use White paint to mark timing belt in relation to sprocket timing marks and direction of belt rotation. See Fig. 6. Count number of teeth between crankshaft sprocket and camshaft sprockets so that belt can be reinstalled in same position. See INSTALLATION MARK MEASUREMENT SPECIFICATIONS table. For location of measurement points, refer to illustration. See Fig. 7. CAUTION: After timing belt has been removed, NEVER rotate intake and exhaust camshaft sprockets. If camshaft sprocket is rotated, intake and exhaust valve heads will strike together and valve stems will bend. 8) Remove timing belt idler pulley A. See Fig. 8. Remove timing belt. 9) Remove idler pulleys B and C, if necessary. See Fig. 8. Remove automatic belt tension adjuster assembly with adjuster rod facing up. See Fig. 9. INSTALLATION MARK MEASUREMENT SPECIFICATIONS Location Number Of Teeth Z-1 .................................................................. ................................................................ 54.5 Z-2 .................................................................. ................................................................... 51 Z-3 .................................................................. ................................................................... 28
Courtesy of Subaru of America, Inc.

Courtesy of Subaru of America, Inc.

Fig. 2: Identifying Crank Pulley Wrench (499977400 Shown)

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Timing Belt Covers & Bolts

Inspection 1) Inspect timing belt teeth for breaks, cracks or wear. Inspect belt for signs of oil contamination. When inspecting timing belt, do not bend less than a radius of 2.36 (6.0 mm). Replace belt if any fault is present. 2) Inspect automatic belt tension adjuster oil seal for leaks. Slight trace of oil at adjuster rod oil seal does not indicate a problem. Inspect adjuster rod end for abnormal wear and scratches.

Fig. 4: Identifying Crankshaft Socket (499987500) 3) Measure extension of adjuster rod beyond tensioner body. Holding tensioner with adjuster rod facing up, adjuster rod extension should be .204-.244 (5.2-6.2 mm). See Fig. 10. Replace automatic timing belt tensioner assembly if adjuster rod extension is not as specied.

SUBARU
2.0L 4-Cylinder DOHC (Cont.)

631

Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Timing & Directional Arrow Marks On Timing Belt & Sprockets

Courtesy of Subaru of America, Inc.

Fig. 7: Identifying Tooth Measurement Locations On Timing Belt

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Fig. 5: Identifying Location of Timing Belt Guides

Courtesy of Subaru of America, Inc.

Fig. 8: Identifying Timing Belt Idler Pulley Location

632

SUBARU
2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 9: Removing Automatic Timing Belt Tension Adjuster Assembly CAUTION: DO NOT use a bench vise to compress adjuster rod. Always use a vertical type pressing tool to compress adjuster rod. It should take more than 3 minutes to compress adjuster rod. 4) Place automatic belt tension adjuster assembly in a press with adjuster rod facing up. Apply 66 lbs. (30 kg) of pressure on rod. If adjuster rod moves down easily, replace automatic timing belt tensioner assembly. 5) Inspect automatic belt tension adjuster and idler pulleys for abnormal surface wear, oil leakage, rough rotation, noise and excessive play. Replace if any fault is present.

Courtesy of Subaru of America, Inc.

Fig. 11: Identifying DOHC Valve Position In Cylinder Head

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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 gure, if intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves. See Fig. 11. 2) When timing belts are not installed, four camshafts are held at Zero Lift position, where all cams on camshafts do not push the intake and exhaust valves down. Under this condition, all valves remain unlifted. 3) When camshafts are rotated to install the timing belts, No. 2 intake and No. 4 exhaust cam of left-hand camshafts are held to push their corresponding valves down. Under this condition, these valves are held lifted. Right-side camshafts are held so that their cams do not push valves down. 4) Left-hand camshafts must be rotated from Zero Lift position where timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. 5) Do not allow camshafts to rotate in direction shown in gure, as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads. See Fig. 12. Installation 1) Align mark on crankshaft sprocket with mark on oil pump cover at cylinder block. See Fig. 6. 2) Align single mark on right hand exhaust camshaft sprocket with notch on belt cover.

Courtesy of Subaru of America, Inc.

Fig. 12: Rotating Camshafts To Align Timing Marks 3) Align single mark on right hand intake camshaft sprocket with notch on belt cover. Ensure double line marks on intake and exhaust camshaft sprockets are aligned. 4) Align single line mark A on left hand exhaust camshaft sprocket with notch B on belt cover by turning sprocket counterclockwise (as viewed from front of engine). See Fig. 13. 5) Align single line mark A on left hand intake camshaft sprocket with notch B on belt cover by turning sprocket clockwise (as viewed from front of engine). Ensure double line marks C on intake and exhaust camshaft sprockets are aligned. See Fig. 14.

SUBARU
2.0L 4-Cylinder DOHC (Cont.)
CAUTION: To prevent damage, DO NOT apply more than 2205 lbs. (1000 kg) to automatic adjuster rod. DO NOT press automatic adjuster rod past top surface of housing. Always use a vertical type press to move adjuster rod down. 6) Install automatic belt tension adjuster assembly into vertical pressing tool. Slowly apply 66 lbs. (30 kg) pressure to adjuster rod (taking more than 3 minutes) until hole in adjuster rod is aligned with hole in cylinder. See Fig. 15. CAUTION: Do not release pressure on adjuster rod until stopper pin is completely inserted. 7) Use a 0.08 (2.0 mm) diameter stopper pin or hex wrench, and insert it through stopper pin hole in cylinder and adjuster rod to secure adjuster rod. See Fig. 15. 8) Install automatic belt tension adjuster assembly on engine with stopper pin in place. Install idler pulleys. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 9) Ensure crankshaft and camshaft timing marks are still aligned. See Figs. 6 and 16. Install timing belt on sprockets in alphabetical order shown in gure. See Fig. 16. Ensure installation marks align with crankshaft and camshaft sprockets. Count number of teeth between crankshaft sprocket and camshaft sprockets so that belt will be installed in same position. See Fig. 16. If reusing old belt, ensure direction of belt rotation arrow is correct and installation marks are aligned with crankshaft and camshaft sprockets. 10) Install timing belt idler pulleys (if removed). Ensure timing marks are aligned. Remove stopper pin from automatic timing belt tensioner assembly. On manual transmission models, install timing belt guides over crankshaft pulley and at corners by camshaft pulleys. See Fig. 5. Adjust clearance between all belt guides and timing belt to .020-.058 (.5-1.5 mm). See Fig. 17. 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 specication. See TORQUE SPECIFICATIONS. 12) Install accessory drive belts. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

633

Courtesy of Subaru of America, Inc.

Fig. 13: Aligning Left Exhaust Camshaft

Courtesy of Subaru of America, Inc.

Fig. 14: Aligning Left Intake Camshaft

Courtesy of Subaru of America, Inc.

Fig. 15: Installing Adjuster Rod Stopper Pin

634

SUBARU
2.0L 4-Cylinder DOHC (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 16: Identifying Order For Installing Timing Belt

Courtesy of Subaru of America, Inc.

Fig. 17: Checking Clearance Between Timing Belt Guides & Timing Belt

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 72 (98) Crankshaft Pulley Bolt ............................................................................................. 94 (127) Idler Pulley Bolt ......................................................................................................... 29 (39)

TORQUE SPECIFICATIONS (Cont.) Application Ft. Lbs. (N.m) Timing Belt Automatic Tensioner Bolt ....................................................................... 29 (39) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 44 (5) Timing Belt Guide Bolt (M/T) Center Guide ........................................................................................................... 89 (10) Corner Guides 2002 ....................................................................................................................... 89 (10) 2003 ......................................................................................................................... 44 (5) 2004 ................................................................................................................... 61.2 (6.4)

2.2L & 2.5L 4-Cylinder SOHC


TIMING BELT APPLICATION Application 2.2L 4-Cyl. Impreza 1999-01 ..................................................... Legacy 1999 ........................................................... 2.5L 4-Cyl. Baja 2003-04 ..................................................... Forester 1999-04 ..................................................... Impreza 1999-04 ..................................................... Legacy & Outback 2000-04 ..................................................... Labor Time Belt Part No.

SUBARU

635

2.3 Hours ... ..... T304 2.3 Hours ... ..... T304 2.3 Hours ... ..... T307 2.3 Hours ... ..... T304 2.3 Hours ... ..... T304 2.3 Hours ... ..... T307

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 105,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove engine under cover. 2) Lower vehicle. Remove radiator coolant reservoir, and set aside. Remove electric cooling fan and radiator shroud. 3) On Impreza and Forester, remove accessory drive belt cover. On all models, remove accessory drive belts. 4) Hold crankshaft pulley stationary, and remove crankshaft pulley center bolt. Remove crankshaft pulley. Remove timing belt covers. 5) Turn crankshaft to align crankshaft and camshaft timing notches with marks on rear timing cover and engine block. See Figs. 1 and 2. On manual transmission models, remove timing belt guide from top of crankshaft pulley.

Courtesy of Subaru of America, Inc.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Subaru of America, Inc.

Fig. 3: Removing No. 2 Timing Belt Idler Pulley 2) Inspect belt automatic tensioner oil seals for leaks. Slight trace of oil at rod oil seal does not indicate a problem. Inspect rod ends for abnormal wear and scratches. 3) Measure extension of rod beyond tensioner body. Holding tensioner with rod facing up, rod extension should be .204-.244 (5.2-6.2 mm). See Fig. 4. Replace automatic tensioner if rod extension is not as specied.
Courtesy of Subaru of America, Inc.

Fig. 1: Identifying Timing Belt Routing & Timing Marks 6) On all models, if reusing old belt, use White paint to mark timing belt in relation to sprocket timing marks. Also mark timing belt direction of rotation. 7) Remove No. 2 timing belt idler pulley. See Fig. 3. Remove timing belt. Remove timing belt automatic tensioner with rod facing up. Inspection 1) Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated.

CAUTION: Always use a vertical type pressing tool to compress automatic tensioner rod. DO NOT use a bench vise to compress rod. It may take more than 3 minutes to compress the automatic tensioner rod. 4) Place automatic tensioner in a press with tensioner rod facing up. Apply 66 lbs. (294 N) of pressure on rod. If rod moves down easily, replace automatic tensioner. 5) Inspect automatic tensioner and idler pulleys for worn bearings or lubricant leaks. Replace as necessary.

636

2.2L & 2.5L 4-Cylinder SOHC (Cont.)

SUBARU

Courtesy of Subaru of America, Inc.

Fig. 4: Checking Automatic Tensioner Rod Extension CAUTION: To prevent damage, DO NOT apply more than 2205 lbs. (9807 N) of pressure to automatic adjuster rod. Do NOT press automatic tensioner rod past the top surface of the housing. Installation 1) Ensure crankshaft and camshaft timing marks are still aligned. Place automatic adjuster in a press with rod facing up. Apply 66 lbs. (294 N) pressure to end of rod. SLOWLY compress rod (taking more than 3 minutes) into housing until rod and housing holes are aligned. Insert locking pin through holes. See Fig. 5. 2) Install automatic tensioner on engine with locking pin in place. Install idler pulleys (if removed). 3) Ensure crankshaft and camshaft timing marks are still aligned. See Fig. 2. Install timing belt. If reusing old belt, ensure belt direction of rotation is correct and mating marks are aligned. If using new belt, ensure arrows on belt match direction of rotation. See Fig. 6. 4) Install No. 2 idler pulley on engine. Remove automatic tensioner locking pin. On manual transmission models, install timing belt guide over crankshaft pulley. Adjust clearance between belt guide and belt to .020-.058 (.5-1.5 mm). See Fig. 7. CAUTION: If tightening angle of crankshaft pulley bolt is less than 65 degrees, bolt is damaged. Bolt must be replaced. 5) On all models, install timing belt covers. Clean crankshaft pulley bolt and bolt hole. Install crankshaft pulley. Coat crankshaft pulley bolt threads with engine oil. Install bolt. While holding crankshaft pulley stationary, tighten bolt to specication. See TORQUE SPECIFICATIONS. 6) Install accessory drive belts. Install radiator fan assembly. To complete installation, reverse removal procedures. Adjust drive belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 6: Identifying Timing Belt Direction Of Rotation (New Belt)

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Fig. 7: Checking Timing Belt Guide Clearance

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 58 (78) Crankshaft Pulley Bolt 2.2L ........................................................................................................................ 94 (127) 2.5L ...................................................................................................................... 130 (177) Idler Pulley Bolt ......................................................................................................... 29 (39) Timing Belt Automatic Tensioner Bolt ....................................................................... 29 (39) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................................................................ 44 (5) Timing Belt Guide Bolt (M/T) .................................................................................... 89 (10) Valve Cover Bolt ......................................................................................................... 44 (5) Water Pump Bolt ........................................................................... ............... 89-124 (10-14)

Courtesy of Subaru of America, Inc.

Fig. 5: Installing Automatic Tensioner Pin

SUBARU
2.5L 4-Cylinder DOHC
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

637

2.5L 4-Cyl. DOHC Forester 1998 .................................... 2.3 Hours ... ...... ..... ...... ..... T277 Impreza 1998 ................................... 1 2.8 Hours .. .. TCK277 .. ..... T277 Legacy & Outback 1996-99 .............................. 1 2.8 Hours .. .. TCK277 .. ..... T277
1

6) Check mating surfaces of timing belt and contact point of tension adjuster rod for abnormal wear or scratches. Replace belt tensioner if faulty. Check spacer and tensioner bushing for wear. Check tensioner for smooth rotation. Replace if noise or excessive play is noted. Check tensioner for grease leakage.

With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles on 1996-97 Federal vehicles. Replace belt at 105,000 miles on all 1998-99 vehicles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Remove drive belt cover. See Fig. 2. Remove drive belt. Remove A/C compressor belt tensioner assembly (if equipped). Holding crankshaft stationary, remove crankshaft pulley bolt. See Fig. 3. Remove crankshaft pulley. 2) Remove left and right timing belt covers. Remove front belt cover. See Fig. 4. Rotate crankshaft and align crankshaft and camshaft timing notches. See Figs. 5 and 6. If alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks on belt before removing timing belt. See Fig. 1. 3) On manual transmission models, remove timing belt guide from top of crankshaft pulley. On all vehicles, if reusing timing belt, mark belt with arrow to indicate original direction of rotation. Also, place mating marks on timing belt and crankshaft and camshaft sprockets. 4) Remove both timing belt idler pulleys. Remove timing belt automatic tensioner and spacer. Remove timing belt. CAUTION: To prevent intake and exhaust valves from contacting each other, DO NOT rotate crankshaft or camshafts with timing belt removed. Inspection 1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. Check the condition of back side of belt; if any crack is found, replace belt. Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. 2) Inspect belt automatic tensioner oil seals for leaks. Slight trace of oil at rod oil seal does not indicate a problem. Inspect rod ends for abnormal wear and scratches. 3) Measure the extension of rod beyond the body. If it is not within specications, replace with a new one. Rod extension: 0.606-0.646 in (15.4-16.4 mm). See Fig. 7. 4) Place automatic tensioner in a press with tensioner rod facing up. Apply 33 lbs. (15 kg) of pressure on rod. If rod moves down easily, replace automatic tensioner. 5) Apply a force of 33 to 110 lbs (15 to 50 kg,), the rod section should maintain a projectionally acting force and should not sink within 8.5 seconds.
Courtesy of Subaru of America, Inc.

Fig. 1: Placing Alignment &/Or Rotation Marks On Timing Belt

Courtesy of Subaru of America, Inc.

Fig. 2: Removing Drive Belt Cover

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Crankshaft Pulley Bolt

638

SUBARU
2.5L 4-Cylinder DOHC (Cont.)
Installation 1) Ensure crankshaft and camshaft timing marks are still aligned. Place automatic adjuster in a press with rod facing up. Apply pressure to end of rod. SLOWLY (taking more than 3 minutes) compress rod into housing until rod and housing holes are aligned. Insert locking pin through holes. See Fig. 8. 2) Install automatic tensioner on engine with locking pin in place. Install idler pulleys (if removed). Install timing belt in correct routing order. Ensure camshaft double marks are aligned. If reusing old belt, ensure belt direction of rotation is correct and mating marks are aligned. 3) Count number of teeth between crankshaft and camshaft pulleys to ensure belt is correctly installed. See Fig. 6. When belt is correctly installed, remove automatic tensioner locking pin. 4) On manual transmission models, install timing belt guide over crankshaft pulley. Clearance between belt guide and belt should be .039 (1.0 mm). 5) Install timing belt covers. Install crankshaft pulley, Holding crankshaft stationary, tighten bolt to specication. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

7) Check idler for smooth rotation. Replace if noise or excessive play is noted. Check outer contacting surfaces of idler pulley for abnormal wear and scratches. Check idler for grease leakage. CAUTION: Do not allow press pressure to exceed 2205 lbs (1000 kg,). Do not release press pressure until stopper pin is completely inserted. Push tension adjuster rod vertically. Press-in the push rod gradually, taking 3 minutes or more.

Courtesy of Subaru of America, Inc.

Fig. 4: Removing & Installing Front Belt Cover

Courtesy of Subaru of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Related Components

SUBARU
2.5L 4-Cylinder DOHC (Cont.)

639

Courtesy of Subaru of America, Inc.

Fig. 6: Aligning Timing Marks & Sprocket Alignment Marks

Courtesy of Subaru of America, Inc.

Fig. 7: Measuring Belt Tensioner Rod Extension (2.5L Engine)

640

SUBARU
2.5L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 58 (78) Crankshaft Pulley Bolt ........................................................................................... 130 (177) Timing Belt Idler Pulley Bolt ..................................................................................... 29 (39) Timing Belt Tensioner Bolt ........................................................................................ 29 (39) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................................................................. 44 (5.0) Timing Belt Guide Bolt .............................................................................................. 89 (10) Water Pump Bolt ........................................................................... ......... 89-124 (10.0-14.0)

Courtesy of Subaru of America, Inc.

Fig. 8: Installing Belt Tensioner Stopper Pin

SUBARU
2.7L 6-Cylinder
TIMING BELT APPLICATION Application
1

641

Labor Time

Belt Part No.

2.7L 6-Cyl. XT6 1988-91 Left Side ................................................. 2.9 Hours ... ..... T151 Right Side ............................................... 2.9 Hours ... ..... T150
1

Both Belts. With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

Courtesy of Subaru of America, Inc.

Fig. 2: Loosening Right Hand Timing Belt Tension

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Loosen water pump pulley and alternator mounting bolts. Loosen serpentine belt tensioner pulley lock nut, and release belt tension. Ensure adjuster bolt is turned fully counterclockwise and remove serpentine belt. 2) Remove water pump pulley. Remove crankshaft pulley. Crankshaft can be held using Flywheel Stopper (498277000) or equivalent for M/T models, or using Drive Plate Stopper (498497000) or equivalent for A/T models. 3) Unplug oil pressure switch connector. Remove oil level gauge guide from front of engine. See Fig. 1. Remove center, left and right timing belt covers. 4) Loosen right (passenger side) hand timing belt tensioner bolts 1/2 turn. Rotate tensioner to release belt tension and retighten bolts. See Fig. 2. If right (passenger side) timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. 5) Remove crankshaft outer sprocket. To remove left (driver side) timing belt, remove idler pulley. See Fig. 3. Remove rubber plug and retaining bolt located below belt tension adjuster in rear timing cover. See Figs. 4 and 5. 6) Remove Phillips screw from bottom of belt tension adjuster. See Fig. 6. Insert slot screwdriver in bottom of belt tension adjuster and rotate screw clockwise to release belt tension. Install Belt Adjuster Stopper (13082AA000) or equivalent, on tension adjuster. See Fig. 7. 7) Remove left hand timing belt tensioner. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove belt tension adjuster.

Courtesy of Subaru of America, Inc.

Fig. 3: Removing Left Timing Belt Idler Pulley Inspection Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect idler pulleys and tensioners for smooth rotation. Check belt tensioner roller for squareness. See Fig. 8. Replace tensioner in out-of-square exceeds .020 (.51 mm). Installation 1) If not already done, remove Phillips screw from bottom of belt tension adjuster. Insert a standard slot screwdriver into hole in bottom of belt tension adjuster. Turn screw clockwise to compress rubber boot. Install belt adjuster stopper on top of belt tension adjuster. 2) Using syringe, add engine oil through vent hole on top of rubber boot. Add oil until it overows. Install Phillips screw and new gasket. 3) Install belt tension adjuster on engine. Keep belt adjuster stopper in place. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 4) Install rubber plug and retaining bolt on engine. Install left timing belt idler pulley. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 5) Install crankshaft sprocket (if removed). Align center line of the 3 lines on ywheel 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 specication. See TORQUE SPECIFICATIONS. Remove belt adjuster stopper from belt tension adjuster. Ensure tensioner moves smoothly after it is installed. CAUTION: Ensure end of tensioner arm contacts top of belt tension adjuster and all timing marks align.

Courtesy of Subaru of America, Inc.

Fig. 1: Removing Oil Level Gauge Guide

642

SUBARU
2.7L 6-Cylinder (Cont.)

Courtesy of Subaru of America, Inc.

Fig. 5: Removing Rubber Plug & Retaining Bolt

Courtesy of Subaru of America, Inc.

Fig. 6: Removing Phillips Screw From Belt Tension Adjuster

Courtesy of Subaru of America, Inc.

Fig. 4: Exploded View Of Timing Belt & Components NOTE: After installing left (drivers side) timing belt, crankshaft is rotated one full turn (360 degrees). This will be the position for installing the right (passenger side) camshaft belt. The camshaft timing mark for the left side timing belt will now be pointing straight down (6 oclock position). See Fig. 10. 7) To install right (passenger side) timing belt, rotate crankshaft clockwise 360 degrees. Align ywheel or drive plate timing marks with mark on housing. Align camshaft sprocket timing mark with notch in rear timing belt cover. See Fig. 9. 8) Install right hand timing belt tensioner. Rotate tensioner assembly down and temporarily tighten retaining bolts. 9) Install outer crankshaft sprocket. Install right timing belt starting from crankshaft. If reusing old timing belt, ensure belt is installed in original direction of rotation. 10) Loosen right hand tensioner bolts, and allow tensioner to apply belt tension. Install Belt Tension Wrench (499437100) on right camshaft sprocket.

Courtesy of Subaru of America, Inc.

Fig. 7: Installing Belt Adjuster Stopper

SUBARU
2.7L 6-Cylinder (Cont.)

643

Courtesy of Subaru of America, Inc.

Fig. 8: Checking Belt Tensioner Roller Squareness 11) Using torque wrench and belt tension wrench, apply 17-18 ft. lbs. (24-25 N.m) of torque in a counterclockwise direction to right camshaft sprocket. While applying torque, temporarily tighten tensioner bolt closest to the tensioner pulley, and then the tensioner pivot bolt. 12) Check belt tension. Belt tension should be 33-55 lbs. (15-25 kg). If belt tension is correct, tighten tensioner bolt closest to the tensioner pulley, and then the tensioner pivot bolt to specication. See TORQUE SPECIFICATIONS. Ensure all timing marks are still aligned. NOTE: When timing belts are properly installed, left camshaft sprocket timing mark will be pointing DOWN and right camshaft sprocket timing mark will be pointing UP. Engine timing mark notches for both camshafts are located on TOP side of rear timing belt covers. See Figs. 9 and 10. 13) Install rubber plug and retaining bolt below belt tension adjuster. Install timing belt covers. Install crankshaft pulley. Apply engine oil to crankshaft pulley bolt threads. Holding crankshaft pulley stationary, install and tighten center bolt to specication. 14) To install remaining components, reverse removal procedure. Tighten alternator belt so belt tension is 143-165 lbs. (65-75 kg) on new belt or 99-143 lbs. (45-65 kg) on used belts. Adjust drive belts to proper tension.

Courtesy of Subaru of America, Inc.

Fig. 10: Identifying Final Installed Position Of Left (Driver Side) Camshaft Sprocket

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27) Crankshaft Pulley Center Bolt 1 .................................................... ............... 66-79 (90-107) Timing Belt Tensioner Bolt Left Hand Tensioner .................................................................... ................. 29-35 (39-47) Right Hand Tensioner ................................................................. ................. 17-20 (23-27) INCH Lbs. (N.m) Camshaft Sprocket Bolt ................................................................................ 97-108 (11-13) Oil Level Guide Bolt ...................................................................... ..................... 40-48 (4-5) Timing Belt Cover Bolt .................................................................. ..................... 40-48 (4-5) Water Pump Pulley Bolt ................................................................ ................... 80-92 (9-10)
1

Coat bolt threads with oil before installation.

Courtesy of Subaru of America, Inc.

Fig. 9: Aligning Camshaft & Crankshaft Timing Marks

644

SUBARU
3.3L 6-Cylinder
Labor Time Belt Part No. Installation 1) If tension adjuster was removed or replaced, use a press to push adjuster rod down far enough to install a stopper pin. See Fig. 2. Turn sprockets to align timing marks with marks on rear timing belt covers and oil pump. See Fig. 1. 2) While aligning marks on timing belt with marks on sprockets, position timing belt properly. Ensure belt rotating direction is correct. Install idler pulleys. Loosen tension adjuster attaching bolts and move adjuster fully left. CAUTION: Readjust new alternator belt after 5 minutes of operation. 3) Tighten adjuster bolts. Once all timing marks are aligned, remove stopper pin from tension adjuster. Install front timing belt covers. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 3.3L 6-Cyl. SVX 1992-97 ....................................................


1

2.6 Hours .. ..... T209

With Air Conditioning, add .4 hours. With Power Steering, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1992-94 model years, the manufacturer recommends belt be replaced every 60,000 miles. For 1995-97 model years, the manufacturer recommends belt be replaced at 60,000 miles on Federal vehicles, and 105,000 miles on California vehicles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Remove undercover. Disconnect power steering cooler hoses from body. Disconnect cooling fan connectors. Remove drive belt cover. Remove upper radiator brackets. Remove radiator fan and sub-fan assemblies. Remove charcoal canister and bracket. Remove alternator/power steering drive belts and A/C drive belt. Remove alternator and drive belt cover bracket. 2) Remove A/C idler pulley. Remove power steering pump and bracket. Remove crankshaft pulley and front timing belt covers. To hold crankshaft, use Crankshaft Pulley Wrench (49997-7000) or equivalent. If rotation indicating marks on timing belt have rubbed off, re-mark timing belt before removing. 3) Turn crankshaft to align marks on crankshaft sprocket and camshaft sprockets with marks on cylinder block and timing belt cover. See Fig. 1. Using White paint, put alignment marks and/or arrows on timing belt in relation to sprockets. Loosen tensioner adjuster bolts. Remove timing belt idlers. See Fig. 1. Remove timing belt. Fig. 2: Setting Tension Adjuster

Courtesy of Subaru of America, Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Idler Bolt ................................................................................. ................. 26-32 (35-43) Belt Tension Adjuster Bolt ............................................................. ................. 17-20 (23-27) Camshaft Sprocket Bolt ................................................................ ............. 80-94 (108-127) Crankshaft Pulley Bolt 1 ................................................................ ......... 108-123 (147-167) Tensioner Bolt ................................................................................ ................. 26-32 (35-43) INCH Lbs. (N.m) 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

Courtesy of Subaru of America, Inc.

Coat bolt threads with oil before installation.

Fig. 1: View Of Timing Belt Components Inspection 1) Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect tension adjuster for leaking oil seals and worn rod ends. Slight traces of oil at rod oil seal do not indicate problem or component failure. Ensure tension adjuster rod does not move with less than 33-110 lbs. (15-50 kg) of force applied. 2) Replace tension adjuster if rod moves. Measure tension adjuster rods extension beyond adjuster body. Distance should be .606-.646 (15.40-16.40 mm). Replace tension adjuster if distance is not correct. Inspect idler pulleys and tensioners for smooth rotation. Replace components if noise or excessive play is noted.

SUZUKI
1.3L 4-Cylinder DOHC
TIMING BELT APPLICATION Application 1.3L 4-Cyl. DOHC Swift 1989-94 ....................................................
1

645

Labor Time

Belt Part No.

Installation 1) Align timing marks. Bolts with anged nuts may be wedged between cam sprocket teeth to hold camshaft on timing mark during belt installation (if necessary). See Figs. 2 and 3. CAUTION: While aligning timing marks, DO NOT turn camshaft sprockets more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. 2) Install timing belt so no slack exists on drive side of belt. Adjust tensioner to remove timing belt slack from other side of belt, and hand-tighten tensioner bolt and nut. Turn crankshaft 2 revolutions to seat timing belt, and readjust tensioner. 3) Tighten tensioner bolt and nut. Ensure drive side of belt is free of slack. Ensure timing marks are aligned. Install timing belt outer covers and tighten to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Tighten bolts to specication. Adjust drive belts to proper tension.

2.6 Hours .. ..... T171

With Air Conditioning, add .4 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1989-92 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1993-94 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove air cleaner and airow meter assembly. Raise vehicle and remove right fender apron extension by pushing center pin into clip. DO NOT push in too far, as pin may fall into fender. Remove water pump pulley and belt. 2) Remove crankshaft pulley 5-mm hexagon bolts. If engine is in vehicle, remove crankshaft pulley center bolt. Remove crankshaft pulley. Loosen right engine mount bolt, and push air cleaner bracket aside. Remove timing belt covers. 3) Align all sprocket timing marks with timing marks on engine. See Fig. 1. Move timing belt tensioner up and secure. Mark timing belt for direction of rotation if it is to be reused. Remove timing belt from sprockets.

Courtesy of Suzuki of America Corp.

Fig. 2: Securing Intake & Exhaust Camshaft Sprocket For Timing Belt Installation

Courtesy of Suzuki of America Corp.

Fig. 1: Aligning Timing Belt Marks

646

SUZUKI
1.3L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28) Alternator Pulley Bolts 1992-94 ........................................................................................ ............... 70-96 (95-130) Camshaft Sprocket Bolt ................................................................ ................. 41-47 (56-64) Crankshaft Sprocket Bolt ............................................................................ 77-85 (105-115) Timing Belt Tensioner Bolt ............................................................ ................. 18-22 (24-30) INCH Lbs. (N.m) Alternator Pulley Bolt 1989-91 ........................................................................................ ............... 90-108 (10-13) Crankshaft Pulley Bolt ................................................................... ................. 80-106 (9-12) Timing Belt Outer Cover Bolt ....................................................... ................. 80-106 (9-12) Timing Belt Tensioner Stud Nut .................................................... ................. 80-106 (9-12) Water Pump Mounting Bolt ........................................................... ................. 80-106 (9-12) Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)

Courtesy of Suzuki of America Corp.

Fig. 3: Identifying Sprocket Movement Limits

SUZUKI
1.3L 4-Cylinder SOHC
TIMING BELT APPLICATION Application 1.3L 4-Cyl. SOHC Samurai 1985 ................................... 1986-93 .............................. 1994 ................................... 1994 ................................... 1995 ................................... Sidekick 1989 8-Valve ............................. 16-Valve ........................... Swift 1989-93 .............................. 1994 ................................... 1995-97 .............................. 1998-01 ..............................
1 2 3

647

Labor Time

Component Belt Kit No. Part No.

1 1

3.0 3.0 1 3.0 1 3.0 1 3.0


1 1

Hours Hours Hours Hours Hours

.. ...... ..... ...... ..... T095 .. .. TCK095 .. ..... T095 .. .. TCK095 .. ... 2 T095 .. ...... ..... ...... ... 3 T243 .. ...... ..... ...... ..... T243

3.6 Hours .. .. TCK095 .. ..... T095 4.0 Hours .. .. TCK095 .. ..... T095 Hours Hours Hours Hours .. .. TCK095 .. ..... .. ...... ..... ...... ..... .. .. TCK272 .. ..... ... TCK194A . ..... T095 T243 T272 T194

1 1

2.6 2.6 1 2.6 1 2.6

With Air Conditioning, add .4 hours. For VIN R4100375 and earlier. For VIN R4100376 and later.
Courtesy of Suzuki of America Corp.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. Fig. 1: Adjusting Valve Clearance NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1985-92 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1993-01 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals.

ADJUSTMENTS
VALVE CLEARANCE SPECIFICATIONS
VALVE CLEARANCE SPECIFICATIONS Valve Cold In. (mm) Hot In. (mm) Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28) Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28)

REMOVAL & INSTALLATION


TIMING BELT
Removal (Samurai & Sidekick) 1) Disconnect negative battery cable. Remove cooling fan and fan shroud. Discharge A/C system using approved refrigerant recovery/recycling equipment and disconnect compressor exible suction hose from suction pipe (if equipped). Remove A/C compressor belt (if equipped). 2) Loosen alternator, and remove water pump pulley and belt. Remove crankshaft pulley. Remove timing belt cover. Loosen timing belt tensioner bolt and move away from timing belt. Secure timing belt tensioner. 3) Mark belt with an arrow indicating direction of rotation for installation reference. Remove timing belt from camshaft and crankshaft sprockets. CAUTION: With timing belt removed, DO NOT turn camshaft sprocket more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Doing so could damage piston(s) and/or valve(s) by interference. Also, DO NOT bend timing belt. Installation (Samurai & Sidekick) 1) Loosen all valve adjusting screws fully before installing timing belt. Allow camshaft to rotate freely

during belt tension adjustment. Align timing mark on camshaft sprocket with V mark on timing belt inner cover. See Figs. 2 and 3. 2) Turn crankshaft clockwise until punch mark on crankshaft sprocket is aligned with arrow mark on oil pump housing. With timing marks aligned, install timing belt. Ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack. 3) Move tensioner plate up with nger pressure, and loosely secure tensioner bolt. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Tighten tensioner nut and then tensioner bolt to specication. See TORQUE SPECIFICATIONS. 4) Ensure timing marks are aligned. Install timing belt outer cover and tighten to specication. See TORQUE SPECIFICATIONS. Reverse removal procedure to complete installation. Adjust valve clearance. See VALVE CLEARANCE SPECIFICATIONS under ADJUSTMENTS. Adjust drive belts to proper tension. Removal (Swift) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right side fender apron extension by pushing center pin into clip. DO NOT push in too far as pin may fall into fender. Lower vehicle. 2) Remove air cleaner assembly. Support engine with oor jack. Remove engine mount from timing belt end of engine. Loosen water pump pulley bolts. Remove accessory drive belts. Remove water pump pulley. 3) Remove crankshaft pulley-to-crankshaft bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft center bolt. 4) Remove resonator and timing belt cover. Rotate crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3. Camshaft sprocket mark should align with V mark on rear cover. Punch mark on crankshaft sprocket should align with mark on oil pump case. 5) If reusing timing belt, mark belt with an arrow indicating direction of rotation for installation reference. 6) Loosen timing belt tensioner eccentric bolt and stud nut. Move tensioner away from belt and snug bolt and nut. Remove timing belt. CAUTION: With timing belt removed, DO NOT turn camshaft sprocket more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Doing so could damage piston(s) and/or valve(s) by interference. Also, DO NOT bend timing belt. Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components.

648

SUZUKI
1.3L 4-Cylinder SOHC (Cont.)
NOTE: It is NOT necessary to loosen valve adjusting screws on 1995 models. 2) On 1989-94 models with 8-valve engine, remove valve cover. Loosen all valve adjusting screws before installing timing belt. Camshaft must be free to rotate during tension adjustment. 3) On all models, ensure all timing marks align. See Fig. 3. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft or crankshaft so timing mark moves more than 90 degrees, or engine damage may occur. 4) Install timing belt. If reusing old belt, ensure belt is installed in original direction of rotation. Ensure there is no slack in belt. 5) Move timing belt tensioner plate up with nger pressure, and loosely secure tensioner bolt. See Fig. 4. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Ensure timing marks are aligned. Tighten tensioner stud nut and then tensioner bolt to specication. See TORQUE SPECIFICATIONS. 6) Install timing belt outer cover and resonator. Make sure there are rubber seals installed between water pump and oil pump case, and another between water pump and cylinder head. Install crankshaft pulley. 7) On 1989-94 Swift with 8-valve engine, adjust valves. See VALVE CLEARANCE SPECIFICATIONS under ADJUSTMENTS. Install valve cover. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.
Courtesy of Suzuki of America Corp.

Fig. 2: Exploded View Of Timing Belt Components

Courtesy of Suzuki of America Corp.

Fig. 4: Releasing Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28) Camshaft Sprocket Bolt ................................................................ ................. 41-47 (56-64) Crankshaft Pulley-To-Crankshaft Bolt ........................................... ................... 7-10 (10-13) Crankshaft Sprocket Center Bolt Except 2000-01 Swift ................................................................................ 77-85 (105-115) 2000-01 Swift ........................................................................................................ 94 (130) Engine Mount Bolt (Swift) ......................................................................................... 40 (55) Timing Belt Tensioner Pulley Bolt ................................................. ................. 18-22 (24-30) INCH Lbs. (N.m)
Courtesy of Suzuki of America Corp.

Fig. 3: Aligning Timing Belt & Tensioner Installation (Swift) 1) If the tensioner was removed, install tensioner plate on tensioner. Ensure tensioner plate lug engages hole on rear of tensioner. Install tensioner spring. Tighten tensioner bolt nger tight to allow movement of tensioner.

Timing Belt Cover Bolt .................................................................. ................. 80-106 (9-12) Timing Belt Tensioner Stud Nut .................................................... ................. 80-106 (9-12) Water Pump Pulley Bolt ................................................................................ 89-115 (10-13)

SUZUKI
1.6L 4-Cylinder
TIMING BELT APPLICATION Application 1.6L 4-Cyl. SOHC Esteem 1995-99 .............................. Esteem (Canadian) 2000-02 .............................. Sidekick (8-Valve) 1989-95 .............................. 1996-98 .............................. Sidekick (16-Valve) 1989-91 .............................. 1992-98 .............................. Vitara (Includes Canadian) 1999-02 .............................. X-90 1996-98 ..............................
1

649

Labor Time

Component Belt Kit No. Part No.

CAUTION: With timing belt removed, DO NOT turn camshaft or crankshaft sprocket more than 90 degrees in either direction from aligned position. Doing so could damage pistons and valves.

2.3 Hours .. .. TCK212 .. ..... T212 2.3 Hours .. .. TCK212 .. ..... T212 3.6 Hours .. .. TCK164 .. ..... T164 3.6 Hours .. ...... ..... ...... ..... T212 4.0 Hours .. .. TCK164 .. ..... T164 4.0 Hours .. .. TCK212 .. ..... T212 4.0 Hours .. .. TCK212 .. ..... T212 4.0 Hours .. .. TCK212 .. ..... T212

1 1

1 1

With Air Conditioning, add .4 hours, except Esteem. For Esteem, add .2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1989-92 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1993-01 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals.
Courtesy of Suzuki of America Corp.

Fig. 1: Exploded View Of Timing Belt Components Removal (Sidekick, Vitara & X-90) 1) Disconnect negative battery cable. Remove accessory drive belts. Remove radiator cooling fan, water pump pulley, and fan shroud. It may be necessary to drain cooling system and remove upper radiator hose to remove fan shroud. 2) Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is NOT necessary to remove crankshaft center bolt. Remove timing belt cover. See Fig. 1. 3) Rotate crankshaft clockwise to align timing marks. See Figs. 2 and 3. Stamped E or punch mark on camshaft sprocket must straight up. Loosen timing belt tensioner bolt and stud nut. Move tensioner away from belt, and hand tighten bolt and nut. See Fig. 4. If reusing old belt, mark belt with an arrow indicating direction of rotation for installation reference. Remove timing belt. CAUTION: With timing belt removed, DO NOT turn camshaft more than 20 degrees in either direction from aligned position. To prevent piston and valve damage, DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Inspection (All Models) Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components. Installation (All Models) 1) If the tensioner was removed, install tensioner plate on tensioner. Ensure tensioner plate lug engages hole on rear of tensioner. Install tensioner spring. Tighten tensioner bolt nger tight to allow movement of tensioner. 2) On 1989-94 Sidekick with 8-valve engine, remove valve cover. Loosen all valve adjusting screws. On all models, ensure timing marks are still aligned. Install timing belt. If reusing old belt, ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack. 3) Loosen tensioner bolt and stud nut to place tension on timing belt. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Tighten tensioner stud nut and then tensioner bolt. See TORQUE SPECIFICATIONS.

ADJUSTMENTS
VALVE CLEARANCE SPECIFICATIONS
VALVE CLEARANCE SPECIFICATIONS Valve Cold In. (mm) Hot In. (mm) Intake ............................................ .005-.007 (.13-.18) ........................ .009-.011 (.23-.28) Exhaust ......................................... .006-.008 (.15-.20) ........................ .010-.011 (.25-.28)

REMOVAL & INSTALLATION


TIMING BELT
Removal (Esteem) 1) Disconnect negative battery cable. Remove right side engine under cover. Remove power steering and A/C compressor drive belts. 2) Remove A/C compressor and power steering pump with hoses attached, and secure out of way. Support engine from above or with oor jack under oil pan. Remove air cleaner case with air cleaner outlet hose. 3) From timing belt end of engine, remove engine mount and mounting bracket. Loosen water pump pulley bolts. Remove water pump drive belt and pulley. 4) Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is NOT necessary to remove crankshaft center bolt. Remove timing belt cover. See Fig. 1. 5) Rotate crankshaft clockwise to align timing marks. See Figs. 2 and 3. Stamped E on camshaft sprocket must point straight up. Loosen timing belt tensioner bolt and stud nut. Move tensioner away from belt, and hand tighten bolt and nut. See Fig. 4. 6) If reusing old belt, mark belt with an arrow indicating direction of rotation for installation reference. Remove timing belt.

650

SUZUKI
1.6L 4-Cylinder (Cont.)

Courtesy of Suzuki of America Corp.

Fig. 3: Aligning Timing Marks

Courtesy of Suzuki of America Corp.

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks 4) Ensure timing marks are aligned. Install timing belt cover and tighten bolts to specication. Reverse removal procedure to complete installation. If coolant was drained, ll and bleed air from system. Adjust drive belts to proper tension. Adjust valve lash on 1989-94 Sidekick with 8-valve engine. See VALVE CLEARANCE SPECIFICATIONS under ADJUSTMENTS.

Courtesy of Suzuki of America Corp.

Fig. 4: Releasing Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt (Esteem) ................................................................ 17 (23) Alternator Mount & Adjusting Bolts .............................................. ................. 13-21 (18-28) Camshaft Sprocket Bolt ............................................................................................ 43 (60) Crankshaft Sprocket Center Bolt .................................................. .......................... 80 (110) Engine Mount Bolt/Nut (Esteem) .............................................................................. 40 (55) Power Steering Pump Bolt (Esteem) ....................................................................... 25 (35)

TORQUE SPECIFICATIONS (Cont.) Application Ft. Lbs. (N.m) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Bolt ..................................................................... 106 (12) Timing Belt Cover Bolt .............................................................................................. 97 (11) Timing Belt Tensioner Stud Nut .................................................... ............................ 97 (11) Water Pump Pulley Bolt ............................................................................................ 97 (11)

SUZUKI
2.0L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Belt Part No.

651

2.0L 4-Cylinder Forenza 2004 ........................................................... 1.6 Hours ... ..... T309 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends that timing belt be inspected every 30,000 miles and be replaced every 60,000 miles.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Turn ignition off. Disconnect negative battery cable. Disconnect manifold air temperature (MAT) sensor electrical connector. Disconnect air cleaner outlet hose from throttle body. Disconnect breather tube from camshaft cover. 2) Remove air cleaner housing bolts and air cleaner housing. Loosen right front wheel lug nuts. Raise and support vehicle, and remove right front wheel. Remove right front wheel splash shield. 3) Using socket wrench, turn drive belt tensioner bolt clockwise to compress tensioner and release tension on serpentine drive belt. See Fig. 1. Remove serpentine drive belt. Remove crankshaft pulley bolts and crankshaft pulley. 4) Support engine assembly using Engine Assembly Support Fixture (J-28467-B) and Engine Assembly Support Channel (X-28467-560). See Fig. 2. Remove right engine mount bracket retaining bolts and right engine mount bracket. See Fig. 3. Remove front timing belt cover bolts and front timing belt cover. 5) Rotate crankshaft clockwise until timing mark on crankshaft gear is aligned with notch at bottom of rear timing belt cover. See Fig. 4. Align camshaft gears with respective notch on camshaft cover. See Fig. 5. If reusing old belt, mark belt with an arrow indicating direction of rotation for installation reference. Loosen timing belt automatic tensioner bolt. Turn hex-key tab counterclockwise to relieve belt tension and remove timing belt. See Fig. 6.
Courtesy of Suzuki of America Corp.

Fig. 2: Installing Engine Support Hardware

Courtesy of Suzuki of America Corp.

Fig. 3: Removing Right Engine Mount Bracket

Courtesy of Suzuki of America Corp.

Fig. 4: Aligning Crankshaft Gear Timing Mark


Courtesy of Suzuki of America Corp.

Fig. 1: Locating Drive Belt Tensioner

652

SUZUKI
2.0L 4-Cylinder (Cont.)
Inspection Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for wear and damage. Replace damaged components. Installation 1) Align crankshaft gear with notch at bottom of rear timing belt cover. See Fig. 4. Align camshaft gears with respective notch on camshaft cover. See Fig. 5. Install timing belt. If reusing old belt, ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. 2) Turn hex-key tab clockwise to tension belt until adjusting arm pointer aligns with notch. See Fig. 6. Install timing belt automatic tensioner bolt and tighten to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise 2 full turns using crankshaft pulley bolt. 3) Recheck timing belt automatic tensioner pointer. If pointer is not aligned with notch, repeat steps 1) and 2). Install front timing belt cover and tighten bolts to specication. See TORQUE SPECIFICATIONS. 4) Install right engine mount bracket and tighten bolts to specication. Ensure timing marks are aligned. Install timing belt cover and tighten bolts to specication. Install crankshaft pulley and tighten crankshaft pulley bolts to specication. See TORQUE SPECIFICATIONS. 5) Using socket wrench, turn drive belt tensioner bolt clockwise to compress tensioner. With tensioner compressed, install serpentine drive belt. Remove socket wrench and belt will tighten itself. Reverse removal procedure to complete installation.

Courtesy of Suzuki of America Corp.

Fig. 5: Aligning Timing Marks On Camshaft Gears

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolts ............................................................................................. 15 (20) Engine Mount Retaining Bolts .................................................................................. 33 (45) Engine Mount Bracket Retaining Bolts .................................................................... 41 (55) Timing Belt Automatic Tensioner Bolt ....................................................................... 18 (25) Timing Belt Idler Pulley Bolt & Nut .......................................................................... 18 (25) Wheel Lug Nuts ...................................................................................................... 74 (100) INCH Lbs. (N.m) Air Cleaner Housing Bolts ........................................................................................ 89 (10) Front Timing Belt Cover Bolts .................................................................................... 53 (6)

Courtesy of Suzuki of America Corp.

Fig. 6: Identifying Timing Belt Tensioner Components

TOYOTA
1.5L 4-Cylinder 1A-C & 3A-C
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

653

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: Do not bend or twist timing belt. Keep belt free of oil, water or dust. .... .. TCK070 .. ..... T070 .... .. TCK070 .. ..... T070 ... .. TCK070 .. ..... T070 Removal 1) Drain engine coolant. Remove radiator. Remove air cleaner assembly. Remove accessory drive belts. Remove water pump pulley. 2) If equipped with A/C, remove A/C drive belt idler pulley with bracket. Remove PCV valve from valve cover. Remove valve cover. 3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Timing notch on crankshaft pulley must align with 0 timing mark on timing belt cover. 4) Ensure cylinder No. 1 rocker arms are loose and cylinder No. 4 rocker arms are tight. If conditions are not as described, rotate crankshaft one complete revolution. 5) Holding crankshaft stationary, remove crankshaft pulley center bolt. Remove crankshaft pulley. 6) Remove timing belt covers and gaskets. Remove timing belt guide. See Fig. 1. If reusing old timing belt, mark belt with arrow indicating direction of rotation. Also place mating marks on timing belt and camshaft timing pulley. Place mating marks on timing belt and crankshaft timing pulley. 7) Loosen idler pulley retaining bolt. Move idler pulley away from timing belt and tighten retaining bolt. Remove timing belt.

1.5L 4-Cyl. Corolla Tercel 1980-82 A/T ................................. .... 2.6 Hrs. M/T ................................. .... 2.8 Hrs. Tercel 1983-86 ............................ ... 1 2.7 Hrs. 1987-88 Wagon 3A-C ............................. ... 1 2.7 Hrs.
1

... .. TCK070 .. ..... T070

With Air Conditioning, add .3 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1980-85 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions.

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

Fig. 1: Exploded View of Timing Belt & Components

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 specied. 3) Measure tension of spring at installed length. Tension should be 8 lbs. at 1.976 (3.83 kg at 50.2 mm) up to 1986 models. For 1987-88 models, tension should be 15.4 lbs. at 1.976 (7 kg at 50.2 mm). Replace tension spring if necessary.

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

Fig. 4: Installing Used Timing Belt

Fig. 2: Measuring Tensioner Spring Free Length Installation 1) Ensure crankshaft and camshaft timing pulley timing marks are correctly aligned. See Fig. 3. 2) Install idler pulley and tension spring (if removed). Secure idler pulley as far to the left as possible and retighten bolt. 3) Install timing belt on engine. If reusing old belt, align mating marks made on disassembly. Ensure belt is installed in original direction of rotation. See Fig. 4. 4) Loosen idler pulley retaining bolt, allowing tension spring to move pulley against timing belt. Use crankshaft retaining bolt to rotate crankshaft clockwise 2 full rotations from TDC to TDC. Ensure camshaft and crankshaft timing marks are still aligned. If they are not aligned, remove and reinstall timing belt. 5) Tighten idler pulley mounting bolt. Measure timing belt tension by applying 4.4 lbs. (2 kg) pressure to belt. See Fig. 5. Timing belt deection should be .236-.276 (6-7 mm). If not, readjust timing belt tension. 6) Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten crankshaft pulley center bolt to specication. See TORQUE SPECIFICATIONS. 7) Install water pump pulley. Install A/C idler pulley (if equipped). Install accessory drive belts. Adjust drive belts to proper tension. 8) Install valve cover and air cleaner assembly. Install radiator. Fill and bleed cooling system.

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

Fig. 5: Checking Timing Belt Tension

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 34 (47) Crankshaft Pulley Bolt ............................................................................................. 87 (118) Idler Pulley Retaining Bolt ........................................................................................ 27 (37)

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

Fig. 3: Aligning Timing Marks

TOYOTA
1.5L 4-Cylinder 3E
TIMING BELT APPLICATION Application
1

655

REMOVAL & INSTALLATION


Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

1.5L 4-Cyl. 3E Tercel Sedan 1987 ................................. .... 2.3 Hrs. ............. ......... ..... T136 Tercel 1988-94 ............................ .... 2.3 Hrs. .... .. TCK233 .. ..... T233
1

TIMING BELT
CAUTION: On models equipped with air bag, DO NOT start work until after 90 seconds from time ignition switch is turned to LOCK position and negative battery cable is disconnected. Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right side engine under cover (splash) shield. Lower vehicle. Remove accessory drive belts. 2) Disconnect accelerator cable. On A/T models, disconnect throttle cable. On all models, disconnect PCV hoses. On 1987-91 models, remove air cleaner assembly. 3) On all models, remove bolt, ground strap and vacuum transmitting valves with bracket on right engine mount. This is mount on timing belt end of engine.

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions.

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

Fig. 1: Exploded View Of Timing Belt & Components (1991-94 Shown; 1987-90 Use One-Piece Crankshaft Pulley)

656

TOYOTA
1.5L 4-Cylinder 3E (Cont.)
5) If timing marks do align, tighten No. 1 idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Install timing belt guide. Install timing belt covers. 6) Install crankshaft pulley. Holding crankshaft pulley stationary, tighten crankshaft pulley bolt to specication. On 1991-94 models, install accessory drive pulley. 7) On all models, install spark plugs. Install valve cover. Install right engine mount to engine and body. Install vacuum switching valves and engine ground strap to engine mount (if equipped). 8) Connect negative battery cable. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

4) Using oor jack, support weight of engine from below. Remove right engine mount from timing belt end of engine. Remove valve cover. Remove spark plugs. 5) Set No. 1 cylinder at TDC on compression stroke. Turn crankshaft pulley, and align groove on crankshaft with 0 mark on timing belt cover. Ensure rocker arms on No. 1 cylinder are loose. If not, turn crankshaft pulley one complete revolution. 6) On 1991-94 models with A/C and/or power steering, remove accessory drive pulley from crankshaft pulley. See Fig. 1. 7) Using Holder (09213-14010) or equivalent, hold crankshaft pulley. Loosen crankshaft pulley center bolt. Remove holder. Remove crankshaft pulley bolt. Use gear puller, remove crankshaft pulley. 8) Remove timing belt cover. Noting installed position for reassembly reference, remove timing belt guide. See Fig. 1. 9) If reusing old timing belt, place arrow on belt to indicate direction of rotation. Place mating marks on belt and crankshaft sprocket, and on camshaft sprocket. 10) Remove timing belt tension spring. See Fig. 1. Loosen No. 1 idler pulley bolt and push pulley to left as far as it will go. See Fig. 1. Tighten bolt. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure No. 1 and No. 2 idler pulleys rotate freely. Inspect all sprockets for damage. Replace damaged components. 2) Measure free length of tension spring. See Fig. 2. Tension spring free length should be 1.528 (38.8 mm) on 1987-89 engines. On 1990-94 engines, free length should be 1.512 (38.4 mm). Replace tension spring if free length is not as specied. 3) Measure tension spring at specied installed length. For 1987-89 engines, spring tension should be 18.3 lbs. at 2.157 (8.3 kg at 54.8 mm). For 1990-94 engines, spring tension should be 11.3 lbs. at 2.028 (5.11 kg at 51.5 mm). Replace spring if tension is not as specied.

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

Fig. 3: Aligning Camshaft Knock Pin With Bearing Cap

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

Fig. 2: Measuring Tensioner Spring Free Length NOTE: Before installing timing belt, remove any oil or water from camshaft sprocket, crankshaft sprocket and idler pulleys. Installation 1) If camshaft sprocket was removed, align knock pin with No. 1 camshaft bearing cap mark. See Fig. 3. Install camshaft sprocket with 3E mark facing up. See Fig. 4. Tighten camshaft sprocket bolt to specication. See TORQUE SPECIFICATIONS. 2) Align crankshaft sprocket timing mark with mark on oil pump housing. See Fig. 4. If removed, install No. 1 idler pulley. Move No. 1 idler pulley as far left as it will go, and temporarily tighten bolt. 3) Install No. 2 idler pulley (if removed). Install timing belt on engine. See Fig. 5. If reusing old belt, ensure all mating marks are aligned and belt is installed in original direction of rotation. 4) Loosen No. 1 idler pulley bolt, and install pulley tension spring. Temporarily install crankshaft pulley bolt. Turn crankshaft CLOCKWISE 2 revolutions from TDC to TDC. Realign camshaft and crankshaft sprocket timing marks. If timing marks do not align, remove and reinstall timing belt.

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

Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

TOYOTA
1.5L 4-Cylinder 3E (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

657

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

Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................................................................ 18 (24) A/C Compressor Mounting Bracket Bolt .................................................................. 20 (27) Accessory Drive Belt Pulley Bolt .............................................................................. 14 (19) Alternator Bracket Bolt .............................................................................................. 13 (18) Camshaft Sprocket Bolt ............................................................................................ 37 (51) Crankshaft Pulley Bolt ........................................................................................... 112 (152) Engine Mount Mount-To-Cylinder Block Bolt/Nut ........................................................................... 47 (64) Through-Bolt 1987-90 .................................................................................................................. 47 (64) 1991-94 .................................................................................................................. 54 (73) Idler Pulley Bracket Bolt 12 mm ..................................................................................................................... 20 (27) 14 mm ..................................................................................................................... 27 (37) No. 1 Idler Pulley Bolt .............................................................................................. 13 (18) No. 2 Idler Pulley Bolt .............................................................................................. 20 (27) Power Steering Bracket Bolt ..................................................................................... 32 (43) Power Steering Pump Bolt ....................................................................................... 32 (43) Spark Plugs ............................................................................................................... 13 (18) Timing Belt Idler Mount Bolt ..................................................................................... 27 (37) Water Pump Bolt/Nut ................................................................................................ 13 (18) INCH Lbs. (N.m) No. 1 Timing Belt Cover Bolt .................................................................................. 66 (7.5) No. 2 Timing Belt Cover Bolt .................................................................................. 66 (7.5) Valve Cover Nut ....................................................................................................... 61 (6.5)

Fig. 5: Routing Timing Belt

658

TOYOTA
1.5L 4-Cylinder 5E-FE
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

1.5L 4-Cyl. Paseo (Includes Canadian) 1992-95 ............................... 1996-99 ............................... Tercel (Includes Canadian) 1995-98 ............................... 1999 ....................................
1

2.5 Hours ... .. TCK208 .. ..... T208 3.5 Hours ... .. TCK208 .. ..... T208 2.8 Hours ... .. TCK208 .. ..... T208 2.8 Hours ... .. TCK208 .. ..... T208

2) Measure tension required to extend tension spring to 1.866 (47.40 mm). Replace tension spring if tension is not 7.3 lbs. (3.3 kg). Installation 1) If removed, install crankshaft sprocket with ange toward engine. Install tension spring and No. 1 idler pulley with bolt loosely installed. DO NOT tighten bolt at this time. Move No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure all sprockets and idler pulleys are clean. Temporarily install crankshaft pulley bolt, and rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 or 3. CAUTION: If reusing timing belt, ensure reference marks on timing belt align with those placed on all sprockets and timing belt is installed in original direction of rotation. 2) Remove crankshaft pulley bolt. Install timing belt on crankshaft sprocket, oil pump drive sprocket, No. 1 idler pulley and then No. 2 idler pulley in sequence. Ensure belt is tensioned between crankshaft sprocket and camshaft sprocket. 3) Loosen No. 1 idler pulley bolt, allowing tension spring to move pulley against timing belt. Rotate crankshaft clockwise 2 full turns from TDC to TDC. Ensure camshaft timing marks are still aligned. If all timing marks are aligned, tighten No. 1 idler pulley bolt to specication. See TORQUE SPECIFICATIONS. 4) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install No. 1 and No. 3 timing belt covers and gasket. Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. 5) Install accessory drive belt pulley on front of crankshaft and tighten bolt to specication. See TORQUE SPECIFICATIONS. Install gasket and No. 2 timing belt cover. 6) To install remaining components, reverse removal procedure. If valve cover was removed, apply sealant at ends of camshafts. See Fig. 4. To ensure proper mount alignment, install all right (timing belt side) engine mount bolts/nuts before tightening to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

With Air Conditioning and Power Steering, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1992-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions. For 1998 model year, the manufacturer recommends the belt be replaced every 90,000 miles for severe service operating conditions. For 1999 model year, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove right engine undercover. Remove accessory drive belts. Remove charcoal canister for access to timing belt covers. 2) Slightly raise engine to remove weight from right (timing belt side) engine mount. Remove the through-bolt and right engine mount insulator. Remove No. 2 timing belt cover and gasket. See Fig. 1. 3) Rotate crankshaft clockwise (viewed from timing belt end of engine) so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. Ensure timing mark on crankshaft pulley aligns with 0. 4) With cylinder No. 1 at TDC on compression stroke, ensure hole (5E timing mark) on camshaft sprocket aligns with timing mark on camshaft bearing cap. See Fig. 2. If timing mark is not aligned, rotate crankshaft clockwise one revolution (360 degrees). 5) Remove bolt and accessory drive belt pulley from front of crankshaft pulley. Using Pulley Holder (SST 09213-14010) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley, and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. 6) Remove No. 3 and No. 1 timing belt cover and gasket. See Fig. 1. Note direction of timing belt guide installation for installation reference. See Fig. 2. Remove timing belt guide. CAUTION: If reusing timing belt, mark direction of timing belt rotation and place reference mark on timing belt at all sprockets for reassembly reference. 7) Remove tension spring from No. 1 idler pulley. See Fig. 1. Loosen No. 1 idler pulley bolt. Move No. 1 idler away from timing belt as far as possible and tighten bolt. Remove timing belt, idler pulley bolt and No. 2 idler pulley (if necessary). 8) If removing crankshaft sprocket, use soft-faced hammer to lightly tap sprocket from crankshaft. DO NOT pry on outer edges of sprocket. Also, note position of outer timing belt guide on crankshaft sprocket. Concave surface should face away from engine. Inspection 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys rotate freely. Inspect all sprockets for damage. Replace damaged components. Measure free length of tension spring. Replace tension spring if free length is not 1.512 (38.40 mm).

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

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA
1.5L 4-Cylinder 5E-FE (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

659

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

Fig. 2: Aligning Timing Marks

Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................................................................ 18 (24) A/C Compressor Mounting Bracket Bolt .................................................................. 20 (27) A/C Idler Pulley Bolt 12 mm Bolt .............................................................................................................. 20 (27) 14 mm Bolt .............................................................................................................. 27 (37) Accessory Drive Belt Pulley Bolts ............................................................................ 14 (19) Camshaft Sprocket Bolt ............................................................................................ 37 (51) Crankshaft Pulley Bolt ........................................................................................... 114 (155) Engine Mount Right (Timing Belt Side) Mount-To-Cylinder Block Bolt/Nut ........................................................................... 47 (64) Through-Bolt ............................................................................................................ 54 (73) Idler Pulley Bolt No. 1 Idler Pulley .................................................................................................... 13 (18) No. 2 Idler Pulley .................................................................................................... 20 (27) Oil Pump Drive Sprocket Nut ................................................................................... 27 (37) Power Steering Pump Adjusting Bracket Bolt .......................................................... 15 (20) Power Steering Pump Bolt Lower Bolt ............................................................................................................... 29 (39) Upper Bolt ............................................................................................................... 32 (43) Spark Plugs ............................................................................................................... 13 (18) Water Pump Bolt/Nut ................................................................................................ 13 (18) INCH Lbs. (N.m) Valve Cover Nut ....................................................................................................... 61 (6.9)

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

Fig. 3: Aligning Crankshaft Timing Marks

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

Fig. 4: Cylinder Head Sealant Application Areas

660

TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. DOHC Corolla FX-16, GTS & Sport (4A-GE) 1985-88 ............................ .......... 1 .......... .. Corolla GTS (4A-GE, 4A-GELC) 1989-91 ............................ .... 1.6 Hrs. .... .. MR2 1985-88 ............................ ... 2 2.7 Hrs. ... .. 1989 ................................. ... 2 2.7 Hrs. ... ..
1 2

TCK176 ........ T112 TCK176 .. ..... T176 TCK176 ........ T112 TCK176 .. ..... T176

Labor time is 2.2 hours with FWD, or 1.6 hours with RWD. With Air Conditioning, add .5 hours.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 1: Aligning Timing Marks

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1985 model year, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-91 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Measuring Tensioner Spring Free Length 2) Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. 3) Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. 4) Measure timing belt deection midway between camshaft sprockets. See Fig. 3. If deection is not correct, readjust timing belt tension. 5) Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten center bolt to specication. See TORQUE SPECIFICATIONS. 6) Install water pump pulley and fan assembly. Install generator drive belt. Install power steering pump pulley and drive belt. Adjust drive belt to proper tension.

REMOVAL & INSTALLATION


TIMING BELT
Removal (1985-87 RWD Corolla) 1) Remove air cleaner intake duct above radiator. If equipped with power steering, remove power steering belt. Remove the power steering pump with hoses attached and set aside. 2) Loosen water pump pulley bolts. Remove cooling fan belt. Remove cooling fan assembly. Remove spark plugs. 3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Crankshaft pulley notch must align with 0 timing mark on lower timing belt cover. With valve cover oil ller cap removed, cavity in camshaft should be visible. If not, turn crankshaft one complete revolution. 4) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing belt covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 5) If reusing timing belt, place mating marks on timing belt and camshaft sprockets, and on timing belt and crankshaft sprocket. Also place arrow on belt indicating original direction of rotation. 6) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (1985-87 RWD Corolla) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) If noticeable wear is found on belt teeth, check timing cover gasket for damage or improper installation. Ensure sprocket teeth are free of foreign material. 3) Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713 (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specication. Installation (1985-87 RWD Corolla) 1) If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt.

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

Fig. 3: Checking Timing Belt Deection Removal (1985-88 FWD Corolla) 1) Raise and support vehicle. Remove right front wheel. Remove engine under cover. Drain engine coolant. 2) If equipped with cruise control, disconnect accelerator cable and cruise control cable from actuator. Disconnect cruise control electrical connector. Remove cruise control actuator. Remove windshield washer tank and set aside.

TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE (Cont.)
3) On FX-16 models, remove ignition coil with wires attached and secure out of way. On all models, remove the upper radiator hose. 4) Loosen water pump pulley bolts. Remove all accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch on crankshaft pulley must align with 0 timing mark on timing belt cover. Remove oil ller cap from valve cover. Cavity in camshaft should be visible in hole. If not, turn crankshaft one complete revolution. 5) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing belt covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 6) If reusing timing belt, place mating marks on timing belt and camshaft sprockets, and on timing belt and crankshaft sprocket. Also place arrow on belt indicating original direction of rotation. 7) Support weight of engine with oor jack. Remove engine mount from timing belt end of engine. 8) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (1985-88 FWD Corolla) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713 (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specication. Installation (1985-88 FWD Corolla) 1) If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt. 2) Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. 3) Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. 4) Measure timing belt deection midway between camshaft sprockets. See Fig. 3. If deection is not correct, readjust timing belt tension. 5) Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten center bolt to specication. See TORQUE SPECIFICATIONS. 6) Install engine mount to timing belt end of engine. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension. Install right front wheel and engine under cover. 8) Install upper radiator hose. Install windshield washer tank. On FX-16, install ignition coil. On all models, install cruise control actuator (if equipped). Fill radiator with coolant and bleed air from system. Removal (MR2) 1) Raise and support vehicle. Remove right front wheel. Remove engine under cover. 2) Loosen water pump pulley bolts. Remove all accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch on crankshaft pulley must align with timing mark on timing belt cover. Remove oil ller cap from valve cover. Cavity in camshaft should be visible in hole. If not, turn crankshaft one complete revolution. 3) Support weight of engine with oor jack. Remove engine mount through bolt from timing belt end of engine. 4) Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing belt covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 5) If reusing timing belt, place mating marks on timing belt and camshaft sprockets, and on timing belt and crankshaft sprocket. Also place arrow on belt indicating original direction of rotation.

661

6) Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (MR2) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713 (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specication. Installation (MR2) 1) If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt. 2) Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. 3) Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. 4) Measure timing belt deection midway between camshaft sprockets. See Fig. 3. If deection is not correct, readjust timing belt tension. 5) Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten center bolt to specication. See TORQUE SPECIFICATIONS. 6) Install engine mount to timing belt end of engine. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install right front wheel and engine under cover. 7) Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 34 (47) Crankshaft Pulley Bolt Corolla (FWD) ..................................................................................................... 101 (137) Corolla (RWD) ..................................................................................................... 105 (142) MR2 1985-86 ................................................................................................................ 87 (118) 1987 ................................................................................................................... 105 (142) 1988-89 .............................................................................................................. 101 (137) Engine Mounts (Corolla FWD) FX-16 Through-Bolt .......................................................................................................... 58 (78) Except FX-16 Mount-To-Engine Bracket Nut ............................................................................... 34 (52) Through-Bolt .......................................................................................................... 64 (87) Engine Mount (MR2) Through-Bolt 1985-87 .................................................................................................................. 58 (78) 1988-89 .................................................................................................................. 43 (58) Power Steering Pump-To-Bracket Bolts ................................................................... 43 (58) Power Steering Pump Pulley Bolt (Corolla RWD) ................................................... 29 (39) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................................................................. 27 (37) Water Pump Bolts ..................................................................................................... 11 (15) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Valve Cover Bolts ..................................................................................................... 69 (7.8)

662

TOYOTA
1.6L 4-Cylinder SOHC
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. SOHC Corolla (FWD) 1984-88 .............................. 1 3.1 Hours .. .. Corolla (RWD) 1983 ................................... 2 2.5 Hours .. .. 1984-87 ............................... 1.6 Hours ... .. Corolla FX 1987-88 ............................... 2.5 Hours ... .. Corolla SR5 1985-87 ............................... 1.6 Hours ... .. 1988 (FWD) ........................ 3.1 Hours ... ..
1 2

TCK070 .. ..... T070 TCK070 .. ..... T070 TCK070 .. ..... T070 TCK070 .. ..... T070 TCK070 .. ..... T070 TCK036 .. ..... T036
Courtesy of Toyota Motor Sales, U.S.A., Inc.

With Air Conditioning and Power Steering, add .4 hours. With Air Conditioning, add .2 hours. With Power Steering, add .1 hours.

Fig. 1: Aligning Timing Marks For Timing Belt Installation 3) Measure tension of spring at installed length. Tension should be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if necessary.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1983-85 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Measuring Tensioner Spring Free Length Installation (FWD Models) 1) Insert timing belt between engine mount and body. Lower engine, and install engine mount through-bolt through body and mount insulator. Tighten bolt to specication. See TORQUE SPECIFICATIONS. 2) Align camshaft sprocket timing hole with camshaft bearing cap mark. Align timing marks on oil pump body and crankshaft timing sprocket. See Figs. 1 and 3. 3) Install idler pulley (tensioner) and spring (if removed). Pry idler pulley toward left and temporarily tighten bolt. Install timing belt. If installing used belt, ensure mating marks are aligned to camshaft sprocket and crankshaft sprocket. See Fig. 4. Ensure arrow on belt points in original direction of rotation. 4) Loosen timing belt idler pulley bolt so that pulley applies tension to belt. Rotate crankshaft 2 revolutions from TDC to TDC. Recheck alignment of sprockets and timing belt. Tighten idler pulley (tensioner) bolt to specication. See TORQUE SPECIFICATIONS. 5) Check timing belt deection. See Fig. 5. If timing belt deection is not correct, readjust timing belt tension. 6) Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley and tighten bolt to specication. 7) Install water pump pulley. Install valve cover. Install air cleaner assembly. Install A/C compressor to engine mount. Install generator. Install valve cover. Apply sealant to cylinder head when installing valve cover. 8) Install upper radiator hose. Rell cooling system. 9) Install right under cover. Install right front wheel. Adjust drive belts to proper tension. Removal (RWD Models) 1) Remove power steering and A/C compressor drive belts (if equipped). On models with power steering, remove power steering pump with hoses attached and set aside. 2) On all models, remove air cleaner assembly. Loosen water pump pulley bolts. Remove cooling fan drive belt. Remove cooling fan. Disconnect PCV hose and remove valve cover. 3) Hold crankshaft stationary and remove crankshaft pulley center bolt. Remove crankshaft pulley using a gear puller. 4) Remove timing belt covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 5) Rotate crankshaft so that No. 1 cylinder is at TDC on compression stroke. Align crankshaft and camshaft timing marks. See Figs. 1 and 3.

REMOVAL & INSTALLATION


TIMING BELT
Removal (FWD Models) 1) Raise and support vehicle. Remove right front wheel. Remove right undercover from wheelwell. Drain engine coolant. Disconnect upper radiator hose. 2) Loosen water pump pulley bolts. Remove all accessory drive belts. Remove generator with wires attached and set aside. Remove A/C compressor from mount with hoses attached, and set aside. Remove water pump pulley. 3) Remove upper and center timing belt covers. Turn crankshaft until No. 1 cylinder is at TDC of compression stroke. Crankshaft pulley notch must align with 0 timing mark on lower timing belt cover. Remove valve cover. Camshaft sprocket timing mark must align with mark on bearing cap. See Fig. 1. 4) Hold crankshaft stationary and remove crankshaft pulley center bolt. Remove crankshaft pulley using a gear puller. Remove lower timing belt cover. 5) Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 6) If reusing timing belt, place mating marks on belt and sprockets for reassembly reference. See Fig. 4. Place arrow on belt to indicate original direction of rotation. 7) Loosen idler pulley bolt. Push idler pulley as far left as possible and temporarily tighten center bolt. 8) Support weight of engine from below with a oor jack. Working from below the vehicle, remove the 4 lower engine mount bolts from the engine crossmember. Remove engine mount through-bolt from mount at timing belt end of engine. Raise engine slightly and remove timing belt. Inspection (FWD Models) 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulley rotates freely. Inspect all sprockets for damage. Replace damaged components. 2) Measure free length of tension spring. Free length should be 1.705 (43.3 mm). See Fig. 2. Replace tension spring if free length is not as specied.

TOYOTA
1.6L 4-Cylinder SOHC (Cont.)

663

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

Fig. 3: Aligning TDC Marks On Crankshaft Sprocket & Oil Pump Body

7) Loosen idler pulley bolt. Push idler pulley as far left as possible and temporarily tighten center bolt. Remove timing belt. Inspection (RWD Models) 1) Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulley rotates freely. Inspect all sprockets for damage. Replace damaged components. 2) Measure free length of tension spring. Free length should be 1.705 (43.3 mm). See Fig. 2. Replace tension spring if free length is not as specied. 3) Measure tension of spring at installed length. Tension should be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if necessary. Installation (RWD Models) 1) Align camshaft sprocket timing hole with camshaft bearing cap mark. Align timing marks on oil pump body and crankshaft timing sprocket. See Figs. 1 and 3. 2) Install idler pulley (tensioner) and spring (if removed). Pry idler pulley toward left and temporarily tighten bolt. Install timing belt. If installing used belt, ensure mating marks are aligned to camshaft sprocket and crankshaft sprocket. See Fig. 4. Ensure arrow on belt points in original direction of rotation. 3) Loosen timing belt idler pulley bolt so that pulley applies tension to belt. Rotate crankshaft 2 revolutions from TDC to TDC. Recheck alignment of sprockets and timing belt. Tighten idler pulley (tensioner) bolt to specication. See TORQUE SPECIFICATIONS. 4) Check timing belt deection. See Fig. 5. If timing belt deection 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 specication. Install valve cover. Install air cleaner assembly. 6) To complete installation, reverse removal procedure. Tighten bolts and nuts to specication. See TORQUE SPECIFICATIONS. Apply sealant to cylinder head when installing valve cover. Adjust drive belts to proper tension.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Block Bolts (4) .......................................................................... 18 (25) Camshaft Sprocket Bolt ............................................................................................ 34 (47) Crankshaft Pulley Bolt ............................................................................................. 87 (118) Engine Mount Through-Bolt (FWD Models) ............................................................. 58 (78) Engine Mount-To-Crossmember Bolt ........................................................................ 29 (39) Timing Belt Idler Pulley Bolt ..................................................................................... 27 (37) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Valve Cover Bolts ..................................................................................................... 69 (7.8)

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

Fig. 4: Installing Timing Belt 6) If reusing timing belt, place mating marks on belt and sprockets for reassembly reference. See Fig. 4. Place arrow on belt to indicate original direction of rotation.

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

Fig. 5: Measuring Timing Belt Tension Deection

664

TOYOTA
1.6L & 1.8L 4-Cylinder DOHC
Labor Time 1 Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

1.6L 4-Cyl. DOHC Celica 1990-92 ............................... 1993 .................................... Corolla (4A-FE) 1988-92 ............................... 1993-97 ............................... 1.8L 4-Cyl. DOHC Celica 1994-97 ............................... Corolla 1993-97 ...............................
1

3.1 Hours ... .. TCK036 .. ..... T036 3.1 Hours ... ...... ..... ...... ..... T239 2.6 Hours ... .. TCK036 .. ..... T036 2.2 Hours ... .. TCK236 .. ..... T236

2.8 Hours ... .. TCK235 .. ..... T235 2.2 Hours ... .. TCK235 .. ..... T235

With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

REMOVAL & INSTALLATION


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 oor jack. Remove engine mount at timing belt end of engine. 3) Loosen water pump pulley bolts, then remove all accessory drive belts. 4) On 1.8L (7A-FE engine), remove A/C compressor front engine mount with hoses attached. Remove A/C compressor mount from engine. 5) On 1.6L and 1.8L engine, remove upper and center timing belt covers. 6) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch in crankshaft pulley must align with 0 timing mark on timing belt cover. Hole in camshaft timing pulley must align with mark on bearing cap. See Fig. 1. 7) Remove water pump pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove lower timing belt cover. See Fig. 2. Remove timing belt guide (large washer) from crankshaft sprocket. 8) If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 3. Place arrow on belt to indicate original direction of rotation. 9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt. Inspection (Celica) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) Check free length of idler pulley tension spring. See Fig. 4. Replace spring if free length is not 1.51 (38.4 mm) for 1.6L (4A-FE engine), or 1.252 (31.8 mm) for 1.8L (7A-FE engine). 3) Check tension at installed length. Tension should be 8.8 lbs. at 1.976 (4 kg at 50.2 mm) for 1.6L (4A-FE engine), or 11.7 lbs. at 1.480 (5.3 kg at 37.6 mm) for 1.8L (7A-FE engine). If tension is not as specied, replace spring. Installation (Celica) 1) Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft Woodruff key will be at 12 oclock position. On

Fig. 1: Aligning Timing Marks (1.6L Shown; 1.8L Uses Same Camshaft Sprocket Timing Mark)

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

Fig. 2: Exploded View Of Timing Belt & Components (1993-97 1.6L & 1.8L) 1.6L engine, timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 1. Crankshaft sprocket on 1.8L engine does not have notch. On 1.6L and 1.8L, hole in camshaft sprocket must align with mark on bearing cap. NOTE: Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Install timing belt guide on crankshaft (dished side facing away from belt). 2) Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt.

TOYOTA
1.6L & 1.8L 4-Cylinder DOHC (Cont.)

665

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

Fig. 3: Placing Mating Marks On Timing Belt & Sprockets

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

Fig. 5: Checking Timing Belt Deection

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

Fig. 4: Measuring Tensioner Spring Free Length 3) Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Install timing belt guide on crankshaft (dished side facing away from belt). 4) Install lower timing belt cover. Install crankshaft pulley. Install crankshaft pulley center bolt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC. 5) Ensure crankshaft pulley notch aligns with 0 timing mark on lower timing belt cover. Ensure camshaft sprocket timing marks align. If timing marks are not aligned, remove and reinstall timing belt. If timing marks are aligned, nal tighten crankshaft pulley center bolt. See TORQUE SPECIFICATIONS. 6) With idler pulley bolt still loose, measure timing belt deection at midway point of belt longest run. See Fig. 5. Deection should be .20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deection is not as specied, readjust tension on belt by moving idler pulley (tensioner). 7) Tighten idler pulley bolt. Install upper and center timing belt covers. When installing valve cover, ensure sealant is apply in correct positions. See Fig. 6. 8) Install water pump pulley. On 1.8L engine, install A/C compressor mount to engine. Install A/C compressor. 9) On 1.6L and 1.8L engines, install all accessory drive belts. Adjust belts to proper tension. Final tighten water pump pulley bolts. 10) Install engine mount to timing belt end of engine. Install front wheel and engine under cover. Install cruise control actuator (if equipped). Removal (1988-92 Corolla) 1) Raise and support vehicle. Remove right front wheel and engine undercover. Remove washer tank. Loosen water pump pulley bolts, then remove all accessory drive belts. Remove valve cover. 2) Disconnect engine wiring harness from upper timing belt cover. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch in crankshaft pulley must align with 0 timing mark on timing belt cover. 3) Support weight of engine with a oor jack. Remove engine mount at timing belt end of engine. 4) Remove water pump pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove timing belt covers. Remove timing belt guide (large washer) from crankshaft sprocket. 5) If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 3. Place arrow on belt to indicate original direction of rotation. 6) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt.

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

Fig. 6: Identifying Cylinder Head Sealant Application Areas Inspection (1988-92 Corolla) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) Check free length of idler pulley tension spring. See Fig. 4. Replace spring if free length is not 1.51 (38.4 mm). Check tension at installed length. Tension should be 8.8 lbs. at 1.976 (4 kg at 50.2 mm). Installation (1988-92 Corolla) 1) Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft key will be at 12 oclock position, and timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 1. Hole in camshaft sprocket must align with mark on bearing cap. NOTE: Engine should be cold when installing timing belt. 2) Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt. 3) Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC. 4) Recheck timing mark alignment. If timing marks are not aligned, remove and reinstall timing belt. 5) With idler pulley bolt still loose, measure timing belt deection at midway point of belt longest run. See Fig. 5. Deection should be .20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deection is not as specied, readjust tension on belt by moving idler pulley (tensioner). 6) Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Install timing belt guide to crankshaft sprocket. 7) Install timing belt covers. Install crankshaft pulley. Tighten center bolt to specication. See TORQUE SPECIFICATIONS. When installing valve cover, ensure sealant is apply in correct positions. See Fig. 6.

666

TOYOTA
1.6L & 1.8L 4-Cylinder DOHC (Cont.)
NOTE: Engine should be cold when installing timing belt. 2) Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt. 3) Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Install timing belt guide on crankshaft (dished side facing away from belt). 4) Install lower timing belt cover. Install crankshaft pulley. Install crankshaft pulley center bolt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC. 5) Ensure crankshaft pulley notch aligns with 0 timing mark on lower timing belt cover. Ensure camshaft sprocket timing marks align. If timing marks are not aligned, remove and reinstall timing belt. If timing marks are aligned, nal tighten crankshaft pulley center bolt. See TORQUE SPECIFICATIONS. 6) With idler pulley bolt still loose, measure timing belt deection at midway point of belt longest run. See Fig. 5. Deection should be .20-.24 with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. If deection is not as specied, readjust tension on belt by moving idler pulley (tensioner). 7) Tighten idler pulley bolt to specication. See TORQUE SPECIFICATIONS. 8) Install upper and center timing belt covers. When installing valve cover, ensure sealant is apply in correct positions. See Fig. 6. 9) Install water pump pulley. Install A/C compressor mount to engine. Install A/C compressor. 10) Install all accessory drive belts. Adjust belts to proper tension. Final tighten water pump pulley bolts. 11) Install engine mount to timing belt end of engine. On 1995-97 models, ensure engine ground strap is connected to ground wire on passenger side shock tower. Install front wheel and engine undercover. Install cruise control actuator (if equipped).

8) Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension. Final tighten water pump pulley bolts. 9) Install front wheel and engine undercover. Removal (1993-97 Corolla) 1) Raise and support vehicle. Remove right front wheel and engine undercover. Lower vehicle. 2) Remove windshield washer tank. Remove cruise control actuator from right side of engine compartment. Loosen water pump pulley bolts, then remove all accessory drive belts. Remove water pump pulley. Remove valve cover. 3) On models with A/C, remove A/C compressor from mount bracket with hoses attached, and set aside. Remove A/C compressor mount bracket from engine. 4) On all models, disconnect engine wiring harness from upper timing belt cover. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch in crankshaft pulley must align with 0 timing mark on timing belt cover. 5) Remove upper timing belt cover. With No. 1 cylinder at TDC, hole in camshaft sprocket must align with mark on bearing cap. See Fig. 1. 6) Support weight of engine with a oor jack. Remove engine mount at timing belt end of engine. 7) Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove center and lower timing belt covers. Remove timing belt guide (large washer) from crankshaft sprocket. 8) If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 3. Place arrow on belt to indicate original direction of rotation. 9) Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt. Inspection (1993-97 Corolla) 1) Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on at side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 2) Check free length of idler pulley tension spring. See Fig. 4. See TENSION SPRING FREE LENGTH (1993-97 COROLLA) table. Replace spring if free length is not to specication. 3) Check tension at installed length. See TENSION SPRING INSTALLED TENSION (1993-97 COROLLA) table. Replace spring if tension is not to specication. TENSION SPRING FREE LENGTH (1993-97 COROLLA) Application Free Length In (mm) 1993-94 1.6L ................................................................................................. 1.453 (36.9) (4A-FE) ............. 1995-97 1.6L ................................................................................................. 1.717 (43.6) (4A-FE) ............. 1993-97 1.8L ................................................................................................. 1.252 (31.8) (7A-FE) ............. TENSION SPRING INSTALLED TENSION (1993-97 COROLLA) Application Tension At Installed Length Lbs. At In. (Kg At mm) 1993-94 1.6L ............................................................................ 13 at 1.988 (5.9 at 50.5) (4A-FE) ............. 1993-94 1.8L ....................................................................... 26.5 at 1.988 (12.4 at 50.5) (7A-FE) ............. 1995-97 1.6L ........................................................................... 8.6 at 1.717 (3.9 at 43.6) (4A-FE) ............. 1995-97 1.8L .......................................................................... 11.7 at 1.480 (5.3 at 37.6) (7A-FE) ............. Installation (1993-97 Corolla) 1) Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft woodruff key will be at 12 oclock position. On 1.6L engine, timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 1. Crankshaft sprocket on 1.8L engine does not have notch. On 1.6L and 1.8L, hole in camshaft sprocket must align with mark on bearing cap.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mount Bracket-To-Engine Celica (1.8L) ............................................................................................................ 35 (47) A/C Compressor-To-Mount Bolts Celica (1.8L) ............................................................................................................ 18 (25) Camshaft Sprocket Bolt ............................................................................................ 43 (58) Crankshaft Pulley Bolt ............................................................................................. 87 (118) Engine Mounts Celica (1993) Mount Bolt ............................................................................................................. 47 (64) Mount Nut .............................................................................................................. 38 (52) Celica (1994-97) & Corolla (1988-92) Mount-To-Engine Bracket Bolt .............................................................................. 47 (64) Mount-To-Engine Bracket Nut ............................................................................... 38 (52) Through-Bolt .......................................................................................................... 64 (87) Corolla (1993-97) Mount-To-Body Bolt ............................................................................................... 19 (25) Mount-To-Engine Bracket Bolt .............................................................................. 47 (64) Mount-To-Engine Bracket Nut ............................................................................... 38 (52) Power Steering Pump-To-Bracket Bolts ................................................................... 29 (39) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................................................................. 27 (37) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................................................................. Valve Cover Cap Nuts 1988-92 1.6L .......................................................................................................... 1993-97 1.6L & 1.8L .............................................................................................. Water Pump Pulley Bolt ........................................................................................... 65 (7.4) 69 (7.8) 52 (5.9) 82 (9.3)

TOYOTA
1.8L 4-Cylinder Diesel
TIMING BELT APPLICATION Application Labor Time Belt Part No.

667

1.8L 4-Cyl. Diesel Camry 1984-86 ..................................................... 5.0 Hours ... ..... T098 Corolla 1984-85 ..................................................... 2.7 Hours ... ..... T098 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


TIMING BELT
Removal (1984) 1) Disconnect negative battery cable. Remove air cleaner. Drain engine coolant and remove radiator hoses, cooling fan shroud and radiator from vehicle. Remove drive belts, cooling fan and pulley. 2) If equipped with A/C, remove compressor pulley from crankshaft pulley. Using Pulley Holder and Socket (09213-14010 and 09330-00020) or equivalent, remove crankshaft pulley set bolt and washer. 3) Using a puller, remove crankshaft pulley. See Fig. 1. If equipped with A/C, remove idler pulley. Remove timing belt cover mount bolts. Remove timing belt cover and belt guide. 4) Disconnect glow plugs by removing 4 screw grommets and glow plug connecting nuts. Disconnect current sensor by removing nut, plate washer, insulator and current connector. Remove glow plug connector and glow plugs. 5) Using crankshaft set bolt, rotate engine and align TDC mark on camshaft timing pulley with top surface of cylinder head on intake manifold side. Using pliers, remove tensioner spring. Loosen tensioner set bolts and remove timing belt.

Removal (1985-86) 1) Disconnect negative battery cable. Remove air cleaner. Drain engine coolant and remove radiator hoses, washer, and radiator reservoir tanks. Remove drive belts, cooling fan and pulley. 2) Remove cruise control actuator (if equipped). Disconnect the accelerator and cruise control cables. Disconnect the actuator vacuum hose. Remove the actuator cover, and the actuator. Disconnect the wiring connector. 3) Remove power steering pump with bracket (if equipped). Remove drive belt and pulley. Remove 3 mounting bolts and power steering pump with bracket. Place pump aside and suspend it. Remove alternator with bracket. 4) Remove No. 2 timing belt cover. Set No. 1 cylinder to TDC on compression stroke. Align mark of camshaft pulley with top end of cylinder head. Using Special Service Socket (09213-14010 and 09330-00020) or equivalent, remove crankshaft pulley. See Fig. 1. 5) Remove No. 1 timing belt cover and belt guide. Jack up engine slightly. Remove RH engine mounting insulator and bracket. Using a screwdriver, remove tension spring. Loosen the No. 1 idler pulley mount bolt. Remove timing belt. If reusing timing belt, scribe a mark on belt, indicating direction of engine rotation. Place match marks on pulleys and timing belt at each position. Inspection (All Models) 1) Check timing belt for wear, cracks or missing teeth. If defective, check if injection pump camshaft is locked or there are nicks on belt side of idler pulley lock. Replace belt and components as needed. 2) Inspect belt for excessive wear on one side only. If damaged, check the belt guide and the alignment of each sprocket. Before installing new belt, remove idler pulleys and spring. Check idler pulley bearings for noise or roughness. 3) Inspect spring for proper free length and tension. Standard free length is 2.045 (51.93 mm). Replace idler pulley and/or spring as necessary. 4) Check camshaft, injection pump and crankshaft timing sprockets for wear or damage. If belt teeth are worn, check timing belt cover gasket for damage and proper installation. Replace components as necessary. Installation (All Models) 1) Install timing belt tensioner, with larger bolt behind water pump, and loosely fasten mounting bolts. Swing tensioner toward the left. Check alignment of timing marks on each pulley. See Fig. 2. NOTE: When tightening idler pulley and timing sprocket mount bolts, do not move idler pulley bracket or apply tension to timing belt. 2) Install timing belt onto camshaft timing pulley. Ensure timing belt is securely meshed and not loose. Align marks of injector pump drive pulley and install timing belt onto pulley. Install timing belt over lower idler pulley and under crankshaft timing belt pulley. Ensure timing belt is not twisted or too tight. 3) Install tensioner spring and loosen bolts until tensioner moves by spring tension. Using crankshaft pulley set bolt, turn crankshaft 2 complete revolutions clockwise from TDC to TDC. Always turn crankshaft clockwise. Check that each pulley aligns with marks. If marks DO NOT align, remove timing belt and repeat procedure in previous step. 4) Ensure that each pulley aligns with timing mark. See Fig. 2. After ensuring proper alignment of pulley marks, tighten tensioner pulley set bolts. Reverse remaining removal procedures to complete installation. Adjust drive belts to proper tension.

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

Fig. 1: Exploded View Of Timing Belt & Components

668

TOYOTA
1.8L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................................ ............... 69-75 (94-102) Crankshaft Pulley Washer/Bolt 1984 ..................................................................................................................... 102 (137) 1985 ......................................................................................................................... 72 (98) Injection Pump Drive Pulley Bolts 1984 ............................................................................................. ................. 43-47 (58-64) 1985 ............................................................................................. ................. 10-15 (20-28) Nozzle Holder Mount Bolt 1984 ............................................................................................. ................. 20-22 (27-29) 1985 ............................................................................................. ................. 51-65 (69-88) Tensioner Pulley Bolts 1984 ......................................................................................................................... 14 (19) 1985 ......................................................................................................................... 27 (37) INCH Lbs. (N.m) Glow Plugs .............................................................................................................. 108 (13)

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

Fig. 2: Aligning Camshaft, Crankshaft & Injection Pump Sprocket Timing Marks

TOYOTA
2.0L 4-Cylinder Except RAV4
TIMING BELT APPLICATION Application
1

669

Labor Time Component Belt Kit No. Part No.

2.0L 4-Cyl. Camry 1983-86 ............................... 1987-91 ............................... Celica 1986 GTS ................................... Exc. GTS .......................... 1987-88 GTS ................................... Exc. GTS .......................... 1989 .................................... 1990-93 ............................... MR2 1991-95 ...............................
1

3.6 Hours ... .. TCK087 .. ..... T087 3.0 Hours ... .. TCK199 .. ..... T138

3.2 Hours ... ...... ..... ...... ..... T125 2.8 Hours ... .. TCK087 .. ..... T087 3.0 2.8 3.0 4.3 Hours Hours Hours Hours ... ...... ..... ...... ..... ... .. TCK199 .. ..... ... .. TCK199 .. ..... ... ...... ..... ...... ..... T125 T138 T138 T125
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Oil Seal Retainer Mark With Camshaft Sprocket Hole

4.0 Hours ... ...... ..... ...... ..... T125

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1983-85 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.

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

Fig. 2: Positioning Sprocket To BTDC Or ATDC retaining bolt 1/2 turn and release spring tension on timing belt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

REMOVAL & INSTALLATION


TIMING BELT
Removal (1983-86 Camry) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove fender apron seal. Remove alternator drive belt. Remove cruise control actuator and bracket. Remove power steering oil reservoir tank and drive belt. 2) Raise engine slightly, and remove right side engine mount insulator and bracket. Remove No. 2 timing belt cover and gasket assembly. Remove spark plugs. Align oil seal retainer mark with center of small hole on camshaft timing sprocket by turning crankshaft pulley clockwise. See Fig. 1. This will position No. 1 cylinder at 90 BTDC of compression stroke. See Fig. 2. 3) Loosen No. 1 idler pulley retaining bolt and move pulley toward left as far as possible, then temporarily tighten retaining bolt. Remove timing belt from camshaft timing sprocket. 4) Using Drive Shaft Holding Tool (09278-54011) or equivalent, hold timing sprocket in place, then remove sprocket retaining bolt and sprocket. Remove No. 1 idler pulley and tension spring. Using Crankshaft Pulley and Companion Flange Holding Tools (09213-14010 and 09330-00020) or equivalents, remove crankshaft pulley retaining bolt, then pulley. 5) Remove No. 1 timing belt cover and gasket assembly. Remove timing belt and belt guide. Remove No. 2 idler pulley and crankshaft timing sprocket. Installation (1983-86 Camry) 1) Install crankshaft timing sprocket over crankshaft key. See Fig. 3. Install No. 2 idler pulley. See Fig. 4. Tighten idler pulley retaining bolt. Temporarily install timing belt onto sprockets. Install timing belt guide. Install No. 1 timing belt cover and gasket assembly. 2) Install crankshaft pulley. Pull timing belt upward and align preset mark on No. 1 timing belt cover with crankshaft pulley groove. See Fig. 5. Align camshaft oil seal retainer preset mark with center of small hole on camshaft timing pulley. Install timing belt. Loosen No. 1 idler pulley

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

Fig. 3: Installing Crankshaft Sprocket Removal (Celica With 3S-GE Engine) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel and engine undercover. Remove radiator reservoir tank. Remove cruise control actuator and bracket. 2) Remove the power steering oil reservoir bolts, and position reservoir aside. Remove accessory drive belts. Remove alternator and bracket. Raise the engine slightly with suitable jack with wooden block between jack and engine. Remove the right engine mount through-bolt, then mount. 3) Remove the valve cover. Remove spark plugs. Remove No. 2 timing belt cover with gasket. Set the cylinder No. 1 to TDC by rotating crankshaft pulley until groove is aligned with 0 timing mark. See Fig. 6. Ensure alignment marks of camshaft pulleys and No. 3 timing belt cover are aligned. See Fig. 7.

670

TOYOTA
2.0L 4-Cylinder Except RAV4 (Cont.)

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

Fig. 4: Installing No. 2 Idler Pulley

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

Fig. 6: Positioning Crankshaft Pulley At TDC (3S-GE)

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

Fig. 7: Aligning Camshaft Sprocket Marks With Marks On No. 3 Timing Belt Cover (3S-GE) 4) Hang the timing belt on camshaft sprocket pulleys with sprocket S markings facing outward. Align the camshaft sprocket alignment marks with No. 3 timing cover match mark, and install sprockets. See Fig. 7. On models equipped with 2-hole camshaft ange, ensure camshaft knock pin is aligned with sprocket hole. 5) On models equipped with 5-hole camshaft ange, insert knock pin into any holes in alignment. On 5-hole ange type cams, if knock pin alignment is not exact, camshafts can be rotated slightly to compensate. While holding the camshafts with suitable wrench, install and tighten camshaft sprocket attaching bolts. 6) Loosen the spring-loaded idler pulley attaching bolt just enough to allow pulley to move by itself under spring tension. Allow the pulley to take up belt tension. Rotate the crankshaft clockwise 2 complete revolutions. Tighten pulley bolt. Ensure that the timing belt has tension between crankshaft sprocket and intake camshaft sprocket. See Fig. 10. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Removal (1987-91 Camry & 1988-89 Celica With 3S-FE Engine) 1) Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove undercover. Remove cruise control actuator and bracket (if equipped). Remove accessory drive belts. Remove alternator and bracket. CAUTION: Position a wooden block between jack and engine to prevent damage. 2) Use a jack to raise engine slightly. Remove right side engine mount through-bolt, and then mount.

Fig. 5: Aligning Mark On No. 1 Timing Belt Cover With Groove In Crankshaft Pulley 4) Loosen the spring loaded idler pulley attaching bolt. Pry pulley as far left as possible and temporarily tighten bolt. Remove the timing belt from the camshaft timing pulleys. Hold the camshaft ats with a suitable wrench and remove the camshaft sprocket attaching bolts, sprockets and pins. Mark the intake and exhaust camshaft sprockets for installation reference before removing. 5) Remove the crankshaft pulley attaching bolt, then using suitable puller, remove the crankshaft pulley. Remove No. 1 timing cover, then the timing belt guide from crankshaft sprocket. Remove the timing belt, spring loaded idler pulley, tension spring and xed idler pulley from engine. Installation (Celica With 3S-GE Engine) 1) Install xed idler pulley. Pry the idler pulley as far to the left as possible, then temporarily tighten attaching bolt. Temporarily install the timing belt on crankshaft sprocket, oil pump sprocket, xed idler pulley and water pump pulleys. 2) Install the timing belt guide on crankshaft sprocket and timing cover No. 1. Install the crankshaft pulley. Ensure crankshaft pulley groove is still aligned with 0 timing mark. This indicates No. 1 cylinder is at TDC of compression stroke. See Fig. 6. 3) On models equipped with 2-hole camshaft anges, use suitable wrench to align camshaft knock pins and cam lobes as shown. See Fig. 8. On models equipped with 5-hole camshaft anges, use suitable wrench to align camshaft alignment marks as shown. See Fig. 9.

TOYOTA
2.0L 4-Cylinder Except RAV4 (Cont.)

671

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

Fig. 8: Aligning Camshaft Sprocket With 2-Hole Camshaft Flange (3S-GE)

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

Fig. 10: Installing Timing Belt

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

Fig. 9: Aligning Marks On 5-Hole Camshaft Flange With Marks On Camshaft Bearing Caps 3) Remove spark plugs. Remove upper timing belt cover and gasket. Rotate crankshaft pulley until pulley groove is aligned with 0 indication on timing marks, then ensure camshaft sprocket hole is aligned with bearing cap No. 1 alignment mark. See Fig. 14. NOTE: If reusing timing belt, place matchmarks on timing belt and camshaft pulley. See Fig. 12. 4) Loosen spring-loaded idler pulley attaching bolt, then pry pulley as far to left as possible. Temporarily tighten attaching bolt. Remove timing belt from camshaft sprocket. 5) Remove crankshaft pulley attaching bolt, then using suitable puller, remove crankshaft pulley. Remove lower timing belt cover and gasket. NOTE: If reusing timing belt, mark a arrow on belt to show rotation direction. Place matchmarks on timing belt and crankshaft sprocket. See Fig. 13. 6) Remove timing belt and belt guide. NOTE: If reusing timing belt, install timing belt with arrow in direction of engine rotation and align matchmarks on timing belt with matchmark on crankshaft sprocket. See Fig. 13. Installation (1987-91 Camry & 1988-89 Celica With 3S-FE Engine) 1) Install timing belt on crankshaft sprocket, oil pump sprocket, xed idler pulley and water pump sprocket. Install camshaft sprocket, washer and attaching bolts. Rotate camshaft by turning sprocket attaching bolt to align bearing cap mark and camshaft sprocket. See Fig. 14.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

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

Fig. 11: Installing Cylinder Head Packing (3S-GE)

Fig. 12: Marking Timing Belt & Camshaft Sprocket For Reuse Of Timing Belt (3S-FE)

672

TOYOTA
2.0L 4-Cylinder Except RAV4 (Cont.)
3) Remove control cables, electrical connectors, vacuum hoses and coolant hoses from throttle body. Remove throttle body assembly. Remove No. 2 timing belt cover. Remove spark plugs. Place No. 1 cylinder at TDC of compression stroke by turning crankshaft pulley to align groove with No. 1 timing belt cover 0 mark. 4) Ensure alignment marks on camshaft sprockets and No. 3 timing belt cover are aligned as shown. See Fig. 15. If not, turn crankshaft one complete revolution (360) to align marks. Remove timing belt from camshaft timing sprockets. 5) Loosen No. 1 idler pulley attaching bolt, and shift to left as far as possible. Temporarily tighten pulley attaching bolt, then relieve tension from timing belt. Remove timing belt from camshaft sprocket. 6) Support timing belt so meshing of crankshaft sprocket and timing belt does not shift. Remove sprockets, No. 1 timing belt covers, timing belt guide and timing belt. Install crankshaft sprocket and No. 2 idler pulley.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 13: Marking Timing Belt & Crankshaft Sprocket For Reuse Of Timing Belt (3S-FE)

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

Fig. 15: Aligning Camshaft Sprocket Timing Marks (3S-GTE) Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine) 1) Temporarily install No. 1 idler pulley and tension spring. See Fig. 16. Install pulley attaching bolt. Do not tighten bolt. Install tension spring, then pry toward left as far as it will go and tighten. Temporarily install timing belt onto crankshaft sprocket, oil pump, No. 2 idler pulley and water pump pulley. 2) Install timing belt guide. Install No. 1 timing belt cover and gasket. Make sure camshaft groove is aligned with drilled out mark of No. 1 camshaft bearing cap. 3) Place No. 1 cylinder at TDC of compression stroke by turning crankshaft pulley and aligning its groove with 0 mark on No. 1 timing belt cover. See Fig. 17. Turn camshaft and align marks on camshaft sprockets and cylinder head cover. 4) Install timing belt. Ensure that tension between crankshaft and intake camshaft timing sprockets exists. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

Fig. 14: Camshaft Sprocket Alignment (3S-FE) NOTE: If reusing timing belt, align matchmarks on timing belt with matchmark on camshaft sprocket. See Fig. 12. 2) Install timing belt on camshaft sprocket. Ensure that belt has tension between crankshaft sprocket, water pump sprocket and camshaft sprocket. Loosen spring loaded idler pulley attaching bolt just enough to allow pulley to move under spring tension. Allow pulley to take up belt tension. 3) Rotate crankshaft clockwise two complete revolutions, from TDC compression stroke to TDC compression stroke, then tighten spring loaded idler pulley. Ensure that timing belt has tension between water pump sprocket and camshaft sprocket. Install upper timing belt cover. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. NOTE: Air bag system must be disarmed before working on vehicle. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 20 seconds before working on vehicle. Removal (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine) 1) Raise and support vehicle, then remove right front wheel (Celica) or right rear wheel (MR2). Remove right engine undercover. Remove radiator reservoir tank. Remove charge air cooler. Remove strut tower-to-rewall 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
2.0L 4-Cylinder Except RAV4 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

673

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

Fig. 16: Installing Tension Spring & Idler Pulley

Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................................................................ 20 (27) Camshaft Timing Sprocket Bolt .................................................... ................. 40-43 (54-59) Crankshaft Pulley Bolt ............................................................................................. 80 (109) Engine Mount Bolt ........................................................................................................................... 65 (88) Nut ........................................................................................................................... 38 (52) Through-Bolt ............................................................................................................ 64 (87) Idler Pulley Bolt No. 1 ........................................................................................................................ 31 (42) No. 2 ........................................................................................................................ 31 (42) Oil Pump Pulley ........................................................................................................ 31 (42) Valve Cover Nut ........................................................................................................ 17 (23) INCH Lbs. (N.m) Timing Cover Attaching Bolts ..................................................................................... 78 (9)

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

Fig. 17: Identifying Crankshaft Pulley Angle

674

TOYOTA
2.0L 4-Cylinder RAV4
1

TIMING BELT APPLICATION Application 2.0L 4-Cyl. RAV4 1996-00 With ABS ......................... Without ABS ...................
1

Labor Time Component Belt Kit No. Part No.

1 1

5.3 Hours .. .. TCK199 .. ..... T199 3.3 Hours .. .. TCK199 .. ..... T199

With Air Conditioning, add .2 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1996-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles for severe service operating conditions. For 1998 model year, the manufacturer recommends the belt be replaced every 90,000 miles for severe service operating conditions. For 1999-00 model years, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Disconnect power steering reservoir, and remove reservoir bracket. Disconnect wire harness bracket for Data Link Connector No. 1. Remove generator and generator bracket. 2) Remove ABS actuator. Raise and support vehicle. Remove right front wheel. Remove right engine undercover. Remove power steering drive belt. Slightly jack up engine and remove right engine mounting insulator. 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 specied, replace spring. Inspect timing belt cover gaskets. Replace if gaskets are cracked or peeling. Installation 1) Ensure that No. 1 cylinder is set to TDC on compression stroke by temporarily installing No. 1 timing belt cover and crankshaft pulley. Align groove with timing mark 0 on No. 1 timing belt cover. Ensure that camshaft and timing belt match marks are aligned. Remove crankshaft pulley and timing belt cover. Install timing belt. If reusing old belt, ensure rotation direction and mating marks are in correct position. 2) Install timing belt guide on crankshaft with cup side facing out. Install No. 1 timing belt cover, crankshaft pulley, and crankshaft pulley bolt. Loosen No. 1 idler pulley 1/2 turn to tension timing belt. Slowly turn crankshaft pulley 2 revolutions from TDC to TDC. 3) Check that each pulley aligns with timing marks as shown. See Fig. 5. Slowly turn crankshaft pulley 1-7/8 revolutions and align groove with mark at 45 degrees BTDC (for No. 1 cylinder) of No. 1 timing belt cover. See Fig. 7. Tighten No. 1 idler pulley mounting bolt to specication. 4) Place right engine mounting bracket in position, but do not install bolts. Install No. 2 timing belt cover. Disconnect engine wire protector

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

Fig. 1: Exploded View Of Timing Belt & Components

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

Fig. 2: Removing No. 2 Timing Belt Cover between cylinder head cover and No. 3 timing belt cover. Install No. 2 timing belt cover. Install engine wire to No. 2 timing belt cover. Install engine wire protector to mounting bolts of No. 2 timing belt cover. 5) Remove crankshaft pulley. Install engine mounting bracket-to-engine bolts and tighten to specication. Install crankshaft pulley, and tighten pulley bolt to specication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TOYOTA
2.0L 4-Cylinder RAV4 (Cont.)

675

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

Fig. 7: Locating 45 Degree BTDC Mark

Fig. 3: Setting No. 1 Cylinder To TDC

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Timing Pulley Bolt .................................................................................... 40 (54) Crankshaft Pulley Bolt ............................................................................................. 80 (108) Generator Bracket Bolts ............................................................................................ 31 (42) Engine Mount Bracket-To-Engine Bolts .................................................................... 38 (52) Engine Mount Insulator-To-Body Bolts ..................................................................... 38 (52) Engine Mount Insulator-To-Bracket Nut .................................................................... 27 (37) No. 1 Idler Pulley Mounting Bolt .............................................................................. 31 (42) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Water Pump Bolts .................................................................................................... 78 (8.8)

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

Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt

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

Fig. 5: Aligning Matching Marks Of Timing Belt & Cams

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

Fig. 6: Measuring Tensioner Spring Free Length

676

TOYOTA
2.2L 4-Cylinder Diesel
1

TIMING BELT APPLICATION Application Labor Time Belt Part No.

2.2L 4-Cyl. Diesel Pickup 1981 ........................................................... 1982 Up To 5/31 .............................................. From 6/1 ................................................. 1983 ...........................................................
1

2.2 Hours ... ..... T079 2.2 Hours ... ..... T079 2.2 Hours ... ..... T084 2.2 Hours ... ..... T084

With Air Conditioning, add .7 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 100,000 miles.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Cylinder Head & Timing Belt

TIMING BELT
NOTE: Late model 1982 engines with extra idler pulley use a different design timing belt. ALL timing pulleys and camshaft pulleys are also different from early 1982 engines. Timing pulleys and camshaft pulleys are not interchangeable between engines. Removal 1) Using starter, turn engine over until No. 1 piston is at TDC on compression stroke. Disconnect negative battery cable. Remove fan belts, fan and pulley. Remove damper attaching bolt. Using puller, remove damper. 2) Remove air cleaner assembly. Drain cooling system. Remove radiator hoses, shroud and radiator as necessary. Identify and remove any wiring, hoses and lines interfering with timing belt cover removal. Remove crankshaft damper bolt. Do not apply tension to timing belt during damper bolt removal. 3) Remove crankshaft damper pulley using Pulley Removal Tool (SST09213-60016) or equivalent. Detach timing belt cover mount bolts, and remove belt cover and belt guide. Discard gasket. See Fig. 1. Loosen idler pulley bolt, and remove timing belt. CAUTION: Before removing bolts securing crankshaft pulley, camshaft pulley, and injection pump pulley, release tension on timing belt. Do not bend or twist belt, and keep belt free from oil, water or steam. 4) On late model 1982 engines, an extra idler pulley is used between the crankshaft and oil pump timing pulleys. Remove center retaining bolt to remove pulley. Inspection 1) Check timing belt for wear, cracks, or missing teeth. Replace belt if defective. Before installing a new belt, remove idler pulley and spring. Check idler pulley bearing for smooth operation. 2) Check the free length of idler pulley spring. Length of spring should be 1.563 (39.70 mm). Under 8.8 lbs. (4 kg) tension, spring should measure 2.05 (52.0 mm) in length. Check camshaft timing pulley, injection pump pulley and crankshaft pulley for wear or damage. Installation 1) Before installing timing belt, engine should be cold. Always turn crankshaft clockwise. Install idler pulley loose enough so it may be moved side to side by hand. Check alignment of timing marks on each pulley. See Fig. 2. Injection pump timing is normally retarded. 2) Install timing belt and idler spring. Turn the crankshaft 2 revolutions clockwise from TDC to TDC. While turning crankshaft make sure idler

pulley bracket is moving. Ensure that each pulley aligns with marks. See Fig. 3. Tighten timing belt idler pulley bolt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

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

Fig. 2: Aligning Timing Marks

TOYOTA
2.2L 4-Cylinder Diesel (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Camshaft Sprocket Bolt ................................................................ ............... Camshaft-To-Timing Pulley ........................................................... ............... Crankshaft Pulley Bolt ................................................................... ...............

677

Ft. Lbs. (N.m) 69-75 (94-102) 69-75 (94-102) 69-75 (94-102)

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

Fig. 3: Realigning Timing Marks

678

TOYOTA
2.2L 4-Cylinder Gasoline
Labor Time Component Belt Kit No. Part No. 9) Using gear puller, remove crankshaft pulley. Remove No. 1 timing belt cover and gasket. Note direction of timing belt guide installation. See Fig. 1. Remove timing belt guide. 10) Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing belt from crankshaft sprocket. Remove idler pulleys (if necessary).

TIMING BELT APPLICATION Application

2.2L 4-Cyl. Camry 1992-01 ........................... .. 1 3.0 Hours .. .. Camry Solara 1999-01 ........................... .. 1 3.0 Hours .. .. Celica 1990-91 ........................... .. 1 3.1 Hours .. .. 1992-99 ........................... .. 1 2.4 Hours .. .. Celica GT & GTS 1990-91 ............................ 1, 2 3.1 Hours . .. 1992-93 ............................ 1, 2 3.1 Hours . .. MR2 1991-95 ........................... .. 1 3.5 Hours .. ..
1

TCK199 .. ..... T199 TCK199 .. ..... T199 TCK199 .. ..... T199 TCK199 .. ..... T199 TCK199 .. ..... T199 TCK199 .. ..... T138 TCK199 .. ..... T199

With Air Conditioning, add .2 hours. On MR2 with Turbo and Air Conditioning, time is 4.5 hours. On Celica AWD, add 1.2 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service driving conditions. For 1998-01 model years, the manufacturer recommends the belt be replaced every 90,000 miles.

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

Fig. 1: Exploded View of Timing Belt & Components

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Raise and support vehicle. Remove lower engine cover. On Celica and Camry, remove right front wheel. On all models, lower vehicle. 2) On MR2, remove right hood side panel and cruise control actuator. Remove right rear wheel. On Celica and Camry, remove alternator from engine and secure out of way. On Camry, remove coolant reservoir tank if it interferes with timing belt removal. Remove engine control (torque) rod from front of engine. 3) On all models, remove accessory drive belts. Using oor jack, slightly raise engine to remove weight from right (timing belt side) engine mount at timing belt cover. 4) Remove right (timing belt side) engine mount and bracket from front of engine. Remove spark plugs. Remove No. 2 timing belt cover and gaskets. See Fig. 1. 5) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. 6) Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Ensure hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2. If hole in camshaft sprocket is not aligned with alignment mark, rotate crankshaft clockwise one full revolution. CAUTION: If reusing timing belt, mark direction of timing belt rotation on belt. Place mating marks on timing belt at camshaft sprocket and at crankshaft sprocket for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover. See Fig. 2. 7) Loosen No. 1 idler pulley bolt. See Fig. 1. Move No. 1 idler pulley outward, away from timing belt as far as possible. Temporarily retighten No. 1 idler pulley bolt. Remove timing belt from camshaft sprocket. 8) Using Pulley Holder (SST 09213-54015) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt.

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

Fig. 2: Aligning Camshaft Timing Marks Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace components if damaged or worn. NOTE: For 1992-96 Camry, the timing belt tension spring procedure has been revised. See REVISED TIMING BELT TENSION SPRING PROCEDURE (1992-96 CAMRY). 2) Ensure free length of tension spring is within specication. See TENSION SPRING SPECIFICATIONS table. Measure free length between from inside edges of hooked portion of spring. Do not measure spring coils. See Fig. 3. 3) Measure tension needed to extend tension spring to specied installed length. Replace spring if tension is not within specication. See TENSION SPRING SPECIFICATIONS table.

TOYOTA
2.2L 4-Cylinder Gasoline (Cont.)
TENSION SPRING SPECIFICATIONS Application Free Length Except 1999-00 Camry ................................ ........................................ 1999-00 Camry ............................................ ........................................ Tension At Spring Installed Length 1 Camry (1992-95) Green Spring ............................................. ........................... 7.2-8.3 Silver Spring ...................................................................... 10.5-11.6 Camry (1996-01) .......................................... ........................... 7.2-8.3 Camry Solara ............................................... ........................... 7.2-8.3 Celica & MR2 .............................................. ........................... 7.2-8.3
1

679

Specication 1.811 (46.00 mm) 1.654 (42.00 mm) Lbs. Lbs. Lbs. Lbs. Lbs. (3.25-3.75 (4.75-5.25 (3.25-3.75 (3.25-3.75 (3.25-3.75 kg) kg) kg) kg) kg)

CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed from timing belt end of engine. 9) Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC to TDC. 10) Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover, and hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. 11) Rotate crankshaft clockwise 1 and 7/8 revolutions and align crankshaft pulley 0 mark with 45-degree Before Top Dead Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5. 12) Tighten No. 1 idler pulley bolt to specication. See TORQUE SPECIFICATIONS. Install No. 2 timing belt cover and gaskets. Install and tighten spark plugs to specication. 13) To install remaining components, reverse removal procedure. Install all bolts/nuts on right (timing belt side) engine mount before tightening to specication. 14) On Camry, when installing control rod and bracket on strut tower and right (timing belt side engine mount, tighten bolts to specication in sequence. See Fig. 6. On MR2, tighten engine mount bolts in correct locations. See Fig. 7. Adjust drive belts to proper tension.

At 1.988 (50.50 mm).

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

Fig. 3: Measuring Tensioner Spring Free Length Revised Timing Belt Tension Spring Procedure (1992-96 Camry) From Toyota technical service bulletin EG001-99; January 29, 1999: For 1992-96 Camry, the timing belt tension spring procedure was revised. When replacing the timing belt on 1992-96 Camry with 2.2L, tension spring MUST be replaced. The revised tension spring 0 (Part No. 905-7-17003) is a 13-coil design which replaces the original 10-coil design. Installation 1) Install No. 2 idler pulley (if removed). Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly. 2) Install No. 1 idler pulley and tension spring (if removed). Pry No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure idler pulley is clean and rotates smoothly. 3) Using crankshaft pulley bolt, rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump housing. See Fig. 4. This will position keyway in crankshaft sprocket at 12 oclock position. CAUTION: If reusing timing belt, ensure reference marks on timing belt align with reference marks placed on crankshaft and camshaft sprockets. Ensure timing belt is installed in original direction of rotation. 4) Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump sprocket, No. 1 idler pulley, and then No. 2 idler pulley in sequence. 5) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install No. 1 timing belt cover and new gasket. 6) Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. 7) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. If reusing timing belt, ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover. 8) Rotate camshaft and align hole in camshaft sprocket with alignment mark on camshaft bearing cap. See Fig. 2. Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt aligns with reference mark on camshaft sprocket. Ensure tension exists on timing belt between crankshaft and camshaft sprockets.

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

Fig. 4: Aligning Crankshaft Sprocket Timing Marks

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

Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC Mark

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

Fig. 6: Control Rod & Bracket Bolt Installation Sequence (Camry)

680

TOYOTA
2.2L 4-Cylinder Gasoline (Cont.)
TORQUE SPECIFICATIONS (CELICA) Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................................................................ 18 (24) Alternator Bracket Bolt .............................................................................................. 18 (24) Camshaft Sprocket Bolt ............................................................................................ 40 (54) Crankshaft Pulley Bolt ............................................................................................. 80 (109) Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ................. 38 (52) Right (Timing Belt Side) Engine Mount To-Bracket Bolt ........................................................................................................................... 27 (37) Nut ........................................................................................................................... 38 (52) No. 1 Idler Pulley Bolt ............................................................................................... 31 (42) No. 2 Idler Pulley Bolt ............................................................................................... 31 (42) Power Steering Pump Bracket Bolt .......................................................................... 32 (43) Power Steering Pump-To-Bracket Bolt Adjusting Bolt ........................................................................................................... 29 (39) All Others ................................................................................................................. 32 (43) Spark Plug ................................................................................................................. 13 (18) Valve Cover Nut ........................................................................................................ 17 (23) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt .................................................................................. 69 (7.8) Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8) TORQUE SPECIFICATIONS (MR2) Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................................................................ 18 (24) Camshaft Sprocket Bolt ............................................................................................ 40 (54) Crankshaft Pulley Bolt ............................................................................................. 80 (109) Left (Flywheel Side) Engine Mount Through-Bolt ............................................................................................................ 58 (79) Bracket Bolt ................................................................................. ..................................... 1 Right (Timing Belt Side) Engine Mount Support Bracket Bolt/Nut ........................................................................................ 54 (73) Bracket-To-Cylinder Block Bolt ............................................................................... 45 (61) Mounting Bracket Nut ............................................................................................. 38 (52) Through-Bolt ............................................................................................................ 58 (79) Idler Pulley Bracket-To-Cylinder Block Bolt 12-mm Head ............................................................................................................ 20 (27) 14-mm Head ............................................................................................................ 27 (37) Fuel Pulsation Damper ............................................................................................. 25 (34) No. 1 Idler Pulley Bolt .............................................................................................. 31 (42) No. 2 Idler Pulley Bolt .............................................................................................. 31 (42) Spark Plug ................................................................................................................. 13 (18) Valve Cover Nut ........................................................................................................ 17 (23) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt .................................................................................. 68 (7.8) Water Pump-To-Cylinder Block Bolt ............................................. ..................................... 2 Water Pump-To-Water Pump Cover Bolt ................................................................ 78 (8.8)
1 2

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

Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts (MR2)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (CAMRY) Application Ft. Lbs. (N.m) Alternator Bracket Bolt .............................................................................................. 31 (42) Camshaft Sprocket Bolt ............................................................................................ 40 (54) Coolant Outlet Bolt .................................................................................................... 11 (15) Crankshaft Pulley Bolt ............................................................................................. 80 (109) Engine Mounts & Brackets Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ............... 38 (52) No. 1 Idler Pulley Bolt ............................................................................................... 31 (42) No. 2 Idler Pulley Bolt ............................................................................................... 31 (42) Oil Pump Sprocket Nut ............................................................................................. 21 (29) Power Steering Pump Bracket Bolt .......................................................................... 32 (43) Power Steering Pump-To-Bracket Bolt ..................................................................... 32 (43) Spark Plug ................................................................................................................. 13 (18) Valve Cover Nut ........................................................................................................ 17 (23) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) Coolant By-Pass Pipe-To-Water Pump Nut ............................................................ No 3 Timing Belt Cover Bolt ................................................................................... Oil Pan Bolt/Nut ....................................................................................................... Oil Pump Body Cover Bolt ...................................................................................... Oil Pump Pick-Up Tube Bolt/Nut ............................................................................. Oil Pump-To-Cylinder Block Bolt ............................................................................. Water Pump-To-Water Pump Cover Bolt ................................................................ 78 69 48 78 48 82 82 (8.8) (7.8) (5.4) (8.8) (5.4) (9.3) (9.3)

Tighten bolts to specication. See Fig. 7. Tighten bolts to 78 INCH lbs. (8.8 N.m) in sequence. See Fig. 7. On models without A/C, tighten large bracket bolt to 20 ft. lbs. (27 N.m).

TOYOTA
2.4L 4-Cylinder Diesel
TIMING BELT APPLICATION Application Labor Time Belt Part No.

681

2.4L 4-Cyl. Diesel Pickup 1984-87 ..................................................... 2.2 Hours ... ..... T084 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 100,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Drain engine coolant and radiator hoses, fan shroud, and radiator from vehicle. Remove water pump pulley, drive belts, cooling fan and pulley. See Fig. 1. 2) If equipped with A/C, remove compressor pulley from crankshaft pulley. Using Crankshaft Pulley Holding Tool (09213-54011) and Companion Flange Holding Tool (09330-00020) or equivalent, remove crankshaft pulley set bolt and washer.

3) Using Puller (09213-60017) or equivalent, remove crankshaft pulley. If equipped with A/C, remove idler pulley. On 2L, remove timing belt cover mount bolts, timing belt cover, and belt guide. On 2L-T, remove No. 1 turbocharger water pipe, air cleaner pipe, No. 1 air cleaner hose, and timing cover. On all models, disconnect glow plugs by removing 4 screw grommets and glow plug connecting nuts. Disconnect current sensor by removing nut, plate washer, insulator and current connector. Remove glow plug connector and glow plugs. 4) Using crankshaft set bolt, rotate engine and align TDC mark on camshaft timing pulley with top surface of cylinder head. See Fig. 2. Using pliers, remove tensioner spring. Loosen tensioner set bolts, and remove timing belt. Using Pulley Holder (09278-54011), and a wrench, remove camshaft pulley set bolt. Using Puller (09950-20015), remove camshaft pulley. Using Pulley Holder (09278-54011), and a wrench on injection pump drive pulley, remove set bolt on pulley. 5) Using Puller (09213-60017), remove injection pump drive pulley. Remove lower timing belt idler pulley. Using Puller (09213-60017), remove crankshaft timing belt pulley. Inspection 1) Check timing belt for wear, cracks or missing teeth. If defective, check if injection pump camshaft is locked or if there are nicks on belt side of idler pulley lock. Replace belt and components as needed. Inspect belt for excessive wear on one side only. If damaged, check belt guide and alignment of each pulley. Before installing new belt, remove idler pulleys and spring. Check idler pulley bearings for noise or roughness. 2) Inspect spring for proper free length and tension. Standard free length is 1.563 (39.70 mm). See Fig. 3. Installed tension is 8.8 lbs. at 2.05 (4.0 kg at 52 mm). Replace idler pulley and/or spring as necessary.

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

Fig. 1: Exploded View Of Timing Belt & Components

682

TOYOTA
2.4L 4-Cylinder Diesel (Cont.)
4) Ensure that each pulley aligns with timing mark. See Fig. 4. Tighten tensioner pulley set bolts to 14 ft. lbs. (19 N.m). Install glow plugs and tighten to 9 ft. lbs. (13 N.m). Install current sensor, insulator, plate washer and nut. Install 4 glow plug connecting nuts and 4 screw grommets. 5) Align set key on crankshaft with key groove of timing belt guide, and install guide with curved side facing out. Using a new gasket, install belt cover. On 2L-T, install air cleaner pipe and No. 1 air cleaner hose. Connect accelerator cable and PCV hose. Install timing belt cover and No. 1 water pipe. Connect turbocharger water hoses. 6) If equipped with A/C, install idler pulley. On all models, install crankshaft pulley using Driver (09214-60010). Install washer and bolt and tighten bolt to 101 ft. lbs. (137 N.m). Install drive pulley onto crankshaft drive pulley. Install water pump pulley and cooling fan. Install radiator, hoses and fan shroud. Fill engine cooling system and connect negative battery cable. Install drive belts. Adjust drive belts to proper tension. Start engine and check for leaks.

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

Fig. 2: Aligning Timing Marks 3) Check camshaft, injection pump and crankshaft timing sprockets for wear or damage. If there is noticeable wear on belt teeth, check timing belt cover gasket for damage and proper installation. Replace components as necessary.

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

Fig. 3: Measuring Tensioner Spring Free Length Installation 1) Install lower idler pulley. Install timing belt tensioner, with large bolt behind water pump, and loosely fasten mounting bolts. Swing tensioner toward the left. Set No. 1 cylinder to TDC of compression stroke and check alignment of timing marks on each pulley. See Fig. 2. If using a new timing belt, note that injection pump timing is normally in the retarded position. CAUTION: When tightening idler pulley and timing sprocket mount bolts, DO NOT move idler pulley bracket or apply tension to timing belt. 2) Install timing belt onto camshaft timing pulley. Ensure timing belt is securely meshed and not loose. Align marks of injector pump drive pulley, and install timing belt onto pulley. Install timing belt over lower idler pulley and under crankshaft timing belt pulley. Ensure timing belt is not twisted or too tight. 3) Install tensioner spring and loosen bolts until tensioner moves by spring tension. Using crankshaft pulley set bolt, turn crankshaft 2 complete revolutions clockwise from TDC to TDC. Check that each pulley aligns with marks. If marks DO NOT align, remove timing belt and repeat the procedure in this step.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Realigning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ................................................................................................. 73 (98) Crankshaft Pulley Bolt ........................................................................................... 101 (137) Glow Plugs .................................................................................................................. 9 (13) Injector Pump Drive Pulley Bolt ............................................................................... 47 (64) Timing Belt Idler Pulley Bolt ..................................................................................... 29 (39) Timing Belt Tensioner Pulley Bolts ........................................................................... 14 (19)

TOYOTA
2.5L & 3.0L V6 DOHC 1988-97
TIMING BELT APPLICATION Application 2.5L V6 Camry 1988-91 3.0L V6 Avalon 1995-97 Camry 1992-93 1994-97 Labor Time Component Belt Kit No. Part No.

683

REMOVAL & INSTALLATION


WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.

............................... 3.8 Hours ... .. TCK157 .. ..... T157

TIMING BELT
Removal (2.5L & 1992-93 3.0L V6) 1) Disconnect negative battery cable. Remove cruise control actuator and vacuum pump. Remove power steering reservoir with hoses attached, and secure them aside. Raise and support vehicle. Remove right front wheel. Remove right lower engine cover. Remove all drive belts. 2) Remove top braces on right engine mount at timing belt cover. Slightly raise engine to remove weight from right engine mount. Remove retaining bolts/nuts and right engine mount assembly. Remove spark plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right engine mount bracket. See Fig. 1. Note bolt length and location of No. 2 timing belt cover bolts for reassembly reference. CAUTION: If timing belt is to be reused, mark direction of timing belt rotation and location on camshaft sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover.

............................... 3.0 Hours ... .. TCK257 .. ..... T257 ............................... 3.0 Hours ... .. TCK200 .. ..... T200 ............................... 3.0 Hours ... .. TCK257 .. ..... T257

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months for severe operating conditions.

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

Fig. 1: Exploded View Of Timing Belt & Components

684

TOYOTA
2.5L & 3.0L V6 DOHC 1988-97 (Cont.)
5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). CAUTION: If reusing timing belt, ensure 3 reference marks and front mark are on timing belt. See Fig. 4. If reference marks or front mark are not apparent, place reference mark on timing belt at timing mark area on camshaft sprockets or dot area on crankshaft sprocket for reassembly reference. Place front mark on timing belt to indicate direction of timing belt installation. 6) Remove retaining bolts, timing belt tensioner and dust boot. Remove crankshaft pulley bolt from crankshaft. Install Camshaft Sprocket Holder (09960-10010) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Remove idler pulleys (if necessary). 7) If removing camshaft sprocket, use Camshaft Sprocket Holder (09960-10010) to hold camshaft sprocket. On right camshaft sprocket, Adapter (09249-63010) must also be used. Remove bolt and camshaft sprocket. 8) If removing crankshaft sprocket, remove timing belt plate. See Fig. 1. Using Crankshaft Sprocket Puller (0921360017), remove crankshaft sprocket.

3) Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets are aligned with timing marks on No. 3 timing belt cover. See Fig. 2. Remove retaining bolts and timing belt tensioner. 4) Install Camshaft Sprocket Holder (09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. 5) Using Pulley Holder (09213-54014) or equivalent, and Handle (09330-00021), hold crankshaft pulley, and remove retaining bolt. If timing belt is to be reused, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. 6) Using puller, remove crankshaft pulley. DO NOT allow crankshaft to rotate. Remove No. 1 timing belt cover and gasket. If timing belt is to be reused, mark direction of belt rotation, and place reference marks on timing belt and crankshaft sprocket for reassembly reference. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide and timing belt. Remove idler pulleys (if necessary).

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

Fig. 3: Aligning Timing Marks (1994-97 3.0L)


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

Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L) Removal (1994-97 3.0L V6) 1) Disconnect negative battery cable. Remove coolant reservoir. Raise and support vehicle. Remove right side front wheel. Remove right lower engine cover. Remove accessory drive belts. 2) Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Remove the alternator bracket for access to timing belt covers. Remove No. 2 timing belt cover. See Fig. 1. 3) Use Pulley Holder (09213-54015) or equivalent and Holder (09330 00021) to hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover. 4) Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.

Inspection (2.5L & 3.0L V6) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body. Press rod against solid surface. Replace timing belt tensioner if rod moves. 2) Measure timing belt tensioner rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 5. On 2.5L engines, replace timing belt tensioner if distance is not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace timing belt tensioner if distance is not .394-.413 (10.01-10.49 mm). Installation (2.5L & 1992-93 3.0L V6) 1) Install No. 1 idler pulley (if removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining bolt. Install and tighten retaining bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates smoothly.

TOYOTA
2.5L & 3.0L V6 DOHC 1988-97 (Cont.)

685

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 specication. See TORQUE SPECIFICATIONS. 8) Place washer on bottom side of timing belt tensioner. Using press, apply pressure on rod of timing belt tension until rod is retracted, and holes in rod and housing are aligned. Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press, and install dust boot on timing belt tensioner. Install timing belt tensioner. Tighten retaining bolts to specication. 9) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft sprockets align with those on No. 3 timing belt cover. See Fig. 2. CAUTION: Crankshaft must always be rotated clockwise. DO NOT rotate crankshaft counterclockwise. 10) To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L)

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

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion 2) Install timing belt on crankshaft sprocket with installation mark on timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2. Install timing belt guide with cupped side away from crankshaft sprocket. Install No. 1 timing belt cover and gasket. Align crankshaft key with key groove of crankshaft pulley and install crankshaft pulley. Tighten retaining bolt to specication. CAUTION: If reusing timing belt, ensure timing mark on crankshaft sprocket is aligned with reference mark placed on timing belt, and timing belt is installed in original direction of rotation. 3) Install No. 2 idler pulley. Tighten retaining bolt to specication. Ensure idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. 4) Rotate right camshaft so knock pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. 5) Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket. 6) Using camshaft sprocket holder, slightly rotate left camshaft sprocket, and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft reference mark on timing belt with timing mark on right camshaft sprocket. Install right camshaft sprocket on camshaft with ange side toward cylinder head. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2.

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

Fig. 6: Retracting Timing Belt Tensioner Rod Installation (1994-97 3.0L V6) 1) Install No. 1 and No. 2 idler pulleys (if removed). Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) If installing crankshaft sprocket, align crankshaft sprocket with key in crankshaft. Using hammer and Sprocket Installer (09223-46011), install crankshaft sprocket with ange toward cylinder block. 3) Install timing belt plate. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Install No. 1 and 2 idler pulleys (if removed). Install and tighten bolts to specication. Ensure idler pulleys are clean and rotate smoothly. 4) If installing camshaft sprockets, ensure camshaft sprockets are installed with ange in correct direction. Right camshaft sprocket must be installed with ange outward (away from cylinder head), while left camshaft sprocket must be installed with ange inward (against cylinder head). See Fig. 1. 5) Align hole in camshaft sprocket with pin in camshaft and install sprocket. Install and tighten camshaft sprocket bolt to specication. See TORQUE SPECIFICATIONS. 6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. 7) Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. See Fig. 4. Ensure front mark is pointing toward timing belt end of engine. 8) Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then on No. 1 idler pulley.

686

TOYOTA
2.5L & 3.0L V6 DOHC 1988-97 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (2.5L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Engine Crossmember-To-Body Bolt .......................................................................... 29 (39) Engine Mount Through-Bolt ...................................................................................... 64 (87) Engine Mount-To-Engine Crossmember Bolt ........................................................... 54 (73) Idler Pulley Bolt No. 1 Idler Pulley .................................................................................................... 25 (34) No. 2 Idler Pulley .................................................................................................... 29 (39) Idler Pulley Support Bolt ........................................................................................... 13 (18) Right (Timing Belt Side) Engine Mount Bolt ........................................................................................................................... 47 (64) Nut Bracket Side .......................................................................................................... 38 (52) Body Side .............................................................................................................. 65 (88) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 14 (19) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ..................................................................................... 65 (7) Valve Cover Nut .......................................................................................................... 52 (6) TORQUE SPECIFICATIONS (3.0L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 94 (127) Crankshaft Pulley Bolt ........................................................................................... 159 (215) Front Engine Mount-To-Crossmember Bolt Toyota Motor Corporation Bolt ................................................................................ 59 (80) Toyota Motor Manufacturing Bolt ............................................................................ 49 (66) Front Engine Mount-To-Cylinder Block Bolt ............................................................. 47 (64) Power Steering Pump Bolt ....................................................................................... 31 (42) Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43) Pulsation Damper ...................................................................................................... 24 (33) Right Engine Mount Brace Bolt ................................................................................ 23 (31) Stabilizer Bar Link-To Lower Control Arm Nut ......................................................... 29 (39) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt ............................................................................................ 25 (34) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Wheel Lug Nut ........................................................................................................ 76 (103) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ........................................................................... No. 3 Timing Belt Cover Bolt .................................................................................. Timing Belt Plate Bolt .............................................................................................. Valve Cover Bolt ...................................................................................................... Water Pump Bolt/Nut ............................................................................................... 75 75 71 71 71 (8.5) (8.5) (8.0) (8.0) (8.0)

9) Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. Install 1.27 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Remove 1.27 mm hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 11) Install timing belt guide with cupped side away from crankshaft sprocket. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. 12) Ensure No. 1 and No. 2 timing belt cover gaskets do not have any cracks, peeling or damage. Install No. 1 and No. 2 timing belt covers. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 13) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication using Pulley Holder (09213-54015) and Holding Tool (09330 00021) or equivalent. To complete installation, reverse removal procedures. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

TOYOTA
2.8L 6-Cylinder
TIMING BELT APPLICATION Application 2.8L 6-Cyl. Celica Supra 1982-83 A/T .................................... M/T .................................... 1984-85 A/T .................................... M/T .................................... Cressida 1983 .................................... 1984-88 ............................... Supra 1986 .................................... Labor Time Component Belt Kit No. Part No.

687

3.5 Hours ... ...... ..... ...... ..... T074 3.3 Hours ... ...... ..... ...... ..... T074 3.5 Hours ... .. TCK101 .. ..... T101 3.3 Hours ... .. TCK101 .. ..... T101 3.1 Hours ... ...... ..... ...... ..... T074 3.1 Hours ... .. TCK101 .. ..... T101 3.4 Hours ... .. TCK101 .. ..... T101

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1982-85 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Camshaft Pulley Match Marks

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove air cleaner, upper radiator hose, fan shroud and air intake connector. Remove all drive belts. Position No. 1 cylinder at TDC of compression stroke. See Fig. 1. Remove camshaft covers and No. 3 timing cover. See Fig. 2. 2) To relieve timing belt tension, loosen idler pulley set bolt. Rotate idler pulley toward alternator side of engine. Using gear puller, remove crankshaft pulley. Remove No. 1 timing cover. If timing belt is to be reused, place arrow on belt to indicate belt rotation. Remove timing belt. 3) If necessary, remove camshaft timing pulley or oil pump drive pulley by holding the pulley with Holding Tool (09278-54011) and loosening set bolt. See Fig. 3. Remove exhaust valve cover and oil ller cap. If necessary, use Puller (09308-10010) to remove crankshaft timing pulley. See Fig. 4. Inspection Inspect drive belt for wear, cracks or damage to teeth. Check pulleys for wear or damage. If defective, service or repair as necessary. Check idler pulley bearing for smooth operation. Idler pulley tension spring free length must be 2.72 (69.0 mm) or less. See Fig. 5. Replace spring if not within specication. Installation 1) Install oil pump drive pulley (if removed). Tighten bolt to specication. See TORQUE SPECIFICATIONS. Install idler pulley and tension spring. Position idler pulley to alternator side of engine as far as possible. Using Pulley Installer (09214-60010), install crankshaft timing pulley. Install timing belt on crankshaft pulley. If used belt is installed, ensure belt is installed in proper direction of rotation. Install No. 1 timing cover and gasket. See Fig. 2. 2) Install crankshaft pulley, and tighten bolt to specication. Ensure No. 1 cylinder is on TDC of compression stroke. Install timing belt on crankshaft pulley. 3) Rotate engine 2 complete revolutions in direction of rotation, and position No. 1 cylinder at TDC of compression stroke. Recheck alignment of match marks. 4) Install timing belt cover and crankshaft pulley. To complete installation, reverse removal procedure. See Figs. 6, 7 and 8. Adjust drive belts to proper tension.

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

Fig. 2: Exploded View of Timing Belt & Components CAUTION: Ensure camshaft timing pulleys are installed in original location. Guide on exhaust side must be toward No. 2 timing cover and intake side guide facing away from No. 2 timing cover. See Fig. 2.

688

TOYOTA
2.8L 6-Cylinder (Cont.)

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

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

Fig. 3: Identifying Pulley Holding Tool

Fig. 6: Camshaft Housing Bolt Tightening Sequence

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

Fig. 4: Identifying Crankshaft Sprocket Puller

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

Fig. 7: Aligning Camshaft Match Hole

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

Fig. 5: Measuring Tensioner Spring Free Length

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Bolt ........................................................................................... 1 16 (22) Camshaft Timing Pulley Bolt .................................................................................... 51 (69) Crankshaft Pulley Bolt ........................................................................................... 195 (265) Idler Pulley Bolt ......................................................................................................... 36 (49) Oil Pump Drive Pulley Bolt ....................................................................................... 16 (22) Rear Timing Cover Bolt ............................................................................................ 36 (49) Timing Belt Case Bolt 8 mm ....................................................................................................................... 13 (18) 10 mm ..................................................................................................................... 27 (37) INCH Lbs. (N.m) No. 2 Timing Belt Cover ......................................................................................... 108 (12)
1

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

Fig. 8: Aligning Camshaft & Pulley

Tighten in 3 steps in proper sequence. See Fig. 6.

TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97
TIMING BELT APPLICATION Application 3.0L 6-Cyl. 2JZ Supra 1993-97 ....................................................
1

689

Labor Time

Belt Part No.

2.7 Hours .. ..... T215

With Turbo, add .9 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles or 96 months for severe operating conditions.

REMOVAL & INSTALLATION


TIMING BELT
WARNING: To prevent air bag deployment which may cause personal injury, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal 1) Disconnect negative battery cable. Remove battery, and drain cooling system. Place reference mark on fan clutch and water pump for reassembly reference. Remove drive belt, cooling fan, fan clutch and water pump pulley. 2) Remove radiator and lower engine cover. Remove oil ller cap, No. 2 and No. 3 timing belt covers, gasket and drive belt tensioner. See Fig. 1. 3) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 4) Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 2. If conditions are not as described, rotate crankshaft clockwise one complete revolution. 5) Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. 6) Using Handle (09330-00021) and Pulley Holder (09213-70010), or equivalent, hold crankshaft pulley and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. 7) Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide. Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. Replace timing belt tensioner if distance is not .315-.343 (8.00-8.80 mm). Installation 1) Install idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. 2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 2. Install timing belt on crankshaft sprocket. 3) Install timing belt guide with cupped side away from crankshaft sprocket and at side against timing belt. Install gaskets and No. 1
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components

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

Fig. 2: Aligning Camshaft & Crankshaft Timing Marks

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

Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley, and tighten pulley bolt to specication. See TORQUE SPECIFICATIONS.

690

TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97 (Cont.)

4) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 5) Using sprocket holder, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. 6) Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 4. 7) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 4. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise. 8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. 9) Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. 10) To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. 11) Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust uid levels and check ignition timing. Adjust drive belts to proper tension.

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

Fig. 4: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt/Nut .......................................................................................... 38 (52) Alternator Mount Bolt ................................................................................................ 27 (37) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Crankshaft Pulley Bolt ........................................................................................... 239 (324) Drive Belt Tensioner Bolt .......................................................................................... 15 (20) Fan Clutch-To-Water Pump Nut ............................................................................... 12 (16) Idler Pulley Bolt ......................................................................................................... 25 (34) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 15 (20) INCH Lbs. (N.m) No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8) Valve Cover Bolt/Nut ................................................................................................ 73 (8.3)

TOYOTA
3.0L 6-Cylinder 2JZ, 1998
TIMING BELT APPLICATION Application 3.0L 6-Cyl. 2JZ-GE & 2JZ-GTE Supra 1998 ..........................................................
1

691

Labor Time

Belt Part No.

2.7 Hours .. ..... T215

With Turbo, add .9 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 90,000 miles or 72 months for severe operating conditions.
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 1: Aligning Camshaft Timing Marks (Non-Turbo) Inspection (Non-Turbo) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .315-.346 (8.00-8.80 mm). Installation (Non-Turbo) 1) Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. 2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 2, STEP 3. Clean oil or water off of crankshaft sprocket and install timing belt on crankshaft sprocket and around idler pulley. CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align, and timing belt is installed in original direction of rotation. 3) Install timing belt guide with cupped side away from crankshaft sprocket and at side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. 4) Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is aligned with 0 timing mark of No. 1 timing belt cover. See Fig. 2, STEP 4. Temporarily install crankshaft pulley bolt. CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft sprockets align and timing belt is installed in original direction of rotation. 5) If necessary, use spanner wrench to rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 1. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. 6) Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. 7) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS.

REMOVAL & INSTALLATION


TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal (Non-Turbo) 1) Remove battery and battery tray. Raise and support vehicle. Drain cooling system. 2) Remove air cleaner duct located above radiator. Remove lower fan shroud and radiator assembly. Rotate drive belt tensioner clockwise. Remove drive belt. 3) Place reference mating marks on fan clutch, water pump pulley, and water pump stud for reassembly reference. Remove cooling fan, fan clutch, and water pump pulley. 4) Remove power steering pump with hoses attached, and hang out of way. Remove power steering pump front bracket. Remove No. 2 and No. 3 timing belt covers and gaskets. Remove drive belt tensioner. 5) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 6) Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 1. If not, rotate crankshaft clockwise one complete revolution (360 degrees). CAUTION: Crankshaft must be correctly positioned by aligning sub-timing mark with 0 mark on timing belt cover to prevent valves from contacting pistons. 7) Rotate crankshaft pulley 60 degrees counterclockwise. Align subtiming mark with 0 mark on timing belt cover. Perform STEP 1. See Fig. 2. Ensure dot marks of camshaft sprockets are aligned with timing marks of No. 4 timing belt cover. See Fig. 2, STEP 2. CAUTION: If reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft sprocket for reassembly reference. 8) Using Handle (09330-00021) and Pulley Holder (09213-70010) or equivalent to hold crankshaft pulley, remove crankshaft pulley bolt. DO NOT allow the crankshaft pulley to rotate. 9) Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 3. Remove timing belt from camshaft sprockets. 10) Remove crankshaft pulley using gear puller. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference (at 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.

692

TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)

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

Fig. 3: Exploded View Of Typical Timing Belt & Components

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

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion 9) Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. If timing marks are not aligned, remove timing belt and reinstall. 10) Tighten crankshaft pulley bolt to specication. Install No. 2 and No. 3 timing belt covers. To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. 11) Ensure water pump and fan clutch reference marks are aligned. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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

Fig. 2: Aligning Sub-Timing Marks (Non-Turbo) CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise. 8) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC.

TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)

693

7) Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 7. If not, rotate crankshaft clockwise one complete revolution (360 degrees). CAUTION: It reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft sprocket for reassembly reference. 8) Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 3. Remove timing belt from camshaft sprockets. On automatic transmission models, remove clamps securing oil cooler lines near crankshaft pulley. 9) On all models, use Handle (09330-00021) and Pulley Holder (09213-70010) or equivalent to hold crankshaft pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. 10) Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference (at side toward timing belt). See Fig. 3. Remove timing belt guide. If reusing timing belt, place mating reference marks on timing belt and crankshaft sprocket. Remove timing belt.

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

Fig. 5: Aligning Camshaft & Crankshaft Timing Marks

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

Fig. 7: Aligning Camshaft Timing Marks (Turbo) Inspection (Turbo) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2) Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .315-.346 (8.00-8.80 mm). 3) Compress and extend drive belt tensioner damper. Make sure there is no abnormal resistance or unusual operation sounds. Replace if defective. CAUTION: Before discarding drive belt tensioner damper, gas must be released from damper. Fully extend damper. Drill small hole in damper, just above lower mounting stud hole. Use care, as gas will force metal chips to y out while drilling hole. Installation (Turbo) 1) Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. 2) Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 5. Install timing belt on crankshaft sprocket.

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

Fig. 6: Retracting Timing Belt Tensioner Rod WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. Removal (Turbo) 1) Disconnect the negative battery cable. Remove battery and battery tray. Raise and support vehicle. Remove lower engine cover. Drain cooling system. 2) Remove No. 2 air tube located below radiator. Remove air intake hose to air intake chamber for access to timing belt covers. Remove air cleaner duct located above radiator. Remove lower fan shroud and radiator assembly. 3) On manual transmission models, remove drive belt tensioner damper (located between drive belt tensioner and stud on front of engine). See Fig. 3. Rotate drive belt tensioner clockwise. Remove drive belt. 4) On all models, place reference mating marks on fan clutch, water pump pulley, and water pump stud for reassembly reference. Remove cooling fan, fan clutch, and water pump pulley. 5) Remove front bracket for power steering pump for access to timing belt covers. It may be necessary to remove pump pulley. Remove oil ller cap and No. 3 timing belt cover. See Fig. 3. Remove No. 2 timing belt cover and gasket. Remove drive belt tensioner. CAUTION: DO NOT rotate crankshaft counterclockwise. Rotate crankshaft clockwise (as viewed from front of engine). 6) Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover.

694

TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 60 (81) Crankshaft Pulley Bolt ........................................................................................... 243 (330) Drive Belt Tensioner Bolt .......................................................................................... 15 (21) Drive Belt Tensioner Damper Bolt ............................................................................ 15 (21) Fan Clutch-To-Water Pump Nut ............................................................................... 12 (16) Idler Pulley Bolt 1 ....................................................................................................... 26 (35) Power Steering Pump Pulley Bolt (Turbo) ............................................................... 32 (43) Power Steering Pump-To-Front Bracket (Non-Turbo) Right Side Bolt 2 ...................................................................................................... 29 (39) Left Side Bolt 2 ........................................................................................................ 42 (58) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 15 (21) INCH Lbs. (N.m) Fan-To-Fan Clutch Nuts ........................................................................................... 65 (7.5) No. 1 & No. 2 Timing Belt Cover Bolt ....................................................................... 71 (8) No. 4 Timing Belt Cover Bolt .................................................................................. 78 (8.8)
1 2

CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align, and timing belt is installed in original direction of rotation. 3) Install timing belt guide with cupped side away from crankshaft sprocket and at side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley, and tighten pulley bolt to specication while holding crankshaft. See TORQUE SPECIFICATIONS. 4) On automatic transmission models, reinstall clamps for oil cooler lines near crankshaft pulley. 5) On all models, rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 6) Using spanner wrench, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 7. Clean oil or water off of crankshaft sprocket and install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft sprockets align and timing belt is installed in original direction of rotation. 7) Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. 8) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specication. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise. 9) Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. 10) Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 7. If timing marks are not aligned, remove timing belt and reinstall. 11) To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. 12) Ensure water pump and fan clutch reference marks are aligned. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

Apply Loctite 242 or equivalent to bolt threads. Right and left side as viewed from rear of engine.

TOYOTA
3.0L 6-Cylinder 7M-GE & 7M-GTE
TIMING BELT APPLICATION Application 3.0L 6-Cyl. 7M-GE Cressida 1989-91 ..................................................... 1992 ........................................................... Supra 7M-GE 1986-90 ..................................................... 1991-92 ..................................................... Supra 7M-GTE 1987-90 ..................................................... 1991-92 ..................................................... Labor Time Belt Part No.

695

3.1 Hours ... ..... T126 3.1 Hours ... ..... T237 3.4 Hours ... ..... T126 3.4 Hours ... ..... T237 3.8 Hours ... ..... T126 3.8 Hours ... ..... T237

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles for severe service operating conditions.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove radiator. Remove all accessory drive belts. Remove power steering pump with hoses attached, and secure aside (if equipped). Remove spark plugs. Disconnect hoses from air pipe. 2) Remove coolant outlet and fan. Remove spark plug wire clamps across front of No. 2 timing belt cover. Remove retaining bolts, No. 3 timing belt cover and gaskets. See Fig. 1. 3) Rotate crankshaft so cylinder No. 1 is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 4) Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft 360 degrees and recheck alignment. 5) Remove power steering belt pulley. Using Pulley Holder (09213-58011) and Handle (09330-00021), or equivalent, hold crankshaft pulley and remove retaining bolt. 6) Using puller, remove crankshaft pulley. Remove fan bracket, No. 1 timing belt cover and gasket. See Fig. 1. 7) Note direction of timing belt guide installation. Mark direction of timing belt rotation. Remove timing belt guide and tension spring. See Fig. 1. Loosen No. 1 idler pulley retaining bolt. 8) Position No. 1 idler pulley as far to the left as possible (away from timing belt), and temporarily tighten retaining bolt. Remove timing belt. Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Inspect idler pulleys and fan for smooth rotation. Replace component if defective. 2) Inspect tension spring for damage, and measure spring free length. Replace tension spring if damaged or free length is not 2.216 (56.274 mm). Installation 1) Install No. 1 idler pulley as far to the left as possible (away from timing belt), and temporarily tighten retaining bolt. Align timing marks on camshaft sprockets with timing mark on No. 4 timing belt cover. See Fig. 2. Install timing belt. 2) Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pulley as far to the right as possible (toward timing belt), and temporarily tighten retaining bolt. Install tension spring. Loosen No. 1 idler pulley retaining bolt until idler pulley moves with spring force of tension spring. 3) Temporarily install crankshaft pulley retaining bolt. Using crankshaft pulley retaining bolt, rotate crankshaft clockwise (viewed from front of engine) 2 full revolutions.

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

Fig. 1: Exploded View Of Timing Belt & Components

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

Fig. 2: Aligning Timing Marks CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise. 4) Ensure all timing marks are properly aligned. See Figs. 2 and 3. Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37 N.m). Check timing belt deection. 5) To remove slack in timing belt, rotate intake and exhaust camshaft timing pulleys inward by applying a turning torque of 14 ft. lbs. (19 N.m). See Fig. 4. 6) Remove crankshaft pulley retaining bolt. Install timing belt guide with cupped side toward front of engine.

696

TOYOTA
3.0L 6-Cylinder 7M-GE & 7M-GTE (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Coolant By-Pass Outlet Bolt ..................................................................................... 13 (18) Coolant Inlet Nut ....................................................................................................... 14 (19) Crankshaft Pulley Bolt ........................................................................................... 181 (245) Fan Bracket Bolt ....................................................................................................... 30 (41) Idler Pulley Bolt No. 1 Pulley ............................................................................................................. 27 (37) No. 2 Pulley ............................................................................................................. 13 (18) Power Steering Pump Pulley Nut ............................................................................. 32 (43) Spark Plug ................................................................................................................. 13 (18) Tension Spring Bracket Bolt ..................................................................................... 13 (18) INCH Lbs. (N.m) Fan Retaining Nut ....................................................................................................... 48 (5) Timing Belt Cover Bolt No. 1 & 2 Covers ...................................................................................................... 48 (5) No. 3 & 4 Covers ...................................................................................................... 74 (8)

CAUTION: Ensure timing belt guide is installed with cupped side toward front of engine and at side against crankshaft sprocket. 7) To install remaining components, reverse removal procedure. Apply sealant to coolant outlet before installing. Tighten bolts and nuts to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

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

Fig. 3: Aligning Camshaft Sprocket Timing Marks

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

Fig. 4: Checking Timing Belt Tension

TOYOTA
3.0L V6 DOHC 1998-04
TIMING BELT APPLICATION Application 3.0L V6 1MZ-FE Avalon 1998-04 ............................... Camry 1998-02 ............................... 2003-04 ............................... Camry Solara 1999-03 ............................... Highlander 2001-03 ............................... Sienna 1998-00 ............................... 2001-03 ............................... Labor Time Component Belt Kit No. Part No.

697

REMOVAL & INSTALLATION


TIMING BELT
WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal (Avalon, Camry 1998-01 & Camry Solara) 1) Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. 2) Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. On Camry Solara, remove shock tower suspension brace. 3) On all models, remove engine moving control rod and No. 2 right engine mounting bracket. Remove generator-to-engine bracket for access to timing belt covers. 4) Using Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove right engine mounting bracket from front (timing belt end) of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.

3.0 Hours ... .. TCK257 .. ..... T257 3.0 Hours ... .. TCK257 .. ..... T257 3.0 Hours ... ...... ..... ...... ..... T257 3.0 Hours ... .. TCK257 .. ..... T257 2.5 Hours ... .. TCK257 .. ..... T257 3.8 Hours ... .. TCK257 .. ..... T257 4.0 Hours ... .. TCK257 .. ..... T257

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

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

Fig. 1: Exploded View Of Timing Belt & Components

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 crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 or 3. 6) Ensure timing mark on each camshaft sprocket is aligned with appropriate timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution (360 degrees). 7) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 4. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. Do NOT hold tensioner with push rod facing DOWN. Remove timing belt.

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

Fig. 3: Aligning Timing Marks (1999-04)

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

Fig. 2: Aligning Timing Marks (1998) Inspection (Avalon, Camry 1998-01 & Camry Solara) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Check water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing DOWN. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing UP. Press rod against solid surface. Replace timing belt tensioner if push rod moves. 3) Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 5. Replace timing belt tensioner if distance is not .394-.425 (10.01-10.8 mm). NOTE: Engine should be cold when installing timing belt. Installation (Avalon, Camry 1998-01 & Camry Solara) 1) Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 or 3.

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

Fig. 4: Identifying Timing Belt Reference Marks & Front Mark

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

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion 3) Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with appropriate timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3.

TOYOTA
3.0L V6 DOHC 1998-04 (Cont.)
CAUTION: Clean timing belt sprockets before installing timing belt. Wipe off any oil or water with rag. DO NOT use any cleaning solvents. 4) Install timing belt in following order: a) Crankshaft sprocket b) Water pump pulley c) Left camshaft sprocket (front of vehicle side) d) No. 2 idler pulley e) Right camshaft sprocket (rewall side) f) No. 1 idler pulley If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. 5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of pressure on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install 1.5 mm hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure there are no gaps in gasket. Cut off any excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten fasteners to specication. Connect engine ground strap. Adjust drive belts to proper tension.

699

4) Using gear puller and crankshaft pulley bolt, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. See Fig. 4. NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing belt side of engine. 5) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. 6) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt rear cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution (360 degrees). 7) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 4. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 8) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. Do NOT hold tensioner with push rod facing DOWN. Remove timing belt in following order a) No. 1 idler pulley b) Right camshaft sprocket (rewall side) c) No. 2 idler pulley d) Left camshaft sprocket (front of vehicle side) e) Water pump pulley f) Crankshaft sprocket Inspection (Camry 2002-04 & Highlander) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing. CAUTION: Never hold timing belt tensioner with push rod facing DOWN. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing UP. Press rod against solid surface. Replace timing belt tensioner if push rod moves. NOTE: Engine should be cold when installing timing belt. Installation (Camry 2002-04 & Highlander) 1) Install No. 1 and 2 idler pulleys (if removed). Install and tighten bolts to specication. 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. Wipe off any oil or water with rag. DO NOT use any cleaning solvents. 4) Install timing belt in following order: a) Crankshaft sprocket b) Water pump pulley c) Left camshaft sprocket (front of vehicle side) d) No. 2 idler pulley e) Right camshaft sprocket (rewall side) f) No. 1 idler pulley If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction.

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

Fig. 6: Retracting Timing Belt Tensioner Rod Removal (Camry 2002-04 & Highlander) 1) Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. 2) Remove control (torque) rod from timing belt end of engine. Remove engine mount from timing belt end of engine. Remove generator mounting bracket from engine for access to timing belt covers. 3) Using Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, hold crankshaft pulley. Loosen crankshaft pulley bolt.

700

TOYOTA
3.0L V6 DOHC 1998-04 (Cont.)
CAUTION: Never hold timing belt tensioner with push rod facing DOWN. 2) Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing UP. Press rod against solid surface. Replace timing belt tensioner if push rod moves. 3) Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 5. Replace timing belt tensioner if distance is not .394-.425 (10.01-10.8 mm). NOTE: Engine should be cold when installing timing belt. Installation (Sienna) 1) Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. 2) Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 or 3. 3) Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3. CAUTION: Clean timing belt sprockets before installing timing belt. Wipe off any oil or water with rag. DO NOT use any cleaning solvents. 4) Install timing belt on crankshaft sprocket, water pump pulley, left (front of vehicle side) camshaft sprocket, No. 2 idler pulley, right (rewall side) camshaft sprocket, and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. 5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of pressure on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Using new gaskets, install No. 1 and 2 timing belt covers. Ensure there are no gaps in gasket. Cut off excess gasket. Install and tighten bolts to specication. 11) Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. 12) Install generator bracket. Install engine stabilizer rod and engine mounting bracket, located near timing belt cover. Connect engine ground strap. 13) To install remaining components, reverse removal procedure. Tighten fasteners to specication. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.

5) Using press, SLOWLY apply about 200-2200 lbs. (100-1000 kg) of pressure on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install 1.5 mm hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. 6) Install timing belt tensioner. Install and alternately tighten bolts to specication. See TORQUE SPECIFICATIONS. 7) Remove 1.5 mm hexagon wrench from timing belt tensioner. Slowly rotate crankshaft CLOCKWISE 2 revolutions until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. 8) Ensure timing mark on each camshaft sprocket is aligned with appropriate timing mark on No. 3 timing belt rear cover. See Fig. 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. 9) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install right side engine mounting bracket on front of cylinder block. Install and tighten bolts to specication. See TORQUE SPECIFICATIONS. 10) Using NEW gaskets, install No. 1 and 2 timing belt covers. Ensure there are no gaps in gasket. Cut off excess gasket. Install and tighten bolts to specication. 11) Install generator bracket. Install crankshaft pulley. Install and tighten crankshaft pulley bolt. See TORQUE SPECIFICATIONS. 12) Install engine mounting stay and engine moving control rod to engine and body. Connect engine ground strap. 13) Install accessory drive belts. Adjust drive belts to proper tension. Install right fender apron seal. Install right front wheel. Removal (Sienna) 1) Remove the outer cowl top panel along with the ventilation louvers and windshield wiper arm assembly. See Fig. 7. Raise and support vehicle. 2) Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect Data Link Connector 1 (DLC-1) from right side engine mounting bracket. 3) Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. 4) Remove engine stabilizer rod, engine mounting stay and engine mounting bracket, located near timing belt cover. Remove generator-toengine bracket for access to timing belt covers. 5) Using Pulley Holder (09213-54015) or equivalent, and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. NOTE: Always turn crankshaft CLOCKWISE, as viewed from timing belt side of engine. 6) Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft CLOCKWISE until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2 or 3. 7) Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt rear cover. See Fig. 2 or 3. If timing marks are not aligned, rotate crankshaft CLOCKWISE one full revolution (360 degrees). 8) If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 4. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 9) Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. Do NOT hold tensioner with push rod facing DOWN. Remove timing belt. Inspection (Sienna) 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing.

TOYOTA
3.0L V6 DOHC 1998-04 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

701

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

Fig. 7: Exploded View Of Outer Cowl Top Panel (Sienna)

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt (Except Highlander) Left Hand (Front End of Vehicle Side) ................................................................. 92 (125) Right Hand (Firewall Side of Vehicle) .................................................................... 65 (88) Camshaft Sprocket Bolt (Highlander) ..................................................................... 92 (125) Crankshaft Pulley Bolt ........................................................................................... 159 (215) Engine Mount Bracket-to-Engine Bolt ...................................................................... 21 (28) Engine Mounting Stay ............................................................................................... 23 (32) Engine Moving Control Rod Bolts ............................................................................ 47 (64) Generator Adjusting Lock Bolt .................................................................................. 13 (18) Generator Bracket No. 2 ........................................................................................... 21 (28) Generator Pivot Bolt Avalon ...................................................................................................................... 41 (56) Except Avalon .......................................................................................................... 38 (52) Power Steering Pump Bolt ....................................................................................... 32 (43) Power Steering Pump Bracket To-Cylinder Head Bolt ............................................ 32 (43) Right Engine Mount Brace Bolt ................................................................................ 23 (31) Shock Tower Brace-to-Shock Tower Nuts Camry Solara .......................................................................................................... 59 (80) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt 1 .......................................................................................... 25 (34) No. 2 Idler Pulley Bolt ............................................................................................ 32 (43) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Wheel Lug Nut ........................................................................................................ 76 (103) Wiper Arm Nuts Sienna ...................................................................................................................... 15 (20) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ........................................................................... No. 3 Timing Belt Cover Bolt .................................................................................. Timing Belt Plate Bolt .............................................................................................. Water Pump Bolt/Nut Except Sienna ........................................................................................................ Sienna .....................................................................................................................
1

75 (8.5) 75 (8.5) 71 (8.0) 71 (8.0) 69 (7.8)

Apply Loctite 242 or equivalent to bolt threads.

702

TOYOTA
3.0L V6 SOHC
Labor Time Component Belt Kit No. Part No.
2

TIMING BELT APPLICATION Application 3.0L V6 Pickup 1988-91 .............................. 1992 8/92 & Earlier .................. 9/92 & Later .................... 1993-95 .............................. T100 1993-94 .............................. 4Runner 1988-91 .............................. 1992 8/92 & Earlier .................. 9/92 & Later .................... 1993-95 ..............................
1 2

4.1 Hours .. .

TCK240 . ..... T154

1 1

4.1 Hours .. . 2 TCK240 . ..... T154 4.1 Hours ... TCK240A . ..... T240 1 4.1 Hours ... TCK240A . ..... T240
1

7) Install Camshaft Sprocket Holder (09278-54012), or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. 8) Remove timing belt from camshaft sprockets. Remove power steering belt pulley. Using Pulley Holder (09213-58012) and Handle (09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. NOTE: If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. 9) Using puller, remove crankshaft pulley. Remove bolts, No. 1 timing belt cover and gasket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. 10) If reusing timing belt, mark direction of timing belt rotation. Ensure reference mark exists on timing belt at reference mark (dot) on crankshaft sprocket. See Fig. 3. 11) If reference mark does not exist, install reference mark on timing belt in alignment with timing mark (dot) on crankshaft sprocket for reassembly reference. See Fig. 3. 12) Remove timing belt. Remove bolt, No. 1 idler pulley and plate washer (if necessary). See Fig. 1 or 2.

4.1 Hours ... TCK240A . ..... T240 4.1 Hours .. .


2

TCK240 . ..... T154

4.1 Hours .. . TCK240 . ..... T154 1 4.1 Hours ... TCK240A . ..... T240 1 4.1 Hours ... TCK240A . ..... T240

With Air Conditioning, add .5 hours. Timing belt component kit does not include camshaft tensioner hydraulic assembly.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 60,000 miles for severe operating conditions.

REMOVAL & INSTALLATION


TIMING BELT
Removal 1) Disconnect negative battery cable. Drain cooling system. Remove lower engine covers. Remove radiator. Remove all accessory drive belts. 2) Remove power steering pump with hoses attached, and secure aside (if equipped). Remove spark plugs. Disconnect hoses from air pipe. NOTE: If separating uid coupling from fan bracket, place reference mark on uid coupling and fan bracket for reassembly reference. 3) Remove coolant outlet. See Fig. 1 or 2. Remove fan. Remove spark plug wire clamps across front of No. 2 timing belt cover. If necessary, remove studs for coolant outlet from mount. Remove bolts, No. 2 timing belt cover and gaskets. CAUTION: If reusing timing belt, mark direction of timing belt rotation and ensure reference marks are on timing belt. See Fig. 3. If reference marks are not apparent, place reference mark on timing belt and all sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover with cylinder No. 1 at TDC on compression stroke. See Fig. 3. 4) Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 5) Ensure timing marks on camshaft sprockets align with timing marks on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned, rotate crankshaft clockwise one complete revolution and recheck alignment. 6) On 1988-92 models, remove timing belt guide and tension spring. See Fig. 1. Loosen No. 1 idler pulley retaining bolt. Shift No. 1 idler pulley to left as far as possible, and temporarily tighten bolt. Go to step 8). On 1993-95 models, remove bolts and timing belt tensioner with dust boot. Remove bolts/nuts, fan bracket and gasket. See Fig. 2.

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

Fig. 1: Exploded View of Timing Belt & Components (1988-92 Models) Inspection 1) Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. 2) On 1988-92 models, go to step 4). On 1993-95 models, inspect timing belt tensioner for oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner housing and press rod against solid surface. Replace timing belt tensioner if rod moves. 3) Measure timing belt tensioner rod protrusion from end of rod to edge of housing on timing belt tensioner. See Fig. 5. Replace timing belt tensioner if distance is not .394-.413 (10.00-10.50 mm). 4) Inspect No. 1 and No. 2 idler pulleys and fan for smooth rotation. Replace component if defective.

TOYOTA
3.0L V6 SOHC (Cont.)

703

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

Fig. 2: Exploded View Of Timing Belt & Components (1993-95 Models)

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

Fig. 4: Aligning Timing Marks

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

Fig. 3: Identifying Timing Belt Reference Marks

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

Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion

704

TOYOTA
3.0L V6 SOHC (Cont.)
12) Install hexagon wrench through holes in housing and rod to hold rod in retracted position. Release press. Install dust boot on end of timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts. See TORQUE SPECIFICATIONS. CAUTION: Crankshaft must always be rotated clockwise. DO NOT rotate crankshaft counterclockwise. 13) On 1993-95 models, remove hexagon wrench from timing belt tensioner. On 1988-92 models, loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pulley to right as far as possible and temporarily tighten retaining bolt. Install tension spring. Loosen No. 1 idler pulley retaining bolt until pulley moves with spring force tension. Tighten idler pulley bolt. On all models, rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure crankshaft pulley timing mark aligns with 0 mark on No. 1 timing belt cover. 14) Ensure timing marks on camshaft sprockets align with timing marks on No. 3 timing belt cover. See Fig. 4. If timing marks are not aligned, remove timing belt and reinstall using proper procedure. 15) Install No. 2 idler pulley gasket. See Fig. 1 or 2. Install No. 2 timing belt cover and gaskets. Install crankshaft pulley. 16) To install remaining components, reverse removal procedure. Apply sealant on coolant outlet before installing. Tighten all bolts/nuts to specication. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension.

Installation 1) Install plate washer and No. 1 idler pulley (if removed). See Fig. 1 or 2. Install and tighten bolt to specication. See TORQUE SPECIFICATIONS. Ensure No. 1 idler pulley is clean and rotates smoothly. 2) Install crankshaft pulley bolt in end of crankshaft. Rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 4. 3) Install timing belt on crankshaft sprocket with reference mark on timing belt aligned with reference mark (dot) on crankshaft sprocket. See Fig. 3. Install timing belt on water pump. CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation and reference mark on timing belt aligns with reference mark (dot) on crankshaft sprocket. 4) Install timing belt guide with cupped side away from crankshaft sprocket and at side against timing belt. Install No. 1 timing belt cover and gasket. Align groove of crankshaft pulley with crankshaft key. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specication. See TORQUE SPECIFICATIONS. Install power steering belt pulley on crankshaft pulley. 5) Rotate crankshaft so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. 6) Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 4. Rotate right camshaft so pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. 7) Pull timing belt outward (toward outside of cylinder block) at area near sprocket on water pump. Ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover when crankshaft pulley timing mark is aligned with 0 mark on No. 1 timing belt cover. See Fig. 3. 8) Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise. Install timing belt on left camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket. 9) Using camshaft sprocket holder, slightly rotate left camshaft sprocket and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. See Fig. 4. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft sprocket. 10) Align reference mark on timing belt with timing mark on right camshaft sprocket. See Fig. 3. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. 11) Using new gasket, install fan bracket. Install and tighten bolt/nuts to specication. See TORQUE SPECIFICATIONS. On 1988-92 models, go to step 13). On 1993-95 models, use press to apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6.

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

Fig. 6: Retracting Timing Belt Tensioner Rod

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Bracket-To-Cylinder Head Bolt ................................................................. 27 (37) Camshaft Sprocket Bolt .......................................................................................... 80 (109) Crankshaft Pulley Bolt ........................................................................................... 181 (245) No. 1 Idler Pulley Bolt .................................................................. ................. 25-27 (34-37) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) INCH Lbs. (N.m) Camshaft Housing Rear Cover Bolt ........................................................................ Fan Retaining Nut .................................................................................................... No. 3 Timing Belt Cover Bolt .................................................................................. No. 4 Timing Belt Cover Bolt .................................................................................. Valve Cover Bolt ...................................................................................................... 43 48 73 73 48 (4.9) (5.4) (8.3) (8.3) (5.4)

TOYOTA
3.4L V6
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

705

3.4L V6 Tacoma 1995-04 .............................. 1 2.7 Hours .. .. Tundra 2000-04 Automatic ........................ 2 2.9 Hours .. .. Manual ............................. 2 2.7 Hours .. .. T100 1995-98 .............................. 1 2.7 Hours .. .. 4Runner 1996-00 .............................. 1 2.7 Hours .. .. 2001-02 ............................... 3.2 Hours ... ..
1 2

TCK271 .. ..... T271

TCK271 .. ..... T271 TCK271 .. ..... T271 TCK271 .. ..... T271 TCK271 .. ..... T271 TCK271 .. ..... T271

8) If reusing timing belt, check that there are 3 installation marks and a front mark on belt. See Fig. 3. If marks are missing, place 3 NEW marks on belt to match position of belt on camshaft and crankshaft pulleys. Also place front facing arrow on belt. 9) Alternately loosening the bolts, remove timing belt tensioner and dust boot. DO NOT hold tensioner with push rod facing DOWN. Remove timing belt. 10) On Tundra and T100, loosen right camshaft timing pulley bolt using Pulley Holder (09960-10010) or equivalent to hold pulley. Remove bolt, knock pin and camshaft timing pulley. Inspection (All Models) 1) Inspect idler pulleys for oil leakage at seal area. Inspect idler pulley bearings for smoothness. Replace if defective. CAUTION: DO NOT hold tensioner with push rod facing DOWN. 2) Inspect timing belt tensioner for oil leakage. Hold tensioner (push rod facing upward) with both hands and push the push rod against a hard surface. If push rod moves, replace tensioner. Measure protrusion of push rod. If protrusion is not .394-.425 (10.0-10.8 mm), replace tensioner. See Fig. 4. NOTE: Only wipe timing belt pulleys and sprockets clean. Do NOT use any cleaning agents or solvents. NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or equivalent to 2 or 3 threads of pivot bolt. Installation (Tacoma & 4Runner) 1) Ensure No. 1 cylinder is at TDC of compression stroke by aligning crankshaft sprocket with mark on oil pump body. See Fig. 5. Ensure camshaft sprockets are still aligned at TDC positions. See Fig. 6. 2) Install timing belt in following order: a) Left (drivers side) camshaft pulley b) No. 2 idler pulley c) Right (passengers side) camshaft pulley d) Water pump pulley e) Crankshaft pulley f) No. 1 idler pulley If reusing old belt, ensure all reference marks are aligned. 3) Using a press, SLOWLY press in tensioner push rod with pressure of 200-2205 lbs. (100-1000 kg). Align holes of push rod and housing, and insert a 1.27 mm hexagon wrench. Release pressure on push rod. See Fig. 7. 4) Install dust boot on tensioner. Install tensioner and alternately tighten 2 bolts to specication. See TORQUE SPECIFICATIONS. Remove hexagon wrench from tensioner. 5) Ensure timing marks of crankshaft timing pulley and oil pump body are aligned, and check camshaft timing marks. See Fig. 2. If timing marks do not align, remove timing belt and reinstall it. Remove crankshaft pulley bolt, if necessary. 6) Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. Install starter wire bracket and lower timing belt cover with NEW gaskets. Install crankshaft pulley. Install crankshaft pulley bolt and tighten to specication. 7) Turn crankshaft CLOCKWISE 2 revolutions from TDC to TDC. Ensure V notch (TDC mark) on crankshaft pulley aligns with 0 mark on lower timing belt cover. Ensure camshaft timing marks are still aligned with marks on rear cover. 8) Install fan bracket. Install power steering adjusting strut. Install upper timing belt cover with NEW gasket. Connect electrical connectors and install clamps on timing belt cover. Using a NEW O ring with an application of soapy water, install oil dipstick tube. Install A/C compressor bracket and A/C compressor. Install power steering pump. Connect 2 power steering hoses to air intake chamber and resonator. Install fan and lower fan shroud. Install accessory drive belts. Install engine undercover. 9) To complete installation, reverse removal procedure. Tighten all nuts and bolts to specication. See TORQUE SPECIFICATIONS. Fill cooling system and bleed air from system. Adjust drive belts to proper tension.

With Air Conditioning, add .5 hours. With Air Conditioning, add .4 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1990-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe driving conditions. For 1998-04 model years, the manufacturer recommends the belt be replaced every 90,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (All Models) 1) Remove lower engine cover (if equipped). Drain cooling system. Disconnect upper radiator hose. Remove accessory drive belts. Disconnect 2 power steering hoses from the air intake chamber and resonator. Remove power steering pump drive belt. Remove power steering pump with hoses attached, and hang out of way. Remove A/C compressor with hoses attached, and hang out of way. 2) Loosen cooling fan with uid coupling and fan pulleys. Remove lower fan shroud. Remove fan and fan pulleys. 3) Remove A/C compressor bracket from engine. On Tacoma and 4Runner, remove engine oil dipstick and tube. On all models, disconnect electrical connectors and clamps from upper timing belt cover. Remove upper timing belt cover. See Fig. 1. Remove power steering pump adjusting strut. Remove fan bracket. NOTE: Always turn crankshaft CLOCKWISE as viewed from timing belt end of engine. 4) Ensure No. 1 cylinder is set at TDC of compression stroke (crankshaft pulley groove aligned with zero mark on lower timing belt cover, and camshaft sprocket timing marks are aligned with marks on back cover). Use Pulley Holder (09213-54015) or equivalent to hold crankshaft pulley. Remove crankshaft pulley bolt. Use gear puller to remove crankshaft pulley. 5) Remove starter wire bracket and lower timing belt cover. Noting installed position for reassembly reference, remove timing belt guide. 6) Check that the crankshaft sprocket timing mark is aligned with mark on oil pump body. Check that camshaft sprocket timing marks are aligned with timing marks on back cover. See Fig. 2. 7) If marks are not aligned, temporarily install crankshaft pulley bolt. Turn crankshaft CLOCKWISE one revolution (360 degrees). Recheck alignment of timing marks. Remove crankshaft pulley bolt.

706

TOYOTA
3.4L V6 (Cont.)

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

Fig. 1: Exploded View Of Timing Belt & Components

TOYOTA
3.4L V6 (Cont.)

707

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

Fig. 6: Aligning Camshaft Sprocket Timing Marks

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

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

Fig. 7: Retracting Timing Belt Tensioner Rod


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

Fig. 3: Locating Timing Belt Installation Marks

NOTE: If No. 1 idler pulley was removed, apply Loctite 242 or equivalent to 2 or 3 threads of pivot bolt. Installation (Tundra & T100) 1) Ensure No. 1 cylinder is at TDC of compression stroke by aligning crankshaft sprocket with mark on oil pump body. See Fig. 5. Wipe any oil or water from timing pulleys. DO NOT use any cleansing agent. 2) Align installation mark on timing belt with drilled mark on crankshaft timing pulley. See Fig. 8. Install timing belt on crankshaft timing pulley, No. 1 idler pulley and water pump pulley. Install timing belt guide with cupped side away from crankshaft sprocket and at side toward timing belt. 3) Install lower timing belt cover and starter wire bracket, and tighten bolts to specication. See TORQUE SPECIFICATIONS. Install crankshaft pulley. Install crankshaft pulley bolt and tighten to specication. Ensure V notch (TDC mark) on crankshaft pulley aligns with 0 mark on lower timing belt cover. 4) Ensure left camshaft sprocket timing mark is aligned with timing mark on back cover, and right camshaft knock pin hole is aligned with timing mark on back cover. See Fig. 9. 5) Using Pulley Holder (09960-10010), slightly rotate left camshaft pulley CLOCKWISE. Align installation mark on timing belt with timing mark on left camshaft pulley, and install timing belt on left camshaft pulley. See Fig. 10. 6) Rotate left camshaft COUNTERCLOCKWISE to align timing mark with timing mark on back cover. Ensure timing belt has tension between crankshaft pulley and left camshaft pulley. Align installation mark on timing belt with timing mark on right camshaft pulley, and install timing belt on right camshaft pulley. See Fig. 11. 7) Slide right camshaft pulley onto camshaft. Align camshaft knock pin hole with camshaft pulley knock pin groove marked R. Install knock pin. See Fig. 12. Install camshaft pulley bolt, and tighten to specication. See TORQUE SPECIFICATIONS.

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

Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion

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

Fig. 5: Aligning Crankshaft Sprocket Timing Mark

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 specication. 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 specication. See TORQUE SPECIFICATIONS. Fill cooling system and bleed air from system. See COOLING SYSTEM BLEEDING. Check for leaks. Adjust drive belts to proper tension.

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

Fig. 11: Aligning Installation Mark On Timing Belt With Timing Mark On Right Camshaft Pulley (Tundra & T100)

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

Fig. 8: Aligning Timing Belt Installation Mark With Drilled Mark On Crankshaft Timing Pulley (Tundra & T100)

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

Fig. 12: Installing Camshaft Timing Pulley Knock Pin (Tundra & T100)

COOLING SYSTEM BLEEDING


1) Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. 2) Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary.

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

Fig. 9: Aligning Camshafts For Timing Belt Installation (Tundra & T100)

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

Fig. 10: Aligning Installation Mark On Timing Belt With Timing Mark On Left Camshaft Pulley (Tundra & T100)

TOYOTA
3.4L V6 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket-To-Engine ......................................................................... 35 (47) A/C Compressor-To-Bracket ..................................................................................... 18 (25) Camshaft Pulley Bolt ............................................................................................... 81 (110) Crankshaft Pulley Bolt T100 & 1995-98 Tacoma & 4Runner ................................................................. 184 (250) 1999-03 4Runner ................................................................................................ 217 (295) 1999-04 Tacoma .................................................................................................. 217 (295) 2000-04 Tundra ................................................................................................... 217 (295) No. 1 Idler Pulley Pivot Bolt ................................................................................... 1 25 (35) No. 2 Idler Pulley Bolt .............................................................................................. 30 (40) Power Steering Pump Bolt/Nut ................................................................................. 31 (43) Spark Plug ................................................................................................................. 13 (18) Timing Belt Tensioner Bolt ........................................................................................ 20 (27) Water Pump Bolt ....................................................................................................... 14 (20) INCH Lbs. (N.m) Fan Retaining Nut .................................................................................................... 48 (5.4) Lower Timing Belt Cover Bolt ..................................................................................... 80 (9) Oil Dipstick Tube ......................................................................................................... 71 (8) Upper Timing Belt Cover Bolt ..................................................................................... 80 (9)
1

709

Apply Loctite 242 or equivalent to 2 or 3 threads of pivot bolt

710

VOLKSWAGEN
1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application 1.5L 4-Cyl. Diesel Dasher 1979-80 ..................................................... Rabbit 1977-80 ..................................................... Rabbit Pickup 1980 ........................................................... 1.6L 4-Cyl. Diesel & Turbo Diesel Dasher 1981 ........................................................... Golf 1985-87 ..................................................... 1988-92 (Canadian) .................................. Jetta 1981-86 ..................................................... 1986 (Canadian) ....................................... 1989-92 ..................................................... 1988-92 (Canadian) .................................. Quantum 1982-85 ..................................................... Rabbit 1981-84 ..................................................... Rabbit Pickup 1981-83 ..................................................... Vanagon 1982 ...........................................................

2.8 Hours ... ..... T043 1.5 Hours ... ..... T043 2.8 Hours ... ..... T043

2.8 Hours ... ..... T043 2.8 Hours ... ..... T043 2.2 Hours ... ..... T043 2.8 2.8 2.2 2.2 Hours Hours Hours Hours ... ..... ... ..... ... ..... ... ..... T043 T043 T043 T043
Courtesy of Volkswagen United States, Inc.

Fig. 1: Installing Camshaft Setting Bar belt so there is no slack between camshaft sprocket and injection pump, and between injection pump and crankshaft sprocket. 2) Tighten tension adjuster to keep belt rmly in place. Remove injection pump locking pin. Adjust belt tension by turning tensioner until scale reads 12-13 on Tension Gauge (210) or equivalent. See Fig. 2. Tighten camshaft sprocket bolt and tensioner adjuster lock nut. Remove lock from camshaft. 3) Turn crankshaft 2 revolutions in direction of engine rotation. Using a rubber hammer, strike belt once between camshaft sprocket and injection pump sprocket. Recheck belt tension and install remaining components in reverse order of removal. Check injection pump timing. Adjust drive belts to proper tension.

2.8 Hours ... ..... T043 1.5 Hours ... ..... T043 2.8 Hours ... ..... T043 2.8 Hours ... ..... T043

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: Sprockets do not have to be removed to replace drive belt. Removal 1) Disconnect negative battery cable. Loosen alternator and remove drive belt. Remove crankshaft drive belt pulley. Remove air cleaner and ducting. Remove timing belt and cylinder head cover. Remove timing plug on top of bellhousing. Rotate engine to bring No. 1 cylinder to TDC. Check that TDC mark on ywheel is aligned with reference. 2) Using Setting Bar (2065A for Vanagon, 2065 for other models) or equivalent, lock camshaft in position. See Fig. 1. Align tool by turning camshaft until one end of tool touches cylinder head. Measure gap at other end with feeler gauge. Insert feeler gauges of 1/2 thickness measured between tool and cylinder head at each end of tool. 3) Lock injection pump sprocket at TDC with Special Pin (2064) or equivalent. Loosen belt tensioner and remove timing belt from sprockets. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. Installation 1) Ensure that ywheel is still aligned with TDC mark. With camshaft and injection pump locked in place, loosen camshaft sprocket bolt 1/2 turn. Lightly tap camshaft gear loose from camshaft. Install drive

Courtesy of Volkswagen United States, Inc.

Fig. 2: Installing Timing Belt Tension Gauge

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Bolts ............................................................................................. 15 (20) Crankshaft Sprocket Bolt Except Vanagon .................................................................................................... 81 (110) Vanagon ............................................................................................................... 110 (150) Intermediate Sprocket Bolt ........................................................................................ 33 (45) Timing Belt Tensioner Lock Nut ............................................................................... 33 (45) Water Pump Pulley Bolt ............................................................................................ 15 (20)

VOLKSWAGEN
1.5L, 1.6L & 1.7L 4-Cylinder Gasoline
TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No.

711

3) Reverse removal procedure for remaining components. Adjust drive belts to proper tension.

1.5L 4-Cyl. Dasher 1974-75 ............................ .... 1.3 Hrs. Rabbit 1975-79 ............................ .... 1.5 Hrs. Scirocco 1978 ................................. .... 1.8 Hrs. 1.6L 4-Cyl. Dasher 1976-80 ............................ .... 1.5 Hrs. Jetta 1980 ................................. .... 1.8 Hrs. Pickup 1980 ................................. .... 1.8 Hrs. Rabbit 1980 ................................. .... 1.5 Hrs. Scirocco 1976-80 ............................ .... 1.8 Hrs. 1.7L 4-Cyl. Jetta 1981-84 ............................ .... 1.8 Hrs. Quantum 1982-83 ............................ ... 1 1.8 Hrs. Rabbit 1981 ................................. .... 1.5 Hrs. 1982-84 ............................ .... 1.8 Hrs. Rabbit Pickup 1981-83 ............................ .... 1.8 Hrs. Scirocco 1981-83 ............................ .... 1.8 Hrs.
1

.... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017

.... .. TCK017 .. ..... T017 ... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017 .... .. TCK017 .. ..... T017

Courtesy of Volkswagen United States, Inc.

Fig. 1: Aligning Crankshaft & Intermediate Sprockets

With Air Conditioning, Without Factory Air Conditioning, With Radiator removal, labor time is 3.9 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Courtesy of Volkswagen United States, Inc.

Fig. 2: Aligning Camshaft With Cylinder Head Flange

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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolts ............................................................................................. 15 (20) Crankshaft Sprocket Bolt .......................................................................................... 59 (80) Intermediate Sprocket Bolt 1 ..................................................................................... 59 (80) Timing Belt Tensioner Lock Nut ............................................................................... 33 (45) Water Pump Bolts ..................................................................................................... 15 (20) Water Pump Pulley Bolts .......................................................................................... 15 (20)
1

TIMING BELT
Removal Disconnect negative battery cable. Remove alternator belt, water pump pulley, and upper and lower drive belt covers. If equipped, remove air conditioning compressor drive belt. Remove timing belt guide, if equipped. Loosen belt tensioner, and work belt off sprockets toward front of engine. Installation 1) Rotate camshaft sprocket until index punch mark on camshaft sprocket is lined up with top surface of valve cover mounting ange 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 rst, 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.

Use Loctite.

712

VOLKSWAGEN
1.8L 4-Cylinder Golf, GTI & Jetta AWD, AWP & AWW Engines
REMOVAL & INSTALLATION
Labor Time Belt Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

TIMING BELT APPLICATION Application

1.8L 4-Cylinder Turbo (AWD, AWP & AWW Engines) Golf 2000-01 ..................................................... 2.9 Hours ... ..... T306 GTI & Jetta 2000-04 ..................................................... 2.9 Hours ... ..... T306 NOTE: Engine code is located on machined pad on bellhousing ange, where engine connects to transaxle. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

TIMING BELT
NOTE: To identify engine, check engine code located on a pad on engine block near bellhousing of transmission. Removal 1) Working under hood, remove engine cover. Working under vehicle, remove insulation tray. 2) On Golf and GTI, remove mounting screws and pull right headlight housing out slightly forward. Disconnect electrical connection and pull right headlight housing out from vehicle.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 120,000 mile intervals.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Identifying Turbocharger Charge Air Cooling System Components

VOLKSWAGEN
1.8L 4-Cylinder Golf, GTI & Jetta AWD, AWP & AWW Engines (Cont.)
3) On Jetta, Remove screws and pull right headlight access cover upward. Disconnect harness connector and remove securing screws at top of right headlight. Remove securing screws at bottom of right headlight and pull headlight housing out forward to remove from vehicle. 4) Remove charge air cooler duct at bottom of right-hand crossmember. See Fig. 1. Rotate serpentine drive belt tensioner clockwise (as viewed from front of engine) to relieve belt tension using a 16 mm wrench. See Fig. 2. Lock tensioner in place using Mandrel (T10060). Remove serpentine drive belt and tensioner. 5) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Ensure that TDC marks on ywheel and bellhousing are aligned. See Fig. 3 or 4. 6) Remove cooling system expansion tank and power steering reservoir bolts. Leaving hoses attached, secure expansion tank and reservoir out of way. 7) Remove vacuum hose connecting fuel evaporative canister to throttle body. Unplug coolant expansion tank and fuel evaporative canister harness connectors. Remove upper timing belt cover. See Fig. 5. 8) Attach Engine Support Bridge (10-222A) with Bracket (10222A/1), and engage retainer in right lifting eye bolt located at cylinder head. Lift engine slightly to remove weight from engine mounts. Engine may also be supported from below with a oor 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 pulley. It is NOT necessary to remove crankshaft pulley center bolt. 11) Remove lower and middle timing belt covers. See Fig. 5. Remove engine bracket from engine block. See Fig. 6. If reusing old timing belt, mark timing belt with arrow to indicate original direction of rotation. 12) Screw Tensioning Bolt (T10092) or a M5 x 55 stud into the timing belt tensioner bracket. See Fig. 7. Install hex nut and washer onto stud. 13) SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that Locking Pin (T40011) or drill bit can be inserted through the tensioner body, locking the tensioner in place. 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.

713

Courtesy of Volkswagen United States, Inc.

Fig. 3: Setting Crankshaft To TDC (Automatic Transmission)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Setting Crankshaft To TDC (Manual Transmission)

Courtesy of Audi of America, Inc.

Fig. 5: Exploded View Of Timing Belt & Components 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.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Belt Tensioner

714

VOLKSWAGEN
1.8L 4-Cylinder Golf, GTI & Jetta AWD, AWP & AWW Engines (Cont.)

Courtesy of Audi of America, Inc. Courtesy of Volkswagen United States, Inc.

Fig. 8: Aligning Timing Marks

Fig. 6: Locating Engine Bracket-To-Block Bolts

Courtesy of Audi of America, Inc.

Fig. 7: Compressing Timing Belt Tensioner


Courtesy of Audi of America, Inc.

NOTE: Before installing engine mount, insert bolts into engine mount. 2) Install timing belt around crankshaft sprocket. If installing used belt, ensure it is installed in original direction of rotation. Install engine mount bracket to block. Install lower timing belt guard. Use Locking Fluid (D 000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley, and tighten bolt to specication. See TORQUE SPECIFICATIONS. 3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 8. Place timing belt on water pump, tensioner pulley and camshaft sprocket. 4) Compress tensioner and remove locking pin or drill bit from timing belt tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions in normal direction of rotation. Align camshaft and crankshaft timing marks. Install crankshaft pulley. 5) Install center and upper timing belt covers. Install engine right-hand engine support arm and console using NEW bolts. Adjust engine console and right-hand engine support arm so clearance is about .50 (13 mm). See Fig. 9. 6) Remove Engine Support Bracket (10-222) or oor jack from under vehicle. Install serpentine belt tensioner and serpentine belt. 7) Install coolant expansion tank and power steering reservoir. Install vacuum line between fuel evaporative canister and throttle body. To install remaining components, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

Fig. 9: Locating Right-Hand Engine Support Arm

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Sprocket ............................................................... 18 (25) Engine Mount-To-Body 1 Step 1 ...................................................................................................................... 30 (40) Step 2 ................................................................................................... Additional 1/4 Turn Engine Mount-To-Engine Bracket 1 Step 1 ...................................................................................................................... 44 (60) Step 2 ................................................................................................... Additional 1/4 Turn Serpentine Belt Tensioner Bolt ................................................................................. 18 (25) Timing Belt Tensioner Bottom Bolt .............................................................................................................. 11 (15) Top Bolt ................................................................................................................... 15 (20) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) Water Pump Bolt ....................................................................................................... 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10)
1

Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.

VOLKSWAGEN
1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines
TIMING BELT APPLICATION Application Labor Time Belt Part No.

715

1.8L 4-Cylinder DOHC (APH, AWP & AWV Engines) New Beetle 1999-04 ..................................................... 2.9 Hours ... ..... T306 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

CAUTION: Engine mount assembly is secured by torque-to-yield bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt. These bolts MUST be replaced if they are loosened or removed. 8) Remove bolts from engine mount assembly at timing belt end of engine. Remove engine mount. 9) Remove 4 crankshaft pulley socket-head bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft pulley center bolt. 10) Remove lower and middle timing belt covers. Remove engine bracket from engine block. See Fig. 7. If reusing old timing belt, mark timing belt with arrow to indicate original direction of rotation. 11) Screw Tensioning Bolt (T10092) or M5 x 55 x 1 stud into timing belt tensioner bracket. See Fig. 8. Install hex nut and washer onto stud. 12) SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that Locking Pin (T40011) or drill bit can be inserted through the tensioner body, locking the tensioner in place. CAUTION: When turning camshaft, crankshaft must not be at TDC, or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm. 13) Remove timing belt. Turn crankshaft back just slightly to ensure that crankshaft is not at TDC for any cylinder in case camshaft moves.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the timing belt AND tensioner be replaced at 105,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove engine cover. Remove noise insulation pan from under engine compartment. 2) Remove air duct pipe between turbocharger and charge air cooler. See Fig. 1. Air duct pipe is located along bottom right of cross member.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Serpentine Drive Belt Tension (1 Of 2)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Identifying Air Duct 3) Mark rotation direction of serpentine drive belt. Move serpentine drive belt tensioner as shown to release tension on belt. See Fig. 2. Secure tensioner using a drift, about .18 (4.5 mm) x 2.2 (55 mm). See Fig. 3. Remove serpentine drive belt. Remove serpentine drive belt tensioner. NOTE: On vehicles without headlight cleaning system, Connecting Rod Support (3090) can also be used to secure tensioner. 4) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Ensure that TDC marks on ywheel and bellhousing are aligned. See Fig. 4 or 5. 5) Remove coolant expansion tank and set aside. Label all vacuum hoses for reassembly reference, and disconnect vacuum hoses from fuel evaporative canister. Disconnect vacuum hoses at throttle body. 6) Remove upper timing belt cover. See Fig. 6. 7) Attach Engine Support Bridge (10-222A) with Bracket (10222), and engage retainer in right lifting eye bolt located at cylinder head. Lift engine slightly to remove weight from engine mounts. Engine may also be supported from below with a oor jack.
Courtesy of Volkswagen United States, Inc.

Fig. 3: Releasing Serpentine Drive Belt Tension (2 Of 2) Installation 1) Ensure camshaft is still at TDC of compression stroke for No. 1 cylinder. Align timing marks on camshaft sprocket with mark on cylinder head cover. See Fig. 9.

716

VOLKSWAGEN

1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Setting Crankshaft to TDC (Automatic Transmission)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Locating Engine Bracket-To-Block Bolts

Courtesy of Volkswagen United States, Inc.

Fig. 5: Setting Crankshaft to TDC (Manual Transmission)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Installing Timing Belt Tensioner Locking Pin 4) Remove Locking Pin (T40011) or drill bit and unscrew Tensioning Bolt (T10092). See Fig. 8. 5) Turn crankshaft 2 revolutions, and check that camshaft and crankshaft marks align properly. See Fig. 9. 6) Install middle and upper timing belt covers. Tighten bolts to specication. 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 oor jack. Install serpentine drive belt tensioner. Install serpentine drive belt. Install the A/C compressor drive belt (if equipped). Ensure used belts are installed in original direction of rotation. 9) To complete installation, reverse remaining removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Exploded View of Timing Belt & Components NOTE: Before installing engine mount, insert bolts into engine mount. 2) Install timing belt around crankshaft sprocket. If installing used belt, ensure it is installed in original direction of rotation. Install engine mount bracket to block. Install lower timing belt guard. Use Locking Fluid (D 000 600 A2) on lower timing belt cover bolts. Install crankshaft pulley, and tighten bolts to specication. See TORQUE SPECIFICATIONS. 3) Rotate crankshaft to TDC No. 1 cylinder. See Fig. 9. Place timing belt on water pump, tensioner pulley and camshaft sprocket.

VOLKSWAGEN
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

717

1.8L 4-Cylinder New Beetle APH, AWP & AWV Engines (Cont.)

Courtesy of Audi of America, Inc.

Fig. 9: Aligning Camshaft & Crankshaft Timing Marks

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Center Bolt 1 Step 1 ...................................................................................................................... 66 (90) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Engine Mount Bracket-To-Engine ............................................................................. 33 (45) Engine Mount-To-Body 1 Step 1 ...................................................................................................................... 30 (40) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Engine Mount-To-Engine Bracket 1 Step 1 ...................................................................................................................... 44 (60) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Serpentine Drive Belt Tensioner Bolt ....................................................................... 18 (25) Timing Belt Cover Bolt .............................................................................................. 15 (20) Timing Belt Idler Pulley Bolt ..................................................................................... 15 (20) Timing Belt Tensioner Mount Bolt ................................................ ............................ 11 (15) Timing Belt Tensioner Pulley Bolt ............................................................................. 18 (25) Water Pump Bolt ....................................................................................................... 11 (15)
1

Replace bolts if loosened or removed.

Courtesy of Volkswagen United States, Inc.

Fig. 10: Adjusting Engine Mount Clearance

718

VOLKSWAGEN
1.8L 4-Cylinder Passat AEB & ATW Engines
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.8L 4-Cylinder DOHC (AEB & ATW Engines) Passat 1998-00 152 Tooth Belt ........................................ 3.6 Hours ... ..... T291 153 Tooth Belt ........................................ 3.6 Hours ... ..... T317 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998-99 model years, the manufacturer suggests the belt be replaced at 90,000 mile intervals. For 2000 model year, the manufacturer suggests the belt AND tensioner be replaced at 105,000 mile intervals.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Volkswagen United States, Inc.

Fig. 1: Exploded View Of Front Bumper Assembly

TIMING BELT
NOTE: ATW engines use T317 (153 tooth belt). AEB engines are originally equipped with T291 (152 tooth belt), but may have had tensioner and belt upgraded to T317 (153 tooth belt). NOTE: Front lock carrier (radiator support) must be moved forward to remove timing belt. Removal 1) Raise and support vehicle. Remove front, lower engine cover. Lower vehicle. Separate release lever from hood lock. Remove front bumper cover. See Fig. 1. Remove bumper carrier from impact damper. 2) Unbolt air duct between lock carrier and air cleaner on lock carrier. Remove support bolt on passenger side of lock carrier and insert one Lock Carrier Guide (3369) into hole. See Fig. 2. 3) Remove lock carrier front support bolts. Remove lock carrier-to-side panel bolts. Insert Lock Carrier Guide (3369) into hole on drivers side of vehicle. Slide lock carrier forward on lock carrier guides. 4) On vehicles with A/C, mark direction of rotation on belt, and remove A/C drive belt. On all vehicles, rotate accessory drive belt tensioner clockwise to remove tension from belt. Mark belt with rotation direction, and remove accessory drive belt. See Fig. 3. 5) Remove accessory drive belt tensioner pulley and lever. Turn crankshaft to TDC of compression stroke on No. 1 cylinder. See Fig. 4. 6) Remove crankshaft pulley. It is NOT necessary to remove center crankshaft pulley center bolt. Remove upper and lower timing belt covers. Loosen timing belt tensioner lever bolt. 7) If reusing timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt. CAUTION: When turning camshaft, crankshaft must not be at TDC or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm. Installation 1) Align timing marks on camshaft sprocket with mark on cylinder head cover. See Fig. 4. Ensure crankshaft is still at TDC position. Install timing belt around crankshaft sprocket. Temporarily install crankshaft pulley to ensure crankshaft is still at TDC of compression stroke for No. 1 cylinder. 2) Place timing belt on intermediate shaft sprocket, tensioner pulley and camshaft sprocket. To tension timing belt, use spanner wrench to rotate tensioner pulley clockwise until tensioner piston No. 1 is fully extended, and tensioner piston No. 2 lifts about .040 (1 mm). See Fig. 5.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Exploded View Of Lock Carrier Assembly 3) Tighten tensioner pulley bolt to specication. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions. Make sure camshaft and crankshaft timing marks are aligned. 4) Belt tension is correct if edge of tensioner lever aligns with piston upper edge (Area A), or piston No. 1 is extended 0.98-1.14 (25-29 mm) (dimension D). See Fig. 6. Check for wear in Areas B and C if dimension is not correct. 5) Remove crankshaft pulley. Install lower and upper timing belt covers. Install crankshaft pulley. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install accessory drive belt tensioner. Install accessory drive belt. Install the A/C compressor drive belt (if equipped). Ensure used belts are installed in original direction of rotation. 6) Install lock carrier in original location. Install bumper and bumper cover.

VOLKSWAGEN
1.8L 4-Cylinder Passat AEB & ATW Engines (Cont.)

719

Courtesy of Volkswagen United States, Inc.

Fig. 6: Checking Timing Belt Tension


Courtesy of Volkswagen United States, Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Bolt ........................................................................ 18 (25) A/C Drive Belt Tensioner Bolt ................................................................................... 22 (30) Bumper Carrier-To-Impact Damper Vertical Bolt ...................................................... 15 (20) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Impact Damper-To-Lock Carrier Bolt ........................................................................ 68 (50) Lock Carrier Front Support Bolt ................................................................................................... 37 (50) Timing Belt Tensioner Pulley Bolt ............................................................................. 18 (25) INCH Lbs. (N.m) Bumper Guide-To-Side Panel Bolt .............................................................................. 18 (2) Lock Carrier-To-Side Panel Bolt ................................................................................. 71 (8) Timing Belt Cover Bolt .............................................................................................. 89 (10) Timing Belt Tensioner Bolt ........................................................................................ 89 (10)

Fig. 3: Removing Timing Belt

Courtesy of Volkswagen United States, Inc.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of Volkswagen United States, Inc.

Fig. 5: Adjusting Timing Belt Tension

720

VOLKSWAGEN
1.8L 4-Cylinder Passat AUG & AWM Engines
Labor Time Belt Part No. NOTE: If necessary, align pressure piston using needle nose pliers or a thin wire (hole in piston and hole in housing must align). 6) On vehicles built through July 2000, align holes in timing belt tensioner piston rod and housing. Insert Tensioning Bolt (T10092) into timing belt tensioner bracket. See Fig. 7. Turn tensioning bolt just enough so that holes in tensioner piston rod and housing align. Insert Locking Pin (T40011) into holes to secure tensioner in place. CAUTION: Tensioners on vehicles built after July 2000 are oil-lled. Excessive force during compression can damage tensioner. 7) On vehicles built after July 2000, insert a hex wrench into hex socket on tensioner and push pulley counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with Locking Plate (T10008). See Fig. 8. 8) To loosen tensioner on models built after July 2000, install Pin Wrench (3387). Ensure tab on Pin Wrench is not bent. Loosen nut in center of tensioner, and rotate clockwise using Pin Wrench. 9) On all models, remove timing belt. Turn crankshaft back just slightly to ensure that crankshaft is not at TDC for any cylinder. CAUTION: When turning camshaft, crankshaft must not be at TDC, or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm. Installation 1) Align timing marks on camshaft sprocket with mark on cylinder head cover. Ensure crankshaft sprocket is still aligned with timing mark. See Fig. 6. 2) Install timing belt around crankshaft sprocket. Install lower timing belt cover. Install NEW vibration damper bolts, and tighten to specication. See TORQUE SPECIFICATIONS. 3) Set crankshaft pulley to TDC No. 1 cylinder. Place timing belt on water pump, tensioner pulley and camshaft sprocket. For models built through July 2000, go to next step. For models built after July 2000, go to step 5). NOTE: Engine must be cool (not more than lukewarm) when tensioning timing belt. 4) On models built through July 2000, remove Locking Pin (T40011) and unscrew Tensioning Bolt (T10092). See Fig. 7. CAUTION: If tensioner is fully extended at any time, it must be pressed back into compressed position using tensioner assembly and Pin Wrench. Excessive force during this compression procedure can damage tensioner assembly. 5) On models built after July 2000, rotate tensioner counterclockwise using Pin Wrench (3387), removing all tension until Locking Plate (T10008) can be removed without force. After removing Locking Plate, rotate tensioner clockwise using Pin Wrench until a 5/16 (8 mm) drill bit can be inserted between tensioner lever and housing through underside of tensioner. While holding tensioner in this position, tighten tensioner retaining bolt to specication. See TORQUE SPECIFICATIONS. 6) On all models, turn crankshaft 2 revolutions in normal direction of rotation. Check that camshaft and crankshaft timing marks align properly. See Fig. 6. 7) On models built after July 2000, using a drill bit check dimension between tightening lever and housing of tightening device. Specied value .236-.393 (6-10 mm). If dimension is not as specied, repeat timing belt tensioning procedure. 8) To nish installation, reverse remaining removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

TIMING BELT APPLICATION Application

1.8L 4-Cylinder DOHC (AUG & AWM Engines) Passat 2000-04 ..................................................... 3.6 Hours ... ..... T306 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the timing belt AND tensioner be replaced at 105,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion. Removal 1) For vehicles manufactured up to September, 2000, disconnect front turn signal light assembly wiring harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 2. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools. 2) For vehicles manufactured from October, 2000, remove bumper cover from bumper carrier. See Fig. 3. Remove noise insulation panel from under engine compartment. Remove air intake duct at lock carrier. Remove bolts from front of bumper carrier. See Fig. 4. Install guide rods on right and left sides. Pull lock carrier forward about 4 (10 cm) on guide rods into service position. CAUTION: DO NOT hang condenser or oil cooler from their lines. 3) On all vehicles, loosen bolts for air conditioning drive belt and remove belt. Remove serpentine drive belt. Remove serpentine drive belt tensioner. NOTE: Mark direction of ribbed belt with chalk or felt-tip pen prior to removal. Running a used belt in the opposite direction could destroy it. 4) Remove upper timing belt cover. See Fig. 5. Rotate crankshaft to TDC No. 1 cylinder. See Fig. 6. CAUTION: Vibration damper outer bolts and center bolt are torqueto-yield type. If loosened or removed, bolts must be replaced. 5) Remove vibration damper. It is NOT necessary to remove center bolt from vibration damper. Remove lower and middle timing belt covers. See Fig. 5. For vehicles built through July 2000, go to next step. For vehicles built after July 2000, go to step 7).

VOLKSWAGEN
1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)

721

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Front Bumper Cover (Up To September, 2000)


Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing Front Bumper Cover (From October, 2000)

Courtesy of Volkswagen United States, Inc. Courtesy of Volkswagen United States, Inc.

Fig. 2: Moving Lock Carrier To Service Position (Up To September, 2000)

Fig. 4: Moving Lock Carrier To Service Position (From October, 2000)

722

VOLKSWAGEN
1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Exploded View Of Timing Belt Components

Courtesy of Volkswagen United States, Inc.

Fig. 7: Compressing Timing Belt Tensioner (Up To July, 2000)


Courtesy of Volkswagen United States, Inc.

Fig. 6: Aligning Camshaft & Crankshaft Timing Marks

VOLKSWAGEN
1.8L 4-Cylinder Passat AUG & AWM Engines (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

723

Courtesy of Audi of America, Inc.

Application Ft. Lbs. (N.m) Bumper Carrier-To-Impact Absorber Vertical Bolt .................................................... 15 (20) Camshaft Sprocket Bolt ............................................................................................ 50 (65) Crankshaft Pulley Center Bolt 1 Step 1 ...................................................................................................................... 66 (90) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Idler Pulley Bolt ......................................................................................................... 18 (25) Impact Damper-To-Lock Carrier Bolt (From Oct. 2000) .......................................... 68 (50) Lock Carrier Front Support Bolt ................................................................................................... 37 (50) Timing Belt Tensioner Bolt ........................................................................................ 11 (15) Serpentine Drive Belt Tensioner Bolt ....................................................................... 18 (25) Timing Belt Tensioner Pulley Bolt ............................................................................. 20 (27) Water Pump Bolt ....................................................................................................... 11 (15) INCH Lbs. (N.m) 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

Fig. 8: Compressing Timing Belt Tensioner (From July, 2000)

Replace bolt if loosened or removed.

724

VOLKSWAGEN
1.8L 4-Cylinder SOHC, 1983-93
Labor Time Component Belt Kit No. Part No.

TIMING BELT APPLICATION Application

1.8L 4-Cyl. SOHC Cabriolet 1985-93 ............................ 1, 2 1.8 Hours . .. Corrado 1990-92 ........................... ... 1.8 Hours ... .. Fox 1987-93 ............................ 1, 2 1.8 Hours . .. Golf 1985-92 ............................ 1, 2 1.8 Hours . .. Golf (Canadian) 1993-95 ........................... ... 1.8 Hours ... .. GTI 1984-87 ............................ 1, 2 1.8 Hours . .. 1988-89 ........................... ... 1.9 Hours ... .. 1990-92 ............................ 1, 2 1.8 Hours . .. Jetta 1984-92 ........................... ... 1.8 Hours ... .. Jetta (Canadian) 1993-95 ........................... ... 1.8 Hours ... .. Passat (Canadian) 1992-94 ........................... ... 1.8 Hours ... .. Quantum 1985 ................................ .. 1 1.8 Hours .. .. Rabbit 1983-84 ............................ 1, 2 1.8 Hours . .. Scirocco 1983-88 ............................ 1, 2 1.8 Hours . ..
1

TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 TCK017 .. ..... T017 Fig. 1: Removing Timing Belt 3) Rotate tensioner clockwise to tighten belt and install lock nut. Proper deection is achieved when longest span of belt between sprockets can be twisted 90 degrees. See Fig. 4. 4) By hand, rotate crankshaft 2 turns and check timing mark alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
Courtesy of Audi of America, Inc.

With Air Conditioning, Without Factory Air Conditioning, With Radiator removal, labor time is 3.9 hours. With Air Conditioning, Without Factory Air Conditioning, Without Radiator removal, labor time is 3.6 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of Audi of America, Inc.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

Fig. 2: Aligning Ignition Rotor

REMOVAL & INSTALLATION


TIMING BELT
CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. Removal Disconnect negative battery cable. Match mark all components to ensure reassembly in original position. See Fig. 1. DO NOT turn crankshaft with belt removed. Valve damage may result. Remove upper drive belt cover, drive belt, and pulley. Remove timing belt guide, if equipped. Loosen belt tensioner. Remove vibration damper. Remove lower belt cover. Remove timing belt. Installation 1) Align ywheel/explate 0 mark with pointer. This is TDC. Remove distributor cap and check position of ignition rotor. Rotate intermediate shaft and position ignition rotor at No. 1 cylinder mark on housing. See Fig. 2. 2) With intermediate shaft/ignition rotor positioned, rotate crankshaft and align mark on crankshaft pulley with mark on intermediate shaft sprocket. Position camshaft sprocket mark even with valve cover surface. See Fig. 3. Install timing belt.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Aligning 1.8L Timing Marks (8-Valve)

VOLKSWAGEN
1.8L 4-Cylinder SOHC, 1983-93 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

725

Application Ft. Lbs. (N.m) A/C Bracket-To-Engine Bolt ...................................................................................... 22 (30) Crankshaft Timing Sprocket Bolt .............................................................................. 66 (90) Intermediate Shaft Sprocket Bolt .............................................................................. 59 (80) Lower Pulley Bolt ...................................................................................................... 15 (20) Timing Belt Tensioner Nut ........................................................................................ 33 (45) Water Pump Pulley Bolt ............................................................................................ 15 (20) INCH Lbs. (N.m) Valve Cover Retaining Nut ....................................................................................... 89 (10) Water Pump-To-Housing ........................................................................................... 89 (10)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Checking 1.8L Timing Belt Tension (8-Valve)

726

VOLKSWAGEN
1.8L & 2.0L 4-Cylinder DOHC
Labor Time Belt Part No. noting offset holes. If valve cover is installed, mark on front of camshaft sprocket must align with mark on valve cover. If valve cover is removed, place camshaft sprocket mark even with valve cover surface. See Fig. 3. 2) Align crankshaft sprocket mark with mark on lower timing belt cover. See Fig. 3. Install timing belt around camshaft sprocket. Rotate tensioner clockwise until Timing Belt Tension Scale (VW 210), or equivalent, reads 13-14. 3) Rotate crankshaft 2 revolutions and check timing mark alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 1.8L 4-Cyl. DOHC GTI 1987-89 ..................................................... Jetta 1987-89 ..................................................... Scirocco (Canadian) 1988-89 ..................................................... Scirocco 1987-88 ..................................................... 2.0L 4-Cyl. DOHC GTI 1990-92 ..................................................... Jetta 1990-92 ..................................................... Passat 1990-92 .....................................................

1.9 Hours ... ..... T292 1.9 Hours ... ..... T292 1.8 Hours ... ..... T292 1.9 Hours ... ..... T292

1.9 Hours ... ..... T292 1.9 Hours ... ..... T292 1.9 Hours ... ..... T292
Courtesy of Volkswagen United States, Inc.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Fig. 2: Aligning Ignition Rotor

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Match mark all components to ensure reassembly to original position. Remove accessory drive belts. 2) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Remove fan belt and water pump pulleys. See Fig. 1. Remove timing belt covers. Remove tensioner pulley. Remove timing belt.
Courtesy of Volkswagen United States, Inc.

Fig. 3: Timing Mark Alignment

Courtesy of Volkswagen United States, Inc.

Fig. 1: Exploded View Of Timing Belt & Components Installation 1) Install timing belt around crankshaft and intermediate shaft sprockets. Install lower timing belt cover. Install vibration damper,

Courtesy of Volkswagen United States, Inc.

Fig. 4: Proper Timing Belt Tension

VOLKSWAGEN
1.8L & 2.0L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Nut ............................................................................................... 15 (20) Crankshaft Sprocket Bolt 16-Valve ............................................................................................................... 148 (200) Intermediate Shaft Sprocket Bolt 16-Valve ................................................................................................................... 48 (65) Timing Belt Tensioner Pulley Nut ............................................................................. 33 (45) Water Pump Pulley ................................................................................................... 15 (20) INCH Lbs. (N.m) Upper & Lower Timing Belt Cover Bolt ..................................................................... 53 (6) Water Pump-To-Housing ........................................................................................... 84 (10)

727

728

VOLKSWAGEN
1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.9L 4-Cylinder Turbo Diesel (AAZ, AHU & 1Z Engines) Golf & Golf III 1 1993-95 ..................................................... 2.8 Hours ... ..... 1996-97 ..................................................... 2.8 Hours ... ..... Jetta & Jetta III 1 1993-95 ..................................................... 2.8 Hours ... ..... 1996-98 ..................................................... 2.8 Hours ... ..... Passat (USA) 1 1996-97 ..................................................... 2.8 Hours ... ..... Passat (Canada) 1 1993-98 ..................................................... 2.2 Hours ... .....
1

T242 T242 T242 T242 T242 T242

Code is stamped on pad on engine block between diesel injection pump and exhaust manifold. Engine code is also included on vehicle data plate and timing belt cover.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt AND tensioner be replaced at 60,000 mile intervals.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Serpentine Belt CAUTION: Use spanner wrench to hold camshaft sprocket while loosening center bolt. Do not use camshaft setting bar to hold camshaft sprocket. 2) Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch through hole in rear of timing belt cover until it contacts rear of camshaft sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft sprocket on camshaft taper. 3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. Remove Lock Pin (2064) from injection pump sprocket. 4) On models without semiautomatic timing belt tensioner, apply tension to timing belt using Tension Pin Wrench (Matra V159). See Fig. 6. Turn tensioner clockwise to tension belt. Install Tension Tool (VW210) set to 12 to 13. Measure tension midway between camshaft sprocket and injection pump sprocket. Tighten lock nut on timing belt tensioner to 33 ft. lbs. (45 N.m). 5) On models with semiautomatic timing belt tensioner, install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). 6) On all models, tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Remove setting bar from camshaft. 7) Turn crankshaft 2 revolutions in normal direction of rotation. Recheck timing belt tension. 8) On models with semiautomatic tensioner, apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner. 9) On all models, install timing belt covers. Install vibration damper and belt pulleys (if removed). Install accessory drive belts. To prevent damage to serpentine belt, install in original direction of rotation. 10) Install valve cover. On engine code AAZ, check fuel injection delivery. Consult service information for procedure.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Golf, Jetta & Passat w/AAZ Engine, Up To Sept., 1994) 1) On models with tensioner, install Tensioner Tool (3299) and rotate clockwise. Mark serpentine belt with arrow to indicate rotation direction, and remove belt. See Fig. 1. Remove tensioner pulley. On models without serpentine belts, remove accessory drive belts. 2) On all models, remove upper timing belt cover. See Fig. 2. Remove valve cover. 3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Flywheel TDC mark must be aligned to mark on transmission mating ange. See Fig. 3. 4) Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. 5) Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and one side of cylinder head. 6) Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. 7) Lock injection pump in place using Lock Pin (2064). See Fig. 5. Loosen timing belt tensioner. Remove crankshaft vibration damper. Remove the lower timing belt cover. See Fig. 3. 8) If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Move timing belt tensioner, and remove timing belt. Installation (Golf & Jetta w/AAZ Engine, Up To Sept., 1994) 1) Ensure TDC mark on ywheel and transmission mating ange are still aligned. See Fig. 3.

VOLKSWAGEN
CAUTION: Timing belt replacement for Passat (1Z engine) requires using factory scan tool VAG 1551/1552 to check injection pump start of delivery after timing belt is installed. Removal (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ Engine, From October 1994) 1) On models with tensioner, install Tensioner Tool (3299) and rotate clockwise. Mark serpentine belt with arrow to indicate rotation direction, and remove belt. See Fig. 1. Remove tensioner pulley. On models without serpentine belts, remove accessory drive belts. 2) On all models, remove upper timing belt cover. See Fig. 2. Remove valve cover. 3) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Flywheel TDC mark must be aligned to mark on transmission mating ange. 4) Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. 5) Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and one side of cylinder head. 6) Lock injection pump in place using lock pin. See Figs. 5and 8. Loosen injection pump sprocket mounting bolt(s). 7) Loosen timing belt tensioner. On Passat with 1Z engine, remove water pump pulley and power steering pump pulley. 8) On all models, remove crankshaft vibration damper. Remove the lower timing belt cover. See Fig. 2. 9) If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Move timing belt tensioner, and remove timing belt. Installation (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ Engine, From Oct., 1994) 1) Ensure TDC mark on ywheel and transmission mating ange are still aligned. See Fig. 3. CAUTION: Use spanner wrench to hold camshaft sprocket while loosening center bolt. Do not use camshaft setting bar to hold camshaft sprocket. 2) Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch through hole in rear of timing belt cover until it contacts rear of camshaft sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft sprocket on camshaft taper. 3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. 4) Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). 5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Tighten injection pump sprocket mounting bolt(s). 6) Remove setting bar from camshaft. Remove lock pin from injection pump 7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set No. 1 cylinder to TDC of compression stroke. 8) On models with semiautomatic tensioner, apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner. 9) On engine codes AHU and 1Z, ensure injection pump sprocket can be locked using Lock Pin (2064). See Fig. 5. On engine code AAZ, ensure injection pump sprocket can be locked using Lock Pin (3359). See Fig. 8. If injection pump cannot be locked using correct lock pin, loosen injection pump sprocket mounting bolt(s), and turn sprocket until lock pin can be inserted in place. Tighten mounting bolt(s). 10) Install timing belt covers. Install vibration damper and belt pulleys (if removed). Install valve cover. Install accessory drive belts. To prevent damage to serpentine belt, install in original direction of rotation.

729

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)


11) For Passat with 1Z engine, check injection pump start of delivery. Consult service information for procedure using VAG 1551/1552 factory scan tool. CAUTION: Timing belt replacement for 1998 Passat (AHH engine) requires using factory scan tool VAG 1551/1552 to check injection pump start of delivery after timing belt is installed. Removal (1998 Passat, w/AHH Engine) 1) Disconnect front turn signal light assembly wiring harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 9. Remove bumper beam. 2) Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 10. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools. 3) Mark serpentine drive belt with arrow to indicate direction of rotation. Rotate tensioner counterclockwise, and remove serpentine drive belt. Remove upper timing belt cover. See Fig. 3. 4) Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. 5) Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and one side of cylinder head. 6) Remove timing belt tensioner. Lock injection pump in place using lock pin. See Fig. 8. Loosen injection pump sprocket mounting bolts. 7) Remove crankshaft vibration damper. Remove lower timing belt cover. See Fig. 2. 8) If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Move timing belt tensioner, and remove timing belt. Installation (1998 Passat w/AHH Engine) 1) Ensure TDC mark on ywheel and transmission mating ange are still aligned. See Fig. 3. CAUTION: Use spanner wrench to hold camshaft sprocket while loosening center bolt. Do not use camshaft setting bar to hold camshaft sprocket. 2) Holding camshaft stationary, loosen camshaft sprocket bolt 1/2 turn. Place drift punch through rear timing belt cover and LIGHTLY tap camshaft sprocket loose from tapered end of camshaft. 3) With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. 4) Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). 5) Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Tighten injection pump sprocket mounting bolts. 6) Remove setting bar from camshaft. Remove lock pin from injection pump. 7) Rotate crankshaft 2 revolutions in normal direction of rotation. Set No. 1 cylinder to TDC of compression stroke. 8) Apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner. 9) Ensure injection pump sprocket can be locked using Lock Pin (3359). See Fig. 8. If injection pump cannot be locked using correct lock pin, loosen injection pump sprocket mounting bolt(s), and turn sprocket until lock pin can be inserted in place. Tighten mounting bolts. 10) Install timing belt covers. Install vibration damper. Install valve cover. To prevent damage to serpentine belt, install in original direction of rotation. 11) Place lock carrier in original position on body. Install front bumper assembly. 12) Check injection pump start of delivery. Consult service information for procedure using VAG 1551/1552 factory scan tool.

730

VOLKSWAGEN

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 2: Exploded View of Timing Belt & Components

Courtesy of Volkswagen United States, Inc.

Fig. 4: Locking Camshaft With Setting Bar (2065A)

Courtesy of Volkswagen United States, Inc.

Fig. 3: Locating TDC Mark on Flywheel/Flexplate


Courtesy of Volkswagen United States, Inc.

Fig. 5: Locking Diesel Fuel Injection Pump Sprocket (AHU & 1Z Engines; AAZ Engines Up To September 1994)

VOLKSWAGEN

731

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Tensioning Timing Belt (AAZ Engines Up To October 1994, Without Semi-Automatic Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Exploded View of Bumper Assembly (1998 Passat)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Adjusting Timing Belt Tension (Semi-Automatic Timing Belt Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 10: Exploded View Of Lock Carrier Assembly (1998 Passat)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Locking Diesel Fuel Injection Pump Sprocket (AHH Engine & AAZ Engines From October 1994)

732

VOLKSWAGEN
TECHNICAL SERVICE BULLETIN
TIMING BELT RUNS TOWARD OUTSIDE, WEARS OUT, JUMPS OFF SPROCKET OR CRACKS
1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines) 1) If this condition exists, replace timing belt and semiautomatic tensioner (Part No. 028 109 243F). 2) BEFORE installing new timing belt, clean all timing belt sprockets. Install new belt. Before installing vibration damper, start and run engine at idle for a few seconds. Turn off engine. 3) Belt must not protrude past edge of crankshaft sprocket. If it does, remove diesel injection pump. Loosen 3 injection pump bracket mount bolts. Tighten bolts to 18 ft. lbs. (25 N.m) while pressing mount down at A and lifting mount at B. See Fig. 11. 4) Start and run engine at idle for a few seconds. Turn off engine. Belt must not protrude past edge of crankshaft sprocket. NOTE: This information is from Volkswagen technical service bulletin Group 15, No. 97-01; June 4, 1997.

1.9L 4-Cylinder Turbo Diesel AAZ, AHU & 1Z Engines (Cont.)


TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Center Bolt Step 1 ...................................................................................................................... 66 (90) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Injection Pump Sprocket Mounting Bolt Center Mounting Bolt .............................................................................................. 33 (45) Three Mounting Bolts .............................................................................................. 18 (25) Intermediate Shaft Sprocket Bolt .............................................................................. 33 (45) Timing Belt Tensioner Pulley Lock Nut With Semi-Automatic Tensioner .............................................................................. 15 (20) Without Semi-Automatic Tensioner ......................................................................... 33 (45) INCH Lbs. (N.m) Lower Timing Belt Cover Bolt ................................................................................... 89 (10) Valve Cover Nut ........................................................................................................ 89 (10)
1

ALWAYS replace if loosened or removed.

TORQUE SPECIFICATIONS (PASSAT) Application Ft. Lbs. (N.m) Bumper Beam-To-Impact Absorber Bolt (1998) ....................................................... 15 (20) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Center Bolt Step 1 ...................................................................................................................... 66 (90) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Injection Pump Sprocket Mounting Bolts Step 1 ...................................................................................................................... 15 (20) Step 2 .......................................................................................... ........ Plus 1/4 Turn (90) Intermediate Shaft Sprocket Bolt .............................................................................. 33 (45) Timing Belt Tensioner Pulley Lock Nut .................................................................... 18 (25) INCH. Lbs. (N.m) Bumper Cover Bolt (1998) .......................................................................................... 18 (2) Lower Timing Belt Cover Bolt ................................................................................... 89 (10) Valve Cover Nut ........................................................................................................ 89 (10)
1

Courtesy of Volkswagen United States, Inc.

ALWAYS replace if loosened or removed.

Fig. 11: Injection Pump Mounting Bracket (1994-97 Golf, Jetta & Passat w/AAZ & 1Z Engines)

VOLKSWAGEN
1.9L 4-Cylinder Turbo Diesel ALH Engine
TIMING BELT APPLICATION Application Labor Time Belt Part No.

733

1.9L 4-Cylinder Turbo Diesel (ALH Engine) Golf 1 1999 ........................................................... 4.0 Hours ... ..... Or 2000-01 Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... After Eng. No. 500,001 .......................... 4.4 Hours ... ..... 2002-04 ..................................................... 4.4 Hours ... ..... Jetta 1 1999 ........................................................... 4.0 Hours ... ..... Or 2001-00 Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... After Eng. No. 500,001 .......................... 4.4 Hours ... ..... 2002-04 ..................................................... 4.4 Hours ... ..... New Beetle 1 1998 ........................................................... 4.4 Hours ... ..... 1999 ........................................................... 4.4 Hours ... ..... Or 2000-01 Before Eng. No. 500,000 ....................... 4.4 Hours ... ..... After Eng. No. 500,001 .......................... 4.4 Hours ... ..... 2002-04 ..................................................... 4.4 Hours ... .....
1

3) If serpentine belt is to be reused, mark rotational direction of belt. Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine belt tensioner. CAUTION: The valve cover has an integrated, vulcanized gasket. If gasket is damaged or leaking, replace the valve cover. 4) Remove brake booster vacuum pump. Remove upper timing belt cover. Remove engine valve cover using care not to damage gasket. 5) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed through access hole in engine-totransmission mating ange. See Fig. 1. 6) Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head.

T301 T321 T301 T321 T321 T301 T321 T301 T321 T321 T301 T301 T321 T301 T321 T321

Code is stamped on pad on engine block between diesel injection pump and exhaust manifold. Engine code is also included on vehicle data plate and timing belt cover.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


SCHEDULED MAINTENANCE INTERVAL
1 Interval Model Year 1998-99 .......................................................... ............................................................ 60,000 2000 ............................................................... ............................................................ 40,000 2001 2 ............................................................. ............................................................ 40,000 2001 3 ............................................................. ............................................................ 60,000 2002 ............................................................... ............................................................ 80,000 2003-04 .......................................................... .......................................................... 100,000 1 2 3

Replace timing belt and tensioner together. Models equipped with automatic transmissions. Models equipped with manual transmission.

REMOVAL & INSTALLATION


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

TIMING BELT
NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing. Removal (Golf & Jetta) 1) Working under hood, remove fuel supply and return lines from fuel lter. Seal fuel lines to prevent contamination of fuel system. Remove upper and lower right headlight assembly mounting screws. Disconnect harness connectors and remove right headlight assembly. 2) Remove pipe between charge air cooler (intercooler) and intake manifold. Remove upper engine cover. Remove right sound damper cover.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating TDC Mark on Flywheel/Flexplate 7) Lock injection pump in place using Lock Pin (3359). See Fig. 3. CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter injection pump basic setting. 8) Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Replace these bolts with NEW bolts during installation. Attach Engine Support (10-222A) with legs (10-222A/1) or equivalent. Remove coolant reservoir bottle and power steering reservoir, and leaving hoses attached set aside.

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.

Fig. 2: Locking Camshaft With Setting Bar CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt. This bolt MUST be replaced if loosened or removed. 9) Remove engine mount from timing belt end of engine. Remove 4 crankshaft pulley socket-head bolts and remove crankshaft pulley (it is not necessary to remove center bolt). Remove middle and lower timing belt covers. Remove engine mount bracket. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 10) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing belt tensioner lock nut. Turn tensioner to release belt and remove timing belt.

NOTE: The 3 diesel injection pump bolts are torque-to-yield type. Manufacturer recommends replacing bolts during nal assembly. 8) Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Manufacturer recommends replacing these torque-toyield bolts during nal assembly. Support engine weight from above or below with oor jack. NOTE: On New Beetle, engine mount bolts are torque-to-yield type. Manufacturer recommends replacing bolts if they are loosened or removed. 9) Remove engine mount from timing belt end of engine. CAUTION: Crankshaft pulley CENTER bolt is a torque-to-yield bolt. This bolt MUST be replaced if loosened or removed. 10) Remove 4 crankshaft pulley socket-head bolts, and remove crankshaft pulley (it is not necessary to remove center bolt). Remove timing belt covers. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 11) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing belt tensioner lock nut. Turn tensioner to release belt and remove timing belt. NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing. Installation (All Models) 1) Ensure cylinder No. 1 is at TDC. Check reference mark on ywheel and bellhousing. See Fig. 1. CAUTION: Use Spanner Wrench (3036) to hold camshaft sprocket while loosening and tightening camshaft sprocket bolt. DO NOT use Camshaft Setting Bar (3418) to hold camshaft sprocket.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Locking Diesel Fuel Injection Pump Sprocket Removal (New Beetle) 1) Remove tube between charge air cooler and air intake pipe. Disconnect and plug fuel supply and return lines at fuel lter. Remove fuel lter from bracket. CAUTION: The valve cover has an integrated, vulcanized gasket. If gasket is damaged or leaking, replace the valve cover. 2) Remove upper timing belt cover. Remove valve cover. Remove brake booster vacuum pump. Remove pipe between charge air cooler and turbocharger. 3) If serpentine belt is to be reused, mark rotational direction of belt. Using a 16 mm box wrench, rotate serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine belt tensioner. 4) Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed through access hole in engine-totransmission mating ange. See Fig. 1.

2) Using Spanner Wrench (3036) counter-hold camshaft and loosen camshaft sprocket bolt 1/2 turn. See Fig. 4. On New Beetle, place drift punch through rear timing belt cover and LIGHTLY tap camshaft sprocket loose from tapered end of camshaft. On Golf and Jetta, use a Two Arm Puller (T40001) to remove sprocket. Remove camshaft sprocket. 3) Install timing belt onto crankshaft sprocket, idler pulley, water pump, injection pump sprocket, and tensioner pulley. Adjust injection pump sprocket on mount so mounting slots are centered. If installing old belt, note direction of rotation mark. 4) Install camshaft sprocket together with timing belt. Install camshaft sprocket bolt nger tight. Camshaft sprocket should still be free to turn. 5) On Golf and Jetta with automatic transaxle, use an Allen wrench to turn timing belt tensioner clockwise until notch and pointer align. See Fig. 5. If tensioner is turned too far and correct tension is exceeded, tension must be fully released, and then readjusted. Tighten center lock nut on tensioner pulley to specication. See TORQUE SPECIFICATIONS.

VOLKSWAGEN
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 specication. See TORQUE SPECIFICATIONS. 7) On all models, ensure tensioner is correctly installed in rear timing belt cover. See Fig. 7. Ensure TDC marks on ywheel are still aligned. Using Spanner Wrench (3036) counter-hold camshaft and tighten camshaft sprocket center bolt to specication. See TORQUE SPECIFICATIONS. 8) Install NEW torque-to-yield mounting bolts in diesel injection pump sprocket. Tighten injection pump bolts to 15 ft. lbs. (20 N.m). Before nal tightening of injection pump mounting bolts, perform start of injection procedure (dynamic timing) using factory scan tester (VAG 1551/1552). After performing start of injection procedure, tighten injection pump sprocket mounting bolts an additional 90 degrees (1/4 turn). 9) Remove camshaft setting bar from rear of camshaft. Remove lock pin from injection pump. 10) Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC and ensure belt timing is correct. Ensure timing belt tensioner pulley marks are still aligned. 11) To complete installation, reverse removal procedure. When installing engine mount, install mounting bolts in holes on bracket before attempting to t bracket to engine block. Tighten nuts and bolts to specication. See TORQUE SPECIFICATIONS. Check fuel lines for leaks. Adjust drive belts to proper tension. 12) Using scan tester (VAG 1551/1552), check Diesel injection pump start of delivery.

735

Courtesy of Volkswagen United States, Inc.

Fig. 6: Adjusting Timing Belt Tension (Golf & Jetta With Manual Transaxle, & New Beetle)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Installing Timing Belt Tensioner

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Diesel Injection Pump Sprocket Bolts 1 ......................................................... 15 (20) + 90 Engine Mount Bracket-To-Engine Bolt ...................................................................... 33 (45) Idler Pulley Bolt ......................................................................................................... 15 (20) Serpentine Drive Belt Tensioner ............................................................................... 18 (25) Timing Belt Tensioner Pulley Nut ............................................................................. 15 (20) Vacuum Pump Bolt ................................................................................................... 15 (20) Water Pump Bolts ..................................................................................................... 16 (22) INCH. Lbs. (N.m)
Courtesy of Volkswagen United States, Inc.

Fig. 4: Securing Camshaft Sprocket

Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10)
1

Replace with new torque-to-yield bolts on installation.

TORQUE SPECIFICATIONS (NEW BEETLE) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 33 (45) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Diesel Injection Pump Sprocket Bolts 1 ......................................................... 15 (20) + 90 Engine Mount Bracket-To-Engine Bolt 1 ........................................................ 30 (40) + 90 Engine Mount-To-Bracket Bolt 1 ..................................................................... 44 (60) + 90 Idler Pulley Bolt ......................................................................................................... 15 (20) Timing Belt Tensioner Pulley Nut ............................................................................. 15 (20) Water Pump Bolts ..................................................................................................... 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Nut ........................................................................................................ 89 (10)
1

Replace with new torque-to-yield bolts on installation.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With Automatic Transaxle)

736

VOLKSWAGEN
1.9L 4-Cylinder Turbo Diesel, BEW Engine
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

1.9L 4-Cylinder Turbo Diesel (BEW Engine) Golf 1 2004 ........................................................... 3.9 Hours ... ..... T321 Jetta 1 2004 ........................................................... 3.9 Hours ... ..... T321 New Beetle 1 2004 ........................................................... 3.9 Hours ... ..... T321
1

Code is stamped on pad on engine block between diesel injection pump and exhaust manifold. Engine code is also included on vehicle data plate and timing belt cover.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer suggests the belt be replaced at 90,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal (Golf & Jetta) 1) Remove right sound damper cover. If poly V-belt is to be reused, mark rotational direction of belt. Using appropriate wrench, rotate poly V-belt tensioner clockwise to relieve belt tension, and remove belt. Lock tensioner using Locking Pin (T10060) or appropriate sized drift pushed through hole in tensioner. Remove poly V-belt tensioner. 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 lter 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 oor jack. Use care not to damage components. 5) Remove engine bracket-to-body mounting bolts, and remove complete mounting assembly. 6) Raise engine slightly with the support device, and unbolt engine mounting bracket-to-cylinder block bolts (arrows) and remove. See Fig. 2. CAUTION: Engine mount assembly is secured by torque-to-yield bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These bolts MUST be replaced if they are loosened or removed. 7) Remove 4 crankshaft/vibration damper pulley socket-head bolts, and crankshaft/vibration damper pulley. It is NOT necessary to remove crankshaft pulley center bolt. 8) Remove timing belt covers. Turn crankshaft to TDC No. 1 cylinder. Turn the crankshaft so far that the marking on the crankshaft sprocket is at the top and the arrow on the rear timing belt guard aligns with the lugs on the sender wheel of the hub. See Fig. 3. 9) Lock camshaft pulley with Locking Pin (3359). See Fig. 3. To do this, slide locking pin through free elongated hole on left side of cylinder head. Lock crankshaft pulley with Crankshaft Stop (T10050). To do this,

Courtesy of Volkswagen United States, Inc.

Fig. 1: Attaching Engine Support & Removing Engine Mount

Courtesy of Volkswagen United States, Inc.

Fig. 2: Removing Engine Mount From Engine Block push Crankshaft Stop from face side of timing belt pulley into pulley teeth. The marks on the crankshaft pulley and the Crankshaft Stop must align. At the same time, the pin of the Crankshaft Stop must engage in hole in the sealing ange. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. 10) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but do not remove, camshaft pulley securing bolts (1) until camshaft pulley can be moved within elongated holes. See Fig. 4.

VOLKSWAGEN
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 rst from coolant pump and then from remaining pulleys.

737

Courtesy of Volkswagen United States, Inc.

Fig. 5: Removing Timing Belt tensioner clockwise to relieve belt tension. Lock tensioner using Locking Pin (T10060) or appropriate sized drift pushed through hole in tensioner, and remove belt. Remove poly V-belt tensioner. 3) Remove coolant expansion tank (leave coolant hoses connected). Remove fuel lter 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 oor jack. Use care not to damage components. 5) Remove engine bracket-to-body mounting bolts, and remove complete mounting assembly. See Fig. 1. 6) Remove upper timing belt guard. Remove lower charge air pipe (1). See Fig. 6. Remove bolt/screw (2) and release connector (arrow). Carefully cover or close open ends of charge air pipe. Remove center and right side sound insulation. 7) Raise engine slightly with the support device, and unbolt engine mounting bracket-to-cylinder block bolts (arrows) and remove mount. See Fig. 2.
Courtesy of Volkswagen United States, Inc.

Fig. 3: Locating TDC Position; Locking Cam & Crankshafts Into Position

CAUTION: Engine mount assembly is secured by torque-to-yield bold. Crankshaft pulley bolts are also a torque-to-yield bolt. These bolts MUST be replaced if they are loosened or removed. 8) Remove 4 crankshaft/vibration damper pulley socket-head bolts. Remove crankshaft/vibration damper pulley. It is NOT necessary to remove crankshaft pulley center bolt. 9) Remove timing belt covers. Turn crankshaft to TDC No. 1 cylinder. Turn the crankshaft so far that the marking on the crankshaft sprocket is at the top and the arrow on the rear timing belt guard aligns with the lugs on the sender wheel of the hub. See Fig. 3. 10) Lock camshaft pulley with Locking Pin (3359). See Fig. 3. To do this, slide locking pin through free elongated hole on left side of cylinder head. Lock crankshaft pulley with Crankshaft Stop (T10050). To do this, push Crankshaft Stop from face side of timing belt pulley into pulley teeth. The marks on the crankshaft pulley and the Crankshaft Stop must align. At the same time, the pin of the Crankshaft Stop must engage in the hole in the sealing ange. CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed.

Courtesy of Volkswagen United States, Inc.

Fig. 4: Loosening Camshaft Pulley Securing Bolts Removal (New Beetle) 1) Working under hood, remove engine cover. Pull front of engine cover abruptly upward and then pull forward out of rear securing elements. 2) Remove upper charge air line and connecting hose. Carefully cover or close open ends of charge air line. If poly V-belt is to be reused, mark rotational direction of belt. Using appropriate wrench, rotatep poly V-belt

11) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Loosen timing belt tensioner lock nut. Loosen, but do not remove, camshaft pulley securing bolts (1) until camshaft pulley can be moved within elongated holes. See Fig. 4. 12) Turn Pin Wrench (3387) counterclockwise (opposite direction of arrow on tensioner) until timing belt tensioner can be locked in position using Locking Pin (T10115). See Fig. 5. Turn pin wrench clockwise (in direction of arrow on tensioner) until stop and tighten securing nut hand-tight. Remove timing belt rst from coolant pump and then from remaining pulleys.

738

VOLKSWAGEN
1.9L 4-Cylinder Turbo Diesel, BEW Engine (Cont.)
engaged, check whether camshaft pulley hub can be xed in place using Locking Pin. If the hub cannot be locked; pull Crankshaft Stop pin out of hole in sealing ange 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 ange (arrow). See Fig. 8. Turn crankshaft in engine direction of rotation until Crankshaft Stop pin engages in sealing ange while turning. Tighten camshaft pulley securing bolts to 18 ft. lbs. (25 N.m). Remove Locking Pin and Crankshaft Stop.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing Lower Charge Air Pipe (New Beetle) Installation (All Models) 1) Adjustment work on timing belts must only be performed on cold engines as the indicator on the tensioner changes depending on the engine temperature. The tensioning roller must be locked with Locking Pin (T10115) and secured to the right limit stop before proceeding. 2) Turn camshaft pulley in elongated holes counterclockwise onto centered position. See Fig. 4. Install timing belt to crankshaft pulley, belt tensioner and camshaft pulley. Install timing belt onto coolant pump timing belt pulley. If installing old belt, note direction of rotation mark. 3) Ensure that tab on tensioning roller seats correctly in rear timing belt guard. Loosen tensioning roller securing nut. Relieve tension on tensioning roller by turning pin wrench and remove locking pin from tensioning roller. 4) Carefully turn tensioning roller with Pin Wrench (3387) in direction of arrow (on tensioner) until indicator is in middle of gap in base plate (arrow). See Fig. 7. Hold tensioning roller in this position, and tighten tensioning roller securing nut to 15 ft. lbs. (20 N.m) plus an additional 45 (1/8 turn). Counter-hold camshaft pulley, and tighten securing bolts to 18 ft. lbs. (25 N.m). Remove Locking Pin and Crankshaft Stop. Turn crankshaft two rotations in direction of engine rotation and set again to TDC No. 1 cylinder.

Courtesy of Volkswagen United States, Inc.

Fig. 8: Positioning Crankshaft Gear With Crankshaft Stop Pin (T10050) 7) Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again. With engine at TDC No. 1 cylinder, the shaft of the Crankshaft Stop (T10050) must be able to engage in the sealing ange from direction of engine rotation. If the crankshaft is turned past TDC No. 1 cylinder and the Crankshaft Stop could not engage in the sealing ange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in the direction of engine rotation again to set it to TDC No. 1 cylinder. DO NOT turn the engine opposite to the normal direction of rotation when turning to ensure the Crankshaft Stop will engage. 8) Once Crankshaft Stop has engaged, check whether camshaft pulley hub can be xed in place using Locking Pin. Repeat timing mark alignment check. CAUTION: Engine mount assembly is secured by torque-to-yield bold. Crankshaft pulley CENTER bolt is also a torque-to-yield bolt. These bolts MUST be replaced if they are loosened or removed. 9) Install lower timing belt guard and vibration damper/belt pulley. Install center timing belt guard. Tighten nuts and bolts to specication. See TORQUE SPECIFICATIONS. 10) To complete installation, reverse removal procedure. When installing engine mount, install mounting bolts in holes on bracket before attempting to t bracket to engine block. Tighten nuts and bolts to specication. See TORQUE SPECIFICATIONS.

Courtesy of Volkswagen United States, Inc.

Fig. 7: Tensioning Timing Belt 5) With engine at TDC No. 1 cylinder, the shaft of the Crankshaft Stop (T10050) must be able to engage in the sealing ange 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 ange, 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
1.9L 4-Cylinder Turbo Diesel, BEW Engine (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 74 (100) Crankshaft Gear Bolt 1 .................................................................. ..................................... 2 Engine Mount-To-Engine Bolts ................................................................................. 33 (45) Engine Mounting Bracket-To-Engine Bolt ............................................................... 74 (100) Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3 Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25) Poly V-Belt Tensioner ................................................................................................ 18 (25) Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4 INCH. Lbs. (N.m) Crankshaft Pulley Bolts ............................................................... ..................................... Timing Belt Cover Bolts ............................................................................................ 89 (10)
1 2 3 4 5 1 5 1

739

TORQUE SPECIFICATIONS (NEW BEETLE) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 74 (100) Crankshaft Gear Bolt 1 .................................................................. ..................................... 2 Engine Mount-To-Engine Bolts ................................................................................. 33 (45) Engine Mount-To-Engine Bracket Bolt .................................................................... 74 (100) Engine Mount Bracket-To-Body Bolts (Large Bolts) 1 .................. ..................................... 3 Engine Mount Bracket-To-Body Bolt (Small Bolt) .................................................... 18 (25) Poly V-Belt Tensioner ................................................................................................ 18 (25) Timing Belt Tensioner Pulley Nut 1 ............................................... ..................................... 4 INCH. Lbs. (N.m) Crankshaft Pulley Bolts ............................................................... ..................................... 5 Timing Belt Cover Bolts ............................................................................................ 89 (10)
1 2 3 4 5

Replace with new torque-to-yield bolts on installation. Tighten to 89 ft. lbs. (120 N.m) plus an additional 90 (1/4 turn). Tighten to 30 ft. lbs. (40 N.m) plus an additional 90 (1/4 turn). Tighten to 15 ft. lbs. (20 N.m) plus an additional 45 (1/8 turn). Tighten to 89 INCH lbs. (10 N.m) plus an additional 90 (1/4 turn).

Replace with new torque-to-yield bolts on installation. Tighten to 89 ft. lbs. (120 N.m) plus an additional 90 (1/4 turn). Tighten to 30 ft. lbs. (40 N.m) plus an additional 90 (1/4 turn). Tighten to 15 ft. lbs. (20 N.m) plus an additional 45 (1/8 turn). Tighten to 89 INCH lbs. (10 N.m) plus an additional 90 (1/4 turn).

740

VOLKSWAGEN
2.0L 4-Cylinder ABA Engine
Labor Time Component Belt Kit No. Part No. CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. Valve damage may result. 4) If reusing timing belt, mark belt with arrow to indicate original direction of rotation. 5) Place crankshaft at TDC by aligning ywheel (M/T) or drive plate (A/T) TDC marks. See Fig. 5. Ensure camshaft timing mark is aligned with mark on belt guard. See Fig. 6. Loosen belt tensioner. Remove timing belt.

TIMING BELT APPLICATION Application 2.0L 4-Cyl. (ABA Engine) Cabrio 1995-02 ........................... ... Golf 1993-99 ........................... ... Golf (Canadian) 1995 ................................ ... GTI 1996-99 ........................... ... GTI (Canadian) 1993-95 ........................... ... Jetta 1993-99 ........................... ... Passat 1993-96 ........................... ...

1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262 1.9 Hours ... .. TCK262 .. ..... T262

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. NOTE: Engine code (ABA) is stamped into machined pad on front of cylinder block above crankcase breather, near cylinder head mating surface. See Fig. 1.
Courtesy of Volkswagen United States, Inc.

Fig. 2: Removing & Installing Ribbed (Accessory) Drive Belts (Without A/C)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating Engine Identication Code (2.0L ABA)

REMOVAL & INSTALLATION


Courtesy of Volkswagen United States, Inc.

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

Fig. 3: Removing & Installing Ribbed (Accessory) Drive Belts (With A/C) NOTE: Disregard marking on intermediate shaft drive belt sprocket. Installation (Standard Tensioner Up To 1997) 1) Ensure crankshaft is still at TDC position. See Fig. 5. Remove distributor cap. Rotate intermediate shaft counterclockwise until rotor is pointed at No. 1 cylinder mark. See Fig. 5. Ensure camshaft timing mark is still aligned with mark on belt guard. See Fig. 6. 2) Install timing belt around crankshaft, intermediate shaft, tensioner, and camshaft sprockets.

TIMING BELT
Removal (Standard Tensioner Up To 1997) 1) Remove accessory drive belts. See Fig. 2 or 3. Remove accessory drive belt tensioner bracket. See Fig. 4. 2) Remove crankshaft pulley bolts and pulley (it is NOT necessary to remove center bolt). 3) Remove water pump pulley. Remove upper and lower timing belt covers.

VOLKSWAGEN
2.0L 4-Cylinder ABA Engine (Cont.)

741

Courtesy of Volkswagen United States, Inc. Courtesy of Volkswagen United States, Inc.

Fig. 6: Aligning Camshaft Timing Marks

Fig. 4: Exploded View Of Timing Belt & Components (With Standard Tensioner)

Courtesy of Volkswagen United States, Inc.

Fig. 7: Adjusting Timing Belt Tension CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. Valve damage may result. Removal (Thermo Tensioner Roller 1997 & Up) 1) Remove air cleaner with hot air intake and intake air duct. 2) Remove accessory drive belts. Release tension on ribbed (accessory) belt tensioner using Ribbed Belt Installation Tool (3299) and remove ribbed belt at generator. Remove ribbed belt tension roller and upper timing belt guard. Remove lower V-belt cover. Hold hydraulic (P/S) pump pulley using (VAG1590) or mandrel, and remove fasteners for coolant pump pulley. Remove coolant pump pulley and V-belt. Remove vibration damper/pulley. See Figs. 2 and 3. 3) Turn drive plate (A/T) or ywheel (M/T) to align mark (arrows in illustration) and place No. 1 cylinder at TDC. See Fig. 5. Remove lower timing belt guard. 4) Mark the running direction on the timing belt. Remove fastener for timing belt thermo tension roller. Remove belt and roller. Remove timing belt thermo tensioner. See Fig. 8. CAUTION: DO NOT turn the camshaft while any piston is at TDC position. There is risk of damage to valves and piston crowns. Installation (Thermo Tensioner Roller 1997 & Up) Assemble NEW thermo tension roller and install on engine block. See Fig. 9. Tighten bolt/washer assembly (2), Collar screw and 6-mm fastening nut to specication. See TORQUE SPECIFICATIONS.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Aligning Crankshaft & Distributor Timing Marks 3) Loosen timing belt tensioner center nut. Using spanner wrench, rotate tensioner pulley clockwise to tension belt. Belt tension is correct when it is possible to rotate belt 90 degrees with thumb and forenger, half-way between camshaft and intermediate shaft sprockets. See Fig. 7. 4) While holding tensioner pulley stationary, tighten tensioner pulley center nut to specication. Rotate crankshaft 2 revolutions and recheck check belt tension. Adjust tension as necessary. Recheck all timing marks again. 5) Install timing belt covers. Install drive belt tensioner bracket. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

742

VOLKSWAGEN
2.0L 4-Cylinder ABA Engine (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 8: Exploded View Of Timing Belt & Components (With Thermo Tensioner Roller) 1) Place timing belt on crankshaft gear (note running direction of belt). Ensure crankshaft timing is correct. See Fig. 5. Align mark on camshaft drive sprocket with mark on cylinder head cover and/or timing belt guard. See Fig. 6. 2) Turn tension roller to the right using two-pin spanner wrench, with one pin inserted in hole in roller and other pin in slot at bottom of roller pivot bracket (arrows in illustration) until tensioner piston No. 1 is driven all the way out, and piston No. 2 lifts up about 0.040 (1.0 mm). See Fig. 10. 3) Tighten mounting bolt by hand. See Fig. 10. Rotate engine 2 revolutions in running direction. Counter-hold thermo tension roller with two-pin spanner, and tighten mounting bolt to specication. See TORQUE SPECIFICATIONS. Install lower timing belt guard. Install vibration damper/pulley. 4) Install ribbed belt tension roller. Using Ribbed Belt Installation Tool (3299), adjust tension on ribbed belt tensioner and position belt. Position V-belt, and bolt coolant pump pulley to coolant pump. Install upper timing belt guard. Install air cleaner with pre-heated air hose and intake air duct.

Courtesy of Volkswagen United States, Inc.

Fig. 10: Installing & Adjusting Thermo Tensioner Roller

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (STANDARD TENSIONER UP TO 1997) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 59 (80) Crankshaft Pulley Bolt ............................................................................................... 18 (25) Crankshaft Sprocket Center Bolt ................................................................. 1 66 (90) + 90 Drive Belt Tensioner Bracket Bolt ............................................................................. 15 (20) Intermediate Shaft Sprocket Bolt .............................................................................. 59 (80) Timing Belt Tensioner Center Nut ............................................................................ 33 (45) Water Pump Pulley Bolt ............................................................................................ 18 (25) INCH Lbs. (N.m) Timing Belt Cover Nut .............................................................................................. 89 (10) Valve Cover Retaining Nut ....................................................................................... 89 (10)
1

Replace torque-to-yield bolt on installation.

TORQUE SPECIFICATIONS (THERMO TENSIONER 1997 & UP) Application Ft. Lbs. (N.m) Collar Screw Bolt ............................................................................................ 11-15 (15-20) Torx Bolt .................................................................................................................. 18 (25) INCH Lbs. (N.m) Bolt & Washer Assembly (2) ............................................................................ 62-97 (7-11) Nut ..................................................................................................................... 62-97 (7-11)

Courtesy of Volkswagen United States, Inc.

Fig. 9: Identifying Thermo Tensioner Roller Assembly

VOLKSWAGEN
2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines
TIMING BELT APPLICATION Component Belt Kit No. Part No. 2.0L 4-Cyl. (AEG, AVH, AZG, BDC & BEV Engines) Golf 1999-2004 ........................... 2.9 Hours ... .. TCK296 .. ..... T296 GTI 1999-00 ............................... 2.9 Hours ... ...... ..... ...... ..... T296 Jetta 1999-2004 ........................... 2.9 Hours ... .. TCK296 .. ..... T296 New Beetle 1998-04 ............................... 2.9 Hours ... .. TCK296 .. ..... T296 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING. Application Labor Time

743

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998-00 model years, although the manufacturer does not recommend a specic scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 2001-03 model years, the manufacturer recommends the belt be replaced at 105,000 mile intervals. NOTE: For 2004, manufacturer does not provide a timing belt replacement interval.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Locating Engine Identication Code (AVH, AZG, BDC & BEV)

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Engine code AEG is stamped into machined pad on front of cylinder block above crankcase breather, near cylinder head mating surface. See Fig. 1. For all other 2.0L engines, engine code is stamped on transmission mating ange at the rear of the engine. See Fig. 2. For all engines, code can also be found on the vehicle data plate and on a sticker on the timing belt cover.

Courtesy of Volkswagen United States, Inc.

Fig. 3: Releasing Serpentine Belt Tensioner 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 oor jack to take engine weight off of mounts. Remove coolant reservoir and set aside. On Golf and Jetta, remove power steering reservoir (hoses attached), and set aside. On Beetle, pull off EVAP hoses at EVAP canister and throttle valve housing. 4) On all models, remove engine mount from timing belt end of engine. See Fig. 7. Remove crankshaft pulley from crankshaft sprocket. It is NOT necessary to remove center bolt (center bolt is torque-to-yield type that must be replaced if removed). 5) Remove timing belt covers. Remove engine support from front of engine. See Fig. 4. CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. 6) If reusing old belt, mark belt with arrow to indicate original direction of rotation. Loosen timing belt tensioner nut and rotate timing belt tensioner away from belt to remove timing belt. See Fig. 8.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating Engine Identication Code (AEG)

TIMING BELT
Removal (AEG, AVH, AZG, BEV & BDC Engine Codes) 1) Remove right hand insulation tray from engine compartment. Remove engine cover. Rotate serpentine belt tensioner clockwise to relieve belt tension. Remove serpentine belt. See Fig. 3. Lock in place using Mandrel (T10060) or a drift.

744

VOLKSWAGEN
2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Exploded View Of Timing Belt & Components (AEG, AVH, AZG, BDC & BEV Engine Codes)

Courtesy of Volkswagen United States, Inc.

Fig. 6: Locating TDC Mark on Transaxle

Courtesy of Volkswagen United States, Inc.

Fig. 5: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Volkswagen United States, Inc.

Fig. 7: Identifying Right-Hand Engine Mount

VOLKSWAGEN
2.0L 4-Cylinder AEG, AVH, AZG, BDC & BEV Engines (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

745

Courtesy of Volkswagen United States, Inc.

Fig. 8: Releasing/Adjusting Timing Belt Tension Installation (AEG, AVH, AZG, BDC & BEV Engine Codes) 1) Ensure crankshaft and camshaft timing marks are still aligned. See Figs. 5 and 6. 2) Install timing belt around crankshaft and water pump sprockets. Install engine support on front of engine block. Tighten mounting bolts to specication. See TORQUE SPECIFICATIONS. 3) Install timing belt lower and center covers. Install crankshaft pulley and tighten bolts to specication. Install engine mount-to-body and engine support. Remove oor 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 specication. Rotate crankshaft 2 revolutions in normal direction of rotation, and recheck check belt tension. Adjust tension as necessary. Recheck all timing marks again. 7) Install upper timing belt cover. Install serpentine belt tensioner and serpentine belt. To complete installation, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 74 (100) Camshaft Sprocket Sealing Plug .............................................................................. 18 (25) Crankshaft Pulley Socket-Head Bolts Golf, GTI & Jetta ..................................................................................................... 30 (40) New Beetle .............................................................................................................. 18 (25) Crankshaft Sprocket Center Bolt ......................................................................... 1, 2 66 (90) Engine Mounting Bolts Engine Support-To-Engine Block ............................................................................ 33 (45) Mounting Bracket-To-Body (Small Bolt) .................................................................. 18 (25) Mounting Bracket-To-Body Bolts (Large Bolts) 1 ........................ ..................................... 2 Mount-To-Body ....................................................................................................... 74 (100) Serpentine Belt Tensioner Bolt ................................................................................. 18 (25) Timing Belt Tensioner Center Nut ............................................................................ 15 (20) Water Pump Bolt ....................................................................................................... 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Retaining Nut ....................................................................................... 89 (10)
1 2

Replace torque-to-yield bolt on installation. First tighten to (40 N.m), then tighten bolts an additional 90 (1/4 turn).

746

VOLKSWAGEN
2.0L 4-Cylinder BBW Engines
Labor Time Component Belt Kit No. Part No. 2) Remove upper intake manifold as follows. Turn ignition off. Check whether a coded radio is installed, and obtain radio code as necessary. Disconnect battery ground strap. 3) Open cap on coolant expansion tank. Clamp off hose (3). See Fig. 3. Disconnect hoses (1), (2) and (3). Disconnect harness connector (1) and pull off hoses (4), (5), (6) and (7). See Fig. 4.

TIMING BELT APPLICATION Application

2.0L 4-Cyl. (BBW Engine) Golf 2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296 Jetta 2004 .................................... 5.5 Hours ... .. TCK296 .. ..... T296 NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


NOTE: For 2004, manufacturer does not provide a timing belt replacement interval.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: For 2.0L engines, engine code is stamped on transmission mating ange at the rear of the engine. See Fig. 1. For all engines, code can also be found on the vehicle data plate and on a sticker on the timing belt cover.

Courtesy of Volkswagen United States, Inc.

Fig. 2: Releasing Serpentine Belt Tensioner

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing & Installing Upper Intake Manifold (1 Of 2)

Courtesy of Volkswagen United States, Inc.

Fig. 1: Locating Engine Identication Code

TIMING BELT
NOTE: 2004 Golf and Jetta models equipped with engine code BEV engine are tted with variable valve timing. Removal (2004 Golf & Jetta W/BBW Engine Code) 1) Remove engine cover. Remove right hand insulation tray from engine compartment. Rotate serpentine belt tensioner clockwise to relieve belt tension. Remove serpentine belt. See Fig. 2. Lock tensioner in place using Mandrel (T10060) or a appropriate sized drift. Remove serpentine belt tensioner.

Courtesy of Volkswagen United States, Inc.

Fig. 4: Removing & Installing Upper Intake Manifold (2 Of 2)

VOLKSWAGEN
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 deector 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.

747

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing Vibration Damper & Engine Mount Bracket

Courtesy of Volkswagen United States, Inc.

Fig. 7: Identifying Adjustment Bar (2065A) NOTE: When starting installation of timing belt pistons must not be positioned at TDC. Installation (2004 Golf & Jetta W/BBW Engine Code) 1) Place a at container under camshaft sprocket to collect oil which will leak out when camshaft sealing plug (1) is loosened. See Fig. 8. Unscrew sealing plug (1) carefully and collect leaking oil. 2) Clean oil from camshaft sprocket with a cloth. Counter-holding camshaft with Counter Bracket (T10172) with Pins (T10172/3) or equivalent, remove camshaft pulley bolt. See Fig. 9. DO NOT rotate camshaft, if possible. Remove camshaft sprocket from camshaft and clean it.

Courtesy of Volkswagen United States, Inc.

Fig. 5: Attaching Engine Support & Removing Engine Mount

748

VOLKSWAGEN
2.0L 4-Cylinder BBW Engines (Cont.)

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. Courtesy of Volkswagen United States, Inc.

Fig. 11: Tensioning Timing Belt

Fig. 9: Removing & Installing Camshaft Pulley NOTE: At this point, manufacturer recommends replacing camshaft seal as a preventative and inexpensive measure. 3) Install camshaft sprocket and camshaft bolt. Set camshaft to TDC No. 1 cylinder and insert Adjustment Bar. See Fig. 7. Loosen camshaft bolt until using Counter Bracket (T10172), camshaft sprocket can be turned easily. Place toothed belt on crankshaft pulley and coolant pump (observe direction of rotation). Install center and lower timing belt guards. Install vibration damper/belt pulley. See Fig. 6. 4) Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder notch (2) on vibration damper/belt pulley must align with notch (1) on timing belt guard. See Fig. 10. 5) Turn camshaft sprocket so that Counter Bracket can be inserted. Place timing belt on tensioning roller and camshaft sprocket. Turn tensioning roller on eccentric with two hole Pin Wrench (T10004) ve times to limit stop in both directions. See Fig. 11. Tension toothed belt by turning eccentric to left (direction of arrow) with two hole Pin Wrench (T10004) onto limit stop. Release tension on toothed belt until notch (1) and indicator (2) align (use mirror). Tighten tensioner securing nut to 15 ft. lbs. (20 N.m). Verify that crankshaft is at TDC, correcting if necessary. 6) Using Counter Bracket hold camshaft sprocket and tighten camshaft bolt to 30 ft. lbs. (40 N.m). See Fig. 12. Remove Adjustment Bar from rear of camshaft. Counter-hold camshaft sprocket and tighten camshaft bolt to 96 ft. lbs. (130 N.m).

Courtesy of Volkswagen United States, Inc.

Fig. 12: Counter-Holding & Torquing Camshaft Sprocket Bolt 7) Turn crankshaft two rotations in direction of engine rotation until Adjustment Bar can be inserted. It is essential that the last 45 (1/8 turn) is performed without stopping. If the crankshaft has been turned to far, turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1 cylinder again (insert the Adjustment Bar). 8) Check that crankshaft is at TDC. Notch (2) on vibration damper/belt pulley must be at positioned a (maximum 5 mm) after TDC marking on lower timing belt guard. See Fig. 10. If the crankshaft is not positioned as specied repeat adjustment.

VOLKSWAGEN
2.0L 4-Cylinder BBW Engines (Cont.)
9) If the crankshaft positioned as specied, verify timing belt tension, indicator and notch align, adjusting as necessary. 10) Install sealing plug (1) with NEW O-ring to camshaft pulley. See Fig. 8. Tightening sealing plug to 18 ft. lbs. (25 N.m). Install engine mounting to cylinder block. Tighten to bolts specication. See TORQUE SPECIFICATIONS. Insert bolts into engine bracket before installing engine bracket. Tighten all bolts of the engine bracket to specication, before installing the engine mounting. 11) Remaining installation is performed in reverse order to removal. Replace all O ring seals or gaskets that were disturbed during removal. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Check and top off engine oil level as necessary. Note the following concerning intake manifold installation: Considering installed position, replace intake manifold lower part seal. After connecting battery cables, turn ignition on engine off, for 10 seconds before starting engine. Adapt (match) ECM to throttle valve control module. Generate readiness code again if DTC memory has been erased or ECM was disconnected from battery voltage. See appropriate service information.

749

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .......................................................................................... 74 (100) Camshaft Sprocket Bolt Step 1 1 .................................................................................................................... 30 (40) Step 2 1 .................................................................................................................. 96 (130) Camshaft Sprocket Sealing Plug .............................................................................. 18 (25) Crankshaft Pulley Socket-Head Bolts ....................................................................... 18 (25) Crankshaft Sprocket Center Bolt ......................................................................... 2, 3 66 (90) Engine Mounting Bolts Engine Support-To-Engine Block ............................................................................ 33 (45) Mounting Bracket-To-Body (Small Bolt) .................................................................. 18 (25) Mounting Bracket-To-Body Bolts (Large Bolts) 2 ........................ ..................................... 3 Mount-To-Body ....................................................................................................... 74 (100) Intake Manifold Lower Part ............................................................................................................... 15 (20) Upper Part-To-Lower Part ........................................................... ..................................... 4 Upper Part-To-Bracket Bolt ..................................................................................... 18 (25) Serpentine Belt Tensioner Bolt ................................................................................. 18 (25) Timing Belt Tensioner Center Nut ............................................................................ 15 (20) Water Pump Bolt ....................................................................................................... 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................................................................. 89 (10) Valve Cover Retaining Nut ....................................................................................... 89 (10)
1

2 3 4

For step 1, with Adjustment Bar installed, use Counter Bracket tool to hold camshaft sprocket and tighten camshaft bolt to specication. See Fig. 12. Step 2, remove Adjustment Bar from rear of camshaft. Counter-hold camshaft sprocket and tighten camshaft bolt to nal specication. Replace torque-to-yield bolt on installation. First tighten to (40 N.m), then tighten bolts an additional 90 (1/4 turn). Tighten to 89 INCH lbs. (10 N.m).

750

VOLKSWAGEN
2.5L 5-Cylinder
Labor Time Belt Part No. 2) For ALL engines, place timing belt on crankshaft sprocket, relay roller or tensioning roller and coolant pump (note direction of rotation). 3) For vehicles build up to July, 1995, install lower timing belt cover and install mounting bolt M8 for coolant pump. If tensioning roller is installed, tighten to 15 ft. lbs. (20 N.m). 4) For ALL engines, torque vibration damper to crankshaft timing belt sprocket (4 M8 bolts): V- Belt Pulley 15 ft. lbs. (20 N.m). Serpentine Belt Pulley 15 ft. lbs. (20 N.m), pull another 1/4 turn (90 degrees further). 5) Install vibration damper center bolt. Vehicles With Long Center Bolt (110 mm) Insert Counter-Hold Tool (3419). See Fig. 6. Tighten crankshaft vibration damper and crankshaft timing belt sprocket center bolt to 118 ft. lbs. (160 N.m), plus 180 degree (1/2) additional turn. The additional 1/2 turn can be completed in several stages. Vehicles With Short Center Bolt (65 mm) Coat threads and bolt head contact surface of center bolt with (AMV 188 001 02), or equivalent. Insert Counter-Hold Tool (3419). See Fig. 6. Tighten center bolt to 340 ft. lbs. (460 N.m). 6) For ALL engines, Set camshaft sprocket to marking TDC Cyl. 1. The marking on the camshaft sprocket must align with the mark on the rear timing belt cover. See Fig. 7. NOTE: Adjust timing belt tension with engine cold. 8) For vehicles WITH tensioning roller built up to July, 1995, loosen nut (1) and check that tensioning roller moves freely, then place timing belt on camshaft sprocket (note direction of rotation). See Fig. 9. Tighten tensioning roller mounting bolt hand tight. Turn engine about 2 turns until just before TDC. To tension timing belt, turn crankshaft slowly to TDC position (crankshaft must not jump back). Tighten tensioning roller nut to 11 ft. lbs. (15 N.m). Go to step 11). 7) If the engine is installed in the vehicle, set ywheel (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 forenger between camshaft and intermediate shaft sprockets. See Fig. 12. Tighten coolant pump mounting bolts to 15 ft. lbs. (20 N.m). See Fig. 11. Go to step 11). 11) On ALL engines, rotate crankshaft two full turns and check adjustment. Install upper timing belt cover 12) Install serpentine belt. See Figs. 13-15. Check ignition timing and adjust, if necessary.

TIMING BELT APPLICATION Application

2.5L 5-Cylinder Eurovan 1992-96 ..................................................... 2.3 Hours ... ....... N/A Transporter (Canadian) 1992-96 ..................................................... 2.3 Hours ... ....... N/A NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Although the manufacturer does not recommend a specic scheduled maintenance interval, aftermarket belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal Remove lower sound dampening pan. 1) Removing V-belt or serpentine belt. 2) Remove timing belt upper cover. 3) Fit counter Hold Tool (3419) and loosen vibration damper and crankshaft sprocket. See Fig. 1.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing/Installing Crankshaft Vibration Damper 4) Remove vibration damper center bolt. 5) Remove the 4 x M8 crankshaft vibration damper/timing belt pulley mounting bolts. 6) Remove vibration damper. 7) Remove timing belt lower cover. 8) If reusing old timing belt, mark direction of rotation on timing belt. 9) Loosen tensioning roller or coolant pump and remove timing belt. CAUTION: Pistons should not be positioned at TDC. Danger of damage to valve train and/or piston crowns exist. NOTE: When turning the camshaft the crankshaft must not be at TDC. Installation 1) For vehicles built from August, 1995 and up, install tensioning roller (1) so that the tensioning roller tab seats in the timing belt cover lower section moving pin (arrow A). See Fig. 5. Tighten tensioning roller mounting bolt hand tight.

VOLKSWAGEN
2.5L 5-Cylinder (Cont.)

751

Courtesy of Volkswagen United States, Inc.

Fig. 2: Identifying Timing Belt & Components (2.5L, Up To July, 1995)

Courtesy of Volkswagen United States, Inc.

Fig. 3: Identifying Timing Belt & Components (2.5L, From August, 1995 & Up)

752

VOLKSWAGEN
2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Identifying Crankshaft Vibration Damper & Components (2.5L)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Setting Up & Installing Tensioning Roller (Vehicles Built From August, 1995 & Up)

VOLKSWAGEN
2.5L 5-Cylinder (Cont.)

753

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 6: Removing/Installing Crankshaft Vibration Damper

Fig. 9: Tensioning Timing Belt (Vehicles Built Up To July, 1995)

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 7: Setting Camshaft Sprocket To TDC Cylinder No. 1.

Fig. 10: Tensioning Timing Belt (Vehicles Built From August, 1995 & Up)

Courtesy of Volkswagen United States, Inc.

Courtesy of Volkswagen United States, Inc.

Fig. 8: Setting Crankshaft To TDC Cylinder No. 1.

Fig. 11: Tensioning Timing Belt Vehicles Without Tensioning Roller

754

VOLKSWAGEN
2.5L 5-Cylinder (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 15: Serpentine Drive Belt Routing (2.5L Without A/C)


Courtesy of Volkswagen United States, Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) A/C Bracket-To-Engine Bolt ...................................................................................... 22 (30) Center Engine Mounting Bolt (M10 x 60) ................................................................ 48 (65) Coolant Fan Thermo Switch ..................................................................................... 18 (25) Coolant (Water) Pump-To-Cylinder Block ................................................................. 15 (20) Coolant (Water) Pump Pulley ................................................................................... 15 (20) Drive Axle-To-Flange Shaft ....................................................................................... 41 (55) Idler Roller-To-Tensioner Bracket .............................................................................. 15 (20) Serpentine Belt Tensioner Bracket-To-Engine Block ................................................ 30 (40) Timing Belt Tensioner Nut ........................................................................................ 15 (20) Transmission Mount-To-Sub Frame .......................................................................... 33 (45) Vibration Damper Center Bolt ....................................................... ..................................... 1 INCH Lbs. (N.m) Radiator Mounting Bolt ............................................................................................. 89 (10) Sound Dampening Pan Hex Nut ................................................................................ 80 (9) Timing Belt Covers (M6 Short) ............................................................................... 2 89 (10) Timing Belt Covers (M8 Long) ............................................................................. 2 177 (20) Timing Belt Inner Covers .............................................................. ..................................... 2 Thermostat Housing .................................................................................................. 89 (10) Valve Cover ............................................................................................................... 89 (10)
1 2

Fig. 12: Adjustment Timing Belt Tension

Courtesy of Volkswagen United States, Inc.

Fig. 13: Serpentine Drive Belt Routing (2.5L Basic)

For torque specications, see Fig. 4. For torque specications related to timing belt components, refer to appropriate illustration. See Figs. 2 and 3.

Courtesy of Volkswagen United States, Inc.

Fig. 14: Serpentine Drive Belt Routing (2.5L With A/C)

VOLKSWAGEN
2.8L V6 Passat AHA & ATQ Engines
TIMING BELT APPLICATION Application Labor Time Belt Part No.

755

2.8L V6 (AHA & ATQ Engines) Passat 1998-04 ..................................................... 4.4 Hours ... ..... T297 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

9) Remove serpentine belt tensioner. Remove center and left timing belt covers. 10) Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley clockwise to compress timing belt tensioner. See Fig. 9. Compress timing belt tensioner just enough so a 2-mm pin can be inserted through the holes in top of tensioner body and push rod. This will hold the tensioner in the compressed position. CAUTION: If reusing old timing belt, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation. 11) Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley. 12) Remove fan retainer and belt pulley toothed belt protection. Remove timing belt. Installation 1) Install Camshaft Locator Bar (3391) into locking plates of camshafts. See Fig. 10. Loosen camshaft sprocket bolts about 5 turns. Remove locator bar. 2) Leaving camshaft sprocket bolts in place, use gear puller to loosen camshaft sprockets on camshaft taper. NOTE: Camshaft sprockets must be loose enough to rotate on camshaft, but not loose enough to tilt. 3) Ensure all timing marks are still aligned. Install timing belt on engine. Ensure belt routing is correct and there is no slack in belt. See Fig. 11. Install Camshaft Locator Bar (3391) into locking plates of camshafts. 4) Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner so that 2-mm pin can be removed from tensioner. 5) Pre-load timing belt tension, using 8-mm hex socket and torque wrench on timing belt tensioner pulley, apply 11 ft. lbs. (15 N.m) to tensioner in direction of tension (clockwise). 6) Tighten camshaft sprocket bolts to specication. See TORQUE SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft holder. Install sealing plug. 7) Install timing belt cover. Install crankshaft pulley. Install serpentine drive belt. 8) To complete installation, reverse remaining removal procedure. When installing crankshaft pulley, ensure notches in pulley are aligned with locating lugs in crankshaft. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


SCHEDULED REPLACEMENT INTERVAL Model Year Interval 1998 ............................................................... ............................................................ 90,000 1999 ............................................................... ............................................................ 75,000 2000-04 .......................................................... .......................................................... 105,000

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: Obtain the radio anti-theft code before disconnecting the battery. NOTE: Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion. Removal 1) Disconnect negative battery cable. Remove engine top cover. Remove noise insulation panel from under front of vehicle. 2) For vehicles manufactured up to September, 2000, disconnect front turn signal light assembly wiring harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 2. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools. 3) For vehicles manufactured from October, 2000, remove bumper cover from bumper carrier. See Fig. 3. Remove noise insulation panel from under engine compartment. Remove air intake duct at lock carrier. Remove bolts from front of bumper carrier. See Fig. 4. Install guide rods on right and left sides. Pull lock carrier forward about 4 (10 cm) on guide rods into service position. 4) Hold cooling fan pulley with spanner wrench (3312). See Fig. 5. Unscrew and remove viscous cooling fan clutch from pulley. Viscous cooling fan is LEFT-HAND threaded. 5) Use a long 17-mm box wrench to turn serpentine belt tensioner counterclockwise and relieve belt tension. Secure tensioning roller with pin 3204 when both holes are positioned over one another. Remove serpentine belt. If reusing belt, mark belt rotation direction with arrow for reassembly reference. 6) Unclip timing belt guard on front of both camshafts and remove. Position crankshaft to top dead center No. 3 cylinder. Mark on toothed belt guard must align with notch on belt pulley. See Fig. 6. 7) Note securing plate on front end of each camshaft sprocket. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. See Fig. 7. Ensure crankshaft timing marks are still aligned. See Fig. 6. 8) Remove sealing plug from left side of engine block. See Fig. 8. TDC mark on crankshaft must be visible or be felt through sealing hole. Install Crankshaft Holding Tool (Audi 3242) into sealing plug hole.

Courtesy of Volkswagen United States, Inc.

Fig. 1: Removing Front Bumper Cover (Up To September, 2000)

756

VOLKSWAGEN
2.8L V6 Passat AHA & ATQ Engines (Cont.)

Courtesy of Volkswagen United States, Inc.

Fig. 4: Moving Lock Carrier To Service Position (From October, 2000)


Courtesy of Volkswagen United States, Inc.

Fig. 2: Moving Lock Carrier To Service Position (Up To September, 2000)

Courtesy of Volkswagen United States, Inc.

Fig. 5: Removing & Installing Viscous Fan

Courtesy of Volkswagen United States, Inc.

Fig. 3: Removing Front Bumper Cover (From October, 2000)

Courtesy of Audi of America, Inc.

Fig. 6: Aligning Crankshaft Timing Marks

VOLKSWAGEN
2.8L V6 Passat AHA & ATQ Engines (Cont.)

757

Courtesy of Audi of America, Inc.

Fig. 7: Aligning Camshaft Sprocket Holes

Courtesy of Audi of America, Inc.

Fig. 10: Installing Camshaft Locator Bar

Courtesy of Audi of America, Inc.

Fig. 8: Installing Crankshaft Holding Tool


Courtesy of Audi of America, Inc.

Fig. 11: Identifying Timing Belt Routing

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 40 (55) Crankshaft Pulley Center Bolt ......................................................................... 1, 2 148 (200) Crankshaft Pulley-To-Crankshaft Hex Bolt ............................................................... 18 (25) Lock Carrier-To-Body Bolts ....................................................................................... 37 (50) Timing Belt Idler Pulley Bolt ..................................................................................... 33 (45) Timing Belt Tensioner Center Bolt ............................................................................ 15 (20) INCH Lbs. (N.m) Lock Carrier-To-Body Torx Bolts ............................................................................... 89 (10) Timing Belt Tensioner Bolt/Nut ................................................................................. 89 (10) Water Pump Bolt ....................................................................................................... 89 (10)
1 2

If removed, manufacturer recommends using NEW bolt. Tighten to initial specication than an additional 180 (1/2 turn).

Courtesy of Audi of America, Inc.

Fig. 9: Compressing Timing Belt Tensioner

758

VOLVO
1.9L 4-Cylinder Turbo 2000-01
Labor Time Belt Part No. 5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn tensioner counterclockwise until tensioner indicator passes marked position. See Fig. 8. 6) Turn tensioner eccentric back so that indicators position is in center of window. See Fig. 8. Holding eccentric in this position, tighten bolt B to 15 ft. lbs (20 N.m) without moving tensioner. 7) Recheck adjustment by pressing pin A clockwise and counterclockwise to check. Rotate crankshaft two complete revolutions, and check that markings on crankshaft pulley and timing gears align with marks on timing gear cover. Ensure indicator pin A is in middle. Readjust if necessary. See Fig. 12. After readjustment, always turn crankshaft 2 complete revolutions to check if tensioner indicator returns to correct position. NOTE: Timing belt tensioner indicator will be in different positions depending on engine temperature. At very low or high temperatures, tensioner indicator will be to the left or right of center. See Fig. 13. 8) Install engine bracket (if removed), timing belt covers, and snow cap. NOTE: Close lid in side cover and move wheels to straight-ahead position. 9) Install serpentine drive belt. Reinstall engine mount and body support. Install power steering hose. Install right front wheel. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

TIMING BELT APPLICATION Application

1.9L 4-Cyl. Turbo S40 & V40 2000-01 Up To VIN 1219110 ................................ 3.1 Hours ... ..... T252 From Engine Vin 1219111 ..................... 3.1 Hours ......... T311 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 2000-01 model years, the manufacturer recommends the timing belt and belt tensioner be replaced every 105,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while belt is removed. Removal 1) Remove right engine compartment cover and cover above right headlight unit. Release serpentine drive belt by turning tensioner clockwise. Remove serpentine drive belt. See Fig. 1. 2) Remove two screws securing upper timing belt covers. Remove upper cover by releasing the two clips then remove the screw and the cover. See Fig. 2. 3) Use an appropriate engine lifting tool to support the weight of the engine at timing belt end of engine. 4) Remove engine mount bolts and nuts on timing end of engine. Remove engine mount. See Fig. 3 or 4. 5) Remove lower timing gear cover by releasing the bottom cover and moving it backwards. See Fig. 5. On 2000 models, engine bracket may have to be removed for clearance to remove belt. See Fig. 6. 6) On all models, remove right front wheel. Turn crankshaft clockwise until camshaft sprocket timing marks align with inner timing gear cover, and crankshaft sprocket aligns with the oil pump housing. See Fig. 7. 7) Loosen timing belt tensioner pulley bolt. See Fig. 8. Holding tensioner pulley bolt stationary, rotate pulley eccentric clockwise with a 6-mm Allen wrench. Remove timing belt from tensioner pulley, camshaft sprockets and water pump. 8) Remove splashguards from under engine compartment. Remove bolts and snow cap. See Fig. 9. Remove timing belt with a turning motion. Remove timing belt tensioner. Inspection Spin tensioner and idler pulleys and listen for bearing noise. Ensure pulley surfaces in contact with belt are clean and smooth. Installation 1) Place timing belt between vibration damper and engine block, and route belt upwards. Reinstall the lower snow cap and replace the bolts. Install splashguards under engine compartment. 2) Ensure camshaft and crankshaft timing marks are still aligned. Position new timing belt tensioner, and nger tighten bolt A. See Fig. 10. Turn eccentric from tensioner in lowest position. 3) Install timing belt in correct sequence. See Fig. 11. Install upper rear timing cover on engine (do not tighten). CAUTION: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature. 4) With timing belt installed, turn crankshaft clockwise until timing belt is tensioned. Belt must be tensioned between intake camshaft sprocket, idler pulley and crankshaft.

Courtesy of Volvo Cars of North America.

Fig. 1: Removing Accessory Drive Belt

VOLVO
1.9L 4-Cylinder Turbo 2000-01 (Cont.)

759

Courtesy of Volvo Cars of North America.

Fig. 2: Removing Timing Gear Covers

Courtesy of Volvo Cars of North America.

Fig. 5: Removing Lower Timing Gear Cover

Courtesy of Volvo Cars of North America.

Fig. 3: Locating Engine Mount (2000)

Courtesy of Volvo Cars of North America.

Fig. 6: Locating Engine Bracket Bolts

Courtesy of Volvo Cars of North America.

Fig. 4: Locating Engine Mount (2001)

Courtesy of Volvo Cars of North America.

Fig. 7: Locating Upper Rear Timing Belt Cover

760

VOLVO
1.9L 4-Cylinder Turbo 2000-01 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 8: Adjusting Timing Belt Tension

Courtesy of Volvo Cars of North America.

Fig. 10: Installing New Tensioner


Courtesy of Volvo Cars of North America.

Fig. 9: Locating Snow Cap & Bolts

VOLVO
1.9L 4-Cylinder Turbo 2000-01 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

761

Application Ft. Lbs. (N.m) Engine Bracket-To-Engine Block Bolt Step 1 ...................................................................................................................... 26 (35) Step 2 ........................................................................................................... Plus 75 Turn Engine Mount (2000) To-Body Through-Bolt .............................................................................................. 72 (98) To-Engine Bolt ......................................................................................................... 50 (67) Engine Mount (2001) To-Body Nut ............................................................................................................. 37 (50) To-Engine Bolt ......................................................................................................... 50 (67) Idler Pulley Bolt ......................................................................................................... 18 (24) Timing Belt Tensioner Pulley Bolt ............................................................................. 15 (20) Water Pump Bolt ....................................................................................................... 13 (17) Wheel Lug Nut ........................................................................................................ 81 (110) INCH Lbs. (N.m) Power Steering Hose Bolt ........................................................................................ 89 Snow Cap Bolt .......................................................................................................... 89 Timing Belt Cover Front ....................................................................................................................... 106 Upper ....................................................................................................................... 89 (10) (10) (12) (10)

Courtesy of Volvo Cars of North America.

Fig. 11: Installing New Timing Belt

Courtesy of Volvo Cars of North America.

Fig. 12: Aligning Timing Marks

Courtesy of Volvo Cars of North America.

Fig. 13: Identifying Timing Belt Tension Positions

762

VOLVO
1.9L 4-Cylinder Turbo 2002-04
Labor Time Belt Part No. 5) Holding tensioner bolt stationary, use a 6-mm hex wrench to turn tensioner counterclockwise until tensioner indicator passes marked position. See Fig. 5. 6) Turn tensioner eccentric back so that indicators position is in center of window. See Fig. 5. Holding eccentric in this position, tighten bolt B to 15 ft. lbs (20 N.m) without moving tensioner. 7) Recheck adjustment by pressing pin A clockwise and counterclockwise to check. See Fig. 10. Install upper timing cover. Rotate crankshaft 2 complete revolutions, and check that markings on crankshaft pulley and timing gears align with marks on timing gear cover. Ensure indicator pin A is in middle. Readjust if necessary. After readjustment, always turn crankshaft 2 complete revolutions to check if tensioner indicator returns to correct position. NOTE: Timing belt tensioner indicator will be in different positions depending on engine temperature. At very low or high temperatures, tensioner indicator will be to left or right of center. See Fig. 9. 8) Install timing covers. Install engine mount. Tighten bolts on engine side to specication. See TORQUE SPECIFICATIONS. Tighten bolts on body side to specication. Install power steering reservoir. NOTE: Close lid in side cover and move wheels to straight-ahead position. 9) Remove engine lifting tool. Install metal bracket for power steering hose on rotation protection for serpentine drive belt. Install right front wheel. Install serpentine drive belt. Install right hand engine cover and cover over right headlight unit. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS.

TIMING BELT APPLICATION Application

1.9L 4-Cyl. Turbo S40 & V40 2002-04 ..................................................... 3.1 Hours ......... T311 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the timing belt and belt tensioner be replaced every 105,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while belt is removed. Removal 1) Remove right engine compartment cover and cover above right headlight unit. Release serpentine drive belt by turning tensioner clockwise. Remove serpentine drive belt. See Fig. 1. 2) Remove 2 screws securing upper timing belt covers. Remove upper cover by releasing 2 clips, then remove screw and cover. See Fig. 2. 3) Remove metal bracket for power steering hose from rotation protection for serpentine drive belt. See Fig. 3. Install Lifting Beam (999-5006), Lifting Arm (999-5383) and Lifting Hook (999-5460) to support weight of engine at timing belt end of engine. See . 4) Remove screws for power steering holder. Remove engine mount bolts and nuts on timing belt end of engine. Remove engine mount. See Fig. 4. Remove lower timing cover. 5) Remove right front wheel. Position upper timing cover. Turn crankshaft until camshaft sprocket timing marks align with inner timing gear cover, and crankshaft sprocket aligns with oil pump housing. See Fig. 2. Turn crankshaft further a 1/4 turn clockwise and then back again until marks correspond. Remove upper timing cover. 6) Loosen timing belt tensioner pulley bolt. See Fig. 5. Holding tensioner pulley bolt stationary, rotate pulley eccentric clockwise with a 6-mm Allen wrench to 10 oclock position. Remove timing belt from tensioner pulley, camshaft sprockets and water pump. 7) Remove splash guards from under engine compartment. See Fig. 6. Remove bolts and snow cap. See Fig. 7. Remove timing belt with a turning motion. Clean surrounding area. Inspection Spin idler pulley and tensioner pulley, and listen for noise. Ensure pulley surfaces in contact with belt are clean and smooth. Installation 1) Install timing belt over pulley on the crankshaft and route belt upwards. Install lower snow cap and bolts. Install splash guards under engine compartment. 2) Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 2. When installing a new idler pulley, tighten bolt to specied torque. See TORQUE SPECIFICATIONS. When installing a new timing belt tensioner, screw tension pulley into place using center screw. Screw in center screw by hand. Ensure that tensioner fork is centered over cylinder block rib. Ensure that Allen hole on eccentric is at 10 oclock. 3) Install timing belt in correct sequence shown in Fig. 8. CAUTION: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature. See Fig. 9. 4) With timing belt installed, turn crankshaft clockwise until timing belt tensions. Belt must have tension between intake camshaft sprocket, idler pulley and crankshaft.

Courtesy of Volvo Cars of North America.

Fig. 1: Removing Accessory Drive Belt

VOLVO
1.9L 4-Cylinder Turbo 2002-04 (Cont.)

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. Courtesy of Volvo Cars of North America.

Fig. 6: Removing Splash Guards

Fig. 3: Removing Power Steering Hose Metal Bracket

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Fig. 7: Removing Snow Cap & Bolts


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Fig. 4: Removing Engine Mount

764

VOLVO
1.9L 4-Cylinder Turbo 2002-04 (Cont.)

Courtesy of Volvo Cars of North America.

Fig. 10: Aligning Timing Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Engine Mount To-Body Nut ............................................................................................................. 37 (50) To-Engine Bolt ......................................................................................................... 50 (67) Idler Pulley Bolt ......................................................................................................... 18 (24) Timing Belt Tensioner Pulley Bolt ............................................................................. 15 (20) Wheel Lug Nut 1 ...................................................................................................... 81 (110) INCH Lbs. (N.m) Timing Belt Cover Front ....................................................................................................................... 106 (12) Upper ......................................................................................................................... 71 (8)
1

Courtesy of Volvo Cars of North America.

Fig. 8: Installing Timing Belt

Use anti-corrosion agent (Volvo P/N 1161038-3 or equivalent).

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Fig. 9: Identifying Timing Belt Tension Positions

VOLVO
2.1L & 2.3L 4-Cylinder B21 & B23
TIMING BELT APPLICATION Application
1

765

REMOVAL & INSTALLATION


Labor Time Component Belt Kit No. Part No. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

2.1L 4-Cyl. B21 242, 244 & 245 1976-79 ............................ .... DL & GL 1980-83 ............................ .... DL (Canadian) 1983 ................................. .... GLT 1981-83 ............................ .... GT Turbo 1984-85 ............................ .... 2.3L 4-Cyl. B23 DL & GL 1982-85 ............................ .... GLE (Canadian) 1984 ................................. .... GLT (Canadian) 1983 ................................. .... 760 GLE 1984 ................................. ....
1

1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032

TIMING BELT
Removal Disconnect negative battery cable. Remove fan shroud and accessory drive belts. Remove timing belt cover. Rotate crankshaft until timing marks are aligned. See Fig. 1. Loosen belt tensioner and pull belt outward until tensioner spring is compressed. Tighten tensioner nut. Remove timing belt. Installation 1) Ensure that timing marks are still aligned. See Fig. 1. Install belt around crankshaft and intermediate shaft so that lines on belt are aligned with timing mark on crankshaft. Install belt over camshaft pulley and tensioner roller. Loosen tensioner nut to release spring tension. Tighten tensioner nut. 2) To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032 1.3 Hrs. .... .. TCK032 .. ..... T032

With Air Conditioning, add .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1976-85 engines, the manufacturer recommends the belt be replaced every 40,000 miles. On 1986-88 engines, the manufacturer recommends the belt be replaced every 50,000 miles.

Fig. 1: Locating Timing Marks for Crankshaft, Intermediate Shaft & Camshaft

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket .................................................................................................... 37 (50) Crankshaft Sprocket ................................................................................................ 22 (166) Drive Belt Tensioner Nut ........................................................................................... 37 (50) Fan Bolt ..................................................................................................................... 33 (45) Intermediate Shaft Sprocket ..................................................................................... 37 (50)

766

VOLVO
2.3L & 2.4L 5-Cylinder 1998-01
Labor Time Belt Part No. 4) Turn crankshaft clockwise (as viewed from timing belt end of engine) to align the timing marks on the crankshaft pulley and camshaft sprockets. See Fig. 2. Turn crankshaft an additional 1/4 turn clockwise, and then back again until the timing marks align. 5) Loosen timing belt tensioner pulley center bolt. Holding center bolt, turn the tensioner eccentric clockwise with a 6-mm Allen wrench. Turn eccentric until the hole for the Allen wrench is at the 10 oclock position. CAUTION: Vibration damper pulley bolts are torque-to-yield type. If vibration damper pulley bolts are removed so that Counterhold (999 5433) or equivalent can be installed, pulley bolts MUST be replaced. 6) Raise and support vehicle. Holding vibration damper stationary with Counterhold (999 5433) or equivalent, remove vibration damper center bolt. Remove vibration damper. Lower vehicle. Remove timing belt.

TIMING BELT APPLICATION Application 2.3L 5-Cyl. Turbo C70, S70 & V70 1998-01, Up To VIN 1266127 ................... 1998-01, From VIN 1266128 .................... S60 2001, Up To VIN 1266127 ........................ 2001, From VIN 1266128 ......................... 2.4L 5-Cyl. C70, S70 & V70 1998-01, Up To VIN 1266127 ................... 1998-01, From VIN 1266128 .................... S60 2001, Up To VIN 1266127 ........................ 2001, From VIN 1266128 .........................

2.4 Hours ... ..... T252 1.8 Hours ......... T311 2.2 Hours ... ..... T252 2.2 Hours ......... T311

2.4 Hours ... ..... T252 1.8 Hours ......... T311 2.2 Hours ... ..... T252 2.2 Hours ......... T311

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For 1998 model year, the manufacturer recommends the belt be replaced every 70,000 miles. For 1999-01 model years, the manufacturer recommends the belt be replaced every 105,000 miles. In addition, manufacturer recommends replacing timing belt tensioner on 2001 C70.

REMOVAL & INSTALLATION


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

TIMING BELT
Courtesy of Volvo Cars of North America.

CAUTION: DO NOT turn crankshaft or camshafts while belt is removed. Removal 1) Remove key from ignition switch. Remove accessory drive (serpentine) belt. See Fig. 1. On S60 models, remove the cross brace between the front shock towers.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks Inspection Spin tensioner and idler pulleys and listen for bearing noise. Ensure pulley surfaces in contact with belt are clean and smooth. Installation 1) If timing belt tensioner was removed, ensure tensioner fork is installed with fork centered over rib on engine block. 2) Place timing belt around crankshaft pulley. Install vibration damper. Install vibration damper center bolt. Hold vibration damper stationary with Counterhold (999 5433) or equivalent, and tighten center bolt to specication. See TORQUE SPECIFICATIONS. Install NEW vibration damper pulley bolts (if removed). 3) Place timing belt around idler pulley, intake camshaft pulley, exhaust camshaft pulley, water pump and timing belt tensioner. See Fig. 3. NOTE: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature. 4) Slowly turn crankshaft clockwise (as viewed from timing belt end of engine) until the timing belt is tensioned. The belt should be tight between the intake camshaft sprocket, idler pulley and crankshaft sprocket. 5) Hold timing belt tensioner pulley bolt secure, and turn tensioner eccentric counterclockwise until the tensioner needle passes to the right of center position. See Fig. 4. 6) Turn tensioner eccentric back until the needle reaches the marked position corresponding to engine temperature. At 68F (20C), the needle must be centered in the window. 7) Holding the timing belt tensioner eccentric steady, tighten the center bolt to 15 ft. lbs. (20 N.m). Ensure tensioner needle is still in correct position. Press timing belt to see if the indicator on the tensioner moves easily. 8) Turn crankshaft clockwise 2 turns. Align camshaft and crankshaft timing marks. Ensure the timing belt tensioner indicator is within the correct area.

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Fig. 1: Removing Accessory Drive (Serpentine) Belt & Drive Belt Routing 2) On all models, remove upper timing belt cover. Remove power steering pump reservoir with hoses attached, and set aside. Remove coolant reservoir and set aside. Remove accessory drive belt. 3) Remove front timing belt cover. Raise and support vehicle. Remove right front wheel. Remove nut from fender liner cover. Remove upper timing belt cover.

VOLVO
2.3L & 2.4L 5-Cylinder 1998-01 (Cont.)
9) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft sprocket timing marks are still aligned. Ensure timing belt tensioner indicator is in the correct position for engine temperature. 10) Install front and upper timing belt covers. Install accessory drive belt. Install power steering reservoir. Check power steering uid level. Rell, if necessary. 11) Install coolant reservoir. Install fender liner cover. Install front wheel. On S60, install shock tower brace.

767

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Shock Tower Brace (S60) Engine Bracket Bolt ................................................................................................ 37 (50) Shock Tower Bolt .................................................................................................... 59 (80) Timing Belt Idler Pulley Bolt ......................................................... ................. 17-18 (24-25) Timing Belt Tensioner Bolt ........................................................................................ 15 (20) Vibration Damper Center Bolt ............................................................................... 133 (180) Vibration Damper Pulley Bolts 1 Step 1 ...................................................................................................................... 18 (25) Step 2 .................................................................................................................... Plus 30 Water Pump Bolt ....................................................................................................... 13 (17) Wheel Lug Nut ...................................................................................................... 100 (130) INCH Lbs. (N.m) Front Timing Belt Cover Bolt .................................................................................. 106 (12) Upper Timing Belt Cover Bolt ..................................................................................... 71 (8)
1

Always replace bolts if loosened or removed.

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Fig. 3: Identifying Timing Belt Routing

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Fig. 4: Adjusting Timing Belt Tension

768

VOLVO
2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder 1992-98
Labor Time Belt Part No. Removal (6-Cylinder) 1) Remove auxiliary drive belt, front transmission cover splash guard under engine, vibration damper guard, and ignition coil cover. 2) Turn crankshaft clockwise until timing marks on camshaft pulleys/ transmission plate and crankshaft pulley/oil pump housing are aligned. See Fig. 1. Remove upper transmission cover. 3) Remove tensioner upper mounting bolt, and loosen lower mounting bolt. Twist tensioner to free plunger/pulley. If reusing old timing belt, mark belt with arrow to indicate rotation direction. Remove lower bolt, tensioner, and timing belt. CAUTION: DO NOT turn crankshaft or camshafts while belt is removed. Inspection Spin tensioner and idler pulleys and listen for bearing noise. See Fig. 2. Ensure pulley surfaces in contact with belt are clean and smooth. Check tensioner pulley arm and idler pulley mountings, and tighten bolts as necessary. See TORQUE SPECIFICATIONS. Check tensioner for signs of leakage, no resistance when depressed, or a plunger that cannot be depressed. Installation 1) Compress tensioner and tighten center nut. Wait until compression has taken place and insert a 2-mm locking pin in plunger. Install tensioner and tighten mounting bolts to specication. See TORQUE SPECIFICATIONS. 2) Place timing belt around crankshaft pulley and right idler. Place belt over camshaft pulleys. Position belt around water pump and press over tensioner pulley. 3) Remove tensioner locking pin. To complete installation, reverse removal procedure. Turn crankshaft 2 revolutions to ensure timing marks on crankshaft and camshaft pulleys are aligned. See Fig. 1. Adjust drive belts to proper tension.

TIMING BELT APPLICATION Application 2.3L 5-Cyl. Turbo 850 1994 .......................................................... 1994 .......................................................... 1995-97 .................................................... 850 (Canadian) 1996 .......................................................... 2.4L 5-Cyl. 850 1993 .......................................................... 1993 .......................................................... 1994-97 .................................................... 850 (Canadian) 1995 .......................................................... 1995 .......................................................... 2.9L 6-Cyl. S90 & V90 1997-98 .................................................... 960 1992-93 .................................................... 1994 .......................................................... 1995-97 ....................................................
1

1 1

2.4 Hours .. ... 2 T217 2.4 Hours .. ... 3 T252 1 2.4 Hours .. ..... T252
1

2.4 Hours .. ..... T252

2.4 Hours .. ... 2 T217 1 2.4 Hours .. ... 3 T252 1 2.4 Hours .. ..... T252
1 1

2.4 Hours .. ... 2.4 Hours .. ...

2 3

T217 T269

2.2 Hours .. ..... T270

1 1

2.2 Hours .. ..... T217 2.2 Hours .. ..... T252 1 2.2 Hours .. ..... T270

2 3

With Air Conditioning, add .5 hours. With shimmed Air Conditioning belt, add .5 hours. Through engine number 131034. From engine number 131035.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


On 1992 960 models, the manufacturer recommends the belt be replaced every 30,000 mile intervals, starting at the rst 40,000 mile service. On 1993 960 models, the manufacturer recommends the belt be replaced at 30,000 mile intervals, starting at the rst 30,000 mile service. On 1994 960 models, the manufacturer recommends the belt be replaced every 50,000 miles. On 1993 850 models, with engine number 131034 and earlier, the manufacturer suggests the belt be replaced every 50,000 miles. On 1994 850 models and 1993 850 models from engine number 131035, the manufacturer recommends the belt be replaced every 70,000 miles. On ALL 1995-98 models, the manufacturer recommends the belt be replaced every 70,000 miles.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Camshaft & Crankshaft Timing Marks

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
2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder 1992-98 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS

769

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Fig. 2: Checking Tensioner & Idler Pulleys

Application Ft. Lbs. (N.m) Camshaft Cover Bolt ................................................................................................. 13 (17) Camshaft Pulley Bolt ................................................................................................. 15 (20) Spark Plug ................................................................................................................. 18 (25) Timing Belt Pulley Bolt .............................................................................................. 30 (40) Timing Belt Tensioner Bolt ........................................................................................ 18 (25) Vibration Damper Center Nut 5-Cylinder ............................................................................................................. 133 (180) 6-Cylinder ............................................................................................................. 221 (300) Vibration Damper-To-Crankshaft Bolt 5-Cylinder Step 1 .................................................................................................................... 18 (25) Step 2 ......................................................................................................... Plus 30 Turn 6-Cylinder Step 1 .................................................................................................................... 26 (35) Step 2 ......................................................................................................... Plus 50 Turn Water Pump Bolt ....................................................................................................... 13 (17) Wheel Lug Nut ........................................................................................................ 81 (110)

770

VOLVO
2.3L 4-Cylinder B230, B230F & B230FT
1

TIMING BELT APPLICATION Application Labor Time Component Belt Kit No. Part No. NOTE: If reusing timing belt, mark direction of rotation for installation reference. 4) Place mark on timing belt to indicate direction of belt rotation. Loosen belt tensioner nut one turn. Pull on timing belt to compress belt tensioner spring. Tighten belt tensioner nut. 5) Install a 3-mm drill bit through hole of belt tensioner bolt to lock belt tensioner spring in place. Remove timing belt from camshaft sprocket.

2.3L 4-Cyl. SOHC Coupe 1991 ................................. .... 2.7 Hrs. .... .. 240 Series 1986 ................................... 2, 3 2.0 Hrs. .. .. 1987-92 ............................ ... 3 2.0 Hrs. ... .. 1993 ................................. ... 3 2.0 Hrs. ... .. 740 Series 1986-92 ............................ .... 2.2 Hrs. .... .. 760 Series 1985-90 ............................ .... 2.2 Hrs. .... .. 780 Series 1989-90 ............................ .... 2.7 Hrs. .... .. 940 Series 1991-92 ............................ .... 2.2 Hrs. .... .. 1993-95 ............................ .... 2.2 Hrs. .... ..
1 2

TCK032 .. ..... T032 TCK032 .. ..... T032 TCK032 .. ..... T032 TCK234 .. ..... T234 TCK032 .. ..... T032 TCK032 .. ..... T032 TCK032 .. ..... T032 TCK032 .. ..... T032 TCK234 .. ..... T234

With Air Conditioning, add .5 hours. On Diesel engines, Front Belt labor time is 3.6 hours. On Diesel engines, Rear Belt labor time is 1.9 hours. On 240 model, with Shimmed Air Conditioning Belt, add, .5 hours.

NOTE: A timing belt component kit is available for this application. See page A1 for information on component kits. NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Timing Marks

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 50,000 miles, except for 1994 and later B230FT engines with EGR. On these engines, the manufacturer recommends the timing belt be replaced at 100,000 mile intervals.

REMOVAL & INSTALLATION


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

Inspection Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner for roughness in rotation. Replace components if damaged. Installation 1) Install belt tensioner if previously removed. Ensure all timing marks align. See Fig. 1Fig. 1. 2) Outer side of timing belt has 2 lines, which should t toward crankshaft marks. Install belt over crankshaft sprocket rst, then over intermediate shaft. Stretch belt on tension side and t over camshaft sprocket. Slide back of belt onto belt tensioner. 3) Loosen bolt on belt tensioner to apply spring tension against drive belt. Tighten belt tensioner nut. Ensure timing marks align. To install remaining components, reverse removal procedure. CAUTION: Readjust timing belt when engine reaches normal operating temperature. 4) Warm engine to normal operating temperature. Remove plug from front timing belt cover. Loosen belt tensioner bolt one turn, and allow for belt tensioner spring to apply pressure on timing belt. This readjusts timing belt to allow for belt stretch. Tighten belt tensioner nut. Install rubber plug. Adjust drive belts to proper tension.

TIMING BELT
CAUTION: Ensure timing marks align before removing timing belt. DO NOT rotate crankshaft or camshaft with timing belt removed, or valves may contact pistons. Removal 1) Disconnect negative battery cable. Loosen adjusters and remove all drive belts and water pump pulley. Remove fan, preheater hose (below fan shroud) and fan shroud. 2) Using center bolt on crankshaft, rotate crankshaft so mark on camshaft pulley aligns with timing mark on inner timing belt cover, and crankshaft pulley mark aligns with TDC mark on timing belt cover. 3) Remove nut and washer from belt tensioner. Install Crankshaft Holder (5284), or equivalent, on crankshaft pulley and belt tensioner stud. Install nut on stud. Remove crankshaft center bolt, crankshaft pulley and lower timing belt cover. Ensure timing marks are aligned. See Fig. 1.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................................................................ 37 (50) Crankshaft Pulley Bolt 1 Step 1 ...................................................................................................................... 44 (60) Step 2 ........................................................................................................... Additional 60 Intermediate Shaft Sprocket Bolt .............................................................................. 38 (51)
1

Apply light coat of oil to bolts before installation.

VOLVO
2.3L 4-Cylinder B234
TIMING BELT APPLICATION Application
1

771

Labor Time

Belt Part No.

2.3L 4-Cyl. B234 740 Series (Canadian) 1986-88 Balance Shaft ...................................... .......... 2 .......... ..... Camshaft ................................................ 2.8 Hours ... ..... 1989 (With Automatic Tensioner) Balance Shaft ...................................... .......... 2 .......... ..... Camshaft ................................................ 2.8 Hours ... ..... 1989 (With Manual Tensioner) Balance Shaft ...................................... .......... 2 .......... ..... Camshaft ................................................ 2.8 Hours ... ..... 1990 Balance Shaft ...................................... .......... 2 .......... ..... Camshaft ................................................ 2.8 Hours ... ..... 940 Series (Canadian) 1991-92 Balance Shaft ...................................... .......... 2 .......... ..... Camshaft ................................................ 2.8 Hours ... .....
1 2

T174 T173 T174 T198 T174 T173 T174 T173

T174 T198

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With Air Conditioning, add .5 hours. Balance shaft belt labor time is included in camshaft belt labor time.

Fig. 1: Aligning Camshaft & Crankshaft Markings

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: Ensure timing marks align before removing timing belt. DO NOT rotate crankshaft or camshaft with timing belt removed, as it is possible valves may contact pistons. Removal 1) Disconnect negative battery cable. Remove radiator fan and pulley. Remove fan shroud and servo pump. Remove A/C compressor drive belts, if equipped. Remove timing cover attaching bolts, then all three covers starting with top cover. 2) Rotate crankshaft until No. 1 cylinder is at TDC position. Check that marks on camshaft pulleys align with those on transmission mounting plate. Marking on belt guide plate on crankshaft should be opposite TDC marking on cylinder block. See Fig. 1. 3) Loosen tensioner lock nut, then compress tensioner spring. Tighten tensioner lock nut and remove camshaft timing belt. 4) Do not turn crankshaft and camshafts while timing belt is removed. Remove balance shaft belt idler pulley. Loosen lock nut and remove balance shaft belt. See Fig. 2. Installation 1) Check that balance shaft marking aligns with markings on transmission mounting plate. See Fig. 3. Ensure that crankshaft marking is opposite TDC marking on cylinder head. Install balance shaft belt under crankshaft pulley assembly. Ensure that blue dot (marking B) is opposite bottom TDC marking on belt guide plate at bottom of crankshaft. See Fig. 4. 2) Install balance shaft belt around left (upper) balance shaft with marking C opposite marking on pulley. See Fig. 4. Install balance shaft belt on right (lower) balance shaft with marking A opposite marking on pulley. Install balance shaft belt around tensioner. Ensure that markings are still aligned.

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Fig. 2: Removing Balance Shaft Belt 3) Tighten balance shaft belt tensioner using an Allen key inserted in adjusting hole in tensioner. See Fig. 5. Carefully rotate crankshaft a few degrees on either side of TDC position to ensure that balance shaft belt engages properly in pulleys. Return crankshaft to TDC position. 4) Ensure that adjusting hole in balance shaft belt tensioner is below 3 oclock position when tightening locking bolt. Torque locking bolt to 29.5 ft. lbs. (40.5 N.m) using an Allen key inserted in adjusting hole as counter hold. See Fig. 5. Check balance shaft belt tension using Volvo Gauge Tool (No. 998 8500) or equivalent.

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 equivalent, between exhaust camshaft pulley and idler. Belt tension should be within 5.3 to 5.7 unit range. See Fig. 9. Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Replace protective cap in measuring zone. See Fig. 10. 11) Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Replace protective cap. If belt tension reading is outside above range, remove protective cap, then loosen tensioner lock nut. Position Volvo Gauge (998 8500) or equivalent in measuring zone. See Fig. 10. If belt tension is low, move roller to adjust belt tension to 5.8 to 6.2 units. 12) If belt tension is high, adjust to obtain a reading of 4.8 to 5.2 units. Torque tensioner lock nut to 37 ft. lbs. (51 N.m), and rotate crankshaft clockwise. Measure belt tension. Belt tension should be 5.3 to 5.7 unit range. 13) Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Remove protective cap, then loosen tensioner. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.

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Fig. 4: Installing Balance Shaft Belt

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Fig. 5: Adjusting Tensioner

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Fig. 3: Aligning Balance Shaft & Crankshaft Markings

VOLVO
2.3L 4-Cylinder B234 (Cont.)

773

Courtesy of Volvo Cars of North America.

Fig. 6: Checking Balance Shaft Belt Tension


Courtesy of Volvo Cars of North America.

Fig. 8: Rotating Crankshaft

Courtesy of Volvo Cars of North America.

Fig. 9: Checking Belt Tension

Courtesy of Volvo Cars of North America.

Fig. 7: Installing Timing Belt

774

VOLVO
2.3L 4-Cylinder B234 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Tensioner Locking Bolt ........................................................................................... 29.5 (40) Tensioner Lock Nut ................................................................................................ 37.0 (49)

Courtesy of Volvo Cars of North America.

Fig. 10: Adjusting Belt Tension

VOLVO
2.3L, 2.4L & 2.5L 5-Cylinder 2002-04
TIMING BELT APPLICATION Application 2.3L 5-Cyl. Turbo C70, S60 & V70 2002-04 ..................................................... 2.4L 5-Cyl. Non-Turbo S60 & V70 2002-04 ..................................................... 2.4L 5-Cyl. Turbo C70, S60 & V70 2002-04 ..................................................... 2.5L 5-Cyl. Turbo XC90 2003-04 ..................................................... Labor Time Belt Part No.

775

2.2 Hours ... ..... T252

2.2 Hours ... ..... T252

2.2 Hours ... ..... T331

2.3 Hours ... ..... T331

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


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.

Courtesy of Volvo Cars of North America.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks

REMOVAL & INSTALLATION


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

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while timing belt is removed. Removal 1) Remove key from ignition switch. On all models except C70, remove cross brace between front shock towers. WARNING: DO NOT spill power steering uid. It is extremely ammable. 2) On all models, remove upper timing belt cover. Remove power steering pump reservoir with hoses attached, and set aside. Remove coolant reservoir and set aside. If necessary, use a small screwdriver and remove plastic cover on accessory belt tensioner. Use a wrench and turn accessory belt tensioner clockwise to release tension and remove accessory drive belt. 3) Remove front timing belt cover. Raise and support vehicle. Remove right front wheel. Remove nut from fender liner cover. 4) Install upper timing belt cover. Turn crankshaft clockwise (as viewed from timing belt end of engine) to align timing marks on timing belt cover, crankshaft pulley and camshaft sprockets. See Fig. 1. Turn crankshaft an additional 1/4 turn clockwise, and then back again until timing marks align. 5) Remove upper timing belt cover. Loosen timing belt tensioner pulley center bolt slightly. Holding center bolt, turn tensioner eccentric clockwise with a 6-mm Allen wrench. Turn eccentric until hole for Allen wrench is at 10 oclock position. See Fig. 2. 6) Remove timing belt from tension pulley, camshaft pulley and water pump. 7) Holding vibration damper stationary with Counterhold (999 5433) or equivalent, work vibration damper loose. Remove timing belt. Inspection Spin tensioner and idler pulleys, and listen for bearing noise. Ensure pulley surfaces in contact with belt are clean and smooth. Installation 1) If timing belt tensioner was removed, ensure tensioner fork is installed with fork centered over rib on engine block.
Courtesy of Volvo Cars of North America.

Fig. 2: Identifying Timing Belt Tensioner 2) Place timing belt around crankshaft pulley. Install vibration damper. Install vibration damper center bolt. Hold vibration damper stationary with Counterhold (999 5433) or equivalent, and tighten center bolt to specication. See TORQUE SPECIFICATIONS. Remove Counterhold and install NEW screws. Tighten to specication. See TORQUE SPECIFICATIONS. 3) Place timing belt around idler pulley, intake camshaft pulley, exhaust camshaft pulley, water pump and timing belt tensioner. See Fig. 3. NOTE: Timing belt tension MUST be adjusted when engine is cold. Around 68F (20C) is best temperature. 4) Slowly turn crankshaft clockwise (as viewed from timing belt end of engine) until timing belt is tensioned. Belt should be tight between intake camshaft sprocket, idler pulley and crankshaft sprocket. 5) Hold timing belt tensioner pulley bolt secure, and turn tensioner eccentric counterclockwise until tensioner needle passes to right of center position. See Fig. 4. 6) Turn tensioner eccentric back until needle reaches marked position corresponding to engine temperature. At 68F (20C), needle must be centered in window. 7) Holding timing belt tensioner eccentric steady, tighten center bolt to 15 ft. lbs. (20 N.m). Ensure tensioner needle is still in correct position. Press timing belt to see if indicator on tensioner moves easily. 8) Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft sprocket timing marks are still aligned. Ensure timing belt tensioner indicator is in correct position for engine temperature.

776

VOLVO
2.3L, 2.4L & 2.5L 5-Cylinder 2002-04 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Idler Pulley ................................................................................................................. 17 (24) Shock Tower Brace Brace-To-Bracket Bolt ............................................................................................. 37 (50) Bracket-To-Shock Tower Bolt .................................................................................. 59 (80) Timing Belt Tensioner Bolt ........................................................................................ 15 (20) Vibration Damper Center Bolt ............................................................................... 133 (180) Vibration Damper Pulley-To-Cranshaft Sprocket Screw 1 Step 1 ...................................................................................................................... 18 (25) Step 2 .................................................................................................................... Plus 30 Wheel Lug Nut C70 ........................................................................................................................ 81 (110) S60, V70, XC70 & XC90 .................................................................................... 103 (140) INCH Lbs. (N.m) Front Timing Belt Cover Bolt .................................................................................. 106 (12) Upper Timing Belt Cover Bolt ..................................................................................... 71 (8)
1

9) Install front timing belt cover. Install upper timing belt cover. Tighten bolts to specication. See TORQUE SPECIFICATIONS. Install accessory drive belt. Install power steering reservoir. Check power steering uid level. Rell, if necessary. 10) Install coolant reservoir. Install fender liner cover. Install front wheel. On all models except C70, install cross brace between shock towers. Tighten fasteners to specication. See TORQUE SPECIFICATIONS.

Always replace bolts if loosened or removed.

Courtesy of Volvo Cars of North America.

Fig. 3: Identifying Timing Belt Routing

Courtesy of Volvo Cars of North America.

Fig. 4: Adjusting Timing Belt Tension

VOLVO
2.4L & 2.5L 5-Cylinder Turbo 2004 1/2
TIMING BELT APPLICATION Application 2.4L 5-Cyl. S40 2004 1/2 2.5L 5-Cyl. S40 2004 1/2 Turbo ................................................. ........ N/A ........ ..... T331 Turbo ................................................. ........ N/A ........ ..... T331 Labor Time Belt Part No.

777

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


Manufacturer recommends timing belt, tensioner and idler pulley replacement every 120,000 miles.

REMOVAL & INSTALLATION


CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
Courtesy of Volvo Cars of North America.

Fig. 2: Removing Engine Mount & Limiter

TIMING BELT
Removal 1) Lift coolant expansion tank out of holder and place on top of engine. Fit Lifting Beam (999-7103). See Fig. 1.

Courtesy of Volvo Cars of North America.

Fig. 3: Disconnecting Power Steering Pressure Line From Pump

Courtesy of Volvo Cars of North America.

Fig. 1: Installing Lifting Beam 2) Remove bolts for engine mount limiter. Remove limiter. Remove bolts holding engine mount to cylinder head. See Fig. 2. Remove engine mount. 3) Remove front transmission cover bolts and covers. 4) Raise and support vehicle. Remove right front wheel. Remove fender liner. Lower vehicle so that timing belt pulley is visible and Lifting Beam is accessible. 5) Disconnect power steering pressure line from pump. See Fig. 3. Clean any spilled uid 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 rst using crankshaft center nut to counter. Use Counterhold (999-5433) to hold damper and remove crankshaft center nut. See Fig. 4. Remove Counterhold and work vibration damper loose. 8) Turn crankshaft clockwise until crankshaft and camshaft timing marks align. See Fig. 5. Lower engine so that belt tensioner bolts are accessible from underneath.

Courtesy of Volvo Cars of North America.

Fig. 4: Using Counterhold To Remove Vibration Damper 9) Loosen belt tensioner center bolt slightly. Hold center bolt and turn eccentric clockwise using a 6mm Allen key. Turn to 10 oclock position and remove timing belt from pulleys.

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 NOTE: Tensioner and idler pulley will not be reused. 10) Remove belt tensioner and idler pulley. Discard both. NOTE: Timing belt tensioner and idler pulley MUST be replaced with timing belt. Installation 1) Fit new tensioner with center bolt. Ensure tensioner fork is centered over rib in engine block. Ensure Allen key hole on eccentric is at 10 oclock position. Install new idler pulley and tighten bolts to specication. See TORQUE SPECIFICATIONS. 2) Ensure timing marks are aligned. Install timing belt in the following order: Crankshaft. Idler pulley. Intake camshaft. Exhaust camshaft. Water pump. Tensioner. NOTE: Engine MUST be cold to accurately adjust timing belt tension. Approximately 20C (68F) is a suitable temperature. At higher temperatures (engine at operating temperature or a high outside temperature, for example) the indicator is further to the right. See Fig. 6.

Fig. 7: Adjusting Timing Belt Tensioner 6) Ensure tensioner indicator is within marked area. If not, adjust belt tension again. If so, go to next step. 7) Install vibration damper. Use Counterhold (999-5433) to tighten crankshaft center nut. Tighten bolts to specication. See TORQUE SPECIFICATIONS. 8) Install outer accessory drive belt. Connect pressure hose to power steering pump. Do not forget to remove seals from pipe and pump openings. 9) Install fender liner and front wheel. Tighten wheel lugs to specication. See TORQUE SPECIFICATIONS. 10) Lower vehicle. Install front transmission covers. Install engine mount and limiter. Remove Lifting Beam. Fit coolant expansion tank. 11) Fit all remaining components. Start engine and check function.

Courtesy of Volvo Cars of North America. Courtesy of Volvo Cars of North America.

Fig. 6: Adjusting Timing Belt Tension 3) Install crankshaft center nut. Turn crankshaft slowly clockwise until timing belt tension is correct. Belt must be in tension between intake camshaft pulley, idler pulley and crankshaft pulley. 4) Hold tensioner center bolt still and turn eccentric clockwise until tensioner indicator passes marked position. Then turn eccentric back so indicator reaches marked position in center of window. Hold eccentric still and tighten center bolt to specication. See Fig. 7 and TORQUE SPECIFICATIONS. Ensure indicator is still in correct position. 5) Press on timing belt between pulleys and ensure tensioner moves easily. Install upper timing cover. Turn crankshaft clockwise 2 revolutions and ensure crankshaft and camshaft timing marks align.

Fig. 8: Identifying Timing Belt Routing

VOLVO
2.4L & 2.5L 5-Cylinder Turbo 2004 1/2 (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Engine Mount-To-Engine Bolts Step 1 ...................................................................................................................... 26 (35) Step 2 .................................................................................................................... Plus 75 Engine Mount Limiter-To-Chassis ............................................................................. 59 (80) Idler Pulley Bolts ....................................................................................................... 17 (24) Power Steering Pressure Line Connection .............................................................. 13 (18) Timing Belt Tensioner Center Bolt ............................................................................ 15 (20) Vibration Damper Center Bolt ............................................................................... 133 (180) Vibration Damper Pulley Screw 1 Step 1 ...................................................................................................................... 18 (25) Step 2 .................................................................................................................... Plus 60 Wheel Bolts Step 1 ...................................................................................................................... 15 (20) Step 2 ...................................................................................................................... 70 (95) INCH Lbs. (N.m) Upper Timing Belt Cover Bolt ................................................................................... 89 (10) Front Timing Belt Cover Bolt ...................................................................................... 71 (8)
1

779

Always replace bolts if loosened or removed.

780

VOLVO
2.4L 6-Cylinder Diesel
Labor Time Belt Part No.

TIMING BELT APPLICATION Application

2.4L 6-Cyl. Diesel DL 1982 Camshaft ............................................... 1 3.6 Hours .. ..... Injection Pump ....................................... 1.9 Hours ... ..... GL 1982-84 Camshaft ............................................... 1 3.6 Hours .. ..... Injection Pump ....................................... 1.9 Hours ... ..... 740 Series 1985-86 Camshaft ............................................... 1 3.6 Hours .. ..... Injection Pump ....................................... 1.9 Hours ... ..... 760 GLE 1983-84 Camshaft ............................................... 1 3.9 Hours .. ..... Injection Pump ....................................... 1.9 Hours ... ..... 760 Series 1985 Camshaft ............................................... 1 3.9 Hours .. ..... Injection Pump ....................................... 1.9 Hours ... .....
1

T083 T082

T083 T082

T083 T082
Courtesy of Volvo Cars of North America.

T083 T082

Fig. 1: Camshaft Timing & Injection Timing At TDC

T083 T082

With Air Conditioning, add .5 hours.

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends the belt be replaced every 75,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Remove splash guard, cooling fan, spacer, and pulley. Remove fan and power steering pump belts, power steering pump and expansion tank cap. Drain and remove radiator. Disconnect battery ground cable. 2) Remove valve cover and front and rear timing belt covers. Using a 1 1/16 (27 mm) socket on damper pulley bolt, set No. 1 cylinder at TDC (timing mark on ywheel at 0). Loosen water pump and idler pulley bolts to remove timing belt from camshaft gear. See Fig. 1. 3) Using Damper Pulley Wrench (5187) or equivalent, and Damper Pulley Bolt Tool (5188) or equivalent, remove damper pulley bolt. Using a 6-mm socket, remove 4 screws from damper pulley and pulley (it may be necessary to tap pulley from shaft). Remove lower belt shield and timing gear belt. 4) Remove center bolt from idler pulley. Using Idler Pulley Removal Tool (5202) or equivalent, remove idler pulley. Replace and tap new idler pulley into position. Using Spanner Wrench Tool (5199) or equivalent, hold front camshaft drive gear in place and remove center retaining bolt. See Fig. 2. CAUTION: Idler pulley must be replaced when replacing timing gear belt. Use Puller (5202) to remove pulley. CAUTION: Camshaft MUST NOT rotate, or damage to valves and pistons may result. 5) Tap gear loose from camshaft tapered end. Remove injection pump drive belt by loosening retaining bracket bolts. Tighten one screw to hold pump in upper position. Use Spanner Wrench Tool (5199) or equivalent to hold rear camshaft sprocket, and Wrench (5201) or equivalent to remove center retaining bolt. Tap gear loose from camshaft. See Fig. 2.
Courtesy of Volvo Cars of North America.

Fig. 2: Using Camshaft Gear Retaining Wrench Installation 1) Check that No. 1 cylinder is at TDC, timing mark on ywheel is at 0, and camshaft lobes for No. 1 cylinder are facing up with equally large angles in comparison with cylinder head. See Fig. 1. Place Camshaft Lock Gauge Tool (5190) or equivalent in camshaft groove at rear of cylinder head. NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool (5190) or equivalent is to compensate for timing gear clearance. 2) Place a .008 (.2 mm) feeler gauge under left side of Camshaft Locking Gauge Tool (5190) or equivalent. See Fig. 3. Install timing gear belt and damper pulley. Replace 4 damper pulley bolts, and torque to 15 ft. lbs. (20 N.m). 3) Using Damper Pulley Wrench Tools (5187 and 5188) or equivalent, install and torque center bolt (use sealing agent on center bolt threads) of damper pulley to 255 ft. lbs. (350 N.m). Install front timing gear belt and camshaft timing gear (ensuring camshaft does not turn). Torque to 33 ft. lbs. (45 N.m) after setting timing marks. 4) Remove Camshaft Gauge Locking Tool (5190) and feeler gauge from rear of camshaft. Install rear camshaft gear and injection pump belt. Set injection pump timing. See Fig. 4. 5) Position Belt Tension Gauge Tool (5197) or equivalent on timing and injection pump belt, set gauge to .50 (12.5 mm). Place tension on belt until mark on plunger is ush with gauge sleeve, and tighten bolts.

VOLVO
2.4L 6-Cylinder Diesel (Cont.)
6) Using coolant pump to adjust timing gear belt tension, place tension on belt until mark on plunger is ush with gauge sleeve. Install valve cover and new gaskets. Install front and rear timing gear covers. Install lower belt shield. Reverse removal procedure to complete installation. Adjust drive belts to proper tension.

781

Courtesy of Volvo Cars of North America.

Fig. 4: Locating Injection Pump Alignment Marks

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Gear Bolt Front ......................................................................................................................... 33 (45) Rear ....................................................................................................................... 74 (100) Crankshaft Pulley Nut ........................................................................................... 258 (350) Injector Pump Gear ................................................................................................... 33 (45)

Courtesy of Volvo Cars of North America.

Fig. 3: Setting Timing Using Camshaft Locking Gauge

782

VOLVO
2.8L & 2.9L 6-Cylinder
Labor Time Belt Part No. 4) Remove air duct, cover, surround and control module box. Remove hose between thermostat housing and expansion tank. Remove front timing belt cover. 5) Seal hose between expansion tank and radiator. Disconnect hose at expansion tank. Lift expansion tank and place on top of engine. 6) Raise and support vehicle. Remove right front wheel. Remove plastic nuts from cover in fender liner. Install upper timing belt cover. 7) Rotate crankshaft clockwise until timing marks are aligned. See Fig. 2. Rotate crankshaft further 1/4 turn clockwise, then rotate counterclockwise until marks are aligned. 8) Remove upper timing belt cover. Remove 4 vibration damper screws. Remove vibration damper. Remove accessory drive belt. On models with hydraulic timing belt tensioner, go to next step. On models without hydraulic timing belt tensioner, go to step 11). 9) Install Counterhold (999 5433), and remove crankshaft center nut. See Fig. 3. Remove counterhold and accessory drive belt pulley. 10) Remove timing belt tensioner/hydraulic unit upper screw, then loosen lower screw. Turn tensioner/hydraulic unit so that cylinder comes free. Remove lower screw. Remove tensioner/hydraulic unit. Remove timing belt. 11) Remove belt cover behind crankshaft pulley for accessory drive belt. Spray universal oil around rubber sleeve on underside of oil pump. Remove rubber sleeve. 12) Slightly loosen timing belt tensioner center screw. Hold screw from turning. Using a 6-mm hex wrench in eccentric, turn tensioner counterclockwise until eccentric is at 10 oclock position. See Fig. 4. Remove timing belt.

TIMING BELT APPLICATION Application 2.8L 6-Cyl. Turbo S80 1999 ........................................................... 2000-01 ..................................................... 2.9L 6-Cyl. Turbo S80 2002-03 ..................................................... XC90 2003-04 ..................................................... 2.9L 6-Cyl. Non-Turbo S80 1999 ......................................................... 2000-03 ...................................................

4.4 Hours ... ..... T270 3.5 Hours ... ..... T319

3.5 Hours ... ..... T319 3.5 Hours ... ..... T319

2.7 Hours ... ..... T270 3.6 Hours ... ..... T319

NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


For S80 models, manufacturer recommends the timing belt and belt tensioner be replaced every 105,000 miles. For 2003-04 XC90 models, manufacturer recommends the timing belt and belt tensioner be replaced every 120,000 miles.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Remove ignition key. Remove engine stabilizer brace. On turbo models, remove plastic pipes between turbocharger and charge air cooler, and between turbocharger and air cleaner. Set them aside. 2) Remove clamp from intake manifold for turbocharger for cylinders Nos. 1, 2 and 3. Turn upper section of pipe toward rewall. On all models, lift power steering uid reservoir, and place on top of engine. NOTE: Ensure power steering uid does not leak out of ventilation hole. 3) Using a 15-mm wrench, rotate accessory drive belt tensioner clockwise to relieve tension on belt. See Fig. 1. Lift off accessory drive belt. Remove upper timing belt cover.
Courtesy of Volvo Cars of North America.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks

Courtesy of Volvo Cars of North America. Courtesy of Volvo Cars of North America.

Fig. 3: Removing Crankshaft Center Nut

Fig. 1: Identifying Accessory Drive (Serpentine) Belt Routing

VOLVO
2.8L & 2.9L 6-Cylinder (Cont.)

783

11) To complete installation, reverse removal procedure. Tighten all fasteners to specication. See TORQUE SPECIFICATIONS. Fill coolant and power steering uid.

Courtesy of Volvo Cars of North America.

Fig. 4: Identifying Timing Belt Tensioner Inspection Spin tensioner and idler pulleys and listen for bearing noise. Ensure pulley surfaces in contact with belt are clean and smooth. On models with hydraulic timing belt tensioner, ensure tensioner/ hydraulic unit shows no visible signs of leakage. NOTE: The variable valve timing unit on B6304S engine does not have a return spring. The unit is easily dislodged when installing timing belt. 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 specication. See TORQUE SPECIFICATIONS. NOTE: Tensioner/hydraulic unit must be replaced if there is no resistance when pushing piston in or if piston cannot be pushed in. 3) On all models, ensure timing marks are aligned. See Fig. 2. Install timing belt in order shown in illustration. See Fig. 6. 4) On models with hydraulic timing belt tensioner, go to next step. On models without hydraulic timing belt tensioner, go to step 6). 5) Pull lock pin out of tensioner/hydraulic unit. Install accessory drive belt pulley. Install crankshaft center nut. Rotate crankshaft clockwise 2 revolutions, and ensure timing marks are aligned. Install Counterhold (999 5433), and tighten crankshaft center nut to specication. See TORQUE SPECIFICATIONS. Go to step 10). 6) Carefully rotate crankshaft clockwise until timing belt is tensioned. Timing belt must be tight between intake camshaft pulley, idler pulley and crankshaft. CAUTION: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature. 7) Hold tensioner center screw from turning. Using 6-mm hex wrench, turn tensioner eccentric clockwise until tensioner indicator passes marked position. See Fig. 7. 8) Turn tensioner eccentric back so that indicators position is in center of window. See Fig. 7. Holding eccentric in this position, tighten center screw to specication. See TORQUE SPECIFICATIONS. 9) Ensure indicator is in correct position. Press belt to ensure that tensioner indicator moves easily. Install upper timing belt cover. Rotate crankshaft clockwise 2 revolutions, and ensure timing marks are aligned and tensioner indicator is in correct position. 10) On all models, install accessory drive belt around crankshaft pulley. Install vibration damper with NEW screws. Tighten screws to 26 ft. lbs. (35 N.m), then angle tighten 50 degrees. Use crankshaft center nut as a counterhold.
Courtesy of Volvo Cars of North America.

Fig. 5: Compressing Timing Belt Tensioner/Hydraulic Unit Piston (Hydraulic Tensioner)

Courtesy of Volvo Cars of North America.

Fig. 6: Identifying Timing Belt Installation Order

784

VOLVO
2.8L & 2.9L 6-Cylinder (Cont.)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Center Nut .......................................................................................... 221 (300) Engine Stabilizer Brace To-Body Bolt ............................................................................................................ 37 (50) To-Engine Bracket Bolt ........................................................................................... 59 (80) Idler Pulley Bolt ......................................................................................................... 18 (24) Timing Belt Tensioner Center Screw (Except Hydraulic Tensioner) .......................................................... 18 (24) Tensioner Pulley Screw (Hydraulic Tensioner) ....................................................... 22 (30) Hydraulic Unit Screw ............................................................................................... 18 (24) Vibration Damper-To-Crankshaft Sprocket Screw 1 Step 1 ...................................................................................................................... 26 (35) Step 2 .......................................................................................... ......................... Turn 50 Wheel Lug Nut ........................................................................................................ 81 (110) INCH Lbs. (N.m) Timing Belt Cover Front ....................................................................................................................... 106 (12) Upper ......................................................................................................................... 71 (8)
1

Courtesy of Volvo Cars of North America.

Fig. 7: Identifying Timing Belt Tension Positions (Mechanical Tensioner)

Use NEW screws.

YUGO
1.1L & 1.3L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Belt Part No.

785

1.1L 4-Cyl. GV Series 1986-89 ..................................................... 2.5 Hours ... ..... T018 1.3L 4-Cyl. GV Series 1987 ........................................................... 2.5 Hours ... ..... T018 NOTE: For information about tensioners and/or pulleys (when available), see ALPHABETICAL MODEL LISTING.

MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE


The manufacturer recommends inspection of the timing belt every 15,000 miles. Although the manufacturer does not recommend a specic scheduled replacement interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

REMOVAL & INSTALLATION


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

TIMING BELT
Removal 1) Disconnect negative battery cable. Position No. 1 cylinder at TDC of compression stroke. Disconnect positive battery cable. Remove accessory drive belt. Remove cooling fan and shroud. Remove crankshaft pulley. Remove timing belt covers. 2) Align camshaft sprocket with timing mark. See Fig. 1. Loosen tensioner lock nut and move tensioner pulley toward engine mount. Tighten nut to secure tensioner in slack position. Remove and discard timing belt. 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.

Fig. 1: Identifying Camshaft-To-Crankshaft Alignment

Courtesy of Yugo America, Inc.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Bolts ........................................................................................... 14 (19) Camshaft Sprocket Bolt ............................................................................................ 61 (83) Camshaft Pulley Nut ............................................................................................. 101 (137) Tensioner Pulley Support Nut ................................................................................... 33 (45)

Fig. 2: Exploded View Of Timing Belt & Related Components

786

Changeover Listing PowerGrip Timing System Products


Showing Competitive Numbers with Our Corresponding PowerGrip Numbers

The Gates numbers shown in the following listings were determined by comparing the applications and physical characteristics of the product. This is a guide for changing over stocks to Gates numbers, and does not mean that the competitive number shown will fit all applications recommended for the Gates number. If a customer asks for a product to replace a product of another brand, do not use this list. Ask for the make, model, year and engine size on which it is to be used, and refer to the alphabetical listing to determine the proper replacement.

Competitive No.

Gates No.

Competitive No.

Gates No.

Competitive No.

Gates No.

Competitive No.

Gates No.

Competitive No.

Gates No.

ACDELCO Timing Belts TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB020................. T020 TB028................. T028 TB032................. T032 TB036................. T036 TB037................. T037 TB039................. T039 TB041................. T041 TB043................. T043 TB061................. T061 TB062................. T062 TB064................. T064 TB065................. T065 TB067................. T067 TB068................. T068 TB069................. T069 TB070................. T070 TB071................. T071 TB073................. T073 TB074................. T074 TB075................. T075 TB076................. T076 TB077................. T077 TB078................. T078 TB079................. T079 TB081................. T081 TB082................. T082 TB083................. T083 TB084................. T084 TB087................. T087 TB088................. T088 TB089................. T089 TB090................. T090 TB091................. T091 TB092................. T092 TB093................. T093 TB094................. T094 TB095................. T095 TB096................. T096 TB097................. T097 TB098................. T098 TB099................. T099 TB100................. T100 TB101................. T101 TB102................. T102 TB103................. T103 TB104................. T104 TB106................. T106 TB107................. T107 TB112................. T112 TB113................. T113 TB114................. T114 TB117................. T117 TB118................. T118 TB119................. T119 TB120................. T120 TB121................. T121 TB122................. T122 TB123................. T123 TB124................. T124 TB125................. T125 TB126................. T126 TB127................. T127 TB128................. T128 TB129................. T129 TB130................. T130 TB131................. T131 TB132................. T132 TB134................. T134 TB135................. T135 TB136................. T136 TB137................. T137

ACDELCO - Cont. Timing Belts - Cont. TB138................. TB139................. TB140................. TB141................. TB142................. TB143................. TB144................. TB145................. TB146................. TB147................. TB148................. TB149................. TB150................. TB151................. TB152................. TB153................. TB154................. TB155................. TB157................. TB158................. TB159................. TB160................. TB161................. TB162................. TB163................. TB164................. TB165................. TB166................. TB167................. TB168................. TB169................. TB170................. TB171................. TB172................. TB173................. TB174................. TB176................. TB177................. TB178................. TB179................. TB180................. TB181................. TB182................. TB183................. TB184................. TB185................. TB186................. TB187................. TB188................. TB189................. TB190................. TB191................. TB192................. TB193................. TB194................. TB195................. TB196................. TB197................. TB198................. TB199................. TB200................. TB201................. TB203................. TB204................. TB205................. TB206................. TB207................. TB208................. TB209................. TB210................. TB211................. TB212................. TB213................. TB214................. TB215................. T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T203 T204 T205 T206 T207 T208 T209 T210 T211 T212 T213 T214 T215

ACDELCO - Cont. Timing Belts - Cont. TB216................. TB217................. TB218................. TB219................. TB220................. TB221................. TB222................. TB223................. TB224................. TB225................. TB226................. TB227................. TB228................. TB229................. TB230................. TB232................. TB233................. TB234................. TB235................. TB236................. TB237................. TB239................. TB240................. TB241................. TB242................. TB243................. TB244................. TB245................. TB246................. TB247................. TB248................. TB249................. TB251................. TB252................. TB253................. TB254................. TB255................. TB256................. TB257................. TB258................. TB259................. TB260................. TB262................. TB263................. TB264................. TB265................. TB266................. TB267................. TB269................. TB270................. TB271................. TB272................. TB273................. TB276................. TB277................. TB278................. TB279................. TB280................. TB281................. TB282................. TB283................. TB284................. TB285................. TB286................. TB287................. TB288................. TB289................. TB290................. TB291................. TB292................. TB293................. TB294................. TB295................. TB296................. TB297................. T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T260 T262 T263 T264 T265 T266 T267 T269 T270 T271 T272 T273 T276 T277 T278 T279 T280 T281 T282 T283 T284 T285 T286 T287 T288 T289 T290 T291 T292 T293 T294 T295 T296 T297

ACDELCO - Cont. Timing Belts - Cont. TB298................. T298 TB299................. T299 TB300................. T300 TB301................. T301 TB302................. T302 TB303................. T303 TB304................. T304 TB305................. T305 TB306................. T306 TB307................. T307 TB308................. T308 TB309................. T309 TB310................. T310 TB311................. T311 TB312................. T312 TB313................. T313 TB314................. T314 TB315................. T315 TB316................. T316 TB317................. T317 TB318................. T318 TB319................. T319 TB320................. T320 TB321................. T321 TB322................. T322 TB323................. T323 TB324................. T324 TB326................. T326 TB327................. T327 TB329................. T329 Timing Belt Tensioners T41000............... T41000 T41001............... T41001 T41002............... T41002 T41003............... T41003 T41004............... T41004 T41005............... T41005 T41006............... T41006 T41007............... T41007 T41008............... T41008 T41009............... T41009 T41010............... T41010 T41011............... T41011 T41012............... T41012 T41013............... T41013 T41014............... T41014 T41015............... T41015 T41016............... T41016 T41017............... T41017 T41018............... T41018 T41019............... T41019 T41020............... T41020 T41021............... T41021 T41022............... T41022 T41023............... T41023 T41024............... T41024 T41025............... T41025 T41026............... T41026 T41027............... T41027 T41028............... T41028 T41029............... T41029 T41030............... T41030 T41031............... T41031 T41032............... T41032 T41033............... T41033 T41034............... T41034 T41035............... T41035 T41036............... T41036 T41037............... T41037 T41038............... T41038 T41039............... T41039 T41040............... T41040 T41041............... T41041 T41042............... T41042

ACDELCO - Cont. Timing Belt Tensioners - Cont. T41043............... T41043 T41044............... T41044 T41045............... T41045 T41046............... T41046 T41047............... T41047 T41048............... T41048 T41049............... T41049 T41050............... T41050 T41051............... T41051 T41052............... T41052 T41053............... T41053 T41054............... T41054 T41055............... T41055 T41056............... T41056 T41057............... T41057 T41058............... T41058 T41059............... T41059 T41060............... T41060 T41061............... T41061 T41062............... T41062 T41063............... T41063 T41064............... T41064 T41065............... T41065 T41066............... T41066 T41067............... T41067 T41068............... T41068 T41069............... T41069 T41070............... T41070 T41071............... T41071 T41072............... T41072 T41073............... T41073 T41074............... T41074 T41075............... T41075 T41076............... T41076 T41077............... T41077 T41078............... T41078 T41079............... T41079 T41080............... T41080 T41081............... T41081 T41083............... T41083 T41084............... T41084 T41085............... T41085 T41087............... T41087 T41088............... T41088 T41089............... T41089 T41090............... T41090 T41091............... T41091 T41092............... T41092 T43001............... T43001 T43002............... T43002 T43003............... T43003 T43004............... T43004 T43005............... T43005 T43006............... T43006 T43007............... T43007 T43008............... T43008 T43010............... T43010 Timing Belt Pulleys T42001............... T42001 T42002............... T42002 T42003............... T42003 T42004............... T42004 T42005............... T42005 T42006............... T42006 T42007............... T42007 T42008............... T42008 T42009............... T42009 T42010............... T42010 T42011............... T42011 T42012............... T42012 T42013............... T42013 T42014............... T42014 T42015............... T42015

Changeover Listing - PowerGrip Timing System Products


Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

787

ACDELCO - Cont. Timing Belt Pulleys - Cont. T42016............... T42016 T42017............... T42017 T42018............... T42018 T42020............... T42020 T42021............... T42021 T42022............... T42022 T42023............... T42023 T42024............... T42024 T42025............... T42025 T42026............... T42026 T42027............... T42027 T42028............... T42028 T42029............... T42029 T42030............... T42030 T42031............... T42031 T42032............... T42032 T42033............... T42033 T42034............... T42034 T42035............... T42035 T42036............... T42036 T42037............... T42037 T42038............... T42038 AQUA POWER Timing Belts 1221 ................... T032 ATLAS Timing Belts 689900 ............... T067 689901 ............... T071 689902 ............... T014 689903 ............... T061 689904 ............... T017 689905 ............... T081 689906 ............... T070 689907 ............... T089 689908 ............... T077 689909 ............... T094 ATLAS (CANADA) Timing Belts TB1001............... T121 TB1002............... T127 TB1003............... T128 TB1004............... T101 TB1005............... T125 TB1006............... T126 TB1007............... T130 TB1008............... T129 TB1010............... T114 TB1011............... T300 TB1012............... T299 TB1013............... T091 TB1014............... T092 TB1015............... T117 TB1016............... T119 TB1017............... T292 TB1018............... T134 TB1020............... T136 TB1021............... T137 TB1022............... T138 TB1023............... T139 TB1024............... T140 TB1026............... T141 TB1027............... T123 TB1028............... T090 TB1031............... T113 TB1032............... T132 TB1033............... T142 TB1034............... T143 TB1035............... T144 TB1036............... T145 TB1037............... T146 TB1038............... T147 TB1039............... T148 TB1040............... T149 TB1041............... T150 TB1042............... T151 TB1044............... T102 TB1045............... T103 TB1047............... T124 TB1048............... T154 TB1049............... T155 TB1051............... T157 TB1052............... T158 TB1053............... T159 TB1054............... T160 TB1055............... T161 TB1056............... T162 TB1057............... T153

ATLAS (CANADA) - Cont. Timing Belts - Cont. TB1058............... T163 TB1059............... T164 TB1060............... T165 TB1061............... T166 TB1062............... T169 TB1063............... T167 TB1064............... T168 TB6401............... T014 TB6402............... T013 TB6403............... T037 TB6404............... T017 TB6406............... T018 TB6408............... T020 TB6409............... T039 TB6410............... T032 TB6411............... T041 TB6412............... T062 TB6415............... T028 TB6416............... T064 TB6417............... T065 TB6418............... T061 TB6419............... T073 TB6424............... T069 TB6425............... T070 TB6426............... T068 TB6427............... T071 TB6428............... T067 TB6429............... T076 TB6430............... T075 TB6431............... T078 TB6432............... T077 TB6433............... T043 TB6434............... T074 TB6435............... T081 TB6436............... T088 TB6437............... T087 TB6438............... T093 TB6439............... T094 TB6440............... T104 TB6442............... T100 TB6443............... T084 TB6444............... T099 TB6446............... T082 TB6447............... T083 TB6448............... T095 TB6450............... T176 TB6451............... T089 TB6452............... T118 TB6453............... T079 TB6454............... T122 AUTO VALUE Timing Belts R0100................. T100 R0101................. T101 R0102................. T102 R0103................. T103 R0104................. T104 R013................... T013 R014................... T014 R017................... T017 R018................... T018 R020................... T020 R028................... T028 R032................... T032 R036................... T036 R037................... T037 R039................... T039 R041................... T041 R042................... T068 R043................... T043 R061................... T061 R062................... T062 R063................... T073 R064................... T064 R065................... T065 R067................... T067 R069................... T069 R070................... T070 R071................... T071 R073................... T073 R074................... T074 R075................... T075 R076................... T076 R077................... T077 R078................... T078 R079................... T079 R081................... T081 R084................... T084 R087................... T087 R088................... T088

AUTO VALUE - Cont. Timing Belts - Cont. R089................... T089 R090................... T090 R091................... T091 R092................... T092 R093................... T093 R094................... T094 R095................... T095 R096................... T096 R098................... T098 R099................... T099 AUTOZONE (See GOODYEAR) AVON AUTO Timing Belts B0100................. T100 B0101................. T101 B0102................. T102 B0103................. T103 B0104................. T104 B0114................. T114 B0118................. T162 B013................... T013 B014................... T014 B017................... T017 B018................... T018 B020................... T020 B028................... T028 B032................... T032 B036................... T036 B037................... T037 B039................... T039 B041................... T041 B043................... T043 B061................... T061 B062................... T062 B063................... T073 B064................... T064 B065................... T065 B067................... T067 B068................... T068 B069................... T069 B070................... T070 B071................... T071 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B079................... T079 B081................... T081 B082................... T082 B083................... T083 B084................... T084 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B091................... T091 B092................... T092 B093................... T093 B094................... T094 B095................... T095 B096................... T096 B099................... T099 BALKAMP Timing Belts 9-013.................. T013 9-014.................. T014 9-017.................. T017 9-018.................. T018 9-020.................. T020 9-028.................. T028 9-032.................. T032 9-036.................. T036 9-037.................. T037 9-039.................. T039 9-041.................. T041 9-043.................. T043 9-061.................. T061 9-062.................. T062 9-063.................. T073 9-064.................. T064 9-065.................. T065 9-067.................. T067 9-068.................. T068 9-069.................. T069 9-070.................. T070 9-071.................. T071 9-073.................. T073

BALKAMP - Cont. Timing Belts - Cont. 9-074.................. T074 9-075.................. T075 9-076.................. T076 9-077.................. T077 9-078.................. T078 9-079.................. T079 9-081.................. T081 9-082.................. T082 9-083.................. T083 9-084.................. T084 9-087.................. T087 9-088.................. T088 9-089.................. T089 9-090.................. T090 9-091.................. T091 9-092.................. T092 9-093.................. T093 9-094.................. T094 9-095.................. T095 9-096.................. T096 9-098.................. T098 9-099.................. T099 9-100.................. T100 9-101.................. T101 BANDO Timing Belts 100ZA19............. T061 109ZA19............. T088 111ZA19............. T121 113ZA19............. T065 118ZA19............. T069 121ZA19............. T017 124ZA25............. T071 135ZA25............. T043 142ZA25............. T074 206AL050........... T062 315AL075........... T028 326AHL125 ........ T075 330AL075........... T070 345AL075........... T073 398AL075........... T077 458AL075........... T013 89ZA19............... T095 94ZA19............... T036 97ZA25............... T067 99ZA15............... T037 99ZA19............... T039 BAP-GEON Timing Belts 54-70301............ T062 54-70302............ T073 54-70303............ T064 54-70901............ T041 54-70902............ T028 54-70904............ T073 54-71501............ T070 54-72001............ T017 54-72100............ T065 54-76000............ T020 54-76300............ T069 54-76301............ T018 54-77801............ T014 54-77802............ T067 54-79800............ T013 BECK ARNLEY Timing Belts 026-0018............ T028 026-0026............ T020 026-0034............ T020 026-0042............ T018 026-0067............ T036 026-0075............ T041 026-0083............ T013 026-0091............ T014 026-0109............ T032 026-0117............ T065 026-0125............ T068 026-0133............ T062 026-0158............ T064 026-0174............ T069 026-0175............ T070 026-0176............ T017 026-0177............ T043 026-0178............ T083 026-0179............ T073 026-0180............ T082 026-0182............ T088 026-0183............ T078

BECK ARNLEY - Cont. Timing Belts - Cont. 026-0184............ 026-0185............ 026-0186............ 026-0187............ 026-0188............ 026-0189............ 026-0190............ 026-0191............ 026-0192............ 026-0193............ 026-0194............ 026-0195............ 026-0196............ 026-0197............ 026-0198............ 026-0199............ 026-0201............ 026-0202............ 026-0205............ 026-0206............ 026-0207............ 026-0208............ 026-0209............ 026-0210............ 026-0212............ 026-0213............ 026-0215............ 026-0216............ 026-0217............ 026-0218............ 026-0219............ 026-0220............ 026-0221............ 026-0222............ 026-0223............ 026-0224............ 026-0225............ 026-0226............ 026-0228............ 026-0229............ 026-0230............ 026-0231............ 026-0232............ 026-0233............ 026-0234............ 026-0235............ 026-0236............ 026-0237............ 026-0238............ 026-0239............ 026-0240............ 026-0242............ 026-0243............ 026-0244............ 026-0245............ 026-0246............ 026-0247............ 026-0248............ 026-0249............ 026-0250............ 026-0251............ 026-0252............ 026-0253............ 026-0255............ 026-0256............ 026-0258............ 026-0259............ 026-0260............ 026-0261............ 026-0262............ 026-0263............ 026-0264............ 026-0265............ 026-0266............ 026-0267............ 026-0268............ 026-0269............ 026-0270............ 026-0271............ 026-0272............ 026-0273............ 026-0274............ 026-0275............ 026-0276............ 026-0277............ 026-0278............ 026-0279............ 026-0280............ 026-0281............ 026-0282............ 026-0283............ 026-0284............ T077 T089 T090 T092 T091 T084 T074 T087 T079 T076 T075 T107 T093 T096 T106 T140 T196 T100 T097 T101 T095 T161 T160 T120 T300 T299 T158 T104 T112 T293 T119 T138 T071 T162 T113 T117 T149 T141 T122 T124 T128 T134 T129 T139 T146 T148 T292 T170 T143 T131 T144 T142 T135 T179 T147 T126 T136 T125 T164 T166 T165 T130 T121 T167 T043 T197 T137 T171 T177 T179 T103 T102 T157 T159 T151 T182 T184 T181 T155 T144 T178 T104 T150 T187 T180 T186 T176 T191 T174 T183 T154 T168

788
Competitive No.

Changeover Listing - PowerGrip Timing System Products


Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

BECK ARNLEY - Cont. Timing Belts - Cont. 026-0285............ 026-0286............ 026-0287............ 026-0288............ 026-0289............ 026-0290............ 026-0293............ 026-0294............ 026-0295............ 026-0296............ 026-0297............ 026-0298............ 026-0299............ 026-0300............ 026-0301............ 026-0302............ 026-0303............ 026-0304............ 026-0305............ 026-0306............ 026-0307............ 026-0308............ 026-0309............ 026-0310............ 026-0311............ 026-0312............ 026-0314............ 026-0316............ 026-0317............ 026-0318............ 026-0319............ 026-0320............ 026-0322............ 026-0323............ 026-0324............ 026-0325............ 026-0326............ 026-0327............ 026-0329............ 026-0330............ 026-0331............ 026-0332............ 026-0334............ 026-0335............ 026-0336............ 026-0338............ 026-0339............ 026-0340............ 026-0341............ 026-0344............ 026-0345............ 026-1000............ 026-1001............ 026-1002............ 026-1003............ 026-1004............ 026-1005............ 026-1006............ 026-1007............ 026-1008............ 026-1009............ 026-1010............ 026-1011............ 026-1012............ 026-1013............ 026-1014............ 026-1015............ 026-1016............ 026-1017............ 026-1018............ 026-1021............ 026-1022............ 026-1023............ 026-1024............ 026-1025............ 026-1026............ 026-1027............ 026-1028............ 026-1029............ 026-1030............ 026-1031............ 026-1033............ 026-1034............ 026-1035............ 026-1037............ 026-1038............ 026-1039............ 026-1040............ 026-1042............ 026-1043............ 026-1044............ 026-1045............ T173 T172 T207 T152 T189 T188 T198 T208 T211 T201 T204 T218 T216 T203 T212 T193 T185 T221 T220 T194 T224 T226 T223 T227 T214 T209 T229 T230 T232 T217 T195 T234 T235 T252 T241 T236 T262 T228 T252 T281 T253 T247 T249 T263 T259 T120 T244 T243 T264 T271 T316 T158 T196 T161 T160 T199 T159 T254 T242 T262 T276 T272 T200 T266 T190 T240 T267 T215 T126 T257 T246 T287 T284 T286 T277 T278 T282 T279 T270 T205 T207 T297 T296 T302 T298 T288 T303 T308 T310 T309 T305 T311

BECK ARNLEY - Cont. Timing Belt Tensioners LER80038 .......... T41037 LER88893 .......... T41041 024-0953............ T41055 024-0954............ T41042 024-0955............ T41057 024-0963............ T41079 024-0964............ T41045 024-0966............ T41043 024-0976............ T41035 024-0981............ T41058 024-0982............ T41088 024-0985............ T41080 024-0986............ T41081 024-0987............ T41083 024-0991............ T41012 024-0992............ T41017 024-1008............ T41062 024-1012............ T41005 024-1028............ T41069 024-1046............ T41061 024-1050............ T41064 024-1074............ T41059 024-1076............ T41011 024-1077............ T41003 024-1079............ T41076 024-1081............ T41067 024-1083............ T41073 024-1086............ T41074 024-1087............ T41066 024-1088............ T41025 024-1089............ T41029 024-1090............ T41056 024-1091............ T41060 024-1106............ T41026 024-1118............ T41075 024-1119............ T41015 024-1144............ T41013 024-1145............ T41014 024-1147............ T41052 024-1151............ T41018 024-1152............ T41053 024-1153............ T41016 024-1154............ T41020 024-1155............ T41021 024-1156............ T41030 024-1160............ T41044 024-1162............ T41031 024-1164............ T41051 024-1165............ T41034 024-1166............ T41009 024-1167............ T41033 024-1168............ T41039 024-1172............ T41072 024-1177............ T41078 024-1187............ T41071 024-1193............ T41048 024-1195............ T41063 024-1197............ T41027 024-1199............ T41023 024-1204............ T41065 024-1206............ T41054 Timing Belt Pulleys 024-1006............ T42025 024-1082............ T42028 024-1092............ T42011 024-1148............ T42009 024-1149............ T42010 024-1150............ T42001 024-1157............ T42013 024-1163............ T42005 024-1174............ T42008 024-1176............ T42030 024-1178............ T42031 024-1180............ T42021 024-1184............ T42020 024-1190............ T42029 024-1203............ T42012 BORG WARNER Timing Belts TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB020................. T020 TB028................. T028 TB029................. T104 TB032................. T032 TB036................. T036 TB037................. T037 TB039................. T039

BORG WARNER - Cont. Timing Belts - Cont. TB041................. TB042................. TB043................. TB061................. TB062................. TB063................. TB064................. TB065................. TB067................. TB068................. TB069................. TB070................. TB071................. TB073................. TB074................. TB075................. TB076................. TB077................. TB078................. TB079................. TB081................. TB082................. TB083................. TB084................. TB087................. TB088................. TB089................. TB090................. TB091................. TB092................. TB093................. TB094................. TB095................. TB096................. TB098................. TB099................. TB100................. TB101................. TB102................. TB103................. TB104................. TB106................. TB107................. TB110................. TB112................. TB113................. TB114................. TB115................. TB116................. TB117................. TB118................. TB119................. TB121................. TB122................. TB123................. TB124................. TB125................. TB126................. TB127................. TB128................. TB129................. TB130................. TB131................. TB132................. TB133................. TB134................. TB135................. TB136................. TB137................. TB138................. TB139................. TB140................. TB141................. TB142................. TB143................. TB144................. TB145................. TB146................. TB147................. TB148................. TB153................. TB154................. TB155................. TB157................. TB158................. TB159................. TB160................. TB161................. TB162................. TB163................. TB164................. TB165................. T041 T068 T043 T061 T062 T073 T064 T065 T067 T068 T069 T070 T071 T073 T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T098 T099 T100 T101 T102 T103 T104 T106 T107 T196 T112 T113 T114 T299 T300 T117 T118 T119 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165

BORG WARNER - Cont. Timing Belts - Cont. TB166................. T166 TB167................. T167 TB168................. T168 TB169................. T169 TB170................. T170 TB171................. T171 TB172................. T172 TB177................. T177 TB178................. T178 TB179................. T179 TB183................. T183 TB184................. T184 TB185................. T185 TB186................. T186 TB187................. T187 TB191................. T191 TB192................. T192 TB194................. T194 TB195................. T195 TB199................. T199 TB200................. T200 TB201................. T201 TB202................. T248 TB204................. T204 TB206................. T206 TB208................. T208 TB210................. T210 TB214................. T214 TB228................. T228 TB233................. T233 TB235................. T235 TB236................. T236 TB237................. T237 T219................... T219 BOSCH Timing Belts 914416094 ......... T036 9144161055 ....... T062 9144161084 ....... T088 9144161092 ....... T073 9144161095 ....... T041 9144161113 ....... T065 9144161116 ....... T018 9144161118 ....... T069 9144161121 ....... T017 9144161122 ....... T013 9144161146 ....... T020 9144161148 ....... T068 9144165075 ....... T082 9144165119 ....... T083 9144165135 ....... T043 BRYCO Timing Belts B013................... T013 B014................... T014 B017................... T017 B028................... T028 B036................... T036 B041................... T041 B043................... T043 B062................... T062 B064................... T064 B067................... T067 B070................... T070 B071................... T071 B073................... T073 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B079................... T079 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B091................... T091 B092................... T092 B093................... T093 B094................... T094 B095................... T095 B096................... T096 B099................... T099 B100................... T100 B101................... T101 B102................... T102 B103................... T103 B104................... T104 B112................... T112

BRYCO - Cont. Timing Belts - Cont. B113................... T113 B114................... T114 B115................... T299 B116................... T300 B117................... T117 B118................... T118 B121................... T121 B122................... T122 B123................... T123 B124................... T124 B126................... T126 B127................... T127 B128................... T128 B130................... T130 B132................... T132 B133................... T292 B134................... T134 B136................... T136 B137................... T137 B138................... T138 B139................... T139 B141................... T141 B142................... T142 B143................... T143 B144................... T144 B145................... T145 B146................... T146 B147................... T147 B149................... T149 B153................... T153 B154................... T154 B155................... T155 B157................... T157 B158................... T158 B159................... T159 B160................... T160 B161................... T161 B162................... T162 B164................... T164 B165................... T165 B167................... T167 B168................... T168 B169................... T169 B176................... T176 B177................... T177 B179................... T179 B182................... T182 B184................... T184 B185................... T185 B186................... T186 B187................... T187 B191................... T191 B194................... T194 B195................... T195 B199................... T199 B201................... T201 B204................... T204 B208................... T208 B210................... T210 B223................... T223 B224................... T224 B227................... T227 B228................... T228 B229................... T229 B230................... T230 B235................... T235 B236................... T236 B237................... T237 B258................... T258 T115................... T299 54700 ................. T095 54742 ................. T075 54754 ................. T112 54755 ................. T176 54788 ................. T076 CARQUEST Timing Belts T013................... T013 T014................... T014 T096................... T096 T097................... T097 T098................... T098 T099................... T099 T100................... T100 T101................... T101 T102................... T102 T103................... T103 T104................... T104 T106................... T106 T107................... T107

Changeover Listing - PowerGrip Timing System Products


Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

789

CARQUEST - Cont. Timing Belts - Cont. T112................... T113................... T114................... T117................... T118................... T119................... T120................... T121................... T122................... T123................... T124................... T125................... T126................... T127................... T128................... T129................... T130................... T131................... T132................... T134................... T135................... T136................... T137................... T138................... T139................... T140................... T141................... T142................... T143................... T144................... T145................... T146................... T147................... T148................... T149................... T150................... T151................... T152................... T153................... T154................... T155................... T157................... T158................... T159................... T160................... T161................... T162................... T163................... T164................... T165................... T166................... T167................... T168................... T169................... T170................... T171................... T172................... T173................... T174................... T176................... T177................... T178................... T179................... T180................... T181................... T182................... T183................... T184................... T185................... T186................... T187................... T188................... T189................... T190................... T191................... T192................... T193................... T194................... T195................... T196................... T197................... T198................... T199................... T200................... T201................... T203................... T204................... T205................... T206................... T207................... T208................... T209................... T112 T113 T114 T117 T118 T119 T120 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T203 T204 T205 T206 T207 T208 T209

CARQUEST - Cont. Timing Belts - Cont. T210................... T211................... T212................... T213................... T214................... T215................... T216................... T217................... T218................... T219................... T220................... T221................... T222................... T223................... T224................... T225................... T226................... T227................... T228................... T229................... T230................... T232................... T233................... T234................... T235................... T236................... T237................... T239................... T240................... T241................... T242................... T243................... T244................... T245................... T246................... T247................... T248................... T249................... T251................... T252................... T253................... T254................... T255................... T256................... T257................... T258................... T259................... T260................... T262................... T263................... T264................... T265................... T266................... T267................... T269................... T271................... T272................... T273................... T276................... T277................... T278................... T279................... T280................... T281................... T282................... T283................... T284................... T285................... T286................... T287................... T288................... T289................... T290................... T291................... T292................... T293................... T294................... T295................... T296................... T297................... T298................... T299................... T300................... T301................... T302................... T303................... T304................... T305................... T306................... T210 T211 T212 T213 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T260 T262 T263 T264 T265 T266 T267 T269 T271 T272 T273 T276 T277 T278 T279 T280 T281 T282 T283 T284 T285 T286 T287 T288 T289 T290 T291 T292 T293 T294 T295 T296 T297 T298 T299 T300 T301 T302 T303 T304 T305 T306

CLEVELAND MOTIVE Timing Belts B013................... T013 B014................... T014 B037................... T037 B043................... T043 B068................... T068 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B081................... T081 CLEVITE ENGINE PARTS Timing Belts TB-100 ............... T100 TB-101 ............... T101 TB-102 ............... T102 TB-103 ............... T103 TB-104 ............... T104 TB-106 ............... T106 TB-107 ............... T107 TB-112 ............... T112 TB-113 ............... T113 TB-114 ............... T114 TB-117 ............... T117 TB-118 ............... T118 TB-119 ............... T119 TB-120 ............... T120 TB-121 ............... T121 TB-122 ............... T122 TB-123 ............... T123 TB-124 ............... T124 TB-125 ............... T125 TB-126 ............... T126 TB-127 ............... T127 TB-128 ............... T128 TB-129 ............... T129 TB-13 ................. T013 TB-130 ............... T130 TB-131 ............... T131 TB-132 ............... T132 TB-134 ............... T134 TB-135 ............... T135 TB-136 ............... T136 TB-137 ............... T137 TB-138 ............... T138 TB-139 ............... T139 TB-14 ................. T014 TB-140 ............... T140 TB-141 ............... T141 TB-142 ............... T142 TB-143 ............... T143 TB-144 ............... T144 TB-145 ............... T145 TB-146 ............... T146 TB-147 ............... T147 TB-148 ............... T148 TB-149 ............... T149 TB-150 ............... T150 TB-151 ............... T151 TB-152 ............... T152 TB-153 ............... T153 TB-154 ............... T154 TB-155 ............... T155 TB-157 ............... T157 TB-158 ............... T158 TB-159 ............... T159 TB-160 ............... T160 TB-161 ............... T161 TB-162 ............... T162 TB-163 ............... T163 TB-164 ............... T164 TB-165 ............... T165 TB-166 ............... T166 TB-167 ............... T167 TB-168 ............... T168 TB-169 ............... T169 TB-17 ................. T017 TB-170 ............... T170 TB-171 ............... T171 TB-172 ............... T172 TB-173 ............... T173 TB-174 ............... T174 TB-176 ............... T176 TB-177 ............... T177 TB-178 ............... T178 TB-179 ............... T179 TB-18 ................. T018 TB-180 ............... T180 TB-181 ............... T181 TB-182 ............... T182 TB-183 ............... T183

CLEVITE ENGINE PARTS - Cont. Timing Belts - Cont. TB-184 ............... TB-185 ............... TB-186 ............... TB-187 ............... TB-188 ............... TB-189 ............... TB-190 ............... TB-191 ............... TB-192 ............... TB-193 ............... TB-194 ............... TB-195 ............... TB-196 ............... TB-197 ............... TB-198 ............... TB-199 ............... TB-20 ................. TB-200 ............... TB-201 ............... TB-203 ............... TB-204 ............... TB-205 ............... TB-206 ............... TB-208 ............... TB-209 ............... TB-210 ............... TB-211 ............... TB-212 ............... TB-214 ............... TB-215 ............... TB-216 ............... TB-217 ............... TB-218 ............... TB-219 ............... TB-220 ............... TB-221 ............... TB-222 ............... TB-223 ............... TB-224 ............... TB-226 ............... TB-227 ............... TB-228 ............... TB-229 ............... TB-230 ............... TB-232 ............... TB-233 ............... TB-234 ............... TB-235 ............... TB-236 ............... TB-237 ............... TB-239 ............... TB-240 ............... TB-241 ............... TB-242 ............... TB-243 ............... TB-244 ............... TB-245 ............... TB-246 ............... TB-247 ............... TB-248 ............... TB-249 ............... TB-251 ............... TB-252 ............... TB-253 ............... TB-254 ............... TB-255 ............... TB-256 ............... TB-257 ............... TB-258 ............... TB-259 ............... TB-262 ............... TB-263 ............... TB-264 ............... TB-265 ............... TB-266 ............... TB-267 ............... TB-271 ............... TB-273 ............... TB-276 ............... TB-277 ............... TB-278 ............... TB-279 ............... TB-28 ................. TB-281 ............... TB-282 ............... TB-284 ............... TB-285 ............... TB-286 ............... TB-287 ............... TB-288 ............... TB-291 ............... T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T020 T200 T201 T203 T204 T205 T206 T208 T209 T210 T211 T212 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T262 T263 T264 T265 T266 T267 T271 T273 T276 T277 T278 T279 T028 T281 T282 T284 T285 T286 T287 T288 T291

CLEVITE ENGINE PARTS - Cont. Timing Belts - Cont. TB-292 ............... T292 TB-296 ............... T296 TB-297 ............... T297 TB-298 ............... T298 TB-300 ............... T300 TB-302 ............... T302 TB-303 ............... T303 TB-308 ............... T308 TB-309 ............... T309 TB-310 ............... T310 TB-32 ................. T032 TB-36 ................. T036 TB-37 ................. T037 TB-39 ................. T039 TB-41 ................. T041 TB-43 ................. T043 TB-61 ................. T061 TB-62 ................. T062 TB-64 ................. T064 TB-65 ................. T065 TB-67 ................. T067 TB-69 ................. T069 TB-70 ................. T070 TB-71 ................. T071 TB-73 ................. T073 TB-74 ................. T074 TB-75 ................. T075 TB-76 ................. T076 TB-77 ................. T077 TB-78 ................. T078 TB-79 ................. T079 TB-81 ................. T081 TB-82 ................. T082 TB-83 ................. T083 TB-84 ................. T084 TB-87 ................. T087 TB-88 ................. T088 TB-89 ................. T089 TB-90 ................. T090 TB-91 ................. T091 TB-92 ................. T092 TB-93 ................. T093 TB-94 ................. T094 TB-95 ................. T095 TB-96 ................. T096 TB-97 ................. T097 TB-98 ................. T098 TB-99 ................. T099 CLOYES GEAR Timing Belts B013................... T013 B014................... T014 B017................... T017 B018................... T018 B020................... T020 B028................... T028 B032................... T032 B036................... T036 B037................... T037 B039................... T039 B041................... T041 B043................... T043 B061................... T061 B062................... T062 B063................... T073 B064................... T064 B065................... T065 B067................... T067 B068................... T068 B069................... T069 B070................... T070 B071................... T071 B073................... T073 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B079................... T079 B081................... T081 B082................... T082 B083................... T083 B084................... T084 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B091................... T091 B092................... T092

790
Competitive No.

Changeover Listing - PowerGrip Timing System Products


Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

CLOYES GEAR - Cont. Timing Belts - Cont. B093................... B094................... B095................... B096................... B097................... B098................... B099................... B100................... B101................... B102................... B103................... B104................... B106................... B107................... B108................... B112................... B113................... B114................... B115................... B116................... B117................... B118................... B119................... B121................... B122................... B123................... B124................... B125................... B126................... B127................... B128................... B129................... B130................... B131................... B132................... B133................... B134................... B135................... B136................... B137................... B138................... B139................... B140................... B141................... B142................... B143................... B144................... B145................... B146................... B147................... B148................... B149................... B150................... B151................... B152................... B153................... B154................... B155................... B157................... B158................... B159................... B160................... B161................... B162................... B163................... B164................... B165................... B166................... B167................... B168................... B169................... B170................... B171................... B172................... B174................... B176................... B177................... B178................... B179................... B180................... B181................... B182................... B183................... B184................... B185................... B186................... B187................... B189................... B190................... B191................... B192................... B193................... T093 T094 T095 T096 T097 T098 T099 T100 T101 T102 T103 T104 T106 T107 T293 T112 T113 T114 T299 T300 T117 T118 T119 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T189 T190 T191 T192 T193

CLOYES GEAR - Cont. Timing Belts - Cont. B194................... B195................... B196................... B199................... B200................... B201................... B203................... B204................... B205................... B206................... B208................... B209................... B210................... B211................... B212................... B214................... B216................... B219................... B220................... B221................... B223................... B224................... B225................... B226................... B227................... B228................... B229................... B230................... B232................... B233................... B234................... B235................... B236................... B237................... B239................... B240................... B241................... B243................... B244................... B245................... B246................... B247................... B248................... B249................... B251................... B252................... B253................... B254................... B255................... B256................... B257................... B258................... B259................... B262................... B263................... B264................... B265................... B266................... B267................... B271................... B272................... B273................... B276................... B277................... B278................... B279................... B280................... B281................... B282................... B283................... B284................... B285................... B286................... B287................... B288................... B289................... B291................... B292................... B294................... B295................... B296................... B297................... B298................... B299................... B300................... B301................... B302................... B303................... B304................... B305................... B308................... T194 T195 T196 T199 T200 T201 T203 T204 T205 T206 T208 T209 T210 T211 T212 T214 T216 T219 T220 T221 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T262 T263 T264 T265 T266 T267 T271 T272 T273 T276 T277 T278 T279 T280 T281 T282 T283 T284 T285 T286 T287 T288 T289 T291 T292 T294 T295 T296 T297 T298 T299 T300 T301 T302 T303 T304 T305 T308

CLOYES GEAR - Cont. Timing Belt Tensioners 9-5011................ T41005 9-5032................ T41055 9-5033................ T41042 9-5038................ T41057 9-5066................ T41066 9-5075................ T41058 9-5089................ T41080 9-5091................ T41000 9-5096................ T41069 9-5097................ T41068 9-5104................ T41070 9-5105................ T41043 9-5106................ T41053 9-5107................ T41050 9-5108................ T41049 9-5114................ T41006 9-5117................ T41077 9-5124................ T41059 9-5126................ T41017 9-5135................ T41074 9-5148................ T41079 9-5154................ T41061 9-5155................ T41062 9-5156................ T41081 9-5160................ T41056 9-5161................ T41045 9-5162................ T41011 9-5163................ T41012 9-5164................ T41030 9-5165................ T41035 9-5166................ T41029 9-5182................ T41064 9-5183................ T41026 9-5192................ T41001 9-5194................ T41046 9-5195................ T41048 9-5196................ T41044 9-5197................ T41047 9-5198................ T41015 9-5202................ T41019 9-5203................ T41014 9-5204................ T41013 9-5206................ T41076 9-5209................ T41073 9-5213................ T41031 9-5221................ T41010 9-5224................ T41051 9-5226................ T41020 9-5262................ T41016 9-5263................ T41025 9-5269................ T41003 9-5270................ T41004 9-5271................ T41039 9-5272................ T41052 9-5275................ T41060 9-5282................ T41065 9-5292................ T41036 9-5293................ T41033 9-5299................ T41071 9-5301................ T41067 9-5342................ T41072 9-5343................ T41009 9-5350................ T41007 9-5354................ T41018 9-5357................ T41002 9-5390................ T41008 9-9228................ T41021 Timing Belt Pulleys S675................... T42022 9-5110................ T42026 9-5118................ T42027 9-5184................ T42001 9-5207................ T42028 9-5214................ T42005 9-5215................ T42003 9-5216................ T42011 9-5222................ T42006 9-5223................ T42007 9-5225................ T42017 9-5244................ T42020 9-5283................ T42021 9-5300................ T42029 9-5302................ T42025 9-5303................ T42030 9-5325................ T42010 9-5326................ T42009 CONTINENTAL Timing Belts 6585901 ............. T065 6585902 ............. T017

CONTINENTAL - Cont. Timing Belts - Cont. 6585910 ............. T013 6585911 ............. T082 6585912 ............. T083 6585913 ............. T032 6585914 ............. T043 6585916 ............. T018 6585918 ............. T020 6585921 ............. T068 6585924 ............. T078 6585929 ............. T064 6585933 ............. T062 6585934 ............. T073 6585935 ............. T077 6585939 ............. T028 6585943 ............. T041 6585945 ............. T069 6585949 ............. T070 6589089 ............. T131 6589092 ............. T084 6589095 ............. T107 6589100 ............. T081 6589103 ............. T106 6598500 ............. T062 6598506 ............. T028 6598512 ............. T073 6598513 ............. T041 6598519 ............. T077 6598521 ............. T088 6598523 ............. T069 6598530 ............. T087 6598534 ............. T075 6598550 ............. T094 6598551 ............. T293 6598554 ............. T196 CONTITECH Timing Belts TB014................. T014 TB017................. T017 TB018................. T018 TB032................. T032 TB036................. T036 TB041................. T041 TB043................. T043 TB061................. T061 TB063................. T073 TB064................. T064 TB065................. T065 TB068................. T068 TB069................. T069 TB070................. T070 TB074................. T074 TB075................. T075 TB076................. T076 TB077................. T077 TB078................. T078 TB079................. T079 TB081................. T081 TB082................. T082 TB083................. T083 TB084................. T084 TB087................. T087 TB088................. T088 TB089................. T089 TB090................. T090 TB091................. T091 TB092................. T092 TB093................. T093 TB094................. T094 TB095................. T095 TB096................. T096 TB097................. T097 TB098................. T098 TB099................. T099 TB100................. T100 TB101................. T101 TB102................. T102 TB103................. T103 TB104................. T104 TB106................. T106 TB107................. T107 TB108................. T293 TB110................. T196 TB112................. T112 TB113................. T113 TB115................. T299 TB116................. T300 TB117................. T117 TB118................. T118 TB119................. T119 TB121................. T121

CONTITECH - Cont. Timing Belts - Cont. TB122................. TB123................. TB124................. TB125................. TB126................. TB127................. TB128................. TB129................. TB130................. TB131................. TB133................. TB134................. TB135................. TB136................. TB137................. TB138................. TB139................. TB140................. TB141................. TB142................. TB143................. TB144................. TB145................. TB146................. TB147................. TB148................. TB150................. TB151................. TB152................. TB154................. TB155................. TB157................. TB158................. TB159................. TB160................. TB162................. TB163................. TB164................. TB165................. TB166................. TB167................. TB168................. TB169................. TB170................. TB171................. TB172................. TB173................. TB174................. TB176................. TB177................. TB178................. TB179................. TB180................. TB181................. TB182................. TB183................. TB184................. TB185................. TB186................. TB187................. TB188................. TB189................. TB190................. TB191................. TB193................. TB195................. TB196................. TB197................. TB198................. TB199................. TB200................. TB201................. TB203................. TB204................. TB205................. TB208................. TB209................. TB210................. TB211................. TB212................. TB213................. TB214................. TB215................. TB216................. TB217................. TB218................. TB220................. TB221................. TB222................. TB224................. TB225................. TB227................. T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T150 T151 T152 T154 T155 T157 T158 T159 T160 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T193 T195 T196 T197 T198 T199 T200 T201 T203 T204 T205 T208 T209 T210 T211 T212 T213 T214 T215 T216 T217 T218 T220 T221 T222 T224 T225 T227

Changeover Listing - PowerGrip Timing System Products


Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

791

CONTITECH - Cont. Timing Belts - Cont. TB228................. T228 TB229................. T229 TB230................. T230 TB232................. T232 TB233................. T233 TB235................. T235 TB236................. T236 TB239................. T239 TB240................. T240 TB241................. T241 TB252................. T252 CY-LENT Timing Belts C013................... T013 C014................... T014 C017................... T017 C018................... T018 C020................... T020 C028................... T028 C032................... T032 C037................... T037 C039................... T039 C041................... T041 C043................... T043 C061................... T061 C062................... T062 C063................... T073 C064................... T064 C065................... T065 C067................... T067 C069................... T069 C070................... T070 C071................... T071 C073................... T073 C075................... T075 C076................... T076 C077................... T077 C078................... T078 C081................... T081 DAYCO Timing Belts A206L050........... T062 A234L075........... T073 A315L075........... T028 A356L075........... T041 A371L059........... T037 A375L075........... T061 A450L075........... T064 A453L075........... T017 A457L075........... T013 A484L088........... T014 A547L075........... T020 94011 ................. T092 94075 ................. T070 94078 ................. T203 94080 ................. T203 94098 ................. T089 94100 ................. T090 94123 ................. T117 94133 ................. T128 94165 ................. T146 94169 ................. T148 94185 ................. T163 94266 ................. T091 94283 ................. T124 94284 ................. T185 94293 ................. T165 94294 ................. T179 94340 ................. T155 94341 ................. T139 94350 ................. T167 94351 ................. T168 94430 ................. T155 95013 ................. T013 95014 ................. T014 95017 ................. T017 95018 ................. T018 95020 ................. T020 95028 ................. T028 95032 ................. T032 95036 ................. T036 95037 ................. T037 95039 ................. T039 95041 ................. T041 95042 ................. T068 95043 ................. T043 95061 ................. T061 95062 ................. T062 95063 ................. T073

DAYCO - Cont. Timing Belts - Cont. 95064 ................. 95065 ................. 95067 ................. 95068 ................. 95069 ................. 95070 ................. 95071 ................. 95073 ................. 95074 ................. 95075 ................. 95076 ................. 95077 ................. 95078 ................. 95079 ................. 95081 ................. 95082 ................. 95083 ................. 95084 ................. 95087 ................. 95088 ................. 95089 ................. 95090 ................. 95091 ................. 95092 ................. 95093 ................. 95094 ................. 95095 ................. 95096 ................. 95097 ................. 95098 ................. 95099 ................. 95100 ................. 95101 ................. 95102 ................. 95103 ................. 95104 ................. 95106 ................. 95107 ................. 95108 ................. 95110 ................. 95112 ................. 95113 ................. 95114 ................. 95115 ................. 95116 ................. 95117 ................. 95118 ................. 95119 ................. 95120 ................. 95121 ................. 95122 ................. 95123 ................. 95124 ................. 95125 ................. 95126 ................. 95127 ................. 95128 ................. 95129 ................. 95130 ................. 95131 ................. 95132 ................. 95133 ................. 95134 ................. 95135 ................. 95136 ................. 95137 ................. 95138 ................. 95139 ................. 95140 ................. 95141 ................. 95142 ................. 95143 ................. 95144 ................. 95145 ................. 95146 ................. 95147 ................. 95148 ................. 95150 ................. 95151 ................. 95152 ................. 95153 ................. 95154 ................. 95155 ................. 95157 ................. 95158 ................. 95159 ................. 95160 ................. 95161 ................. 95162 ................. 95163 ................. 95164 ................. 95165 ................. T064 T065 T067 T068 T069 T070 T071 T073 T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T097 T098 T099 T100 T101 T102 T103 T104 T106 T107 T293 T196 T112 T113 T114 T299 T300 T117 T118 T119 T120 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165

DAYCO - Cont. Timing Belts - Cont. 95166 ................. 95167 ................. 95168 ................. 95169 ................. 95170 ................. 95171 ................. 95172 ................. 95173 ................. 95174 ................. 95176 ................. 95177 ................. 95178 ................. 95179 ................. 95180 ................. 95181 ................. 95182 ................. 95183 ................. 95184 ................. 95185 ................. 95186 ................. 95187 ................. 95188 ................. 95190 ................. 95191 ................. 95192 ................. 95193 ................. 95194 ................. 95195 ................. 95196 ................. 95197 ................. 95198 ................. 95199 ................. 95200 ................. 95201 ................. 95202 ................. 95203 ................. 95204 ................. 95205 ................. 95206 ................. 95207 ................. 95208 ................. 95210 ................. 95211 ................. 95212 ................. 95214 ................. 95215 ................. 95216 ................. 95217 ................. 95218 ................. 95219 ................. 95220 ................. 95221 ................. 95223 ................. 95224 ................. 95225 ................. 95226 ................. 95227 ................. 95228 ................. 95229 ................. 95230 ................. 95232 ................. 95233 ................. 95234 ................. 95235 ................. 95236 ................. 95237 ................. 95240 ................. 95241 ................. 95244 ................. 95245 ................. 95246 ................. 95247 ................. 95248 ................. 95249 ................. 95251 ................. 95252 ................. 95253 ................. 95254 ................. 95255 ................. 95257 ................. 95258 ................. 95259 ................. 95262 ................. 95263 ................. 95264 ................. 95265 ................. 95266 ................. 95269 ................. 95271 ................. 95272 ................. 95273 ................. 95276 ................. T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T248 T203 T204 T205 T206 T207 T208 T210 T211 T212 T214 T215 T216 T217 T218 T219 T220 T221 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T240 T241 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T257 T258 T259 T262 T263 T264 T265 T266 T269 T271 T272 T273 T276

DAYCO - Cont. Timing Belts - Cont. 95277 ................. T277 95278 ................. T278 95281 ................. T281 95283 ................. T283 95284 ................. T284 95286 ................. T286 95287 ................. T287 95288 ................. T288 95289 ................. T289 95291 ................. T291 95292 ................. T292 95293 ................. T293 95294 ................. T294 95295 ................. T295 95296 ................. T296 95298 ................. T298 95299 ................. T299 95300 ................. T300 95302 ................. T302 95303 ................. T303 95304 ................. T304 95308 ................. T308 95311 ................. T311 DAYCO EUROPE Timing Belts 19084 ................. T028 19113 ................. T065 19116 ................. T018 19121 ................. T017 19122 ................. T013 19123 ................. T032 19146 ................. T020 DURKEE-ATWOOD Timing Belts 24-436PD........... T018 24-457PD........... T017 24-542PD........... T020 28-457PD........... T013 28-487PD........... T014 88013 ................. T013 88014 ................. T014 88017 ................. T017 88018 ................. T018 88020 ................. T020 88028 ................. T028 88032 ................. T032 88037 ................. T037 88039 ................. T039 88041 ................. T041 88042 ................. T068 88043 ................. T043 88046 ................. T013 88047 ................. T014 88050 ................. T018 88052 ................. T020 88057 ................. T037 88058 ................. T039 88060 ................. T017 88061 ................. T061 88062 ................. T062 88063 ................. T073 88064 ................. T064 88065 ................. T065 88067 ................. T067 88069 ................. T069 88070 ................. T070 88071 ................. T071 88074 ................. T074 88075 ................. T075 88076 ................. T076 88077 ................. T077 88078 ................. T078 88079 ................. T079 88081 ................. T081 88082 ................. T082 88083 ................. T083 88084 ................. T084 88087 ................. T087 88088 ................. T088 88089 ................. T089 88090 ................. T090 88091 ................. T091 88092 ................. T092 88093 ................. T093 88094 ................. T094 88095 ................. T095 88099 ................. T099 88100 ................. T100 88101 ................. T101

DURKEE-ATWOOD - Cont. Timing Belts - Cont. 88102 ................. T102 88104 ................. T104 88106 ................. T106 88107 ................. T107 88112 ................. T112 88113 ................. T113 88114 ................. T114 88115 ................. T299 88116 ................. T300 88117 ................. T117 88118 ................. T118 88121 ................. T121 88122 ................. T122 88124 ................. T124 88125 ................. T125 88126 ................. T126 88127 ................. T127 88130 ................. T130 88131 ................. T131 88132 ................. T132 88133 ................. T292 88134 ................. T134 88136 ................. T136 88138 ................. T138 88141 ................. T141 88143 ................. T143 88144 ................. T144 88146 ................. T146 88153 ................. T153 88157 ................. T157 88158 ................. T158 88159 ................. T159 88160 ................. T160 88161 ................. T161 88162 ................. T162 88163 ................. T163 88165 ................. T165 88170 ................. T170 DYNAFLEX (See DAYCO) DYNAGEAR Timing Belts B013................... T013 B014................... T014 B017................... T017 B018................... T018 B020................... T020 B028................... T028 B032................... T032 B037................... T037 B039................... T039 B041................... T041 B043................... T043 B061................... T061 B062................... T062 B063................... T073 B064................... T064 B065................... T065 B067................... T067 B068................... T068 B069................... T069 B070................... T070 B071................... T071 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B081................... T081 B087................... T087 B088................... T088 B093................... T093 B094................... T094 B095................... T095 B099................... T099 B104................... T104 B112................... T112 TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB020................. T020 TB028................. T028 TB029................. T104 TB032................. T032 TB036................. T036 TB037................. T037 TB039................. T039 TB041................. T041 TB043................. T043 TB061................. T061

792
Competitive No.

Changeover Listing - PowerGrip Timing System Products


Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

DYNAGEAR - Cont. Timing Belts - Cont. TB062................. TB063................. TB064................. TB065................. TB067................. TB068................. TB069................. TB070................. TB071................. TB073................. TB074................. TB075................. TB076................. TB077................. TB078................. TB079................. TB081................. TB082................. TB083................. TB084................. TB087................. TB088................. TB089................. TB090................. TB091................. TB092................. TB093................. TB094................. TB095................. TB096................. TB098................. TB099................. TB100................. TB101................. TB102................. TB103................. TB104................. TB106................. TB107................. TB108................. TB110................. TB112................. TB113................. TB114................. TB115................. TB116................. TB117................. TB118................. TB119................. TB121................. TB122................. TB123................. TB124................. TB125................. TB126................. TB127................. TB128................. TB129................. TB130................. TB131................. TB132................. TB133................. TB134................. TB135................. TB136................. TB137................. TB138................. TB139................. TB140................. TB141................. TB142................. TB143................. TB144................. TB145................. TB146................. TB147................. TB148................. TB149................. TB150................. TB151................. TB152................. TB153................. TB154................. TB155................. TB157................. TB158................. TB159................. TB160................. TB161................. TB162................. TB163................. TB164................. T062 T073 T064 T065 T067 T068 T069 T070 T071 T073 T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T098 T099 T100 T101 T102 T103 T104 T106 T107 T293 T196 T112 T113 T114 T299 T300 T117 T118 T119 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164

DYNAGEAR - Cont. Timing Belts - Cont. TB165................. T165 TB166................. T166 TB167................. T167 TB168................. T168 TB169................. T169 Timing Belt Tensioners 7206 ................... T41076 7209 ................... T41073 9011 ................... T41005 9032 ................... T41055 9033 ................... T41042 9038 ................... T41057 9066 ................... T41066 9075 ................... T41058 9089 ................... T41080 9091 ................... T41000 9096 ................... T41069 9097 ................... T41068 9104 ................... T41070 9105 ................... T41043 9106 ................... T41053 9107 ................... T41050 9108 ................... T41049 9114 ................... T41006 9117 ................... T41077 9124 ................... T41059 9126 ................... T41017 9135 ................... T41074 9148 ................... T41079 9154 ................... T41061 9155 ................... T41062 9156 ................... T41081 9160 ................... T41056 9161 ................... T41045 9162 ................... T41011 9163 ................... T41012 9164 ................... T41030 9165 ................... T41035 9166 ................... T41029 9182 ................... T41064 9183 ................... T41026 9192 ................... T41001 9194 ................... T41046 9195 ................... T41048 9196 ................... T41044 9197 ................... T41047 9198 ................... T41015 9202 ................... T41019 9203 ................... T41014 9204 ................... T41013 9213 ................... T41031 9221 ................... T41010 9224 ................... T41051 9226 ................... T41020 9262 ................... T41016 9263 ................... T41025 9268 ................... T41021 9269 ................... T41003 9270 ................... T41004 9271 ................... T41039 9272 ................... T41052 9275 ................... T41060 9276 ................... T41027 9282 ................... T41065 9292 ................... T41036 9293 ................... T41033 9299 ................... T41071 9301 ................... T41067 9343 ................... T41009 9900 ................... T41007 9903 ................... T41018 9904 ................... T41072 Timing Belt Pulleys S675................... T42022 7184 ................... T42001 7207 ................... T42028 7214 ................... T42005 7215 ................... T42003 7216 ................... T42011 7222 ................... T42006 7223 ................... T42007 7227 ................... T42018 7244 ................... T42020 7274 ................... T42017 7283 ................... T42021 7300 ................... T42029 7302 ................... T42025 7303 ................... T42030 9110 ................... T42026 9118 ................... T42027

DYNAGEAR - Cont. Timing Belt Pulleys - Cont. 9325 ................... T42010 9326 ................... T42009 ELGIN MACH. Timing Belts LB-013................ T013 LB-014................ T014 LB-017................ T017 LB-018................ T018 LB-020................ T020 LB-028................ T028 LB-032................ T032 LB-036................ T036 LB-037................ T037 LB-039................ T039 LB-041................ T041 LB-043................ T043 LB-061................ T061 LB-062................ T062 LB-063................ T073 LB-064................ T064 LB-065................ T065 LB-067................ T067 LB-068................ T068 LB-069................ T069 LB-070................ T070 LB-071................ T071 LB-073................ T073 LB-074................ T074 LB-075................ T075 LB-076................ T076 LB-077................ T077 LB-078................ T078 LB-081................ T081 LB-088................ T088 LB-093................ T093 FEDERAL MOGUL Timing Belts LB013................. T013 LB014................. T014 LB020................. T020 LB028................. T028 LB032................. T032 LB036................. T036 LB037................. T037 LB039................. T039 LB041................. T041 LB043................. T043 LB061................. T061 LB062................. T062 LB064................. T064 LB065................. T065 LB067................. T067 LB069................. T069 LB070................. T070 LB071................. T071 LB073................. T073 LB074................. T074 LB075................. T075 LB076................. T076 LB077................. T077 LB078................. T078 LB081................. T081 LB082................. T082 LB083................. T083 LB087................. T087 LB088................. T088 LB089................. T089 LB090................. T090 LB093................. T093 LB094................. T094 LB095................. T095 LB099................. T099 LB101................. T101 LB102................. T102 LB103................. T103 LB104................. T104 LB107................. T107 LB108................. T293 LB110................. T196 LB112................. T112 LB113................. T113 LB114................. T114 LB115................. T299 LB116................. T300 LB117................. T117 LB118................. T162 LB119................. T119 LB122................. T122 LB124................. T124

FEDERAL MOGUL - Cont. Timing Belts - Cont. LB125................. T125 LB126................. T237 LB128................. T128 LB129................. T129 LB130................. T130 LB131................. T131 LB132................. T132 LB133................. T292 LB134................. T134 LB135................. T135 LB136................. T233 LB138................. T199 LB139................. T139 LB141................. T141 LB142................. T142 LB143................. T143 LB144................. T144 LB145................. T145 LB146................. T146 LB147................. T147 LB148................. T148 LB149................. T149 LB152................. T152 LB153................. T153 LB154................. T154 LB155................. T155 LB157................. T157 LB158................. T158 LB159................. T159 LB160................. T160 LB161................. T161 LB162................. T162 LB163................. T163 LB164................. T164 LB165................. T165 LB166................. T166 LB167................. T167 LB168................. T168 LB169................. T169 LB170................. T170 LB172................. T254 LB176................. T176 LB177................. T177 LB179................. T179 LB180................. T180 LB183................. T183 LB184................. T184 LB185................. T185 LB186................. T186 LB187................. T187 LB193................. T193 LB194................. T194 LB202................. T248 LB210................. T210 FIRESTONE Timing Belts 51309510 ........... T017 51309618 ........... T061 51309677 ........... T067 51309693 ........... T071 51309766 ........... T081 FRESHSTART (See GOODYEAR) GENERAL CHAIN Timing Belts B4013................. T013 B4014................. T014 B4017................. T017 B4018................. T018 B4020................. T020 B4028................. T028 B4032................. T032 B4036................. T036 B4037................. T037 B4039................. T039 B4041................. T041 B4042................. T068 B4043................. T043 B4061................. T061 B4065................. T065 B4067................. T067 B4070................. T070 B4071................. T071 B4073................. T073 B4075................. T075 B4076................. T076 B4501................. T196 B4507................. T100 B4510................. T077

GENERAL CHAIN - Cont. Timing Belts - Cont. B4511................. T078 B4512................. T079 B4513................. T087 B4514................. T084 B4515................. T101 B4516................. T070 B4518................. T112 B4519................. T084 B4540................. T127 B4550................. T089 B4551................. T090 B4580................. T094 B4590................. T082 GMB Timing Belt Tensioners GT10010 ............ T41042 GT10022 ............ T41037 GT10031 ............ T41043 GT10032 ............ T41044 GT10040 ............ T41045 GT10060 ............ T41046 GT10070 ............ T41047 GT10072 ............ T41038 GT10080 ............ T41048 GT10100 ............ T41039 GT10130 ............ T41049 GT10140 ............ T41050 GT10150 ............ T41041 GT20010 ............ T41029 GT20040 ............ T41030 GT20050 ............ T41031 GT40010 ............ T41003 GT80010 ............ T41066 GT80020 ............ T41067 GT80050 ............ T41060 GT80070 ............ T41079 GT80090 ............ T41051 GT80100 ............ T41011 GT80110 ............ T41058 GT80140 ............ T41068 GT80170 ............ T41012 GT80250 ............ T41025 GT80280 ............ T41080 GT80310 ............ T41009 GT80320 ............ T41064 GT80340 ............ T41059 GT80360 ............ T41069 GT80370 ............ T41070 GT80390 ............ T41013 GT80400 ............ T41052 GT80410 ............ T41004 GT80420 ............ T41071 GT80430 ............ T41072 GT80440 ............ T41014 GT80480 ............ T41053 GT80490 ............ T41005 GT80500 ............ T41006 GT80550 ............ T41015 GT80560 ............ T41061 GT80570 ............ T41062 GT80580 ............ T41016 GT80590 ............ T41017 GT80600 ............ T41073 GT80610 ............ T41018 GT80620 ............ T41026 GT80630 ............ T41074 GT80640 ............ T41065 GT80650 ............ T41019 GT80660 ............ T41033 GT80670 ............ T41034 GT80680 ............ T41075 GT80700 ............ T41076 GT80710 ............ T41077 GT80800 ............ T41054 GT80820 ............ T41000 GT80830 ............ T41001 GT80860 ............ T41021 GT80890 ............ T41055 GT80900 ............ T41056 GT80940 ............ T41010 GT80950 ............ T41057 GT80970 ............ T41035 420-8820............ T41000 420-8830............ T41001 420-9010............ T41002 422-4010............ T41003 422-8410............ T41004 425-8490............ T41005 425-8500............ T41006 425-8960............ T41007

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793

GMB - Cont. Timing Belt Tensioners - Cont. 425-9000............ T41008 430-8310............ T41009 430-8940............ T41010 435-8100............ T41011 435-8170............ T41012 435-8390............ T41013 435-8440............ T41014 435-8550............ T41015 435-8580............ T41016 435-8590............ T41017 435-8610............ T41018 435-8650............ T41019 435-8850............ T41020 435-8860............ T41021 435-9030............ T41022 435-9040............ T41023 435-9120............ T41024 440-8250............ T41025 440-8620............ T41026 440-9070............ T41027 440-9110............ T41028 445-2010............ T41029 445-2040............ T41030 445-2050............ T41031 445-2140............ T41032 445-8660............ T41033 445-8670............ T41034 445-8970............ T41035 445-9100............ T41036 446-1022............ T41037 446-1061............ T41087 446-1072............ T41038 446-1100............ T41039 446-1101............ T41040 446-1150............ T41041 448-1010............ T41042 448-1031............ T41043 448-1032............ T41044 448-1040............ T41045 448-1060............ T41046 448-1070............ T41047 448-1080............ T41048 448-1130............ T41049 448-1140............ T41050 448-8090............ T41051 448-8400............ T41052 448-8480............ T41053 448-8800............ T41054 448-8890............ T41055 448-8900............ T41056 448-8950............ T41057 450-8110............ T41058 450-8340............ T41059 450-8910............ T41085 460-8050............ T41060 460-8560............ T41061 460-8570............ T41062 460-9080............ T41063 465-8320............ T41064 465-8640............ T41065 470-8010............ T41066 470-8020............ T41067 470-8140............ T41068 470-8360............ T41069 470-8370............ T41070 470-8420............ T41071 470-8430............ T41072 470-8600............ T41073 470-8630............ T41074 470-8680............ T41075 470-8700............ T41076 470-8710............ T41077 470-9090............ T41078 480-8070............ T41079 480-8280............ T41080 490-9143............ T41081 Timing Belt Pulleys GT10050 ............ T42017 GT10110 ............ T42018 GT10160 ............ T42015 GT10170 ............ T42016 GT20020 ............ T42003 GT20030 ............ T42004 GT20060 ............ T42005 GT20090 ............ T42006 GT20100 ............ T42007 GT80030 ............ T42025 GT80040 ............ T42008 GT80150 ............ T42026 GT80330 ............ T42027

GMB - Cont. Timing Belt Pulleys - Cont. GT80350 ............ T42028 GT80380 ............ T42029 GT80510 ............ T42009 GT80520 ............ T42010 GT80530 ............ T42011 GT80540 ............ T42030 GT80690 ............ T42022 GT80870 ............ T42012 GT80880 ............ T42013 GT80910 ............ T42021 GT80930 ............ T42020 425-9350............ T42033 425-9360............ T42032 425-9390............ T42034 425-9400............ T42035 440-8840............ T42001 440-9060............ T42002 445-2020............ T42003 445-2030............ T42004 445-2060............ T42005 445-2090............ T42006 445-2100............ T42007 445-8040............ T42008 445-8510............ T42009 445-8520............ T42010 445-8530............ T42011 445-8870............ T42012 445-8880............ T42013 446-1111............ T42014 446-1160............ T42015 446-1170............ T42016 448-1050............ T42017 448-1110............ T42018 450-8920............ T42020 450-8930............ T42021 460-8690............ T42022 460-9020............ T42023 460-9130............ T42024 470-8030............ T42025 470-8150............ T42026 470-8330............ T42027 470-8350............ T42028 470-8380............ T42029 470-8540............ T42030 470-9050............ T42031 GOODYEAR Timing Belts CD-100............... T100 CD-101............... T101 CD-104............... T104 CD-106............... T106 CD-112............... T112 CD-113............... T113 CD-114............... T114 CD-115............... T299 CD-116............... T300 CD-117............... T117 CD-118............... T118 CD-122............... T122 CD-124............... T124 CD-125............... T125 CD-126............... T126 CD-127............... T127 CD-128............... T128 CD-129............... T129 CD-13................. T013 CD-130............... T130 CD-131............... T131 CD-132............... T132 CD-133............... T292 CD-134............... T134 CD-136............... T136 CD-137............... T137 CD-138............... T138 CD-139............... T139 CD-14................. T014 CD-140............... T140 CD-141............... T141 CD-142............... T142 CD-143............... T143 CD-144............... T144 CD-145............... T145 CD-146............... T146 CD-147............... T147 CD-148............... T148 CD-149............... T149 CD-150............... T150 CD-151............... T151 CD-152............... T152 CD-153............... T153

GOODYEAR - Cont. Timing Belts - Cont. CD-154............... CD-155............... CD-157............... CD-158............... CD-159............... CD-160............... CD-161............... CD-162............... CD-163............... CD-164............... CD-165............... CD-166............... CD-167............... CD-168............... CD-169............... CD-17................. CD-170............... CD-171............... CD-172............... CD-173............... CD-174............... CD-176............... CD-177............... CD-178............... CD-179............... CD-18................. CD-180............... CD-181............... CD-182............... CD-183............... CD-184............... CD-185............... CD-186............... CD-187............... CD-188............... CD-189............... CD-190............... CD-191............... CD-192............... CD-193............... CD-194............... CD-195............... CD-196............... CD-197............... CD-198............... CD-199............... CD-20................. CD-200............... CD-201............... CD-202............... CD-203............... CD-204............... CD-205............... CD-206............... CD-207............... CD-208............... CD-209............... CD-210............... CD-211............... CD-212............... CD-213............... CD-214............... CD-215............... CD-216............... CD-217............... CD-218............... CD-219............... CD-220............... CD-221............... CD-222............... CD-223............... CD-224............... CD-225............... CD-226............... CD-227............... CD-228............... CD-229............... CD-230............... CD-232............... CD-233............... CD-234............... CD-235............... CD-236............... CD-237............... CD-239............... CD-240............... CD-241............... CD-242............... CD-243............... CD-244............... CD-245............... CD-246............... T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T017 T170 T171 T172 T173 T174 T176 T177 T178 T179 T018 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T020 T200 T201 T248 T203 T204 T205 T206 T207 T208 T209 T210 T211 T212 T213 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246

GOODYEAR - Cont. Timing Belts - Cont. CD-247............... CD-248............... CD-249............... CD-251............... CD-252............... CD-253............... CD-254............... CD-255............... CD-256............... CD-257............... CD-258............... CD-259............... CD-260............... CD-262............... CD-263............... CD-264............... CD-265............... CD-266............... CD-267............... CD-269............... CD-271............... CD-272............... CD-273............... CD-276............... CD-277............... CD-278............... CD-279............... CD-28................. CD-280............... CD-281............... CD-282............... CD-283............... CD-284............... CD-285............... CD-286............... CD-287............... CD-288............... CD-289............... CD-290............... CD-291............... CD-292............... CD-293............... CD-294............... CD-295............... CD-296............... CD-297............... CD-298............... CD-299............... CD-300............... CD-301............... CD-302............... CD-303............... CD-304............... CD-305............... CD-306............... CD-32................. CD-36................. CD-37................. CD-39................. CD-41................. CD-42................. CD-43................. CD-61................. CD-62................. CD-63................. CD-64................. CD-65................. CD-67................. CD-69................. CD-70................. CD-71................. CD-74................. CD-77................. CD-78................. CD-81................. CD-87................. CD-88................. CD-89................. CD-90................. CD-91................. CD-92................. CD-93................. CD-94................. CD-95................. CD-99................. 40013 ................. 40014 ................. 40017 ................. 40018 ................. 40020 ................. 40028 ................. 40032 ................. T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T260 T262 T263 T264 T265 T266 T267 T269 T271 T272 T273 T276 T277 T278 T279 T028 T280 T281 T282 T283 T284 T285 T286 T287 T288 T289 T290 T291 T292 T293 T294 T295 T296 T297 T298 T299 T300 T301 T302 T303 T304 T305 T306 T032 T036 T037 T039 T041 T068 T043 T061 T062 T073 T064 T065 T067 T069 T070 T071 T074 T077 T078 T081 T087 T088 T089 T090 T091 T092 T093 T094 T095 T099 T013 T014 T017 T018 T020 T028 T032

GOODYEAR - Cont. Timing Belts - Cont. 40036 ................. 40037 ................. 40039 ................. 40041 ................. 40042 ................. 40043 ................. 40046 ................. 40047 ................. 40050 ................. 40052 ................. 40057 ................. 40058 ................. 40060 ................. 40061 ................. 40062 ................. 40063 ................. 40064 ................. 40065 ................. 40067 ................. 40068 ................. 40069 ................. 40070 ................. 40071 ................. 40073 ................. 40074 ................. 40075 ................. 40076 ................. 40077 ................. 40078 ................. 40079 ................. 40081 ................. 40082 ................. 40083 ................. 40084 ................. 40087 ................. 40088 ................. 40089 ................. 40090 ................. 40091 ................. 40092 ................. 40093 ................. 40094 ................. 40095 ................. 40096 ................. 40097 ................. 40098 ................. 40099 ................. 40100 ................. 40101 ................. 40102 ................. 40103 ................. 40104 ................. 40106 ................. 40107 ................. 40112 ................. 40113 ................. 40114 ................. 40115 ................. 40116 ................. 40117 ................. 40118 ................. 40119 ................. 40121 ................. 40122 ................. 40123 ................. 40124 ................. 40125 ................. 40126 ................. 40127 ................. 40128 ................. 40129 ................. 40130 ................. 40131 ................. 40132 ................. 40133 ................. 40134 ................. 40135 ................. 40136 ................. 40137 ................. 40138 ................. 40139 ................. 40140 ................. 40141 ................. 40142 ................. 40143 ................. 40144 ................. 40145 ................. 40146 ................. 40147 ................. 40148 ................. 40149 ................. 40151 ................. T036 T037 T039 T041 T068 T043 T013 T014 T018 T020 T037 T039 T017 T061 T062 T073 T064 T065 T067 T068 T069 T070 T071 T073 T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T097 T098 T099 T100 T101 T102 T103 T104 T106 T107 T176 T113 T114 T299 T300 T117 T118 T119 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T151

794
Competitive No.

Changeover Listing - PowerGrip Timing System Products


Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

GOODYEAR - Cont. Timing Belts - Cont. 40152 ................. 40153 ................. 40154 ................. 40155 ................. 40157 ................. 40158 ................. 40159 ................. 40160 ................. 40161 ................. 40162 ................. 40163 ................. 40164 ................. 40165 ................. 40166 ................. 40167 ................. 40168 ................. 40169 ................. 40170 ................. 40171 ................. 40172 ................. 40173 ................. 40174 ................. 40176 ................. 40177 ................. 40178 ................. 40179 ................. 40180 ................. 40181 ................. 40182 ................. 40183 ................. 40184 ................. 40185 ................. 40186 ................. 40187 ................. 40188 ................. 40189 ................. 40190 ................. 40191 ................. 40192 ................. 40193 ................. 40194 ................. 40195 ................. 40196 ................. 40197 ................. 40198 ................. 40199 ................. 40200 ................. 40201 ................. 40202 ................. 40203 ................. 40204 ................. 40205 ................. 40206 ................. 40207 ................. 40208 ................. 40209 ................. 40210 ................. 40211 ................. 40212 ................. 40213 ................. 40214 ................. 40215 ................. 40216 ................. 40217 ................. 40218 ................. 40219 ................. 40220 ................. 40221 ................. 40222 ................. 40223 ................. 40224 ................. 40225 ................. 40226 ................. 40227 ................. 40228 ................. 40229 ................. 40230 ................. 40232 ................. 40233 ................. 40234 ................. 40235 ................. 40236 ................. 40237 ................. 40239 ................. 40240 ................. 40241 ................. 40242 ................. 40243 ................. 40244 ................. 40245 ................. 40246 ................. 40247 ................. T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T248 T203 T204 T205 T206 T207 T208 T209 T210 T211 T212 T213 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247

GOODYEAR - Cont. Timing Belts - Cont. 40248 ................. T248 40249 ................. T249 40251 ................. T251 40252 ................. T252 40253 ................. T253 40254 ................. T254 40255 ................. T255 40256 ................. T256 40257 ................. T257 40258 ................. T258 40259 ................. T259 40260 ................. T260 40262 ................. T262 40263 ................. T263 40264 ................. T264 40265 ................. T265 40266 ................. T266 40267 ................. T267 40269 ................. T269 40271 ................. T271 40272 ................. T272 40273 ................. T273 40274 ................. T274 40275 ................. T275 40276 ................. T276 40277 ................. T277 40278 ................. T278 40279 ................. T279 40280 ................. T280 40281 ................. T281 40282 ................. T282 40283 ................. T283 40284 ................. T284 40285 ................. T285 40286 ................. T286 40287 ................. T287 40288 ................. T288 40289 ................. T289 40290 ................. T290 40291 ................. T291 40292 ................. T292 40293 ................. T293 40294 ................. T294 40295 ................. T295 40296 ................. T296 40297 ................. T297 40298 ................. T298 40299 ................. T299 40300 ................. T300 40301 ................. T301 40302 ................. T302 40303 ................. T303 40304 ................. T304 40305 ................. T305 40306 ................. T306 40307 ................. T307 40308 ................. T308 40309 ................. T309 40310 ................. T310 40311 ................. T311 40312 ................. T312 40313 ................. T313 40314 ................. T314 40315 ................. T315 40316 ................. T316 40317 ................. T317 40318 ................. T318 40319 ................. T319 40320 ................. T320 40321 ................. T321 40322 ................. T322 40323 ................. T323 40324 ................. T324 40325 ................. T325 Timing Belt Tensioners 48001 ................. T43005 48002 ................. T43002 48003 ................. T43003 48004 ................. T43008 48005 ................. T43004 48007 ................. T43001 48008 ................. T43007 HOOF PRODUCTS Timing Belts HB013 ................ T013 HB014 ................ T014 HB017 ................ T017 HB018 ................ T018 HB020 ................ T020 HB028 ................ T028

HOOF PRODUCTS - Cont. Timing Belts - Cont. HB032 ................ T032 HB036 ................ T036 HB037 ................ T037 HB039 ................ T039 HB041 ................ T041 HB042 ................ T068 HB043 ................ T043 HB061 ................ T061 HB062 ................ T062 HB063 ................ T073 HB064 ................ T064 HB065 ................ T065 HB067 ................ T067 HB069 ................ T069 HB070 ................ T070 HB071 ................ T071 HB073 ................ T073 HB074 ................ T074 HB075 ................ T075 HB076 ................ T076 HB077 ................ T077 HB078 ................ T078 HB079 ................ T079 HB081 ................ T081 HB082 ................ T082 HB083 ................ T083 HB084 ................ T084 HB087 ................ T087 HB088 ................ T088 HB089 ................ T089 HB090 ................ T090 HB091 ................ T091 HB092 ................ T092 HB093 ................ T093 HB094 ................ T094 HB095 ................ T095 HB096 ................ T096 HB099 ................ T099 HB100 ................ T100 HB102 ................ T102 HB103 ................ T103 HB104 ................ T104 HB114 ................ T114 HB115 ................ T299 HB116 ................ T300 HB118 ................ T118 HB121 ................ T121 HB122 ................ T122 HB127 ................ T127 HB128 ................ T128 LAZORLITE Timing Belts L55-4014............ T013 L55-4022............ T062 L55-4030............ T064 L55-4049............ T028 L55-4057............ T041 L55-4065............ T041 L55-4081............ T073 L55-4103............ T078 L55-4111............ T077 L55-4120............ T074 L55-4138............ T079 L55-4154............ T088 L55-4162............ T089 L55-4170............ T090 L55-4189............ T092 L55-4200............ T070 L55-4219............ T075 L55-4227............ T076 L55-4235............ T117 L55-4243............ T093 L55-4251............ T091 L55-4260............ T095 L55-4286............ T104 L55-4294............ T101 L55-4308............ T084 L55-4316............ T087 L55-4324............ T094 L55-4332............ T099 L55-4405............ T017 L55-4472............ T300 L55-4480............ T299 L55-4499............ T112 L55-4502............ T161 L55-4510............ T118 L55-4529............ T104 L55-4537............ T137 L55-4596............ T149 L55-4600............ T141

LAZORLITE - Cont. Timing Belts - Cont. L55-4618............ T141 L55-4626............ T117 L55-4634............ T134 L55-4642............ T128 L55-4650............ T124 L55-4669............ T139 L55-4677............ T103 L55-4685............ T135 L55-4693............ T136 L55-4707............ T126 L55-4715............ T098 L55-4723............ T138 L55-4731............ T130 L55-4740............ T129 L55-4758............ T145 L55-4766............ T122 L55-4774............ T121 L55-4782............ T148 L55-4790............ T138 L55-4812............ T146 L55-4820............ T159 L55-4839............ T168 L55-4847............ T144 L55-4855............ T142 L55-4863............ T143 L55-4880............ T167 L55-4898............ T165 L55-4901............ T164 L55-4910............ T150 L55-4928............ T151 L55-4936............ T166 L55-4944............ T113 L55-4952............ T157 L55-4960............ T154 L55-4979............ T125 U55-4359 ........... T069 U55-4367 ........... T018 U55-4375 ........... T068 U55-4383 ........... T020 U55-4405 ........... T017 U55-4413 ........... T065 U55-4421 ........... T127 U55-4430 ........... T083 U55-4448 ........... T032 U55-4456 ........... T082 U55-4464 ........... T043 U55-4545 ........... T082 U55-4553 ........... T083 U55-4561 ........... T293 U55-4570 ........... T107 U55-4588 ........... T119 U55-4871 ........... T292 LEMPCO Timing Belts TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB028................. T028 TB037................. T037 TB039................. T039 TB041................. T041 TB063................. T073 TB064................. T064 TB071................. T071 TB112................. T112 LINK-BELT Timing Belts B013................... T013 B014................... T014 B037................... T037 LITENS AUTOMOTIVE Timing Belt Tensioners 979002 ............... T43004 MBL THREE STARS Timing Belts 100ZA19............. T061 106ZA19............. T077 109ZA19............. T088 113ZA19............. T065 116ZA19............. T018 118ZA19............. T069 120ZA19............. T064 121ZA19............. T017 122ZA19............. T013 123ZA19............. T032 124ZA25............. T071

MBL THREE STARS - Cont. Timing Belts - Cont. 129ZA22............. T014 134ZA30............. T076 134ZB301........... T076 135ZB25............. T043 139ZA25............. T087 142ZA25............. T074 146ZA19............. T020 148ZA19............. T068 55ZA13............... T062 84ZA19............... T028 87ZA34............... T075 87ZB34............... T075 88ZA19............... T070 92ZA19............... T073 95ZA19............... T041 97ZA25............... T067 98ZA19............... T078 99ZA15............... T037 99ZA19............... T039 MCQUAY-NORRIS Timing Belts TC013 ................ T013 TC014 ................ T014 TC017 ................ T017 TC018 ................ T018 TC020 ................ T020 TC028 ................ T028 TC032 ................ T032 TC036 ................ T036 TC037 ................ T037 TC039 ................ T039 TC041 ................ T041 TC042 ................ T068 TC043 ................ T043 TC061 ................ T061 TC062 ................ T062 TC063 ................ T073 TC064 ................ T064 TC065 ................ T065 TC067 ................ T067 TC068 ................ T068 TC069 ................ T069 TC070 ................ T070 TC071 ................ T071 TC074 ................ T074 TC075 ................ T075 TC076 ................ T076 TC077 ................ T077 TC078 ................ T078 TC081 ................ T081 TC087 ................ T087 TC088 ................ T088 TC089 ................ T089 MELLING AUTOMOTIVE Timing Belts B0100................. T100 B0101................. T101 B0102................. T102 B0103................. T103 B0104................. T104 B0106................. T106 B0107................. T107 B0108................. T293 B0112................. T176 B0113................. T113 B0114................. T114 B0115................. T299 B0116................. T300 B0117................. T117 B0118................. T162 B0119................. T119 B0121................. T121 B0122................. T122 B0123................. T123 B0124................. T124 B0125................. T125 B0126................. T126 B0127................. T127 B0128................. T128 B0129................. T129 B013................... T013 B0130................. T130 B0131................. T131 B0132................. T132 B0133................. T292 B0134................. T134 B0135................. T135 B0136................. T136 B0137................. T137

Changeover Listing - PowerGrip Timing System Products


Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

795

MELLING AUTOMOTIVE - Cont. Timing Belts - Cont. B0138................. B0139................. B014................... B0140................. B0141................. B0142................. B0143................. B0144................. B0145................. B0146................. B0147................. B0148................. B0149................. B0150................. B0151................. B0152................. B0153................. B0154................. B0155................. B0157................. B0158................. B0159................. B0160................. B0161................. B0162................. B0163................. B0164................. B0165................. B0166................. B0167................. B0168................. B0169................. B017................... B0170................. B0171................. B0172................. B0174................. B0176................. B0177................. B0178................. B0179................. B018................... B0180................. B0181................. B0182................. B0183................. B0184................. B0185................. B0186................. B0187................. B0189................. B0191................. B0192................. B0193................. B0194................. B0195................. B0199................. B020................... B0202................. B0203................. B0204................. B0205................. B0208................. B0210................. B0216................. B0219................. B0223................. B0224................. B0226................. B0228................. B0229................. B0230................. B0232................. B0233................. B0237................. B0239................. B028................... B029................... B032................... B036................... B037................... B039................... B041................... B042................... B043................... B061................... B062................... B063................... B064................... B065................... B067................... T138 T139 T014 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T017 T170 T171 T172 T174 T176 T177 T178 T179 T018 T180 T181 T182 T183 T184 T185 T186 T187 T189 T191 T192 T193 T194 T195 T199 T020 T248 T203 T204 T205 T208 T210 T216 T219 T223 T224 T226 T228 T229 T230 T232 T233 T237 T239 T028 T104 T032 T036 T037 T039 T041 T068 T043 T061 T062 T073 T064 T065 T067

MELLING AUTOMOTIVE - Cont. Timing Belts - Cont. B069................... T069 B070................... T070 B071................... T071 B074................... T074 B075................... T075 B076................... T076 B077................... T077 B078................... T078 B079................... T079 B081................... T081 B082................... T082 B083................... T083 B084................... T084 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B091................... T091 B092................... T092 B093................... T093 B094................... T094 B095................... T095 B096................... T096 B097................... T097 B098................... T098 B099................... T099 MIGHTY Timing Belts CD100................ T100 CD101................ T101 CD102................ T102 CD103................ T103 CD104................ T104 CD111................ T140 CD112................ T176 CD113................ T113 CD114................ T114 CD115................ T299 CD116................ T300 CD117................ T117 CD118................ T118 CD119................ T119 CD121................ T121 CD122................ T122 CD123................ T123 CD124................ T124 CD125................ T125 CD126................ T126 CD127................ T127 CD128................ T128 CD129................ T129 CD13.................. T013 CD130................ T130 CD131................ T131 CD132................ T132 CD133................ T292 CD134................ T134 CD135................ T135 CD136................ T136 CD137................ T137 CD138................ T138 CD139................ T139 CD14.................. T014 CD141................ T141 CD142................ T142 CD143................ T143 CD144................ T144 CD145................ T145 CD146................ T146 CD147................ T147 CD148................ T148 CD153................ T153 CD154................ T154 CD155................ T155 CD157................ T157 CD158................ T158 CD159................ T159 CD160................ T160 CD161................ T161 CD162................ T162 CD163................ T163 CD164................ T164 CD165................ T165 CD166................ T166 CD167................ T167 CD17.................. T017 CD176................ T176 CD18.................. T018 CD185................ T185

MIGHTY - Cont. Timing Belts - Cont. CD186................ T186 CD187................ T187 CD191................ T191 CD20.................. T020 CD208................ T208 CD210................ T210 CD28.................. T028 CD32.................. T032 CD36.................. T036 CD37.................. T037 CD39.................. T039 CD41.................. T041 CD42.................. T068 CD43.................. T043 CD61.................. T061 CD62.................. T062 CD63.................. T073 CD64.................. T064 CD65.................. T065 CD67.................. T067 CD69.................. T069 CD70.................. T070 CD71.................. T071 CD74.................. T074 CD75.................. T075 CD76.................. T076 CD77.................. T077 CD78.................. T078 CD79.................. T079 CD81.................. T081 CD82.................. T082 CD83.................. T083 CD84.................. T084 CD87.................. T087 CD88.................. T088 CD89.................. T089 CD90.................. T090 CD91.................. T091 CD92.................. T092 CD93.................. T093 CD94.................. T094 CD95.................. T095 CD99.................. T099 MITSUBOSHI Timing Belts 106ZA19............. T077 111ZA19............. T121 116ZA19............. T018 120ZA19............. T064 122ZA19............. T013 123ZA19............. T032 127ZA25............. T079 129ZA22............. T014 134ZB30............. T076 139ZA25............. T087 146ZA19............. T020 148ZA19............. T068 55ZA13............... T062 55ZB13............... T090 83ZB19............... T092 84ZA19............... T028 87ZB34............... T075 88ZA19............... T070 89ZA19............... T095 92ZA19............... T073 94ZA19............... T036 95ZA19............... T041 98ZA19............... T078 MOPAR Timing Belts BTC-13............... T013 BTC-14............... T014 BTC-37............... T037 BTC-39............... T020 B0040013........... T013 B0040017........... T017 B0040062........... T062 B0040063........... T073 B0040064........... T064 B0040071........... T071 MOTORCRAFT Timing Belts CET13................ T013 CET135.............. T135 CET14................ T014 CET17................ T017 CET207.............. T207 CET230.............. T230

MOTORCRAFT - Cont. Timing Belts - Cont. CET257.............. T257 CET262.............. T262 CET263.............. T263 CET264.............. T264 CET265.............. T265 CET271.............. T271 CET272.............. T272 CET273.............. T273 CET277.............. T277 CET278.............. T278 CET279.............. T279 CET28................ T028 CET280.............. T280 CET281.............. T281 CET282.............. T282 CET284.............. T284 CET285.............. T285 CET286.............. T286 CET287.............. T287 CET288.............. T288 CET289.............. T289 CET290.............. T290 CET291.............. T291 CET37................ T037 CET39................ T039 CET41................ T041 CET61................ T061 CET67................ T067 CET70................ T070 CET71................ T071 CET94................ T094 MOTORCRAFT CANADA Timing Belts CET13................ T013 CET135.............. T135 CET14................ T014 CET17................ T017 CET207.............. T207 CET230.............. T230 CET257.............. T257 CET262.............. T262 CET263.............. T263 CET264.............. T264 CET265.............. T265 CET271.............. T271 CET272.............. T272 CET273.............. T273 CET277.............. T277 CET278.............. T278 CET279.............. T279 CET28................ T028 CET280.............. T280 CET281.............. T281 CET282.............. T282 CET284.............. T284 CET285.............. T285 CET286.............. T286 CET287.............. T287 CET288.............. T288 CET289.............. T289 CET290.............. T290 CET291.............. T291 CET37................ T037 CET39................ T039 CET41................ T041 CET61................ T061 CET67................ T067 CET70................ T070 CET71................ T071 CET94................ T094 NAPA Timing Belts 25-90073............ T073 25-90096............ T096 25-90097............ T097 25-90130............ T013 25-90140............ T014 25-90150............ T032 25-90160............ T041 25-90166............ T166 25-90167............ T167 25-90168............ T168 25-90169............ T169 25-90170............ T017 25-90171............ T171 25-90172............ T172 25-90173............ T173 25-90174............ T174 25-90176............ T176

NAPA - Cont. Timing Belts - Cont. 25-90177............ 25-90178............ 25-90179............ 25-90180............ 25-90181............ 25-90182............ 25-90183............ 25-90184............ 25-90185............ 25-90186............ 25-90187............ 25-90188............ 25-90189............ 25-90191............ 25-90192............ 25-90193............ 25-90194............ 25-90195............ 25-90196............ 25-90197............ 25-90198............ 25-90199............ 25-90200............ 25-90201............ 25-90202............ 25-90203............ 25-90204............ 25-90205............ 25-90206............ 25-90207............ 25-90208............ 25-90209............ 25-90210............ 25-90211............ 25-90212............ 25-90213............ 25-90214............ 25-90215............ 25-90216............ 25-90217............ 25-90218............ 25-90219............ 25-90220............ 25-90221............ 25-90222............ 25-90223............ 25-90224............ 25-90225............ 25-90226............ 25-90227............ 25-90228............ 25-90229............ 25-90232............ 25-90233............ 25-90234............ 25-90235............ 25-90236............ 25-90237............ 25-90239............ 25-90250............ 25-90260............ 25-90270............ 25-90280............ 25-90290............ 25-90310............ 25-90320............ 25-90330............ 25-90340............ 25-90350............ 25-90360............ 25-90370............ 25-90380............ 25-90390............ 25-90400............ 25-90410............ 25-90420............ 25-90430............ 25-90440............ 25-90450............ 25-90460............ 25-90470............ 25-90480............ 25-90490............ 25-90510............ 25-90520............ 25-90530............ 25-90540............ 25-90550............ 25-90560............ 25-90570............ 25-90590............ 25-90600............ T177 T178 T179 T018 T181 T182 T183 T184 T185 T186 T187 T188 T189 T191 T192 T193 T194 T195 T196 T197 T198 T199 T020 T201 T248 T203 T204 T205 T206 T207 T208 T209 T039 T211 T212 T213 T214 T215 T216 T217 T218 T219 T062 T221 T222 T223 T224 T225 T226 T227 T228 T229 T232 T233 T234 T235 T236 T237 T239 T028 T061 T064 T065 T073 T069 T036 T070 T068 T071 T067 T037 T076 T075 T078 T077 T043 T074 T081 T088 T087 T093 T094 T104 T100 T084 T099 T098 T082 T083 T095 T112 T089

796
Competitive No.

Changeover Listing - PowerGrip Timing System Products


Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

NAPA - Cont. Timing Belts - Cont. 25-90610............ 25-90620............ 25-90630............ 25-90640............ 25-90650............ 25-90670............ 25-90680............ 25-90690............ 25-90700............ 25-90710............ 25-90720............ 25-90730............ 25-90740............ 25-90750............ 25-90760............ 25-90770............ 25-90780............ 25-90790............ 25-90800............ 25-90810............ 25-90820............ 25-90830............ 25-90840............ 25-90850............ 25-90860............ 25-90870............ 25-90880............ 25-90890............ 25-90900............ 25-90910............ 25-90920............ 25-90930............ 25-90940............ 25-90950............ 25-90960............ 25-90970............ 25-90980............ 25-90990............ 25-91000............ 25-91001............ 25-91002............ 25-91003............ 25-91004............ 25-91005............ 25-91006............ 25-91007............ 25-91008............ 25-91009............ 25-91010............ 25-91011............ 25-91012............ 25-91014............ 25-91015............ 25-91016............ 25-91017............ 25-91018............ 25-91019............ 25-91020............ 25-91021............ 25-91022............ 25-91023............ 25-91120............ 25-91170............ 25-91180............ 25-91190............ 25-91200............ 25-91210............ 25-91220............ 25-91230............ 25-91240............ 250013 ............... 250014 ............... 250017 ............... 250018 ............... 250020 ............... 250028 ............... 250032 ............... 250036 ............... 250037 ............... 250039 ............... 250041 ............... 250043 ............... 250061 ............... 250062 ............... 250064 ............... 250065 ............... 250067 ............... 250068 ............... 250069 ............... 250070 ............... 250071 ............... 250073 ............... T118 T079 T122 T121 T127 T101 T125 T126 T130 T129 T106 T114 T300 T299 T091 T092 T117 T119 T292 T134 T135 T136 T137 T138 T139 T140 T131 T141 T123 T090 T293 T196 T113 T132 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T102 T103 T107 T124 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T153 T120 T170 T180 T190 T200 T210 T220 T230 T240 T013 T014 T017 T018 T020 T028 T032 T036 T037 T039 T041 T043 T061 T062 T064 T065 T067 T068 T069 T070 T071 T073

NAPA - Cont. Timing Belts - Cont. 250074 ............... 250075 ............... 250076 ............... 250077 ............... 250078 ............... 250079 ............... 250081 ............... 250082 ............... 250083 ............... 250084 ............... 250087 ............... 250088 ............... 250089 ............... 250090 ............... 250091 ............... 250092 ............... 250093 ............... 250094 ............... 250095 ............... 250096 ............... 250097 ............... 250098 ............... 250099 ............... 250100 ............... 250101 ............... 250102 ............... 250103 ............... 250104 ............... 250106 ............... 250107 ............... 250108 ............... 250112 ............... 250113 ............... 250114 ............... 250115 ............... 250116 ............... 250117 ............... 250118 ............... 250119 ............... 250120 ............... 250121 ............... 250122 ............... 250123 ............... 250124 ............... 250125 ............... 250126 ............... 250127 ............... 250128 ............... 250129 ............... 250130 ............... 250131 ............... 250132 ............... 250133 ............... 250134 ............... 250135 ............... 250136 ............... 250137 ............... 250138 ............... 250139 ............... 250140 ............... 250141 ............... 250142 ............... 250143 ............... 250144 ............... 250145 ............... 250146 ............... 250147 ............... 250148 ............... 250149 ............... 250150 ............... 250151 ............... 250152 ............... 250153 ............... 250154 ............... 250155 ............... 250157 ............... 250158 ............... 250159 ............... 250160 ............... 250161 ............... 250162 ............... 250163 ............... 250164 ............... 250165 ............... 250166 ............... 250167 ............... 250168 ............... 250169 ............... 250170 ............... 250171 ............... 250172 ............... 250173 ............... T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T097 T098 T099 T100 T101 T102 T103 T104 T106 T107 T293 T112 T113 T114 T299 T300 T117 T118 T119 T120 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T292 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173

NAPA - Cont. Timing Belts - Cont. 250174 ............... 250176 ............... 250177 ............... 250178 ............... 250179 ............... 250180 ............... 250181 ............... 250182 ............... 250183 ............... 250184 ............... 250185 ............... 250186 ............... 250187 ............... 250188 ............... 250189 ............... 250190 ............... 250191 ............... 250192 ............... 250193 ............... 250194 ............... 250195 ............... 250196 ............... 250197 ............... 250198 ............... 250199 ............... 250200 ............... 250201 ............... 250202 ............... 250203 ............... 250204 ............... 250205 ............... 250206 ............... 250207 ............... 250208 ............... 250209 ............... 250210 ............... 250211 ............... 250212 ............... 250213 ............... 250214 ............... 250215 ............... 250216 ............... 250217 ............... 250218 ............... 250219 ............... 250220 ............... 250221 ............... 250222 ............... 250223 ............... 250224 ............... 250225 ............... 250226 ............... 250227 ............... 250228 ............... 250229 ............... 250230 ............... 250232 ............... 250233 ............... 250234 ............... 250235 ............... 250236 ............... 250237 ............... 250239 ............... 250240 ............... 250241 ............... 250242 ............... 250243 ............... 250244 ............... 250245 ............... 250246 ............... 250247 ............... 250248 ............... 250249 ............... 250251 ............... 250252 ............... 250253 ............... 250254 ............... 250255 ............... 250256 ............... 250257 ............... 250258 ............... 250259 ............... 250260 ............... 250262 ............... 250263 ............... 250264 ............... 250265 ............... 250266 ............... 250267 ............... 250269 ............... 250270 ............... 250271 ............... T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T248 T203 T204 T205 T206 T207 T208 T209 T210 T211 T212 T213 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T260 T262 T263 T264 T265 T266 T267 T269 T270 T271

NAPA - Cont. Timing Belts - Cont. 250272 ............... T272 250273 ............... T273 250274 ............... T274 250275 ............... T275 250276 ............... T276 250277 ............... T277 250278 ............... T278 250279 ............... T279 250280 ............... T280 250281 ............... T281 250282 ............... T282 250283 ............... T283 250284 ............... T284 250285 ............... T285 250286 ............... T286 250287 ............... T287 250288 ............... T288 250289 ............... T289 250290 ............... T290 250291 ............... T291 250292 ............... T292 250293 ............... T293 250294 ............... T294 250295 ............... T295 250296 ............... T296 250297 ............... T297 250298 ............... T298 250299 ............... T299 250300 ............... T300 250301 ............... T301 250302 ............... T302 250303 ............... T303 250304 ............... T304 250305 ............... T305 250306 ............... T306 250307 ............... T307 250308 ............... T308 250309 ............... T309 250310 ............... T310 250311 ............... T311 250312 ............... T312 250313 ............... T313 250314 ............... T314 250315 ............... T315 250316 ............... T316 250317 ............... T317 250318 ............... T318 250319 ............... T319 250320 ............... T320 250321 ............... T321 250322 ............... T322 250323 ............... T323 250324 ............... T324 250325 ............... T325 250326 ............... T326 250327 ............... T327 250329 ............... T329 Timing Belt Tensioners T43001............... T43001 T43002............... T43002 T43003............... T43003 T43004............... T43004 T43005............... T43005 T43006............... T43006 T43007............... T43007 T43008............... T43008 T43010............... T43010 PAREX TRANS. PARTS Timing Belts 013 ..................... T013 018 ..................... T018 020 ..................... T020 028 ..................... T028 032 ..................... T032 037 ..................... T037 041 ..................... T041 043 ..................... T043 062 ..................... T062 065 ..................... T065 067 ..................... T067 068 ..................... T068 069 ..................... T069 070 ..................... T070 071 ..................... T071 074 ..................... T074 075 ..................... T075 076 ..................... T076 077 ..................... T077 078 ..................... T078 081 ..................... T081

PAREX TRANS. PARTS - Cont. Timing Belts - Cont. 087 ..................... T087 088 ..................... T088 093 ..................... T093 094 ..................... T094 095 ..................... T095 099 ..................... T099 104 ..................... T104 PEP BOYS (See DAYCO) PERFECT CIRCLE Timing Belts 9-100.................. T100 9-101.................. T101 9-102.................. T102 9-103.................. T103 9-104.................. T104 9-13.................... T013 9-14.................... T014 9-17.................... T017 9-18.................... T018 9-20.................... T020 9-28.................... T028 9-32.................... T032 9-36.................... T036 9-37.................... T037 9-39.................... T039 9-41.................... T041 9-43.................... T043 9-61.................... T061 9-62.................... T062 9-63.................... T073 9-64.................... T064 9-65.................... T065 9-67.................... T067 9-69.................... T069 9-70.................... T070 9-71.................... T071 9-74.................... T074 9-75.................... T075 9-76.................... T076 9-77.................... T077 9-78.................... T078 9-79.................... T079 9-81.................... T081 9-84.................... T084 9-87.................... T087 9-88.................... T088 9-89.................... T089 9-90.................... T090 9-91.................... T091 9-92.................... T092 9-93.................... T093 9-94.................... T094 9-96.................... T096 9-98.................... T098 9-99.................... T099 PERFECTION AM Timing Belts B0101................. T101 B0102................. T102 B0103................. T103 B0104................. T104 B0114................. T114 B0118................. T162 B013................... T013 B014................... T014 B017................... T017 B018................... T018 B020................... T020 B028................... T028 B032................... T032 B036................... T036 B037................... T037 B039................... T039 B041................... T041 B043................... T043 B061................... T061 B062................... T062 B063................... T073 B064................... T064 B065................... T065 B067................... T067 B069................... T069 B070................... T070 B071................... T071 B074................... T074 B075................... T075 B076................... T076 B077................... T077

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797

PERFECTION AM - Cont. Timing Belts - Cont. B078................... T078 B081................... T081 B082................... T082 B083................... T083 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B093................... T093 B094................... T094 B095................... T095 B099................... T099 013 ..................... T013 014 ..................... T014 017 ..................... T017 018 ..................... T020 037 ..................... T037 039 ..................... T039 PETRO-CANADA Timing Belts 742-P014............ T014 742-P017............ T017 742-P028............ T028 742-P061............ T061 742-P067............ T067 742-P071............ T071 PIRELLI Timing Belts TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB020................. T020 TB028................. T028 TB032................. T032 TB036................. T036 TB037................. T037 TB039................. T039 TB041................. T041 TB042................. T068 TB043................. T043 TB061................. T061 TB062................. T062 TB063................. T073 TB064................. T064 TB065................. T065 TB067................. T067 TB069................. T069 TB070................. T070 TB071................. T071 TB074................. T074 TB075................. T075 TB076................. T076 TB077................. T077 TB078................. T078 TB081................. T081 TB082................. T082 TB083................. T083 TB087................. T087 TB088................. T088 TB089................. T158 TB090................. T159 TB093................. T093 TB094................. T160 TB095................. T095 TB099................. T161 TB101................. T101 TB102................. T102 TB103................. T103 TB104................. T104 TB112................. T176 TB113................. T113 TB114................. T114 TB115................. T299 TB116................. T300 TB117................. T117 TB118................. T162 TB119................. T119 TB122................. T122 TB124................. T124 TB125................. T125 TB126................. T237 TB127................. T127 TB128................. T128 TB129................. T129 TB130................. T130 TB131................. T131 TB132................. T132 TB133................. T292

PIRELLI - Cont. Timing Belts - Cont. TB134................. TB135................. TB136................. TB138................. TB139................. TB141................. TB142................. TB143................. TB144................. TB145................. TB146................. TB147................. TB148................. TB153................. TB154................. TB155................. TB157................. TB158................. TB159................. TB160................. TB161................. TB162................. TB163................. TB164................. TB165................. TB166................. TB167................. TB168................. TB169................. TB170................. TB172................. TB176................. TB177................. TB179................. TB180................. TB183................. TB184................. TB185................. TB186................. TB187................. TB190................. TB191................. TB192................. TB193................. TB194................. TB199................. TB201................. TB202................. TB205................. TB210................. 80013 ................. 80014 ................. 80017 ................. 80018 ................. 80020 ................. 80028 ................. 80032 ................. 80037 ................. 80039 ................. 80041 ................. 80042 ................. 80043 ................. 80061 ................. 80062 ................. 80064 ................. 80065 ................. 80067 ................. 80069 ................. 80070 ................. 80071 ................. 88013 ................. 88014 ................. 88017 ................. 88018 ................. 88020 ................. 88028 ................. 88032 ................. 88037 ................. 88039 ................. 88041 ................. 88042 ................. 88043 ................. 88061 ................. 88062 ................. 88063 ................. 88064 ................. 88065 ................. 88067 ................. 88069 ................. 88070 ................. 88071 ................. 88074 ................. T134 T135 T233 T199 T139 T141 T142 T143 T144 T145 T146 T147 T148 T153 T154 T155 T157 T158 T159 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T254 T176 T177 T179 T180 T183 T184 T185 T186 T187 T190 T191 T192 T193 T194 T199 T201 T248 T205 T210 T013 T014 T017 T018 T020 T028 T032 T037 T039 T041 T068 T043 T061 T062 T064 T065 T067 T069 T070 T071 T013 T014 T017 T018 T020 T028 T032 T037 T039 T041 T068 T043 T061 T062 T073 T064 T065 T067 T069 T070 T071 T074

PIRELLI - Cont. Timing Belts - Cont. 88075 ................. T075 88076 ................. T076 88077 ................. T077 88078 ................. T078 88081 ................. T081 88082 ................. T082 88083 ................. T083 88087 ................. T087 88088 ................. T088 88089 ................. T158 88090 ................. T159 88093 ................. T093 88094 ................. T160 88095 ................. T095 88099 ................. T161 88101 ................. T101 88102 ................. T102 88104 ................. T104 88112 ................. T176 88113 ................. T113 88114 ................. T114 88115 ................. T299 88116 ................. T300 88117 ................. T117 88118 ................. T162 88122 ................. T122 88124 ................. T124 88125 ................. T125 88126 ................. T237 88130 ................. T130 88131 ................. T131 88132 ................. T132 88134 ................. T134 88136 ................. T233 88138 ................. T199 88141 ................. T141 88143 ................. T143 88144 ................. T144 88146 ................. T146 88153 ................. T153 88157 ................. T157 88158 ................. T158 88159 ................. T159 88160 ................. T160 88161 ................. T161 88162 ................. T162 88163 ................. T163 88165 ................. T165 88170 ................. T170 PRO-1 Timing Belts 013 ..................... T013 014 ..................... T014 017 ..................... T017 037 ..................... T037 039 ..................... T039 061 ..................... T061 067 ..................... T067 081 ..................... T081 PROVEN VALU Timing Belts TB-013 ............... T013 TB-014 ............... T014 TB-017 ............... T017 TB-018 ............... T018 TB-020 ............... T020 TB-028 ............... T028 TB-032 ............... T032 TB-036 ............... T036 TB-037 ............... T037 TB-039 ............... T039 TB-041 ............... T041 TB-043 ............... T043 TB-061 ............... T061 TB-062 ............... T062 TB-063 ............... T073 TB-064 ............... T064 TB-065 ............... T065 TB-067 ............... T067 TB-068 ............... T068 TB-069 ............... T069 TB-070 ............... T070 TB-071 ............... T071 TB-073 ............... T073 TB-074 ............... T074 TB-075 ............... T075 TB-076 ............... T076 TB-077 ............... T077 TB-078 ............... T078

PROVEN VALU - Cont. Timing Belts - Cont. TB-079 ............... T079 TB-081 ............... T081 TB-082 ............... T082 TB-083 ............... T083 TB-084 ............... T084 TB-087 ............... T087 TB-088 ............... T088 TB-089 ............... T089 TB-090 ............... T090 TB-091 ............... T091 TB-092 ............... T092 TB-093 ............... T093 TB-094 ............... T094 TB-095 ............... T095 TB-096 ............... T096 TB-098 ............... T098 TB-099 ............... T099 TB-100 ............... T100 TB-101 ............... T101 TB-102 ............... T102 TB-103 ............... T103 TB-104 ............... T104 TB-112 ............... T112 TB-113 ............... T113 TB-114 ............... T114 TB-115 ............... T299 TB-116 ............... T300 TB-117 ............... T117 TB-118 ............... T118 TB-119 ............... T119 TB-121 ............... T121 TB-122 ............... T122 TB-123 ............... T123 TB-125 ............... T125 TB-126 ............... T126 TB-127 ............... T127 TB-128 ............... T128 TB-129 ............... T129 TB-130 ............... T130 TB-134 ............... T134 TB-139 ............... T139 REPCOPARTS Timing Belts 4013 ................... T013 4014 ................... T014 4017 ................... T017 4018 ................... T018 4020 ................... T020 4028 ................... T028 4029 ................... T104 4032 ................... T032 4036 ................... T036 4037 ................... T037 4039 ................... T039 4041 ................... T041 4042 ................... T068 4043 ................... T043 4061 ................... T061 4065 ................... T065 4070 ................... T070 4071 ................... T071 4073 ................... T073 4074 ................... T074 4077 ................... T077 4078 ................... T078 4079 ................... T079 4081 ................... T081 4082 ................... T082 4083 ................... T083 4084 ................... T084 4089 ................... T089 4091 ................... T091 4092 ................... T092 4093 ................... T093 4094 ................... T094 4095 ................... T095 4096 ................... T096 4097 ................... T097 4098 ................... T098 4099 ................... T099 4100 ................... T100 4101 ................... T101 4102 ................... T102 4103 ................... T103 4104 ................... T104 4106 ................... T106

REPUBLIC Timing Belts R0112................. T176 R0113................. T113 R0114................. T114 R0115................. T299 R0116................. T300 R0117................. T117 R0118................. T162 R0119................. T119 R0122................. T122 R0124................. T124 R0125................. T125 R0126................. T126 R0127................. T127 R0128................. T128 R0129................. T129 R0130................. T130 R0132................. T132 R0133................. T292 R0134................. T134 R0135................. T135 R0136................. T233 R0138................. T138 R0139................. T139 R0141................. T141 R0142................. T142 R0143................. T143 R0144................. T144 R0145................. T145 R0146................. T146 R0147................. T147 R0148................. T148 R0153................. T153 R0154................. T154 R0157................. T157 R0158................. T158 R0159................. T159 R0160................. T160 R0161................. T161 R0162................. T162 R0163................. T163 R0164................. T164 R0166................. T166 R0167................. T167 R0168................. T168 R0169................. T169 R0170................. T170 R0176................. T176 R0177................. T177 R0179................. T179 R0184................. T184 R0185................. T185 R0186................. T186 R0187................. T187 R082................... T082 R083................... T083 REPUBLIC PARTS Timing Belts R-0100 ............... T100 R-0101 ............... T101 R-0102 ............... T102 R-0103 ............... T103 R-0104 ............... T104 R-0112 ............... T112 R-013 ................. T013 R-014 ................. T014 R-017 ................. T017 R-018 ................. T018 R-020 ................. T020 R-028 ................. T028 R-032 ................. T032 R-036 ................. T036 R-037 ................. T037 R-039 ................. T039 R-041 ................. T041 R-042 ................. T068 R-043 ................. T043 R-061 ................. T061 R-062 ................. T062 R-063 ................. T073 R-064 ................. T064 R-065 ................. T065 R-067 ................. T067 R-068 ................. T068 R-069 ................. T069 R-070 ................. T070 R-071 ................. T071 R-073 ................. T073 R-074 ................. T074 R-075 ................. T075 R-076 ................. T075 R-077 ................. T077

798
Competitive No.

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Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

REPUBLIC PARTS - Cont. Timing Belts - Cont. R-078 ................. T078 R-079 ................. T079 R-081 ................. T081 R-084 ................. T084 R-087 ................. T087 R-088 ................. T088 R-089 ................. T089 R-090 ................. T090 R-091 ................. T091 R-092 ................. T092 R-093 ................. T093 R-094 ................. T094 R-095 ................. T095 R-096 ................. T096 R-098 ................. T098 R-099 ................. T099 ROCKHILL Timing Belts TB-100 ............... T100 TB-101 ............... T101 TB-102 ............... T102 TB-103 ............... T103 TB-104 ............... T104 TB-112 ............... T176 TB-118 ............... T118 TB-13 ................. T013 TB-14 ................. T014 TB-17 ................. T017 TB-18 ................. T018 TB-20 ................. T020 TB-28 ................. T028 TB-32 ................. T032 TB-36 ................. T036 TB-37 ................. T037 TB-39 ................. T039 TB-41 ................. T041 TB-43 ................. T043 TB-61 ................. T061 TB-62 ................. T062 TB-63 ................. T073 TB-64 ................. T064 TB-65 ................. T065 TB-67 ................. T067 TB-68 ................. T068 TB-69 ................. T069 TB-70 ................. T070 TB-71 ................. T071 TB-73 ................. T073 TB-74 ................. T074 TB-75 ................. T075 TB-76 ................. T076 TB-77 ................. T077 TB-78 ................. T078 TB-79 ................. T079 TB-81 ................. T081 TB-82 ................. T082 TB-83 ................. T083 TB-84 ................. T084 TB-87 ................. T087 TB-88 ................. T088 TB-89 ................. T158 TB-90 ................. T159 TB-91 ................. T091 TB-92 ................. T092 TB-93 ................. T093 TB-94 ................. T094 TB-95 ................. T095 TB-98 ................. T098 TB-99 ................. T161 SEALED POWER Timing Belts 222-100.............. T100 222-13................ T013 222-14................ T014 222-17................ T017 222-18................ T018 222-20................ T020 222-28................ T028 222-32................ T032 222-36................ T036 222-37................ T037 222-39................ T039 222-41................ T041 222-42................ T068 222-43................ T043 222-61................ T061 222-62................ T062 222-63................ T073 222-64................ T064

SEALED POWER - Cont. Timing Belts - Cont. 222-65................ 222-67................ 222-69................ 222-70................ 222-71................ 222-73................ 222-74................ 222-75................ 222-76................ 222-77................ 222-78................ 222-81................ 222-87................ 222-88................ 222-89................ 222-90................ 222-91................ 222-92................ 222-93................ 222-94................ 222-95................ 222-99................ 222B160............. 222B161............. 222B162............. 222B163............. 222B164............. 222B165............. 222B166............. 222B167............. 222B168............. 222B169............. 222B170............. 222B172............. 222B177............. 222B179............. 222B180............. 222B183............. 222B184............. 222B185............. 222B186............. 222B187............. 222B193............. 222B194............. 222B202............. 222B210............. 222013 ............... 222014 ............... 222017 ............... 222018 ............... 222020 ............... 222028 ............... 222032 ............... 222036 ............... 222037 ............... 222039 ............... 222041 ............... 222043 ............... 222061 ............... 222062 ............... 222063 ............... 222064 ............... 222065 ............... 222067 ............... 222069 ............... 222070 ............... 222071 ............... 222074 ............... 222075 ............... 222076 ............... 222077 ............... 222078 ............... 222082 ............... 222083 ............... 222087 ............... 222088 ............... 222089 ............... 222090 ............... 222093 ............... 222094 ............... 222095 ............... 222099 ............... 222101 ............... 222102 ............... 222103 ............... 222104 ............... 222107 ............... 222108 ............... 222110 ............... 222112 ............... 222113 ............... 222114 ............... T065 T067 T069 T070 T071 T073 T074 T075 T076 T077 T078 T081 T087 T088 T089 T090 T091 T092 T093 T094 T095 T161 T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T254 T177 T179 T180 T183 T184 T185 T186 T187 T193 T194 T248 T210 T013 T014 T017 T018 T020 T028 T032 T036 T037 T039 T041 T043 T061 T062 T073 T064 T065 T067 T069 T070 T071 T074 T075 T076 T077 T078 T082 T083 T087 T088 T158 T159 T093 T160 T095 T161 T101 T102 T103 T104 T107 T293 T196 T176 T113 T114

SEALED POWER - Cont. Timing Belts - Cont. 222115 ............... T299 222116 ............... T300 222117 ............... T117 222118 ............... T162 222119 ............... T119 222122 ............... T122 222124 ............... T124 222125 ............... T125 222126 ............... T237 222128 ............... T128 222129 ............... T129 222130 ............... T130 222131 ............... T131 222132 ............... T132 222133 ............... T292 222134 ............... T134 222135 ............... T135 222136 ............... T233 222138 ............... T199 222139 ............... T139 222141 ............... T141 222142 ............... T142 222143 ............... T143 222144 ............... T144 222145 ............... T145 222146 ............... T146 222147 ............... T147 222148 ............... T148 222152 ............... T152 222153 ............... T153 222154 ............... T154 222155 ............... T155 222157 ............... T157 222158 ............... T158 222159 ............... T159 SIERRA Timing Belts 18-4029.............. T032 SKF Timing Belt Tensioners VKM11000 ......... T41079 VKM11010 ......... T41080 VKM11113 ......... T43010 VKM16300 ......... T41081 VKM18100 ......... T41083 VKM51001 ......... T41002 VKM51003 ......... T41084 VKM54000 ......... T41006 VKM54001 ......... T41005 VKM54002 ......... T41008 VKM54003 ......... T43003 VKM61000 ......... T41001 VKM61001 ......... T41000 VKM64000 ......... T41007 VKM70001 ......... T43002 VKM71001 ......... T41068 VKM71003 ......... T41067 VKM71004 ......... T41075 VKM71007 ......... T41072 VKM71008 ......... T41078 VKM71100 ......... T41077 VKM71101 ......... T41070 VKM71201 ......... T41076 VKM71202 ......... T41066 VKM71400 ......... T41071 VKM71401 ......... T41074 VKM71404 ......... T41069 VKM71800 ......... T41073 VKM72000 ......... T41058 VKM72004 ......... T41059 VKM72200 ......... T41088 VKM72300 ......... T41089 VKM73000 ......... T41011 VKM73001 ......... T41015 VKM73002 ......... T41019 VKM73003 ......... T41018 VKM73004 ......... T41021 VKM73005 ......... T41023 VKM73006 ......... T41024 VKM73007 ......... T41022 VKM73011 ......... T41013 VKM73101 ......... T41017 VKM73200 ......... T41012 VKM73201 ......... T41016 VKM73600 ......... T41014 VKM73605 ......... T41090 VKM74000 ......... T41034 VKM74001 ......... T41035 VKM74002 ......... T41091

SKF - Cont. Timing Belt Tensioners - Cont. VKM74005 ......... T41036 VKM74007 ......... T41033 VKM74200 ......... T41030 VKM74201 ......... T41031 VKM74600 ......... T41029 VKM75000 ......... T41039 VKM75001 ......... T41051 VKM75002 ......... T41052 VKM75004 ......... T41048 VKM75006 ......... T41037 VKM75008 ......... T41045 VKM75033 ......... T41044 VKM75044 ......... T41047 VKM75064 ......... T41054 VKM75100 ......... T41042 VKM75101 ......... T41055 VKM75108 ......... T41056 VKM75113 ......... T41053 VKM75119 ......... T41057 VKM75130 ......... T41043 VKM75144 ......... T41046 VKM75601 ......... T41050 VKM75612 ......... T41049 VKM75613 ......... T41038 VKM76001 ......... T41065 VKM76200 ......... T41010 VKM76202 ......... T41064 VKM76203 ......... T41009 VKM77300 ......... T41003 VKM77500 ......... T41004 VKM78000 ......... T41063 VKM78001 ......... T41062 VKM78002 ......... T41061 VKM78003 ......... T41092 VKM78105 ......... T41060 VKM79000 ......... T41026 VKM79001 ......... T41025 VKM79007 ......... T41028 Timing Belt Pulleys VKM64001 ......... T42032 VKM64002 ......... T42033 VKM64003 ......... T42034 VKM64004 ......... T42035 VKM64005 ......... T42036 VKM81000 ......... T42030 VKM81001 ......... T42026 VKM81004 ......... T42025 VKM81005 ......... T42031 VKM81007 ......... T42037 VKM81100 ......... T42027 VKM81200 ......... T42028 VKM81400 ......... T42029 VKM82000 ......... T42021 VKM82001 ......... T41085 VKM82501 ......... T42020 VKM83003 ......... T42038 VKM84000 ......... T42008 VKM84001 ......... T42010 VKM84002 ......... T42009 VKM84003 ......... T42013 VKM84004 ......... T42012 VKM84005 ......... T42007 VKM84006 ......... T42006 VKM84007 ......... T42011 VKM84201 ......... T42005 VKM84600 ......... T42003 VKM84601 ......... T42004 VKM85000 ......... T42017 VKM85002 ......... T42018 VKM88000 ......... T42023 VKM88001 ......... T42024 VKM88002 ......... T42022 VKM89000 ......... T42002 SUNOCO Timing Belts TB063................. T073 TB070................. T070 TB077................. T077 TB401................. T014 TB402................. T013 TB403................. T037 TB404................. T017 TB409................. T039 TB411................. T041 TB415................. T028 TB418................. T061 TB428................. T067 T1043................. T043 T1064................. T064

SUNOCO - Cont. Timing Belts - Cont. T1071................. T071 T1081................. T081 T.R.W. Timing Belts LB042................. T068 LB074................. T074 LB075................. T075 LB077................. T077 LB078................. T078 LB079................. T079 LB081................. T081 LB082................. T082 LB083................. T083 LB084................. T084 LB087................. T087 LB088................. T088 LB090................. T090 LB091................. T091 LB092................. T092 LB093................. T093 LB094................. T094 LB095................. T095 LB100................. T100 LB101................. T101 LB102................. T102 LB103................. T103 LB104................. T104 LB112................. T112 LB113................. T113 LB114................. T114 LB115................. T299 LB116................. T300 LB117................. T117 LB118................. T162 LB119................. T119 LB121................. T121 LB122................. T122 LB123................. T123 LB124................. T124 LB125................. T125 LB126................. T237 LB128................. T128 LB129................. T129 LB13................... T013 LB130................. T130 LB132................. T132 LB134................. T134 LB136................. T233 LB137................. T137 LB138................. T199 LB139................. T139 LB14................... T014 LB141................. T141 LB142................. T142 LB143................. T143 LB144................. T144 LB146................. T146 LB148................. T148 LB149................. T149 LB150................. T150 LB151................. T151 LB153................. T153 LB155................. T155 LB157................. T157 LB158................. T158 LB159................. T159 LB160................. T160 LB161................. T161 LB163................. T163 LB164................. T164 LB165................. T165 LB166................. T166 LB167................. T167 LB168................. T168 LB169................. T169 LB17................... T017 LB18................... T018 LB20................... T020 LB28................... T028 LB32................... T032 LB36................... T036 LB37................... T037 LB39................... T039 LB41................... T041 LB43................... T043 LB61................... T061 LB62................... T062 LB63................... T073 LB64................... T064 LB65................... T065

Changeover Listing - PowerGrip Timing System Products


Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No. Competitive No. Gates No.

799

T.R.W. - Cont. Timing Belts - Cont. LB67................... T067 LB68................... T068 LB69................... T069 LB70................... T070 LB71................... T071 LB73................... T073 LB74................... T074 LB75................... T075 LB76................... T076 LB77................... T077 LB78................... T078 LB79................... T079 LB81................... T081 LB82................... T082 LB83................... T083 LB84................... T084 LB87................... T087 LB88................... T088 LB89................... T158 LB90................... T159 LB91................... T091 LB92................... T092 LB93................... T093 LB94................... T160 LB95................... T095 LB96................... T096 LB98................... T098 LB99................... T161 TEXACO Timing Belts TB401................. T014 TB402................. T013 TB403................. T037 TB404................. T017 TB409................. T039 TB411................. T041 TB415................. T028 ULTRALAST Timing Belts B013................... T013 B014................... T014 B017................... T017 B028................... T028 B032................... T032 B036................... T036 B037................... T037 B039................... T039 B041................... T041 B043................... T043 B061................... T061 B064................... T064 B067................... T067 B070................... T070 B071................... T071 B073................... T073 B074................... T074 B077................... T077 B078................... T078 B081................... T081 B087................... T087 B088................... T088 B089................... T089 B090................... T090 B094................... T094 B095................... T095 B099................... T099 B101................... T101 B104................... T104 B112................... T112 B113................... T113 B114................... T114 B116................... T300 B117................... T117 B118................... T118 B122................... T122 B124................... T124 B125................... T125 B126................... T126 B128................... T128 B129................... T129 B130................... T130 B132................... T132 B134................... T134 B136................... T136 B138................... T138 B139................... T139 B141................... T141 B142................... T142 B143................... T143

ULTRALAST - Cont. Timing Belts - Cont. B145................... T145 B146................... T146 B147................... T147 B148................... T148 B153................... T153 B154................... T154 B155................... T155 B157................... T157 B158................... T158 B159................... T159 B160................... T160 B161................... T161 B162................... T162 B163................... T163 B164................... T164 B166................... T166 B167................... T167 B168................... T168 B172................... T172 B177................... T177 B179................... T179 B184................... T184 B185................... T185 B186................... T186 B187................... T187 B191................... T191 B194................... T194 B199................... T199 B233................... T233 B236................... T236 B32..................... T032 TB063................. T073 TB070................. T070 TB077................. T077 TB401................. T014 TB402................. T013 TB403................. T037 TB404................. T017 TB409................. T039 TB411................. T041 TB415................. T028 TB418................. T061 TB428................. T067 T013................... T013 T014................... T014 T017................... T017 T028................... T028 T032................... T032 T037................... T037 T039................... T039 T041................... T041 T043................... T043 T061................... T061 T063................... T073 T064................... T064 T067................... T067 T070................... T070 T071................... T071 T073................... T073 T077................... T077 T081................... T081 T087................... T087 T089................... T089 T092................... T092 T094................... T094 T099................... T099 T1043................. T043 T1064................. T064 T1071................. T071 T1081................. T081 T115................... T299 T203................... T203 T210................... T210 T228................... T228 UNIROYAL Timing Belts A206L050........... T062 A206L050S ........ T090 A315L075........... T028 A326L134B ........ T075 A330L075........... T070 A345L075........... T073 A356L075........... T041 A363L100........... T067 A367L075........... T078 A371L060........... T037 A371L075........... T039 A375L075........... T061 A397L075........... T077 A408L075........... T088

UNIROYAL - Cont. Timing Belts - Cont. A416L075R ........ T081 A423L075........... T065 A435L075........... T018 A442L075........... T069 A443L075........... T069 A450L075........... T064 A450L075S ........ T093 A453L075........... T017 A457L075........... T013 A457L075S ........ T158 A461L075........... T032 A465L100........... T071 A483L087........... T014 A484L088........... T014 A502L118B ........ T076 A506L100B ........ T043 A521L100........... T087 A532L100........... T074 A547L075........... T020 A555L075........... T068 UNOCAL Timing Belts TB063................. T073 TB070................. T070 TB077................. T077 TB401................. T014 TB402................. T013 TB403................. T037 TB404................. T017 TB409................. T039 TB411................. T041 TB415................. T028 TB418................. T061 TB428................. T067 T013................... T013 T014................... T014 T017................... T017 T028................... T028 T032................... T032 T037................... T037 T039................... T039 T041................... T041 T043................... T043 T061................... T061 T063................... T073 T064................... T064 T067................... T067 T070................... T070 T071................... T071 T073................... T073 T077................... T077 T081................... T081 T094................... T094 T1043................. T043 T1064................. T064 T1071................. T071 T1081................. T081 VERA Timing Belts A326L134B ........ T075 45-00070............ T062 45-00096............ T062 45-00724............ T028 45-00732............ T036 45-00740............ T020 45-00773............ T032 45-00781............ T018 45-00799............ T014 45-00807............ T013 45-00815............ T043 45-00823............ T017 45-00849............ T065 45-00856............ T069 45-00864............ T070 45-00930............ T073 45-00948............ T064 45-00955............ T041 45-01051............ T082 45-01069............ T083 45-01127............ T076 45-01135............ T075 45-01150............ T078 45-01168............ T077 45-01176............ T074 45-01200............ T107 45-01226............ T158 45-01234............ T091 45-01267............ T106 45-01275............ T196

VERA - Cont. Timing Belts - Cont. 45-01283............ T088 45-01291............ T087 45-01325............ T104 45-01341............ T099 45-01366............ T094 45-01382............ T093 45-01408............ T062 45-01424............ T100 45-01440............ T103 45-01481............ T090 45-01499............ T092 45-01580............ T127 45-01614............ T293 45-01622............ T292 45-01630............ T118 45-01648............ T095 45-01655............ T137 45-01663............ T300 45-01671............ T299 45-01689............ T131 45-01697............ T135 45-01705............ T136 45-01713............ T176 45-01721............ T126 45-01739............ T101 45-01754............ T138 45-01762............ T129 45-01770............ T071 45-01788............ T122 45-01796............ T141 45-01804............ T134 45-01812............ T113 45-01820............ T117 45-01838............ T124 45-01853............ T121 45-01861............ T140 45-01879............ T147 45-01887............ T102 45-01895............ T119 45-01911............ T152 45-01945............ T187 45-01952............ T186 45-01960............ T143 45-01978............ T145 45-01986............ T144 45-01994............ T142 45-02009............ T124 45-02017............ T169 45-02025............ T149 45-02033............ T146 45-02041............ T155 45-02066............ T167 45-02074............ T168 45-02082............ T139 45-02090............ T300 45-02108............ T299 45-02116............ T164 45-02124............ T157 45-02140............ T199 45-02157............ T154 45-02199............ T127 45-02215............ T128 45-05074............ T168 WESTERN AUTO Timing Belts 74-2736-2........... T067 74-2737-0........... T061 74-2738-8........... T039 74-2739-6........... T037 74-2741-2........... T013 74-2742-0........... T014 74-2743-8........... T017 74-2744-6........... T071 WOLVERINE Timing Belts TB013................. T013 TB014................. T014 TB017................. T017 TB018................. T018 TB020................. T020 TB028................. T028 TB032................. T032 TB036................. T036 TB037................. T037 TB039................. T039 TB041................. T041 TB043................. T043 TB061................. T061 TB062................. T062

WOLVERINE - Cont. Timing Belts - Cont. TB063................. T073 TB064................. T064 TB067................. T067 TB069................. T069 TB070................. T070 TB071................. T071 TB073................. T073 TB077................. T077 TB078................. T078 TB081................. T081 TB095................. T095 WORLD PARTS Timing Belts W11-600............. T018 W11-601............. T020 W11-631............. T075 W11-636............. T013 W11-639............. T013 W11-640............. T076 W11-643............. T017 W11-645............. T020 W11-651............. T028 W11-654............. T041 W11-655............. T014 W11-657............. T036 W11-658............. T032 W11-659............. T043 W11-660............. T064 W11-661............. T062 W11-665............. T070 W11-669............. T073 W11-670............. T065 W11-673............. T068 W16-801............. T079 W16-802............. T084 W16-803............. T078 W16-804............. T087 W16-805............. T101 W16-807............. T090 W16-808............. T158 W16-811............. T083 W16-812............. T082 W16-814............. T299 W16-815............. T094 W16-816............. T300

800

Manufacturers Part Numbers PowerGrip Timing System Products


Showing Factory Part Numbers for Timing Belts, Tensioners and Pulleys With the Corresponding PowerGrip Replacement Numbers
Gates No. T090 T090 T264 T028 T185 T185 T185 T185 T185 T185 T141 T179 T179 T179 T179 T179 T179 T141 T141 T123 T123 T123 T141 T141 T41030 T41030 T41030 T141 T141 T149 T149 T149 T41031 T41031 T42005 T42005 T42005 T165 T099 T099 T013 T41005 T014 T014 T014 T014 T014 T129 T067 T067 T194 T067 T067 T067 T103 T102 T41006 T41006 T067 T014 T142 T092 T091 T014 T141 T141 T141 T077 T248 T41031 T179 T41029 T020 T020 T142 T088 T113 T113 T113 T088 T088 Mfr. Part No. FE0212205.......... FE0312205.......... FE03122050........ FE0412205.......... FE04122050........ FE0612205.......... FE0812205.......... FE08122050........ FE0912205.......... FE09122050........ FE1H12205A....... FE1H12700A....... FE1H12730 ......... FE1H12730A....... FE1J12205.......... FE3N12730 ......... FE7912205.......... FE7915205.......... FP0112205A ....... FSY112205 ......... FS0112205A ....... FS0112700A ....... FS0112700B ....... FS0112730A ....... FS0212205.......... F0BZ 6268 A ...... F0CZ 6K 254A.... F0EE 6K 254AA . F1ZZ 6268 A ...... F17E 6268 AA .... F2CE 6268 AA ... F2Y112205.......... F20212205 .......... F20312205 .......... F21012205 .......... F3BZ 6268 A ...... F3CZ 6268 A ...... F3DZ 6268 A ...... F3XY 6268 A ...... F32Z 6268 A....... F32Z 6268 B....... F37E 6268 AA .... F4BZ 6268 A ...... F4XY 6268 A ...... F42Z 6268 A....... F47E 6268 AA .... F47Z 6268 B....... F5CE 6268 AA ... F5RZ 6K 254A.... F5RZ 6268 A ...... F50112700A........ F50112730A........ F50512700B........ F57E 6K 254AA.. F57E 6268 AA .... F57E 6268 BB .... F57Z 6K 254A .... F57Z 6268 A....... F7CZ 6268 AA.... F8CZ 6K 254AA . F8CZ 6268 AA.... F80112205 .......... F80212205 .......... F80512700 .......... F80512700A........ F80512700C ....... F9JY 6268 A....... GC01201200....... GC01201201....... GTB1208............. GTB1237............. HM8268BA.......... JE1512730 .......... JE1512730A........ JE1512730D ....... JE1512750 .......... JE1512750A........ JE2612205 .......... JE2612205A........ JE2612205B........ JE26122050 ........ JE2612730A........ Gates No. T088 T113 T113 T113 T113 T117 T117 T113 T117 T113 T264 T41029 T42003 T42003 T264 T42004 T113 T113 T316 T228 T228 T41091 T41091 T42008 T228 T185 T41007 T41007 T210 T210 T194 T134 T134 T134 T134 T185 T179 T248 T104 T228 T214 T210 T185 T249 T228 T210 T210 T283 T41008 T258 T41091 T42008 T41091 T41005 T276 T276 T41005 T276 T283 T43003 T294 T077 T077 T41035 T41035 T41035 T179 T068 T068 T129 T142 T013 T42011 T42011 T42011 T41033 T41033 T183 T183 T183 T183 T42006 Mfr. Part No. JE2612740 .......... JE2612740A........ JE2612750 .......... JE4812730 .......... JE4812740 .......... JF0112205 .......... JF0112205A........ JF0112205D........ JF0112730 .......... JF0112730A........ JF0112750 .......... J0856351 ............ KJ0112205 .......... KLY212SJ0 ......... KL0112205.......... KL0112730.......... KL0112730A ....... KL0112740.......... KL0112750.......... KL0212750.......... KL0212750A ....... K0AA352700 ....... K0BA352700 ....... LHN100420L ....... LNH100410L ....... MBP0112205B K ia ....................... MBP0112205B M itsubishi ............. MB6S712205C.... MD008960........... MD008961........... MD008965........... MD008968........... MD008969........... MD009277........... MD009352........... MD009650........... MD009651........... MD009666........... MD009667........... MD011536........... MD013805........... MD015310........... MD015311........... MD015701........... MD030599........... MD030600........... MD030605........... MD030610........... MD040754........... MD040756........... MD040797........... MD041390........... MD041407........... MD050119........... MD050125........... MD050130........... MD050135........... MD050175........... MD060461........... MD068173........... MD095866........... MD098491........... MD098492........... MD098706........... MD099706........... MD099707........... MD099708........... MD100103........... MD100619........... MD100620........... MD100632........... MD100679........... MD100814........... MD102248........... MD102249........... MD104578........... MD106103........... MD109958........... MD110029........... MD110041........... Gates No. T42007 T42007 T41036 T42012 T42013 T146 T146 T146 T42011 T42011 T41033 T140 T267 T41034 T214 T42010 T42010 T42009 T41034 T41034 T41034 T248 T248 T326 T327
T185

Mfr. Part No. ADO41407 .......... AD041407 ........... A405RU100......... BNP2955............. BPY112205 ......... BP0112205 ......... BP0112205A ....... BP0112205B ....... BP0212205 ......... BP0212205A ....... B10112205A ....... B59712205.......... B6S712205A ....... B6S712205B ....... B6S712205C Kia B6S712205C Ma zda .................... B6S712205D....... B6Y212205 ......... B63012205.......... B63012205A ....... B63012205B ....... B63012205C ....... B63012205D ....... B63012205E ....... B63012700C ....... B63012700D ....... B63012700E ....... B63212205.......... B632122050........ B66012205.......... B66012205B ....... B66012205C ....... B66012700D ....... B66012700E ....... B66012730A ....... B66012730B ....... B66012730C ....... C3905942............ DBP4131............. DBP9289............. D1FZ 6268 A ...... D4FZ 6K 254A.... D4FZ 6268 A ...... D4ZE 6268 AE ... D42E 6268 AB.... D8EE 6268 AA ... D9EE 6268 AA ... ECP244............... E1EE 6268 DA ... E1FZ 6268 D ...... E2CE 6268 AA ... E2EE 6268 AA ... E3EE 6268 AA ... E3FZ 6268 A ...... E43Z 6268 B ...... E43Z 6268 C ...... E5EE 6K 254AA . E5FZ 6K254 A.... E5FZ 6268 A ...... E5RE 6268 AA ... E5RE 8286 AA ... E5TZ 6268 A ...... E5TZ 6268 B ...... E5ZZ 6268 A ...... E7GZ 6268 A...... E7GZ 6268 B...... E7GZ 6268 C ..... E80112205.......... E9DZ 6268 A...... E9JY 6K 254A .... E9JY 6268 A ...... E92Z 6K 254A .... FC01201202 ....... FC01201203 ....... FDU1464............. FEO1122050....... FEY812205 ......... FEY8122050 ....... FEY912205 ......... FE0112205.......... FE01122050........

Mfr. Part No. MD110709........... MD111427........... MD113561........... MD113562........... MD113563........... MD113564........... MD113790........... MD115976........... MD115977........... MD120487........... MD121993........... MD128765........... MD129033........... MD129355........... MD133115........... MD133116........... MD134377........... MD13805............. MD140070........... MD140071........... MD140227........... MD140228........... MD140229........... MD145713........... MD145714........... MD145716........... MD145813........... MD146186........... MD151447........... MD152243........... MD152622........... MD154243........... MD156604........... MD160103........... MD161427........... MD171748........... MD171749........... MD175375........... MD176387........... MD182195........... MD182201........... MD182291........... MD182292........... MD182293........... MD182294........... MD182295 Chrys ler ...................... MD182295 Mitsu bishi................... MD182537........... MD183005........... MD183006........... MD185544........... MD189522........... MD191982........... MD192068........... MD193874........... MD193875........... MD199418........... MD307487........... MD315265........... MD319022........... MD322641........... MD325854........... MD326059........... MD336149........... MD340625........... MO4667611 ........ OHC013 .............. OHC014 .............. OHC017 .............. OHC018 .............. OHC020 .............. OHC028 .............. OHC032 .............. OHC036 .............. OHC037 .............. OHC039 .............. OHC041 .............. OHC043 .............. OHC061 .............. OHC062 ..............

Gates No. T124 T139 T064 T013 T073 T128 T158 T41047 T168 T155 T42017 T41045 T41044 T41046 T167 T165 T091 T093 T195 T41039 T155 T158 T124 T167 T165 T168 T191 T41051 T42018 T159 T092 T204 T42017 T090 T195 T167 T168 T41052 T201 T168 T165 T167 T256 T232 T230 T168
T168

Mfr. Part No. OHC064 .............. OHC065 .............. OHC067 .............. OHC068 .............. OHC069 .............. OHC070 .............. OHC071 .............. OHC073 .............. OHC074 .............. OHC075 .............. OHC076 .............. OHC077 .............. OHC078 .............. OHC079 .............. OHC081 .............. OHC082 .............. OHC083 .............. OHC084 .............. OHC087 .............. OHC088 .............. OHC089 .............. OHC090 .............. OHC091 .............. OHC092 .............. OHC093 .............. OHC094 .............. OHC095 .............. OHC096 .............. OHC097 .............. OHC098 .............. OHC099 .............. OHC100 .............. OHC101 .............. OHC102 .............. OHC103 .............. OHC104 .............. OHC106 .............. OHC107 .............. OHC112 .............. OHC113 .............. OHC114 .............. OHC117 .............. OHC118 .............. OHC119 .............. OHC120 .............. OHC121 .............. OHC122 .............. OHC123 .............. OHC124 .............. OHC125 .............. OHC126 .............. OHC127 .............. OHC128 .............. OHC129 .............. OHC130 .............. OHC131 .............. OHC132 .............. OHC134 .............. OHC135 .............. OHC136 .............. OHC137 .............. OHC138 .............. OHC139 .............. OHC140 .............. OHC141 .............. OHC142 .............. OHC143 .............. OHC144 .............. OHC145 .............. OHC146 .............. OHC147 .............. OHC148 .............. OHC149 .............. OHC150 .............. OHC151 .............. OHC152 .............. OHC153 .............. OHC154 .............. OHC155 .............. OHC157 .............. OHC158 .............. OHC159 ..............

Gates No. T064 T065 T067 T068 T069 T070 T071 T073 T074 T075 T076 T077 T078 T079 T081 T082 T083 T084 T087 T088 T089 T090 T091 T092 T093 T094 T095 T096 T097 T098 T099 T100 T101 T102 T103 T104 T106 T107 T112 T113 T114 T117 T118 T119 T120 T121 T122 T123 T124 T125 T126 T127 T128 T129 T130 T131 T132 T134 T135 T136 T137 T138 T139 T140 T141 T142 T143 T144 T145 T146 T147 T148 T149 T150 T151 T152 T153 T154 T155 T157 T158 T159

T185 T179 T013 T062 T41055 T013 T062 T064 T013 T41057 T062 T064 T064 T41043 T093 T093 T159 T089 T073 T073 T41042 T073 T41053 T062 T062 T158 T159 T092 T41049 T091 T41050 T092 T091 T124 T093 T089 T124 T073 T073 T091 T090 T090 T064 T013 T062 T139 T128 T093 T158 T41048 T159 T41056 T167 T165

T41054 T195 T253 T41038 T229 T288 T41038 T195 T253 T165 T259 T41052 T42018 T287 T289 T167 T232 T289 T246 T013 T014 T017 T018 T020 T028 T032 T036 T037 T039 T041 T043 T061 T062

Interference engine application.

Manufacturers Part Numbers - PowerGrip Timing System Products


Mfr. Part No. OHC160 .............. OHC161 .............. OHC162 .............. OHC163 .............. OHC164 .............. OHC165 .............. OHC166 .............. OHC167 .............. OHC168 .............. OHC169 .............. OHC170 .............. OHC171 .............. OHC172 .............. OHC173 .............. OHC174 .............. OHC176 .............. OHC177 .............. OHC178 .............. OHC179 .............. OHC180 .............. OHC181 .............. OHC182 .............. OHC183 .............. OHC184 .............. OHC185 .............. OHC186 .............. OHC187 .............. OHC188 .............. OHC189 .............. OHC190 .............. OHC191 .............. OHC192 .............. OHC193 .............. OHC194 .............. OHC195 .............. OHC196 .............. OHC197 .............. OHC198 .............. OHC199 .............. OHC200 .............. OHC201 .............. OHC203 .............. OHC204 .............. OHC205 .............. OHC206 .............. OHC207 .............. OHC208 .............. OHC209 .............. OHC210 .............. OHC211 .............. OHC212 .............. OHC213 .............. OHC214 .............. OHC215 .............. OHC216 .............. OHC217 .............. OHC218 .............. OHC219 .............. OHC220 .............. OHC221 .............. OHC222 .............. OHC223 .............. OHC224 .............. OHC225 .............. OHC226 .............. OHC227 .............. OHC228 .............. OHC229 .............. OHC230 .............. OHC232 .............. OHC233 .............. OHC234 .............. OHC235 .............. OHC236 .............. OHC237 .............. OHC239 .............. OHC240 .............. OHC241 .............. OHC242 .............. OHC243 .............. OHC244 .............. OHC245 .............. OHC246 .............. OHC247 .............. OHC248 .............. OHC249 .............. OHC251 .............. OHC252 .............. OHC253 .............. OHC254 .............. OHC255 .............. OHC256 .............. OHC257 .............. OHC258 .............. OHC259 .............. OHC260 .............. Gates No. T160 T161 T162 T163 T164 T165 T166 T167 T168 T169 T170 T171 T172 T173 T174 T176 T177 T178 T179 T180 T181 T182 T183 T184 T185 T186 T187 T188 T189 T190 T191 T192 T193 T194 T195 T196 T197 T198 T199 T200 T201 T203 T204 T205 T206 T207 T208 T209 T210 T211 T212 T213 T214 T215 T216 T217 T218 T219 T220 T221 T222 T223 T224 T225 T226 T227 T228 T229 T230 T232 T233 T234 T235 T236 T237 T239 T240 T241 T242 T243 T244 T245 T246 T247 T248 T249 T251 T252 T253 T254 T255 T256 T257 T258 T259 T260 Mfr. Part No. OHC262 .............. OHC263 .............. OHC264 .............. OHC265 .............. OHC266 .............. OHC267 .............. OHC269 .............. OHC270 .............. OHC271 .............. OHC272 .............. OHC273 .............. OHC274 .............. OHC275 .............. OHC276 .............. OHC277 .............. OHC278 .............. OHC279 .............. OHC280 .............. OHC281 .............. OHC282 .............. OHC283 .............. OHC284 .............. OHC285 .............. OHC286 .............. OHC287 .............. OHC288 .............. OHC289 .............. OHC290 .............. OHC291 .............. OHC292 .............. OHC293 .............. OHC294 .............. OHC295 .............. OHC296 .............. OHC297 .............. OHC298 .............. OHC299 .............. OHC300 .............. OHC301 .............. OHC302 .............. OHC303 .............. OHC304 .............. OHC305 .............. OHC306 .............. OHC307 .............. OHC308 .............. OHC309 .............. OHC310 .............. OHC311 .............. OHC312 .............. OHC313 .............. OHC314 .............. OHC315 .............. OHC316 .............. OHC317 .............. OHC318 .............. OHC319 .............. OHC320 .............. OHC321 .............. OHC322 .............. OHC323 .............. OHC324 .............. OHC325 .............. OHC326 .............. OHC327 .............. OHC329 .............. OJE2612730A Ki a ........................ OJE2612730A M azda .................. OJE2612740A..... OJE2612750 Kia. OJE2612750 Ma zda .................... OK24712700 ....... OK90012700 ....... OK93712700A..... OK93712730 ....... OK95412730 ....... OK95512730A..... OK97212205 ....... OK97212700 ....... OK97212700A..... OK97212730 ....... OK97312700 ....... RF0312205 ......... RF03122050 ....... RF0312206A ....... RF4312205 ......... RF7112205 ......... RF7912205 ......... R1463635109...... T0718752 ............ T0718836 ............ T0729581 ............ T830 .................... Gates No. T262 T263 T264 T265 T266 T267 T269 T270 T271 T272 T273 T274 T275 T276 T277 T278 T279 T280 T281 T282 T283 T284 T285 T286 T287 T288 T289 T290 T291 T292 T293 T294 T295 T296 T297 T298 T299 T300 T301 T302 T303 T304 T305 T306 T307 T308 T309 T310 T311 T312 T313 T314 T315 T316 T317 T318 T319 T320 T321 T322 T323 T324 T325 T326 T327 T329 T42006 T42006 T42007 T41036 T41036 T41032 T41035 T41031 T42005 T42004 T42004 T264 T41029 T41029 T42004 T41029 T103 T103 T102 T103 T103 T103 T140 T119 T140 T140 T264 Mfr. Part No. XHM460 .............. XS4Z 6M 250AA. XS4Z 6M 250BA. YF0912205.......... ZZM112205......... ZZM312205......... Z50112205 .......... Z50212205 .......... 0B59712205........ 0K24712205........ 0K24712700........ 0K30E12205 ....... 0K95412205........ 0K97212205........ 0060562106 ........ 026109243 .......... 026109243E........ 026109243L ........ 027109119A........ 027109119C........ 028109119D........ 028109119K........ 028109119M ....... 028109119P........ 028109243E........ 028109243F ........ 034109119 .......... 034109119A........ 03510911 ............ 035109119 .......... 037109119C........ 038109119 .......... 038109119B........ 038109119D........ 038109119M ....... 038109243N........ 048109119D........ 054109119A........ 054109119E........ 054109119G ....... 054109119H........ 056109119A........ 056109243D........ 058109119A........ 058109119B........ 058109119C........ 058109119D........ 06A109119C ....... 06A109479A ....... 06A109479B ....... 06A109479C ....... 06B109119A ....... 06B109119B ....... 06B109119F........ 06141PH9305 ..... 06141679305 ...... 068109119 .......... 068109119A........ 068109119E........ 068109243F ........ 069109119A........ 069130113A........ 074109119 .......... 075RH200 ........... 075109119B........ 077109119B........ 077109119C........ 077109119D........ 077109119E........ 078109119A........ 078109119C........ 078109119D........ 078109119G ....... 078109119H........ 081616 ................ 081619 ................ 081629 ................ 081632 ................ 081640 ................ 088AG19 ............. 09128500 ............ 10068553 ............ 101R24................ 10162006 ............ 102500 ................ 108R24................ 1125360160 ........ 113R190.............. 11311272384 ...... 11311286168 ...... 11311711082 ...... 11311711153 ...... 11311713361 ...... 119RH250 ........... 1191303105 ........ 119130310500 .... Gates No. T129 T42036 T42034 T294 T210 T276 T266 T308 T179 T302 T42032 T318 T281 T264 T120 T41079 T41079 T41079 T292 T292 T242 T242 T242 T242 T43006 T43006 T127 T197 T065 T065 T262 T301 T301 T301 T321 T43007 T262 T197 T225 T197 T225 T017 T41079 T291 T317 T317 T291 T296 T43010 T43010 T43010 T306 T306 T306 T070 T274 T043 T043 T043 T41080 T083 T082 T170 T082 T083 T207 T297 T207 T207 T218 T297 T218 T297 T297 T018 T069 T189 T140 T188 T070 T285 T163 T099 T192 T078 T094 T075 T065 T106 T106 T131 T41083 T131 T083 T120 T120 Mfr. Part No. 1257223 .............. 1257237 .............. 12581899 ............ 12612650017 ...... 12612650044 ...... 1272382 .............. 1272384 .............. 12723842 ............ 1276150G00 ....... 1276153B00........ 1276153B01........ 1276160A00........ 1276160B10........ 1276160E00........ 1276163B00........ 1276163E00........ 1276170C00........ 1276171C00........ 1276172F00 ........ 1276173000 ........ 1276173001 ........ 1276178400 ........ 1276180C00........ 1276182000 ........ 1276185Z00 ........ 1281053B00........ 1281053B01........ 1281071C00........ 1281071C01........ 1281082001 ........ 1281082002 ........ 1281082003 ........ 1281086500 ........ 1281086501 ........ 1286168 .............. 12861684 ............ 130RG25............. 13028AA010 ....... 13028AA040 ....... 13028AA072 ....... 13028AA101 ....... 13028AA102 ....... 13028AA120 ....... 13028AA150 ....... 13028AA170 ....... 13028AA181 ....... 13028AA21A ....... 13028D0100........ 13028D1700........ 13028D4200........ 13028D4210........ 13028D4211........ 13028KA021 ....... 13028V4000........ 13028V4310........ 13028V5100........ 13028V5200........ 13028V5201........ 13028V5210........ 13028V5220........ 13028V5221........ 130280B700........ 130280B785........ 1302810M00 ....... 1302811M00 ....... 1302811M10 ....... 1302812C00........ 1302812G00 ....... 1302816A01........ 1302816A10........ 1302816E00........ 1302816E10........ 1302816E85........ 1302816V00........ 1302820R00........ 1302845P00........ 1302851E00........ 1302851E10........ 1302861A00........ 1302885 .............. 1302885E00........ 13029AA010 ....... 13029AA011 ....... 13029AA040 ....... 13029AA070 ....... 13029AA080 ....... 13029AA11 ......... 13069AA034 ....... 13069AA035 ....... 13069AA036 ....... 13069AA037 ....... 13069AA063 ....... 13070AA00 ......... 13070AA000 ....... 13070AA001 ....... 13070D0100........ Gates No. T083 T082 T329 T41015 T129 T106 T106 T106 T194 T171 T171 T164 T166 T241 T095 T243 T194 T212 T272 T028 T028 T070 T243 T095 T309 T41010 T41010 T41065 T41065 T41064 T41064 T41064 T41009 T41009 T106 T106 T084 T300 T150 T277 T172 T172 T209 T254 T300 T304 T307 T100 T078 T137 T137 T137 T135 T017 T093 T104 T104 T104 T104 T104 T104 T249 T249 T077 T077 T077 T100 T104 T096 T096 T104 T104 T104 T180 T078 T251 T137 T137 T077 T104 T104 T299 T299 T151 T299 T299 T299 T41063 T41063 T41063 T41063 T41092 T41062 T41061 T41062 T41088 Mfr. Part No. 13070KA020 ....... 13070V5001........ 1307001M00 ....... 1307016A00........ 1307016A02 Nis san .................... 1307016A02 Sub aru..................... 1307016A03........ 1307042L00 ........ 13071AA001 ....... 13071AA002 ....... 13073AA000 ....... 13073AA080 ....... 13073AA081 ....... 13073AA140 ....... 13073AA142 ....... 13077F6200 ........ 13077F6510 ........ 13077F6512 ........ 1307745V00........ 13085AA010 ....... 1320811M00 ....... 1326288 .............. 13404PT0003...... 13404PT0004...... 13404P13003...... 13405PAAA01..... 13405PAAA02..... 13405PAAA03..... 13405PTO004..... 13405PT0004...... 13440P5A004 ..... 1350311010 ........ 1350311011 ........ 1350311020 ........ 1350311030 ........ 1350311040 ........ 1350350010 ........ 1350350011 ........ 1350354010 ........ 1350354020 ........ 1350362010 ........ 1350362030 ........ 1350363010 ........ 1350363011 ........ 1350363020 ........ 1350363021 ........ 1350364010 ........ 1350364020 ........ 1350365010 ........ 1350388360 ........ 1350388380 ........ 1350501010 ........ 1350502020 ........ 1350511010 ........ 1350511011 ........ 1350511020 ........ 1350511040 ........ 1350511050 ........ 1350515031 ........ 1350515040 ........ 1350515041 ........ 1350515050 ........ 1350516020 ........ 1350516021 ........ 1350520010 ........ 1350520020 ........ 1350543010 ........ 1350550010 ........ 1350550011 ........ 1350550021 ........ 1350550022 ........ 1350562031 ........ 1350562050 ........ 1350562060 ........ 1350563011 ........ 1350563021 ........ 1350564010 ........ 1350564011 ........ 1350564020 ........ 1350564021 ........ 1350565020 ........ 1350565040 ........ 1350574010 ........ 1350574011 ........ 1350587102 ........ 1350587702 ........ 1351415010 ........ 1351487711 ........ 135148771100 .... 1351487711000 .. 1356422021 ........ 135680A010........ 1356803010 ........ 1356803020 ........ Gates No. T41060 T41059 T41058 T41089 T41089 T41089 T41089 T41059 T41062 T41062 T42022 T42023 T42023 T42023 T42023 T42021 T42020 T42021 T42021 T42024 T077 T174 T41013 T41013 T41022 T186 T186 T186 T186 T186 T280 T42028 T42028 T42028 T42029 T42029 T42031 T42031 T42026 T42026 T42030 T42030 T42025 T42025 T42025 T42025 T42027 T42027 T42037 T42025 T42025 T41066 T41074 T41076 T41076 T41076 T41071 T41071 T41066 T41066 T41066 T41072 T41074 T41074 T41075 T41075 T41069 T41078 T41078 T41078 T41078 T41075 T41075 T41075 T41070 T41070 T41077 T41077 T41077 T41077 T41073 T41073 T41067 T41067 T41004 T41003 T070 T178 T178 T178 T126 T257 T138 T199

801

Interference engine application.

802
Mfr. Part No.

Manufacturers Part Numbers - PowerGrip Timing System Products


Gates No. T199 T199 T199 T257 T257 T136 T233 T233 T233 T208 T208 T208 T070 T070 T070 T070 T036 T036 T239 T036 T112 T176 T236 T236 T236 T236 T235 T235 T235 T235 T236 T236 T235 T235 T233 T233 T208 T208 T070 T239 T112 T257 T257 T257 T257 T126 T237 T126 T126 T237 T074 T074 T101 T101 T215 T237 T215 T215 T074 T101 T190 T298 T079 T079 T079 T079 T079 T084 T084 T079 T079 T079 T084 T084 T084 T190 T298 T157 T200 T200 T157 T271 T087 T087 T087 T098 T098 T154 T154 T240 T200 T157 T087 T154 T098 T098 Mfr. Part No. 1356869075 ........ 1356869095 ........ 1356874010 ........ 1356874011 ........ 1356874012 ........ 1356874012B...... 1356874013 ........ 1356874020 ........ 1356874021 ........ 1356879025 ........ 1356879045 ........ 1356879095 ........ 1356887101 ........ 1356887101000 .. 1356887102 ........ 1356887102000 .. 1356887103 ........ 1356887103000 .. 1356887104 ........ 1356887104000 .. 1356887708 ........ 1356888360 ........ 1356888361 ........ 1356888380 ........ 1356888381 ........ 1356888382 ........ 139AG25 ............. 14001168 ............ 14400MG9000 .... 14400MG90000 .. 14400PAAA01..... 14400PAAA02..... 14400PC6004 ..... 14400PC60040 ... 14400PC60042 ... 14400PD2004 ..... 14400PD6004 ..... 14400PE0004 ..... 14400PE00040 ... 14400PE3004 ..... 14400PE30040 ... 14400PG6004 ..... 14400PG60040 ... 14400PG6014 ..... 14400PG6040 ..... 14400PH7004 ..... 14400PH70040 ... 14400PH7014 ..... 14400PH70140 ... 14400PH90040 ... 14400PH90040P. 14400PK1004 ..... 14400PK10040 ... 14400PK2004 ..... 14400PK20040 ... 14400PK3004 ..... 14400PLM004..... 14400PMMA01 ... 14400PM3004..... 14400PM30040... 14400PM6004..... 14400PM70040... 14400PR3004 ..... 14400PR4A01..... 14400PR4A01M1 14400PT0004...... 14400PV1004 ..... 14400PY3A010 ... 14400PY3004 ..... 14400P0A004 ..... 14400P0GA01..... 14400P0GA010M 1 ........................ 14400P08004...... 14400P13004...... 14400P14004...... 14400P2E004 ..... 14400P2FA01 ..... 14400P2T004...... 14400P28004...... 14400P5A004 ..... 14400P7J004 ...... 14400P72004...... 14400P72014...... 14400P8AA01 ..... 14400P8AA02 ..... 14400RCAA01 .... 14400TG6004 ..... 14400634003 ...... 14400634004 ...... 14400634005 ...... 144006340050 .... 144006340051 .... 14400634014 ...... 144006340141 .... 14400657004 ...... Gates No. T240 T271 T138 T138 T199 T199 T199 T138 T199 T199 T125 T199 T181 T181 T181 T181 T182 T182 T182 T182 T178 T125 T125 T125 T125 T125 T087 T061 T070 T070 T244 T244 T160 T094 T160 T160 T160 T099 T099 T099 T161 T130 T130 T130 T130 T129 T129 T129 T129 T070 T070 T144 T144 T142 T142 T142 T312 T312 T143 T143 T145 T142 T227 T184 T184 T187 T211 T193 T193 T244 T263 T263 T223 T226 T216 T224 T224 T227 T224 T279 T184 T247 T247 T286 T286 T329 T130 T028 T028 T028 T028 T028 T028 T028 T036 Mfr. Part No. 144006570040 .... 144006570042 .... 14400657014 ...... 144006570140 .... 14400657024 ...... 144006570240 .... 144006570241 .... 144006570242 .... 1440065704 ........ 14400673004 ...... 144006730040 .... 144006730041 .... 144006730042 .... 14400679003 ...... 144006790040 .... 144006790041 .... 14400679014X.... 14401MN5004..... 14401MN50040... 14401MT3004 ..... 14401MT30041 ... 14450P8AA01 ..... 14510PC6004 ..... 14510PE0003 ..... 14510PE0005 ..... 14510PG6013 ..... 14510PH1003 ..... 14510PH1004 ..... 14510PH3003 ..... 14510PH7003 ..... 14510PH7004 ..... 14510PK1014 ..... 14510PM3003..... 14510PM7003..... 14510PM7004..... 14510PR3003 ..... 14510PR3004 ..... 14510PT0003...... 14510PT0004...... 14510PV0003 ..... 14510PY3003 ..... 14510PY3004 ..... 14510P08003...... 14510P08004...... 14510P13003...... 14510P30003...... 14510P8AA01 ..... 146R190.............. 1649170 .............. 1649171 .............. 1680616A00........ 1680616A10........ 1711082 .............. 1713361 .............. 177RG25............. 2335238010 ........ 2335632010 ........ 2335632020 ........ 2335632030 ........ 2335633110 ........ 2335633120 ........ 2335633130 ........ 2335633140 ........ 2335633150 ........ 2335633160 ........ 2335638000 ........ 2335638010 ........ 2335638020 ........ 2335732000 ........ 2335732010 ........ 2335732020 ........ 2335733120 ........ 2335742000 ........ 2335742010 ........ 2413232010 ........ 2431032010 ........ 243122Y000........ 2431221040 ........ 2431222010 ........ 2431222611 ........ 2431222612 ........ 2431223001 ........ 2431223201 ........ 2431223202 Hyu ndai ................... 2431223202 Kia.. 2431223400 ........ 2431224000 ........ 2431224010 ........ 2431224050 ........ 2431226000 ........ 2431226001 ........ 2431232610 ........ 2431232620 ........ 2431232820 ........ 2431233010 ........ Gates No. T036 T041 T036 T036 T041 T041 T041 T041 T036 T073 T073 T073 T073 T274 T274 T274 T274 T275 T275 T325 T325 T42038 T41012 T41017 T41017 T41018 T41012 T41012 T41019 T41015 T41015 T41019 T41011 T41011 T41011 T41016 T41016 T41014 T41014 T41020 T41021 T41021 T41023 T41023 T41024 T41016 T41090 T020 T067 T067 T097 T097 T131 T131 T098 T314 T159 T159 T159 T168 T168 T168 T168 T168 T168 T314 T314 T314 T41053 T41053 T41053 T41047 T41050 T41050 T089 T41044 T302 T073 T191 T324 T324 T278 T284 T284 T284 T284 T128 T128 T128 T282 T282 T124 T124 T089 T165 Mfr. Part No. 2431233020 ........ 2431233030 ........ 2431233040 ........ 2431233050 ........ 2431233060 ........ 2431233110 ........ 2431233120 ........ 2431233130 ........ 2431233140 ........ 2431233150 ........ 2431233160 ........ 2431235000 ........ 2431235010 ........ 2431235040 ........ 2431237100 ........ 2431237400 ........ 2431237500 Hyu ndai ................... 2431237500 Kia.. 2431238210 Hyu ndai ................... 2431238210 Kia.. 2431238220 ........ 2431239400 ........ 2431239800 Hyu ndai ................... 2431239800 Kia.. 24410-38001 ....... 2441021010 ........ 2441022000 ........ 2441022020 ........ 2441023011 ........ 2441023500 Hyu ndai ................... 2441023500 Kia.. 2441026000 ........ 2441032000 ........ 2441032010 ........ 2441032553 ........ 2441035010 ........ 2441035020 ........ 2441039001 Hyu ndai ................... 2441039001 Kia.. 2445033010 ........ 2445033020 ........ 2445037100 Hyu ndai ................... 2445037100 Kia.. 2445038010 ........ 24502982 ............ 24503363 ............ 248102X700........ 2481023011 ........ 2481023500 ........ 2481026020 ........ 2481033021 ........ 2481033024 ........ 2481035530 Hyu ndai ................... 2481035530 Kia.. 2481037100 Hyu ndai ................... 2481037100 Kia.. 2481037120 ........ 271705 ................ 2717056 .............. 271713 ................ 271714 ................ 2717148 .............. 271720 ................ 271747 ................ 2717478 .............. 271834 ................ 2718344 .............. 271835 ................ 2718351 .............. 271856 ................ 2718567 .............. 271876 ................ 2718765 .............. 271952 ................ 2719524 .............. 272327 ................ 272329 ................ 2723294 .............. 272386 ................ 274184 ................ 2900009150 ........ 3250141 .............. 3342103 .............. 3507227 .............. 3507651 .............. 3507704 .............. 3514323 .............. 3531358 .............. Gates No. T165 T165 T165 T165 T165 T167 T167 T167 T167 T167 T167 T139 T139 T139 T315 T315 T315 T315 T313 T313 T313 T322 T323 T323 T41087 T41042 T41037 T41037 T41041 T41041 T41041 T41037 T41044 T41044 T41046 T41048 T41048 T41040 T41039 T41046 T41046 T41040 T41040 T41087 T192 T273 T42005 T42015 T42015 T42016 T42017 T42017 T42014 T42018 T42014 T42014 T42014 T217 T217 T032 T198 T198 T173 T234 T234 T252 T252 T252 T269 T252 T252 T270 T270 T217 T217 T252 T311 T311 T270 T319 T305 T017 T119 T083 T217 T234 T173 T198 Mfr. Part No. 3547459 .............. 35474592 ............ 360525 ................ 376388 ................ 376401 ................ 414701001 .......... 414705601 .......... 4164869 .............. 4176840 .............. 4182426 .............. 4201379 .............. 4201738 .............. 4201739 .............. 4242396 .............. 4300516 .............. 4302971 .............. 4304099 .............. 4315705 .............. 4343824 .............. 4343946 .............. 43439469 ............ 4387534 .............. 4387549 .............. 4401261 .............. 4401269 .............. 4406634 .............. 4420507 .............. 4484494 .............. 4504163 .............. 4573347 .............. 4573348 .............. 4573944 .............. 460165 ................ 4621348 .............. 4621844 .............. 46337 .................. 463377 ................ 4633772 .............. 463633 ................ 4636338 .............. 4663515 .............. 4663598 .............. 4667530 .............. 4667606 .............. 4667611 .............. 4667625 .............. 4770491 .............. 477393 ................ 4781570AB ......... 4792353 .............. 484981001 .......... 4884320AA ......... 5010371AA ......... 512430160 .......... 512536016 .......... 5125360160 ........ 5203401 .............. 52267904 ............ 52289664 ............ 524034 ................ 5240346 .............. 5862021480 ........ 5862021620 ........ 5862059260 ........ 5862059340 ........ 5985163 .............. 60507464 ............ 60562106 ............ 636350 ................ 636359 ................ 636363 ................ 636365 ................ 636368 ................ 636370 ................ 636560 ................ 636562 ................ 636565 ................ 6842469 .............. 70HM 6268 AB ... 70HM 6268 BA ... 7533266 .............. 7533267 .............. 7700618657 ........ 7700663550 ........ 7700666593 ........ 7700717284 ........ 7700718725 ........ 7700718726 ........ 7700718752 ........ 7700718836 ........ 7700729581 ........ 7700853660 ........ 7701348801 ........ 8091287220 ........ 82317934 ............ 85867058 ............ Gates No. T174 T174 T037 T037 T037 T028 T079 T020 T018 T020 T068 T068 T068 T069 T122 T122 T075 T41001 T114 T071 T071 T132 T153 T069 T069 T032 T018 T206 T285 T41084 T41084 T219 T039 T285 T265 T032 T032 T032 T41081 T41081 T41002 T255 T206 T245 T246 T265 T285 T41002 T43008 T295 T028 T43001 T43005 T075 T075 T075 T071 T163 T163 T017 T017 T186 T187 T186 T244 T087 T120 T120 T081 T081 T081 T148 T148 T081 T081 T148 T081 T198 T013 T013 T013 T013 T018 T018 T069 T140 T140 T140 T119 T140 T140 T140 T018 T305 T065 T096

1356803021 ........ 1356809040 ........ 1356809041 ........ 1356809050 ........ 1356809080 ........ 1356811030 ........ 1356811031 ........ 1356811032 ........ 1356811033 ........ 1356811100 ........ 1356811101 ........ 1356811111 ........ 1356815010 ........ 1356815011 ........ 1356815020 ........ 1356815030 ........ 1356815040 ........ 1356815041 ........ 1356815042 ........ 1356815050 ........ 1356816010 ........ 1356816020 ........ 1356816040 ........ 1356816041 ........ 1356816050 ........ 1356816051 ........ 1356816060 ........ 1356816061 ........ 1356816070 ........ 1356816071 ........ 1356819045 ........ 1356819046 ........ 1356819055 ........ 1356819056 ........ 1356819085 ........ 1356819086 ........ 1356819115 ........ 1356819116 ........ 1356819125 ........ 1356819135 ........ 1356819145 ........ 1356820010 ........ 1356820020 ........ 1356829015 ........ 1356829025 ........ 1356842010 ........ 1356842011 ........ 1356842012 ........ 1356842020 ........ 1356842021 ........ 1356843010 ........ 1356843020 ........ 1356843030 ........ 1356843040 ........ 1356846020 ........ 1356849015 ........ 1356849035 ........ 1356849036 ........ 1356849046 ........ 1356849055 ........ 1356850010 ........ 1356850020 ........ 1356854010 ........ 1356854020 ........ 1356854030 ........ 1356854031 ........ 1356854038 ........ 1356854050 ........ 1356854051 ........ 1356859015 ........ 1356859016 ........ 1356859017 ........ 1356859025 ........ 1356859026 ........ 1356859027 ........ 1356859045 ........ 1356859095 ........ 1356862020 ........ 1356862030 ........ 1356862030A...... 1356862040 ........ 1356862050 ........ 1356863010 ........ 1356863020 ........ 1356863022 ........ 1356864010 ........ 1356864011 ........ 1356865010 ........ 1356865010A...... 1356865020 ........ 1356869025 ........ 1356869035 ........ 1356869045 ........ 1356869055 ........ 1356869065 ........ 1356869066 ........

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Manufacturers Part Numbers - PowerGrip Timing System Products


Mfr. Part No. 8920639440 ........ 894109626 .......... 8941096260 ........ 8941583270 ........ 8941606560 ........ 8941743060 ........ 894200372A........ 8942151970 ........ 8942151971 ........ 8942152540 ........ 8942187820 ........ 894220372A........ 8942209220 ........ 8942220922 ........ 8942353620 ........ 8942372420 ........ 894337708 .......... 8943377080 ........ 8943624350 ........ 8943648160 ........ 8943648161 ........ 8943864881 ........ 8943864882 ........ 8943864883 ........ 8943864970 ........ 8944161450 ........ 8944233311 ........ 8944294860 ........ 8944520940 ........ Gates No. T305 T162 T118 T121 T122 T147 T122 T41025 T41025 T121 T088 T122 T076 T076 T088 T121 T177 T177 T41027 T41028 T41028 T42002 T42002 T42002 T220 T088 T42001 T169 T162 Mfr. Part No. 8944723490 ........ 8944723491 ........ 8944795230 ........ 8970163260 ........ 8970270620 ........ 8970417840 ........ 8970422680 ........ 8971160020 ........ 8971363210 Hon da ...................... 8971363210 Isuz u ........................ 90122429 ............ 90231883 ............ 90234902 ............ 90324698 ............ 90324699 ............ 90325576 ............ 90325578 ............ 90353179 ............ 90353211 ............ 90354783 ............ 90409900 ............ 90410014 ............ 90410223 ............ 90410768 ............ 90410771 ............ 90500360 ............ 90530599 ............ Gates No. T41026 T41026 T162 T221 T205 T122 T147 T41028 T303 T303 T081 T148 T081 T148 T148 T081 T081 T203 T081 T148 T081 T081 T203 T285 T285 T285 T285 Mfr. Part No. 91112009 ............ 91171175 ............ 91172367 ............ 91172368 ............ 91173157 ............ 912761 ................ 9128500 .............. 9128722 .............. 9135031 .............. 9135450 .............. 9135733 .............. 9151772280 ........ 91540557 ............ 9154055780 ........ 91541318 ............ 9180954 .............. 92029834 ............ 92063917 ............ 92066312 ............ 928M 6K254 AC . 928M 6M250 BC 928M 6M250 DC 928M 6268 AB.... 92810515710 ...... 92810515730 ...... 92810515740 ...... 92810515750 ...... 93202400 ............ 94029834 ............ Gates No. T070 T272 T194 T41010 T194 T014 T285 T305 T252 T173 T252 T189 T188 T188 T188 T252 T075 T309 T309 T41008 T42036 T42032 T258 T196 T196 T196 T196 T43002 T075 Mfr. Part No. 94109626 ............ 94158327 ............ 94160656 ............ 94215197 ............ 94215254 ............ 94220922 ............ 94337708 ............ 94386497 ............ 9440383 .............. 94410221902 ...... 94410221904 ...... 94410513703 ...... 94410515703 ...... 94410515704 ...... 94410515706 ...... 94410532300 ...... 94410532301 ...... 94410532302 ...... 94429486 ............ 94452094 ............ 94479523 ............ 94840054 ............ 94844702 ............ 94846144 ............ 94847323 ............ 94848472 ............ 94849175 ............ 94849597 ............ 94854403 ............ Gates No. T118 T121 T122 T41025 T121 T076 T177 T220 T311 T293 T293 T107 T107 T107 T152 T152 T152 T152 T169 T118 T162 T070 T112 T036 T41066 T176 T036 T036 T236 Mfr. Part No. 94854404 ............ 94856081 ............ 94856082 ............ 95ZA19................ 95951646 ............ 96051646 ............ 96057945 ............ 96060050 ............ 96065049 ............ 96067809 ............ 96068423 ............ 96068424 ............ 96068591 ............ 96144976 ............ 96183352 Daewo o Int................... 96183352 Gener al Motors........... 96414718702 ...... 97016326 ............ 97027062 ............ 97041784 ............ 97042268 ............ 978M 6M250 AA. 978M 6M250 BA. 978M 6268 AA.... 99314718701 ...... 99919213150 ...... Gates No. T235 T236 T235 T100 T095 T095 T164 T166 T41009 T095 T241 T243 T212 T148 T310 T309 T222 T221 T205 T122 T147 T42035 T42036 T294 T290 T213

803

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